Installation Manual 447-503-582 Rev.0 05/1999
Contents
1. ground Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 18 3 Initial issue May 01 99 AIRCRAFT ENGINES INSTALLATION MANUAL wiring diagram in conjunction with battery fuse 16A 12U DC consumer consumer s t I E er D green 866 080 2 lt EES 2 IT white To Tl yel black green 5 x brown 02824 ground L wiring diagram for electric starter Ba a AA en a pE 23 green gt d white white a green yel black brown ground a 3 02823 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 18 4 Initial issue May 01 99 d00328 AIRCRAFT ENGINES INSTALLATION MANUAL 18 5 2 Wiring diagram for rectifier regulato not limited to minimum of 1 Ampere co not connected 264 870 Capacitor min 2000 uF 25 U yel black brown r 264 870 nsumption wiring diagram in a circuit without battery 12U DC consumer HRES fig 42 L 02828 wiring diagram in conjunction with a battery o gt a E E 8 g 264 870 fuse 16A 5 O green A AT SL EN S en KI E a oc a white i ct T Ee 2 T green yel black 5 COA S 2 brown T ground fig 43 wiring diagram for 02827 user C N electric starter Se Fa PE S gg o s z 5 5 a z E gr2. AIRCRAFT ENGINES INSTALLATION MANUAL Lighting circuit In the stator 8 lighting coils are incorporated The output is 170W A 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 consumers 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 arectifier 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 8 Wiring diagram for rectifier regulator 866 080 E Attention To avoid excessive voltage in conjunction with the rectifier regulator 866080 a con stant minimum ballast load of 1 amp is re quired example lamp 12 V 15 W 02825 Capacitor min 2000 uF 25 U yel black green D x brown u
3. 1 crankcase 2 cylinder 3 cylinder head 4 inlet tube 5 return line 6 oil tank 7 spark plug 8 vent plug 02810 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 13 2 Initial issue May 01 99 d00323 d00324 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 14 Gearbox installation and gearbox lubrication P m ATTENTION Use only suitable oil Oil capacity on the new gearbox position ofinstallation B EL JEE see fig 27 anaes MH ATTENTION For gearbox installation refer to SI9UL94andSI10UL94 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 lb 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 14 1 Initial issue May 01 99 ROTAX AIRCR
4. 2 P Permissible fitting positions 9 2 Preface 0 2 Preparations 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 3 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 3 2 Initial issue May 01 99 400313 ROTAX AIRCRAFT ENGINES 400314 INSTALLATION MANUAL 4 Index of pages 00522 Chap Page Date ae Page Date ter 0 0 1 99 05 01 13 1 99 05 01 0 2 99 05 01 19 2 99 05 01 1 da 990501 14 14 1 99 05 01 tee 99 05 01 14 2 99 05 01 Mie Se 15 15 1 99 05 01 ie SE 15 2 99 05 01 S E SE 16 16 1 99 05 01 EE SE 16 2 99 05 01 S 31 SE 17 17 1 99 05 01 ge en 17 2 99 05 01 4 4 1 99 05 01 17 3 99 05 01 4 2 99 05 01 17 4 99 05 01 5 5 1 99 0501 18 18 1 99 05 01 5 2 99 05 01 18 2 99 05 01 6 6 1 99 05 01 18 3 99 05 01 6 3 990501 18 5 990501 god 990501 18 6 990
5. 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 11 1 Initial issue May 01 99 11 3 3 11 3 4 AIRCRAFT ENGINES INSTALLATION MANUAL Anti freeze additives NOTE Anti freeze additives reduce the cooling effect This should be taken into consideration at choice and instal lation of the radiator 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 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 NOTE If at 582 UL DCDI model 99 a straight water outlet socket is used vent the cooling system well check after a short operating period at a temperature higher than 65 C 150 F and refill coolant as required Effectivity 447 UL SCDI 503 UL DCD
6. 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 0 2 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 Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page 1 2 Initial issue May 01 99 d00287 400311 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 1 Safety Although the mere reading of such an instruction does not eliminate ahazard the understand ing 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 improvement 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 figures in this Maintenance Manual show the typical construction They may not represent in full detail or the exact shape of the parts which have the same or s
7. 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 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 after 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 Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page 21 2 Initial issue May 01 99 d00331 d00332 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 22 ROTAX authorized Distributors for ROTAX Aircraft Engines 1 EUROPE AUSTRIA HB FLUGTECHNIKGES 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 GERGANOV AIRCRAFT EINGINES LTD 25B Post 20 23 peh Shlp polk Blvd BG 6100 KAZANLAK Tel 431 27 247 Fax 431 23 777 Contact person Radosslav D Gerganov CROATIA fo
8. 1 11 3 2 Cooling liquid temperature ooooooooooo oo oom 11 1 11 3 3 Anti freeze additives uuunuununnnnannnnnnnnnnnnnannannannnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn anne 11 2 11 3 4 1 ee EE EE 11 2 11 3 5 Cooling CIRCUIT nia ia en aa naa 11 3 11 36 Cooling Ciu aa ana AA 11 4 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 2 1 ROTAX AIRCRAFT ENGINES Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 11 3 7 Water pump performance diagram and cooling system flow resistance 11 6 12 Lubrication Syst m aka aman 12 1 12 1 Mixture lubrication na 12 1 12 2 Oil injection for engine lubrication 12 1 12271 General advice kasa naa 12 1 12 2 2 Technical data and configuration oo 12 1 1223 Installation Jin asn aan 12 1 Installation at ROTAX 582 UL DCDI and 582 UL DCDI mod og 12 2 Installation at ROTAX 503 UL DCDI oooo o mo maan 12 3 13 Rotary valve and water pump drive ooo oo 13 1 13 1 Oil circuit for engine installation with spark plugs UP mo oo 13 1 13 2 Oil circuit for engine installation with spark plugs down oo 13 2 14 Gearbox installation and gearbox lubrication oooooo EE EEn 14 1 15 Fuel System ankam 15 1 16 Car BU Qtr ea 16 1 16 1 _ Carburetor air intake mama ama 16 2 17 Air intake ea kebal 17 1 17 1 Intakessilence nn NANANA 17 1 172 Air filter one
9. Installation Manual Operator s Manual t Maintenance Manual rs Service Informations rs Spare parts list are based on data and experience that are considered applicable for professionals under normal conditions The fast technical progress and variations of installation might render present laws and regulations inapplicable or inadequate The illustrations in this Manual are mere sketches and show a typical 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 illustra tions is not permitted All necessary documentation is available from the ROTAX Distribution and Service Centers see Chapter 22 NOTE The Illustrations in this Operator e Manual are storedin a graphic data file and are provided with a consecutive irrelevant number This number e g 00277 is of no significance for the content Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 2 4 Initial issue May 01 99 d00311 400312 INSTALLATION MANUAL 2 Table of contents 0 Pref e AA ami 0 2 0 1 A a AA AA 0 2 0 2 Engine serial number aa anna 0 2 Na GA 1 1 1 1 Repeating symbols nyaa 1 1 1 2 Salely information anne ee 1 1 1 3 Technical documentation Mn aa 1 4 2 Table of eonlenis mann 2 1 x y Tt na AA AA AA AA 3 1 4 Tn de OF PAGES asa 4 1 5 LISTOF menamens aan ee 5 1 6 Description OF design ans 6 1 6 1 De
10. a CNN C O G Powerplant with propshaft towards cyl C O G Engine ce Y3cy torwards cyl Ta Y3ba fi X3cy O ech si WY 3cy uf g NG ae X3ba i a ngine Y A 3ba X24 Pro shaft 1 torwards base C 0 G Powerplant gi with propshaft towards base je g 02794 T Es Ag gt B 2 dr C O G Reduction gear A c with propshaft towards base u ze Z2 Z1 7 1 Installation dimensions all dimensions in mm Total dimension gt 47 UL SCDI 503 UL DCDI 02851 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 7 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 7 2 Weights Weight of engine defined to the following conditions rs Engine dry from serial production see chapter description of design Weight of electric starter ee 3 5 kg 7 71 Ib gearbox Bi mine amanah 4 5 NG 9 99 Ib gearbox e NAAT 8 0 kg 17 64 Ib gearbox e GE 11 2 kg 24 69 Ib generator 220 W DC eee 1 1 kg 2 42 Ib 2 radiators big 582 only 2 2 kg 4 85 Ib radiator 995 697 582 only 1 0 kg 2 20 Ib fresh oil pump not 447 00 eee 0 1 kg 0 22 Ib intake silencer oooooWo Wo oo 1 1 kg 2 42 Ib after muffler oooooWoo oom 1 6 kg 3 52 Ib 7 3 Centre of gravity and moments of inertia Power Plant Engine assy with carb and exhaust mani
11. engine installation only All shipping and preservation devices must be removed prior to engine operation Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 8 2 Initial issue May 01 99 d00318 d00319 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 9 Engine suspension and position E 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 02862 Pa AI 02863 9 1 2 447 UL SCDI m lm ml Dem www Gu O AA CC 02864 Ja gece WT UNL I ATA Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 9 1 Initial issue May 01 99 9 2 9 3 A WARNING A WARNING ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL The engine suspension must be designed by the aircraft or fuse lage 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 Tighten all engine suspension
12. 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 2 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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
13. 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 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 ccm 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 1 crankcase 2 cylinder cylinder head inlet tube return line oil tank spark plug 3 4 5 6 7 8 vent plug Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 air vent 02809 page 13 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 BM ATTENTION 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
14. modules of ignition 10 ignition housing 6 3 1 447 UL SCDI Pa del lob a PTO ne MS af TT CR Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 6 2 Initial issue May 01 99 d00316 d00316 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 6 3 2 503 UL DCDI LI D A t 2 2 5 Ir di 02780 A A Cyl 1 Cyl 2 aby BC GA Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 6 3 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 6 3 3 582 UL DCDI and 582 UL DCDI mod 99 Cyl 1 Cyl 2 SE NM MON AA NT PAN ect E IN 1 N HAUAL TH un PTO Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page6 4 Initial issue May 01 99 d00316 d00317 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 7 Technical data 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 filling capacities drive and reduction ratios elec tric output etc can be found in the respective chapter of engine installation Z3 Z1 C O G Reduction gear 22 with propshaft towards cyl WO
15. 2 UL DCDI mod 99 page 2 2 Initial issue May 01 99 d00311 400311 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 guit 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 2 3 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 1 3 Technical documentation The information given in the t
16. 47 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 17 3 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 17 2 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 Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page 17 4 Initial issue May 01 99 d00327 d00328 18 AIRCRAFT ENGINES INSTALLATION MANUAL Electric system 18 1 18 2 General The engine is equipped with a breakerless 12V 170W DUCATI capacitor discharge dualignition system 447 UL SCDlis only equipped with a single ignition unit 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 of them are used for feeding auxiliary equipment and 4 are used for the dual ignition The grey cable is f
17. 501 18 7 99 05 01 7 Zed 99 05 01 18 8 99 05 01 722 99 05 01 19 19 1 99 05 01 8 8 1 99 05 01 19 2 99 05 01 8 2 99 05 01 20 20 1 99 05 01 9 9 1 99 05 01 20 2 99 0501 9 2 99 05 01 20 3 99 0501 10 10 1 99 05 01 20 4 99 05 01 mee 930501 2 21 1 99 05 01 11 11 1 99 05 01 21 2 99 05 01 11 2 99 05 01 22 22 1 99 05 01 11 3 99 05 01 02 2 99 05 01 11 4 99 05 01 3 5 99 0501 11 5 99 05 01 11 6 99 05 01 12 121 99 05 01 122 99 05 01 12 4 99 05 01 12 4 99 05 01 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 4 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL Chap Page Date Chap Page Date ter ter 400314 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 4 2 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 5 List of amendments Currt Chap Pages Date Note no ter of of modification approval 0 0 22 all 99 05 01 not required approval by 00521 Date of Marks insertion Signature 99 05 01 AA HeC d00315 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 5 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL Currt Chap Pages Date Date of Marks no ter approval by insertion Signature of modification approval authority d00315 Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page 5 2 Initial issue May 01 99 d00316 ROTAX AIRCRAFT E
18. 803 77 11 Fax 91 803 55 22 E mail aviaspor bcsnetwork es Contact person Mariano de Castro 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 gt KLASIK HALI A S Klasik Hali is Merkezi Bozkurt Caddesi No 25 A 35230 Kapilar IZMIR TURKEY Tel 232 441 4911 Fax 232 445 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 A Mupeng Street 3 AUSTRALIA Mn GN OE LTD P O Box 84 Boonah QLD 4310 Tel 07 5463 2755 Fax dr 5463 2987 E mail sales austflight com au Contact person Jim Fenton gt 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 BAL MOALLA P O Box 7787 ABU DHABI Tel 2 723 248 Fax 2 788 073 E mail almoalla emirates
19. AFT ENGINES INSTALLATION MANUAL 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 Enquire for moment of inertia and have it confirmed by the manufacturer of propeller in writing E ATTENTION Gearbox B with reduction ratio i 3 00 is only allowed to be used only for engine versions up to 40 HP 29 4 kW d00324 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 14 2 Initial issue May 01 99 d00325 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 15 Fuel System Schematic arrangement 1 carburetor version Schematic arrangement 2 carburetor version 7 7 q q 02941 Fuel contamination is a major cause of engine failure The best place to avoid contamination is at the source Once fuel is in your container a very harzardous potential exists Usea 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 ventilat
20. CDI 503 UL DCDI 582 UL DCDI mod 99 page 2 2 Initial issue May 01 99 400312 d00313 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 C 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 liquid 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 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 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
21. I 582 UL DCDI mod 99 page 11 2 Initial issue May 01 99 d00321 d00321 11 3 5 AIRCRAFT ENGINES INSTALLATION MANUAL Cooling circuit for engine installation with spark plugs up eee ee ee pm ec rm mem fig 13 02801 02799 JJ u NOTE illustration shows 582 UL DCD 1 crankcase 10 overflow hose 2 cylinder 11 overflow bottle 3 cylinder head 12 bottle venting 4 water pump 13 expansion tank 5 radiator 14 cylinder head venting hose 6 hose from radiator to the water pump 15 excess pressure valve 7 hose from cylinderhead to the radiator 16 return valve 8 radiator cap with excess pressure valve and return valve 9 temperature gauge for cooling water Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 11 3 Initial issue May 01 99 AIRCRAFT ENGINES INSTALLATION MANUAL 11 3 6 Cooling circuit for engine installation with spark plugs down For this installation position a venting hose must be con nected on top of the waterpump housing 4 leading to the expansion chamber 10 or to the water chamber of the radia tor Vent the cooling system well check after a short operating period and refill coolant as required Only a perfectly vented co
22. NDONESIA MALAYSIA PHILIPPINES SINGAPORE THAILAND TAIWAN 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 gt H F DORNA CO P O Box 16315 345 Tehran Tel 21 285 4827 Fax 21 284 1831 Contact persons Y Antesary 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 gt JUA LTD 1793 Fukazawa Gotemba City SHIZUOKA PREF 412 Tel 550 83 8860 Fax 550 83 8224 Contact person Yoshihiko Tajika President KOREA HWA YOUNG MEDICAL 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 PAPUA NEW GUINEA JP 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 22 3 Initial issue May 01 99 TM ME MM Me FREUND si au AIRCRAFT ENGINES ia en au u a as ROTAX Vertriebspartner ROTAX authorizied distributo
23. NGINES INSTALLATION MANUAL 6 Description of design 6 1 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 6 2 Standard engine design Refer to latest version of the current Operator s Manual 447 UL SCDI 503 UL DCD 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 IS IS IS IS IS IS to the standards of aviation The user assumes all risks possibly arising by utilizing auxiliary equipment Exhaust system Intake filter Coolant radiator Flydat Electric rev counter Hour meter Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 6 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 1 propeller flange 6 2 propeller gear box 7 3 intake manifold 8 4 carburetor 9 5 coolant pump unit exhaust socket electric starter fresh oil lubrication pump electronic
24. NS AN mit s rhe bi mela Installation AIRCRAFT ENGINES pra for 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 The manual must remain with the engine aircraft in case of sale MO TV IV SV SV KV KV KV KV SY SY IK Approval of translation to best knowledge and judgement in any case the original text in German language is authoritative Edition 0 of 1999 05 01 Copyright ROTAX GmbH ROTAX part no 899 482 paa a o CR KN O O O ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 familiarize the owner user of this aircraft engine with basic installation instructions and safety information For more detailed information on operation maintenance
25. TD 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 gt HALLEY Baktai t 45 P O Box 425 H 3300 EGER Tel 36 313 830 Fax 36 320 208 ITALY MALTA ICARO MOTORI S R L Via Emilia 61 B 1 27050 REDAVALLE PV Tel 0385 74 591 Fax 0385 74 592 E mail icaro energy it Contact person Corrado Gavazzoni POLAND gt FASTONLTD ul Szeroka 2 PL 05 860 PLOCHOCIN Tel 22 722 5858 Fax 22 840 0196 Contact person Wojtek Madry Manager page 22 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL ROMANIA 5 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 STEVESOS 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 MPIPISTREL doa Strancarjeva UI 11 5270 AJDOVSCINA Tel 065 63 873 Fax 065 61 263 E mail pipistrel eunet si Contact person Ivo Boscarol SPAIN PORTUGAL MAVIASPORT S A Almazara 11 E 28760 TRES CANTOS MADRID Tel 91
26. ainst loss and vibration see Service Information 11 UL 87 E page 5 02795 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 10 1 Initial issue May 01 99 AIRCRAFT ENGINES INSTALLATION MANUAL E ATTENTION Vibration due to improper suspension is by far the most common reason for damage to the exhaust system A WARNING Don tuse any sharp tool for removal of the tension spring for reason of possible damage of spring wire A hook bent out of a5 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 At the installation of the after muffler 1 in final position drill the two 5 7 mm holes in the bend and muffler end pipe for securing pin 5 The outer situ ated holes 2 have been already machined on the serial production S line Remove accumulated chips from the exhaust system To ensure lasting fixed position of the after OSS 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 daan 10 3 Exhaust gas t
27. cinity 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 02816 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 has been altered Consult the engine supplier or manufacturer in writing for details The correct carburetor calibration is also described in the parts list Ifthe aircraftisto be operated in climatic conditions where carburetor icing is likely to occur a heating system must be fitted No modifications should be made to the carburetor and air intake system without consulting the engine manufacturer in writing Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 16 2 Initial issue May 01 99 d00326 d00327 117 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 BATTENTION Atemploymentof an intake silencer a different carburetor jetting wi
28. ease starting procedures especially in flight Electric starter fitted on E type gearbox There is also the possibility to use a rewind start Electric starter fitted on magneto side However for use on engines utilizing a ROTAX gear reduction unit this electric starter system prevents rewind starter application consumers fuse 16A fuse Dc starter button battery 12V 16 Ah min I HHHHH 02829 electric starter Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 18 7 Initial issue May 01 99 AIRCRAFT ENGINES INSTALLATION MANUAL Battery 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 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 18 8 Initial issue May 01 99 d00328 d00329 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 19 Propeller drive A WARNING Neverrunthe engine without a propeller installed as engine would suffer severe damage by overspeeding Never fit prop
29. ed 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 condensate from the pump diaphragm chamber If possible the pump should be located below the fuel tank level 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 15 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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
30. een E 8 d Zei white i ktarter button x white green yel black brown electric starter ground Na _ BU Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 18 5 Initial issue May 01 99 AIRCRAFT ENGINES INSTALLATION MANUAL 18 5 3 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 provided by one of the transducers supply winding where it is connected It does not require any external power supply It is connected by two wires without polarity The indicating range is up to 8000 r p m The weight is 235 gram Connection to dual ignition system 02960 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 evenif one of the two ignition systems is turned off for ignition testing procedure or a transducer failure occurs Maximum allowed deviation 100 1 min d00328 Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page 18 6 Initial issue May 01 99 d00328 AIRCRAFT ENGINES INSTALLATION MANUAL 18 5 4 Electric starter Two types of electric starters can be fitted to
31. eller 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 19 1 1 B type gearbox Reduction ratio 2 0 2 24 2 58 Attachment holes on propeller flange TN Ta Zh 02840 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 19 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 1 Io Il N LA 8 o Qa S 5 N A gt NE 1 02841 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 19 2 Initial issue May 01 99 d00329 d00330 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 20 Connections for instrumentation 20 1 Sensor for cylinder head temperature Spark plug seat temperature location and connection one each per cylinder fastened by one spark plug A Torque of spark plug 15 133 in IB fig 49 fig 49 5 20 2 Air and coolant sensor location and connection coolant only at 582 UL DCDI and 582 UL DCDI mod 99 on cylinderhead AI pa NG AR eege location free to c
32. emperature EGT 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 meas ured about 100 mm 4 in from the piston with separate sensors for each cylinder EGT max 650 1200 F E ATTENTION The exhaust manifold is pro vided with tapped holes Ifthe EGT is not measured the holes must be closed with screws which must be safety wired X 100mm 02798 Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page 10 2 Initial issue May 01 99 d00320 d00321 AIRCRAFT ENGINES INSTALLATION MANUAL 11 Cooling system 11 1 11 2 11 3 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 sufficient size and ina 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 p
33. exhaust system is tuned for the respective engine and performance and must not be changed If modifications are inevitable then the mid length 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 modification Engine muffler Motor Auspufftopf medium length of tube mittlere Rohrlange Hans 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 mM ATTENTION 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 cccccccecssesssceesssssesssteeseees 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 exhaust components Springs used on exhaust system must be secured ag
34. fold Moment of inertia around axis kgcm y1 y1 zi zi seston of C G mm Exhaust manifold weight kg 02852 Reduction gear assy kg kgcm2 un CA D Tee vv 2z 53 92 46 166 256 184 ee 02975 Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page 7 2 Initial issue May 01 99 d00317 d00318 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 8 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 8 2 Protective covering All openings are protected against ingress of contamination and dampness It is recommended not to remove these plugs until installation of the specific feed line NOTE If the engine will be sent to the manufacturer or distributor reuse transport equipment and replug openings List of protective covering IS IS IS IS carburetor inlet zu 1 each cover tresh oil PUMP nok ee 1 plug vent screw gearbox oooooo Wo Woman 1 cap Ee Eege adhesive tape A WARNING Protective covering to be utilized for transport and at
35. gram and cooling system flow resistance graph measured on Standard 582 UL DCDI with double radiator set Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page 11 6 Initial issue May 01 99 d00321 d00322 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 12 1 Mixture lubrication Refer to latest version of current Operator s Manual 12 2 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 Incase of fresh oil lubrication the carburetors are supplied with pure gasoline no oil gasoline
36. hoose 01005 Tightening Torque 6 Nm 53 in IB LOCTITE Anti SC 01004 Effectivity 447 UL SCDI 503 UL DCDI 582ULDCDI mod 99 page20 1 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 20 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 20 3 Exhaust gas temperature sensor location and connection Exhaust manifold assy 01002 Tightening Torque 20 Nm 177 in IB LOCTITE Anti Seize Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 20 2 Initial issue May 01 99 d00330 d00330 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 20 4 Installation plan for the sensors on 582 UL DCDI and 582 UL DCDI mod 99 01008 1 2 3 4 Sensor at spark plug seat CHT Air and liguid temperature sensor EGT sensor ZZ Ka Sealing ring Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 20 3 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 20 5 Installation plan for the sensors on 447 UL SCDI 503 UL DCDI 1 Sensor at spark plug seat CHT 2 Air and liquid temperature sensor 3 EGT sensor 4 Sealing ring d00330 Effectivity 447 ULSCDI 503 UL DCDI 582 UL DCDI mod 99 page 20 4 Initial issue May 01 99 d00331 21 engine rpm x 1000 max rpm refer to OM ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL Break in procedure for airc
37. imilar 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 MH 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 1 2 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 air speeds 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 Itis for use in experimental uncertificated aircraft and vehicles only in which an
38. ll be necessary DUAL CARBURETOR VERSION 02817 af ee Ge 02818 E ATTENTION Weight of silencer must not influence position of carburetor If need be support silencer accordingly Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 17 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 02954 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 combus tion temperature and finally to piston seizure Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 17 2 Initial issue May 01 99 d00327 d00327 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL fig 36 02953 Fitting position 1 Fitting position 2 Fitting position 3 Fitting position 4 Position 1 would be best Positions 3 and 4 are also acceptable but avoid unfavour able position 2 A WARNING Screw on filter and silencer must be wire secured against slacken ing and loss on the assigned lug 3 All parts liable to become loose have to be secured Effectivity 4
39. mixture 12 2 2 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 12 2 3 Installation 1 Oiltank 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 atthe greatest possible inclination of the aircraft i e dimension Hs must be greater than zero see fig no 20 3 Use a firm oil resistant suction hose which cannot be squeezed Secure it with clamps at the connections 4 Install an adequate oil filter between oil tank and oil pump 5 Install a Bowden cable to actuate the pump lever simultaneously with the carburetors m ATTENTION Ata 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 12 1 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 mixi
40. n 17 4 18 Ele trie8ysten u nn 18 1 18 1 Generali ana AA PI 18 1 18 2 Function of the ignition unit ee 18 1 18 3 Wiring diagrami aa aa une 18 2 18 4 Lighting CU CU nm ka mata 18 3 18 5 Technical Data and connection of components o o oom 18 3 18 5 1 Wiring diagram for rectifier regulator 866 080 o oo ooooooo 18 3 18 5 2 Wiring diagram for rectifier regulator 264 870 oooo o oo 18 5 18 5 3 Electronic revolution counter oo oom ana 18 6 Connection to dual ignition system ooo oom 18 6 18 54 Electri startet ANAKAN 18 7 Starter relay 992 819 18 7 BUS E aa 18 7 Banery ae aan ada 18 7 Power SOUNGE didanai ata KAIN NAA AA CEET 18 7 19 Proper eka aka akan inadi 19 1 19 1 Technical data maa aman 19 1 19 1 1 B type gearbox mo oom nana 19 1 19 1 2 C CL and E EL type gearbox oo oom oi 19 2 20 Connections for instrumentation EE nnmnnn 20 1 20 1 Sensor for cylinder head temperature spark plug seat temperature 20 1 20 2 Air and ET E TE 20 1 20 3 Exhaust gas temperature sensor oooo oo oom 20 2 20 4 Installation plan for the sensors at 582 UL DCDI and 582 UL DCD mod Q9 ai ea an aa maa alan ana aah 20 3 20 5 Installation plan for the sensors at 447 UL SCDI 503 UL DCDI 20 4 21 Br ak in ProtedU ea anak sak ee 21 1 22 ROTAX authorized Distributors o oo o mo mommmmmenanenanaan 22 1 Effectivity 447 UL S
41. net ae Contact person Hussain Al Moalla ANGOLA BOTSWANA LESOTHO MADAGASCAR MALAWI MOZAMBIQUE NAMIBIA SOUTH AFRICA SWAZILAND ZAMBIA ZIM BABWE 2 AVIATION ENGINES ANDACCESSORIES PTY LTD Private Bag X10021 Edenvale 1610 South Africa Tel 011 455 4203 4 5 6 9 Fax 011 455 4499 E mail flying iafrica com Contact person Mike Blyth 5 ASIA CHINA HONG KONG MACAO PDUEN 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 gt AVIAGAMMA 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 NASSAU BA General Director Tel 242 356 5377 Fax 242 322 6784 E mail custsupport kodiakbs com website www kodiakbs com Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 22 2 Initial issue May 01 99 d00332 d00332 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL INDIA UNITED ARAB EMIRATES gt GREA VES LIMITED WAL MOALLA 22 A Janpath P O Box 7787 NEW DELHI 110001 ABU DHABI Tel 11 338 50 61 338 26 53 Dir Fax 11 37 82 Tel 2 723 248 Fax 2 788 073 553 Tlx 031 62663 E mail almoalla emirates net ae E mail Contact person Hussain Al Moalla reaves GRVSDEL XEEDEL XEEMAIL com ontact person Wg Cdr S N Chhabra Divisional Manager I
42. ng ratio of 100 1 This is for safety until the complete system is properly filled with oil NOTE This oil injection will not affect or replace the rotary valve gear lubrication nor the reduction gearbox lubrication Installation at ROTAX 582 UL DCDI and 582 UL DCDI mod 99 1 Engine 2 Oiltank 3 Suction hose 4 Oilpump 5 Discharge line 6 Checkvalve 7 Oilintake port 8 Adjuster nuts 9 Venting 10 Oil filter Hs Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page12 2 Initial issue May 01 99 400322 d00322 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL Installation at ROTAX 503 UL DCDI 4 oil tank 5 oilfilter 6 suction hose 7 oil pump 8 pressure hose 9 check valve Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 12 3 Initial issue May 01 99 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL A si s 02807 NOTE The dimension Hs must be positive also at descent or climb Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 12 4 Initial issue May 01 99 d00322 d00323 ROTAX AIRCRAFT ENGINES INSTALLATION MANUAL 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 for the rotary valve drive same as used for 2 stroke
43. oling system will operate satisfactorily A WARNING Do not open cooling system until engine has cooled to outside air temperature failure to respect this information will result in severe scalds and injuries sm sm gm Km ga may n me ve SE sagi Me EEE 02802 Gi 7 GH ra ae e sr SE E et A 4 ee Ee a fig 16 02804 7 y W fig 17 02803 LA NOTE illustration shows 582 UL DCD Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 11 4 Initial issue May 01 99 d00321 d00321 AIRCRAFT ENGINES INSTALLATION MANUAL 1 crankcase 10 2 cylinder 11 3 cylinder head 12 4 water pump 13 5 radiator 14 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 15 16 overflow hose overflow bottle bottle venting expansion tank cylinder head venting hose excess pressure valve return valve Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 11 5 Initial issue May 01 99 AIRCRAFT ENGINES INSTALLATION MANUAL 11 3 7 Water pump performance dia
44. operate engine if bystanders are close To prevent unauthorized 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 atidle for several minutes before turning off the engine Effectivity 447 UL SCDI 503 UL DCDI 58
45. oreseen 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 capacitors 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 18 1 Initial issue May 01 99 18 3 AIRCRAFT ENGINES INSTALLATION MANUAL Wiring diagram NOTE When replacing wiring on the ignition system connections must be as per wiring diagram below 1 Electronic box 6 charging cable green 10 rev counter cable gray 2 eight lighting coils 7 charging cable white 11 mass cable brown 3 four charging coils 8 shorting cables black yellow 12 ignition cables 4 pickup 9 lighting cables yellow 13 spark plug connectors 5 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 18 2 Initial issue May 01 99 d00328 18 4 18 5
46. r Motornummer Engine serial no Flugzeugtype Type of aircraft xo oo a o o o u o o Flugzeugkennzeichen Aircraft registration no LY LM IX II II g N A 4
47. raft 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 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 02854 On a liquid cooled engine it is possible that the cooling air flow speed on ground is not enough to provide adequate cooling for extended periods of time Therefore it is necessary to observe carefully the temperature of the cooling liquid during break in procedure to avoid overheating Before exceeding the maximum allowed cooling temperature on cylinder head outlet of 80 C 180 F interrupt the run in and cool down the engine atidle 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 C 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 21
48. rmer YUGOSLAVIA except SLOVENIA SHAFTD O O B L Mandica 161 a HR 54000 OSIJEK Tel Fax 031 280 046 Contact person Ing Ivan Vdovjak CZECHIA STEVESOS R E Skroupova 9441 CS 50002 HRADECKRALOVE 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 gt FLIGHT CENTER Flugplatz D 27777 GANDERKESEE GERMANY Tel 04222 3789 Fax 04222 6042 E mail flightcenter olis de Contact person Robert Heilig FINLAND NORWAY SWEDEN ESTONIA LATVIA LITHUANIA gt LYCON ENGINEERING AB H rkeberga SE 74596 ENKOPING Tel 171 414039 FAX 171 414116 E mail info lycon se Contact person Yard Johansson FRANCE BELGIUM MONACO LUXEMBURG gt 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 Edition 1999 01 05 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 GREAT BRITAIN IRELAND ICELAND XSKYDRIVE L
49. ropeller 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 mod 99 has a two circuit cooling system see latest revision of the current operators manual 447 UL SCDI 503 UL DCDI 582 UL DCDI 11 3 1 Coolant flow Should be in the range of 60 70 litres min at engine r p m 6500 See ill 18 11 3 2 Cooling liquid temperature The radiator must be of adequate size and the airstream of sufficient intensity to maintain the coolant temperature below the maximum permit ted 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 and9 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 Effectivity
50. screws as specified by the aircraft builder Do not overtighten engine hardware Follow recommended manufacturers torques Permissible fitting positions Take care that all limits are in compliance with the Operator s Manual and Installation Manual m 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 A WARNING The engine suspension must be designed to prevent any exces sive engine movement and to minimize noise emission and vibra tion on air frame side Respect manufacturers recommended torques at engine installa tion Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 9 2 Initial issue May 01 99 d00319 d00320 AIRCRAFT ENGINES INSTALLATION MANUAL 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
51. signation Of TY Pe ana ana 6 1 6 2 Standard engine deslian maha 6 1 6 3 Engine components engine views numbering of cylinders 6 2 6 3 1 447 UL SOD 2a a agan a 6 2 6 3 2 503 UL ne AE 6 3 6 3 3 582 UL DCDI and 582 UL DCDI mod 99 ooooo oma anna 6 4 O CECR E ama 7 1 7 1 Installation dimensions all dimensions in mm moon 7 1 7 2 Weight 7 2 7 3 Centre of gravity and moments of inertia oooo on 7 2 8 Preparations for engine installation ooooooo oo 8 1 8 1 Engine pesenan aa aa 8 1 8 2 Protective COVERING ia aa 8 2 9 Engine suspension and position 9 1 9 1 Definition of attachment points oo oo oom 9 1 9 1 1 503 UL DCDI 582 UL DCDI and 582 UL DCDI mod 99 o oooo mana 9 1 9 1 2 447 TT Een mata 9 1 9 2 Permissible fitting positions ooooo oom 9 2 9 3 General directives for engine suspension o ooo o oo oom 9 2 10 Exhaust System ema ma 10 1 10 1 Installation of the exhaust system o oo oom 10 1 10 2 After muffler system sa aman 10 2 10 3 Exhaust gas temperature EGT mo oom 10 2 11 Cooling sysliem nase een 11 1 11 1 Fan cooling ROTAX 447 UL SCDI ROTAX 503 UL DCDI nessuuussennnennenn 11 1 11 2 Free air cooling ROTAX 447 UL SCDI ROTAX 503 UL DODI mo 11 1 11 3 Liquid cooling ROTAX 582 UL DCDI and 582 UL DCDI mod 99 11 1 113 1 Coolant flow er a dE 11
52. 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 different jetting Contact your dealer In no case should jet changes be made by unqualified persons or those who do not have ROTAX technical information to do so A WARNING All parts liable to become loose have to be secured 02815 Q j Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 16 1 Initial issue May 01 99 16 1 AIRCRAFT ENGINES INSTALLATION MANUAL 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 vi
53. water A screen of 0 3 mm mesh size should be fitted to the fuel line in the tank Never restrict the normal fuel flow 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 A WARNING The carburetor needle valve is not sufficiently 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 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 page 15 2 Initial issue May 01 99 d00325 d00326 AIRCRAFT ENGINES INSTALLATION MANUAL 16 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 atidle 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 require 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
Download Pdf Manuals
Related Search