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20 | ROTEC AEROSPORT

www.RotecAerosport.com

INSTALLATION, 

OPERATION &

SERVICE DOCUMENT

The Rotec Radial engine has been carefully engineered and constructed to meet all the performance requirements of 

the modern aero piston engine.

The following service / operations manual is the result of many hours of testing and observing the Rotec Radials in a 

range of operating conditions and situations and, therefore, Rotec Aerosport strongly advise strict adherence to the 

procedures and information supplied in this document.

Summary of Contents for AEROSPORT R2800

Page 1: ...www rotecaerosport com Revison Published 15 04 2007 10 08 2017 Version V3 ROTEC AEROSPORT PROPRIETARY INFORMATION THIS DOCUMENT IS PROPRIETARY PROPERTY OF ROTEC AEROSPORT PTY LTD IT IS NOT TO BE COPI...

Page 2: ...f 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...

Page 3: ...ed 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 suppo...

Page 4: ...5 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...

Page 5: ...OLER 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...

Page 6: ...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 IC...

Page 7: ...OMPRESSION 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...

Page 8: ...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...

Page 9: ...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...

Page 10: ...10 ROTEC AEROSPORT www RotecAerosport com REAR VIEW CYLINDER DENOMINATION Figure 3 R2800 Cylinder Denomination 1 2 7 3 6 4 5 RADIAL ENGINE DESCRIPTION...

Page 11: ...Chernikeef Configuration 7 Cylinder Radial Engine Four Stroke Ignition Systems Duel Rotec Electronic Magneto Firing Order 1 3 5 7 2 4 6 Carburettor TBI Mk II 40 S Bing mixture control Rated Power 110h...

Page 12: ...12 ROTEC AEROSPORT www RotecAerosport com DIMENSIONED FRONT VIEW R3600 9 CYLINDER ENGINE 840 mm 33 1 Figure 5 R3600 Front View RADIAL ENGINE DESCRIPTION...

Page 13: ...ROTEC AEROSPORT 13 www RotecAerosport com DIMENSIONED SIDE VIEW Figure 6 R3600 Side View 830 mm 32 7 965 mm 38 685 mm 27 0...

Page 14: ...14 ROTEC AEROSPORT www RotecAerosport com REAR VIEW CYLINDER DENOMINATION Figure 7 R3600 Cylinder Denomination 1 2 9 3 8 4 7 5 6 RADIAL ENGINE DESCRIPTION...

Page 15: ...aul Chernikeef Configuration 9 Cylinder Radial Engine Four Stroke Ignition Systems Rotec Electronic Firing Order 1 3 5 7 9 2 4 6 8 Carburettors TBI Mk II 40 S Bing mixture control Rated Power 150hp 24...

Page 16: ...ature 50 110 C 176 225 F Max Head Temperature Climb 220 C 420 F Continuous Head Temperature Cruise 180 C 365 F NOTE Read Cylinder Head Temp under inner most inlet flange bolt on cylinder 1 Crimp an 8m...

Page 17: ...OOLING SYSTEM The Rotec Radial engines are air cooled For any internal combustion engine an increase in power output results in an increase in heat energy As Rotec Radials share the cooling of 110hp o...

Page 18: ...CHT ring probe is placed under the inner intake M8 screw of the number 1 cylinder head top cylinder head A step washer can be used to adapt a larger ring probe to the underside of the screw M8 socket...

Page 19: ...ROTEC AEROSPORT 19 www RotecAerosport com...

Page 20: ...meet all the performance requirements of the modern aero piston engine The following service operations manual is the result of many hours of testing and observing the Rotec Radials in a range of oper...

Page 21: ...ROTEC AEROSPORT 21 www RotecAerosport com...

Page 22: ...arter motor alternator and carburettor all of which must be refitted prior to operation Step 1 Remove screws from lid of container Step 2 Remove lid from container Step 3 Remove screws from base of co...

Page 23: ...der upper most dead vertical The engine can now be hoisted via the inner most exhaust bolt see below of the 1 cylinder head This is the recommended hoisting position Once the engine is properly positi...

Page 24: ...neering draw ing will be generated and then sent back to you for your approval 4 We schedule fabrication once your approval is received ENGINE MOUNT FRAME NOTE While we have previously designed engine...

Page 25: ...all requires a cross brace to increase the rigidity of the mount Top Bottom Cross Braces The propeller rotates counter clockwise viewing from in front of the engine resulting in an opposing torque on...

Page 26: ...m 12 8 325mm 12 8 450mm TYP 17 7 3 8 Bolts required 10mm Bolt Holes 20mm TYP 0 8 Mount Verticies P1 and P2 must be exactly 20mm vertically offset from the centre to avoid interference with the Starter...

Page 27: ...the fuel pump TOP alternator SIDE and starter motor SIDE All tubes OD 250mm 8 9 250mm 2 9 20mm 0 8 Mount Verticies P1 and P2 must be exactly 20mm vertically offset from the centre to avoid interferenc...

Page 28: ...Aerosport com ENGINE MOUNT FRAME SIDE VIEW NOTE Typical engine frame geometry The stagger pf the upper and lower weldable cup and hollow pin Tubes OD Figure 22 R2800 Engine Mount Side View Figure 23 R...

Page 29: ...ROTEC AEROSPORT 29 www RotecAerosport com TOP VIEW NOTE Typical engine frame geometry See Rotec cup type mounts welded to frame Tubes OD 254mm Figure 24 Engine Mount Top View...

Page 30: ...nt assembly all supplied the steel centre section is the weldable cup which will be welded to the engine frame It supports the engine via the four rubber engine mount cushions the entire assembly is c...

Page 31: ...ROTEC AEROSPORT 31 www RotecAerosport com Figure 14 R3600 Engine Mount ISO Front View Figure 15 R3600 Engine Mount ISO Rear View...

Page 32: ...ubber cushions to the correct amount once the metal componenents have bottomed out out at a length set by design Further tightening beyond this point will not increase the crush on the rubber cushions...

Page 33: ...ROTEC AEROSPORT 33 www RotecAerosport com Figure 18 R2800 Engine Mount ISO Front View Figure 19 R2800 Engine Mount ISO Rear View...

Page 34: ...al of Alternator Connect the main battery 5mm wire to ALTERNATOR Check the Alternator base mount is tight Check the Alternator adjuster is tight Check the Alternator belt is aligned tight and in pulle...

Page 35: ...ROTEC AEROSPORT 35 www RotecAerosport com...

Page 36: ...sfully used on a Zenith CH 200 PERFORMANCE BY POWER SETTING MOUNTING BOLTS Rotec Radial Power Setting Target Engine RPM Target Propeller RPM 100 Static 3000 3100 2000 2067 100 Take Off 3250 3350 2167...

Page 37: ...supply aircraft propellers We can recommended the following manufacturers and you are welcome to source your own For more information on propellers try Culver Props Valley Engineering http www culverp...

Page 38: ...Oil pump suction pick up AN fitting to suit 3 8 ID hose mounted slightly above lowest point on tank so as to avoid sedimentary debris G Oil temperature sender mounted to lowest point on tank could als...

Page 39: ...fled away from other ports 1 x Oil Outlet Size 3 8 NPT Threaded Port Location Underside 1 x Oil Temperature Sender Size 1 4 NPT Threaded Port Location Low so that it is submerged in oil at all times 1...

Page 40: ...ounted slightly above lowest point on tank so as to avoid sedimentary debris G Oil temperature sender mounted to lowest point on tank could also be sued as a sump plug H Oil filler port and cap Could...

Page 41: ...conditions where oil temp will be above 120C Castrol GPS 4 stroke bike oil 10W 50 NOTE As a general guide Rotec use Castrol GPS 10W 50 grade oil for all testing year round in Melbourne Australia whic...

Page 42: ...appropriate viscosity for your climate 40 C 100 F 80 60 40 20 0 20 30 20 10 0 10 20 30 0 0 Multi Grade Oils Climatic Conditions Tropical Temperate Arctic SAE 20W 50 SAE 20W 40 SAE 15W 50 SAE 15W 40 SA...

Page 43: ...intake 1 The oil leaves the engine from drain ports located beneath the engine Oil drains down and fills the cylindrical scavenge sump located between the two lower cylinders The upper most connection...

Page 44: ...suction or port side of the scavenge pump Fig 26 3 The oil then exits the same pump on the starboard side of the scavenge pump Fig 27 where it then connects to a nipple mounted in a high position on...

Page 45: ...suction side yellow arrow of the pressure pump Fig 28 5 The oil then exits the pressure pump from it s port side fitting fig 28 Red arrow a hose connects this fitting to the three way oil filter reli...

Page 46: ...ow The remaining oil pressure exits the unit via the lower fitting indicated by the white arrow where it then finally connects to the engine via a fitting located between Fig 31 Final oil pressure inl...

Page 47: ...gh the unfiltered scavenge pump gears No oil can actually enter the engine unfiltered due to the main oil filter but without the in line filter oil could be drawn from the engine unfiltered through th...

Page 48: ...ure Warning Light Oil Pressure Send Port both are 1 8 NPT Oil Temp Sensor optional R2800 Capacity 8 Litres 2 1 US Gal R3600 Capacity 10 Litres 2 64 US Gal A 1 8 NPT Port for a temp sensor is required...

Page 49: ...49 www RotecAerosport com ief Valve Fuel Pump Optional Extra Scavenger Pump Fitting ional cavenger mp der Engine Sump Main Oil Pressure Pump Carburettor Manifold Oil Pressure Into Engine 9 16 JIC F Oi...

Page 50: ...QUIREMENTS The following section covers in depth the steps required to install electrical sub systems on your radial engine with a brief description of the components function INSPECTION The alternato...

Page 51: ...00 alternator drive belt The belt tension being too low The close center distance between the two pulleys makes the belt tension feel a lot tighter than it really is Misaligned pulley grooves Shim bas...

Page 52: ...STARTER MOTOR STARTER MOTOR WIRING REQUIREMENTS WARNING TO AVOID HYDRAULIC LOCK IT IS MOST IMPORTANT THAT IN YOUR WIRING DURING CONSTRUCTION THAT THE STARTER MOTOR IS SEPARATED FROM THE IGNITION MAG...

Page 53: ...NNECTING Pin 4 and 5 connect to the 12VDC bus For a tachometer pulse connect pin 8 on the tachometer to Wire 7 on the ignition module which provides a digital signal square wave The negative side of t...

Page 54: ...e battery Aircraft using a metal air frame can ground components to the chassis much like a car Aircraft using a composite or wooden air frame can use a negative bus for ease of grounding ELECTRICAL S...

Page 55: ...SPORT 55 www RotecAerosport com LTERNATOR LAMP 3WATT LEC IGN SWITCH CAVENGER PUMP PTIONAL EXTRA SERVO LEAD IGN MODULE MAG TRIGGER NOT REQUIRED ON CURRENT MODEL IGN COIL MAGNETO KILL SWITCH ALTERNATOR...

Page 56: ...and control fuel mixture at higher power settings They should not be tampered without first consultation a Rotec technician A too lean mixture due to the installation of incorrect jet specifications...

Page 57: ...advise customers who intend to use unleaded fuels to first consult with Rotec Carburettor and ignition timing may need alteration FUEL TYPES As mentioned earlier the R 2800 utilises two full time inde...

Page 58: ...ming set to 22 degrees to avoid any uncontrolled detona tion When using Premium Unleaded fuels 95 RON or higher usage should be interrupted from time to time with the one or more tanks of AVGAS AVGAS...

Page 59: ...t cases fuel pressure will be too high Parallel Better redundancy as if the mechanical pump were to rupture fuel sup ply will continue Can be used with the Bing Carburettor Electrical pump re quires a...

Page 60: ...p cylinder number one for the R2800 and number nine cylinder for the R3600 From this same front view the firing order is every alternate cylinder i e 1 3 5 7 2 4 6 etc see fig 33 34 Both rotor buttons...

Page 61: ...ROTEC AEROSPORT 61 www RotecAerosport com...

Page 62: ...her flight should cease if you experience one or more of these symptoms until the cause can be accounted for If the deformation is slight the engine may start and run seemingly without problem In gene...

Page 63: ...cuum strong enough to remove any accumulated oil However once the engine is started under power ignition on the piston speed does become sufficient to create a vacuum strong enough to suck the oil bac...

Page 64: ...th can be recognised 1 Check the intake drains were left open from a previous engine start A If they were left shut open them and allow any oil to drain completely before proceeding No drips at all mu...

Page 65: ...n If this occurs remove lower spark plugs and drain out trapped oil and start hydraulic procedure over Switch master ON but leave all spark and fuel sources OFF Crank engine by starter motor for a few...

Page 66: ...engines by nature when static or allowed to idle at very low rpm s for an extended period of time tend to ac cumulate excess oil in any area below the horizontal centre line of the engine s crank case...

Page 67: ...ready to be hand propped for starting 5 Turn on ignition 6 Standing in front of engine throw the propeller from the top to bottom CCW whilst stepping back in caution 7 Engine starts NOTE Inadequate a...

Page 68: ...shutdown may position the intake valves allow oil to seep past and into the intake pipe This accumulated oil unless removed can be sucked back into the combustion chamber resulting in hydraulic lock...

Page 69: ...ROTEC AEROSPORT 69 www RotecAerosport com...

Page 70: ...ng may occur in the venturi of the carburettor Left unchecked it can lead to failure of the fuel system Rectifying this engine debilitating condition requires directing preheated air though the carbur...

Page 71: ...ROTEC AEROSPORT 71 www RotecAerosport com...

Page 72: ...gine mount rubbers for looseness or deterio ration Remove nose and visually inspect PSRU condition see PSRU Check for missing or loose bolts nuts clamps and pins Check all accessories intake and exhau...

Page 73: ...s via these hollows to feed oil to the planet gear bushings 7 Refit nose with T mark to the top 8 Tighten all 14 x M6 Nylok nuts to 90 INCH pounds of torque MAX TO INSPECT PSRU INTERIOR Drain oil from...

Page 74: ...tion oil leaks at the very least Save time and hassle of doing it yourself Price Instead of purchasing replacement overhaul parts then potentially causing more harm than good by installing them contac...

Page 75: ...egraded Parts Rubber and Gaskets Serviceable Parts Oil Filter Alternator Belt and Oil seals Technically Obsolete Parts designs improved to extend reliability Rotec is always improving Cosmetically Obs...

Page 76: ...uare of an approximately 250mm see Figure The blocks themselves are screwed to the ply plate via long screws from beneath the 400 square ply plate Then the ply plate with blocks attached is screwed do...

Page 77: ...Electric Ignition Module 1 x Fan Belt 1 x Fan Belt 2 x Rotor Buttons 2 x Rotor Buttons 1 x Wiring Harness 1 x Wiring Harness 2 x Distributor Cap Clips 2 x Distributor Cap Clips 14 x Rocker Cover Gaske...

Page 78: ...in Engine Tunning Trouble Shooting chapter p 81 Do not sand blast or use similar abrasives to clean spark plugs Also never wire brush or buff plugs this can transfer thread damage to delicate ally cyl...

Page 79: ...thin rod like a pen or dowel don t drop it and feel the piston come up jog the crank back and forth until you are approx at TDC on this the compression stroke This is close enough for setting the tap...

Page 80: ...r to the seat on the head on the valve 2 Loosen the valve adjuster 1 8th of a turn 3 Tighten the valve adjuster so it can no longer move 4 Confirm with a feeler gauge the correct valve lash has been s...

Page 81: ...istort the rocker cover Using a 5 mm hex key torque settings for rocker cover screws M6 X 25 are to be between 8 9 N m 70 80 lbs in Run the engine as normal to warm the oil Switch off the engines fuel...

Page 82: ...t NOT too much or you can pull the end of the crank thread off Rattle guns can apply over 250 ft lbs There is no need to safety wire the bell nut just use the same anaerobic adhesive on the thread and...

Page 83: ...tainers on the exhaust pipes to catch oil as it drains You can catch oil from the intake drains by connecting 1 2 hose Drained oil is always reused by using a strainer and funnel to recy cle it back i...

Page 84: ...is fitted to an air frame refer to the manufacturer s service manual for all airframe recommendations and procedures If the engine is not fitted to an air frame ignore those items refer ring to the a...

Page 85: ...spark plug hole of each cylinder Possible Anti Corrosion Oils include Shell Aero Fluid 2XN Anti Corrosion Oil WD 40 or similar penetrating oil 4 Rotate the crankshaft by hand to lubricate any reciproc...

Page 86: ...Bolts 8 25 Magneto Coil Bolts 5 10 Item Sealant Oil Pump Bolts Loctite 620 Distributor Scavenge Pump Bolts Loctite 262 Carburettor Manifold Bolts Loctite 262 Front Oil Seal Retainer Bolts Loctite 620...

Page 87: ...ROTEC AEROSPORT 87 www RotecAerosport com...

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