Rotec AEROSPORT R2800 - User Manual

ROTEC
RADIAL ENGINE
OPERATIONS MANUAL
AEROSPORT
Date Published
Rotec Aerosport
Radial Engine Operations Manual
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 COPIED OR REPRODUCED IN ANY MANNER,
NOR SUBMITTED TO OTHER PARTIES FOR EXAMINIATION WITHOUT PRIOR WRITTEN APPROVAL.

Summary

Introduction

General Note

Guide to maintain, service, and operate a Rotec Radial aircraft engine.

Warning

General Warning

Discloses safety issues to be followed when operating Rotec radial engines.

Radial Engine Description

R2800 (7 Cylinder Engine) Dimensioned Front View

Detailed front view dimensions of the R2800 engine.

Dimensioned Side View

Detailed side view dimensions of the R2800 engine.

Rear View Cylinder Denomination

Illustration showing cylinder numbering for the R2800 engine from the rear.

R2800 Technical Data

Engine Description

Details designers, configuration, ignition systems, firing order, and carburettor.

Dimensions & Weight

Specific dimensions and weight for the R2800 engine.

Performance Data

Rated power, RPM limits, and propeller specifications for the R2800.

Fuel Consumption

Fuel consumption rate for the R2800 engine at 75% power.

Radial Engine Description

R3600 (9 Cylinder Engine) Dimensioned Front View

Detailed front view dimensions of the R3600 engine.

Dimensioned Side View

Detailed side view dimensions of the R3600 engine.

Rear View Cylinder Denomination

Illustration showing cylinder numbering for the R3600 engine from the rear.

R3600 Technical Data

Engine Description

Details designers, configuration, ignition systems, firing order, and carburettors.

Dimensions & Weight

Specific dimensions and weight for the R3600 engine.

Performance Data

Rated power, RPM limits, and propeller specifications for the R3600.

Fuel Consumption

Fuel consumption rate for the R3600 engine at 75% power.

Universal Engine Data

Normal Data

General system specifications including ignition, spark plugs, charge system, etc.

Fuel Type

Recommended and alternate fuel types for the engines.

Operating RPMs & Limits

Specifies maximum, continuous, and idle RPMs, plus oil pressure and temperature limits.

Serial Number

Cooling System

Exposed Engines

Benefits and drawbacks of aircraft with exposed engines.

Cowled Engines

Requirements for air outlets in cowled engines to prevent overheating.

Noise & Emissions

Gear Reduction Ratio

Universal Engine Data

CHT (Cylinder Head Temperature)

Monitoring status, gauge range, and operating CHTs for exposed and cowled engines.

EGT (Exhaust Gas Temperature)

Monitoring status, gauge range, and probe location for EGT.

Installation, Operation & Service Document

Un-packing & Mounting

Packaging Removal Process

Step-by-step instructions for safely removing the engine from its packaging.

Engine Mounting Process

Engine Mount Frame

Manufactured by Rotec Aerosport

Information on ordering custom engine mounts from Rotec Aerosport.

Engine Mount Frame

Do It Yourself

Specifications for fabricating a Rotec Radial engine mount.

Engine Mount Frame

Front View

Dimensional drawing of the R2800 engine mount front view.

Engine Mount Frame

Rear View

Dimensional drawing of the R2800 engine mount rear view.

Engine Mount Frame

Side View

Side view drawings of R2800 and R3600 engine mounts.

Engine Mount Frame

Top View

Top view drawing of a typical engine mount.

Engine Installation

R3600 & 2800 Cup Mounts

Details the assembly and components of the R3600/R2800 cup mounts.

Engine Installation

R2800 Lower Pin Mounts

Details the assembly and components of the R2800 lower pin mounts.

Installing the Engine on the Frame

Installation Checklist

Propeller

Recommended Specifications

Details propeller specifications based on engine type (R2800/R3600).

Performance by Power Setting

Engine and propeller RPM targets based on power settings.

Mounting Bolts

Information on propeller bolts and torque settings.

Propeller Manufacturers

Lubrication System; Plumbing

General

Importance of lubrication system for engine survival and longevity.

Oil Tank

Discusses the dry sump lubrication system and requirements for the oil tank.

Oil Tank by Rotec Aerosport

Information on ordering custom oil tanks from Rotec Aerosport.

Lubrication System; Plumbing

Oil Tank Do It Yourself

Specifications for fabricating a Rotec Radial oil tank.

Lubrication System; Plumbing

Oil Tank Basic Design Requirements

Essential design requirements for oil tanks.

Engine Connections

Details of oil circuit connections for the engine.

Engine Oil Recommendations

Oil Specifications

Oil Types

Oil Changes 25 Hourly

Oil Cooler

General Recommendation

Oil Viscosity

Oil Lines & Where They Go

In Line Scavenge Pump Fittment

Oil Flow Schematic

Electrical Systems

General

Overview of the electrical system, including alternator and ignition.

Wiring Requirements

Steps to install electrical sub-systems on the radial engine.

Alternator

Description of the 12-volt alternator and its function.

Alternator Wiring Requirements

Specifics on connecting the alternator's M6 stud and T plug terminals.

Inspection

Guidelines for inspecting the alternator and starter motor.

Electrical Systems

Alternator Drive Belt

Common installation mistakes and maintenance for the alternator drive belt.

Electrical Systems

Starter Motor

Description of the 12-volt starter motor and its solenoid.

Starter Motor Wiring Requirements

Requirements for starter motor main earth strap and solenoid connections.

Electrical Ignition

Information on the second ignition system requiring external power.

Electrical Ignition Wiring Requirements

Wiring requirements for the Hall Effect electronic ignition system.

Electrical Systems

Electrical Fuel Pump

Recommendation for a backup electric fuel pump.

Electrical Fuel Pump Wiring Requirements

Wiring requirements for the electric fuel pump.

Engine Gauges

Details optional VDO electrical engine gauges and their connections.

Tachometer

Information on the Rotec Radial Tachometer and its programming.

Electrical Systems

Grounding Electronics

Methods for grounding electrical components in various aircraft frame types.

Basic Wiring Diagram

A simplified wiring diagram for the engine's electrical system.

Fuel System

General

Overview of the fuel system, comprising mechanical and electrical pumps.

Fuel Metering

Options for fuel metering, including Rotec TBI and Bing carburettors.

Rotec TBI-Mk.II Adjustment

Procedure for adjusting the Rotec TBI-Mk.II mixture screw.

Bing Carburettor Operation

Details the Bing 40mm Type 94 carburettor and its operation.

Fuel System

Magneto Ignition Set-Up

Description of the magneto ignition system and its components.

Fuel Types

Recommended fuel types for Rotec radial engines, including AVGAS and premium unleaded.

Fuel & Additives

Recommended Fuel

Fuel recommendations for R2800 and R3600 engines, including specifications and timing.

Recommended Fuel Additive

Recommendation for Flash Lubes Valve Saver and its benefits.

Fuel Supply

Mechanical Pump

Details of the mechanical fuel pump's location and capabilities.

Electrical Booster Pump

Status and secondary function of the electrical booster pump.

Fuel System

Ignition Leads & Firing Order

Details ignition leads and firing order for R2800 and R3600 engines.

Engine Operating Procedure

Warning: Hydraulic Lock

Warning regarding hydraulic lock phenomenon and potential engine damage.

Hydraulic Lock Symptoms

Lists typical symptoms indicating hydraulic lock.

Flying with a Bent Rod

Risks associated with flying with a bent connecting rod.

Engine Operating Procedure

Cylinders Most Subject to Hydraulic Lock

Identifies cylinders most prone to hydraulic lock and provides an example situation.

Key Points

Essential points regarding oil accumulation and hydraulic lock prevention.

Intake Pipe Drain Cocks

Details the function and importance of intake pipe drain cocks.

Engine Operating Procedure

Hydraulic Lock Quick Checklist

Checklist for preventing and checking for hydraulic lock.

Prevention

Steps to prevent hydraulic lock.

Checking

Procedures for checking for hydraulic lock before starting.

Initial Engine Start Procedure

Engine Operating Procedure

Avoiding Hydraulic Lock

Procedures to prevent hydraulic lock.

Best Practice Start Procedure

Recommended steps for starting the engine.

Best Practice Engine Shutdown Procedure

Recommended steps for shutting down the engine.

Starting: Rotec TBI Fuel System

Conventional Starting

Standard procedure for starting the engine with the TBI fuel system.

Hand Starting

Procedure for hand-starting the engine.

Engine Operating Procedure

Summary

Summary of hydraulic lock causes and prevention, emphasizing complacency.

Adverse Operating Conditions

Winter Operation

Recommendations for engine servicing and oil selection for cold weather.

Carburettor Icing

Distinguishes between types of carburettor icing and rectifying methods.

Water in Fuel

Causes of water in fuel and remedies to prevent fuel system issues.

Periodic Checks

Daily Checks

Daily checks for throttle, choke, oil level, security, and leaks.

25 Hour Checks

Checks and maintenance tasks required every 25 hours.

Periodic Checks

PSRU Inspection

Instructions for inspecting the Propeller Speed Reduction Unit (PSRU).

50 Hour Checks

Maintenance tasks required every 50 hours.

100 Hour Checks

Maintenance tasks required every 100 hours.

Periodic Checks

2000 Hour TBO

Information on engine overhaul procedures and service.

Propeller Strike

Procedures for engine overhaul after a propeller strike.

By Rotec Aerosport

Reasons to use Rotec for engine overhauls.

Do It Yourself

Disclaimer for users performing their own engine overhauls.

Details

Periodic Checks

Shipping

Steps for preparing and shipping an engine to Rotec facilities.

Spare or Replacement Parts

Engine Maintenance

Lubrication

Engine oil change, filter replacement, and oil level checks.

Air Intake Filter

Cleaning and maintenance of the air intake filter.

Carburettor Adjustment

Procedure for adjusting the carburettor mixture.

Compression Test

Procedure and acceptable ranges for cylinder compression testing.

Spark Plugs

Spark plug cleaning, gap adjustment, and torque specifications.

Engine Maintenance

Exhaust & Intake System

Visual checks for leaks and security in exhaust and intake systems.

All Bolts & Nuts

Checking bolt tightness and re-torquing.

Tappet Adjustment Procedure

Step-by-step procedure for setting tappet clearances.

Engine Tuning & Trouble Shooting

Engine Inversion

Requirements for enabling inverted use of the Rotec Radial engine.

Valve Lash

Procedure for setting valve lash or clearance on Rotec Radial engines.

Ignition Module & Pin Plug Outlets

Details wire numbers on the ignition coil plug for the ignition module.

Engine Tuning & Trouble Shooting

Rocker Cover Oil Leaks

Options and procedures for addressing oil leaks from rocker covers.

Cylinder Compression Testing

Procedure for measuring cylinder compression using a gauge.

Potential Causes & Rectification

Common causes and rectification for low cylinder compression.

Engine Tuning & Trouble Shooting

Gearbox Noise (PSRU)

Fixes and causes for noisy gearbox (PSRU) issues.

Ignition Testing

Hall Electronic test procedure for the ignition system.

Starting Issues

Common starting issues and potential causes.

Lower Cylinder Oil Leaks

Storage & Preservation

General

Definitions of flyable and indefinite storage.

Corrosion & Storage

Recommendations to prevent rust formation during storage.

Flyable Storage

Procedures for flyable storage, including fuel starvation and propeller position.

Corrosion Avoidance

Indefinite Storage

Assorted Specifications

Torque Specifications for User

Table of torque specifications for various engine parts.

Prescribed Sealants & Primers

Recommended sealants and primers for engine assembly.

Rotec AEROSPORT R2800 Specifications

General

Brand	Rotec
Model	AEROSPORT R2800
Category	Engine
Language	English