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 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 benet.
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

ROTEC AEROSPORT | 11
www.RotecAerosport.com
R2800 TECHNICAL DATA
Bore: 80mm (3.15’’)
Stroke: 80mm (3.15’’)
Displacement: 2800cc (172 cu’’)
Compression Ratio: 8.5 : 1
Direction of Prop Rotation: Clockwise Pilot’s View, tractor
Engine Dry Weight: 110kg (220lb) inc. Starter, Alternator & Exhaust (Stubs)
Designers: Matthew & Paul Chernikeef
Conguration: 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 110hp @ 2450 Prop RPM (via 3:2 PSRU)
Take O / Maximum Continuous RPM 110hp @ 3700 RPM
Propeller / RPM Fixed 76’’ Diameter x 55’’ Pitch @ 2,450 RPM
Fuel Consumption @ 75% Power (cruise) AVGAS 100 LL 22 Litres / hr (5.8 gallons)
ENGINE DESCRIPTION
DIMENSIONS & WEIGHT
PERFORMANCE DATA
FUEL CONSUMPTION
Figure 4. R2800 ISO View

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

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’

14 | ROTEC AEROSPORT
www.RotecAerosport.com
REAR VIEW CYLINDER DENOMINATION
Figure 7. R3600 Cylinder Denomination
1
29
38
47
56
RADIAL ENGINE
DESCRIPTION

ROTEC AEROSPORT | 15
www.RotecAerosport.com
R3600 TECHNICAL DATA
Bore: 80mm (3.15’’)
Stroke: 80mm (3.15’’)
Displacement: 3600cc (220 ci’’)
Compression Ratio: 8.5 : 1
Direction of Prop Rotation: Clockwise Pilot’s View, tractor
Engine Dry Weight: 120kg (265lb) inc. Starter, Alternator & Exhaust (Stubs)
Designers: Matthew & Paul Chernikeef
Conguration: 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 @ 2450 Prop RPM (via 3:2 PSRU)
Take O / Maximum Continuous RPM 150hp @ 3700 RPM
Propeller / RPM Fixed 80’’ Diameter x 55’’ Pitch @ 2,450 RPM
Fuel Consumption @ 75% Power (cruise) AVGAS 100 LL 28 Litres / hr (7.4 gallons)
ENGINE DESCRIPTION
DIMENSIONS & WEIGHT
PERFORMANCE DATA
FUEL CONSUMPTION
Figure 8. R3600 ISO View

16 | ROTEC AEROSPORT
www.RotecAerosport.com
UNIVERSAL ENGINE
DATA
FUEL TYPE
Fuel Description
AVGAS 100 LL Recommended
Highest Octane Premium Unleaded Automotive Petrol Alternate*
NOTE:
* When using unleaded fuel, carburettor & ignition timing adjustment may be required to avoid detonation.
OPERATING RPM’S & LIMITS
Max RPM: 3700 RPM
Continuous RPM: 3500 RPM
Idle RPM: 900 RPM
Oil Pressure Cruise: Min. 220 kPa (31 psi)
Max. 520 kPa (72 psi)
Oil Pressure Idle: Min. 80 kPa (11 psi)
Oil Pressure Warm Up: Max. 520 kPa (72 psi)
Oil Temperature: Min 15 C (59 F)
Max. 120 C (250 F)
Continuous Oil Temperature: 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 ange bolt on cylinder # 1.
Crimp an 8mm ID terminal to a “K” type thermo couple and place under inlet ange cap screw. Use an alloy washer
so as not to tear face of terminal.
NORMAL DATA
System: Description
Ignition Timing: 22 Deg. BTDC
Spark Plugs: NGK DCPR8E
Electrode Gap: 0.55 - 0.60mm (0.22’’ - 0.024’’)
Charge System: 35 Amp 12 Volt DC Alternator
Fuel Filtration: 0.1 mm Maximum Particle Size
Fuel Pump: Mechanical Cam Driven
Starter Motor: Electric 12V / 1.0kW
Lubrication: Geared Oil Pressure & Scavenge Pump
Bore / Stroke: (3.15’’) 80 mm x 80 mm
Heads: Two Overhead Valves, Push Rod Operated
Spark Plugs: Two Per Head (NGK DCPR8E)

ROTEC AEROSPORT | 17
www.RotecAerosport.com
SERIAL NUMBER
Purpose:
Determine engine history and upgrades that may be required.
Engine Serial Number Location (pilots view of engine)
R2800 7ANNNNN In line with the No. 6 cylinder, LHS Mount Plate (part R.147)
R3600 9ANNNNN In line with the No. 7 cylinder, LHS Mount Plate (part R.148)
NOTE:
A - Alphabetic character
N - Numeric character
Any additional numbers at the end of the serial code signify specic design changes in the engine batch
NOISE & EMISSIONS
EXPOSED ENGINES:
COWLED ENGINES:
For maximum performance, the Rotec Radial uses an exhaust collector ring, absent of noise or emission control sys-
tems by default.
The noise and emissions produced by the engines have not been tested. If these factors are of concern, you can add
muers or catalytic converters to the exhaust system.
GEAR REDUCTION RATIO
The gear reduction ratio for the R2800 and R3600 engines is 3:2. For example, if the engine is running at 3600 RPM,
then the propeller will be rotating at 2400 RPM.
There are no future plans to alter this ratio, as it would require a complete redesign of the engines.
COOLING 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 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 congurations, (i.e. at, V and straight), the radial conguration oers the greatest frontal area for
air-cooling. Even with this in mind, some consideration must be taken to cool the engine properly.
• Aircraft with exposed engines (without a cowl), boast the lowest cylinder head temperatures
• The only disadvantage to having an exposed engine is a moderate increase in drag
• Aircraft with cowled engines require appropriate air outlets, otherwise the engine will overheat. Ignoring uid
compressibility, air can only enter the engine as fast as it can escape. Air outlets can be designed to use the ventu-
ri eect, having the outside airspeed draw air from the engine bay.
• Cylinder baing can be used to encourage air over the cooling ns of both the cylinders and the cylinder heads.
We currently do not have prefabricated baing available.
No inter baing is required so long as full air stream contacts all heads and cylinder barrels.

18 | ROTEC AEROSPORT
www.RotecAerosport.com
CHT (CYLINDER HEAD TEMPERATURE)
Monitoring Status:
• Recommended on a closed cowl aircraft
• Optional on open cowled aircraft. For example Paul’s Flybaby, powered by an open cowled R2800 billet head
engine, generally ies at 80 knots and has traveled over 700 hours, but he does not monitor cylinder head tem-
perature.
Gauge Range: Approximately 100 °F to 600 °F (38 °C to 315 °C)
Approximate Operating CHTs:
• Exposed Engines:
• < 270 °F (137 °C) @ cruise, 90 °F (32 °C) ambient temperature
• < 240 °F (115 °C) @ cruise, 50 °F (10 °C) ambient temperature
• Cowled Engines:
• As discussed in Chapter # ‘Cooling’
Probe / Sensor Location:
• The 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 head cap screws
are removed using a 6mm hex key.
• Placing a ring probe under the 12mm spark plug is dicult as it is recessed into the head by a 22 mm (0.866″)
diameter bore. 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). A port
needs to be added to accommodate the probe.
UNIVERSAL ENGINE
DATA

ROTEC AEROSPORT | 19
www.RotecAerosport.com

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.