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Rotax 447 UL SCDI, Installation Manual

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INSTALLATION MANUAL

AIRCRAFT ENGINES

page 18 - 2

Initial issue, May 01/99

Effectivity: 447 UL SCDI, 503 UL DCDI, 582 UL DCDI /mod. 99

d00328

18.3)

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.

02822

15

02821

fig. 38

Summary of Contents for 447 UL SCDI

Page 1: ......

Page 2: ...ervice 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 deta...

Page 3: ...owing symbols to emphasize particular information These indications are important and must be respected WARNING Identifies an instruction which if not followed may cause serious injury including the p...

Page 4: ...propeller turning while on the ground Do not operate engine if bystanders are close To prevent unauthorized use never leave the aircraft unattended with the engine running Keep an engine log and resp...

Page 5: ...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...

Page 6: ...tion 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...

Page 7: ...7 3 Centre of gravity and moments of inertia 7 2 8 Preparations for engine installation 8 1 8 1 Engine preservation 8 1 8 2 Protective covering 8 2 9 Engine suspension and position 9 1 9 1 Definition...

Page 8: ...ake silencer 17 1 17 2 Air filter 17 4 18 Electric system 18 1 18 1 General 18 1 18 2 Function of the ignition unit 18 1 18 3 Wiring diagram 18 2 18 4 Lighting circuit 18 3 18 5 Technical Data and con...

Page 9: ...e 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...

Page 10: ...UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00313 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 documentat...

Page 11: ...8 2 99 05 01 9 9 1 99 05 01 9 2 99 05 01 10 10 1 99 05 01 10 2 99 05 01 11 11 1 99 05 01 11 2 99 05 01 11 3 99 05 01 11 4 99 05 01 11 5 99 05 01 11 6 99 05 01 12 12 1 99 05 01 12 2 99 05 01 12 3 99 0...

Page 12: ...INSTALLATIONMANUAL AIRCRAFT ENGINES page 4 2 Initial issue May 01 99 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00314 Chap Page Date ter Chap Page Date ter...

Page 13: ...NMANUAL AIRCRAFT ENGINES page 5 1 Initial issue May 01 99 d00315 5 List of amendments Currt no Chap ter Pages Date of modification Note of approval Date of approval by authority Date of insertion Mark...

Page 14: ...ENGINES page 5 2 Initial issue May 01 99 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00315 Currt no Chap ter Pages Date of modification Note of approval Date of approval by authority Date...

Page 15: ...47 UL SCDI 503 UL DCDI 582 UL 582 UL DCDI mod 99 Auxiliary equipment ATTENTION Any equipment not included as part of the standard engine version and thus not a fix component of the engine is not in th...

Page 16: ...e 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 2 propeller gear box 3 intake manifold 4 carbur...

Page 17: ...ectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 INSTALLATIONMANUAL AIRCRAFT ENGINES page 6 3 Initial issue May 01 99 d00316 6 3 2 503 UL DCDI 4 6 A A 02780 1 2 3 7 9 10 fig 2 Cyl 1 Cyl 2 02779 PTO...

Page 18: ...L AIRCRAFT ENGINES page 6 4 Initial issue May 01 99 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00316 6 3 3 582 UL DCDI and 582 UL DCDI mod 99 4 5 3 6 8 02042 1 2 7 9 10 fig 3 Cyl 1 Cyl 2...

Page 19: ...ine installation Joint face gearbox engine D X2 X2 X2 X2 Z2 Z2 Z3 Z1 Z1 Z3 A B C X1 X1 X3cy X3cy X3ba X3ba G E F C C C Engine Y2 Y2 Y2 Y2 Y3cy Y3ba Y3ba Y1 Y1 Y3cy C O G Reduction gear with propshaft...

Page 20: ...0 1 kg 0 22 lb intake silencer 1 1 kg 2 42 lb after muffler 1 6 kg 3 52 lb 7 3 Centre of gravity and moments of inertia 02852 02975 A D X2 X2 Y2 Y2 Z2 Z2 B 5 3 92 46 166 256 184 C 8 1 102 37 317 456...

Page 21: ...01 99 d00318 8 Preparations for engine installation ATTENTION The stated directives are measures needing your attention at engine installation to prevent accidents and engine damage 8 1 Engine preserv...

Page 22: ...se 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 carbu...

Page 23: ...e 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 WARNING All four attach...

Page 24: ...s torques 9 2 Permissible fitting positions Take care that all limits are in compliance with the Operator s Manual and Installation Manual ATTENTION Ensure that the carburetors are positioned vertical...

Page 25: ...ary modifications ask for manufacturer s approval in writing Check engine performance with serial exhaust system prior to any modification 02795 fig 8 For engine type 582 UL DCDI 40 with reduced perfo...

Page 26: ...nd and muffler end pipe for securing pin 5 The outer situ ated holes 2 have beenalreadymachined on the serial production line Remove accumulated chips from the exhaust system To ensure lasting fixed p...

Page 27: ...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 fol...

Page 28: ...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 h...

Page 29: ...e 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 valv...

Page 30: ...p 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 perfect...

Page 31: ...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...

Page 32: ...tial issue May 01 99 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00321 11 3 7 Water pump performance diagram and cooling system flow resistance graph measured on Standard 582 UL DCDI with...

Page 33: ...ned 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 WARNING In case...

Page 34: ...ug carefully 8 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 with oil NOTE Thi...

Page 35: ...L DCDI 582 UL DCDI mod 99 INSTALLATIONMANUAL AIRCRAFT ENGINES page 12 3 Initial issue May 01 99 d00322 Installation at ROTAX 503 UL DCDI 4 oil tank 5 oil filter 6 suction hose 7 oil pump 8 pressure ho...

Page 36: ...MANUAL AIRCRAFT ENGINES page 12 4 Initial issue May 01 99 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00322 Hs 4 5 6 7 8 9 fig 22 02807 NOTE The dimension Hs must be positive also at desce...

Page 37: ...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 appro...

Page 38: ...mp 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 ATTENTION For inverted installation the oil...

Page 39: ...f gear box fit magnetic plug and sealing ring 1 tightening torque 24 Nm 212 in lb and vent screw with sealing ring 2 tightening torque 6 Nm 53 in lb Generally replenish oil until oil emerges at the re...

Page 40: ...h of 6 5 mm and 8 2 mm dia but screws are not in the supply scope 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 typ...

Page 41: ...engine is running Thecarburetor s is are suppliedwithfuelbythefuelpumpprovidedwiththe engine Thepumpisactuatedpneumaticallyviaan impulselineleadingfromthenippleonthe crankcase to the fuel pump This li...

Page 42: ...cock for condensed 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...

Page 43: ...istribution 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 thrott...

Page 44: ...ainst 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 suppl...

Page 45: ...s as an option Intake silencer for single and dual carbs are available from ROTAX ATTENTION Atemploymentofanintakesilenceradifferentcarburetor jetting will be necessary 117 ROTAX DUAL CARBURETOR VERSI...

Page 46: ...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 situ...

Page 47: ...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 WARNING Screw on filter and silenc...

Page 48: ...ating 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 fi...

Page 49: ...ermanent 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 foreseen for connection of a revolution...

Page 50: ...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...

Page 51: ...ower 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...

Page 52: ...INSTALLATIONMANUAL AIRCRAFT ENGINES page 18 4 Initial issue May 01 99 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00328 fig 40 02824 fig 41 02823...

Page 53: ...582 UL DCDI mod 99 INSTALLATIONMANUAL AIRCRAFT ENGINES page 18 5 Initial issue May 01 99 d00328 fig 44 02826 fig 43 02827 fig 42 02828 18 5 2 Wiring diagram for rectifier regulator 264 870 not limited...

Page 54: ...rs 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 Conn...

Page 55: ...tton consumers fuse fig 46 02829 18 5 4 Electric starter Two types of electric starters can be fitted to ease starting procedures especially in flight Electric starter fitted on E type gearbox There i...

Page 56: ...ilized 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 mm2 flexible multi strand cable Power source from...

Page 57: ...it 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 instruction...

Page 58: ...1 99 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00329 d i a 8 2 M 8 0 1 5 d i a 6 5 0 1 5 P C D 100 P C D 7 5 dia 114 12 dia 25 4 0 1 fig 48 02841 19 1 2 C CL and E EL type gearbox Reduct...

Page 59: ...er head temperature spark plug seat temperature location and connection one each per cylinder fastened by onesparkplug Tightening Torque of spark plug 15 Nm 133 in lB fig 50 01004 fig 49 01005 20 2 Ai...

Page 60: ...20 2 Initial issue May 01 99 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00330 20 3 Exhaust gas temperature sensor location and connection Exhaust manifold assy 01002 fig 51 Tightening To...

Page 61: ...ALLATIONMANUAL AIRCRAFT ENGINES page 20 3 Initial issue May 01 99 d00330 20 4 Installation plan for the sensors on 582 UL DCDI and 582 UL DCDI mod 99 fig 52 01008 1 Sensor at spark plug seat CHT 2 Air...

Page 62: ...nitial issue May 01 99 Effectivity 447 UL SCDI 503 UL DCDI 582 UL DCDI mod 99 d00330 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...

Page 63: ...eed 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 a...

Page 64: ...horized 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 curre...

Page 65: ...l 171 414039 FAX 171 414116 E mail info lycon se Contact person Yard Johansson FRANCE BELGIUM MONACO LUXEMBURG MOTEURAERODISTRIBUTION 11 Blvd Albert 1 98000 MONACO Tel 7 93 30 17 40 Fax 7 93 30 17 60...

Page 66: ...ies rotec com website www rotec com NORTH MIDDLE SOUTH AMERICA KODIAKRESEARCHLTD P O Box N 7113 Marlborough House Cumberland Street NASSAU BAHAMAS Tel 242 356 5377 Fax 242 322 6784 E mail custsupport...

Page 67: ...SRAEL CONDOR AVIATIONINDUSTRIESLTD 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 J A P A N JUA LTD 1793...

Page 68: ...www cps parts com 800 247 9653...

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