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Rotax 582 rod big end failures
I'm curious if anyone has experienced or might have some insight as to
why the Rotax 582 (blue head) seems to be prone to bearing failures on the connecting rod big end. I have examples of this occuring on three engines, all of which have about 250 hours on them. These engines have been carefully maintained and followed the factory service recomendations to the letter. The failures have been occuring on the magneto-end cylinder and seem to be initiated by a failure of the thrust washer on the rod big end. The exact same thrust washer failed on all the engines. (The one that fails is the thrust washer on the mag-end cylinder, PTO side of the rod.) When the washer fails, the rod gets hot enough to severely distort it and lock the engine. There is no indication on any of the engine gauges (CHT, EGT, water temp) that anything is wrong unitl the engine begins to loose power and then locks up a few seconds later. There is no indication of a lubrication failure either (all the engines are oil injected). The problem has me stumped. Any ideas? |
#2
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Rotax 582 rod big end failures
When
the washer fails, the rod gets hot enough to severely distort it and lock the engine. .... There is no indication of a lubrication failure either (all the engines are oil injected). Overheating big end, hmm ? What makes you think this is NOT a lubrication issue ? Regards, Gilles Thesee Grenoble, France http://contrails.free.fr |
#3
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Rotax 582 rod big end failures
GTH wrote:
When the washer fails, the rod gets hot enough to severely distort it and lock the engine. .... There is no indication of a lubrication failure either (all the engines are oil injected). Overheating big end, hmm ? What makes you think this is NOT a lubrication issue ? Regards, Gilles Thesee Grenoble, France http://contrails.free.fr Because there is no indication of friction burns on the cylinder walls or piston skirts. Also, you can still feel the oil film on the cylinder walls when breaking down the engine for inspection. It's possible that the cylinders are getting lubrication, but not the crank. If so, it's a design problem with the 582. From what I've gathered (off the record) from some of the rotax service centers is that the 582 crank is having problems when used in a training environment such as ours. It seems the high number of landing / take off cycles at high throttle settings may be causing the premature crank failures. Rotax claims the crank is rated for 300 hours. The longest we've had one last is 236 hours. Incidently, you might be able to spot this problem before it goes catastrophic by examining the pulse line hose (assuming you are using a clear urethane hose). The hot air produced by the failure turns the first couple of inches of the pulse line black. |
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