ASTM Working Doc Engine

Standard Practice for the Design and Manufacturer
of 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
1.1 This practice covers minimum requirements for a
the design and manufacture of engines for light sport
aircraft.
1.2 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 and
determine the applicability of regulatory limitations
prior to use.
2. Referenced Documents
2.1 AWS Standards:2
As applicable.
2.2 ASME Standards:3
As applicable.
2.3 ASTM XXX Standard Practice for light sport
aircraft manufacturer quality assurance program.
2.4 ASTM XXX Standard Practice Maintenance
Procedures for light sport aircraft.
2.5 ASTM XXX Standard Specification for Physical
information to be provided for light sport aircraft,
engines and propellers.
3. Significance and Use
3.1 This practice provides designers and
manufacturers of engines for light sport aircraft
design references and criteria to use in designing and
manufacturing engines.
4. Engine Model Designation
4.1 Engine Parts List A parts list is required for
each engine model qualified in accordance with this
specification.
4.2 New Engine Model Designations
4.2.1 Each new engine model must be qualified in
accordance with this specification.
4.2.2 Design or configuration changes that impact the
installation interface, performance, or operability of
the engine require a new engine model designation.
4.3 Design Changes of Parts Each design change of
a part or component of an engine model qualified to
this specification should be evaluated relative to the
requirements of this specification.
5. Data Requirements
5.1 Retained Data The following data and
information should be retained on file at the
manufacturers facility for ????
5.1.1 Drawings that define the engine configuration
5.1.2 Material and process specifications referenced
in the parts drawings
5.1.3 Engineering analyses and test data prepared for
qualification with this specification.
5.2 Delivered Data The following data should be

delivered to the airplane manufacturer to support
design and operation of the applicable airplane.
5.2.1 An Engine Performance Specification that
defines the engine performance under all anticipated
operating environments.
5.2.2 An Installation Manual that defines all
functional and physical interface requirements of the
engine. This should include an engine
outline/installation drawing.
5.2.3 An Operating Manual that defines normal and
abnormal operating procedures and that defines any
applicable operating limitations.
5.2.4 A Maintenance Manual that defines periodic
installed maintenance, major inspection or overhaul
intervals, and defines any other maintenance
limitations.
5.2.5 An Overhaul Manual that provides instruction
for disassembling the engine to replace and/or repair
parts as required to return the engine to airworthy
condition that is safe for operation to the next major
overhaul.
6. Design Criteria
6.1 Materials The materials used in the engine must
be adequate for the intended design conditions of the
engine.
6.2 Fire Prevention The design and construction of
the engine and the materials used must minimize the
probability of the occurrence and spread of fire by:
6.2.1 Using fire resistant lines, fittings and other
components which contain a flammable liquid when
supplied with the engine.
6.2.1 Shielding or locating components to safeguard
against the ignition of leaking flammable fluid.
6.3 Engine Cooling The engine design must include
provisions for cooling and the Installation Manual
must specify engine and component temperature
limitations.
6.4 Engine mounting The maximum allowable limit
and ultimate loads for the engine mounting
attachments and related structure must be specified.
6.5 Mechanical Ignition Systems Each sparkignition engine must have a dual ignition system that
includes dual spark plugs and separate sources of
electrical energy.
6.6 Electronic Engine Controllers (EEC)
6.6.1 Single Fault Tolerance: The EEC should be
designed to accommodate single failures of the
electrical circuit.
6.6.2 The functioning of EECs must not be adversely

affected by the declared environmental conditions,
including temperature, moisture, Electromagnetic
Interference (EMI), and High Intensity Radiated
Fields (HIRF). The limits to which the system has
been qualified shall be documented in the Installation
Manual.
6.6.3 EEC software must be designed and
implemented in accordance with RTCA Document
No. RTCA/DO-178B, "Software Considerations in
Airborne Systems and Equipment Certification",
dated December 1, 1992 or the most current revision
6.7 Fuel and Induction System
6.7.1 Induction System Icing: The fuel and air
intake passages must be designed to minimize the
accretion of ice.
6.7.2 Filtering: The type and degree of fuel and air
filtering necessary to prevent obstruction of air or
fuel flow must be specified.
6.7.3 Liquid Lock: Each passage in the induction
systme that conducts a mixture of fuel and air must
be self-draining.
6.8 Lubrication system
6.8.1 The lubrication system of the engine must be
designed and constructed so that it will function
properly in all flight attitudes and atmospheric
conditions in which the airplane is expected to
operate. In wet sump engines, this requirement must
be met when only one-half of the maximum lubricant
supply is in the engine.
6.8.2 The lubrication system of the engine must be
designed and constructed to allow installing a means
of cooling the lubricant.
6.8.3 The crankcase must be vented to the
atmosphere to preclude leakage of oil from excessive
pressure in the crankcase.
6.9 Vibration - The engine must be designed and
constructed to function throughout its normal
operating range of crankshaft rotational speeds and
engine powers without inducing the following
conditions:
6.9.1 Excessive stress in any of the engine parts
6.9.2 Excessive vibration forces transmitted to the
aircraft structure.
7. Qualification Tests
7.1 Calibration Test Each engine design shall be
tested and the basic characteristics of engine rated
power, speeds, and fuel consumption shall be
determined.
7.2 Detonation Test each engine shall be tested to
confirm that the engine will not detonate throughout
its range of intended conditions of operation using the
fuel which the designer/manufacturer has specified
for the engine.
7.3 Accelerated Overhaul Test Each engine model

must be subjected to an engine test that simulates an
engine overhaul interval. This test shall incorporate:
7.3.1 At least 100% of the time at maximum power
that would occur over the overhaul interval.
7.3.2 At least 10% of the time at cruise power that
would occur over the overhaul interval.
7.3.3 At least 1 cycle per hour of test from maximum
power to cruise power and back.
7.3.4 At least one engine start for each five hours of
testing.
7.3.5 During operation at maximum power, one
cylinder must be maintained within 10F of the
limiting cylinder head temperature, the other
cylinders must be operated at a temperature not lower
than 50 degrees F below the limiting temperature,
and the oil inlet temperature must be maintained
within 10 degrees F of the limiting temperature.
7.3.6 The engine must be fitted with a propeller that
thrust-loads the engine to the maximum thrust which
the engine is designed to resist at each applicable
operating condition specified in this section.
7.3.7 Each accessory drive and mounting attachment
must be loaded. During operation at maximum
power, the load imposed by each accessory used only
for an aircraft service must be the limit load specified
by the applicant for the engine drive or attachment
point.
7.3.8 After completing the Accelerated Overhaul Test
each engine must be completely disassembled and
each component must conform to the new or overhaul
limits established by the designer/manufacturer.
8. Manufacturing Requirements The engine
manufacturer shall establish inspections and tests
necessary to ensure that each article produced
conforms to the type design and is in a condition for
safe operation, including as applicable:
8.1 Inspections for raw materials, purchased items,
and parts and assemblies produced by suppliers,
including methods used to ensure acceptable quality
of parts and assemblies that cannot be completely
inspected for conformity and quality when delivered
to the engine manufacturers facility.
8.2 Production inspection of individual parts and
complete 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.
8.3 A non-conforming materials review system, that
includes documentation of parts disposition
decisions, and a system to dispose of rejected parts.
8.4 A system for informing company inspectors of
current changes in engineering drawings,
specifications, and quality control procedures.
This practice is under the jurisdiction of ASTM Committee F?? on Recreational Aviation Products and is the direct responsibility of Subcommittee F?? on
Design and Manufacture. Current edition approved ???. Published ???. Originally published as ??. Last previous edition ??. 2 Available from American
Welding Society, 550 N. LeJeune Rd., Miami, FL 33126. 3 Available from Society of Mechanical Engineers, 345 E. 47th St., New York, NY 10017.
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Standard Practice for the Design and Manufacturer

of Reciprocating Engines for Light Sport Aircraft

5.2 Delivered Data The following data should be

6.6.2 The functioning of EECs must not be adversely

7.3 Accelerated Overhaul Test Each engine model

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