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Tom Jones
Joined: 12 Mar 2006
Posts: 752
Location: Ellensburg, WA
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 Posted: Fri Jan 23, 2015 7:39 am Post subject: 503 Oil Cable end wearing out |
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This 503 came from the factory without oil injection. At 80 hours I installed an injection system. The engine now has 136 hours so only 56 hours on this cable. You can see it is worn about 1/4 of the way through the barrel swedge on both ends where it contacts the oil pump lever. The pump lever is not worn at all. I noticed the swedge is brass. Too soft??? I have lubed it with LPS about every 10 hours.
The engine is on a Kitfox so I had California Power Sports make a cable with the 503 oiler swedge on the pump end and a barrel swedge to fit the Kitfox throttle reverser bellcrank on the other end. I think I gave them measurements either too short for the inner cable or too long for the outer cable.
I had to put both lock nuts on the adjuster below the bracket as shown to make the line on the lever line up at 3000 rpm. This caused the cable to not pull straight up on the lever at full throttle as shown in the photos. Could that be my problem
I really like the convenience of the injection and it is supposed to be better for the engine but this is no good. Anyone else have this problem or have any ideas. I called CPS and they do not custom make cables anymore.
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Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA |
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blumax008(at)aol.com
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| Posted: Fri Jan 23, 2015 7:59 am Post subject: 503 Oil Cable end wearing out |
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Tom,
I started flying ultralights in '78 with a Pterodactyl, currently own a Hornet and a Trike. I've had oil injection on a Maxair only which I think is just something else to go wrong. I understand what you're saying about oil injection but to me, adding oil to a 5 gallon can of fuel is much more reliable. Just takes a little effort is all & you eliminate a possible break in the chain.
When the guy who originally ran CPS sold out, we all lost an incredibly knowledgeable guy who put out a fantastic catalog, loaded with not only great products but also with an explanation of what they do on almost every page.
I don't have a lot of confidence in the new folks.
Bill Catalina
Tallahassee
blumax008(at)aol.com
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BARRY CHECK 6
Joined: 15 Mar 2011
Posts: 738
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| Posted: Fri Jan 23, 2015 8:27 am Post subject: 503 Oil Cable end wearing out |
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Tom:
Looking at your pictures three (3) things come to mind:
1 - This may sound very strange but with over 20 years in QA and test engineering - The cable has a LEFT TWIST to it. I have see many strange ware patterns with LEFT TWIST cable. See if you can find a RIGHT TWIST cable. If you go to a bicycle shop they may have the Right Twist cable and be able to swag the end fittings.
2 - The PLATE that guides the cable is not at the same angle as the arm... Twist the plate so it points more to the arm.
3 - The way you fitted the adjustment fitting and nuts is the way most people and probably the instructions show. BUT! The distance between the end of the adjustment fitting and the arm is TOO SMALL. You want a nice smooth arcing of the cable as it exits the adjustment fitting and the arm. MOVE the double nut mounting point as high - close to the end of the adjustment threads as possible. I do understand that this may not be due to the SUPPLIED parts. Time to be smarter than the manufacture and utilize the Experimental part of the planes certification.
Another trick/item comes to mind... GREASE the cable and inside of the cable guide with a Teflon based grease. Make sure it can handle the temperature range. I would guess a range of +250 F to -20 F should cover the requirements.
Barry
On Fri, Jan 23, 2015 at 10:39 AM, Tom Jones <nahsikhs(at)elltel.net (nahsikhs(at)elltel.net)> wrote:
[quote]--> RotaxEngines-List message posted by: "Tom Jones" <nahsikhs(at)elltel.net (nahsikhs(at)elltel.net)>
This 503 came from the factory without oil injection. At 80 hours I installed an injection system. The engine now has 136 hours so only 56 hours on this cable. You can see it is worn about 1/4 of the way through the barrel swedge on both ends where it contacts the oil pump lever. The pump lever is not worn at all. I noticed the swedge is brass. Too soft??? I have lubed it with LPS about every 10 hours.
The engine is on a Kitfox so I had California Power Sports make a cable with the 503 oiler swedge on the pump end and a barrel swedge to fit the Kitfox throttle reverser bellcrank on the other end. I think I gave them measurements either too short for the inner cable or too long for the outer cable.
I had to put both lock nuts on the adjuster below the bracket as shown to make the line on the lever line up at 3000 rpm. This caused the cable to not pull straight up on the lever at full throttle as shown in the photos. Could that be my problem
I really like the convenience of the injection and it is supposed to be better for the engine but this is no good. Anyone else have this problem or have any ideas. I called CPS and they do not custom make cables anymore.
--------
Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA
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Tom Jones
Joined: 12 Mar 2006
Posts: 752
Location: Ellensburg, WA
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| Posted: Fri Jan 23, 2015 12:55 pm Post subject: Re: 503 Oil Cable end wearing out |
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Thanks for the ideas guys.
I was seriously considering removing the oil injection. I just had the engine resealed by a Rotax service center and asked his opinion on the cable and on removing the injection. He said it is a high wear item and convinced me to see if I can get the cable to last longer. I often don't fly for two weeks or more and then need to drain the fuel if using premix.
I am going to get s new cable made and will ask them to use a right hand lay cable. I'll also make sure it is the proper length so I can adjust the end of the adjuster up higher near the bracket.
I have been doing more research and since I posted this morning I found LEAF Aviation's catalog has a stainless steel oil cable end for the 503. The only others I have found in catalogs seem to be brass.
More opinions still welcome if anyone has some.
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Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA |
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rickofudall
Joined: 19 Sep 2009
Posts: 1392
Location: Udall, KS, USA
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| Posted: Fri Jan 23, 2015 2:35 pm Post subject: 503 Oil Cable end wearing out |
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Tom, Use a good quality motorcycle cable oil. I prefer one with graphite lubricant added to the oil. Soak the cable with the lube a day or two before installing it and hang it up to let the excess oil run out. Make sure when you install it that the cable guide is aligned with actuating lever on the pump at mid stroke to minimize side pressure on the cable and housing.Personally, I premix for my 582 but only because the engine came already converted on my aircraft. The advantage to the injection system is that at mid throttle, i.e. cruise settings, it reduces oil to fuel ratio to about 70 to 1 and consequently reduces carbon packing in the rings.
Rick Girard
On Fri, Jan 23, 2015 at 2:55 PM, Tom Jones <nahsikhs(at)elltel.net (nahsikhs(at)elltel.net)> wrote:
| Quote: | --> RotaxEngines-List message posted by: "Tom Jones" <nahsikhs(at)elltel.net (nahsikhs(at)elltel.net)>
Thanks for the ideas guys.
I was seriously considering removing the oil injection. I just had the engine resealed by a Rotax service center and asked his opinion on the cable and on removing the injection. He said it is a high wear item and convinced me to see if I can get the cable to last longer. I often don't fly for two weeks or more and then need to drain the fuel if using premix.
I am going to get s new cable made and will ask them to use a right hand lay cable. I'll also make sure it is the proper length so I can adjust the end of the adjuster up higher near the bracket.
I have been doing more research and since I posted this morning I found LEAF Aviation's catalog has a stainless steel oil cable end for the 503. The only others I have found in catalogs seem to be brass.
More opinions still welcome if anyone has some.
--------
Tom Jones
Classic IV
503 Rotax, 72 inch Two blade Warp
Ellensburg, WA
Read this topic online here:
http://forums.matronics.com/viewtopic.php?p=437534#437534
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