Rotax 503 UL Manuel utilisateur

ROTAX.

OFERATORIS

IWANUA-L

ENGINE TYPE

SosuL

equipped

with breakerless

dual ignition system

and BING carburetor

EDITION: 12

1990

This

manual

contains

i-po"t ffi

infolmation concerning

your engine.ft mustremain

with

the engine

at time of resale.

Modifications

or spccial

applications

Section

l. Importantprefacc,

genelalsafetypoints...............,..........

2. Forcword.......

3, Fuel&oi1.........................

Mixing

procedure.....

4, Sbrting

proccdurc,pre-st!-n

check

procedure

.................

5. Break-inDroccdure...................-.....

Index Page

Danger!

Thisengine,byitsdesign,

issubjecttosuddenstoppage!

Engine

stoppage

canresult

incrash

landings.Suchcrashlandingscan

lead

toserious

bodily

injuryor death.

Neverfly theaircraft equipped

with thisengine

at locations,

airspeeds,

altitudes,

orother

circumstances

frorn

whichasuccessfulno-powerlanding

cannotbe

made,aftersudden

engine

stoppage.

Warning!

Although

these

enginetypes

have

undergoneconsiderabledurabilityte-

sting,thisengine

isnot a certifiedaircraftengine.Ithasnotreceived

any

individual safetyor durabilitytestingandconformstonoaircraftstan-

dards.

It isfor usein experimentalandultralightuncertifiedaircraftand

vehicles

only,

in whichanenginefailurewill notcompromise

safety.

Userassumes

allriskofuseandacknowledgesbyhisusethatheknows

this

engine

issubject

tosuddenstoppage.

1) Important

preface:

Safcty

i6everyone'sbusiness.Wehaveincludedsomeof theimportant

safetytipshere,

butthe

lisris

notcomplete.It wouldbe

impossible

tolist every

wayin whichonemaybeinjured. Please

notedre

followingsymbols

throughour$e book.

- S,A.FETY

WARNING: Failureto obeyasafety

warningmayresultin injury toyouorothers.

- INFORMATION vital to the operationor maintenance

of your product (this shouldalsobe

considercdnecossaryfor safety).

Generalsafety

points:

- Nevermixfuelin anenclosed

alea,orwherefumes

couldrcachanignitionpoinr.

- Makesureall enginecontrolsareoperative,thatyouknowonandoff positions

of throttle

andignition, thatthey areeasilyaccessible,andrhatyou canoperaletheminstinctively

withouthesitation.

- Nevcrrefu€l

iffuelcouldbespilled

hotenginecomponenrs.

Useonlysafery

applovedfuel

containe$and ever

Eansportfuel

inanunsafemanner.

- Checkengine

suspensionfaequentlyaswellas

fle driveconrponenrs,

fuellines,wirtlg,and

flrel arrdair fllters.

- Checkforfuelcontamination,airvents,

etc.

Prcte{tengine

whilenotin

useftornany

contami-

nationentering

fuel or cmburetion

systembut besureto rcmovestorageuotection befoe

startingengine.

- Maintain

yourengine

intopconditionandassumeit'sgoing

quitrunning

atanydme.I-eave

yourself

awry outin lheevent

of unexpectedfailure.

- Neverruntheeogineonthegrcund

withfte gopeller tuming,unless

youaredoingsoin a

runupareanndcarobserveanyoneorarythilg enteingthedutgerarea.An observerin asafe

place

isadefinite

asset.

- Neverleave

your

aircraftorothervehicleunattendedwhilctheengineisrunning.Ifoperated

by someoneelse

youcouldbesuedeven

if theuse

was

unauthorized

byyou.

- Keepanengine

1og

andenteranyunusualengine

behaviour.

Donotfly unless

you

have

corectedagivenproblem

andrccordedthecorrection

in thelog.

Lr)

2) Foreword:

TheROTAXengineisanair-cooledz-strokeengine,

Carefuland

extensivelytested

design

andrugged

consEuction

aswell astheuse

of highqualityparrs

increasoreliabiliry and

durabiliry,Wirh proper

maintenanceandcareandwiththeuseofsuitablefuelandoil dreengine

should

give

yougoodservice

for manyyears.

TheROTAX designincorporatesthelatesttechnical

developments.In

orderto tate advantage

futue developmentswercseNerhedghrromake

modificationsintheROTAX design

withoutnorice.

NOTE:All fasrenersaremetricwiththeexceptioooftheinternal

thread

ofthe

p.T.

O_cankshaftwhich

is1/2

"narionalfineftread.Itisto

your

advantage

read

thismanual

carefullyforthe

ptotection

ofyour

engine.Theremaybesigrficant

differencesfrom

othettypes

offwocycle

engines

you

mayhaveworkedon.

Alwaysuse

genuine

ROTAX pafis.

I A Neue.r,raenginewirhoutproperloading,

e.g.corect propeller.

Refersection17.

Section

Fuelandoil:

Fuelcoltamination

isa

najorcauseofenginefailure.The

bestplace

toavoidcontamination

atthe

source.Once

inyorufuel

container',averyharzadouspotendal

edsts.

Use

aclean

safety

approved

storage

corltainer.

Filter all fuelenteringandleavingthiscontainer.

nol

over- conlainer.allowforexparrsion.

WARNING: Gasolineisflan]mableandexplosive

undercertain

conditions.Alwaysperform

pioce-

dDresin awellventilatedarea.

Donot

smokeorirllow

openflames

orspaJksin tie vicillity.

Neve'raddfuel while engineisnuudDg.

Refertoteclmicaldata-TheengineisdesigdedtooperateafuelfiitI.yJith

2Eaoil. Beswetouse

ploductsof atleastthestandardshownin thetechnicfll

datasectioD.

Ifthe

engioeistobeusedinverted

(with

spark

plugspointing

down)

selectalubricant

whichfeatures

lowcarbondeposits.Oilresidueteidsrodrain

lowpoints,

i.e.

spark

plug

cavities.

If rhisresidue

fails to burn cleanduring normad

operation,

plug tbuling will occur,possible

prc-ignirion also.

Manufacturersof suitablelubricanrswill guariurtee

theirproducts

in writing.

Do notusefuel whichhasbeenstorcdfor alongperiod

of time.

Do flotleavefuel exposedto sunlightin translucentcontaine$.

3.1)Mixing procedure:

STEPno.1:

Useacleanapproved

container

ofknown

volume.Tohelp

predilute

tle oil,pour

bit of fuel intocontainer.

STEPno.2: I FiI k ro*r, urnoontof oil intocon-

tainer.

Oilmusr

beapprovedforaircooled

enginesat 50:1mi;cing

ratio.Agitate

slighdyto diluteoil with gasotine.

STEPno.

3:Addgasoline

toobtaindesired

mixture

ratio

(use

hne mesh

screen).

Fueimust

beofminimum

M.O.N.

83orR.O.N.

90octane

nting.

STEPro.4:

Replacecontainer

cap

and

shakerhe

con-

tainer

thoroughly.

Then

using

afunnel

withafinemesh

screen

toprevent

the

entry

ofwaterandforcignparticles,

trans-

fer mixturefrom containerinto thefuel

tank.

ffi

4) Startingprocedure:

4,1) Pre-startcheck:

Beforcstartingenginereadsectiondcaling

withstaning

and

cngine

htak-in thoroughly.The

servicelifeofthca[gine

islargelydeteminedbyhowwcllyou

followtheseinstsuctioqs.

Before

starting

enginebesure

your

installationiscomplet€,eosurethatallcontolsopffatc

easilyandsmootbly,and

that

you

caaoperatethem

instinctively.

Alwaysensuethat

you

areinasafc

run-upa!ea-

Ensurctluottlc

link.ge

allows

piston

valveincarbEetor

tobofiominidle

position,

Screwout

idle specdadjustmcntsclgw(no.14,

scction7) until carburcor

pistod(no.3)bottoms.

Carefullytum

inadjustment

scrcwuntilit engages

pisto[andtumh afudrer3to31/2full

tums.Checkif fuelline

isconrlertedardtankvetrtisoDen.

4,2)Procedure;

Oncoldengineapplychoke

fully.Ensureidle

position.(Opening

throtdewill gready

rcducc

chokeeffectlesultinginhard

stardng).

Make

sure

ignition

switchisonandthat

you

can

shut

itoffinstandyifnecessary,Pullstarterurtil firDllyengagsdandthen

pullthroughvigolously.

Above

plocedue

should

berepeateduntilenginebegins

firc.As

soonaselginestafis,shift

the

tbrotde

slowly

tolowspeedandrcmovechokeassoonas

possible(prolonged

useofchoke

can

causeenginetoflood,)

Ifthc engine

fails

tostart

oroperatesonlyononecylinder,chcckwhcthertheignition

wiring

isdisconnccted

orincore{dyconncctedto thespark

plug

connectorsorto th€

spark

plugs

theignitiol s]vitchisinoffposition.

If Feceding

checksdonotsolvethe

problem,

rcmovethespark

plugs

andinspecLwet

spart

plugs

indicateafloodedengine.

Tocorpct,replacewithdryplugs

anddiscontinueuseofchokc,Switchofrignition.Craok

engine

withfully opendrotdo toclcarthcexcess

fucl.

Repeatstan

proccdurc.

Dryspark

plugs

indicatcnofuelinonginc.Toinspect,reEovefloatbowl

and

cnsue

fuelis

present

in suficietlt

quantity,

If not,inspectfuellevelintank,fuelvalyeand

tank

ycnt,

I-ook

forblockage

orobstruction.

Corcat8ndrcpeatst{t proceduc,

Section 5

5) Break-in

procedure:

for aircraft installation (in otherapplications

prcceed

accoldingly)

Thobreak-inhas

tobepcrtbrmed

withdrccngineinstalled,

properlyloaded, i.e. propeuer

installed,

matched for max. r,p.m.In caseof anaircraft,anchorthcplaneto theground.Rutrtheengine

according

to thefollowing graph:

Engine

r.F.m,

H|000

,nta, fp.m.

(rcferpage

32)

20 50

sec sec l2 5

mlnmin min

sec t5

sec

5,5

4,5

5,5

In.6

0 r0 20 30 40 s0 60 illHi

h caseof a

f&g3L!!g:i!c it ispossible

thatthe

coolingairflow onground

isnot cnoughtoprovide

thenecessarycoolingfor alongcrperiod.

Therefoleit is necassary

toobservecarcfullythe

cylinder

hggl temperaturc

(CHT) during breal in procedure

to avoidoverbearing.

Beforc exceeding

tie

maxiorumallowedCHT of 250

oC/ 480o

F intenupttherunandcooldownthcengine atidlc for

approximately

oneminuteand

continuewhere

youhaveintefiupted.

Be sureto usea saferun-rp area-to anchor

aircraft at those

points approved

by the airframe

manufacturer,andtohavesomeone

present

who

isabletoshut

off lheengineinstandy

andtoprcvent

unauthorizerl

people

entcring

the

duDger

area.

Proper

clorhing,ear

plotection etc, shouldbeusedonanyenginerun-uptest.

After thisprocedure

theidlehastobeadjusted.Thenshort

take-offs

canbeconducted.

After afew

short

full-load take-offs,but

notlaterthan2hourstotalrunning

rime,

thecylinderheadnuts

haveto

rc-torquedto22Nm(195

in.lb.). Forthis

procedurc

thecylindercowl(if any)hastobe

takenoff.

I r I r | | ll 2

Engine

mustbecoolfor re-torquingof head.

DiagramJor torquesequencewhen

manifold,sarcin

place s-q

,v,

/T\ /T\

3\-/ \r 5

NOTE: Consider

bothcylindersasoneunitbecausetheyare

joinedbyexhaustandintakemanifolds.

Useacrosssequence

for tightening

the

nuts,

startingfiom thecenter.EnsurE

thalcowlscrcws

aretoroued

less

than

headnuts.

6) Operation

in flight:

It is rc{ommended

to usefull duottleduring uke-off climb. Slightthrctdereducion maycrcare

lealer mixtureaadmustbeavoided.Selectacruisingspeed

where

theengineis runningsmooth.

Donotexceed

rraximunengine

rpm(refer

section18technicaldata).

During cruiseanddescending

it is veryimponant

not tocreatealeanconditionwirhhighrym and

lowtluottleopedng.

Thglessfreshchargetheelgine

gets,

themorehotrcsidual

gas

rcmainsin the

cylinder.This

raisesdretemperaturestoacdticallevel. For this reason,

you

ncay

alsoexpedence

higherexhaust

gas

amdcylinderheadlempentures

atreduc€dthrottleopenings.

Idlingr.p.m.is2000minimum.Highidleseftingwill rcduceenrichment

actionof startingsystemin

carburcto!

(choke),

makingcoldstartingdifficult.

kior toshutdown,

engineshouldbe

runforafewminutes

atthelowestsmoothrunning

r.p.m.

tocool

down,depending

power

selring.

Do|otidlgforFolonge.dpe

odsas

nomul chcondition

atthis

power

settingcancausg

u necessary

carbondeposits

and

spurk

plug

fouling.Avoidrunningconditions

whele

gearbox

shakingoccurs.

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