_ASTM Working Doc Engine

7/25/2019 _ASTM Working Doc Engine

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Standard Practice for the Design andManufacturerof Reciprocating Engines for Light Sport Aircraft

This standard is issued under the fixed designation F XXXX; the number immediately following the designation indicates the year of original adoption or,in the case of revision, the year of last revision. A number in parentheses indicates the year of last reapproval. A superscript epsilon (e) indicates an editorial

change since the last revision or reapproval.

1. Scope

. This practice covers minimum re!uirements for a

the design and manufacture of engines for light sportaircraft.." This standard does not purport to address all of

the safety concerns, if any, associated with its use. It

is the responsibility of the user of this standard to

establish appropriate safety and health practices anddetermine the applicability of regulatory limitations

prior to use.2. Referenced Documents

".AWS Standards:"As applicable.

"."ASME Standards:#

As applicable.

".# A$T% XXX $tandard &ractice for light sportaircraft manufacturer !uality assurance program.

".' A$T% XXX $tandard &ractice %aintenance

&rocedures for light sport aircraft.

".( A$T% XXX $tandard $pecification for &hysicalinformation to be provided for light sport aircraft,

engines and propellers.3. Significance and Use

#. This practice provides designers andmanufacturers of engines for light sport aircraft

design references and criteria to use in designing and

manufacturing engines.

4. Engine Model Designation

'.Engine arts !ist A parts list is re!uired for

each engine model !ualified in accordance with this

specification.'." "ew Engine Model #esignations

'.".*ach new engine model must be !ualified in

accordance with this specification.

'."." +esign or configuration changes that impact theinstallation interface, performance, or operability of

the engine re!uire a new engine model designation.

'.##esign $hanges of arts *ach design change of

a part or component of an engine model !ualified tothis specification should be evaluated relative to the

re!uirements of this specification.

5. Data Requirements

(.%etained #ata & The following data and

information should be retained on file at the

manufacturers facility for

(.. +rawings that define the engine configuration(.." %aterial and process specifications referenced

in the parts drawings

(..# *ngineering analyses and test data prepared for

!ualification with this specification.

(."#eli'ered #ata The following data should be

delivered to the airplane manufacturer to support

design and operation of the applicable airplane.(.". An *ngine &erformance $pecification thatdefines the engine performance under all anticipated

operating environments.

(."." An -nstallation %anual that defines all

functional and physical interface re!uirements of theengine. This should include an engine

outlineinstallation drawing.

(.".# An /perating %anual that defines normal and

abnormal operating procedures and that defines anyapplicable operating limitations.

(.".' A %aintenance %anual that defines periodic

installed maintenance, ma0or inspection or overhaul

intervals, and defines any other maintenancelimitations.

(.".( An /verhaul %anual that provides instruction

for disassembling the engine to replace andor repair

parts as re!uired to return the engine to airworthycondition that is safe for operation to the next ma0or

overhaul.

6. Design riteria

1.Materials The materials used in the engine must

be ade!uate for the intended design conditions of the

engine.

1."(ire re'ention The design and construction ofthe engine and the materials used must minimi2e the

probability of the occurrence and spread of fire by3

1.". 4sing fire resistant lines, fittings and other

components which contain a flammable li!uid whensupplied with the engine.

1.". $hielding or locating components to safeguard

against the ignition of lea5ing flammable fluid.

1.#Engine $ooling The engine design must includeprovisions for cooling and the -nstallation %anual

must specify engine and component temperature

limitations.

1.'Engine mounting The maximum allowable limitand ultimate loads for the engine mounting

attachments and related structure must be specified.

1.(Mechanical Ignition Systems *ach spar56ignition engine must have a dual ignition system thatincludes dual spar5 plugs and separate sources of

electrical energy.

1.1Electronic Engine $ontrollers 7**8)

1.1. $ingle Fault Tolerance3 The **8 should bedesigned to accommodate single failures of the

electrical circuit.


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1.1." The functioning of **89s must not be adversely

affected by the declared environmental conditions,including temperature, moisture, *lectromagnetic

-nterference 7*%-), and :igh -ntensity adiated

Fields 7:-F). The limits to which the system has

been !ualified shall be documented in the -nstallation%anual.

1.1.# **8 software must be designed and

implemented in accordance with T8A +ocument?, @$oftware 8onsiderations inAirborne $ystems and *!uipment 8ertification@,

dated +ecember , " or the most current revision

1.=(uel and Induction System1.=. -nduction $ystem -cing3 The fuel and air

inta5e passages must be designed to minimi2e the

accretion of ice.

1.=." Filtering3 The type and degree of fuel and airfiltering necessary to prevent obstruction of air or

fuel flow must be specified.

1.=.# Bi!uid Boc53 *ach passage in the induction

systme that conducts a mixture of fuel and air mustbe self6draining.

1.>!ubrication system

1.>. The lubrication system of the engine must bedesigned and constructed so that it will function

properly in all flight attitudes and atmospheric

conditions in which the airplane is expected to

operate. -n wet sump engines, this re!uirement mustbe met when only one6half of the maximum lubricant

supply is in the engine.

1.>." The lubrication system of the engine must be

designed and constructed to allow installing a meansof cooling the lubricant.

1.>.# The cran5case must be vented to the

atmosphere to preclude lea5age of oil from excessive

pressure in the cran5case.

).* +ibration6 The engine must be designed andconstructed to function throughout its normaloperating range of cran5shaft rotational speeds and

engine powers without inducing the following

conditions3

1.. *xcessive stress in any of the engine parts1.." *xcessive vibration forces transmitted to the

aircraft structure.!. "ualification #ests

=. $alibration Test *ach engine design shall betested and the basic characteristics of engine rated

power, speeds, and fuel consumption shall be

determined.

=."#etonation Test each engine shall be tested toconfirm that the engine will not detonate throughout

its range of intended conditions of operation using the

fuel which the designermanufacturer has specified

for the engine.

=.#Accelerated 'erhaul Test *ach engine model

must be sub0ected to an engine test that simulates an

engine overhaul interval. This test shall incorporate3=.#. At least CCD of the time at maximum power

that would occur over the overhaul interval.

=.#." At least CD of the time at cruise power that

would occur over the overhaul interval.=.#.# At least cycle per hour of test from maximum

power to cruise power and bac5.=.#.' At least one engine start for each five hours of

testing.

=.#.( +uring operation at maximum power, one

cylinder must be maintained within CEF of thelimiting cylinder head temperature, the other

cylinders must be operated at a temperature not lower

than (C degrees F below the limiting temperature,

and the oil inlet temperature must be maintainedwithin C degrees F of the limiting temperature.=.#.1 The engine must be fitted with a propeller that

thrust6loads the engine to the maximum thrust which

the engine is designed to resist at each applicableoperating condition specified in this section.=.#.= *ach accessory drive and mounting attachment

must be loaded. +uring operation at maximum

power, the load imposed by each accessory used onlyfor an aircraft service must be the limit load specified

by the applicant for the engine drive or attachment

point.

=.#.> After completing the Accelerated /verhaul Testeach engine must be completely disassembled and

each component must conform to the new or overhaul

limits established by the designermanufacturer.

$. Manufacturing Requirements The engine

manufacturer shall establish inspections and tests

necessary to ensure that each article producedconforms to the type design and is in a condition forsafe operation, including as applicable3

>. -nspections for raw materials, purchased items,

and parts and assemblies produced by suppliers,

including methods used to ensure acceptable !ualityof parts and assemblies that cannot be completely

inspected for conformity and !uality when delivered

to the engine manufacturers facility.

>." &roduction inspection of individual parts andcomplete assemblies, including the identification of

any special manufacturing processes involved, the

means used to control the processes, and the final test

procedure for the completed engine.>.# A non6conforming materials review system, thatincludes documentation of parts disposition

decisions, and a system to dispose of re0ected parts.>.' A system for informing company inspectors of

current changes in engineering drawings,

specifications, and !uality control procedures.

This practice is under the 0urisdiction of A$T% 8ommittee F on ecreational Aviation &roducts and is the direct responsibility of $ubcommittee F on

+esign and %anufacture. 8urrent edition approved . &ublished . /riginally published as . Bast previous edition . " Available from Americanelding $ociety, ((C


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