Installation Manual - Pipistrel Aircraft
Contents
1. Proper clothing ear protection etc should be used on any engine run up test After this procedure the idle must be adjusted see also latest revision of the current Maintenance Manual 447 503 582 Then proceed with taxi test to verify proper cooling system Then short take offs can be conducted After a few short full load take offs but not later than 2 hours total running time the cylinder head nuts must be re torqued to 22 Nm 195 in Ib For this procedure the cylinder cowl if any must be taken off Page INSTALL 447 SCDI 503 DCDI Date Modification no d00331 400332 22 ROTAX authorized Distributors for ROTAX Aircraft Engines 1 EUROPE AUSTRIA HB FLUGTECHNIK GES M B H Dr Adolf Scharf Str 44 A 4053 HAID Tel 07229 79104 79117 Fax 07229 79104 15 Contact person Ing Heino Brditschka BULGARIA gt GERGANOV AIRCRAFT EINGINES LTD 25B Post 20 23 peh SODI polk Blvd BG 6100 KAZA ANLA Tel 431 27 247 DE 431 23 777 Contact person Radosslav D Gerganov CROATIA former YUGOSLAVIA except SLOVENIA SHAFT D 0 0 B L Mandica 161 a HR 54000 OSIJEK Tel Fax 031 280 046 Contact person Ing Ivan Vdovjak CZECHIA gt TEVESO S R O Skroupova 9441 CS 50002 HRADEC KRALOVE Tel 049 56 30 127 Fax 049 56 30 226 E mail teveso mbox vol cz Contact persons Ing Samal Ing Halek DENMARK THE NETHERLANDS FLIGHT CENTER Flugplatz D 27777 GANDERKESEE GERMANY Tel 02. 1285 Contact person Tahir Onder President 2 AMERICA CANADA gt ROTECH RESEARCH CANADA LTD 6235 Okanagan Landing Rd VERNON B C VIH 1M5 Canada Tel 250 260 6299 Fax 250 260 6269 E mail inquiries rotec com website www rotec com NORTH MIDDLE SOUTH AMERICA gt KODIAK RESEARCH LTD P O Box N 7113 Marlborough House Cumberland Street NASSAU BAHAMAS Tel 242 356 5377 Fax 242 322 6784 E mail custsupport kodiakbs com website www kodiakbs com 3 AUSTRALIA AIRCRAFT ENGINE DISTRIBUTORS PTY LTD P O Box 84 Boonah QLD 4310 Tel 07 5463 2755 Fax 07 5463 2987 E mail sales austflight com au Contact person Jim Fenton BERT FLOOD IMPORTS PTY LTD P O Box 61 LILYDALE VICTORIA 3140 Tel 03 9735 5655 Fax 03 9735 5699 E mail flood smart net au Contact person Bert Flood NEW ZEALAND TIPPINS INTERNATIONAL P O Box 192 Tuakau SOUTH AUCKLAND Tel 09 233 4898 Fax 09 233 4798 E mail data ets co nz Contact person Murray Tippins 4 AFRICA EGYPT SALEM BALLOONS 40 Talaat Harb St CAIRO Tel 2 2991 946 2 3038 214 Fax 2 3038 214 E mail sballoon ritsec1 com e Contact person Weaam Salem General Manager ANGOLA BOTSWANA LESOTHO MADAGASCAR MALAWI MOZAMBIOUE NAMIBIA SOUTH AFRICA SWAZILAND ZAMBIA ZIMBABWE A VIATION ENGINES ANDACCESSORIES PTY LTD Private Bag X10021 Edenvale 1610 South Africa Tel 011 455 4203 4 5
3. 1999 02 01 ai 582 DCDI 9 1 Permissible fitting positions Take care that all limits of operation are in compliance with the Operator s Manual and Installation Manual E ATTENTION Ensure that the carburetors are positioned vertical in normal flying position to warrant proper operation of the floats in the carburetor General directives for engine mounting Isolation mounts must be used between engine and aircraft frame to neutralize vibrations Damping elements as generally used in the aircraft industry are suitable NOTE The engine suspension must be designed to prevent any excessive engine movement and to minimize noise emission and vibration on air frame side A WARNING Respect manufacturers recommended torques during engine installa tion Page INSTALL 447 SCDI 503 DCDI Preference Date Modification no 9 2 582 DCDI 1999 02 01 0 d00319 d00320 10 Exhaust system A WARNING Considerable effort has gone into the design of the ROTAX exhaust system Any changes to the original system may severely deteriorate performance reliability engine life fuel economy and ability of noise reduction Improper handling or modification of the exhaust system as supplied could ruin the engine E ATTENTION Beware of any accessory systems that advertise an improvement over stock components The exhaust system is tuned for the respective engine and performance and must not be changed If modifications are inevitable then the mid l
4. 992 819 Starter control should be via starter relay supplied with starter kit wired as shown above Fuse A 16 Amp fuse must be installed between battery charging circuit and main power terminal Page INSTALL 447 SCDI 503 DCDI Pref Date Modification no 400328 d00329 Propeller drive A WARNING Never run the engine without a propeller installed as engine would suffer severe damage by overspeeding Never fit propeller directly on crankshaft Normally the propeller gearbox will be supplied and installed on the engine If the gearbox is delivered seperately take note of the gearbox installation instructions in chapter 14 19 1 Technical data direction of rotation of the prop flange clockwise looking towards face of flange B type gearbox Reduction ratio 2 0 2 24 2 58 Attachment holes on propeller flange Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 Men 582 DCDI 19 1 2 C CL and E EL type gearbox Reduction ratio 2 62 3 0 3 47 4 0 Attachment holes of propeller flange Page INSTALL 447 SCDI 503 DCDI Date Modification no d00329 d00330 20 Connections for instrumentation 20 1 fig 49 fig 49 20 2 fig 50 fig 50 Modification no 0 Sensor for cylinder head temperature spark plug seat temperature location and connection one each
5. EGT max 650 1200 F E ATTENTION The exhaust manifold is provided with tapped holes If the EGT is not meas ured the holes must be closed with screws which must be safety wired X 100mm 02798 Page INSTALL 447 SCDI 503 DCDI Date Modification no 400320 d00321 11 Cooling system 11 1 Fan cooling ROTAX 447 UL SCDI ROTAX 503 UL DCDI The engine driven cooling fan provides sufficient cooling air provided that the cooling air has free access and the hot air is not recirculated to the fan On aircraft equipped with engine cowlings the exit must be of sufffcient size and in a low pressure area allowing the air to cool engine cabin and crankcase Free air cooling ROTAX 447 UL SCDI ROTAX 503 UL DCDI Means ram air cooling for engines without fan In case of a tractor propeller configuration with the propeller blowing air onto the cylinder s this air stream serves for engine cooling On 2 cylinder engines the air stream must be directed from the exhaust side towards the carburetor side with suitable ducting available from ROTAX Pusher propeller configurations should not be used with free air cooled engines without consulting the engine manufacturer in writing Liquid cooling ROTAX 582 UL DCDI and 582 UL DCDI mod 99 These engines have an integrated water pump The cooling circuit must be arranged as shown on the illustrations 12 to 17 Pay attention to the following NOTE The 582 UL DCDI mo
6. Gotemba City SHIZUOKA PREF 412 Tel 550 83 8860 Fax 550 83 8224 Contact person Yoshihiko Tajika President KOREA HWA YOUNG MEDICAL amp SCIENCE CO Office address 401 KeumKang Building 1439 1 Seocho 1 dong seocho ku SEOUL 137 071 Tel 02 3472 0271 5 Fax 02 3472 0276 02 3471 4753 Contact person John Lee President Mailing address SL Kang Nam P O Box 918 SEOUL d00332 400332 PAPUA NEW GUINEA BERT FLOOD IMPORTS PTY LTD P O Box 61 LILYDALE VICTORIA 3140 AUSTRALIA Tel 03 9735 5655 Fax 03 9735 5699 E mail flood smart net au Contact person Bert Flood TAIWAN TAIWAN MAXIEM INDUSTRIES 7 1 Tung Feng Street TAIPEI 10 651 Tel 2 2704 6163 Fax 2 2702 84 85 Contact person Lester Lin UNITED ARAB EMIRATES AL MOALLA P O Box 7787 ABU DHABI Tel 2 723 248 Fax 2 788 073 E mail almoalla emirates net ae Contact person Hussain Al Moalla Modification no Date 0 1999 02 01 INSTALL 447 SCDI 503 DCDI Page Preference 582 DCDI Page INSTALL 447 SCDI 503 DCDI Pref Date Modification no d00332
7. SCDI 503 DCDI Preference Date Modification no 15 2 582 DCDI 1999 02 01 0 d00325 400326 Carburetor The carburetor can be adjusted by jet replacement of various approved sizes and by adjusting idle air fuel mixture screw carb piston stop adjustment needle sizes and needle position The air fuel mixture at idle speed is adjusted by the air adjusting screw The idle r p m is adjusted by the carburetor piston adjustment screw NOTE These idle adjustments interact so adjusting one may reguire minor adjustment of the other NOTE On single carb engines the carburetor must be in an exact right angle position in relation to the crankshaft in both views from top and from the intake side to ensure an equal mixture distribution to both cylinders see ill below Replacement of parts should be done only after proper trouble shooting has been carried out and then by an experienced two cycle mechanic Ensure that throttle cable and linkage do not stick and that carb piston valve can be fully opened and closed Minor cable backlash can be adjusted at cable adjustment screw and lock nut Be certain that throttle linkage is not affected by engine or airframe movement This will change throttle settings Air intake filtration and or noise reduction devices must be in place for proper carburation See section on special operating conditions Special operating conditions such as severe climate or altitude change may require d
8. filling capacities drive and reduction ratios electric output etc can be found in the respective chapter of engine installation Z3 Zi C 0 G Reduction gear 22 with propshaft towards cyl i C 0 G Powerplant with propshaft towards cyl C O G Engine c Propshat MIL torwards cyl X2 Y1 Engi Y3ba ngine A X2 _Prop shaft 1 iorwards base I I A 1 I I C 0 G Powerplant with propshaft towards base E tface L j Join gearbox engine 7 r Lean LA OW C 0 G Reduction gear i with propshaft towards base le Z2 Z1 O N W A y 7 2 Installation dimensions all dimensions in mm Total dimension 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 Weights Weight of engine defined to the following conditions rs Engine dry from serial production see chapter description of design Weight of 3 5 kg 7 71 Ib gearbox B 4 5 kg 9 99 Ib gearbox C 8 0 kg 17 64 Ib gearbox E oiaenaniacareteanieds 11 2 24 69 Ib generator 220 W DC 1 1 2 42 lb 4 85 lb 2 20 Ib 0 22 Ib radiator 995 697 582 only 1 0 fresh oil pump not 447 eee 0 1 intake silencer n 1 1 After MUTIO sinden ne 1 6 kg 3 52 Ib kg kg 2 radiators big 582 only 2 2 kg kg kg kg 2 42 Ib Modification no Date INSTALL 447 SC
9. have the same or similar function Specifications are given in the SI metric system with the USA equivalent in parenthesis Where precise accuracy is not required some conversions are rounded off for easier use 1 1 Repeating symbols This Manual uses the following symbols to emphasize particular information These indications are important and must be respected A WARNING Identifies an instruction which if not followed may cause serious injury including the possibility of death E ATTENTION Denotes an instruction which if not followed may severely damage the engine or other component NOTE Indicates supplementary information which may be needed to fully complete or understand an instruction Safety information A WARNING This engine by its design is subject to sudden stoppage Engine stoppage can result in forced landings no power landings or crash landings Such crash landings can lead to serious bodily injury or death A WARNING Never fly the aircraft equipped with this engine at locations airspeeds altitudes of other circumstances from which a successful no power landing cannot be made after sudden engine stoppage Aircraft equipped with this engine must only fly in DAYLIGHT VFR conditions A WARNING This is not a certificated aircraft engine It has not received any safety or durability testing and conforms to no aircraft standards It is for use in experimental uncertificated aircraft and vehicles only i
10. per cylinder fastened by one spark plug see also section 10 3 Tightening Torque of spark plug 15 Nm 133 in IB Air and coolant sensor location and connection coolant only at 582 UL DCDI and 582 UL DCDI mod 99 on cylinderhead Alisea location free to choose Tightening Torque 6 Nm 58 in IB un Anti Seize Date INSTALL 447 SCDI 503 DCDI Page 1999 02 01 Ble teng 582 DCDI Exhaust gas temperature sensor location and connection Exhaust manifold assy Tightening Torque 20 Nm 177 in IB LOCTITE Anti Seize Page INSTALL 447 SCDI 503 DCDI Date Modification no d00330 d00330 20 4 Modification no 0 Installation plan for the sensors at 582 UL DCDI and 582 UL DCDI mod 99 Sensor at spark plug seat CHT Air and liguid temperature sensor EGT sensor 4 Sealing ring Date INSTALL 447 SCDI 503 DCDI Page 1999 02 01 Ble teng 582 DCDI Installation plan for the sensors at 447 UL SCDI 503 UL DCDI 1 Sensorat spark plug seat CHT 2 Air and liquid temperature sensor 3 EGT sensor 4 Sealing ring Page INSTALL 447 SCDI 503 DCDI Pref Date Modification no 400330 d00331 engine rpm x 1000 max rpm refer to OM Break in procedure for aircraft installation in other applications proceed accordingly The break in must be performed with the engine installed and properly loaded with matched propeller for max R P M In case of an aircraft anchor the
11. return valve temperature gauge for cooling water Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 dit 582 DCDI 11 3 Cooling circuit for engine installation with spark plugs down For this installation position a vent tube must be connected on top of the waterpump housing 4 leading to the expansion chamber 10 or to the water chamber of the radiator Vent the cooling system well check after a short operating period and refill coolant as required Only a perfectly vented cooling system will operate satisfactorily A WARNING Do notopen cooling system until engine has cooled to outside air temperature failure to respect this information will result in severe scalds and injuries Bi NOTE illustration shows 582 ULDCDI Page INSTALL 447 SCDI 503 DCDI Pref Date Modification no 400321 d00321 1 crankcase 2 cylinder 3 cylinder head 4 water pump 5 radiator 6 hose from radiator to the water pump 7 hose from cylinder head to the radiator 8 radiator screw cap with excess pressure valve and return valve 9 temperature gauge for cooling water Modification no Date INSTALL 447 SCDI 503 DCDI 0 1999 02 01 Preiarenge
12. to dual ignition system The generator integrated in the DUCATI dual ignition has a special gray cable for revolution counter connection The revolution counter 966 404 must be fitted between the gray cable and mass brown cable The tachometer will indicate correct RPM even if one of the two ignition systems is turned off for ignition testing procedure or a transducer failure occurs Maximum allowed deviation 100 1 min Electric starter Two types of electric starters can be fitted to ease starting procedures especially in flight Page INSTALL 447 SCDI 503 DCDI Pref Date Modification no d00328 d00328 Electric starter fitted on E type gearbox There is also the possibility to use a rewind start Electric starter fitted on magneto side For use with engines utilizing ROTAX gear reduction unit however this electric starter system prevents recoil start capability Battery BLANK PAGE consumers fuse 16A fuse starter button SG S lt 2 gt N gt electric starter Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 Helena 582 DCDI To ensure reliable starting a battery of least 16 Ah high discharge battery must be utilized A higher battery amp hour rate would be preferable Cables supplying power to the starter from the battery and to ground should be a minimum 10 mm flexible multi strand cable Power source from rectifier regulator Starter relay
13. 0 Operating the engine at high rpm at low throttle position for example during descent may increase engine and exhaust temperatures and cause critical overheating Always compensate and match rpm with throttle position Maintain your engine in top condition and assume it s going to quit running at any time Leave yourself a way out in the event of unexpected failure Never mix fuel in an enclosed area or where fumes could reach an ignition point Make sure all engine controls are operative that you know ON and OFF positions of throttle and ignition that they are easily accessible and that you can operate them instinctively without hesitation Never refuel if fuel could be spilled on hot engine components Use only safety approved fuel containers and never transport fuel in an unsafe manner Check engine suspension frequently as well as the drive components fuel lines wiring and fuel and air filters Check for fuel contamination air vents etc Protect engine while not in use from any contamination entering fuel or carburetion system but be sure to remove storage protection before starting engine Date INSTALL 447 SCDI 503 DCDI 1999 02 01 PRENDS 582 DCDI Technical documentation The information given in the Installation Manual Operator s Manual rs Maintenance Manual rs Service Informations rs Spare parts list are based on data and experience that are considered applicable for professionals under normal c
14. 2 400313 3 Index A After muffler 10 2 Air and coolant sensor 20 1 Air filter 17 3 Airintake 16 2 17 1 Anti freeze 11 1 Attachment points 9 1 Auxiliary equipment 6 1 B type gearbox 19 1 Battery 18 7 Break in procedure 21 1 Cc C CL type gearbox 19 1 Centre of gravity 7 2 Charging coil 18 1 Components 6 2 Coolant flow 11 1 Cooling 11 1 Cooling circuit 11 3 Cooling liguid temperature 11 1 Cylinder head temperature 20 1 D Denomination of cylinders 6 2 Design 6 1 Documentation technical 1 3 Dual carburetor 17 1 E E EL type gearbox 19 1 Electric system 18 1 Engine components 6 2 Engine installation 8 1 Engine position 9 1 Engine preservation 8 1 Engine serial number 0 2 Engine suspension 9 1 9 2 Engine views 6 2 Exhaust gas temperature 20 2 Exhaust gas temperature EGT 10 2 Exhaust system 10 1 Modification no Date 0 1999 02 01 F Fan cooling 11 1 Fitting positions 9 2 Free air cooling 11 1 Fuel System 15 1 Fuse 18 7 G Gearbox 14 1 l Ignition circuit 18 1 Index of pages 4 1 Installation dimensions 7 1 Instrumentation 20 1 Intake silencer 17 1 L Lighting circuit 18 3 Liquid cooling 11 1 List of amendments 5 1 Lubrication 12 1 Mixture lubrication 12 1 Moments of inertia 7 2 N Numbering of cylinders 6 2 P Permissible fitting positions 9 2 Preface 0 2 P
15. 4222 3789 Fax 04222 6042 E mail flightcenter olis de Contact person Robert Heilig FINLAND NORWAY SWEDEN ESTONIA LATVIA LITHUANIA BOMBARDIER NORTRAC LTD Box 8039 FIN 96101 ROVANIEMI Tel 16 320 8111 FAX 16 320 8200 E mail order bombardier se Contact person Tommi Ristimella FRANCE BELGIUM MONACO LUXEMBURG MOTEUR AERO DISTRIBUTION 11 Blvd Albert 1 98000 MONACO Tel 7 93 30 17 40 Fax 7 93 30 17 60 E mail mad rotax worldnet fr Contact person Patrick Coyette GERMANY for postcodes 0 5 6 7 8 9 gt FRANZ AIRCRAFT ENGINES VERTRIEB GMBH Am Eckfeld 6e D 83543 ROTT AM INN Tel 08039 90350 Fax 08039 9035 35 E mail Franz Aircraft EF t online de Contact person Eduard Franz for postcodes 1 2 3 4 gt FLIGHT CENTER Flugplatz D 27777 GANDERKESEE Tel 04222 3789 Fax 04222 6042 E mail flightcenter olis de Contact person Robert Heilig Date 1999 02 01 Modification no 0 Edition 1999 01 02 GREAT BRITAIN IRELAND ICELAND XSKYDRIVE LTD Burnside Deppers Bridge LEAMINGTON Spa CV 33 OSU Tel 1926 612 188 Fax 1926 613 781 E mail skydrive avnet co uk Contact person Nigel Beale GREECE CYPRUS gt KINISI Ellis 1 str GR 14563 KIFISSIA Tel 01 620 8611 Fax 01 625 0026 Contact person Michael Poulikakos Nick Siganos HUNGARY HALLEY Baktai ut 45 P O Box 425 H 3300 EGER Tel 36 313 830 Fax 36 320 208 ITALY MALTA ICARO MO
16. 582 DCDI overflow hose overflow bottle bottle venting expansion tank cylinder head venting tube excess pressure valve return valve Page 11 5 11 3 7 Water pump performance diagram and cooling system flow resistance graph measured with Standard 582 UL DCDI with double radiator set Page INSTALL 447 SCDI 503 DCDI Date Modification no 400321 400322 12 Lubrication system If the engine is to be used inverted with spark plugs pointing down select a lubricant which features low carbon deposits Oil residues tend to drain to low points i e spark plug cavities If these residues fail to burn during normal operation plug fouling will occur possibly causing pre ignition Producers of suitable lubricants will issue warranty of their products Mixture lubrication Refer to latest version of current Operator s Manual Oil injection for engine lubrication 12 2 1 General advice The oil pump driven by the crankshaft via the pump gear supplies fresh oil for engine lubrication The oil pump is a piston type pump with a metering system Via diffuser jets in the intake cover or intake socket each cylinder is supplied with exactly proportioned quantity of two stroke oil The oil quantity consumed is defined by the engine r p m and the oil pump lever position This lever is actuated via a Bowden cable connected to the throttle cable The oil flows to the pump from an oil tank by gravity A WARNING In case of fr
17. 6 9 Fax 011 455 4499 E mail flying iafrica com Contact person Mike Blyth Page INSTALL 447 SCDI 503 DCDI Pref Date Modification no 5 ASIA CHINA HONG KONG MACAO gt DUEN MU CO Flat A 3 F Kam Meng Fung Industrial Building 6 Hong Man Street Chai Wan HONG KONG Tel 2756 5725 Fax 2754 4774 E mail cali tfhtech com Contact person W C Choi CIS MA VIAGAMMA JSCo P O Box 51 125 057 MOSCOW Tel 095 158 31 23 Fax 095 158 6222 E mail vkrag city line ru Contact person Vladimir Andriytschuk General Director INDIA GREAVES LIMITED 22 A Janpath NEW DELHI 110 001 Tel 11 338 50 61 338 26 53 Dir Fax 11 37 82 553 Tlx 031 62663 E mail greaves GRVSDEL XEEDEL XEEMAIL com Contact person Wg Cdr S N Chhabra Divisional Manager INDONESIA MALAYSIA PHILIPPINES SINGAPORE THAILAND TPA PTE LTD 12 Little Road 02 01 02 Lian Cheong Industrial Building Singapore 536986 Tel 65 289 8022 Fax 65 289 1011 E mail aviation tpa com sg Contact person Chan Nyuk Lin IRAN TASHAR CO LTD 54 Khaled Eslamboli Ave TEHERAN 15117 Tel 21 871 4787 872 3222 Fax 21 872 2260 Contact persons Morthesar Sadjat Jusufi Nejadan ISRAEL CONDOR A VIATION INDUSTRIES LTD P O Box 1903 14 Topaz st Cesaria 38900 Tel 06 6265080 90 50 290189 Fax 06 62650 95 E mail condor netvision net il Contact person David Viernik JAPAN JUA LTD 1793 Fukazawa
18. C at 6000 I min This alternating current can be used directly to feed A C consumers or via a rectifier regulator for loading a battery and feeding direct current consum ers To avoid the voltage to rise above permissible levels a voltage regulator must be used To operate loads requiring direct current e g charging battery a rectifier regulator is required A rectifier regulator part no 866 080 is available As a power supply for lights only This rectifier regulator can be used without a battery In this case the regulated RMS voltage will be between 11 and 12 Volts as long as a minimum load of 1 amp is provided If a battery is used it must be capable of absorbing approx 1 amp minimum continuous charging load even with full charge suggested minimum battery capacity 9 amp h resp 16 amp h with electric starter Regulated voltage is 13 5 to 14 5 volts When using 3 phase rectifier regulator 264 870 no minimum load is required Technical Data and connection of components 18 5 1 Wiring diagram for rectifier regulator 866 080 E Attention To avoid excessive voltage in conjunction with the rectifier regulator 866080 a constant minimum n N SN we oa eo ae eo WA E yel black n Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 Prersronge 582 DCDI wiring diagram in conjunction with battery fuse 16A 12U DC consumer consumer F 866 080 battery 12V 9Ah m
19. DI 503 DCDI Page 0 1999 02 01 FIRISHONSe 582 DCDI 7 1 7 4 Centreof gravity and moments of inertia Power Plant Engine assy with carb and exhaust manifold Engine type Exhaust manifold weight kg Location of C O G mm Moment of inertia around axis kgem 1 x BING 1 x BING 2 x BING Reduction gear assy Location of O G Moment of inertia around axis Type of Weight kg kgcm2 Y2 Y2 22 22 oe AY i n 256 184 An ae el O 317 456 315 E 11 3 125 5 684 554 EL 12 4 144 13 5 682 717 gearbox Page INSTALL 447 SCDI 503 DCDI Pref Date Modification no d00317 400318 8 Preparations for engine installation E ATTENTION The stated directives are measures needing your attention at engine installation to prevent accidents and engine damage 8 1 Engine preservation See latest revision of the current Operator s Manual 447 UL SCDI 503 UL DCDI 582 UL DCDI and 582 UL DCDI mod 99 Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 Preiarenge 582 DCDI 8 1 Protective covering All openings are protected against ingress of contamination and dampness It is recom mended not to remove these plugs until installation of the specific feed line NOTE Ifthe engine will be sent to the manufacturer or distributor reuse transport eguipment and replug openings List of protective covering IS IS IS IS Carburetor In St ane ata ina alano 1 each cover fresh oil PUMP
20. N 0 0 1 1 1 1 2 2 3 3 4 4 5 5 6 6 6 6 7 7 8 8 9 9 A oO 1 1 NM Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 PIRITENOE 582 DCDI 4 1 Page INSTALL 447 SCDI 503 DCDI Date Modification no i Pref d00314 d00315 5 List of amendments Currt Chap no ter 0 0 22 Pages Date of approval by insertion modifikation approval authority 99 02 01 not reguired 99 02 01 Marks Signature Modification no 0 Date 1999 02 01 INSTALL 447 SCDI 503 DCDI Preference 582 DCDI Page 5 1 Currt Chap Pages Date of Marks no ter of approvalby insertion Signature modifikation approval authority Page INSTALL 447 SCDI 503 DCDI Date Modification no 400315 400316 6 Describtion of design 6 1 6 2 Designation of type Refer to latest version of current Operator s Manual 447 UL SCDI 503 UL DCDI 582 UL 582 UL DCDI mod 99 Standard engine design Refer to latest version of current Operator s Manual 447 UL SCDI 503 UL DCDI 582 UL 582 UL DCDI mod 99 Auxiliary equipment E ATTENTION Any equipment not included as part of the standard engine version and thus not a fix component of the engine is not in the scope of supply Components especially developed and tested for this engine are readily available at ROTAX A WARNING This equipment has not been tested for safety and durability to the standards of aviatio
21. Protective covering Engine suspension and position 9 1 Definition of attachment points 9 1 1 503 UL DCDI 582 UL DCDI and 582 UL DCDI mod 99 9 1 2 447 UL SCDI 9 2 Permissible fitting positions 9 3 General directives for engine suspension Exhaust system 10 1 Installation of the exhaust systemi oooooooo mnta 10 1 102 After muffler SY SICIN urlare 10 2 10 3 Exhaust gas temperature EGT i 10 2 Cooling system 11 1 Fan cooling ROTAX 447 UL SCDI ROTAX 503 UL DCDI 11 2 Free air cooling ROTAX 447 UL SCDI ROTAX 503 UL DCDI 11 3 Liquid cooling ROTAX 582 UL DCDI and 582 UL DCDI mod 99 11 3 1 Coolant flow 11 3 2 Cooling liquid temperature 11 3 3 Anti freeze additives 11 3 4 Cooling system 11 3 5 Cooling circuit 11 3 6 Cooling circuit 11 3 7 Water pump performance diagram and cooling system flow resistance 11 6 Lubrication system 12 1 Mixture lubrication 12 2 Oil injection for engine lubrication 12 21 General Advices miro Dazio laid ee Ati tree a raso 12 1 12 2 2 Technical data and configuration oooooWoWooWooWooW oom 12 1 12 2 3 Installation Installation at ROTAX 582 UL DCDI and 582 UL DCDI mod 99 Installation at ROTAX 503 UL DCDI Modification no Date INSTALL 447 SCDI 503 DCDI Page ce 1999 02 01 Pee 582 DCDI 2 1 13 Rotary valve and water pump drive oooooo oom 13 1 14 15 16 17 18 Page INSTALL 447 SCDI 503 DCDI Pref Dat
22. ROTAX AIRCRAFT ENGINES 7 Installation Manual for engine types ROTAX 447 UL SCDI ROTAX 503 UL DCDI ROTAX 582 UL DCDI ROTAX 582 UL DCDI mod 99 A WARNING Before starting with the engine installation please read the Installation Manual completely as it contains important safety relevant information The Manual must remain with the engine aircraft in case of sale Edition 0 of 1999 02 01 These technical data and the information contained therein are property of ROTAX GmbH and must not be reproduced neither in entirety nor partially and passed on to third parties without previous consent in writing by ROTAX GmbH This text must be written on every complete or partial reproduction Copyright ROTAX GmbH Approval of translation to best knowledge and judgement in any case the original text in German language is authoritative part no 899 482 0 Preface Congratulation on your decision to use a ROTAX aircraft engine Before starting with the engine installation read this Installation Manual carefully The Manual will provide you with basic information on correct engine installation a requirement for safe engine operation If any passages of the Manual are not completely understood or in case of questions please contact an authorized Distribution or Service Partner for ROTAX engines 0 1 Remarks This Installation Manual is to acquaint the owner user of this aircraft engine wi
23. TENTION Use only suitable oil Oil capacity on the new gearbox gearbox type osition ofinstallation B C CL E EL 3 see fig 27 E ATTENTION For gearbox installation refer to SI 9 UL 94 and SI 10 UL 94 The gear box can be installed in two basic positions SZ upright with prop shaft towards cylinder SS inverted with prop shaft towards engine base According to position of gear box fit magnetic plug and sealing ring 1 tightening torque 24 Nm 212 in Ib and vent screw with sealing ring 2 tightening torque 6 Nm 53 in Ib Generally replenish oil until oil emerges at the respective lower oil level plug 3 E ATTENTION The two large ventilation bores 6 on both sides of gear housing have to remain always open to warrant dissipation of heat Wire secure vent screw oil level plugs and drain plug D With the installation of an EL gear box the tapped holes for radiator support are transferred from gear box housing to adapter housing Modification no Date INSTALL 447 SCDI 503 DCDI Page De 1999 02 01 ai 582 DCDI E ATTENTION At trial run check tightness without fail The propeller flange 5 is furnished with 6 tappings M6 and 6 holes each of 6 5 mm and 8 2 mm dia but screws are not in the supply scope E ATTENTION With use of ROTAX gear box type C CL or E EL the moment of inertia of the propeller must not be in excess of 6000 kgcm B type gearbox 3000 kgcm Enguire
24. TORI S R L Via Emilia 61 B I 27050 REDAVALLE P V Tel 0385 74 591 Fax 0385 74 592 E mail icaro energy it Contact person Corrado Gavazzoni POLAND gt FASTON LTD ul Szeroka 2 PL 05 860 PLOCHOCIN Tel 22 722 5858 Fax 22 840 0196 Contact person Wojtek Madry Manager ROMANIA S C BERIMPEX S R L Str Dr Taranu Grigore No 8 Ap 2 Sector 5 R 76241 BUCHAREST Tel 1 410 90 03 Fax 1 410 9020 E mail c_berar sunu rnc ro Contact person Dr Christian Berar SLOVAKIA gt TEVESO S R O Skroupova 441 CS 50002 HRADEC KRALOVE Tel 049 56 30 127 Fax 049 56 30 226 E mail teveso mbox vol cz Contact persons Ing Samal Ing Halek SLOVENIA SPIPISTREL d o o Strancarjeva UI 11 5270 AJDOVSCINA Tel 065 63 873 Fax 065 61 263 E mail pipistrel eunet si Contact person Ivo Boscarol SPAIN PORTUGAL AVIASPORT S A Almazara 11 E 28760 TRES CANTOS MADRID Tel 91 803 77 11 Fax 91 803 55 22 E mail aviaspor bcsnetwork es Contact person Mariano de Castro INSTALL 447 SCDI 503 DCDI Page Preference 582 DCDI SWITZERLAND LIECHTENSTEIN FRANZ AIRCRAFT ENGINES VERTRIEB GMBH Am Eckfeld 6e D 83543 Rott am Inn GERMANY Tel 08039 90350 Fax 08039 9035 35 E mail Franz Aircraft EF t online de Contact person Eduard Franz TURKEY KLASIK HALI A S Klasik Hali is Merkezi Bozkurt Caddesi No 25 A 35230 Kapilar IZMIR TURKEY Tel 232 441 4911 Fax 232 445
25. d 99 has a two way cooling system see latest revision of the current operators manual 447 UL SCDI 503 UL DCDI 582 UL DCDI 11 3 1 Coolant flow It should be in the range of 60 70 litres min at engine r p m 6500 I min See ill 18 11 3 2 Cooling liquid temperature The radiator must be of sufficient size and the airstream of sufficient intensity to maintain the coolant temperature below the maximum permitted value of 80 C 175 F under the most severe conditions i e at full load operation at take off The average coolant temperature must be 60 80 C 140 175 F In case of a pusher propeller installation take particular care that coolant radiator has sufficient air flow The max temperature difference of the coolant between radiator entry and exit must not exceed 6 C 11 F the average difference must be around 3 and 5 C 5 and 9 F If temperature limits are exceeded or coolant flow rate is below specified values excessive flow resistance vapour is produced in the cylinder head causing cooling break down and engine damage Anti freeze additives NOTE Anti freeze additives reduce the cooling effect This should be taken into consideration at choice and installation of the radiator Modification no Date 0 1999 02 01 11 3 4 Cooling system To avoid coolant pump cavitation the cooling system must be under pressure This is achieved by using a pressure cap with a release pressure
26. e Modification no 13 1 Oil circuit for engine installation with spark plugs Up 13 1 13 2 Oil circuit for engine installation with spark plugs down Gearbox installation and gearbox lubrication Fuel System Carburetor 16 1 Carburetor air intake Air intake system 17 1 Intake silencer 17 2 Air filter Electric system 18 1 General enak ABS BENER 18 1 Function of the ignition unit eh aa Be an on onde 18 1 Wiring idiagram Lula eni CaA tameng 18 2 NG ECU ee dre Meee rali io o a ei i SL 18 3 Technical Data and connection of components 18 5 1 Wiring diagram for rectifier regulator 866 080 18 5 2 Wiring diagram for rectifier regulator 264 870 18 5 3 Electronic revolution counter oooooo WoWoooWoW Women 18 6 Connection to dual ignition systemi Woo oWoWo WcoWoW Woo 18 6 18 5 4 Electric starter Starter relay 992 819 Battery cetna e be centel dicees iaia le ill 18 7 POWEL SOUFCEt iicii ian lira 18 7 Propeller drive 19 1 Technical data en Se rallo tanto 19 1 19 1 1 B type gearbox 19 1 2 C CL and E EL type gearbox Connections for instrumentation 20 1 Sensor for cylinder head temperature spark plug seat temperature Air and coolant sensor Exhaust gas temperature sensor Installation plan for the sensors at 582 UL DCDI and 582 UL DCDI mod 99 Installation plan for the sensors at 447 UL SCDI 503 UL DCDI Break in procedure ROTAX authorized Distributors d0031
27. el If the fuel tank is considerably lower than the engine an electric pump should be used This pump is to be connected in parallel as in case of series connection the fuel pressure would be excessive The electric pump must produce a pressure of minimum 0 2 bar 3 psi and together with the pneumatic pump max 0 5 bar 7 psi resp max 0 4 bar 6 psi in case of a diaphragm carburetor and must allow free flow through even when switched off A suitable fuel filter of 0 15 mm mesh size must be fitted between pump and carburetor Do not use paper filters The fuel tank must have a drain cock for condensed water A screen of 0 3 mm mesh size should be fitted to the fuel line in the tank By no means the normal fuel flow should be restricted The fuel lines and impulse line must be of a type to comply with national regulations The minimum diameter is 5 mm 0 2 in If the fuel tank is placed higher than the carburetor the tank connection must have a fuel cock with filter to shut off the fuel supply when the engine is not running Modification no Date INSTALL 447 SCDI 503 DCDI Page DE 1999 02 01 PRIETENOS 582 DCDI A WARNING The carburetor needle valve is not sufficient tight to seal for a prolonged period of time and during transport National regulations may require a fuel cock to be fitted even if the fuel tank is below the carburetor The carburetor needle valve is not to be used as a fuel cock Page INSTALL 447
28. ength of inlet tube between exhaust flange and muffler must be maintained without fail see ill 7 For necessary modifications ask for manufacturer s approval in writing Check engine performance with serial exhaust system prior to any modifica tion Engine muffler Auspufftopf medium length of tube mittlere Rohrl nge For engine type 582 UL DCDI 40 with reduced performance and noise emission an exhaust is offered that consists of items to be fitted by the aircraft manufacturer to suit the aircraft Consult the respective parts list for parts needed NOTE Pay special attention to maintain medium length of tubes When using bent tubes refer to length of centre line Engine type medium length of tube ROTAX 582 40 kW 660 mm 26 Check exhaust system prior to every flight for tightness physical damage or changes in sound pattern Especially inspect springs and hooks 10 1 Installation of the exhaust system The muffler must be supported on vibration damping blocks All ball joints must be greased regularly with heat resistant lubricant e g LOCTITE Anti Seize 297 431 to avoid gripping or seizing of joints and consequent breaking of ex haust components Springs used on exhaust system must be secured againstloss andvibration see Service Information 11 UL 87 E page 5 Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 ja 582 DCDI E ATTENTION Vibration due to improper suspensio
29. eni esa Rae 1 plug vent screw gearbox Hb trad 1 cap EXMAUST EEE E EE EE EEE E E E E adhesive tape A WARNING Protective covering to be utilized for transport and at engine installation Page INSTALL 447 SCDI 503 DCDI Preference Date Modification no 8 2 582 DCDI 1999 02 01 0 only All shipping and preservation devices must be removed prior to engine operation 400318 d00319 9 Engine suspension and position BM ATTENTION At installation of engine be aware of engine weight and assure careful handling The engine suspension is determined essentially by the aircraft design Four attachment points are provided on the engine A WARNING All four attachments points must be utilized 9 1 Definition of attachment points 9 1 1 503 UL DCDI 582 UL DCDI and 582 UL DCDI mod 99 9 1 2 447 UL SCDI A WARNING The engine suspension must be designed by the aircraft or fuselage builder such that it will carry safely the maximum occurring operational loads without exceeding the max allowable forces and moments on the engine attachment points A WARNING Tighten all engine suspension screws as specified by the aircraft builder Do not overtighten engine hardware Follow recommended manufactur ers torques Modification no Date INSTALL 447 SCDI 503 DCDI Page De
30. esh oil lubrication the carburetors are supplied with pure gasoline no oil gasoline mixture Technical data and configuration Oil Super two stroke oil The oil pump assy features an oil return nipple and two oil exit nipples with integrated check valve Installation 1 Oil tank capacity The oil tank size should be more than 5 of the fuel tank Capacity 2 The oil tank bottom outlet must not be below the oil pump inlet nipple even at the greatest possible inclination of the aircraft i e dimension HS must be greater than zero see fig no 20 Use a firm oil resistant suction hose which cannot be squeezed Secure it with clamps at the connections Install an adequate oil filter between oil tank and oil pump Install a Bowden cable to actuate the pump lever simultaneously with the carburetors E ATTENTION At a pump cable breakage or failure On the ROTAX 582 engine oil pump is set to minimum discharge On the ROTAX 503 engine the oil pump is set to maximum discharge Adjustment of oil injection pump alignment marks At throttle lever idle position the 2 marks must align see fig no 19 Vent the suction hose before engine start by opening the vent plug see fig no 19 pos 9 until all air is vented from that line Close vent plug carefully It is recommended to fill the first tank of fuel with a gasoline oil mixture at a mixing ratio of 100 1 This is for safety until the complete system is properly filled w
31. for moment of inertia and have it confirmed by the manufacturer of propeller in writing Page INSTALL 447 SCDI 503 DCDI Date Modification no d00324 d00325 15 Fuel System Schematic arrangement 1 carburetor version Schematic arrangement 2 carburetor version 4 02941 Fuel contamination is a major cause of engine failure The best place to avoid contamina tion is at the source Once fuel is in your container a very harzardous potential exists Use a clean safety approved storage container Filter all fuel entering and leaving this container Do not over fill container allow for expansion A WARNING Gasoline is flammable and explosive under certain conditions Always perform fueling procedures in a well ventilated area Do not smoke or allow open flames or sparks in the vicinity Never add fuel while engine is running The carburetor s is are supplied with fuel by the fuel pump provided with the engine The pump is actuated pneumatically via an impulse line leading from the nipple on the crankcase to the fuel pump This line should not be longer than 500 mm 20 in and must be of stiff and fuel resistant material The fuel pump should be installed in a cool place not on the engine itself with the small drain hole near the impulse connection towards the bottom This hole drains oil conden sate from the pump diaphragm chamber If possible the pump should be located below the fuel tank lev
32. fuselage to the ground Run the engine according to the following graph 10 15 20 30 1 2 3 sec sec sec sec minmin min 10 20 30 40 50 60 time min On a liquid cooled engine it is possible that the cooling air flow speed on ground is not enough to provide adeguate cooling for extended periods of time Therefore it is necessary to observe carefully the temperature of the cooling liguid during break in procedure to avoid overheating Before exceeding the maximum allowed cooling tempera ture on cylinder head outlet of 80 C 180 F interrupt the run in and cool down the engine at idle for approximately one minute and continue the run from where it was interrupted On a free air engine it is possible that the cooling air flow on ground is not enough to provide the necessary cooling for extended periods of time Therefore it is necessary to observe carefully the cylinder head temperature CHT during the break in procedure and avoid overheating Before exceeding the maximum allowed CHT of 250 SC 480 F interrupt the run and cool down the engine at idle for approximately one minute and continue the run from where it was interrupted Modification no Date 0 1999 02 01 Be sure to use a safe run up area to anchor aircraft at those points approved by the airframe manufacturer and to have someone present who is able to shut off the engine instantly and to prevent unauthorized people entering the danger area
33. ifferent jetting Contact your dealer Modification no Date INSTALL 447 SCDI 503 DCDI Page 20 1999 02 01 ena 582 DCDI In no case should jet changes be made by unqualified persons or those who do not have ROTAX technical information to do so 16 1 Carburetor air intake The carburetor air intake must be protected against the ingestion of water dirt and foreign material Use a Rotax approved air filter Avoid paper foam and synthetic material types that absorb water Equal air pressure conditions must prevail in the vicinity of the carburetor air intake and the carburetor float chamber vent pipes i e the pressure must not be influenced by the propeller air stream Z Ausgleichbohrungen f r Vergaser Entl ftung compensation bores for carburetor venting fig 31 If necessary the carburetor intake should be shielded against effects of the slipstream by a sheetmetal shield or air intake box and the carburetor vent pipes should be routed to a calm air zone or connected to a vent chamber see sketch below Engines supplied with an intake silencer must not be operated without it unless the carburetor calibration is altered Consult the engine supplier or manufac turer in writing for details The correct carburetor calibration is also described in the parts list If the aircraft is to be operated in climatic conditions where carburetor icing is likely to occur a heating system must be fitted N
34. in IHHHHHH yel black brown battery 12V 16Ah min E 2 c a Page INSTALL 447 SCDI 503 DCDI Date Modification no d00328 d00328 Modification no 0 Date 1999 02 01 yel black brown yel black brown ground ballast load of 1 amp is required example lamp 12 V15W wiring diagram in a circuit without battery not connected 264 870 Capacitor min 2000 uF 25U 12V DC consumer EO wiring diagram in conjunction with a battery not connected 264 870 fuse 16A t w gt 5 S g N battery 12U 9 Ah min wiring diagram for electric starter yel not connected yel black brown fuse 16A starter rela abb 12V DC consumer ktarter button electric starter ae INSTALL 447 SCDI 503 DCDI Page Preference 582 DCDI Wiring diagram for rectifier regulator 264 870 not limited to minimum of 1 Ampere consumption Electronic revolution counter The revolution counter part no 966 404 has been specifically designed to be connected to the 12 pole flywheel generator used on the Ducati CDI Systems The revolution counter measures the frequency of the pulses pro vided by one of the transducers supply winding where itis connected It does not require any external power supply It is connected by two wires without polarity The indicating range comes up to 8000 r p m The weight is 235 gram Connection
35. is foreseen for connection of a revolution counter Function of the ignition unit Two charging coils fitted on the generator stator and independant from each other each feed one ignition circuit The energy supplied is stored in the ignition capacitor At the moment of ignition the external trigger coils supply an impulse to the control circuits and the ignition condensors are discharged via the primary winding of the ignition coil The secondary winding supplies the high voltage for the ignition spark E ATTENTION When flying both ignition systems must be switched ON Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 PTEISTENGE 582 DCDI 18 3 Wiring diagram NOTE When replacing wiring on the ignition system connections must be as per wiring diagram below Electronic box charging cable green 10 rev counter cable gray eight lighting coils charging cable white 11 mass cable brown four charging coils shorting cables black yellow 12 ignition cables pickup lighting cables yellow 13 spark plug connectors trigger cable red yellow black 14 spark plugs 15 shrink tube After installing all the connections must be protected with the supplied shrink tubing NOTE Wiring diagram shows DCDI ignition mag 913 Page INSTALL 447 SCDI 503 DCDI Date Modification no d00328 d00328 Lighting circuit In the stator 8 lighting coils are incorporated The output is 170W A
36. ith oil NOTE This oil injection will not affect or replace the rotary valve gear lubrication nor the reduction gearbox lubrication Modification no Date INSTALL 447 SCDI 503 DCDI Page re 1999 02 01 BA 582 DCDI Installation at ROTAX 582 UL DCDI and 582 UL DCDI mod 99 Engine Oiltank Suction hose Oil pump Discharge line Checkvalve Oil intake port Adjuster nuts Venting NOTE Oil pump aligning marks for the 503 and 582 are identical LC Page INSTALL 447 SCDI 503 DCDI Date Modification no 400322 d00322 Installation at ROTAX 503 UL DCDI 02783 4 oil tank oil filter oil pump pressure hose suction hose 9 check valve NOTE The dimension Hs must be positive also at descent or climb Modification no Date INSTALL 447 SCDI 503 DCDI Page sa 1999 02 01 Praroronca 582 DCDI su Page INSTALL 447 SCDI 503 DCDI Date Modification no i i Pref d00322 d00323 13 Rotary valve and water pump drive In the center of the crankcase a 90 transfers drive in oil bath is located Use 2 stroke motor oil forthe rotary valve drive same as used for 2 stroke fuel mixture Oil quantity on a new installation approx 310 cc An oil hose leads from the oil tank to the bottom side of the crankcase and a return line from top of the gear leads back
37. n The user assumes all risks possibly arising by utilizing auxiliary eguipment Exhaust system Intake filter Coolant radiator Flydat Electric rev counter ES Li Li E ES ES Hour meter Modification no Date INSTALL 447 SCDI 503 DCDI Page 20 1999 02 01 PRENDS 582 DCDI 6 1 6 3 Engine components engine views numbering of cylinders See fig 1 2 and 3 PTO power take off side MS magneto side A points of attachment for engine transport Cyl 1 cylinder 1 Cyl 2 cylinder 2 propeller flange exhaust socket propeller gear box electric starter intake manifold fresh oil lubrication pump carburetor electronic modules of ignition coolant pump QUI 10 ignition housing 6 3 1 447 UL SCDI Cyl 1 Cyl 2 Page INSTALL 447 SCDI 503 DCDI Date Modification no 400316 d00316 6 3 2 Modification no 0 503 UL DCDI Date 1999 02 01 INSTALL 447 SCDI 503 DCDI Preference 582 DCDI 6 3 3 582 UL DCDI and 582 UL DCDI mod 99 Cyl 1 Cyl 2 400316 Page INSTALL 447 SCDI 503 DCDI Date Modification no d00317 7 Technicaldata For technical data and limits of operation refer to the latest revision of the current Operator s Manual 447 UL SCDI 503 UL DCDI 582 UL DCDI Model 99 NOTE Connecting dimensions
38. n is by far the most common reason for damage to the exhaust system A WARNING Don t use any sharp tool for removal of the tension spring for reason of possible damage of spring wire A hook bent out of a 5 mm bar is the most suitable tool NOTE Ensure that exhaust system is properly supported and maintained 10 2 After muffler system For noise reduction at the tail pipe an after muffler can be fitted This after muffler will only slightly affect engine performance and can be clamped to tail pipe of muffler 2 Atthe installation of the after muffler 1 in final position drill the two i 5 7 mm holes in the bend and muffler end pipe for securing pin 5 The outer situated holes 2 have been already machined on the serial production line Remove accu mulated chips from the exhaust system To ensure lasting fixed position of the after muffler during engine operation the connections of muffler 3 to bend 4 and after muffler 1 are to be secured against twisting by the securing pin 5 Fit clamp 6 in the specific position that the Allen screw 7 prevents the securing pin 5 from dropping out 02797 fig 10 10 10 3 Exhaust gas temperature EGT E Exhaust gas temperature will give the most rapid response in the event of improper mixture pre ignition or detonation Ideally the exhaust temperature should be measured about 100 mm 4 in from the piston with separate sensors for each cylinder
39. n which an engine failure will not compromise safety User assumes all risk of use and acknowledges by his use that he knows this engine is subject to sudden stoppage Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 HN 582 DCDI It should be clearly understood that the choice selection and use of this particular engine on any aircraft is at the sole discretion and responsibility of the aircraft manufacturer assembler and owner user Due to the varying designs equipment and types of aircraft ROTAX makes no warranty or representation on the suitability of its engine s use on any particular aircraft Further ROTAX makes no warranty or representation of this engine s suitability with any other part component or system which may be selected by the aircraft manufacturer assembler or user for aircraft application You should be aware that any engine may seize or stall at any time This could lead to a crash landing and possible severe injury or death For this reason we recommend strict compliance to the maintenance operation and any additional information which may be given to you by your dealer Select and use proper aircraft instrumentation This instrumentation is not included with the ROTAX engine package Only approved instrumentation can be installed Unless in a run up area never run the engine with the propeller turning while on the ground Do not operate engine if bystanders are close To prevent una
40. o modifications should be made to the carburetor and air intake system without consulting the engine manufacturer in writing Page INSTALL 447 SCDI 503 DCDI Date Modification no d00326 d00327 17 Air intake system 17 1 Intake silencer ROTAX offers intake silencers as an option Intake silencer for single and dual carbs are available from ROTAX MATTENTION At employment of an intake silencer a different carburetor jetting will be necessary DUAL CARBURETOR VERSION Modification no 0 SINGLE CARBURETOR VERSION E ATTENTION Weight of silencer must not influence position of carburetor If need be support silencer accordingly Date INSTALL 447 SCDI 503 DCDI Page 1999 02 01 Ble teng 582 DCDI Fit silencer parallel to crankshaft axis with screw on filter 2 not pointing towards propeller The double intake silencer is available with either left or right hand side inlet opening to suit respective position With the silencer on a single carburetor engine pay special attention when fitting as with an inclined silencer the intake situation is unsymmetrical thus badly influencing mixture distribution possibly leaning down one cylinder leading to a rise of combustion tempera ture and finally to piston seizure Page INSTALL 447 SCDI 503 DCDI Date Modification no d00327 d00327 Fitting position 1 Fitting position 2 Fitting position 3 Fitting position 4 Position 1 wo
41. of approx 0 9 bar 13 psi The coolant hoses must be installed in such a way that air and steam bubbles can escape from any point of the system towards the expansion chamber The overflow hose 10 coming from the radiator neck is to be led into a vented overflow bottle 11 It should be half filled with coolant The overflow hose must reach into the coolant or enter at the bottom of the overflow container The overflow bottle should be fitted not lower than 250 mm 10 inch below the radiator cap When the system cools down the originally displaced liquid is sucked back through the breather valve in the radiator cap NOTE If the coolant is not sucked back the cooling system is faulty and must be checked Page INSTALL 447 SCDI 503 DCDI Pref Date Modification no d00321 d00321 11 3 5 Cooling circuit for engine installation with spark plugs up Q na i Mq a UUO BOMBARDIER Ar i gr i NOTE illustration shows 582 UL DCDI crankcase 10 overflow hose cylinder 11 overflow bottle cylinder head 12 bottle venting water pump 13 expansion tank radiator 14 cylinder head venting tube hose from radiator to the water pump 15 excess pressure valve hose from cylinderhead to the radiator 16 return valve ON Oak ON radiator cap with excess pressure valve and
42. onditions The fast technical progress and variations of installation might render present laws and regulations inapplicable or inadeguate The illustrations in this Manual are mere sketches and show atypical arrangement They might not represent the actual part in all its details but depict parts of the same or similar function Therefore deduction of dimensions or other details from illustrations is not permitted All necessary documentation is available from the ROTAX Distribution and Service Centers see Chapter 14 NOTE The Illustrations in this Operator s Manual are stored in a graphic data file and are provided with a consecutive irrelevant number This number e g 00277 is of no significance for the content Page INSTALL 447 SCDI 503 DCDI Preference Date Modification no 1 4 582 DCDI 1999 02 01 0 d00311 400312 2 Table of contents Preface 0 1 Remarks 0 2 Engine serial number Repeating symbols Safety information Technical documentation Table of contents Index of pages List of amendments Describtion of design 6 1 Designation of type 6 2 Standard engine design 6 3 Engine components engine views numbering of cylinders 6 3 1 447 UL SCDI 6 3 2 503 UL DCDI 6 3 3 582 UL DCDI and 582 UL DCDI mod 99 Technical data 7 3 Weights 7 2 Installation dimensions all dimensions in mm 7 4 Centre of gravity and moments of inertia Preparations for engine installation 8 1 Engine preservation 8 2
43. reparations for engine installation 8 1 Preservation 8 1 Preservation engine 8 1 Propeller drive 19 1 Protective covering 8 1 protective covering 8 1 R Rectifier regulator 18 3 Remarks 0 2 Revolution counter 18 6 Rotary valve 13 1 ROTAX authorized Distributors 22 1 INSTALL 447 SCDI 503 DCDI Page Preference 582 DCDI 3 4 S Safety 1 1 Safety information 1 1 Single carburetor 17 1 Starter relay 18 7 Symbols 1 1 T Table of contents 2 1 Technical data 7 1 Technical documentation 1 3 Triggers 18 1 V Views 6 2 W Water pump 13 1 Weights 7 1 Wiring diagram 18 2 Page INSTALL 447 SCDI 503 DCDI Date Modification no 400313 d00314 4 Index of pages Chap Page Date Chap Page Date ter ter 0 99 020 99 020 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 so 30020 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 99 02 01 I Ma N NH RON NH NH N N FWN
44. th basic installation instructions and safety information For more detailed information on operation maintenance safety or flight consult the documentation provided by the aircraft builder and dealer For further information on maintenance and spare part service contact the nearest ROTAX distributor see chapter of Service Partners Engine serial number On all enquiries or spare parts orders always indicate the engine serial number as the manufacturer makes modifications to the engine for further development The engine serial number is on the top of the crankcase magneto side or ignition cover Page INSTALL 447 SCDI 503 DCDI Date Modification no d00287 d00311 1 Safety Although the mere reading of such an instruction does not eliminate a hazard the understanding and application of the information will promote correct use The information and components system descriptions contained in this Maintenance Manual are correct at the time of publication ROTAX however maintains a policy of continuous improve ment of its products without imposing upon itself any obligation to install them on its products previously manufactured ROTAX reserves the right at any time to discontinue or change specifications designs features models or equipment without incurring obligation The fig s in this Maintenance Manual show the typical construction They may not represent in full detail or the exact shape of the parts which
45. to the tank for venting see illustration Before every operation check the oil level approx mid height of the oil tank Check oil tubes for security and condition of connections In case of notable oil consumption more than 1 c c hour look for the leak and check the oil seals inside the crankshaft as necessary 13 1 Oil circuit for engine installation with spark plugs up crankcase cylinder cylinder head inlet tube 9 o return line sas SITI AUT 4 BOMBARDIER air vent 1 2 3 4 5 6 7 8 Modification no Date INSTALL 447 SCDI 503 DCDI Page 0 1999 02 01 Men 582 DCDI 13 2 Oil circuit for engine installation with spark plugs down In this arrangement the oil system for rotary valve drive and water pump drive must be modified by the aircraft manufacturer as per the following illustration The oil tank installation should not be below the oil inlet tube 4 MATTENTION For inverted installation the oil tank must be removed from the bracket and installed in a suitable location above the engine Vent system by removing plug 8 when filling the oil tank 6 air vent crankcase cylinder 6 cylinder head inlet tube return line oil tank spark plug vent plug DISGEEONI GZI0eVENOE AD CONDONO CARRI L 3 D a Page INSTALL 447 SCDI 503 DCDI Date Modification no d00323 d00324 14 Gearbox installation and gearbox lubrication E AT
46. uld be best Positions 3 and 4 are also acceptable but avoid unfavourable position 2 A WARNING Screw on filter and silencer must be wire secured against slackening and loss on the assigned lug 3 Modification no Date INSTALL 447 SCDI 503 DCDI Page sa 1999 02 01 Praroronca 582 DCDI Air filter Only air filters approved by ROTAX are permitted for use The air filters specified by ROTAX are special K amp N air filters Dry filter elements of paper are not allowed for humid operating conditions as they absorb water thus reducing the air intake leading to enrichment of the fuel air mixture Two kinds of filter design are applied on these engines Single air filter Double air filter With 2 carburetors on engine either 2 single air filters or 1 double air filter may be fitted E WARNING Always secure air filters against loss Page INSTALL 447 SCDI 503 DCDI Date Modification no d00327 400328 18 Electric system 18 1 General The engine is equipped with a breakerless 12V 170W DUCATI capacitor discharge dual ignition system It consists of a flywheel magneto generator 2 double ignition coils complete with integrated control circuit and 2 external trigger coils pick up The 12 pole flywheel generator is an outer rotor type with 12 integrated permanent magnets The stator is equipped with 12 coils 8 ofthem are used for feeding auxiliary equipment and 4 are used for the dual ignition The grey cable
47. uthorized use never leave the aircraft unattended with the engine running Keep an engine log and respect engine and aircraft maintenance schedules Keep the engine in top operating condition at all times Do not operate any aircraft which is not properly maintained or has engine operating irregularities which have not been corrected Keep an engine log and enter any unusual engine behaviour Do not fly unless you have corrected a given problem and recorded the correction in the log Since special tools and equipment may be required engine servicing should only be performed by an authorized ROTAX engine dealer or a qualified trained mechanic approved by the local airworthiness authority To eliminate possible injury or damage ensure any loose equipment or tools are properly secured before starting the engine Never leave your aircraft or other vehicle unattended while the engine is running If operated by someone else you could be sued even if the use was unauthorized by you When in storage protect the engine and fuel system from contamination and exposure Never operate the engine and gearbox without sufficient quantities of lubricating oil Periodically verify level of coolant at 582 UL DCDI and 582 UL DCDI mod 99 Never exceed maximum rated rpm and allow the engine to cool at idle for several minutes before turning off the engine Page INSTALL 447 SCDI 503 DCDI Pref Date Modification no d00311 d00311 Modification no
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