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ROTEC
AEROSPORT
RADIAL ENGINE
OPERATIONS MANUAL
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.
Date Published
Revison Published
Rotec Aerosport
Radial Engine Operations Manual
10
08
2017
15
04
2007
www.rotecaerosport.com
Version
V3
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Table of Contents
Summary of Contents for Rotec AEROSPORT R2800
- Page 1 OPERATIONS MANUAL 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. Date Published...
- Page 2 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 benefit. Congratulations on the purchase of your band new Rotec Radial engine. Rotec’s radials are constructed with the high- est level of precision &...
- Page 3 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. NOTE: IMPORTANT: WARNING 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”...
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Page 4: Table Of Contents
CHT (CYLINDER HEAD TEMPERATURE) EGT ( EXHAUST GAS TEMPERATURE) INSTALLATION, OPERATION & SERVICE DOCUMENT UN-PACKING & MOUNTING` PACKAGING REMOVAL PROCESS ENGINE MOUNTING PROCESS ENGINE MOUNT FRAME MANUFACTURED BY ROTEC AEROSPORT DO IT YOURSELF FRONT VIEW REAR VIEW SIDE VIEW TOP VIEW ENGINE INSTALLATION R3600 &... - Page 5 PERFORMANCE BY POWER SETTING MOUNTING BOLTS PROPELLER MANUFACTURERS LUBRICATION SYSTEM/ PLUMBING GENERAL OIL TANK BASIC DESIGN REQUIREMENTS OIL TANK BY ROTEC AEROSPORT OIL TANK DO IT YOURSELF OIL TANK BASIC DESIGN REQUIREMENTS ENGINE CONNECTIONS ENGINE OIL RECOMMENDATIONS OIL SPECIFICATIONS OIL TYPES...
- Page 6 HYDRAULIC LOCK QUICK CHECKLIST PREVENTION: CHECKING: INITIAL ENGINE START PROCEDURE AVOIDING HYDRAULIC LOCK BEST PRACTICE START PROCEDURE BEST PRACTICE ENGINE SHUTDOWN PROCEDURE STARTING: ROTEC TBI FUEL SYSTEM CONVENTIONAL STARTING: HAND STARTING: SUMMARY ADVERSE OPERATING CONDITIONS WINTER OPERATION CARBURETTOR ICING WATER IN FUEL...
- Page 7 POTENTIAL CAUSES & RECTIFICATION: GEARBOX NOISE (PSRU) IGNITION TESTING STARTING ISSUES: LOWER CYLINDER OIL LEAKS STORAGE & PRESERVATION GENERAL CORROSION & STORAGE FLYABLE STORAGE CORROSION AVOIDANCE INDEFINITE STORAGE ASSORTED SPECIFICATIONS TORQUE SPECIFICATIONS FOR USER PRESCRIBED SEALANTS & PRIMERS ROTEC AEROSPORT | 7 www.RotecAerosport.com...
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Page 8: Radial Engine Description
RADIAL ENGINE DESCRIPTION R2800 (7 CYLINDER ENGINE) DIMENSIONED FRONT VIEW 800 mm 31.5 " Figure 1. R2800 Front View 8 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 9: Dimensioned Side View
DIMENSIONED SIDE VIEW 685 mm 27.0 " 793 mm 31.2 " 920 mm 36.2 " Figure 2. R2800 Side View ROTEC AEROSPORT | 9 www.RotecAerosport.com... -
Page 10: Rear View Cylinder Denomination
RADIAL ENGINE DESCRIPTION REAR VIEW CYLINDER DENOMINATION Figure 3. R2800 Cylinder Denomination 10 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 11: R2800 Technical Data
Figure 4. R2800 ISO View ENGINE DESCRIPTION Designers: Matthew & Paul 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 DIMENSIONS & WEIGHT Bore: 80mm (3.15’’) -
Page 12: R3600 (9 Cylinder Engine)
RADIAL ENGINE DESCRIPTION R3600 (9 CYLINDER ENGINE) DIMENSIONED FRONT VIEW Figure 5. R3600 Front View 12 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 13: Dimensioned Side View
DIMENSIONED SIDE VIEW 685 mm 27.0’ 830 mm 32.7’’ 965 mm 38’’ Figure 6. R3600 Side View ROTEC AEROSPORT | 13 www.RotecAerosport.com... -
Page 14: Rear View Cylinder Denomination
RADIAL ENGINE DESCRIPTION REAR VIEW CYLINDER DENOMINATION Figure 7. R3600 Cylinder Denomination 14 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 15: R3600 Technical Data
Take Off / Maximum Continuous RPM 150hp @ 3700 RPM Propeller / RPM Fixed 80’’ Diameter x 55’’ Pitch @ 2,450 RPM FUEL CONSUMPTION Fuel Consumption @ 75% Power (cruise) AVGAS 100 LL 28 Litres / hr (7.4 gallons) ROTEC AEROSPORT | 15 www.RotecAerosport.com... -
Page 16: Universal Engine Data
* Read Cylinder Head Temp under inner most inlet flange bolt on cylinder # 1. Crimp an 8mm ID terminal to a “K” type thermo couple and place under inlet flange cap screw. Use an alloy washer so as not to tear face of terminal. 16 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 17: Serial Number
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 or 150hp over 7or 9 cylinders respective- ly, there is far more margin for air-cooling compared to a 6 cylinder engine producing 120hp. In addition, compared to other engine configurations, (i.e. -
Page 18: Cht (Cylinder Head Temperature)
It may be possible to include a ring probe under the rear spark plug if bent at a 90°. EGT ( EXHAUST GAS TEMPERATURE) Monitoring Status: Optional, although recommended for determining mixtures when using the Rotec TBI Fuel System. Gauge Range: Approximately 32°F to 1652°F (0°C to 900°C) Probe / Sensor Location: Anywhere on the number 1 cylinder exhaust collector ring section (top cylinder). - Page 19 ROTEC AEROSPORT | 19 www.RotecAerosport.com...
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Page 20: Installation, Operation & Service Document
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. - Page 21 ROTEC AEROSPORT | 21 www.RotecAerosport.com...
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Page 22: Un-Packing & Mounting
PACKAGING REMOVAL PROCESS Each Rotec engine is packaged to enable the safest mode of transportation practically possible. To achieve this, the engine has been placed horizontally with the accessories section facing the base of the container, the centre of gravity is further lowered by the removal of the starter motor, alternator and carburettor;... -
Page 23: Engine Mounting Process
Once the engine is properly positioned on the hoist, the engine can be pushed into position and aligned with the en- gine mount housing. When the engine has been fastened to the mount, the hoist can be removed. ROTEC AEROSPORT | 23 www.RotecAerosport.com... -
Page 24: Engine Mount Frame
FRAME MANUFACTURED BY ROTEC AEROSPORT We design and fabricate Rotec Radial engine mounts specifically for your airframe. Save the time and hassle of doing it yourself. The fastest way and often cheapest way to move your project forward is to have one of our experienced fabrications produce auxiliary components for you. -
Page 25: Do It Yourself
DO IT YOURSELF Some customers choose to fabricate their engine mount themselves. All Rotec Radial engine purchases without an engine mount are provided with specific Rotec hardware to make this process easier (see Figure #). The following specifications are to be considered when fabricating a Rotec Radial engine mount: Engine Position: A Radial engine has a central line 10 - 15cm (4 - 6’’) lower than a typical flat engine. -
Page 26: Front View
Starter Motor and Alternator. NOTE: Typical engine frame geometry. Tubes welded to Standard Rotec Mounting Pins (Supplied). Tubes ½’’ OD. Figure 20. R2800 Engine Mount Dimensioned Front View 26 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 27: Rear View
(TOP) alternator (SIDE) and starter motor (SIDE). All tubes ½’’ OD. Figure 21. R2800 Engine Mount Dimensioned Rear View ROTEC AEROSPORT | 27 www.RotecAerosport.com... -
Page 28: Side View
SIDE VIEW Figure 22. R2800 Engine Mount Side View Figure 23. R3600 Engine Mount Side View NOTE: Typical engine frame geometry. The stagger pf the upper and lower weldable cup and hollow pin. Tubes ½’’ OD. 28 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 29: Top View
TOP VIEW 254mm Figure 24. Engine Mount Top View NOTE: Typical engine frame geometry. See Rotec cup type mounts welded to frame. Tubes ½’’ OD. ROTEC AEROSPORT | 29 www.RotecAerosport.com... -
Page 30: Engine Installation
Flared Sleeves R.068 Mount Cups R.063.2 Flat Washers NM10N Nyloc Nut M10 Figure 11. Exploded Engine Mount Cup Side View Figure 12. Engine Mount Cup Detail View Figure 13. Exploded Engine Mount Cup ISO View 30 | ROTEC AEROSPORT www.RotecAerosport.com... - Page 31 Figure 14. R3600 Engine Mount ISO Front View Figure 15. R3600 Engine Mount ISO Rear View ROTEC AEROSPORT | 31 www.RotecAerosport.com...
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Page 32: R2800 Lower Pin Mounts
Nyloc Nut M10 NM8N Nyloc Nut M8 SHCSM8120 SHCS M8 x 120 Figure 15. Exploded Engine Mount Pin Side View Figure 16. Engine Mount Pin Detail View Figure 17. Exploded Engine Mount Pin Side View 32 | ROTEC AEROSPORT www.RotecAerosport.com... - Page 33 Figure 18. R2800 Engine Mount ISO Front View Figure 19. R2800 Engine Mount ISO Rear View ROTEC AEROSPORT | 33 www.RotecAerosport.com...
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Page 34: Installing The Engine On The Frame
• Fit Distributor Caps and make sure all the Distributor Caps are in position. NOTE: If Distributor Caps are not down properly, the brush is probably sticking out to far. • Connect the battery cautiously. 34 | ROTEC AEROSPORT www.RotecAerosport.com... - Page 35 ROTEC AEROSPORT | 35 www.RotecAerosport.com...
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Page 36: Propeller
When selecting a propeller with a pitch greater than recommended, a reduction in propeller diameter is necessary. For example, a Rotec R2800 with a 76’’ diameter propeller, with a pitch of less than 53’’, will see the engine over speed at WOT. -
Page 37: Propeller Manufacturers
PROPELLER MANUFACTURERS Rotec does not 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.culverprops.com/contact.php Whirl Wind Propellers http://whirlwindpropellers.com/aircraft/ ROTEC AEROSPORT | 37... -
Page 38: Lubrication System/ Plumbing
OIL TANK The Rotec Radial utilises a full dry sump lubrication system and, as a result, requires the use of an oil tank, which is mounted separately from the engine. The oil tank construction is the responsibility of the aircraft manufacturer and should be designed within the parameters of the airframe, which, of course, will vary for each machine. -
Page 39: Oil Tank Do It Yourself
1 x Oil Drain Sump Plug • Optional, most customers omit this and just disconnect the outlet when draining • Size - As available. Rotec uses M16 Magnetic sump plug • Location - Underside, so that as much oil as possible can drain out •... -
Page 40: Oil Tank Basic Design Requirements
The above mentioned oil tank does not facilitate inverted flight or negative gravity operation. Oil starvation for just a short period of time can cause engine failure and/or permanent engine damage. ENGINE CONNECTIONS See Rotec Radial Oil Circuit Schematic (Figure #) Engine Oil: •... -
Page 41: Engine Oil Recommendations
Shell Advance VSX4 15W-50 for standard operating conditions where the oil temp will be above 120 C • Castrol GPS (4s stroke motorcycle oil) 10W-50 NOTE: As a general guide, Rotec uses Castrol GPS 10W-50 grade for all year round testing in Melbourne, which falls into the Temperate 10-40C zone. ROTEC AEROSPORT | 41 www.RotecAerosport.com... -
Page 42: Oil Viscosity
OIL VISCOSITY A multi-grade oil is recommended. Refer to Figure # to select the appropriate viscosity for your climate. Climatic Multi-Grade Oils Conditions Tropical Temperate Arctic Figure #. Selection of oil viscosity based on climate conditions. 42 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 43: Oil Lines & Where They Go
(See fig. 25.) Vent Scavenge Port (Figure 25. Red arrow AN ( 5/16” OR 3/8” ID) pick up to main scavenge pump. Yellow arrow to vent on main oil tank.) ROTEC AEROSPORT | 43 www.RotecAerosport.com... - Page 44 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 the main oil tank. (Fig 27.. Scavenge pump exit OUT fitting en-route to tank) 44 | ROTEC AEROSPORT www.RotecAerosport.com...
- Page 45 / relief valve body (fig 29.) which is remotely mounted as close to the engine as practicality possible (eg. fire wall). (Fig. 29. Oil filter/ relief valve block and standard AN fittings) NOTE: Oil Filter Block Threads Large Diameter Hole 3/8 NPT Small Diameter Hole 1/8 NPT ROTEC AEROSPORT | 45 www.RotecAerosport.com...
- Page 46 #5 & 6. (Fig 31.) Note also the two blue arrows these are indicating the positions for the VDO oil pressure sender and the VDO oil pressure warning light / engine hour switch. (Fig. 31. Final oil pressure inlet fitting AN type for 3/8” ID hose) 46 | ROTEC AEROSPORT www.RotecAerosport.com...
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Page 47: In Line Scavenge Pump Fittment
IN LINE SCAVENGE PUMP FITTMENT Rotec radial engines require the use of an in-line filter to the suction hose between the mini collector sump and the main scavenge pump inlet. The filter can be mounted in alternate positions other than shown in (Figure #.) but must always be mounted in series before the gear pump inlet. -
Page 48: Oil Flow Schematic
Light & Oil Pressure Send Rotec built oil Port both are 1/8 NPT tanks. Opti 12 Volt Sc R2800 Capacity = 8 Litres (2.1 US Gal) R3600 Capacity = 10 Litres (2.64 US Gal) 48 | ROTEC AEROSPORT www.RotecAerosport.com... - Page 49 Fuel Oil Scavenger Pump Pump ief Valve Carburettor Manifold Oil Pressure Into Engine 9/16’’ JIC F Main Oil Pressure Pump ional cavenger Engine Sump Optional Extra Scavenger Pump Fitting ROTEC AEROSPORT | 49 www.RotecAerosport.com...
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Page 50: Electrical Systems
SYSTEMS GENERAL The Rotec Radial has the desirable ability to run in full mechanical mode continuously and does not depend solely on electrical supply. However in an endeavor to complement the mechanical features Rotec Aerosport has incorporated a 35amp 12volt alternator, which continuously supplies the entire electrical system. -
Page 51: Alternator Drive Belt
• Forgetting to tighten the lower alternator mount as it is somewhat hidden. When this is not tightened, the loose alternator tends to sit on an angle causing belt misalignment. Contact Rotec for replacement parts. ROTEC AEROSPORT | 51 www.RotecAerosport.com... -
Page 52: Starter Motor
The auto style ignition coil should be mounted with the high-tension post vertical. It is for this reason that push on coil terminals are not permitted as they are fighting gravity. NOTE: Both the magneto and Electronic ignition timing are factory set prior to shipping. 52 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 53: Electrical Fuel Pump
• Tachometer TACHOMETER Rotec Aerosport recommends using the standard Rotec Radial Tachometer - VDO Part # 333 035 011. More informa- tion can be found in the Appendix #. Other tachometers can be used at the users discretion. Connecting: CONNECTING: •... -
Page 54: Grounding Electronics
Aircraft using a composite or wooden air frame, can use a negative bus for ease of grounding. BASIC WIRING DIAGRAM FUSE MASTER SWITCH 18ga MAIN BUS 12ga 12ga 12ga 18ga 18ga 12ga 12ga START SWITCH SPRING RETURN 12V BATTERY STARTER MOTOR 54 | ROTEC AEROSPORT www.RotecAerosport.com... - Page 55 CAVENGER PUMP PTIONAL EXTRA) SERVO LEAD IGN. MODULE MAG. TRIGGER (NOT REQUIRED ON CURRENT MODEL) LEC. IGN. SWITCH LTERNATOR LAMP 3WATT 18ga IGN. COIL MAGNETO ALTERNATOR 18ga KILL SWITCH ROTEC AEROSPORT | 55 www.RotecAerosport.com...
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Page 56: Fuel System
The carburettor is a 40mm type 94 Bing and features automatic pressure compensating mixture control. There is no manual mixture control. The carburettor is factory set on the test run by Rotec and should only require minor adjust- ments. The carburettor is supplied as standard from Bing with stock control levers. The levers and butterfly return spring may require modifications to suit. -
Page 57: Magneto Ignition Set-Up
FUEL TYPES Rotec Aerosport have tested a variety of petrol grades and recommend the use of all types of aviation gas (Petrol) including Shell 100LL or better. AVGAS has proven to be cleaner burning with less spark plug deposits. High-octane premium unleaded or leaded auto fuel is permissible where AVGAS is unavailable;... -
Page 58: Fuel & Additives
RECOMMENDED FUEL: The fuel of choice for the Rotec R2800 and R3600 is AVGAS. The compression ratio of the R2800 and R3600 is 8.5:1. All engines built before late 2005 (“B” specification) should restrict fuel type to AVGAS until ignition timing is reduced to 22 degrees to meet later model engines. -
Page 59: Fuel Supply
NOTE: Fuel pressure supplying the Bing Carburettor should not exceed 4 psi. If it does, a fuel regulator must be used. En- gines using the Rotec TBI Fuel System have greater fuel pressure tolerance. ROTEC AEROSPORT | 59 www.RotecAerosport.com... -
Page 60: Ignition Leads & Firing Order
R2800 DESIGNATION Hall Distributor Mag Distributor (Fig 33. Distributor caps and ignition lead positions in correct firing order) R3600 DESIGNATION Hall Distributor Mag Distributor (Fig #. Distributor caps and ignition lead positions in correct firing order) 60 | ROTEC AEROSPORT www.RotecAerosport.com... - Page 61 ROTEC AEROSPORT | 61 www.RotecAerosport.com...
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Page 62: Engine Operating Procedure
Further flight should cease if you experience one or more of these symptoms until the cause can be accounted for. NOTE If you believe you have suffered Hydraulic Lock, contact Rotec Aerosport to seek technical advice and or rectification strategies. -
Page 63: Cylinders Most Subject To Hydraulic Lock
Once the engine is started, the speed is high enough to suck the oil back into the chamber. It is imperative that the fitted drain cocks be employed. INTAKE PIPE DRAIN COCKS (Fig #. R2800 Drain Cocks example) ROTEC AEROSPORT | 63 www.RotecAerosport.com... -
Page 64: Hydraulic Lock Quick Checklist
After the engine has run, open the intake drains to allow any oil to drain. If the engine is not running, the intake drains should always be open. Intake drain locations: Rotec R2800 – 2 lowest intake pipes Rotec R3600 – 3 lowest intake pipes Do not switch the ignition on until the starter has cranked for at least five seconds. -
Page 65: Initial Engine Start Procedure
It is not recommended to exceed 3700 crankshaft rpm. WARNING: Subsequent restarts should not require oil priming. Hydraulic lock procedure must be employed prior to ALL starts. Hydraulic lock is more prevalent with a hot engine due to lower oil viscosity. ROTEC AEROSPORT | 65 www.RotecAerosport.com... -
Page 66: Avoiding Hydraulic Lock
On subsequent re starts the less oil in the engine the better as the chance of hydraulic lock is greatly reduced. Extended periods of Idling should be avoided as oil will not only build up in the crank case but also the risk of cylinder glazing is increased due to reduced piston ring pressure. 66 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 67: Starting: Rotec Tbi Fuel System
STARTING: ROTEC TBI FUEL SYSTEM CONVENTIONAL STARTING: Hydraulic Lock check Turn on fuel pump Set mixture to Full Rich Set Throttle to WOT Depress the regulator override for 5 seconds, priming the intake with fuel* Set throttle to closed Announce “Clear Prop!”... -
Page 68: Summary
The fact that the Rotec Radial starts easily and runs so smoothly can lead to complacency. Do not allow complacen- cy creep into your start up and shut down procedures. Its important that you memorize the prevention and checking procedure and understand the reasoning behind them. - Page 69 ROTEC AEROSPORT | 69 www.RotecAerosport.com...
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Page 70: Adverse Operating Conditions
Use of carburettor heat is recommended as part of normal landing procedures. If a go around is necessary, first insure you have a positive rate of climb and flight conditions allow before turning the carburettor heat off. Carb heat is not needed for normal take-offs. 70 | ROTEC AEROSPORT www.RotecAerosport.com... - Page 71 ROTEC AEROSPORT | 71 www.RotecAerosport.com...
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Page 72: Periodic Checks
INSPECT PSRU (see next heading). IMPORTANT: Users should STRICTLY change oil and BOTH (2) filters every 25 hours. This will keep the engine clean, free of corro- sion, avoid gallery blockages and keep oil lubricity effective. 72 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 73: Psru Inspection
PSRU INSPECTION Rotec Aerosport instructs all owners to schedule a PSRU/Nose inspection every 25 hours of engine operation. Fail- ure to regularly change the oil and both filters can lead to gallery blockages causing oil starvation to the planet gear bushings. -
Page 74: 2000 Hour Tbo
PERIODIC CHECKS 2000 HOUR TBO • At present all overhaul work to be carried out by Rotec Aerosport Australia Pty Ltd. Or by a Rotec approved ser- vice man (to be advised). • Where necessary, changes to the TBO limit or service schedule will be announced by Rotec Aerosport Australia. -
Page 75: Details
DETAILS When overhauled by Rotec, once received, can take 3 to 4 weeks. There may be delays depending on circumstance. Procedure: • Full engine tear down • Inspection of all parts • Replacement of necessary parts, including: • Degraded Parts - Rubber and Gaskets •... -
Page 76: Shipping
NOTE: If applicable, the engine can be transported with all cylinders removed. This is to reduce shipping costs as the create is much smaller. 76 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 77: Spare Or Replacement Parts
Rotec offers a variety of spare and replacement parts. Please contact Sales@RotecAerosport.com for more details on the following packages. Emergency Kit: Covers most items which are hard to source outside of Rotec. These parts are common service items and can be used as replacement parts in the field. Sometimes called the survival kit. Contents:... -
Page 78: Engine Maintenance
Colouration Signifies Light Tan - Gray Colour Indicates good mixture. Very Light/Chalky White or Melted end Too Lean mixture. Black Velvet Colour Indicates too rich mixture. B;acl wet/glossy Indicates oil and or too rich mixture. 78 | ROTEC AEROSPORT www.RotecAerosport.com... -
Page 79: Exhaust & Intake System
• Firstly the Rotec Radials, like all four stroke engines fires each cylinder every alternate revolution so the piston ar- rives at Top Dead Centre (TDC) twice every four strokes of the piston. The two (TDC) stokes are named both the exhaust stroke and compression stroke. -
Page 80: Engine Tuning & Trouble Shooting
Oil Tank with internal flop tube (not available from Rotec Aerosport) VALVE LASH Valve lash or valve clearance on any Rotec Radial should be set to 0.1 mm (0.004’’), cold engine. A rule of thumb method for achieving this valve lash is: Seat the valve adjuster to the seat on the head on the valve. -
Page 81: Rocker Cover Oil Leaks
Readings between cylinders will also vary slightly due to the natural differences of stroke on a radial engine. POTENTIAL CAUSES & RECTIFICATION: • Piston rings require replacing • Valves require re-seating • Head requires replacing as it is leaking ROTEC AEROSPORT | 81 www.RotecAerosport.com... -
Page 82: Gearbox Noise (Psru)
A noisy gear box (PSRU) will not be gear back lash as measured at the prop tip. It will more likely be the bell gear spline shifting ever so slightly on the crank spline. This is the reason why all Rotec Radial Engines now have a press fit on this spline. -
Page 83: Lower Cylinder Oil Leaks
1/2’’ hose. Drained oil is always reused by using a strainer and funnel to recy- cle it back into the oil tank. The Rotec Radial can fill the containers by up to 2 liters after shutdown, making recycling important. -
Page 84: Storage & Preservation
AVGAS 100LL is the recommended fuel for all Rotec radial engines. However, AVGAS 100LL fueled engines left long term can form rust on the cylinders. Because of this, Rotec Aerosport recommends that their radials be ground run on unleaded fuel at 60% power just prior to anticipated long term stor- age. -
Page 85: Indefinite Storage
• UV radiation, accelerating the degradation of rubber components • Moisture, potentially causing rust of steel components • Dust and contaminates NOTE: After 90 days, if continued storage is intended, repeat all of the above. ROTEC AEROSPORT | 85 www.RotecAerosport.com... -
Page 86: Assorted Specifications
*Tighten finger tight to seat, then with a 5/8’’ plug socket tighten an additional 1/2 turn (11Nm) for a new plug. *** For the easy removal of Loctite “Gasket Eliminator” 515, use Loctite “Chiselit” gasket remover in aerosol form. (Avoid contact with skin, plastic or painted material). 86 | ROTEC AEROSPORT www.RotecAerosport.com... - Page 87 ROTEC AEROSPORT | 87 www.RotecAerosport.com...
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