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1) Inhaltsverzeichnis
2) Index ............................................................................................. 2 - 1
3) Introduction ................................................................................. 3 - 1
3.1) Remarks ........................................................................................... 3 - 2
3.2) Engine serial number ...................................................................... 3 - 2
4) Safety ............................................................................................. 4 - 1
4.1) Repeating symbols ......................................................................... 4 - 1
4.2) Safety information ........................................................................... 4 - 2
4.3) Technical documentation ................................................................ 4 - 6
5) Index of pages .............................................................................. 5 - 1
6) List of amendments ...................................................................... 6 - 1
7) Description of design ................................................................... 7 - 1
7.1) 447 UL SCDI, 503 UL DCDI ............................................................. 7 - 1
7.2) 582 UL DCDI and 582 UL DCDI mod. 99: ....................................... 7 - 2
7.3) Type description: ............................................................................. 7 - 3
7.3.1) For 503 UL DCDI, 447 UL SCDI ........................................ 7 - 3
7.3.2) For ROTAX 582 UL DCDI ................................................... 7 - 3
7.3.3) For ROTAX 582 UL DCDI mod. 99 ..................................... 7 - 3
7.4) Engine views: ................................................................................... 7 - 4
7.4.1) 447 UL DCDI ...................................................................... 7 - 4
7.4.2) 503 UL DCDI ...................................................................... 7 - 5
7.4.3) 582 UL DCDI and 582 UL DCDI mod. 99 .......................... 7 - 6
8) Technical data ............................................................................... 8 - 1
8.1) Dimensions ...................................................................................... 8 - 1
8.2) Weights ............................................................................................. 8 - 1
8.3) Fuel consumption ............................................................................ 8 - 2
8.4) Direction of rotation ......................................................................... 8 - 2
9) Description of systems ................................................................. 9 - 1
9.1) Cooling system ................................................................................ 9 - 1
9.1.1) Cooling system of ROTAX 447 UL SCDI and of ROTAX 503 UL
DCDI .................................................................................. 9 - 1
9.1.1.1) Free air cooling ..................................................... 9 - 1
9.1.1.2) Fan cooling ........................................................... 9 - 1
9.1.2) Cooling system of the ROTAX 582 UL DCDI .................... 9 - 2
9.1.3) Cooling system of the ROTAX 582 UL DCDI mod. 99 ...... 9 - 3
9.2) Fuel system ..................................................................................... 9 - 4
9.3) Lubrication system ........................................................................ 9 - 5
9.3.1) Lubrication ......................................................................... 9 - 5
9.3.2) Oil injection lubrication of ROTAX 503 UL DCDI, 582 UL DCDI and
582 UL DCDI mod. 99 ........................................................ 9 - 5
9.3.3) Lubrication of the rotary valve drive at 582 UL DCDI and 582 UL
DCDI mod. 99 .................................................................... 9 - 6
d00286
03166
03168
A
H
Abnormal operation 10 - 18
High air humidity 10 - 16
C
I
Carburetor icing 10 - 16
Index 2 - 1
Checking of ignition 10 - 15
Index of pages 5 - 1
Checks 11 - 1
Introduction 3 - 1
Coolant 10 - 7
Cooling system 9 - 1, 9 - 2 L
Cylinder head temperature 10 - 1
List of amendments 6 - 1
D Lubricants 10 - 10
Lubrication 9 - 5
Daily checks 10 - 11, 10 - 13
Denomination of cylinders 7 - 4 M
Description of design 7 - 1
Dimensions 8 - 1 Mixing procedure 10 - 9
Direction of rotation 8 - 2 Mixture lubrication 10 - 10
Dry spark plugs 10 - 14 N
E Noise 10 - 16
Electric system 9 - 7 O
Engine lubrication 10 - 10
Engine start 10 - 11, 10 - 14 Oil capacity 10 - 1
Engine stop 10 - 18 Oil injection lubrication 9 - 5, 10 - 10
Engine stoppage of 1 to 4 weeks 11 - Operating media 10 - 7
1 Operating parameters 10 - 1
Exceeding of max. admissible cyl. head Operation in flight 10 - 15
temperature 10 - 18
P
Exceeding of max. admissible engine
speed 10 - 18 Performance graphs 10 - 3
Exceeding of max. admissible exhaust Pre-flight checks 10 - 11, 10 - 12
gas temperature 10 - 18 Preservation 11 - 1
Exhaust gas temperatures 10 - 1 Propeller gearbox 9 - 8
F R
Fan cooling 9 - 3 Rotary valve drive 9 - 6
Free air cooling 9 - 3 Rotary valve drive lubrication 10 - 10
Fuel 10 - 8 ROTAX® authorized Distributors 13 - 1
Fuel consumption 8 - 2
Fuel system 9 - 4
G
Gearbox lubrication 9 - 6, 10 - 10
d00291
d00291
d00292
d00293
d00293
8 8 - 1 99 05 01 11 11 - 1 99 05 01
8 - 2 99 05 01 11 - 2 99 05 01
12 12 - 1 99 05 01
12 - 2 99 05 01
13 13 - 1 99 05 01
13 - 2 99 05 01
13 - 3 99 05 01
13 - 4 99 05 01
d00294
14 14 - 1 99 05 01
14 - 2 99 05 01
14 - 3 99 05 01
14 - 4 99 05 01
14 - 5 99 05 01
14 - 6 99 05 01
14 - 7 99 05 01
d00294
d00295
ROTAX UL
(type)
(ignition)
Type
Zündung
02929
power output
Leistung
02932
Power output: 40 KW or 48 KW
e.g. ROTAX 582 UL DCDI 48
PTO view
02781
fig. 1
lateral view
02782
1
PTO MAG
PTO view
02780
fig. 3
lateral view
02779
MAG
PTO
PTO view
02042
fig. 5
lateral view
2 1
PTO
MAG
8.1) Dimensions
description 447 UL SCDI 503 UL DCDI 582 UL DCDI / mod. 99
bore 67,5 mm (2,66 in) 72 mm (2,84 in) 76 mm (2,99 in)
stroke 61 mm (2,4 in) 61 mm (2,4 in) 64 mm (2,52 in)
displacement 436,5 cm3 (26,64 cu.in) 496,7 cm3 (30,31 cu.in) 580,7 cm3 (35,44 cu.in)
comp. ratio
9,6 : 1 10,8 : 1 11,5 : 1
theoretical
comp. ratio
6,3 : 1 5,75 : 1
effective
02935
8.2) Weights
◆ NOTE: The stated weights are dry weights (without operating
fluids)
without: exhaust system, radiator
Type 447 UL SCDI 503 UL DCDI 582 UL DCDI mod. 99 582 UL DCDI
kg lb kg lb kg lb kg lb
Weight 26,8 59 31,4 69 29,3 64,6 27,4 60,4
02936
02968
d00297
02999
fig. 7
d00297
1 crankcase
2 cylinder
3 cylinder head
4 water pump
5 radiator
6 hose from radiator to water pump
7 hose from cylinder head to radiator
8 radiator screw cap, with excess
pressure valve and return valve
9 temperature gauge for cooling water
10 overflow hose
11 overflow bottle
12 bottle venting
13 expansion tank
14 cylinder head venting hose
fig. 8
02044
d00299
1 crankcase
2 cylinder
3 cylinder head
4 water pump
5 radiator
6 hose from radiator to water pump 02858
7 hose from cylinder head to radiator fig. 9
8 radiator screw cap, with excess
pressure valve and return valve
9 temperature gauge for cooling water
10 overflow hose
11 overflow bottle
12 bottle venting
13 expansion tank
d00299
d00299
9.3.1) Lubrication
Generally the engines are designed to run on a mixture of
gasoline and 2 % oil.
For preparation of fuel-oil mixture refer to section 10.2.2.
1
02783
3
fig. 10
d00299
d00299
weiß
schwarz/gelb
white
black/yellow
yellow
gelb
electronic box 2
schwarz/gelb
black/yellow
Reglergleichrichter
Zündkerze
rectifier regulator
K grün C spark plug
green
D S
P2 rot/weiß
red/white H2
Zündkerze
H1 spark plug
fig. 11 weiß
white
02971
5. Exhaust gas temperatures:
447 UL SCDI 503 UL DCDI 582 UL DCDI mod. 99
dimension °C °F °C °F °C °F
max. 650 1200 650 1200
normal 460-580 860-1000 500-620 930-1150
difference between
cyl. 1 and 2 max. 25 43 max. 25 43
02972
d00308
d00308
40 30
performance [hp]
performance [KW]
30
max. 6800
20
447 UL SCDI 2V
447 UL SCDI 1V
20
10
10
3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM]
02789 fig. 12
MOTORDREHMOMENT / ENGINE TORQUE
50
45
40 30
torque [Nm]
447 UL SCDI 1 V
30
20
25
20
3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM]
02788 fig. 13
TREIBSTOFFVERBRAUCH / FUEL CONSUMPTION
1000
1,6
900
fuel consumption [g/KWh]
447 UL SCDI 2V
1,2
max. 6800
700
600
500
0,8
400
3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM]
fig. 14
02787
d00308
40
35 50
30 40
performance [KW]
performance [hp]
25 503 UL DCDI 2V
503 UL DCDI 1V
max. 6800
30
20
15 20
10
10
5
3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM]
fig. 15 02786
MOTORDREHMOMENT / ENGINE TORQUE
60
55 40
50
45
torque [Nm]
30
torque [ft.lbf.]
40
max. 6800
503 UL DCDI 2V
35
503 UL DCDI 1V
30
20
25
20
15
3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM]
fig. 16 02785
TREIBSTOFFVERBRAUCH / FUEL CONSUMPTION
1200
1100 1,8
fuel consumption [g/kWh]
1000
fuel consumption [lb/hph]
1,6
503 UL DCDI 2V
900 503 UL DCDI 1V
max. 6800
1,4
800
1,2
700
1,0
600
500
fig. 17 3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM]
02784
d00308
45
40
50
35
performance [KW]
30 40
performance [hp]
25
max. 6800
30
20
15 20
10
10
5
0
3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM] 02533_1
70
50
65
60
55 40
torque [Nm]
torque [ft.lbf]
max. 6800
50
45
30
40
35
30
3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM]
02533_2
TREIBSTOFFVERBRAUCH / FUEL CONSUMPTION
600
580
560
0,9
fuel consumption [g/kWh]
540
520
max. 6800
500
0,8
480
fig. 18 460
440
0,7
420
400
2000 3000 4000 5000 6000 7000
engine speed [RPM] 02533_3
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50
45 60
40
50
35
performance [KW]
performance [hp]
30 40
max. 6800
25
30
20
15 20
10
10
5
0
3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM]
02532_1
80
75
70 50
65
torque [ft.lbf]
torque [Nm]
60 max. 6800
55 40
50
45
40 30
35
30
3000 3500 4000 4500 5000 5500 6000 6500 7000
engine speed [RPM]
02532_2
600
580
560
0,9
fuel consumption [g/kWh]
540
520
max. 6800
500
0,8
480
460
440
0,7
420
400
fig. 19 2000 3000 4000 5000 6000 7000
engine speed [RPM] 02532_3
d00308
10.2.1) Coolant
Mixing ratio antifreeze / water
50 % antifreeze concentrate with additives against corrosion and
50 % pure water, or use of an equivalent premixed coolant.
■ ATTENTION: Take note of the specification from the antifreeze
producer.
Satisfactory results were achieved with "BASF Glysantin
Anticorrosion". Use this or an equivalent coolant.
◆ NOTE: If problems are encountered with boiling after
engine stop increase percentage of antifreeze
gradually.
In all cases, antifreeze to water ratios should not exceed the
antifreeze manufacturer's recommendations. Exceeding the
antifreeze manufacturers recommended ratios can lead to the
formation of particulates in the coolant solution or inadequate
protection against freezing.
■ ATTENTION: Particulate formation may be harmful to cooling
system components and may restrict coolant flow
to and from overflow bottle.
◆ NOTE: At verification of the coolant level replenish water
in expansion tank. The coolant level in the
overflow bottle should be between min. and max.
mark.
d00308
03000
Due to higher lead content in AVGAS, the wear and deposits in the
combustion chamber will increase. Therefore, use AVGAS only if
you encounter problems with vapour lock or if the other fuel types
are not available,
or
equivalent fuels according to this Chapter.
■ ATTENTION: Use only fuel suitable for the relevant climatic
conditions.
◆ NOTE: Risk of vapour formation in using winter fuel for
summer operation.
■ ATTENTION: If the engine is not equipped with injection
lubrication a 2 % Super two stroke oil must be
added to the fuel.
d00308
02058
02059
fig. 22
fig. 23 02061
1)
On 503 UL DCDI and 582 UL DCDI and 582 UL DCDI mod. 99.
d00308
d00308
d00333
d00334
d00335
▲ WARNING!
This is not a certificated aircraft engine. It has not received any safety or durability
testing, and conforms to no aircraft standards. It is for use in experimental, uncertificated
aircraft and vehicles only in which an engine failure will not compromise safety.
User assumes all risk of use, and acknowledges by his use that he knows this engine
is subject to sudden stoppage.
d00336
Seller: ...........................................................................
Buyer: ...........................................................................
I have read and understood the operator's manual in its
entirety and carefully followed the described break-in
procedure.
✄ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ ○
d00336
DANGER!
This engine, by its design, is subject to sudden
stoppage! Engine stoppage can result in crash
landings. Such crash landings can lead to serious
bodily injury or death.
Never fly the aircraft equipped with this engine at
locations, airspeeds, altitudes, or other circumstances
from which a successful no-power landing cannot be
made, after sudden engine stoppage.
Aircraft equipped with this engine should only fly in
DAYLIGHT VFR conditions.
WARNING!
This is not a certificated aircraft engine. It has not
received any safety or durability testing, and conforms
Postleitzahl - Code postal
03002
d00336
or
s pf
Engine no.: ...................................................................
rd ee
co k
Gearbox: ........................ Reduction i = .......................
re py,
ur co
Seller: ...........................................................................
cu
Buyer: ...........................................................................
I have read and understood the operator's manual in its
entirety and carefully followed the described break-in
procedure.
d00336
ATA Code
OFFICE
DISTRICT
OPERATOR
AIRCRAFT ENGINES
DESIGNATOR
1.
A/C Reg. No.
MALFUNCTION OR DEFECT REPORT
582 DCDI
Enter pertinent data MANUFACTURER MODEL/SERIES SERIAL NUMBER
2.
AIRCRAFT
POWERPLANT
4.
ACG
PROPELLER
5. SPECIFIC PART (of component) CAUSING TROUBLE
MFG
AIRCRAFT ENGINES
Part Name MFG. Model or Part No. Serial No. Part/Defect Location
———
AIR TAXI
OM
6. ENGINE COMPONENT (Assembly that includes part)
)
MECH
initial issue
OPER
SUBMITTED BY:
03674
May 01/99
page 14 - 7