Rotec AEROSPORT R2800 Manuel utilisateur
ROTEC
RADIAL ENGINE
OPERATIONS MANUAL
AEROSPORT
Date Published Rotec Aerosport
Radial Engine Operations Manual
www.rotecaerosport.com
Revison Published
15 04 2007 10 082017
Version V3
ROTEC AEROSPORT PROPRIETARY INFORMATION THIS DOCUMENT IS PROPRIETARY PROPERTY
OF ROTEC AEROSPORT PTY LTD. IT IS NOT TO BE COPIED OR REPRODUCED IN ANY MANNER,
NOR SUBMITTED TO OTHER PARTIES FOR EXAMINIATION WITHOUT PRIOR WRITTEN APPROVAL.
2 | ROTEC AEROSPORT
www.RotecAerosport.com
INTRODUCTION
GENERAL NOTE
This technical document is a guide to aid the user to correctly maintain, service and operate a Rotec Radial aircraft
engine. This operations manual was completed for your benet.
Congratulations on the purchase of your band new Rotec Radial engine. Rotec’s radials are constructed with the high-
est level of precision & accuracy. Each component has been rigorously tested by technicians to ensure quality, endur-
ance and performance of your radial engine.
The contents of this manual are based on the latest product information available at the time of publication.
Should you have any doubts or question in relation to the contents of this manual please contact Rotec Aerosport
Australia Pty Ltd.
ROTEC AEROSPORT | 3
www.RotecAerosport.com
WARNING
GENERAL WARNING
NOTE, IMPORTANT & WARNING boxes are used through out this manual. This is to disclose safety issues that must be
followed when operating Rotec radial engines.
Always provide a copy of this manual to anyone using this equipment. Read all instructions in this manual and any in-
structions supplied by manufacturers of supporting equipment before operating the radial engine and especially point
out the “Safety Warnings” to prevent the possibility of personal injury to the operator.
NOTE:
WARNING
IMPORTANT:
4 | ROTEC AEROSPORT
www.RotecAerosport.com
RADIAL ENGINE DESCRIPTION 8
R2800 (7 CYLINDER ENGINE) 8
DIMENSIONED FRONT VIEW 8
DIMENSIONED SIDE VIEW 9
REAR VIEW CYLINDER DENOMINATION 10
R2800 TECHNICAL DATA 11
ENGINE DESCRIPTION 11
DIMENSIONS & WEIGHT 11
PERFORMANCE DATA 11
FUEL CONSUMPTION 11
R3600 (9 CYLINDER ENGINE) 12
DIMENSIONED FRONT VIEW 12
DIMENSIONED SIDE VIEW 13
REAR VIEW CYLINDER DENOMINATION 14
R3600 TECHNICAL DATA 15
ENGINE DESCRIPTION 15
DIMENSIONS & WEIGHT 15
PERFORMANCE DATA 15
FUEL CONSUMPTION 15
UNIVERSAL ENGINE DATA 16
NORMAL DATA 16
FUEL TYPE 16
OPERATING RPM’S & LIMITS 16
SERIAL NUMBER 17
COOLING SYSTEM 17
EXPOSED ENGINES: 17
COWLED ENGINES: 17
NOISE & EMISSIONS 17
GEAR REDUCTION RATIO 17
CHT (CYLINDER HEAD TEMPERATURE) 18
EGT ( EXHAUST GAS TEMPERATURE) 18
INSTALLATION, OPERATION & SERVICE DOCUMENT 20
UN-PACKING & MOUNTING` 22
PACKAGING REMOVAL PROCESS 22
ENGINE MOUNTING PROCESS 23
ENGINE MOUNT FRAME 24
MANUFACTURED BY ROTEC AEROSPORT 24
DO IT YOURSELF 25
FRONT VIEW 26
REAR VIEW 27
SIDE VIEW 28
TOP VIEW 29
ENGINE INSTALLATION 30
R3600 & 2800 CUP MOUNTS 30
R3600 COMPONENTS: 30
R2800 LOWER PIN MOUNTS 32
R2800 COMPONENTS: 32
INSTALLING THE ENGINE ON THE FRAME 34
INSTALLATION CHECKLIST 34
TABLE OF CONTENTS
ROTEC AEROSPORT | 5
www.RotecAerosport.com
PROPELLER 36
RECOMMENDED SPECIFICATIONS 36
PERFORMANCE BY POWER SETTING 36
MOUNTING BOLTS 36
PROPELLER MANUFACTURERS 37
LUBRICATION SYSTEM/ PLUMBING 38
GENERAL 38
OIL TANK 38
BASIC DESIGN REQUIREMENTS 38
OIL TANK BY ROTEC AEROSPORT 38
OIL TANK DO IT YOURSELF 39
OIL TANK BASIC DESIGN REQUIREMENTS 40
ENGINE CONNECTIONS 40
ENGINE OIL RECOMMENDATIONS 41
OIL SPECIFICATIONS 41
OIL TYPES 41
OIL CHANGES 25 HOURLY 41
OIL COOLER 41
GENERAL RECOMMENDATION 41
OIL VISCOSITY 42
OIL LINES & WHERE THEY GO 43
IN LINE SCAVENGE PUMP FITTMENT 47
OIL FLOW SCHEMATIC 48
ELECTRICAL SYSTEMS 50
GENERAL 50
WIRING REQUIREMENTS 50
ALTERNATOR 50
INSPECTION 50
ALTERNATOR DRIVE BELT 51
STARTER MOTOR 52
ELECTRICAL IGNITION 52
ELECTRICAL FUEL PUMP 53
ENGINE GAUGES 53
TACHOMETER 53
GROUNDING ELECTRONICS 54
BASIC WIRING DIAGRAM 54
FUEL SYSTEM 56
GENERAL 56
FUEL METERING 56
ROTEC TBI-MK.II ADJUSTMENT 56
BING CARBURETTOR OPERATION 56
MAGNETO IGNITION SET-UP 57
FUEL TYPES 57
FUEL & ADDITIVES 58
RECOMMENDED FUEL: 58
RECOMMENDED FUEL ADDITIVE: 58
FUEL SUPPLY 59
MECHANICAL PUMP: 59
ELECTRICAL BOOSTER PUMP: 59
6 | ROTEC AEROSPORT
www.RotecAerosport.com
TABLE OF CONTENTS
IGNITION LEADS & FIRING ORDER 60
R2800 DESIGNATION 60
R3600 DESIGNATION 60
ENGINE OPERATING PROCEDURE 62
WARNING: HYDRAULIC LOCK 62
HYDRAULIC LOCK SYMPTOMS 62
FLYING WITH A BENT ROD 62
CYLINDERS MOST SUBJECT TO HYDRAULIC LOCK 63
KEY POINTS 63
INTAKE PIPE DRAIN COCKS 63
HYDRAULIC LOCK QUICK CHECKLIST 64
PREVENTION: 64
CHECKING: 64
INITIAL ENGINE START PROCEDURE 65
AVOIDING HYDRAULIC LOCK 66
BEST PRACTICE START PROCEDURE 66
BEST PRACTICE ENGINE SHUTDOWN PROCEDURE 66
STARTING: ROTEC TBI FUEL SYSTEM 67
CONVENTIONAL STARTING: 67
HAND STARTING: 67
SUMMARY 68
ADVERSE OPERATING CONDITIONS 70
WINTER OPERATION 70
CARBURETTOR ICING 70
WATER IN FUEL 70
CARBURETTOR ICING 70
PERIODIC CHECKS 72
DAILY CHECKS 72
25 HOUR CHECKS 72
PSRU INSPECTION 73
50 HOUR CHECKS 73
100 HOUR CHECKS 73
2000 HOUR TBO 74
PROPELLER STRIKE 74
BY ROTEC AEROSPORT 74
DO IT YOURSELF 74
DETAILS 75
SHIPPING 76
SPARE OR REPLACEMENT PARTS 77
ENGINE MAINTENANCE 78
LUBRICATION 78
AIR INTAKE FILTER 78
CARBURETTOR ADJUSTMENT 78
COMPRESSION TEST 78
SPARK PLUGS 78
EXHAUST & INTAKE SYSTEM 79
ALL BOLTS & NUTS 79
TAPPET ADJUSTMENT PROCEDURE 79
ROTEC AEROSPORT | 7
www.RotecAerosport.com
ENGINE TUNING & TROUBLE SHOOTING 80
ENGINE INVERSION 80
VALVE LASH 80
IGNITION MODULE & PIN PLUG OUTLETS 80
ROCKER COVER OIL LEAKS 81
CYLINDER COMPRESSION TESTING 81
PROCEDURE: 81
RESULTS: 81
POTENTIAL CAUSES & RECTIFICATION: 81
GEARBOX NOISE (PSRU) 82
IGNITION TESTING 82
STARTING ISSUES: 82
LOWER CYLINDER OIL LEAKS 83
STORAGE & PRESERVATION 84
GENERAL 84
CORROSION & STORAGE 84
FLYABLE STORAGE 84
CORROSION AVOIDANCE 84
INDEFINITE STORAGE 85
ASSORTED SPECIFICATIONS 86
TORQUE SPECIFICATIONS FOR USER 86
PRESCRIBED SEALANTS & PRIMERS 86
8 | ROTEC AEROSPORT
www.RotecAerosport.com
RADIAL ENGINE
DESCRIPTION
R2800 (7 CYLINDER ENGINE)
DIMENSIONED FRONT VIEW
800 mm
31.5 "
Figure 1. R2800 Front View
ROTEC AEROSPORT | 9
www.RotecAerosport.com
DIMENSIONED SIDE VIEW
685 mm
27.0 "
920 mm
36.2 "
793 mm
31.2 "
Figure 2. R2800 Side View
10 | ROTEC AEROSPORT
www.RotecAerosport.com
REAR VIEW CYLINDER DENOMINATION
Figure 3. R2800 Cylinder Denomination
1
27
36
4
5
RADIAL ENGINE
DESCRIPTION
Ce manuel convient aux modèles suivants
1
Table des matières
