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MAINTENANCE MANUAL

BRP-Powertrain

Effectivity: 912 i Series
Edition 1/Rev. 0

74-20-00

Page 4

July 01/2012

Ignition unit (distribution)

1. Resistance spark plug connector

2. Double ignition coil

3. Ignition cable assy.

4. Fuse box assy.

5. Connector

6. Crankshaft position sensor assy.

7. Stator assy.

Summary of Contents for Rotax 912 i Series

Page 1: ...AIRCRAFT ENGINES ref no MMH 912 i part no 898751 picture ROTAX 912 iS with options HEAVY MAINTENANCE FOR ROTAX ENGINE TYPE 912 i SERIES ...

Page 2: ... part to third parties This legend shall be included on any reproduction of these data in whole or in part The Manual must remain with the engine aircraft in case of sale Copyright 2018 all rights reserved ROTAX is a trade mark of BRP Rotax GmbH Co KG In the following document the short form of BRP Rotax GmbH Co KG BRP Rotax is used Other product names in this documentation are used purely for eas...

Page 3: ...ards The Maintenance Manual is subdivided into the following chapters Subject Chapter Introduction Chapter INTRO List of effective pages Chapter LEP Table of amendments Chapter TOA General note Chapter 00 00 00 Internal alternator Chapter 24 20 00 External alternator Chapter 24 30 00 Vacuum system Chapter 37 00 00 Vacuum pump Chapter 37 10 00 Propeller Chapter 61 00 00 Governor Chapter 61 20 00 Po...

Page 4: ...ffectivity 912 i Series Edition 1 Rev 0 INTRO Page 2 July 01 2012 Sensors and actuators Chapter 76 70 00 Exhaust system Chapter 78 00 00 Exhaust Chapter 78 10 00 Lubrication system Chapter 79 00 00 Electric starter Chapter 80 00 00 Subject Chapter ...

Page 5: ...2 07 01 2012 07 01 2014 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 00 00 00 26 27 28 29 30 31 32 33 34 35 36 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2013 10 01 2013 10 01 2013 10 01 2013 10 01 2013 10 01 2012 07 01 24 20 00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 2012 07 01 2012 07 01 2013 10 01 2012 07 01 2012...

Page 6: ...7 01 2014 07 01 2012 07 01 2014 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 Chapter Page Date 71 00 00 20 21 22 23 24 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 72 00 00 1 2 3 4 2012 07 01 2012 07 01 2012 07 01 2012 07 01 72 10 00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 2018 07 0...

Page 7: ... 01 2012 07 01 2012 07 01 72 30 10 1 2 3 4 5 6 7 8 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 Chapter Page Date 72 30 10 8 9 10 11 12 13 14 15 16 17 18 19 20 2012 07 01 2014 07 01 2012 07 01 2014 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 73 00 00 1 2 3 4 2012 07 01 2012 07 01 2012 07 01 2012...

Page 8: ...014 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 Chapter Page Date 75 00 00 19 20 21 22 2014 07 01 2014 07 01 2012 07 01 2012 07 01 76 00 00 1 2 2012 07 01 2012 07 01 76 10 00 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 2013 10 01 2013 10 01 2013 10 01 201...

Page 9: ...7 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 Chapter Page Date 76 70 00 27 28 29 30 2012 07 01 2012 07 01 2012 07 01 2012 07 01 78 00 00 1 2 3 4 2012 07 01 2012 07 01 2012 07 01 2012 07 01 78 10 00 1 2 3 4 5 6 7 8 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 0...

Page 10: ...ies Edition 1 Rev 3 d06670 fm MAINTENANCE MANUAL BRP Rotax LEP Page 6 July 01 2018 80 00 00 1 2 3 4 5 6 7 8 Rear page 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 Chapter Page Date ...

Page 11: ... 73 00 00 73 10 00 74 00 00 74 20 00 75 00 00 76 00 00 76 10 00 76 50 00 76 70 00 78 00 00 78 10 00 79 00 00 80 00 00 all all all all all all all all all all all all all all all all all all all all all all all all all all all all all 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 07 01 2012 0...

Page 12: ...10 00 76 50 00 79 00 00 1 5 2 3 1 5 7 16 1 8 12 14 3 8 10 1 9 28 9 11 6 8 5 11 14 16 1 8 19 20 15 29 42 14 21 5 13 24 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 DOA DOA DOA DOA DOA DOA DOA DOA DOA DOA DOA DOA DOA 3 3 3 3 LEP TOA 72 10 00 76 10 00 1 6 2 3 1 3 4 7 32 39 07 01 2018 07 01 2018 07 01 201...

Page 13: ...00 00 72 10 00 72 30 10 73 10 00 74 20 00 75 00 00 76 10 00 76 50 00 79 00 00 1 5 7 16 8 1 9 28 11 6 8 14 16 1 8 19 20 15 42 35 14 21 5 13 24 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 07 01 2014 Change of engine type description Additional text Engine storage Index change Chan...

Page 14: ...d06671 fm MAINTENANCE MANUAL BRP Rotax Effectivity 912 i Series Edition 1 Rev 0 TOA Page 4 July 01 2012 NOTES ...

Page 15: ...of the Maintenance Manual contains general and safety informa tion concerning a safe operation and maintenance of the aircraft engine Subject Page General note Page 3 Abbreviations and terms used in this manual Conversion table Page 5 Page 8 Safety notice Safety information Instruction Maintenance Concept Technical documentation Use for intended purpose Page 9 Page 10 Page 12 Page 13 Page 14 Page ...

Page 16: ...d05932 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 00 00 00 Page 2 July 01 2012 NOTES ...

Page 17: ...tation provided by the aircraft manufacturer and or dealer For additional information on engines maintenance or parts you can also cont act your nearest authorized ROTAX aircraft engine distributor ROTAX Distributors For ROTAX Authorized Distributors for Aircraft Engines see latest Operators Manual or on the Internet at the official Website www FLYROTAX com Engine serial number When making inquiri...

Page 18: ...d05932 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 00 00 00 Page 4 July 01 2012 NOTES ...

Page 19: ...ressure Temperature Sensor AC alternating current Ah Ampere hour A C Aircraft AD Airworthiness Directive A F Across flat dimension ASB Alert Service Bulletin ACG Austro Control GmbH API American Petrol Institute ASTM American Society for Testing and Materials ATA Air Transport Association AWG American Wire Gauge CAN CGSB Canadian General Standards Board CPS 1 2 Crankshaft Position Sensor 1 2 CSA C...

Page 20: ...ISA International Standard Atmosphere kg kilograms LEP List of Effective Pages MAPS 1 2 Manifold Air Pressure Sensor 1 2 MATS 1 2 Manifold Air Temperature Sensor 1 2 MM Maintenance Manual MON Motor Octane Number MS Magneto Side N new part only Illustrated Parts Catalog n a not available nB as necessary only Illustrated Parts Catalog NDT Non Destructive Testing Nm newtonmeter OHM Overhaul Manual OM...

Page 21: ...etin SI Service Instruction SL Service Letter SMD Surface Mounted Devices S N Serial Number s v still valid only Illustrated Parts Catalog TOA Table of amendments TC Type certificate TOC Table of Contents TSN Time Since New TSNP Time Since New Part TSO Time Since Overhaul V Volt VFR Visual Flight Rules XXX shows the serial component number Abbreviation Description ...

Page 22: ... 5461 dm3 1 dm3 0 26417 gal US 1 gal US 3 7854 dm3 Units of velocity 1 m s 3 6 km h 1 ft min 0 3048 m min 0 00508 m sec 1 m s 196 85 ft min 1 kt 1 852 km h 1 km h 0 53996 kn Units of mass 1 kg 2 2046 lb 1 lb 0 45359 kg spec fuel consumption 1 g kWh 0 001644 lb hph 1 lb hph 608 277 g kWh Density 1 g cm3 0 016018 lb ft3 1 lb ft3 62 43 g cm3 Units of torque 1 Nm 0 737 ft lb 8 848 in lb 1 ft lb 1 356 ...

Page 23: ...ce or discontinue any design specification feature or other wise Measure Specifications are given in the SI metric system with the USA equivalent in parenthesis Symbols used This Manual uses the following symbols to emphasize particular information This information is important and must be observed NOTE Indicates supplementary information which may be needed to fully complete or understand an inst...

Page 24: ... and cautions described in this Manual These warnings and cau tions advise of specific operating and servicing methods that if not observed can cause a serious engine malfunction or cause the engine to lose power in flight which can result in loss of life injury or damage to equipment It is however important to understand that these warnings and cautions are not exhaustive BRP Powertrain could not...

Page 25: ...ectivity 912 i Series Edition 1 Rev 0 00 00 00 Page 11 July 01 2012 Torque wrench tightening Torque wrench tightening specifications must be strictly adhered to m WARNUNG NOTICE If not specified otherwise the threads are not lubricated when fastened ...

Page 26: ... Standstill After engine standstill longer than 2 months observe without fail the instructions for engine out of use Protect fuel system against contamination Returning When returning the engine or its components e g propeller gearbox to an authorized overhaul or repair company ensure that the necessary documenta tion log book maintenance records etc are enclosed m WARNUNG NOTICE Spare parts must ...

Page 27: ... Maintenan ce Chapter 00 05 and 12 The scope of line maintenance consists of removal installation and adjustment of engine components including part wear All procedures in this Manual are to be considered line maintenance NOTE Where applicable you will be referred to the Heavy Maintenance Ma nual for work above and beyond line maintennace Maintenance II Heavy Main tenance Separate Manual Maintenan...

Page 28: ...ng laws safety prescriptions constructional and operational regulations cannot be transferred completely to the object bought in particular for special constructions or may not be sufficient Documentation Installation Manual Operators Manual Maintenance Manual Line and Heavy Maintenance Overhaul Manual Illustrated Parts Catalog Alert Service Bulletin Service Bulletin Service Instruction Service Le...

Page 29: ...ual are mere sketches and show a typical arrange ment They may not represent in full detail or the exact shape of the parts which have the same or similar function Therefore deduction of dimensions or other details from illustrations is not permitted NOTE The Illustrations in this Manual are stored in a graphic data base sys tem and are provided with a consecutive irrelevant number This number e g...

Page 30: ...tical standards or regulatory safety or durability testing and conform to no aircraft standards These engines are for use in expe rimental uncertificated aircraft and vehicles only in which an engine failure will not compromise safety NOTE These engines are technically equivalent to certified engines and have been manufactured by BRP Powertrain using the same quality as surance system Engine stopp...

Page 31: ...r wear are divided into the columns maximum wear 100 2 and 50 wear 3 The first line 4 gives the maximum permissible value in mm the second line 5 in inches The respective actual value must be entered in the corresponding box 6 in mm or inches The actual value for any part which has been replaced must be entered in the corresponding field 7 in mm or inches m WARNUNG NOTICE If the engine is overhaul...

Page 32: ...bbrevia tions The following table shows the abbreviations used for the control points Abbreviation Description AL alternator CA camshaft CC crankcase CH cylinder head CR conrod CS crankshaft CY cylinder EL electric ES electric starter EX exhaust GB gearbox GO governor OP oil pump PI piston PP piston pin ST stator VT valve train WP water pump ...

Page 33: ...haul Determined measured actual dimension of the respective parts Max permissib le wear Proceed as follows Determine the hours of operation for the part in question logbook etc Determine wear as a percentage of the wear tolerance see the dimension sheets attachted directly after each section for the wear limit 100 of the part in question The classification is carried out as per following table TSN...

Page 34: ...ttachted after each section Determine the actual wear with following formula Fig 3 Fig 3 08217 07532 Legend A New dimension min B New dimension max C Wear limit D New dimension tolerance E Wear tolerance F Actual dimension 1501 1600 96 1601 1700 98 1701 1800 98 1801 1900 99 1901 2000 100 TSN h Time Since New max permissible wear for repair from to TBO 2000 h 912 i Series m WARNUNG NOTICE New dimen...

Page 35: ... the actual dimension F is within the new dimension tolerance D and the part can be used again Example The hours of operation are indicated with 300 h The determined percentage of maximum permissible wear is therefore 36 This part must be replaced because it is excessively worn for only 300 hours of operation New dimension max B 28 03 mm 1 1035 in Wear limit C 28 10 mm 1 1062 in Actual dimension F...

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Page 37: ...ginning of this section Troubleshooting In the Operators Manual possible problems as well as feasible remedies are lis ted At the same time brief reference is made to the necessary remedial action See the respective section in the Operators Manual for 912 i Series Tightening tor ques In general all screw connections on ROTAX aircraft engines must be tightened using a torque wrench If not specified...

Page 38: ...cation of the heat conduction compound will reduce heat transfer resistance The greaselike temperature resistant silicone compound fills cavities between compo nents and cooling elements e g spark plug cylinder head which otherwise do not contribute to heat conduction 150 g B 897651 LOCTITE 243 blue medium duty screw locking agent 10 ml C 899788 LOCTITE 648 green high temperature screw locking age...

Page 39: ... Series Edition 1 Rev 0 00 00 00 Page 25 July 01 2012 R 297710 PU glue for shock absorption 310 ml V 898570 Screw securing paint seals screws 20 ml Z 899789 LOCTITE 603 green oil tolerant retaining compound heavy duty 10 ml No Part no Description application Qty ...

Page 40: ...re quired 2 n a Multipurpose grease LZ Generally usable neutrally colored multipurpose grease water resistant and highly adherent Usable for temperatures from 35 C to 120 C 31 F to 248 F and can be sub jected to high mechanical loads as re quired 3 n a Preservation oil This special oil has excellent penetrating capabilities and re aches even tiny gaps it is highly effective additives protect again...

Page 41: ...ulation can be combined with a shifted phase A C circulation The two magnetizing methods are independent from each other and can be applied separately To achieve the direction changes of the magnetic field vector necessary for indi cation of cracks in any direction the alternating currents serving as the current supply for the different methods of magnetizing are dephased by 120 to each other 5 n ...

Page 42: ...f the propeller shaft is excluded from magnetic particle crack inspection Diassembly de vice Disassembly device for propeller gearbox Fig 5 shows one possible tensioning device for the disassembly of the propel ler gearbox The dimensions given are only intended for easier orientation and are not binding Fig 5 07525 a Current circulation for indication of longitudinal cracks b Field circulation for...

Page 43: ...katalog angeführt m WARNUNG NOTICE When using these instruments observe the manufacturers instructions No Part no Description application Qty 1 4 877615 extractor assy for propeller shaft roller bearing 25x52x15 and oil seal 30x52x7 1 2 877580 pull in spindle M24x1 5 1 3 276155 handle lever 12x250 1 4 842585 hex nut M24x1 5 length 19 1 5 877605 press out mushroom for propeller shaft F2 1 6 877600 ...

Page 44: ... locking device for vacuum pump drive sleeve 1 23 276332 insertion jig assy for pressing out needle sleeve 22x28x12 and ball bearing 15x32x8 vacuum pump 1 24 877276 insertion jig assy for oil seal 22x32x7 vacuum pump 1 25 876518 insertion jig for oil seal 40x55x7 gear cover 1 26 877650 handle for insertion jig for several applications 1 27 240880 thread bolt M8x50 for crankshaft locking 1 28 87732...

Page 45: ...80 110 for oil filter removal 1 44 877295 impeller wrench assy for water pump impeller 1 45 877258 insertion jig for rotary seal 1 46 876510 insertion jig for oil seal 12x30x7 water pump shaft 1 47 877840 hose clamp pliers for spring band hose clip 28 1 48 877390 pin wrench A 90 for slipper clutch 1 49 crankcase splitting tool 1 50 876010 puller assy for ignition housing 1 51 876020 insertion jig ...

Page 46: ...precision dial gauge 1 61 877300 joggling plate 62 976140 dial gauge adapter assy for checking valve seating 1 63 trestle adapter assy for fixation of engine type 912 iS 1 64 876040 engine lift set assy for engine 912 iS 1 65 877930 trestle support assy 1 66 877570 tapping drill M18x1 for cleaning of fine thread when replacing the coolant fitting 1 67 877670 exhaust pipe trimmer to slice the oil f...

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Page 51: ...age 3 Page 3 Page 5 Page 5 6 Removal A Preparation B Ignition housing removal C Fly wheel assy removal D Stator assy removal 7 Inspection A Ignition housing single parts check 1 Ignition housing check 2 Bearing bushing check 3 Oil seal replacement 4 Stator assy inspection 8 Wear limits 9 Assembly A Ignition housing assembly 1 Oil seal installation 2 Stator assy installation 3 Controller connector ...

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Page 53: ...October 01 2013 Chapter 24 20 00 INTERNAL GENERATOR SPECIAL TOOLS SERVICE PRODUCTS Description Part number Puller assy 876010 Insertion jig 876020 Description Part number LOCTITE 243 897651 LOCTITE 648 899788 LOCTITE 603 899789 LOCTITE 5910 899791 KLUEBER ISOFLEX TOPAS Nb5051 898351 Polishing cloth n a ...

Page 54: ...d05619 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 24 20 00 Page 4 July 01 2012 Internal generator ...

Page 55: ...he relevant Maintenance Manual Line for the respective 912 i Series engine type INTERNAL GENERATOR REMOVAL Before the internal generator is removed the work described below must be carried out to identify any further faults in the internal genera tor and rectify them as part of repair work General visual inspection See relevant Main tenance Manual Line for the 912 i Series engine type Engine clean...

Page 56: ...ce Fig 3 m WARNUNG NOTICE Use appropriate protective coverings to prevent the ingress of foreign bodies into all dis connected lines and connections Step Procedure 1 Detach the electrical connection to the stator by disconnecting the controller con nector Mark before detaching 2 Press on the catch and disconnect the connector 1 Controller connector 2 Connection socket Step Procedure 3 Loosen the a...

Page 57: ...I TE 243 1 M6x30 Allen screws 2 M6x50 Allen screws 3 Ignition housing assy 4 Oil seal Step Procedure 7 Place the protective piece on the crank shaft and use a puller to take off the igni tion housing 1 Ignition housing assy 2 Puller assy part no 876010 Step Procedure 8 Remove O rings from the crankcase or the ignition housing 9 The plug screws must be removed and degreased for possible leaks NOTE ...

Page 58: ...freehub body Fig 8 STATOR ASSY REMOVAL Fig 9 Fig 10 1 Dowel pin 2 Plug screws Step Procedure 1 Loosen 6 M6x12 Allen screws 2 Remove the fly wheel 1 Fly wheel 2 M6x12 Allen screw m WARNUNG NOTICE Mark cables before removing the connector receptacle The generator coils A and B have different sizes and powers Step Procedure 1 Mark cables 1 Generator coil A mark black connector 2 Generator coil B mark...

Page 59: ... at the same time carefully pull on the line until the terminal is detached 1 Retaining tab 2 Screwdriver Step Procedure 4 Pull off the rubber seal 1 Cable 2 Rubber seal 3 Filler plug Step Procedure 5 Remove cable clamps 6 Unscrew lock nut and remove the washer disk springs and distance sleeve 7 Remove the adjustment screw and lead through seal 1 M6x16 Allen screw 2 Cable clamp 8 M6 1 Distance sle...

Page 60: ...00 Page 10 October 01 2013 Fig 15 Fig 16 Fig 17 1 Lead through seal 2 Adjustment screw M4x8 Step Procedure 8 Loosen 6 M5x30 Allen screws and re move stator assy 1 M5x30 Allen screw 2 Washer A 5 5 3 Stator assy Step Procedure 9 Push the lead through seal in and pull the cable out 1 Stator assy ...

Page 61: ...g bushing is worn the entire ignition cover with the pressed and ma chined bushing must be replaced Step Procedure 1 Carry out visual inspection of sealing sur faces 2 Unscrew pressure sensor oil To do this see section 76 70 00 Sensors and actua tors 1 Sealing surface Step Procedure 3 Blow compressed air through the lubrica tion bore and check it is clear 4 Check that the caulked ball is leakproof...

Page 62: ... seal sealing lip the channel in the sealing lip can be moved 1 5 mm 0 06 in by omitting the washer 1 Oil seal 2 Washer m WARNUNG NOTICE Danger of consequent damage to engine The stator may not be post machined If the sta tor or its wiring is damaged or worn it must be replaced with a new part m WARNUNG NOTICE Signs of wear on the magnet are not permissib le Damaged parts on the fly wheel are not ...

Page 63: ...lue Tolerance limit Tolerance limit Measurements min max 100 50 Bearing bushing in ig nition housing IH01 28 04 mm 1 104 in 28 05 mm 1 1044 in 28 11 mm 1 1067 in 28 08 mm 1 1055 in current replaced Radial clearance IH01 CS05 0 03 mm 0 0012 in 0 05 mm 0 0020 in 0 12 mm 0 0047 in 0 09 mm 0 0033 in current replaced Crankshaft end CS05 27 970 mm 1 1012 in 28 000 mm 1 103 in 27 930 mm 1 0996 in 27 950 ...

Page 64: ...p Procedure 1 Polish and then clean the contact surface for the oil seal 1 Contact surface Step Procedure 2 Place new oil seal on insertion jig part no 876020 and lubricate Outer LOCTITE 5910 Inner KLUEBER ISOFLEX TO PAS 1 Outer oil seal 2 Inner oil seal 3 Insertion jig part no 876020 Step Procedure 3 Using a soft faced hammer tap the oil seal with the insertion jig to press it in to the ignition ...

Page 65: ...x8 Step Procedure 2 Position the stator assy Then secure 6 M5x30 Allen screws including A 5 5 washers with LOCTITE 243 and tighten them Tightening torque 6 Nm 53 in lb 1 Separation between the two generator coils 2 M5x30 Allen screw 3 Washer A 5 5 Step Procedure 3 Install the distance sleeve disk springs and washer 4 Tighten lock nut M5 Tightening torque 6 Nm 53 in lb 5 Slip on the full length of ...

Page 66: ... conform to the air craft standards of the respective country Fig 31 Fig 32 1 Filler plug 2 Insulator rubber 3 Connector receptacle 4 Marks 5 Cable sleeves 6 Latch Step Procedure 4 Install the lock 1 Lock Step Procedure 5 Install 8 M6 cable clamps NOTE The bends of the cable clamps must be installed in a diametri cally opposed manner 6 Adjust cables Tighten M6x20 Allen screw Tightening torque 10 N...

Page 67: ...wheel on top 3 Secure 6 M6x12 Allen screws 12 9 screw strength with LOCTITE 603 and tighten them Tightening torque 18 Nm 159 3 in lb 1 Fly wheel 2 M6x12 Allen screw 1 Dowel pin Step Procedure 1 Lubricate oil seal bearing bushing and crankshaft stub with KLUEBER ISOFLEX TOPAS Nb5051 2 Insert 5x2 O ring into the crankcase and lubricate with KLUEBER ISOFLEX TO PAS Nb5051 to hold in position 1 Oil sea...

Page 68: ... can be crushed Step Procedure 5 Turn the water pump wheel slightly so that the gear wheels can mesh 6 Fasten the ignition housing to the crank case using Allen screws Tightening torque 10 Nm 88 48 in lb m WARNUNG NOTICE The ignition housing must be attached manually without tapping Ignition housing screw diagram 1 M6x30 Allen screws 2 M6x50 Allen screws 3 Ignition housing assy Step Procedure 7 Se...

Page 69: ...Install electric starter See also section 80 00 00 Electric starter Install pressure sensor See section 76 70 00 Sensors and actuators Install airbox on ignition housing See also section 73 10 00 Fuel system Release crankshaft See relevant Main tenance Manual Line for the 912 i Series engine type 1 M6x50 hex screw 2 Washer A 6 4 3 Cable clamp m WARNUNG NOTICE If the water pump is not installed str...

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Page 71: ...or assembly of the ROTAX 912 i Series engine The description is divided into sub sections and explanations of system functions Subject Page 1 Introduction 2 System description 3 Safety information Page 1 Page 3 Page 3 4 Removal A Preparation B V belt pulley removal C Alternator removal 5 Installation A V belt pulley installation B Alternator installation 6 Finishing work Page 5 Page 5 Page 5 Page ...

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Page 73: ...R REMOVAL Before the external generator is removed the work described below must be carried out to identify any further faults in the external genera tor and rectify them as part of repair work General visual inspection See relevant Main tenance Manual Line for the 912 i Series engine type Carry out a generator inspection during an engine test run See relevant Maintenance Manual Line for the 912 i...

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Page 75: ...rews with lock washers 2 Remove pulley carriers v belt pulley and v belt 1 M5x16 hex screws 2 Lock washers 3 Pulley carrier 4 V belt pulley 5 V belt Step Procedure 1 Loosen 2 M8x20 hex screws along with lock washers and washers 2 Remove the tension bar underneath the external generator 1 M8x20 hex screws 2 Lock washers 3 Washers 4 Tension bar Step Procedure 3 Loosn M10x45 hex screw and remove the ...

Page 76: ...n 24 30 00 Page 6 July 01 2012 Fig 4 Fig 5 1 Alternator bracket 2 Lock washer 3 M8x20 Allen screws Step Procedure 5 Remove 2 M6x50 Allen screws along with lock washers and washers from the gear box housing and alternator support 1 Alternator support 2 Lock washers 3 M6x50 Allen screws ...

Page 77: ...ner side of the propeller flange Step Procedure 2 Insert both pulley carriers with the cen tring towards the inner side of the propel ler flange 3 Push the v belt pulley onto the two pulley carriers and tighten with 8 M5x16 Allen screws and lock washers Tightening torque 6 Nm 53 09 in lb 1 M5x16 Allen screws 2 Lock washers 3 Pulley carrier 4 V belt pulley Step Procedure 1 Fix the alternator suppor...

Page 78: ... with M10x45 hex screw and 10 1 20 0 5 washer 1 Alternator 2 10 1 20 0 5 washer 3 M10x45 hex screw 4 Alternator bracket Step Procedure 4 Tighten the pre mounted M6 and M8 Al len screws Tightening torque 10 Nm 88 48 in lb 5 Place the v belt in the v belt pulley of the alternator 1 V belt 2 M8x20 Allen screw 3 M6x50 Allen screw Step Procedure 6 Attach the tension bar finger tight to the alternator b...

Page 79: ...012 FINISHING WORK Install the propeller See Documentation of aircraft manufacturer Step Procedure 7 Adjust the pulley tension and tighten M10 and M8 hex screws Tightening torque M10 40 Nm 354 in lb Tightening torque M8 22 Nm 194 7 in lb See the most recent Line Maintenance Manual for the respective engine type ...

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Page 81: ...age 1 July 01 2012 Chapter 37 00 00 VACUUM SYSTEM Introduction This section describes the vacuum system of the ROTAX 912 i series engine The description is divided into sub regions and explanations of system functions Subject Section 1 Introduction Chapter 37 00 00 2 Vacuum pump Chapter 37 10 00 ...

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Page 83: ...ations of system functions Subject Section 1 Introduction 2 Special tools 3 Service products 4 System description 5 Safety information Page 1 Page 3 Page 3 Page 5 Page 5 6 Removal A Preparation B Vacuum pump removal 7 Inspection A Drive sleeve inspection B Vacuum pump inspection 8 Installation A Needle sleeve installation B Ball bearing installation C Oil seal installation D Vacuum pump gear insta...

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Page 85: ... 2012 Chapter 37 10 00 VACUUM PUMP SPECIAL TOOLS SERVICE PRODUCTS Description Part number Insertion jig assy 276332 Retaining tool 242660 Puller assy 876489 Press in mushroom 877597 Press in mushroom 877595 Insertion jig assy 877276 Description Part number Engine oil n a LOCTITE 243 897651 LOCTITE 648 899788 ...

Page 86: ...d05338 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 37 10 00 Page 4 July 01 2012 Vacuum pump ...

Page 87: ... Line for the respective 912 i Series engine type REMOVAL VACUUM PUMP REMOVAL Preparation General visual inspection See relevant Main tenance Manual Line for the 912 i Series engine type Carry out a functional test run to identify any damage See Documentation of aircraft manufacturer The propeller gearbox must be removed so that the governor drive can be removed See section 72 10 00 Fig 1 Fig 2 m ...

Page 88: ...vernor drive However for the vacuum pump drive it is only 14 mm 0 55 in long with a normal screw head 1 Retaining tool part no 242660 2 Drive sleeve 3 M8x16 Allen screw 4 Vacuum pump gear Step Procedure 5 Loosen the M5x12 countersunk screw with retaining washer for the ball bearing fastening 6 Lift out the oil seal and press the needle sleeve along with the ball bearing towards the gearbox with a ...

Page 89: ... and fix it with the hex nut 1 Puller part no 876489 2 Hex screw 3 Washer 4 Hex nut 5 Press in mushroom part no 877597 6 Needle sleeve Step Procedure 4 The needle sleeve is pressed in as far as it will go by turning the hex screw clock wise Step Procedure 1 Apply the puller part no 876489 on the vacuum pump side 2 Insert the press in mushroom part no 877595 into the roller bearing and fix it with ...

Page 90: ... 877276 and lubricate with engine oil 1 Insertion jig part no 877276 2 Oil seal Step Procedure 1 Place on the vacuum pump gear and fix the lubricated drive sleeve with the retai ning tool part no 242660 2 Secure M8x16 Allen screw with LOCTITE 648 and tighten it Tightening torque 25 Nm 18 44 ft lb 1 Retaining tool part no 242660 2 Drive sleeve 3 M8x16 Allen screw 4 Vacuum pump gear Step Procedure 1...

Page 91: ... propeller gearbox see section 72 10 00 Step Procedure 2 Position the vacuum pump including the gasket and the attachment flange on the crankcase 3 Screw 4 M6 hex nuts including lock was hers onto M6 studs and tighten them Tightening torque 25 Nm 18 44 ft lb 1 Vacuum pump 3 Attachment flange 2 Gasket 4 M6 stud 1 Vacuum pump 2 6 4 lock washer 3 M6 hex nut ...

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Page 93: ...0 Page 1 July 01 2012 Chapter 61 00 00 PROPELLER Introduction This section describes the maintenance of the ROTAX 912 i series pro peller The description is divided into sub regions and explanations of system functions Subject Section 1 Introduction Chapter 61 00 00 2 Governor Chapter 61 20 00 ...

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Page 95: ...description 5 Safety information Page 1 Page 3 Page 3 Page 5 Page 5 6 Removal A Preparation B Governor removal C Governor flange removal D Governor drive removal E Roller bearing Version 2 removal F Roller bearing Version 3 removal 7 Inspection A Governor drive inspection 8 Installation A Governor drive installation B Needle sleeve installation C Ball bearing installation D Roller bearing Version ...

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Page 97: ... 01 2012 Chapter 61 20 00 GOVERNOR SPECIAL TOOLS SERVICE PRODUCTS Description Part number Puller 876489 Extractor 877615 Press in mushroom 877590 Press in mushroom 877595 Press in mushroom 877597 Insertion jig assy 276332 Retaining device 242660 Description Part number LOCTITE 243 897651 LOCTITE 648 899788 ...

Page 98: ...d05929 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 61 20 00 Page 4 July 01 2012 Hydraulic governor ...

Page 99: ...l visual inspection See relevant Main tenance Manual Line for the 912 i Series engine type Carry out engine test run to check proper functioning of the governor See section 71 00 00 Fig 1 Gear ratio i 912 i Crankshaft Propeller shaft 51 21 2 429 Propeller shaft Governor 22 29 0 759 Total 1 842 m WARNUNG mWARNING Follow the general safety instructions during all work on the engine and the assemblie...

Page 100: ...ng of the oil feed line 3 Remove the governor flange with the O ring and distance sleeve behind it 1 Governor flange 2 M10x1x19 banjo bolt 3 A10x14 gasket rings 4 Governor pressure oil line assy 5 8 4 15 6 distance sleeve 6 8 M8 cable clamp 7 A8 lock washer 8 M8x25 hex screw 9 Oil pump housing 1 M6x20 M6x16 Allen screws 2 Governor flange 3 O ring 4 O ring 5 Distance sleeve Step Procedure 1 Fix the...

Page 101: ...4 Vacuum pump gear Step Procedure 3 Loosen the M5x12 countersunk screw with retaining washer for the ball bearing fastening 4 Press the needle sleeve along with the ball bearing out towards the gearbox with a suitable insertion jig part no 276332 NOTE The needle sleeve and ball bear ing are damaged by this and must be replaced 1 M5x12 countersunk screw 2 Retaining washer 1 Insertion jig part no 27...

Page 102: ...tion 1 Rev 2 d05929 fm MAINTENANCE MANUAL BRP Powertrain 61 20 00 Page 8 July 01 2014 ROLLER BEARING VERSION 2 REMOVAL See section 72 10 00 propeller gearbox ROLLER BEARING VERSION 3 REMOVAL See section 72 10 00 propeller gearbox ...

Page 103: ... the vacuum pump gear is 16 mm long and has a flat screw head for the governor drive but only 14 mm long and with a normal screw head for the vacuum pump drive Step Procedure 1 Measure the inner diameter of the propel ler shaft See wear limits 2 Measure the journal of the oil inlet flange See wear limits NOTE Wear usually appears as a flat tened area on the journal 1 Propeller shaft inner diameter...

Page 104: ...ance limit Tolerance limit Measure ment min max 100 50 Propeller shaft dia 35 mm GB03 31 470 mm 1 2390 in 31 481 mm 1 2394 in 31 460 mm 1 2386 in 31 465 mm 1 2388 in actual renewed Bore at back end of prop shaft on version 3 only GB05 11 00 mm 0 4331 in 11 02 mm 0 4339 in actual renewed Spigot dia On oil inlet flange on version 3 only GB06 10 935 mm 0 4305 in 10 960 mm 0 4315 in actual renewed 074...

Page 105: ...ss in mushroom part no 877597 on the needle sleeve and fix it with the hex nut 1 Puller part no 876489 2 Hex screw 3 Washer 4 Hex nut 5 Press in mushroom part no 877597 6 Needle sleeve Step Procedure 4 The needle sleeve is pressed in as far as it will go by turning the hex screw clock wise Step Procedure 1 Apply the puller part no 876489 on the vacuum pump side 2 Insert the press in mushroom part ...

Page 106: ...ure 1 Install the governor flange including the distance sleeve in the crankcase with a new 32x4 O ring 2 Place one 7x2 O ring each in the flange oil feed line and governor flange and hold them in position with a little grease 1 Distance sleeve 2 32x4 O ring 3 7x2 O ring Step Procedure 3 Place on the governor flange secure it using LOCTITE 243 with 4 M6x20 Allen screws on the crankcase and with 2 ...

Page 107: ... Tightening torque 17 Nm 150 42 in lb 6 Fasten the governor pressure oil line with the cable clamp using the M8x25 hex screw and LOCTITE 243 Tightening torque 15 Nm 132 72 in lb 1 Governor flange 2 M10x1 banjo bolt 3 A10x14 gasket ring 4 Governor pressure oil line assy 5 8 4 distance sleeve 6 8 M8 cable clamp 7 A8 lock washer 8 M8x25 hex screw 9 Oil pump Step Procedure 7 The plug screws usually re...

Page 108: ... See the current edition of SB 912 052 Installation use of governors NOTE Governors manufactured by McCAULEY and WOODWARD can not be installed in the 912 i Series en gine type due to their length The governor is installed in the same way as it is removed See Chapter 61 20 00 FINISHING WORK Install the propeller gearbox see section 72 10 00 m WARNUNG NOTICE The gear tooth system of the governor mus...

Page 109: ...ption of design B Type description C Technical data D Serial and part no E Components engine views Page 9 Page 9 Page 10 Page 10 Page 11 Page 11 6 Removal of the power plant A Preparation B Disconnecting the lines to the aircraft C Removal of the power plant from the aircraft 7 Installation A Preparation B Installation of the power plant in the aircraft C Connecting the lines 8 Removal of the engi...

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Page 111: ...933 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 2 71 00 00 Page 3 July 01 2014 Chapter 71 00 00 POWER PLANT SPECIAL TOOLS Description Part no Engine lifting kit assy 876040 ...

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Page 113: ...ous data Installation date Mechanic surname and forename Installation related point OK Remark Control unit ECU checked for damage and corrosion Insulated construction checked Fuse unit FUSE BOX checked for damage and corrosion Fuses checked Fuse unit FUSE BOX connections checked for secure connection See also section 71 00 00 Power plant Protective coverings removed Fuel filters prefilters on the ...

Page 114: ...l system checked for leaks See section 12 20 00 Planned maintenance Fuel filter checked for blockages See section 12 20 00 Planned maintenance Propeller installed according to the aircraft manufactu rer s and propeller manufacturer s specifications See Documentation of aircraft manufacturer Lubrication system filled To do this see section 12 10 00 Adding operating fluids Engine test run functional...

Page 115: ...tion Step Procedure 1 Remove the wooden lid 2 Remove the protective packaging 3 Remove the protective foil packaging of the engine m WARNUNG NOTICE Use the engine lifting kit part no 876040 to lift the engine out m WARNUNG NOTICE Danger of consequent damage to the engine and aircraft due to corrosion and damage In the event of any kind of negative diagnosis of the engine after the packaging has be...

Page 116: ...y corrosion of the compo nents the engine must be sent to an authorized ROTAX Aircraft engine de aler or their Service Center Installation of the removed gearbox and cylin der Oil change Engine test run Expired engine preservation Thanks to the special cylinder wall coating the ROTAX aircraft engine does not generally need any special anti corrosion measures For oil change see the current Maintena...

Page 117: ... 00 00 SYSTEM DESCRIPTION DESCRIPTION OF DESIGN A ROTAX 912 i Series engine consists basically of several main components and add on assem blies which are described in more detail in the Operators Manual section 1 m WARNUNG mWARNING Non compliance can result in serious injuries or death Work on the engine must be carried out by au thorised personnel and certified See the current Maintenance Manual...

Page 118: ...riable pitch propeller and drive for constant speed propeller go vernor system m WARNUNG NOTICE Detailed technical data relevant for operation is listed in the Operators Manual and must be ob served Certification Configuration Design 4 cylinder normal aspirated engine Bore 84 mm Stroke 61 0 mm Displacement 1352 cm3 Cylinders Light alloy cylinder with Nikasil plating Pistons Light alloy piston with...

Page 119: ...is a consecutive number e g part no ENGINE COMPONENTS ENGINE VIEWS CYLINDER DESIGNATION AND DEFINITI ON OF MAIN AXES Firing order 1 4 2 3 Spark plugs 12 mm DCPR8E Electrode gap See section 74 00 00 Integrated generator Permanent magnet single phase generator Rectifier regulator 12 V 20 A DC External generator optional extra Full wave rectifier with 12 V 40 A DC serial regulator Fuel pumps 2 electr...

Page 120: ...Effectivity 912 i Series Edition 1 Rev 0 71 00 00 Page 12 July 01 2012 Components engine views Fig 1 1 Engine number 2 Propeller flange 3 Propeller gearbox 4 Ignition housing 5 Engine suspension frame optional 6 Water pump housing 7 Muffler assy ...

Page 121: ...BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 71 00 00 Page 13 July 01 2012 Fig 2 8 Oil pump housing 9 Oil filter 10 Fuel rail left right 11 Fuel hose assy 19 Connection for oil feed line 20 Connection for oil return line ...

Page 122: ...ev 0 71 00 00 Page 14 July 01 2012 Fig 3 12 Intake manifold left cyl 1 3 right cyl 2 4 13 Expansion tank assy 14 Airbox 15 Electric starter assy 16 Fuel pressure regulator 17 Fuel pump module assy 18 Oil tank assy 21 Connection for fuel return line 22 Connection for fuel feed line ...

Page 123: ...witch the tank selector switch OFF Remove cowling Disconnect fuel lines Drain the residual fuel out of the lines and seal the lines Drain the coolant Drain the oil DISCONNECTING THE LINES TO THE AIRCRAFT Disconnect all the extension lines between the engine and the aircraft Starter relay See Fig 4 Fig 4 Ambient pressure sensor See Fig 5 Fig 5 Step Procedure 1 Remove the spinner and propeller see s...

Page 124: ...thing cable harness 1 Earthing cable 2 Controller LANE A 3 Controller connector A Step Procedure 2 Mark the controller connector before de taching 3 Push in the tab on the top of the connector and at the same time pull the connector out of the connection socket 1 Controller connector A 2 Controller connector B 1 Connection socket 2 Controller connector Step Procedure 4 Remove the two round connect...

Page 125: ...n M5x12 Allen screws from the cover of the fuel pump assy 1 M5x12 Allen screws 2 LANE IN 3 LANE OUT Step Procedure 2 Detach the connectors Fuel pump 1 Fuel pump 2 from the fuel pumps NOTE First lift one side with a screwdriver fix the tab and then lift the lower tab with the screwdriver and pull out the connector m WARNUNG NOTICE Do not pull on the cable 1 Fuel pump main 2 Fuel pump auxiliary 3 Co...

Page 126: ...he clamp down until it latches 4 Remove the coupler 1 Lock m WARNUNG mWARNING Danger of injury due to falling parts When the engine is removed there is a risk of in jury due to the engine or its assemblies falling Only use permitted lifting gear and special tools for this work Fasten the lifting gear only to the transport brac kets Note center of gravity Do not walk under the lifted engine Wear pr...

Page 127: ...ocedure 2 Slowly tauten the straps by moving the crane upwards 3 Loosen the screw connections between the engine suspension and the fire wall 4 Using the crane gradually move the engi ne vertically and carefully into the horizon tal position to take the weight from the engine suspension frame bolts 5 Completely loosen the screw connections between the engine suspension and the fire wall 6 Lift the...

Page 128: ... 17 to Fig 18 m WARNUNG mWARNING Danger of injury due to falling parts When the engine is installed there is a risk of in jury due to the engine or its assemblies falling Only use permitted lifting gear and special tools for this work Do not walk under the lifted engine Wear protective footwear m WARNUNG NOTICE Danger of damage to the engine If the fuel system has not been cleaned suffi ciently ir...

Page 129: ... 71 00 00 Removal 4 Install the screw connections of the engi ne suspension to the fire wall according to the aircraft manufacturer s instructions and tighten them diagonally from each other 5 Reduce the tension of the installation po sition of the engine by lowering it slightly and tighten the four screw connections li kewise diagonally from each other accor ding to the tightening torque values o...

Page 130: ...rature before starting any work Step Procedure 1 After the Allen screws 1x M10x110 and 3x M10x35 have been removed along with their lock washers the engine suspension frame can be removed 1 Engine suspension frame 2 M10x110 Allen screw 3 DIN 128 A10 lock washer 4 M10x35 Allen screw 5 10 1 20 0 5 thrust washer m WARNUNG NOTICE On the left hand side cylinders 2 4 thrust was hers can be built in for ...

Page 131: ... 23 NOTE If necessary a transfer flight to a re pair company is permissible as long as the tube or strut is not more than 50 detached If they are completely detached immediate replacement is necessary 1 Engine suspension frame 2 M10x35 Allen screw m WARNUNG NOTICE Remove air filter 1 Engine suspension frame 2 M10x35 Allen screw Step Procedure 1 All components must be visually in spected 1 Engine s...

Page 132: ...he engine suspension frame are installed and removed in the same way See Removing the engine suspension frame Note Tightening torque of the M10x110 and M10x35 hex screws is 40 Nm 353 92 in lb FINISHING WORK Install the water pump See section 75 00 00 Install the coolant hoses See section 75 00 00 m WARNUNG NOTICE The engine suspension frame must be installed in a tension free manner Space out the ...

Page 133: ...s section describes the maintenance of the ROTAX 912 i Series engine The description is divided into sub sections and explanations of system functions Subject Section 1 Introduction Chapter 72 00 00 2 System description 3 Safety information Page 3 Page 3 4 Propeller gearbox Chapter 72 10 00 5 Engine block Chapter 72 20 00 6 Cylinder head Chapter 72 30 00 ...

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Page 135: ...tronic engine management system EMS including fuel injec tion map controlled ignition etc Dry sump forced lubrication ensures constant oil pressure SAFETY INFORMATION NOTE Precautions for escaping oil must be taken at the installation site m WARNUNG mWARNING Danger of severe burns and scalds Allow the engine to cool to ambient temperature before starting work m WARNUNG mWARNING Risk of injury due ...

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Page 137: ... roller bearing version 2 5 Removal of the roller bearing version 3 7 Inspection B Propeller gearbox parts check 1 Gear cover assy check 2 Propeller shaft check 3 Dog hub check 4 Thrust washer check bearing bushing check 5 Step collar check disc spring check 6 Checking the splines 7 Gear set check 8 Wear limits 9 Assembly C Assembly of propeller gearbox parts 1 Installation of the oil spray nozzle...

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Page 139: ...ion Part no Hot air gun n a Insert SW 41 877445 Puller 877660 Pushing jig assy 877540 Mounting yoke 876885 Fixture n a Circlip pliers n a Extractor 877615 Press out mushroom version 3 877600 Press out mushroom version 2 877605 Insertion jig 876518 Description Part no Engine oil n a LOCTITE 243 897651 LOCTITE 648 899788 LOCTITE 5910 899791 LOCTITE 7063 n a LITHIUM BASE GREASE 897330 ...

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Page 141: ...gine cleaning See relevant Maintenance Manual Line for the 912 i Series engine type Carry out an engine test run See relevant Maintenance Manual Line for the 912 i Series engine type Remove surrounding assemblies and detach oil lines NOTE The assemblies and lines are only to be removed if necessary and only as far as is necessary m WARNUNG mWARNING Danger of severe burns and scalds Always al low t...

Page 142: ... the oil seal running surface on the roller bearing side of the propeller shaft 1 M8 Allen screw 2 M6 Allen screw 1 Puller part no 877660 2 Handle 3 Gear cover Step Procedure Step Procedure 1 Insert the 8x20 dowel pin into the bore on the right and left of the gearbox housing 2 Install M6x40 hex screw into the pushing jig assy 3 Put the pushing jig assy in the center and fix it with a M10x20 hex s...

Page 143: ...rom the crankshaft NOTE If necessary carefully press off the drive gear with 2 screw drivers 1 Crankshaft 2 Drive gear 3 Friction washer 4 M30x1 5 hex nut m WARNUNG NOTICE Push the dog gear down only until the ring halves can be taken out otherwise the gearbox housing can be damaged The gear cover must be freely rotatable Step Procedure 1 Place the entire gearbox into a suitable fixture and press ...

Page 144: ...h is built in as standard in all certified and non certified aircraft engines 1 Clutch assy 2 Disc springs 3 Step collar 4 Compensating shim 5 Distance sleeves m WARNUNG NOTICE If the propeller shaft is removed the oil seal and the deep groove ball bearing must be replaced see Fig 10 and or Fig 11 Step Procedure 1 Place the gearbox housing on a suitable support 2 Press out the propeller shaft with...

Page 145: ...n 3 onto the end of the propeller shaft as protec tion 4 Place the pull in spindle into the extractor support and screw the M24x1 5 hex nuts onto the spindle from the inside 5 Held with the spanner the propeller shaft is pushed out of the gearbox housing by turning the spindle clockwise 1 Extractor 2 M24x1 5 hex nut 3 Press out mushroom 4 Propeller shaft m WARNUNG NOTICE The shaft seal is damaged ...

Page 146: ... the press in insert part no 877592 into the roller bearing 5 Place the pull in spindle into the extractor and through the crankcase 6 On the rear side of the crankcase push the pullout plate part no 877560 onto the hex screw and attach with the hex nut M10 part no 242091 1 Retaining ring 2 Extractor part no 877615 3 Hex screw M10x45 4 Pull in spindle 5 Hex nut M24x1 5 6 Press in insert part no 87...

Page 147: ...nor is different from that for ver sions 2 and 4 The roller bearing is pressed out together with the oil inlet flange Step Procedure 1 Remove the retaining ring with the circlip pliers 2 Put on puller part no 876489 and push the hex screw through the cap roller bearing and oil inlet flange 1 Retaining ring Step Procedure 3 Install the washer and nut on the rear 4 The roller bearing is pressed out ...

Page 148: ...aling surfaces up to a maxi mum of 0 5 mm in depth and 2 mm in diameter are permissible Traces of corrosion and pitting outside sealing surfaces up to a maximum of 0 3 mm in depth and 2 mm in diame ter are permissible 3 Inspect contact surfaces for Allen screws Indentations up to a maximum of 0 2 mm are permissible Bumps up to a maximum of 0 2 mm are permissible 1 Flat sealing surfaces 2 Contact s...

Page 149: ...here must be no fretting corrosion at the bearing points ei ther Step Procedure 1 Measure both bearing points See also section 72 10 00 Wear limits 2 Roll the propeller shaft and check for runout Check the axial runout of the pro peller flange See section 72 10 00 Wear limits 3 Check the oil seal running surface 1 Ball bearing 2 Outer ring 3 Inner ring Step Procedure 4 Check the groove for the ret...

Page 150: ...tooth system and or in the engagement faces of the dogs see section 72 10 00 Wear limits GB08 NOTE The cam peaks of the gear must never rest in the trough of the dog hub 2 Measure the gap between the cam peak and the cam trough see section 72 10 00 Wear limits GB07 NOTE Slight to moderate traces of wear and pitting on the dogs are permissible 1 Dog hub 2 Gear propeller shaft Step Procedure 1 Measu...

Page 151: ...d temperature stress As well as the material and the heat treatment of it the surface quality and structure surface treatment and lubricant vis cosity at operating temperature and additives are also important NOTE The likely location of pitting formation is the dedendum flank of the driving gear Therefore begin by checking the drive gear Pitting in the gearbox Pitting in the gearbox can cause high...

Page 152: ...ting damage which increases over time A distinction can be made according to the size type and number of pitting as follows Slight pitting initial pitting Destructive pitting Flake pitting large area flank fractures SLIGHT PITTING Features Individual small pits up to approx 0 5 of the flank area or pore like areas of pitting generally only present in the dedendum area of the flank This pit formati...

Page 153: ...f the material due to combined stresses from compression and sliding They are triggered when the material strength is exceeded locally Essential influ ences on pit strength are oil viscosity and oil temperature Conclusion Pitting of up to 5 of the flank area is permissi ble if the individual flank fractures do not exceed a size greatest longitudinal extent of 0 5 mm Otherwise the gear set must be ...

Page 154: ...ure The damage sometimes extends into the addendum region which results in breakage of the tooth tip Max permissible pitting or flake pitting See Destructive pitting Causes This pattern of damage generally occurs at low operating oil viscosities and or high oil tempera tures Apart from these the same causes apply as for pitting Fig 29 Fig 30 m WARNUNG NOTICE If flake pitting is found the gear set ...

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Page 156: ...d06672 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 3 72 10 00 Page 20 July 01 2018 WEAR LIMITS Fig 31 ...

Page 157: ... 470 mm 1 2390 in 31 481 mm 1 2394 in 31 460 mm 1 2386 in 31 465 mm 1 2388 in current replaced Radial run out pro peller flange at Ø 122 mm GB04 0 00 mm 0 000 in 0 05 mm 0 0020 in 0 06 mm 0 0024 in 0 06 mm 0 0022 in current replaced Bore at rear end of propeller shaft only in vers 3 GB05 11 00 mm 0 4331 in 11 02 mm 0 4339 in current replaced Journal diameter at oil inlet flange only in vers 3 GB06...

Page 158: ...e gear GB14 0 95 mm 0 0374 in 1 00 mm 0 0374 in 0 80 mm 0 0315 in 0 88 mm 0 0344 in current replaced Propeller shaft GB15 1 50 mm 0 0591 in 1 60 mm 0 0630 in 1 10 mm 0 0433 in 1 30 mm 0 0512 in current replaced Clutch dog hub GB16 1 50 mm 0 0591 in 1 60 mm 0 0630 in 1 10 mm 0 0433 in 1 30 mm 0 0512 in current replaced 5 Gear set backlash Pitting on drive gear up to 5 0 0 5 2 5 current replaced Pit...

Page 159: ... 0 000 in 0 0 mm 0 000 in 0 2 mm 0 0079 in 0 1 mm 0 0039 in current replaced Crankshaft Measure crankshaft run out installed in housing with drive gear CS24 0 000 mm 0 0000 in 0 060 mm 0 0024 in 0 080 mm 0 0031 in current replaced Crankshaft diameter CS04 27 990 mm 1 1020 in 28 000 mm 1 1024 in 27 950 mm 1 1004 in 27 970 mm 1 1012 in current replaced Description Code Current measurement value Tole...

Page 160: ...oil spray jet must point to the step col lar 2 Secure the M8x1Banjo bolt with LOCTITE 243 Tightening torque 20 Nm 15 ft lb 1 Oil spray nozzle and Banjo bolt M8x1 Step Procedure 1 Press the oil seal into the gearbox hous ing from the inside using insertion jig part no 876518 NOTE Lubricate sealing lips with en gine oil 2 Insert the 36 50 5 5 spacer ring with the radius facing the oil seal 3 Insert ...

Page 161: ... that it presses on the inner ring of the bearing 2 Press on the gearbox housing with a slight turning movement NOTE It is advantageous when the gearbox housing is still warm 1 Gearbox housing 2 Oil seal 3 Sealing lips 4 36 50 5 5 spacer ring 5 Ball bearing 6 7 2 18 8 3 washer 7 M7x16 hex screw 8 Support 9 Propeller shaft 10 Bearing seat 11 Inner ring 12 Sleeve Step Procedure 3 Push 2 x 35 2 42 8 ...

Page 162: ...utch assy Step Procedure 7 Install the lubricated bearing bushing carefully on the propeller shaft with circlip pliers 1 Bearing bushing 2 Propeller shaft m WARNUNG NOTICE The thrust washer must be replaced every re pair Step Procedure 8 Push on the gear propeller shaft 9 Lubricate the plastic 33 2 51 1 2 thrust washer on both sides with LITHIUM BASE GREASE and push it on along with the drive gear...

Page 163: ...ned the contact face for the ring halves must lie 1 mm above the upper edge in the groove of the propel ler shaft 1 Contact face 2 Upper edge m WARNUNG NOTICE If the disc springs do not sit centrally the gear propeller shaft cannot be pressed down enough to insert the ring halves Do not increase the force but remove the clutch again and cen ter the disc springs correctly Step Procedure 1 Place the...

Page 164: ... in mush room part no 877590 in the roller bearing put it on the centring and press it with the spindle into the crankcase as far as it will go NOTE Place the circlip in the groove with the sharp edge pointing out wards 1 Extractor part no 877615 2 Press in mushroom part no 877590 3 Roller bearing 1 52x2 retaining ring Step Procedure 4 Place on the vacuum pump gear and fix the lubricated drive sle...

Page 165: ...E No hammering or pressing The drive gear must only be pushed on manual ly m WARNUNG NOTICE Ensure that the friction washer is in the correct installation position m WARNUNG NOTICE The dog and drive gears are in pairs Only use parts with the same serial number Step Procedure 1 Push the drive gear onto the crankshaft NOTE Due to limited tolerances it may be difficult to push the drive gear onto the...

Page 166: ...lers in position with LITHIUM BASE GREASE Nb5051 and lubricate the bearing position of the propeller shaft and crankshaft 09588 1 3 2 6 4 5 1 6x20 dowel pins m WARNUNG NOTICE If excessive installation force is used the bear ing or vacuum pump gear can be damaged Step Procedure 6 Apply LOCTITE 5910 surface sealing compound to the sealing surface of the gearbox housing and place on the gear cover as...

Page 167: ...rry out an engine test run See relevant Maintenance Manual Line for the 912 i Series engine type After the engine test run check the engine and gearbox for leaks 1 M8 Allen screw 2 M6 Allen screw Step Procedure 8 Tighten 2 M8x45 Allen screws and 8 M6x45 Allen screws with washers 6 4 di agonally from each other Tightening torque M6 10 Nm 89 in lb Tightening torque M8 25 Nm 19 ft lb 9 Inspect the ru...

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Page 169: ...e 3 Page 5 Page 5 6 Removal A Preparation B Removal of the sprag clutch housing 7 Disassembly C Disassembling the sprag clutch housing 8 Inspection D Sprag clutch housing parts check 1 Sprag clutch housing check 2 Sprag clutch check 3 Free wheel gear check 4 Starter intermediate gear check 9 Assembly E Assembly of the sprag clutch housing 10 Installation F Preparation G Installation of the sprag c...

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Page 171: ...SERVICE PRODUCTS Description Part no Hot air gun n a Puller 877375 Seeger ring pliers n a Free wheel gear axial clearance measuring fix ture n a 38x20 insert for SW32 hex nut magneto side crankshaft 876070 A 20x12 5 reducing socket 877460 Protection mushroom 876557 Description Part no Klueber ISOFLEX TOPAS NB5051 898351 LOCTITE 7063 898450 LOCTITE 603 899789 ...

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Page 173: ... for the 912 i Series engine type SPRAG CLUTCH REMOVAL Preparation Remove the electric starter See also chapter 80 00 00 Electric starter Remove the ignition housing and fly wheel See chapter 24 20 00 Internal generator Fix the crankshaft into place See relevant Maintenance Manual Line for the 912 i Series engine type NOTE The assemblies and lines are only to be removed if necessary and only as fa...

Page 174: ...212 F 248 F using a hot air gun 4 Loosen the M32x1 5 hex collar nut from the crankshaft with a SW 38 socket part no 876075 1 M32x1 5 hex collar nut 2 Sprag clutch housing 3 Free wheel gear Step Procedure 5 Lubricate the end of the crankshaft with KLUEBER ISOFLEX TOPAS Nb5051 and press the protection piece onto the crankshaft 6 Pull off the sprag clutch housing using the puller part no 877375 1 Pro...

Page 175: ...ng Seeger ring pliers and take the sprag clutch out of the sprag clutch housing while turning it 1 Circlip 2 Seeger ring 3 Sprag clutch housing 1 Sprag clutch housing 2 Sprag clutch 3 Circlip Step Procedure 1 Check whether oil sludge has accumulat ed in the sprag clutch housing 2 Check that the oil nozzle for the generator is clear NOTE The nozzle is 0 8 mm in di ameter Check using a 0 5 mm wire 3...

Page 176: ...ding helical spring must not be loose or bent in a serpentine manner replace the sprag clutch if necessary 1 Helical spring 2 Spear body Step Procedure 1 Check the gear tooth system of the free wheel gear 2 Check the sprag clutch engagement face on the free wheel gear 3 Check the cone surface 1 Sprag clutch engagement face 2 Gear tooth system 3 Cone surface Step Procedure 1 Check the gear tooth sy...

Page 177: ...ins in posi tion and latches completely with the noses in the sprag clutch body Fig 14 Step Procedure 1 Clean the cone of the sprag clutch hous ing with a cloth 2 Apply KLUEBER ISOFLEX TOPAS to the spear body 1 Cone 2 Sprag clutch housing 3 Sprag clutch 4 Spear body Step Procedure 3 Place the sprag clutch in the sprag clutch housing the Seeger ring must be visible 4 Install the circlip so that its...

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Page 179: ...ith LOC TITE 603 Otherwise the bearing bushing and the free wheel gear may stick to the crankshaft and the sprag clutch may be abraded as a re sult Step Procedure 1 Degrease the thread and cone of the crankshaft with LOCTITE 7063 and place the woodruff key in the crankshaft 1 Woodruff key 2 Cone 3 Thread Step Procedure 2 Degrease the cone in the sprag clutch housing with LOCTITE 7063 and lubricate...

Page 180: ...ubricate the intermediate gear shaft and bore of the starter intermediate gear with KLUEBER ISOFLEX TOPAS 6 Install the starter intermediate gear 7 Install the intermediate gear shaft 1 Intermediate gear shaft 2 Starter intermediate gear im Eingriff engaged frei drehbar freely turning 1 00239 m WARNUNG NOTICE If there is no or too little axial clearance the sprag clutch may not be release and the ...

Page 181: ... the surrounding assemblies Fill with operating fluids or check filling levels See relevant Maintenance Manual Line for the 912 i Series engine type Carry out engine test run See relevant Maintenance Manual Line for the 912 i Series engine type Description Code Current measure ment value Tolerance limit Toleran ce limit Measurements min max 100 50 Axial clearance ES10 0 5 mm 0 020 in 1 1 mm 0 043 ...

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Page 183: ... tube 5 Removal of the coolant elbow outlet 8 Inspection E Cylinder head parts check 1 Cylinder head studs check 2 Cylinder head assy inspection 3 Valve guide check 4 Valve check 5 Valve seats check 6 Valve spring check 7 Washer check 8 Rocker arm and shaft check 9 Rocker arm bushing check 9 Wear limits 10 Assembly F Cylinder head assembly 1 Oil return tube installation 2 Coolant elbow inlet insta...

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Page 185: ...LINDER HEAD SPECIAL TOOLS SERVICE PRODUCTS Description Part no Cylinder aligning tool 877262 Measuring fixture valve spring inspection n a Spring clamp pliers 877840 Valve spring mounting device 877380 Torx T30 ball head insert 876180 Collet n a Description Part no KLUEBER ISOFLEX TOPAS NB5051 898351 LOCTITE 648 899788 Engine oil n a ...

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Page 187: ... relevant Maintenance Manual Line for the 912 i Series engine type INSTALLATION OF SURROUNDING AS SEMBLIES NOTE The assemblies and lines are only to be removed if necessary and only as far as is necessary Fig 1 m WARNUNG mWARNING Danger of severe burns and scalds Always allow the engine to cool down to ambient tempe rature before starting any work m WARNUNG NOTICE If these checks are omitted it ma...

Page 188: ...lar screws from the intake manifold 6 Disconnect the resistance spark plug con nector and remove the spark plugs See also section 74 20 00 Distribution 1 Temperature sensor 2 M6x20 hex torx collar screw 3 Resistance spark plug connector 4 Insulating flange Step Procedure 7 Release the attachment of the airbox to the ignition housing 8 Take off the spring type hose clip 25 using spring clamp pliers...

Page 189: ...tep Procedure 11 Remove the knock sensor from cylinder 1 To do this see section 76 70 00 Sensors and actuators Step Procedure 1 Loosen the M6x30 screw and washer 2 Remove the valve cover with the large and small O rings 1 M6x30 screw 2 6 0 washer 3 Valve cover 4 O rings m WARNUNG NOTICE Do not lose the O rings Step Procedure 3 Loosen 2 hex nuts 4 Loosen 2 M8 collar cap nuts inside the valve cover ...

Page 190: ...dure 5 Lift the intake manifold with the fuel rail slightly and carefully pull the entire cylin der head off the cylinder with both hands 6 Hold both push rods in position in the oil return bores Hold the oil bore closed with a finger and remove the cylinder head 7 Remove 16x5 O rings from the oil return tubes and the crankcase m WARNUNG NOTICE Put down the cylinder head in such a manner that the ...

Page 191: ...d the associated compo nents correspondingly before removing them m WARNUNG NOTICE The rocker arm shaft should never be forced out Step Procedure 1 Pull out the rocker arm shaft and take out the two rocker arms 1 Rocker arm shaft 2 Right rocker arm 3 Left rocker arm m WARNUNG NOTICE Before taking out the valves remove any burrs on the valve stem to avoid damage to the stem seal or guide Mark the v...

Page 192: ...elbow with a hot air gun to max 120 C 2 Remove the coolant elbow 3 Remove adhesive residues in the bore and check the thread 1 Coolant elbow m WARNUNG NOTICE If there are leaks the corresponding oil return tubes must be replaced Step Procedure 1 Pull out the oil return tube 2 Remove adhesive residues in the bore 1 Oil return tube Step Procedure 1 Take off the spring type hose clip 25 using spring ...

Page 193: ...w flange with a hot air gun to max 120 C 6 Remove the coolant elbow 7 Remove adhesive residues in the bore and check the thread Step Procedure 1 M8x20 23 studs are used to attach the ex haust manifold 2 Check that they are securely fitted and undamaged 3 If replacement is necessary the stud is in stalled in such a manner that the longer thread 23 mm is screwed into the cylin der head 4 Secure stud...

Page 194: ...ROTAX overhauling com pany 1 Cone exhaust manifold m WARNUNG NOTICE Cracks in the cylinder head are not permissible If in doubt inspect the affected parts for cracks using then dye penetrant method Step Procedure 2 Check the spark plug bore Check the thread for damage 3 Check the sealing surface of the cylinder block 1 Sealing surface 2 Spark plug bore m WARNUNG NOTICE If the engine has been overh...

Page 195: ...nner diameter of the valve guide 06448 dim m WARNUNG NOTICE Replace the valve if the valve stem is out of spe cification is damaged or shows traces of wear Step Procedure 1 Check the valve visually for damage and wear 2 Determine the valve stem diameter and check the valve disc for wear 3 Check the valve end face for pitting 4 Check the valve stem for any deposits 1 Valve stem 2 Valve end face 3 R...

Page 196: ...alves in the corresponding valve guides 3 Turn the valves with moderate pressure so that a clear print of the sealing surface is produced on the valve seat ring 4 Check that the seal fits properly if neces sary lubricate with valve lapping paste m WARNUNG NOTICE The ring shaped print on the valve seat faces of the valve seat rings must be continuous and have no breaks The width of the print corres...

Page 197: ... used as an indicator of a malfunction of the valve drive relating to poorly or insuf ficiently ventilated hydraulic valve tap pets In normal conditions no mea surable wear can be seen even after a relatively long operating time See also SI 912 018 Ventilation of the lubrication system Fig 25 ROCKER ARM CHECK AND ROCKER ARM SHAFT CHECK System description The rocker arm bearing is lubricated by the...

Page 198: ...m shafts and ro cker arm bushings are available to provide the option of repairing the ro cker arm bearing in the cylinder head In this case ensure that the correct ro cker arm bushing is installed The oversized rocker arm bushing part no 933397 has two mutually opposite bores for identification and differenti ation Fig 28 1 Push rod 2 Ball joint 3 Rocker arm bushing 4 Oil ducts Step Procedure 1 C...

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Page 200: ...d05345 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 72 30 00 Page 18 July 01 2012 06459 F VT04 ...

Page 201: ...e valve stem Intake Valve CH01 VT01 0 026 mm 0 0010 in 0 053 mm 0 0021 in 0 150 mm 0 0059 in 0 102 mm 0 0040 in current replaced Exhaust Valve CH01 VT01 0 026 mm 0 0010 in 0 053 mm 0 0021 in 0 150 mm 0 0059 in 0 102 mm 0 0040 in current replaced Circularity of Valve disc Intake Valve VT02 0 00 mm 0 0000 in 0 03 mm 0 0012 in 0 04 mm 0 0016 in 0 035 mm 0 0014 in current replaced Exhaust Valve VT02 0...

Page 202: ...adial clearance Bore rock er arm shaft Intake Valve CH05 VT05 0 006 mm 0 0002 in 0 035 mm 0 0014 in 0 150 mm 0 0059 in 0 093 mm 0 0036 in current replaced Exhaust Valve CH05 VT05 0 006 mm 0 0002 in 0 035 mm 0 0014 in 0 150 mm 0 0059 in 0 093 mm 0 0036 in current replaced Rocker arm bush ing plas tic Intake Valve VT06 16 000 mm 0 6299 in 16 018 mm 0 6306 in 16 038 mm 0 6314 in 16 028 mm 0 6310 in c...

Page 203: ...w the cylinder head to harden for at least 10 minutes at 100 C 1 Oil return tube Step Procedure 1 Secure the coolant elbow with LOCTITE 243 and install the elbow in the cold cylin der head NOTE Also lubricate the thread in the cylinder head with LOCTITE 243 2 Allow the cylinder head to harden for 10 minutes at 100 C NOTE If the sealing surface of the cylin der has carbon residues it must be remove...

Page 204: ...ers 3 Elbow flange 4 19x2 O ring 5 Cable brackets m WARNUNG NOTICE Risk of engine damage if damaged parts are in stalled All parts must be measured and assessed befo re installation All moving parts must be lubricated with engine oil before installation m WARNUNG NOTICE Oil residues up to max 20 of the running sur face are permissible Step Procedure 1 Push 16 27 9 1 onto the valve guide and instal...

Page 205: ...ioned cor rectly and that there is a uniform gap between the valve cotters 6 Carry out the same procedure for the ex haust valve 1 Valve cotter 2 Mounting device 3 Collet m WARNUNG NOTICE Do not use force The rocker arm bearing is a sliding seat Step Procedure 1 Lubricate the rocker arm shaft on both sides rocker arm bore and valve spring support with KLUEBER ISOFLEX TO PAS 2 Bring the intake rock...

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Page 207: ...from the cylinder head gasket face Otherwise the oil return tube O rings can be damaged Step Procedure 1 Install the corresponding push rods in the oil return tubes 2 Lubricate the push rod heads with KLUE BER ISOFLEX TOPAS 3 Install the lubricated 16x5 O ring on the oil return tube 1 Push rods 2 Oil return tubes 3 16x5 O ring Step Procedure 4 Place on the cylinder head until the O rings of the tw...

Page 208: ...ange between the intake manifold and the cylinder head 2 Install the intake manifold on the cylinder head which has not been removed with 2 M6x20 hex torx collar screws Tightening torque 10 Nm 88 48 in lb 1 Insulating flange 2 M6x20 hex torx collar screw 3 Intake manifold Step Procedure 3 Align the second cylinder head on the in take manifold and fasten it with 2 M6x20 hex torx collar screws Tight...

Page 209: ... and connect the resi stance spark plug connectors See also sec tion 74 20 00 Distribution Install the temperature sensor and connect the wiring harness To do this see section 76 70 00 Sensors and actuators Fig 45 Install the fuel line assy To do this see sec tion 73 10 00 Fuel pump and distribution Install the exhaust system See also section 78 00 00 Exhaust 1 M6x20 Allen screw 2 6 4 washer 3 Coo...

Page 210: ... 3 Intake flange Step Procedure 2 Tighten the collar cap nut and the M8 hex nut diagonally until they are finger tight 3 Fasten the cylinder heads according to the screw diagram See Figure 47 Tightening torque 10 Nm 88 48 in lb 180 1 Screw diagram Step Procedure 4 Loosen 4 Allen screws and remove the cylinder aligning tool m WARNUNG NOTICE There must be a minimum gap of 0 2 mm bet ween the valve c...

Page 211: ... the spark plugs and connect the resi stance spark plug connectors See also sec tion 74 20 00 Distribution Install the temperature sensor and connect the wiring harness To do this see section 76 70 00 Sensors and actuators Install the fuel line inlet and outlet To do this see section 73 10 00 Fuel pump and distribu tion Install the exhaust system See also section 78 00 00 Exhaust Connect the wirin...

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Page 213: ...nformation Page 1 Page 3 Page 3 Page 5 Page 5 6 Removal A Preparation B Cylinder and piston removal C Hydraulic valve tappet removal 7 Inspection D Displacement parts inspection 1 Piston inspection 2 Piston rings inspection 3 Piston pin inspection 4 Cylinder inspection 5 Hydraulic valve tappet inspection 8 Wear limits 9 Installation E Preparation F Cylinder and piston installation 1 Hydraulic valv...

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Page 215: ...3 July 01 2012 Chapter 72 30 10 DISPLACEMENT PARTS SPECIAL TOOLS SERVICE PRODUCTS Description Part no Piston pin extractor assy 877091 Piston ring spanner 84 mm 876967 Monohook circlip remover 976380 Installation tool assy 877802 Description Part no KLUEBER ISOFLEX TOPAS NB5051 898351 Engine oil n a ...

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Page 217: ... identical The pistons are axially offset Fig 1 m WARNUNG mWARNING Danger of severe burns and scalds Always allow the engine to cool down to ambient tempe rature before starting any work Step Procedure 1 Put the piston in the TDC position and ap ply the marking arrow in the direction of the gearbox NOTE When the piston is cleaned the marking arrow becomes visible It points in the direction of the ...

Page 218: ... circlip remover Step Procedure 4 Install the puller spindle in the piston pin and mount M6 extracting nut part no 877455 5 Turn the puller spindle clockwise to pull the piston pin out of the conrod into the puller sleeve until the piston can be taken off 1 Piston pin puller 2 Puller spindle 3 Pistons Step Procedure 6 Loosen the nut and remove the puller Re move the piston and put it down with the...

Page 219: ...NOTE Removed rings must be re in stalled in the same position and location 2 Remove carbon residues from piston rings and ring grooves and from the piston crown NOTE The best way to clean the groo ve root is with an old broken pis ton ring Multiple deposits are likely if AV GAS 100LL is used 3 Check the groove for the piston pin circlip Carefully remove any burrs NOTE If the groove is excessively ...

Page 220: ...the piston ring joint clearance using a feeler gauge See also section 72 30 10 Wear limits PI07 NOTE Examine the ring surface clo sely to identify the supporting part and thus also the wear which has already taken pla ce 1 Cylinders 2 Piston ring 3 Feeler gauge m WARNUNG NOTICE The mono hook circlips for the axial piston pin circlip must only be used once and must there fore be replaced Step Proce...

Page 221: ... the upper side and rear side 1 Cooling fins 2 Cylinder bore 3 Sealing surface Step Procedure 3 Measure the cylinder and enter the mea surement data CY01 CY02 CY03 See also section 72 30 10 Wear limits 4 Determine the installation clearance See also section 72 30 10 Piston inspection Step Procedure 1 Check visually for damage and wear NOTE The hydraulic valve tappet rota tes during operation so th...

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Page 224: ... 0000 in 0 026 mm 0 0010 in 0 130 mm 0 0051 in 0 078 mm 0 0031 in current replaced Piston pin bore PI02 20 001 mm 0 7874 in 20 005 mm 0 7876 in 20 040 mm 0 7890 in 20 023 mm 0 7883 in current replaced Piston pin PI03 19 992 mm 0 7871 in 19 995 mm 0 7872 in 19 970 mm 0 7862 in 19 981 mm 0 7867 in current replaced Piston pin clearance in piston pin bore PI01 PI02 0 006 mm 0 0002 in 0 013 mm 0 0005 i...

Page 225: ...2 in 84 046 mm 3 3089 in current replaced D2 CY02 CY01 0 015 mm CY01 0 0006 in CY01 0 015 0 008 mm CY01 0 0006 0 0003 in current replaced D3 CY03 CY01 0 008 mm CY01 0 0003 mm CY01 0 020 0 008 mm CY01 0 0008 0 0003 in current replaced Cylin der bore B 84 mm 3 3 in D1 CY01 84 012 mm 3 3075 in 84 024 mm 3 3080 in 84 090 mm 3 3106 in 84 057 mm 3 3093 in current replaced D2 CY02 CY01 0 015 mm CY01 0 00...

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Page 227: ...aft This means with axial offset down wards for cylinders 1 and 3 and with axial offset upwards for cylinders 2 and 4 m WARNUNG NOTICE If a hydraulic valve tappet has to be replaced it must be ensured that a hydraulic valve tappet with a polished cam running surface is used m WARNUNG NOTICE If operating faults occur such as operation with a non ventilated hydraulic valve tappet the components plat...

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Page 229: ...tracting nut 4 Piston pin 5 Pistons m WARNUNG NOTICE Always use new mono hook circlips Retaining rings which are used or have already been in stalled have insufficient tangential tension can twist and consequently abrade the groove in the piston m WARNUNG NOTICE The position of the mono hook circlip is defined by the recess in the piston The open side of the mono hook circlip must be opposite the ...

Page 230: ... Installation sleeve 3 Installation tool 4 Punch tool assy 5 Guide tool 6 Groove Step Procedure 8 Place the whole installation tool on the pi ston Support the piston with your hand and push the mono hook circlip into the retaining groove of the piston with a strong pressure on the installation tool 1 Installation tool 2 Installation sleeve 3 Pistons ...

Page 231: ... in the centre of the lower piston skirt 2 Install the compression and oil scraper rings on the upper piston skirt inclined away between 25 and max 30 1 Piston ring 2 Compression ring 3 Oil scraper ring 4 Pistons m WARNUNG NOTICE The ring gap should never come to lie in the re gion of the piston pin eye m WARNUNG NOTICE Double check that piston pin circlips are instal led properly Step Procedure 3...

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Page 233: ...tion describes the maintenance of the fuel system assembly of the ROTAX 912 i Series engine The description is divided into sub sec tions and explanations of system functions Subject Section 1 Introduction A System description B Safety information C Connections for display systems Chapter 73 00 00 Page 4 Page 4 Page 4 2 Fuel pump and distribution Chapter 73 10 00 ...

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Page 235: ...NANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 73 00 00 Page 3 July 01 2012 System description Fig 1 1 Fuel tank 2 3 Fuel pump 4 Water trap fine filter 5 Fuel pressure regulator 06293 1 1 4 5 3 2 ...

Page 236: ... filter The fine filter is installed before the fuel pumps and is not included in the ROTAX delivery SAFETY INFORMATION CONNECTIONS FOR DISPLAY SYSTEMS PRESSURE SENSOR The 2 pressure sensors are situated directly on the airbox and measure the intake air pressure TEMPERATURE SENSOR The 2 temperature sensors are situated directly on the airbox and measure the intake air tempe rature m WARNUNG mWARNI...

Page 237: ... manifold removal 1 Preparation 2 Left hand intake manifold removal 3 Right hand intake manifold removal G Pressure and temperature sensor removal 1 Preparationl H Airbox removal I Throttle body assy removal J Fuel pump assy removal 1 Preparation 7 Inspection A Fuel distribution parts inspection 1 Fuel line assy inspection 2 Fuel pressure regulator assy inspection 3 Pressure regulator housing insp...

Page 238: ...re regulator assembly 9 Installation A Intake manifold installation B Left hand and right hand fuel rail installation C Fuel pressure regulator assy installation D Throttle body assy installation E Airbox installation F Fuel line assy installation 10 Finishing work Page 25 Page 25 Page 26 Page 27 Page 27 Page 29 Page 31 Page 32 Page 33 Page 34 Page 35 Subject Page ...

Page 239: ...Series Edition 1 Rev 0 73 10 00 Page 3 July 01 2012 Chapter 73 10 00 FUEL PUMP AND DISTRIBUTION SPECIAL TOOLS SERVICE PRODUCTS Description Part no Seeger ring pliers n a Description Part no KLUEBER ISOFLEX TOPAS Nb5051 898351 LOCTITE 243 897651 LOCTITE 648 899788 ...

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Page 241: ...ain Effectivity 912 i Series Edition 1 Rev 0 73 10 00 Page 5 July 01 2012 Fuel distribution 1 Fuel pump assy 2 Fuel hose assy 3 Injection valves 4 Right hand fuel rail 5 Fuel pressure regulator assy 6 Throttle body 7 Airbox 8 Intake manifold ...

Page 242: ...ys tem pressure upstream of the injection valves constant relative to the intake manifold pressure differential fuel pressure The injection quantity is therefore only dependent on the activation time of the injection valves and can be repro duced using the activation time in all operating conditions Therefore the same amount of fuel is injected per unit time at all pressure ratios It is essentiall...

Page 243: ...neral visual inspection See relevant Main tenance Manual Line for the 912 i Series engine type Carry out an engine test run See relevant Maintenance Manual Line for the 912 i Series engine type Functional check of the fuel distribution system assy Check that the system is leakproof Check the injection valves Check the spray pattern using the map Measure the resistance of the injection val ves To d...

Page 244: ...nd the return line to fuel rail 2 4 and fuel pres sure regulator and close them with the ap propriate caps 3 Loosen the M6x16 Allen screw of the fuel line assy 1 Fuel rail 1 3 feed line 2 Fuel rail 2 4 outlet line 3 M6x16 Allen screw Step Procedure 4 Loosen 2 M12x1 5 banjo bolts with gasket ring 5 Remove the fuel line assy 1 M12x1 5 banjo bolt 2 Gasket ring 3 Fuel hose assy Step Procedure 1 Drain ...

Page 245: ...Hose 3 Temperature sensor Step Procedure 5 Loosen the banjo bolt with gasket ring in the pressure regulator housing 1 Banjo bolt 2 Gasket ring 3 Pressure regulator housing Step Procedure 6 Loosen the M5 Allen screws NOTE 1 M5x35 Allen screw 1 M5x45 Allen screw 7 Remove the fuel pressure regulator and housing 1 M5x35 Allen screw 2 M5x45 Allen screw ...

Page 246: ...ig 8 Step Procedure 1 Drain the fuel See also section 12 20 00 Planned maintenance 2 Remove the cable ties and pull out the hose 3 Disconnect the plug connection to the temperature sensor 1 Cable ties 2 Hose 3 Temperature sensor Step Procedure 4 Remove the retaining ring using Seeger ring pliers 5 Remove the fuel pressure regulator 1 Retaining ring 2 Fuel pressure regulator ...

Page 247: ...he M6x16 Allen screw of the fuel line assy Remove the fuel line assy Fig 9 Fig 10 Fig 11 Step Procedure 1 Loosen 2 M5 x12 Allen screws from the cover of the fuel rail 2 Lift off the cover 1 M5x12 Allen screw 2 5 3 washer 3 Fuel rail cover 1 M5x12 Allen screw 2 5 3 washer 3 Fuel rail cover Step Procedure 3 Loosen 4 M5x12 Allen screws 1 M5x12 Allen screw 2 5 3 washer 3 Heat shield Step Procedure 4 F...

Page 248: ...sher 3 Heat shield 4 M5x35 Allen screw Step Procedure 6 Disconnect the injectors NOTE The cables are labelled IN J_1 to INJ_8 1 Injector connectors Step Procedure 7 Use a screwdriver to lever out the spring clip and then unplug the connector NOTE Let the wire clip snap back in after the connector has been disconnected so that it does not get lost 1 Injector connectors 2 Screwdriver ...

Page 249: ... the injection valves from the fuel rails Remove the fuel pressure regulator assy IGNITION COIL REMOVAL Step Procedure 8 Loosen the two M5x12 Allen screws of the left hand fuel rail 2 4 attachment and the two M5x12 Allen screws of the right hand fuel rail 1 3 with the lock washers 9 Remove the fuel rail on the left and right of the intake manifold 1 M5x12 Allen screw 2 DIN 128 A5 FST lock washer 3...

Page 250: ...ut the ignition coil plugs 1 Ignition coil connector 2 Double ignition coils 3 EGT connector Step Procedure 3 Carefully pull EGT 1 and EGT 2 cylinders 1 and 2 out of the locking plate 4 Press the metal bracket and unplug the connectors 1 EGT connector 2 Spring clip Step Procedure 5 Loosen the M5x16 Allen screws of the double ignition coils with washers 1 M5x16 Allen screw 2 5 3 washer 3 Plug holde...

Page 251: ... ports rather than bores for the M6 hex torx collar screws 1 Double ignition coils 2 Ignition coil connector coil 1 coil 2 coil 3 coil 4 Step Procedure 1 Remove the 1 ear clamps 1 1 ear clamps 2 Intake manifolds Step Procedure 2 Loosen 4 M6 hex torx collar screws in wards for attachment to the cylinder head 2 4 3 Loosen the two inner hex torx collar screws m WARNUNG NOTICE Screws cannot be complet...

Page 252: ...ors and 2 temperature sensors See also section 76 50 00 Wiring harness Loosen and detach the wiring harness main strand from all fastenings cable ties retai ning fixtures on the engine See also section 76 50 00 Wiring harness 1 Outer screw fastening 2 Inner screw fastening Step Procedure 4 Remove the insulating flange of the cylin der heads 5 Close the intake duct using a plug part no 860397 m WAR...

Page 253: ...RBOX REMOVAL Fig 27 Fig 28 NOTE Remove the nipple and M6x12 hex screw only if absolutely necessary See Fig 29 Fig 29 1 Airbox 2 Temperature sensor 3 Pressure sensors Step Procedure 1 Loosen the M6 hex nut attaching the air box to the ignition housing along with the washer 1 M6 hex nut 2 6 4 washer Step Procedure 2 Remove the two 1 ear clamps 3 Remove the airbox 1 1 ear clamps 2 Connecting piece St...

Page 254: ...ntake hose delivered by manufacturer from the throttle body assy 1 Throttle body assy 2 Connector 3 Air filter 4 Screw hose clamp Step Procedure 3 Remove the throttle cable from the throttle body 4 Loosen 3 M6x12 hex torx collar screws with the fixation latch NOTE They are adhered with LOCTI TE 243 1 M6x12 hex torx collar screws 2 Fixation latch m WARNUNG NOTICE Do not lose the rubber gasket ring ...

Page 255: ...d close them with the appropriate caps Drain the fuel from the fuel pump and close it with appropriate plug caps NOTE The position and type of positioning and attachment of the fuel pump depends on the aircraft type See aircraft manufactu rer documentation See overview and Fig 33 to Fig 36 ENVIRONMENT NOTE All the operating fluids and cleaning agents can damage the environment if not disposed of p...

Page 256: ...isconnect the fuel pumps main aux Lift the latches Unplug the connectors 1 M5x12 Allen screws 2 Fuel inlet 3 Fuel outlet 1 Main pump main 2 Additional pump aux 3 Connector Fuel pump 1 4 Connector Fuel pump 2 1 Connector Step Procedure 4 Remove the fuel pump module from the aircraft according to the aircraft manufac turer s manual 5 Loosen the 4 M6 hex nut and take the fuel pump unit out of the hou...

Page 257: ...ed with a sharpening stone The roughness depth of the flat surfaces must not be changed Step Procedure 1 Check the fuel line assy for cracks scuff ing marks and kinks m WARNUNG NOTICE Cracks in the fuel distribution system its com ponents and hoses are not permissible If in doubt check the affected parts for cracks with a dye penetrant method 1 Fuel hose assy Step Procedure 1 Check all the O rings...

Page 258: ...kinks and cracks m WARNUNG NOTICE The fuel rail must be replaced if damaged 1 Fuel rail 2 Sealing surface for O rings Step Procedure 1 Check the injection valves for damage Scuffing marks including scratches on the valves are permissible up to a maximum depth of 0 2 mm 0 0079 in 2 All O rings must be replaced when the in jection valves are repaired 1 Injection valve 2 O rings Step Procedure 1 Chec...

Page 259: ... contact and flat surfaces for Allen hex screws nuts and sensors Indentations up to a maximum of 0 1 mm 0 0039 in are permissible Bumps up to a maximum of 0 1 mm 0 0039 in are permissible 1 Contact face Step Procedure 1 Check the airbox for damage and wear 2 Check the support plates for damage 3 Check the connecting pieces for brittle ness 4 Check threaded bores for damage 1 Airbox 2 Support plate...

Page 260: ...body for damage and wear 2 Check the bearing of the throttle shaft for damage NOTE Wear of more than 0 1 mm 0 0039 in is not permissib le 3 Check the throttle valve for damage NOTE Traces of wear up to a maxi mum of 0 05 mm 0 0020 in in depth are permissible 4 Check the evenness of the flat and con tact surfaces of the throttle body and bent socket with respect to each other 1 Throttle valve assy ...

Page 261: ... the check valves for damage and wear Step Procedure 1 Check the lines and hoses for damage and wear Step Procedure 1 Check the air filter according to the air craft manufacturer s instructions See the most recent Line Maintenance Manual section 12 20 00 Step Procedure 1 Fix the fuel pump unit in the housing with 4 M6 hex nuts Tightening torque 10 Nm 88 48 in lb 1 M6 hex nut 2 Housing 3 Fuel pump ...

Page 262: ...KLUEBER ISOFLEX TOPAS Nb5051 2 Install the fuel pressure regulator in the pressure regulator housing until it stops 3 Install the retaining ring NOTE When the retaining ring is moun ted it must be possible to rotate the fuel pressure regulator ma nually 1 Fuel pressure regulator 1 36x1 5 retaining ring 2 Fuel pressure regulator 3 Pressure regulator housing Step Procedure 1 Secure the nipple and th...

Page 263: ...ee section 76 70 00 1 Airbox 2 Temperature sensor 3 Pressure sensors Step Procedure 1 Place the insulating flange on the cylinder heads 2 Place on the left hand 2 4 and right hand 1 3 intake manifolds 1 Insulating flange m WARNUNG NOTICE 1 ear clamps may only be used once Step Procedure 3 Fix the 2 4 1 3 intake manifolds with 8 M6x20 hex torx collar screws from the in side outwards Tightening torq...

Page 264: ... coils are labelled and Fig 57 Fig 58 1 Outer screw fastening 2 Inner screw fastening 1 1 ear clamp 2 Intake manifold Step Procedure 5 Plug the connectors into the double igni tion coils 1 Double ignition coil 2 Ignition coil connector Step Procedure 6 Fix the double ignition coils with M5x15 Allen screws with plug holders and A5 lock washers Tightening torque 6 Nm 53 in lb 1 M5x16 Allen screw 2 5...

Page 265: ...nd press the EGT connector into the plug holder NOTE Check for secure connection 1 Ignition coil connector 2 Double ignition coils 3 EGT connector Step Procedure 9 Secure the 12 M6 cable clamp with an M6x14 Allen screw and washer with LOCTITE 243 Tightening torque 10 Nm 88 48 in lb 1 M5x16 Allen screw 2 5 3 washer 3 12 M6 cable clamp m WARNUNG NOTICE Continuous thread the Allen screws go into the ...

Page 266: ...lve 2 O rings 1 Intake manifold 2 Left muffler 3 Right muffler 4 Injection valves Step Procedure 3 Fix the fuel rail on the left and right of the intake manifold with M5x12 Allen screws and 5 3 washers Tightening torque 6 Nm 53 in lb Step Procedure 1 M5x12 Allen screws 2 DIN 128 A5 FST lock washers 3 Fuel rail Step Procedure 4 Plug in the injectors NOTE The cables are labelled INJ_1 to INJ_8 Step ...

Page 267: ...the front M5x35 Allen screw 1 M5x12 Allen screw 2 5 3 washer 3 Heat shield Step Procedure 6 Fix the fuel pressure regulator for cylin ders 2 and 4 with an M5x35 Allen screw Tightening torque 6 Nm 53 in lb 1 M5x12 Allen screw 2 5 3 washer 3 Heat shield 4 M5x35 Allen screw Step Procedure 7 Install the cover with an M5x12 Allen screw and 5 3 lock washer Tightening torque 5 Nm 44 25 in lb 1 M5x12 Alle...

Page 268: ...Heat shield Step Procedure 2 Install the M12x1 5x24 banjo bolt with two A12x18 gasket rings Tightening torque 25 Nm 221 2 in lb 1 M12x1 5x24 banjo bolt 2 A12x18 gasket rings 3 Fuel pressure regulator assy Step Procedure 3 Fix hose 60 regulator airbox with 2 cable ties 4 Plug in temperature sensor CTS 1 94x2 5mm cable ties 2 60 3mm hose 3 Temperature sensor CTS Step Procedure 1 Install the rubber g...

Page 269: ... 2 Fixation latch Step Procedure 3 Install the air filter and air intake hose supplied by manufacturer on the throttle body assy and plug in the EGT connec tor 1 Throttle body assy 2 EGT connector 3 Air filter 4 Screw hose clamp Step Procedure 1 Install a new 1 ear clamp on the connect ing piece 2 Insert the airbox in the connecting piece 1 1 ear clamps 2 Connecting piece Step Procedure 3 Fix the ...

Page 270: ...ble ties 1 Plug holder 2 94x2 5mm cable ties 3 203x7 6mm cable ties 4 142x3 2mm cable ties m WARNUNG NOTICE Install the fuel line assy in a tension free man ner If the line is too far away from the fuel rail the fuel line must be adjusted The sealing sur faces must be parallel Step Procedure 1 Fix the fuel line assy on the left and right of the fuel rails with banjo bolts Tightening torque 25 Nm 1...

Page 271: ... 20 00 Planned maintenance Install the bowden cable on the throttle body See section 70 00 00 Standard work on the engine Adjustment of the throttle position sensor position and idle speed See section 70 00 00 Standard work on the engine 1 M6x16 Allen screw 2 6 4 washer 3 8 M6 cable clamp Step Procedure 3 Install the inlet and outlet lines on the 1 3 and 2 4 fuel rails 1 Inlet line 2 Outlet line ...

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Page 273: ...his section describes the maintenance of the ignition unit assembly of the ROTAX 912 i Series engine The description is divided into sub sec tions and explanations of system functions Subject Section 1 Introduction A System description B Safety information C Connections for display systems Chapter 74 00 00 Page 3 Page 3 Page 3 2 Distribution Chapter 74 20 00 ...

Page 274: ...ain Effectivity 912 i Series Edition 1 Rev 0 74 00 00 Page 2 July 01 2012 Ignition unit 1 Resistance spark plug connector 2 Double ignition coil 3 Ignition cable assy 4 Fuse box assy 5 Connector 6 Crankshaft position sensor assy 7 Stator assy ...

Page 275: ...arge of the capacitors is defined by the control unit The capacitors are discharged via the primary circuit of the double ignition coils INTERNAL GENERATOR B The internal generator B also supplies non engine related consumers of the aircraft If elec tricity consumption is high an external generator 12 V 30 A can be used This is driven by the propeller shaft by means of v belts and already has the ...

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Page 277: ...moval C Double ignition coil assy removal D Resistance spark plug connector and ignition cable assy removal E Spark plug removal F Knock sensor removal 6 Inspection G Double ignition coil assy inspection H Resistance spark plug connector and ignition cable assy inspection I Spark plug inspection J Knock sensor inspection 7 Wear limits 8 Installation K Knock sensor installation L Spark plug install...

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Page 279: ... MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 74 20 00 Page 3 July 01 2012 Chapter 74 20 00 DISTRIBUTION SERVICE PRODUCTS Description Part no SILIKON heat conduction compound 897186 ...

Page 280: ...ectivity 912 i Series Edition 1 Rev 0 74 20 00 Page 4 July 01 2012 Ignition unit distribution 1 Resistance spark plug connector 2 Double ignition coil 3 Ignition cable assy 4 Fuse box assy 5 Connector 6 Crankshaft position sensor assy 7 Stator assy ...

Page 281: ...SP 3 SP 3 r w r w sw sw sw sw sw sw SP 4 SP 4 SP 2 SP 2 SP 4 SP 4 SP 2 SP 2 SP 1 SP 1 SP 1 SP 1 SP 3 SP 3 SP 3 SP 3 r w r w sw sw r w r w g g g g g g SP 4 SP 4 Generator B Generator B Regler A Regler A Regler B Regler B Generator A Generator A LANE B LANE B FUSE BOX FUSE BOX ECU ECU LANE B LANE B LANE A LANE A LANE A LANE A B B B 2 1 3 4 2T 2T 2B 2B 4T 4T 4B 4B 3T 3T 3B 3B 1B 1B r w r w 09728 ...

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Page 283: ...on the resistance spark plug connector side 1 T 1 B 2 T 2 B 3 T 3 B 4 T 4B The label marks the position of the ignition cable on the ignition coil 1 2 3 and 4 cylinder T B Top Bottom e g 3 T ignition coil for cyl 3 at the top connector NOTE The cables are only available as comple te parts ignition cable protection hose ignition coil side connector SPARK PLUGS The spark plugs are not shielded but u...

Page 284: ...eries engine type Carry out an engine test run See relevant Maintenance Manual Line for the 912 i Series engine type NOTE Some work can only be carried out on the whole unit INTERNAL GENERATOR REMOVAL See also section 24 20 00 Internal generator Double DOUBLE IGNITION COIL REMOVAL Fig 2 See Fig 3 Fig 3 m WARNUNG NOTICE The Allen screws go into the intake duct they are therefore glued in with LOCTI...

Page 285: ... EGT connector 2 Connector Step Procedure 5 Loosen M5x16 Allen screws with A5 lock washers 1 M5x16 Allen screw 2 A5 lock washer 3 Cable holder Step Procedure 6 Unplug the connectors to the double igni tion coils 7 Remove the double ignition coils 1 Double ignition coils 2 Ignition coil connector coil 1 coil 2 coil 3 coil 4 Step Procedure 1 Remove cable ties 2 Unplug the resistance spark plug conne...

Page 286: ...d actuators and section 76 50 00 Wiring harness NOTE The knock sensor must only be removed if necessary 1 Cable ties 2 Ignition coils 3 Resistance spark plug connector 4 Ignition cable assy Step Procedure 1 Remove the M14x1 25 SW16 spark plugs anti clockwise from the corresponding cylinder head m WARNUNG NOTICE Risk of damage to spark plugs The spark plugs must only be removed with the spark plug ...

Page 287: ...D IGNITION CABLE ASSY INSPECTION Carry out resistance test on ignition cable assy To do this see section 76 70 00 Sen sors and actuators Step Procedure 1 Check fastening elements screws was hers and plug holders for damage corro sion and deformation 1 M5x20 Allen screw 2 A5 lock washer 3 Plug holder 4 Double ignition coils Step Procedure 2 Check double ignition coils for damage corrosion and defor...

Page 288: ...G INSPECTION Fig 13 KNOCK SENSOR KNOCK INSPECTION To do this see section 76 70 00 Sensors and actuators 1 Ignition cable assy 2 Resistance spark plug connector Step Procedure 1 Check the electrode gap of the spark plug with a feeler gauge and adjust it if neces sary See also section 74 20 00 Wear li mits 1 Spark plug 2 Feeler gauge ...

Page 289: ... BRP Powertrain 74 20 00 Page 13 July 01 2012 WEAR LIMITS Spark plug 00084 SP01 Description Code Current measure ment value Tolerance limit Toleran ce limit Measurements min max 100 50 Electrode gap SP01 0 6 mm 0 0236 in 0 7 mm 0 0276 in 0 9 mm 0 0354 in current replaced ...

Page 290: ...N heat conduction compound and install clockwise in the corresponding cylinder head Tightening torque 20 Nm 176 96 in lb m WARNUNG NOTICE Risk of damage to resistance spark plug connector The resistance spark plug connectors must only be installed using the spark plug pliers If using an equivalent tool ensure that it has no pointed or sharp edges Step Procedure 1 Install the resistance spark plug ...

Page 291: ...abelled and Fig 16 Fig 17 Fig 18 1 Ignition cable assy 2 Cable ties Step Procedure 1 Plug in the double ignition coil connectors 1 Double ignition coils 2 Ignition coil connector coil 1 coil 2 coil 3 coil 4 Step Procedure 2 Fix the double ignition coils with M5x16 Allen screws with plug holders and A5 lock washers Tightening torque 5 Nm 44 25 in lb 1 M5x16 Allen screw 2 A5 lock washer 3 Plug holde...

Page 292: ...or into the plug holder NOTE Check for secure connection 1 Ignition coil connector 2 Double ignition coils 3 EGT connector m WARNUNG NOTICE The Allen screws for the spring type hose clips go into the intake duct they are therefore glued in with LOCTITE 243 Leaking Allen screws can cause an excessively lean mixture Step Procedure 5 Secure the 12 M6 cable clamp with an M6x14 Allen screw and washer w...

Page 293: ...ng disassembly 1 Water pump shaft removal 2 Oil seal and rotary seal removal 3 Coolant hose removal 4 Water pump housing disassembly 8 Inspection A Cooling system parts inspection 1 Axial position of water pump shaft inspec tion 2 Expansion tank inspection 3 Water pump housing inspection 9 Wear limits 10 Assembly A Ignition housing assembly 1 Oil seal installation 2 Water pump housing installation...

Page 294: ...d05938 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 75 00 00 Page 2 July 01 2012 Position on the engine ...

Page 295: ...ion 1 Rev 0 75 00 00 Page 3 July 01 2012 Chapter 75 00 00 COOLING SYSTEM SPECIAL TOOLS SERVICE PRODUCTS Description Part no Spring clamp pliers 877840 Impeller wrench assy 877295 Insertion jig 876510 Insertion jig 877258 Description Part no LOCTITE 243 897651 Engine oil n a ...

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Page 297: ...via a thin hose at atmospheric pressure into the trans parent overflow bottle When the coolant cools down it is sucked back into the cooling circuit OVERFLOW BOTTLE See the current 912 i Series Installation Manual For more detailed information on operation maintenance safety or flight consult the docu mentation provided by the aircraft manufacturer and dealer SAFETY INFORMATION Ensure that the eng...

Page 298: ...is connected lines and connections Step Procedure cyl 2 4 1 Remove the fuel outlet and inlet line on the fuel rail 2 Unplug temperature sensor CTS See section 76 70 00 3 Remove temperature sensor EGT 1 3 4 from the cable bracket and unplug it See section 76 70 00 4 Unplug throttle position sensor TPS See section 76 70 00 5 Unplug the resistance spark plug connec tor See section 74 20 00 6 Remove t...

Page 299: ...sition of the spring type hose clips The spring type hose clips must be re installed in the same position otherwise it may not be possible to install the intake manifold Risk of pressure and scuffing marks m WARNUNG NOTICE When removing the preformed hoses ensure that the coolant elbows are not damaged Step Procedure 1 Take off the spring type hose clip using spring clamp pliers part no 877840 2 R...

Page 300: ...pension frame See Chapt 71 00 00 2 Lift up and remove cooling air duct m WARNUNG NOTICE When removing the preformed hoses do not damage the coolant elbow on the expansion tank Step Procedure 1 Loosen the 2 M6x20 Allen screws of the water inlet elbow with washers and re move the water inlet elbow with the 32x2 o ring NOTE Mark the position of the coolant elbow with a suitable pen touch up pen 1 Wat...

Page 301: ...emove the impeller anti clockwise with the special tool part no 877295 with the crankshaft immobilised NOTE To immobilise the crankshaft see section 12 20 00 in the Maintenance Manual Line 1 Impeller 2 8 2 12 5 1 5 washer Step Procedure 1 Place the ignition cover on a suitable flat surface 2 Press out the water pump shaft with a suitable tool 3 Pull out the water pump gear 1 Press out tool 2 Water...

Page 302: ...cedure 1 Take off the spring type hose clips using spring clamp pliers part no 877840 2 Remove the preformed hoses from the coolant elbows on the expansion tank with a suitable tool 3 Remove the rubber plate 1 Expansion tank 2 Rubber plate 3 Preformed hoses 4 Spring type hose clips Step Procedure 1 Mark the position of the coolant elbow 2 Heat the water pump housing to approx 80 C and unscrew the ...

Page 303: ...mits Check the water pump shaft for wear and cor rosion NOTE If corrosion is found the water pump shaft must be replaced Fig 14 EXPANSION TANK INSPECTION Fig 15 m WARNUNG NOTICE Cracks in cooling system components are not permissible If in doubt check the affected parts for cracks using the dye penetrant method m WARNUNG NOTICE Preformed hoses must not be shortened as this affects the position of ...

Page 304: ...ly 01 2012 WATER PUMP HOUSING INSPECTION Fig 16 Step Procedure 1 Check the water pump housing for dam age deformation and leaks 2 Check the inner side for any signs of con tact with the impeller NOTE If signs of contact are found the water pump housing must be replaced 1 Feeler gauge 2 Water pump housing ...

Page 305: ... Description Code Current measurement value Tolerance limit Tolerance limit Measure ments min max 100 50 Water pump Reference to flat surface WP01 8 55 mm 0 3366 in 8 85 mm 0 3484 in 8 85 mm 0 3484 in current replaced Distance from impel ler WP02 0 3 mm 0 012 in 0 5 mm 0 020 in 0 7 mm 0 028 in 0 6 mm 0 024 in current replaced ...

Page 306: ...eal 2 Insertion jig Step Procedure 1 Lubricate the rotary seal on the inner di ameter with LOCTITE 243 and press it into the insertion jig part no 877258 Then press in the water pump shaft as far as it will go 2 Insert the pump gear in the ignition hous ing 1 Insertion jig 2 Rotary seal 3 Water pump shaft Step Procedure 3 Press the pump shaft with the rotary seal already compressed into the igniti...

Page 307: ... with the crankshaft immobilised see sec tion 12 20 00 Maintenance Manual Line Tightening torque 15 Nm 88 48 in lb NOTE Ensure that the impeller runs true If there is noticeable runout this and possibly also the pump shaft must be repla ced 1 Impeller 2 8 2 12 5 1 5 washer Step Procedure 1 Lubricate the new coolant elbow with LOCTITE 243 2 Screw the coolant elbow at least 5 revolu tions into the w...

Page 308: ...Procedure 1 Install a new rubber plate on preformed hose connection 2 4 and 1 1 Preformed hose connection 1 2 Preformed hose connection 2 3 Rubber plate 4 Preformed hose connection 4 Step Procedure 2 Install the spring type hose clip 35 on the preformed hose radiator outlet 3 Push on the preformed hose radiator out let and align it vertically NOTE Align the spring type hose clip 35 vertically too ...

Page 309: ...se clip 35 2 Spring type hose clip 25 3 Preformed hose 3 4 Expansion tank Step Procedure 6 Install the spring type hose clip 25 on pre formed hose 1 NOTE Align the spring type hose clip 25 so that it is 2 mm 0 0787 in away from the spring type hose clip on preformed hose 3 7 Push on preformed hose 1 and align it horizontally like preformed hose 3 1 Preformed hose 1 2 Preformed hose 3 3 Expansion t...

Page 310: ...ct with the other spring type hose clips 9 Push on preformed hose 4 and align it horizontally like preformed hoses 3 and 1 NOTE Preformed hose 4 is symmetri cal 1 Spring type hose clip 25 2 Preformed hose 4 3 Expansion tank Step Procedure 10 Install the spring type hose clip 25 on pre formed hose 2 and position it vertically 11 Push on preformed hose 2 and align it horizontally NOTE Preformed hose...

Page 311: ...ter pump housing inspection Step Procedure 1 Put on a new gasket and fasten the water pump housing to the ignition housing with 2 M6x90 Allen screws and 3 M6x35 Allen screws with washers 6 4 Tightening torque 10 Nm 88 48 in lb 1 Gasket 2 Water pump housing 3 M6x90 Allen screw 4 M6x35 Allen screw 5 6 4 washers 6 M6x35 Allen screw stainless 7 Gasket ring Step Procedure 2 Insert the o ring in the wat...

Page 312: ...re formed hoses 1 2 3 and 4 3 Position the expansion tank assy with the 5 preformed hoses on the engine 1 Coolant elbow 1 2 Coolant elbow 2 3 Coolant elbow 3 4 Coolant elbow 4 5 Expansion tank m WARNUNG NOTICE Ensure that the push on length is correct The push on length onto the coolant elbow on the cylinder head is 27 mm 1 06 in Step Procedure 4 Fasten preformed hoses 1 to 4 with spring type hose...

Page 313: ...al Line for the 912 i Series engine type Bleed the engine cooling system See rele vant Maintenance Manual Line for the 912 i Series engine type Fill with fuel See relevant Maintenance Manual Line for the 912 i Series engine type Carry out an engine test run See relevant Maintenance Manual Line for the 912 i Series engine type Install the fuel line assy See also section 73 10 00 Fuel system Install...

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Page 315: ...EMS power supply Fuse box FUSE BOX Switches Wiring Table of contents This section describes the maintenance of the ROTAX 912 i Series engine management unit assembly The description is divided into sub sections and explanations of system functions Subject Section 1 Introduction A Overview of engine management Chapter 76 00 00 Page 2 2 Control unit ECU 3 Fuse box FUSE BOX Chapter 76 10 00 Chapter 7...

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Page 317: ...Control unit installation Page 7 Page 7 Page 7 Page 8 Page 8 Page 8 Page 8 Page 8 8 Extracting of ECU Log files A Introduction B Situation 1 Extracting Log files from a removed ECU on workbench 1 Connect computer with ECU 2 Extracting of Log files C Situation 2 Extracting Log files an installed ECU on aircraft 1 Connect computer with ECU 2 Extracting of Log files Page 9 Page 9 Page 9 Page 10 Page ...

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Page 319: ... Part no B U D S SET LEVEL 1 864021 B U D S SET LEVEL 2 864022 B U D S SET LEVEL 3 864023 ECU Adapter 277012 Service Wiring Harness 1 864280 Y Cable Sub D DE9 female on male male junc tion 1 2 3 n a Power Supply Output DC 12 V 1 A with Banana jack sockets 1 na B U D S Aircraft Software n a Computer Notebook Netbook n a 1 5 6 9 1 5 6 9 1 5 9 6 D SUB_DE9_MALE Lane A D SUB_DE9_MALE Lane B D SUB_DE9_F...

Page 320: ...d06674 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 76 10 00 Page 4 July 01 2012 Control unit ECU ...

Page 321: ...during all work on the ECU TECHNICAL DATA Fig 2 SAFETY INFORMATION m WARNUNG NOTICE The coupler must be only installed into respecti ve sockets of the ECU pay attention to the mar king If excessive force is used or the position is wrong the pins can be bent and the ECU must be replaced 1 Connector socket A1 2 Connector socket A2 3 Connector socket B m WARNUNG mWARNING Danger of damage to engine Th...

Page 322: ...d06674 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 1 76 10 00 Page 6 October 01 2013 Fig 3 Control unit ECU 06396 ...

Page 323: ... 5 m WARNUNG NOTICE The plug connection of the ECU must be ope ned and closed no more than 20 times This must be shown on the device by a clearly visible sealing with a stamped numerical se quence 1 20 and by documentation confor ming to self monitoring guidelines Step Procedure 1 Unplug the couplers LANE A1 LANE A2 and LANE B Press in the lock so that the clamp can be rotated Press the clamp down...

Page 324: ...r NOTE Replace damaged screws and nuts Check the corresponding internal thread too when chang ing the screws 4 Check the locking plates for damage and wear 5 Check the rubber grommets for damage 6 Check the label on the ECU for readabili ty m WARNUNG NOTICE The plug connection of the ECU must be ope ned and closed no more than 20 times This must be shown on the device by a clearly visible sealing ...

Page 325: ...acting logs from an installed ECU The ECU is connected to the wiring har ness and installed in the Aircraft Because the situations are essentially different those two situations will be described inde pendently in this chapter NOTE Before loading new ECU Software make sure that you have installed the latest version B U D S Aircraft in ac cordance SI 912 i 002 on your com puter See also SI 912 i 00...

Page 326: ...e Y cable 3 Connect both Sub D DE9 connectors of the Y cable with the Sub D DE9 sockets of the Service Wiring Harness 4 Connect the Service Wiring Harness with the LANE A1 and LANE B connectors of the ECU m WARNUNG NOTICE Please note labeling of the ECU and the Service Wiring Harness Step Procedure 5 Connect Banana jack connectors of Ser vice Wiring Harness with adequate power supply NOTE Don t co...

Page 327: ... Start Programs BUDS run BUDS B U D S Aircraft Start Step Procedure 2 Wait until the program has been started booted completely 3 Change from Diagnostic Mode Tab to Maintenance Mode Tab 09960 B U D S Aircraft Maintenance Mode Step Procedure 4 Open the Preferences window by click ing on the Preferences Button 5 In the Maintenance Mode section the default Log directory can be set Either the path to ...

Page 328: ...onnect the power adapter Step Procedure 10 When both connection state indicators become GREEN change to Logs Tab 11 Click on Extract Logs A settings window named ECU Log Extraction should open 09963 B U D S Aircraft Maintenance Mode Logs Step Procedure 12 In this window ECU Log Extraction choose LANE A and LANE B for Log ex traction field ECU LANE Selection NOTE If only one LANE has been con necte...

Page 329: ...ke several minutes depending on the number of logs Step Procedure 16 Shut down the ECU Unplug the power supply of the ECU 17 Disconnect the wiring attached to connect the ECU with the computer Disconnect B U D S Aircraft Set Disconnect Y cable and Service Wiring Harness connectors 18 With the Windows Explorer navigate to the created Log File This file can now be copied and for example attached to ...

Page 330: ... not exceed 2 meters m WARNUNG NOTICE The battery must provide constant voltage thru the whole extraction process If this can t be en sured an external power supply must be used Step Procedure 1 Connect B U D S Aircraft Set with the USB Port of your computer If the device is connected and installed the RED indicator light should light up 2 Connect the B U D S Aircraft Set Sub D DE9 connector with ...

Page 331: ...rnatively B U D S Aircraft can also be started through the start menu entry e g Start Programm BUDS run BUDS B U D S Aircraft Start Step Procedure 2 Wait until the program has been started completely 3 Change from Diagnostic Mode Tab to Maintenance Mode Tab 09960 B U D S Aircraft Maintenance Mode Step Procedure 4 Open the Preferences window by click ing on the Preferences Button 5 In the Maintenan...

Page 332: ...re RED 8 Set Backup Battery and Master Switch to ON Set LANE A and LANE B Switches to ON if connection Mode in Preferences Menu set to LANE A and LANE B 1 Backup Battery 2 Master Switch 3 LANE A Switch 4 LANE B Switch 09957 3 4 2 1 Step Procedure 9 The connection state bottom right corner of B U D S for both LANES should turn RED to ORANGE and finally to GREEN See also Fig 20 ...

Page 333: ...ld open B U D S Aircraft Maintenance Mode Logs 09963 09964 Step Procedure 12 In this window ECU Log Extraction choose respective LANE A and LANE B for Log extraction field ECU LANE Se lection NOTE If only one LANE has been con nected or the user wants to ex tract the logs from one LANE the corresponding option must be selected here 13 In the field ECU Log Selection the type of extracting Logs must...

Page 334: ...down the ECU 17 Switch OFF Backup Battery switch and Master switch LANE A and LANE B switches OFF 18 Disconnect the wiring specifically at tached to connect the ECU with the com puter Disconnect USB to CAN Converter 19 With the Windows Explorer navigate to the created Log File This file can now be copied and for example attached to an E Mail ...

Page 335: ...AX in form of Service Bulletins Before loading new ECU Software make sure that you have installed the latest version B U D S Aircraft ac cording to SI 912 i 002 on your com puter See also SI 912 i 003 SITUATION 1 UPDATING SOFTWARE OF A REMOVED ECU ON BENCH m WARNUNG NOTICE Removal must be carried out according to the aircraft manufacturer s instructions m WARNUNG NOTICE Do not open and close the E...

Page 336: ...ocket of the Y cable 3 Connect both Sub D DE9 connectors of the Y cable with the Sub D DE9 sockets of the Service Wiring Harness 4 Connect the Service Wiring Harness with the LANE A1 and LANE B connectors of the ECU m WARNUNG NOTICE Please note labeling of the ECU and the Service Wiring Harness Step Procedure 5 Connect Banana jack connectors of Ser vice Wiring Harness with adequate power supply NO...

Page 337: ...at a Baud Rate of 500 kbs is selected Field Maintenance Mode B U D S Aircraft Preferences Step Procedure 3 Closed the window Preferences with OK 4 Change to Maintenance Mode Tab B U D S Aircraft Maintenance Mode 09962 09961 Step Procedure 5 Wait until the Connection State Indicators Bottom Right turn to RED 6 Now connect the power supply with the line voltage 7 Wait until the Connection State Indi...

Page 338: ...tely B U D S Aircraft Connection Step Procedure 9 Switch to Software Load Tab 10 Select Browse in the Software Package Loading section 11 Navigate to the appropriate ECU Soft ware file ath and confirm with Open 12 The path to this file and the Software P N will be shown in the Software Package Loading section 09967 B U D S Aircraft Maintenance Mode Software Load Step Procedure 13 Select Load Packa...

Page 339: ...tep Procedure 1 Change to Diagnostic 2 A window will open to inform the user that a reboot of the ECU is required when changing from Maintenance Mode to Diagnostic Mode Confirm this window with OK 3 Disconnect and reconnect the power sup ply 4 Change to Health Tab and check if the Sensor Status and Device Status is equal the Sensor Status and Device Status in following Fig 29 If there are addition...

Page 340: ...the selected power supply is able to provide constant power Preferably use an addi tional power supply connection to the aircraft battery Before starting with the flashing process make sure that the ECU is powered down Backup Battery Start Power Master and LANE Switches must be set to OFF Step Procedure 1 Connect B U D S Aircraft Set with the USB Port of your computer If the device is connected an...

Page 341: ...f 500 kbs is se lected 3 Close the window Preferences with OK B U D S Aircraft Preferences Step Procedure 4 Change to Maintenance Mode Tab B U D S Aircraft Maintenance Mode 09962 09961 Step Procedure 5 Wait until the Connection State Indicators Bottom Right turn to RED 6 Master Switch to ON 7 Backup Battery Switch to ON 8 Turn LANE A Switch and LANE B Switch to ON The Connection State In dicators ...

Page 342: ... suits a specific engine type is allowed to be flashed on an ECU see SB 912 i 002iS If the set Engine Type set in the ECU deviates from the hardware configu aration of the engine contact a ROTAX Distribu tor immediately Step Procedure 11 Switch to Software Load Tab 12 Select Browse in the Software Package Loading section 13 Navigate to the appropriate ECU Soft ware file ath and confirm with Open 1...

Page 343: ... 2 Change to section Diagnostic Mode 3 A window will open to inform the user that a reboot of the ECU is required when changig from Maintenance to Diagnos tic Mode Confirm the information with OK 4 Reboot the ECU by turning the Master Switch or the LANE A LANE B Switches to OFF and ON again 5 Check warning lamp indicators If both warning lamp indicators section LANE Health top toolbar start to fla...

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Page 345: ...ctions and explanations of system functions Subject Page 1 Introduction 2 System description 3 Safety information Page 29 Page 31 Page 31 4 Removal A Preparation B Fuse box removal C Regulator B removal D Regulator A removal 5 Installation A Regulator B installation B Regulator A installation 6 Fuses 7 Inspection of installation of the rectifier regulator 8 Fuse box installation 9 Inspection of th...

Page 346: ...AINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 2 76 10 00 Page 30 July 01 2014 1 Fuse box assy 2 Rectifier regulator B 3 Rectifier regulator A 4 Sealing insert 5 Fuses 6 Heat transfer pad ...

Page 347: ...e FUSE BOX REMOVAL REGULATOR B REMOVAL Fig 35 m WARNUNG mWARNING Danger of damage to engine There is a risk of short circuits and cable fires during work on the engine management system All installation work on the fuse box should be carried out with the engine switched off and the battery negative terminal disconnected Backup Battery Master and LANE A B Switches must be OFF Step Procedure 1 Unplu...

Page 348: ...bolt B Loosen the M4 lock nut with washer Wrench size A F 7 Loosen the cable from connection bolt 5 Disconnect the 2 BLACK cable from con nection bolt B Loosen the M4 lock nut with washer Wrench size A F 7 Loosen the cable from connection bolt 1 Regulator A 2 Regulator B 3 Connection bolt regulator A 4 Connection bolt regulator B 1 Lock nut M5 with washer 2 Lock nut M4 with washer Step Procedure 6...

Page 349: ...e 2 RED WHITE and the 4 BLACK cables with grommet out of the fuse box To pull out the cables easily avoid tilting of the cable lugs NOTE The connecting thread of seal ing union must not be disman tled if you replace the regulator An exchange of this plastic in sert is only necessary if it is damaged 9 Remove the regulator NOTE Be careful when handling the dismantled regulator On the back side of t...

Page 350: ...ool 866420 DEUTSCH HDT 48 00 866422 1 Regulator A 2 DEUTSCH connector black 1 Regulator B 2 DEUTSCH connector grey m WARNUNG NOTICE All hex nuts self locking must be renewed after each installation e g replacement of a regula tor m WARNUNG NOTICE The adhesive surface on the back of the rectifier regulator must be cleaned before applying the heat transfer pads Remove the protective film with cautio...

Page 351: ... seal ing union is included with each rectifier regulator as replace ment part An exchange of this plastic insert is only necessary if it is damaged 1 Regulator B 2 Cup nut of the gasket screw connection 3 Thread of the gasket screw connection m WARNUNG NOTICE When pressing in the plastic insert avoid dam aging the connecting thread of sealing union Step Procedure 5 Pull all the cables 2 RED WHITE...

Page 352: ...lb Wrench size A F 7 8 RED WHITE cable 2 pcs labeled B connect to connection bolt B Fasten the cable lug with locking nut M5 and washer on the connection bolt The crimping of the lower cable lug must be directed towards the board of fuse box The crimping of the upper cable lug must be directed toward the cover of the fuse box Tightening torque 2 2 Nm 19 6 in lb Wrench size A F 8 1 Regulator A 2 Re...

Page 353: ...ounted See Fig 46 NOTE The connecting thread of seal ing union is included with each rectifier regulator as replace ment part An exchange of this plastic insert is only necessary if it is damaged 1 Regulator A 2 Cup nut of the gasket screw connection 3 Thread of the gasket screw connection m WARNUNG NOTICE When pressing in the plastic insert avoid dam aging the connecting thread of sealing union S...

Page 354: ...Wrench size A F 7 8 RED WHITE cable 2 pcs labeled A connect to connection bolt A Fasten the cable lug with locking nut M5 and washer on the connection bolt The crimping of the lower cable lug must be directed towards the board of fuse box The crimping of the upper cable lug must be directed toward the cover of the fuse box Tightening torque 2 2 Nm 19 5 in lb Wrench size A F 8 1 Regulator A 2 Regul...

Page 355: ...ctor switch B F3 7 5 A Selector switch A F4 10 A Fuel pump B F5 10 A Fuel pump A F6 10 A Ignition 3t F7 10 A Ignition 1b F8 10 A Ignition 3b F9 10 A Ignition 1t F10 5 A Injector 4 F11 5 A Injector 3 F12 5 A Injector 2 F13 5 A Injector 1 F14 2 A Caution lamp A F15 2 A Caution lamp B F16 5 A Injector 8 F17 5 A Injector 7 F18 5 A Start switch F19 Not used F20 20 A ATO fuse F21 35 A ATO fuse F22 5 A I...

Page 356: ...conductive connection continuity is pres ent the installation of the rectifier regulator has to be checked The fuse box must not be in stalled in an aircraft until the error is fixed and the installation corrected 1 Multimeter 2 Regulator A black wire connector 3 Regulator B grey wire connector 1 2 3 m WARNUNG NOTICE Installation must be carried out according to the aircraft manufacturer s instruc...

Page 357: ...stenings e g cable ties holders clamps etc of the wiring harness Carry out an engine test run See section 70 00 00 m WARNUNG NOTICE If a conductive connection continuity is pres ent check the wiring as specified by the aircraft manufacturer and in accordance with the re quirements of the Installation Manual Until the error is not fixed the engine must only be oper ated on the ground m WARNUNG NOTI...

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Page 359: ...nd ignition coil disconnection 7 Temperature sensor CTS disconnection 8 Injector disconnection 9 Throttle potentiometer disconnection 10 Temperature sensor oil and pressure sensor oil disconnection 11 Crankshaft position sensor disconnection 12 Knock sensor disconnection 13 Airbox pressure sensor and temperature sensor disconnection 7 Inspection A Electric test 8 Installation A Preparation B Wirin...

Page 360: ...vity 912 i Series Edition 1 Rev 0 76 50 00 Page 2 July 01 2012 9 Fuel pump connection 10 Fuse box FUSE BOX connection 11 Ambient pressure sensor connection 12 Starter relay connection 9 Finishing work Page 22 Page 22 Page 22 Page 22 Page 22 Subject Page ...

Page 361: ...ctivity 912 i Series Edition 1 Rev 0 76 50 00 Page 3 July 01 2012 Chapter 76 50 00 WIRING HARNESS MAIN STRAND SPECIAL TOOLS SERVICE PRODUCTS Description Part no Maintenance Tool for EMS check ECU Adapter 277012 Description Part no LOCTITE 243 897651 ...

Page 362: ...d05940 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 76 50 00 Page 4 July 01 2012 Wiring harness main strand 1 Wiring harness ...

Page 363: ...or Connector 7 Starter relay 8 Starter relay 9 CPS 1 2 Connector 10 OPS Connector 11 OTS Connector 12 Knock Connector 13 MAPS Connector 14 MATS Connector 15 EGT Connector 16 CTS Connector 17 TPS Connector 18 Injector Connector 19 Fuel pump Connector 20 Coil Connector 21 Coil Connector 22 Ground Connector 23 HIC B Connector 24 HIC A Connector 25 12 M6 cable clamp 26 DIN 128 A6 FST lock washer 27 M6...

Page 364: ...ad and rectify them as part of repair work General visual inspection See section 05 00 00 and 12 00 00 in the corresponding Main tenance Manual Line for the 912 i Series engine type Carry out an engine test run See section 12 20 00 in the corresponding Maintenance Manual Line for the 912 i Series engine type Disconnect the wiring harness from the air craft frame Disconnect all detachable connectio...

Page 365: ...ay 2 M6 hex nut 3 6 4 washer 4 Faston connector 5 Grounding 6 Allen screw Step Procedure 1 Push in the tab on the top of the connector and at the same time pull the connector out of the connection socket 1 Tab 2 Connection socket Step Procedure 1 Loosen M5 hex nut from the earthing ca ble on controller A 1 Fusebox 2 Controller LANE A 3 Controller connector A 4 Controller LANE B 5 Controller connec...

Page 366: ...taching 3 Push in the tab on the top of the connector and at the same time pull the connector out of the connection socket 1 Controller connector A 2 Controller connector B 1 Connection socket 2 Controller connector Step Procedure 4 Loosen the two round connectors label led LANE A LANE B from fuse box NOTE Unscrew the connector cap nut anti clockwise Step Procedure 5 Pull the connectors in the two...

Page 367: ...E First lift one side with a screwdri ver fix the tab and then lift the lower tab with the screwdriver and pull out the connector m WARNUNG NOTICE Do not pull on the cable 1 Fuel pump main 2 Fuel pump auxiliary 3 Connector fuel pump 1 4 Connector fuel pump 2 1 Connector fuel pump 1 2 Screwdriver Step Procedure 1 Unplug the couplers ECU LANE A1 ECU LANE A2 and ECU LANE B 1 Coupler LANE A1 2 Coupler...

Page 368: ...take manifold m WARNUNG NOTICE The Allen screws go into the intake duct The Al len screws are therefore secured with LOCTITE 243 Leaking Allen screws can cause an exces sively lean mixture 1 M6x14 Allen screw 2 6 4 washer 3 12 M6 cable clamp Step Procedure 2 Pull out 4 ignition coil connectors from each side NOTE Use a suitable tool to pull out the ignition coil plugs 1 Ignition coil connector 2 D...

Page 369: ... screws with was hers from double ignition coils 1 M5x16 Allen screw 2 5 3 washer 3 Plug holder Step Procedure 6 Unplug the connection to the double igni tion coils 1 Double ignition coils 2 Ignition coil connector COIL_1 COIL_2 COIL_3 COIL_4 Step Procedure 7 Carefully pull EGT_3 and EGT_4 cylin der 3 4 out of the locking plate 8 Press the metal bracket and separate the connectors 1 EGT connector ...

Page 370: ...th the appropriate caps Loosen the M6x16 Allen screw from fuel line assy Remove the fuel line assy See Fig 20 to Fig 24 Fig 20 Fig 21 Step Procedure 1 Disconnect the plug connection to the temperature sensor 1 Temperature sensor Step Procedure 1 Loosen the 2 M5 x12 Allen screws from cover of the fuel rail 2 Lift off the cover 1 M5x12 Allen screw 2 5 3 washer 3 Fuel rail cover Step Procedure 3 Loos...

Page 371: ...o INJ_8 1 Injector connectors Step Procedure 7 Use a screwdriver to lever out the spring clip and then unplug the connector NOTE Let the wire clip snap back in af ter the connector has been dis connected so that it does not get lost 1 Injector 2 Screwdriver m WARNUNG NOTICE Do not damage the wiring harness Always cut open on the side of the support plate facing away from the wiring harness Step Pr...

Page 372: ... CRANKSHAFT POSITION SENSOR DIS CONNECTION Wiring harness designation CPS_1 for LANE A yellow mark CPS_2 for LANE B Fig 28 1 Throttle valve 2 Throttle potentiometer 3 Cable ties Step Procedure 1 Remove cable ties 2 Unplug the temperature sensor and pres sure sensor Lift the latches pull out the connectors 1 Temperature sensor 2 Cable tie 1 Pressure sensor 2 Cable ties Step Procedure 1 Unplug CPS 1...

Page 373: ...or LANE A MAPS_2 and MATS_2 for LANE B Fig 29 Fig 30 Fig 31 Step Procedure 1 Lift the latch and pull apart Step Procedure 1 Remove the 4 cable ties 2 Unplug the connectors of the 2 pressure sensors 3 Lift the latch and pull off 1 Pressure sensors 2 Temperature sensor 3 Cable ties 1 Pressure sensor Step Procedure 4 Unplug the connectors of the 2 tempera ture sensors 5 Press the metal bracket and se...

Page 374: ...se pins in the plug connec tions Electric test The electric test of the wiring harness takes place in the installed state Fig 33 1 Airbox 2 Cable ties m WARNUNG NOTICE When work is carried out on the components of the engine management system there is a risk that these might get damaged Never put measuring probes in plug connectors or use other aids to carry out tests in the plug connectors m WARN...

Page 375: ...gh areas or fastened to components in which the maximum permissible temperature of 120 C can be exceeded during engine operation m WARNUNG NOTICE The plug connection of the ECU must be ope ned and closed no more than 20 times This must be shown on the device by a clearly visible sealing with a stamped numerical se quence 1 20 and by documentation confor ming to self monitoring guidelines m WARNUNG...

Page 376: ...1290 Crimping pliers TYCO 539 635 1 Jaws TYCO 539 737 2 Disassembly tool TYCO 1 1579007 6 2 881292 3 881296 4 881298 5 881300 NOTE If the wire is broken or the connector is defective the damage can be repaired The cable must be long enough if the connector is cut off Repair with the tools described here must comply with the aircraft standard of the respective country ...

Page 377: ...n 76 50 00 Removal THROTTLE POTENTIOMETER CONNEC TION The sensors are connected and disconnected in the same way See section 76 50 00 Removal TEMPERATURE SENSOR CTS AND IN JECTOR CONNECTION The sensors are connected and disconnected in the same way See section 76 50 00 Removal Note Fig 35 6 881306 Crimping pliers TYCO 539 635 1 Jaws TYCO 539 737 2 Disassembly tool DELPHI 12094429 7 881308 8 881302...

Page 378: ...g 38 Step Procedure 3 Plug in the injectors according to the la belling diagram Labelling diagram m WARNUNG NOTICE The ignition coils are arranged like the cylinders COIL_1 COIL_2 COIL_3 COIL_4 Ignition coils 1 and 2 are the other way round from ignition coils 2 and 4 Step Procedure 1 Plug in the connection to the double igni tion coils 1 Double ignition coil 2 Plug connection Step Procedure 2 Tig...

Page 379: ...en it Tightening torque 10 Nm 88 48 in lb m WARNUNG NOTICE 90 ignition coil connectors should be attached with cable ties to reduce vibration See chapt 74 20 00 Installation of double igni tion coils 1 M6x14 Allen screw 2 6 4 washer 3 12 M6 cable clamp m WARNUNG NOTICE The Allen screws for the spring type hose clips go into the intake duct they are therefore glued in with LOCTITE 243 Leaking Allen...

Page 380: ...onnected and disconnected in the same way See section 76 50 00 Removal AMBIENT PRESSURE SENSOR CONNECTION The sensors are connected and disconnected in the same way See section 76 50 00 Removal STARTER RELAY CONNECTION The sensors are connected and disconnected in the same way See section 76 50 00 Removal FINISHING WORK Check that all plug connections are secure contacted and free from corrosion a...

Page 381: ... Knock sensor KNOCK removal J Crankshaft position sensor assy CPS_1 CPS_2 K Throttle potentiometer TPS removal L Injection valve INJ_1 to INJ_8 removal M Governor removal N Double ignition coil removal O Fuel pump removal P Caution lamp removal Page 7 Page 7 Page 8 Page 8 Page 9 Page 9 Page 10 Page 11 Page 11 Page 11 Page 13 Page 13 Page 14 Page 14 Page 14 Page 14 Page 14 8 Inspection A General te...

Page 382: ...tall D Pressure temperature sensor AAPTS install E Temperature sensor CTS installation F Temperature sensor MATS_1 MATS_2 install G Temperature sensor OTS installation H Temperature sensor EGT_1 to EGT_4 install I Knock sensor KNOCK installation J Crankshaft position sensor assy CPS_1 CPS_2 installation K Throttle potentiometer TPS installation L Injection valve INJ_1 to INJ_8 installation M Gover...

Page 383: ...Rev 0 76 70 00 Page 3 July 01 2012 Chapter 76 70 00 SENSORS AND ACTUATORS SPECIAL TOOLS SERVICE PRODUCTS Description Part no Multimeter n a 21x12 5 insert for MAPS and OPS 876075 19x12 5 insert for CTS and OTS 876130 Description Part no LOCTITE 243 897651 LOCTITE ANTI SEIZE 297434 ...

Page 384: ...70 00 Page 4 July 01 2012 Sensors 1 Crankshaft position sensor CPS 1 2 2 Knock sensor KNOCK 3 Ambient pressure sensor AAPTS 4 Temperature sensor EGT 5 Throttle potentiometer TPS 6 Temperature sensor CTS and OTS 7 Pressure sensor MAPS 1 2 8 Temperature sensor MAPS 1 2 9 Pressure sensor OPS ...

Page 385: ...d05355 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 76 70 00 Page 5 July 01 2012 Actuators 1 Ignition coils 2 Injection valves ...

Page 386: ...ture of the exhaust gas and are used to regulate the injection quantity 1 Temperature sensor cooling system Wiring harness designation CTS The temperature sensor measures the coolant temperature directly in the cylinder head of cylin der 4 1 Temperature sensor oil temperature Wiring harness designation OTS The temperature sensor measures the oil tem perature 1 Knock sensor Wiring harness designati...

Page 387: ...nual Line for the 912 i Series engine type Use the BUDS diagnostic unit for trouble shooting and to read out the error memory Plausibility test BUDS check the plausibility of the values of the sensors with the aid of the Maintenance Tool Elimination process for pressure sensors MAPS temperature sensors MATS and injecti on valves INJ In order to identify a component clearly as defec tive you should...

Page 388: ...ut of the corresponding pres sure sensor MAPS_1 MAPS_2 See also section 76 50 00 Wiring harness main strand 3 Lift the latch and pull off ECU LANE A Sensor LANE B Sensor LANE A LANE B 06341 4 Loosen the pressure sensor with an SW 21 open ended spanner or a similar tool and remove it 5 Close the threaded bore with the appro priate protective covering 1 Pressure sensor Step Procedure 1 Cut open the ...

Page 389: ...part no 876130 or a similar tool and remove it 5 Close the threaded bore with the appro priate protective covering Step Procedure 1 Push in the tab on the top of the connector and at the same time pull the connector out of the connection socket 2 Follow the aircraft manufacturer s instruc tions for disassembly 1 Pressure temperature sensor 2 Connection socket Step Procedure 1 Cut open the cable ti...

Page 390: ...hreaded bore with the appro priate protective covering 1 Temperature sensor 2 Sealing ring Step Procedure 1 Carefully pull temperature sensor EGT out of the locking plate 1 Temperature sensor EGT 2 Locking plate Step Procedure 2 Remove the respective wiring harness plug from the corresponding temperature sensor EGT1 EGT2 EGT3 EGT4 See also section 76 50 00 Wiring harness main strand 3 Press the me...

Page 391: ...e respective connector of the wiring harness main strand from the cor responding temperature sensor See also section 76 50 00 Wiring harness main strand 3 Lift the latch and pull out the connector 1 Temperature sensor 2 Cable ties Step Procedure 4 Use an SW19 open ended spanner part no 876130 or a similar tool to re move the temperature sensor from the crankcase 5 Close the bore with the appropria...

Page 392: ...y and only as far as is necessary Installation position Cylinder head 1 See Fig 13 Fig 13 Fig 14 Fig 15 Step Procedure 1 Unplug the connector of the wiring har ness from the knock sensor See also section 76 50 00 Wiring harness main strand 2 Lift the latch and pull apart 3 Pull the connector out of the support plate 1 Connector 2 Support plate Step Procedure 4 Cut open the cable ties 1 Cable ties ...

Page 393: ...apart 3 Pull the connector out of the support plate 1 Connector CPS_1 2 Connector CPS_2 3 Support plate Step Procedure 4 Loosen the M6x20 Allen screw and wash er with an Allen key 5 or similar tool and remove the cable clamp 5 Remove crankshaft position sensor assy 6 Close the bore with the appropriate pro tective covering m WARNUNG NOTICE Ensure that the O ring is positioned on the crankshaft pos...

Page 394: ... see section 73 10 00 Fuel pump and distribution GOVERNOR REMOVAL See also section 61 20 00 Governor DOUBLE IGNITION COIL REMOVAL See also section 74 20 00 Distribution FUEL PUMP REMOVAL To do this see section 73 10 00 Fuel pump and distribution CAUTION LAMP REMOVAL See documentation of aircraft manufacturer 1 Throttle valve potentiometer 2 Throttle body assy ...

Page 395: ... ignition Disconnect the battery Otherwise the measurement unit can be damaged The ohmmeter is connected to the 2 connections of a consumer or to the 2 ends of an electric line It doesn t matter which cable of the measu rement unit is clamped to which contact Excep tions are resistance measurements on components which contain diodes The resistance measurement on the engine usually covers 2 areas R...

Page 396: ...gger coil NOTE It should be remembered that the static measurement is only meaningful for the determined temperature ranges Exact information can be obtained if the trigger coil has been tested over a wider tempe rature range Fig 20 VOLTAGE MEASUREMENT General note Voltage can be detected with a simple test lamp or a voltage tester However this only indicates whether there any voltage is connected...

Page 397: ...unit can be destroyed by the high currents which occur here A current clamp can be used for measuring such high amperages Step Procedure 1 Before the current measurement the measurement unit is adjusted to the mea surement range in which the amperage you are measuring is likely to be found If this is not known set the highest mea surement range and if there is no display switch down to the next me...

Page 398: ...IN Voltage in V Remarks Supply voltage B 5 V 0 5 OUT C 0 5 4 5 V corresponds to 0 to 2 bar GROUND A 0 V Measurement Pressure bar psi Current in V 2 bar 29 psi 4 5 V 0 0 V Pressure sensor OPS Signal PIN Voltage in V Remarks Supply voltage B 5 V 0 5 OUT C 0 5 4 5 V corresponds to 0 to 10 bar GROUND A 0 V Measurement Pressure bar psi Current in V 10 bar 145 psi 4 5 V 0 0 V A B C A B 5V C 06353 06345 ...

Page 399: ...S 1 MATS 2 Measurement Temperature C F Resistance Ω 10 C 9217 9 0 5808 7 20 C 2500 5 80 C 331 10 Temperature sensor OTS Measurement Temperature C F Resistance Ω 10 C 14 F 9395 7 0 32 F 5895 7 20 C 38 F 2499 6 80 C 176 F 323 3 100 C 212 F 187 2 Temperature sensor CTS Measurement Temperature C F Resistance Ω 10 C 14 F 9395 7 0 32 F 5895 7 20 C 38 F 2499 6 80 C 176 F 323 3 100 C 212 F 187 2 1 2 1 2 0...

Page 400: ...ral visual inspection Check that the sensors are fitted securely Corrosion or damage to the wiring connector contacts or connections Check the O ring on the crankshaft position sensor Check the thread Check the crankshaft position sensor surface Check the crankshaft position sensor bore Voltage and resistance test cannot be tested Temperature sensor EGT 1 EGT 2 EGT 3 EGT 4 Measurement Temperature ...

Page 401: ...s fitted securely Check that the throttle valve sensor is securely fitted Corrosion or damage to the connector and contacts Check that the sensor shaft moves freely Check the parameters of the throttle valve setting with the Maintenance Tool especially if the ECU or the throttle valve sensor have been replaced Throttle potentiometer TPS Signal PIN Value in V Remarks Supply Voltage 1 5 V Earth offs...

Page 402: ... internal resistance is about 12 Ω GOVERNOR ELECTRIC INSPECTION See manual of aircraft manufacturer Pressure temperature sensor AAPTS Signal PIN Value in V Remarks Supply voltage 3 5 V 0 25 V Earth offset 1 0 V Signal temperature 2 45 kΩ 89 Ω Pressure 4 0 25 V 4 75 V Measurement Pressure bar psi Voltage in V 0 35 bar 5 08 psi 1 41 V 0 065 V 0 95 bar 13 78 psi 3 84 V 0 065 V Temperature C F Resista...

Page 403: ...on Corrosion or damage to the wiring connector contacts or connections Check the labelling of the connector FUEL PUMP INSPECTION To do this see section 73 10 00 Fuel pump and distribution CAUTION LAMP INSPECTION See also section 77 40 01 Caution lamps Double ignition coil Measurement Position Resistance Ω Primary side 0 65 Ω 0 07 Ω Secondary side 8 2 Ω 0 8 kΩ primary 06358 secondary side side ...

Page 404: ...6075 or a similar tool to tighten it Tightening torque 15 Nm 88 48 in lb 1 Pressure sensor OPS Step Procedure 3 Plug the respective wiring harness con nector into the corresponding pressure sensor See section 76 50 00 4 Attach cable ties strain relief 1 Pressure sensor OPS 2 Cable ties Step Procedure 1 Clean the thread of the pressure sensor 2 Tighten the pressure sensor with an SW 21 open ended s...

Page 405: ... the pressure sen sor with LOCTITE 243 and use an SW 19 open ended spanner part no 876130 or a similar tool to tighten it Tightening torque 15 Nm 88 48 in lb 3 Plug the respective wiring harness con nector into the corresponding tempera ture sensor See section 76 50 00 1 Temperature sensor CTS Step Procedure 1 Clean the thread of the temperature sen sor 2 Fasten the temperature sensor and seal ing...

Page 406: ...essure sen sor with LOCTITE 243 and use an SW 19 open ended spanner part no 876130 or a similar tool to tighten it Tightening torque 15 Nm 88 48 in lb 3 Plug the respective wiring harness con nector into the corresponding tempera ture sensor See section 76 50 00 1 Temperature sensor OTS Step Procedure 4 Attach cable ties 1 Temperature sensor OTS 2 Cable ties Step Procedure 1 Clean the thread of th...

Page 407: ...00 5 Carefully push the connector EGT in to the locking plate 1 Connector EGT 2 Locking plate Step Procedure 1 Clean the end face of the knock sensor 2 Screw the knock sensor hand tight into engine block 3 Adjust the knock sensor do not let it come into contact with the intake manifold 4 Tighten the knock sensor Tightening torque 20 Nm 176 96 in lb 1 Connector KNOCK 2 Locking plate Step Procedure ...

Page 408: ...rests on the sensor Step Procedure 1 Push the cable clamp onto the cable m WARNUNG NOTICE Arrange the cable so that it does not rest against the engine suspension frame or other compo nents 1 Crankshaft position sensor CPS_1 2 Crankshaft position sensor CPS_2 3 M6x20 allen screw 4 Washer 5 Cable clamp 6 O ring Step Procedure 2 Secure M6x20 Allen screw with LOCTITE 243 and tighten it Tightening tor...

Page 409: ...ution FUEL PUMP INSTALLATION To do this see section 73 10 00 Fuel pump and distribution CAUTION LAMP INSTALLATION See documentation of aircraft manufacturer FINISHING WORK Complete the engine Fill with operating fluids coolant oil or fuel See also section 12 20 00 Planned mainte nance Carry out an engine test run See also section 12 20 00 Planned maintenance Step Procedure 1 Install the throttle b...

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Page 411: ...ion This section describes the maintenance of the exhaust system assembly of the ROTAX 912 i Series engine The description is divided into sub sections and explanations of system functions Subject Page 1 Introduction A System description B Safety information C Connections for display systems Chapter 78 00 00 Page 3 Page 3 Page 3 2 Exhaust Chapter 78 10 00 ...

Page 412: ...d05356 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 78 00 00 Page 2 July 01 2012 Exhaust system ...

Page 413: ...TION CONNECTIONS FOR DISPLAY SYSTEMS EXHAUST GAS TEMPERATURE DISPLAY The engine is equipped with 4 EGT temperature sensors for regulating the optimal fuel air mix ture These can be installed in various ways depending on the exhaust system m WARNUNG NOTICE The muffler assy with part no 973385 is also used in series 912 S ULS engines and can op tionally be used in series 912 UL F A engines m WARNUNG...

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Page 415: ...tions of system functions NOTE For non ORIGINAL ROTAX exhaust systems use the main tenance manual of the aircraft manufacturer Subject Page 1 Introduction 2 Service products 3 System description Page 1 Page 3 Page 5 4 Removal A Preparation B Exhaust assy removal C Exhaust pipe removal 5 Inspection A Exhaust assy inspection B Exhaust pipe and cylinder head inspection 6 Installation A Exhaust pipe o...

Page 416: ...5357 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 78 10 00 Page 2 July 01 2012 1 Muffler assy 2 Tension spring 3 Exhaust pipe 5 Exhaust flange 6 Outflow pipe exhaust elbow ...

Page 417: ...INTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 78 10 00 Page 3 July 01 2012 Chapter 78 10 00 EXHAUST SERVICE PRODUCTS Description Part no LOCTITE 648 899788 LOCTITE ANTI SEIZE 15378 297434 ...

Page 418: ...d05357 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 78 10 00 Page 4 July 01 2012 Exhaust ...

Page 419: ...the relevant Maintenance Manual Line for the respective 912 i Series engine type REMOVAL EXHAUST ASSY REMOVAL Preparation See also section 76 50 00 Wiring harness Unplug the temperature sensor EGT Fig 1 EXHAUST PIPE REMOVAL Fig 2 m WARNUNG mWARNING Danger of severe burns and scalds Allow the engine and exhaust to cool to ambient tempera ture before starting work m WARNUNG NOTICE Follow the aircraf...

Page 420: ...Fig 3 Fig 4 m WARNUNG NOTICE Follow the aircraft manufacturer s instructions for inspection Step Procedure 1 Check the exhaust for cracks dents and leaks m WARNUNG NOTICE A deformed exhaust flange must be replaced Step Procedure 1 Check the conical seal in the cylinder head and on the exhaust pipe for defor mation 1 Conical seal 2 Exhaust flange 3 Exhaust pipe 1 Conical seal 2 Cylinder head ...

Page 421: ...ce Secure them with LOCTITE 648 if neces sary and tighten them Tightening torque 6 Nm 53 09 in lb 2 Fasten the exhaust flange to the cylinder head with 2 new M8 hex nuts Tightening torque 12 Nm 106 18 in lb NOTE The exhaust flange must be pa rallel to the screw face on the cylinder head but must not rest against it 1 M8 hex nut 2 Exhaust flange 3 Exhaust pipe 4 Cylinder head m WARNUNG NOTICE Follo...

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Page 423: ...p 8 Disassembly C Oil pump disassembly 9 Inspection A Oil pump parts inspection 1 Oil pump housing inspection 2 Rotary piston rotor inspection 3 Oil pump shaft inspection 10 Wear limits 11 Assembly A Oil pump assembly 1 Oil pump housing o rings 2 Oil pump cover 12 Installation A Preparation B Oil pump installation C Oil filter installation 13 Finishing work Page 7 Page 7 Page 7 Page 9 Page 9 Page ...

Page 424: ...line installation 26 Finishing work Page 23 Page 23 Page 23 Page 23 Page 23 Page 24 Page 24 Page 24 Page 24 27 Temperature and pressure measurement system A General note 28 Removal A Temperature sensor OIL removal 29 Inspection A Temperature sensor OIL inspection 30 Installation A Temperature sensor OIL installation Page 24 Page 24 Page 25 Page 25 Page 25 Page 25 Page 25 Page 25 31 Removal A Press...

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Page 427: ...ge 5 July 01 2014 Chapter 79 00 00 LUBRICATION SYSTEM SPECIAL TOOLS SERVICE PRODUCTS Description Part no Oil filter wrench 877620 Dial gauge n a Straight edge n a Aligning plate n a Description Part no KLUEBER ISOFLEX TOBAS NB 5051 898351 LOCTITE 5910 899791 LOCTITE 243 897651 Insulating tape n a ...

Page 428: ...d05941 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 79 00 00 Page 6 July 01 2012 Lubrication system ...

Page 429: ...the crank case and measures the oil inlet temperature PRESSURE SENSOR The pressure sensor is situated on the ignition housing and measures the oil pressure MAINTENANCE As well as the maintenance and special checks see the relevant Maintenance Manual Line for the respective 912 i Series engine type NOTE Whenever the lubrication system is re moved or disassembled o rings and other sealing elements m...

Page 430: ...crew regulator piston 3 Loosen the plug screw regulator piston otherwise it is very difficult to unscrew when the oil pump is removed 1 Plug screw for regulator pressure oil line 2 Plug screw regulator piston 3 Regulator pressure oil line Step Procedure 4 Unscrew the oil filter with oil filter wrench part no 877620 1 Oil filter 2 Special tool Step Procedure 5 Loosen 4 Allen screws with lock washer...

Page 431: ...d regulator piston 1 Plug screw 2 Compression spring 3 Regulator piston Step Procedure 2 Remove the oil pump cover 1 Oil pump cover 2 Soft faced hammer m WARNUNG NOTICE The rotary piston and rotor are marked 1 Rotor inner rotor 2 Rotary piston outer rotor 3 Mark Step Procedure 3 Pull out the rotor and rotary piston 4 Remove the feather key 5 Pull out the oil pump shaft m WARNUNG NOTICE The sealing...

Page 432: ...Rev 0 d05941 fm MAINTENANCE MANUAL BRP Powertrain 79 00 00 Page 10 July 01 2012 Fig 8 Fig 9 1 Oil seal 2 Oil pump shaft Step Procedure 6 Carefully lever the oil seal out of the oil pump housing with a screwdriver 1 Screwdriver 2 Oil seal ...

Page 433: ...de of the rotor or outer side of the rotary piston they must both be repla ced Fig 12 Step Procedure 1 Visually inspect all the components of the oil pump 2 All the o rings must be replaced 3 Check the oil pump cover for wear on the inside using a straight edge 1 Straight edge 2 Oil pump cover Step Procedure 4 Check the sealing faces of the oil pump housing and pump cover for striations where nece...

Page 434: ...fm MAINTENANCE MANUAL BRP Powertrain 79 00 00 Page 12 July 01 2012 OIL PUMP SHAFT INSPECTION Fig 13 Step Procedure 1 Check the oil pump shaft at the bearing points 2 Check the feather key groove and feather key for wear 1 Oil pump shaft 2 Feather key ...

Page 435: ...e limit Tolerance limit Measurements min max 100 50 Main pump spacing pump cover rotor OP01 0 02 mm 0 00079 in 0 07 mm 0 0027 in 0 20 mm 0 0079 in 0 14 mm 0 0053 in current replaced Width of feather key in shaft OP02 4 mm 0 1575 in 4 085 mm 0 1604 in 4 150 mm 0 163 in 4 11 mm 0 1619 in current replaced Pressure spring length OP03 65 6 mm 2 58 in 62 6 mm 2 46 in 64 1 mm 2 52 in current replaced ...

Page 436: ... Step Procedure 3 Stick insulating tape over the feather key groove m WARNUNG NOTICE Press in the oil seal so that the closed side points towards the oil pump housing Step Procedure 4 Apply Klueber grease to the oil pump shaft and push oil seal A 14x22x4 onto the oil pump shaft while turning slightly 1 Oil pump shaft 2 Insulating tape 3 Oil seal A 14x22x4 Step Procedure 5 Place the oil pump housin...

Page 437: ...shaft 1 Feather key 2 Oil pump shaft m WARNUNG NOTICE The rotor and rotary piston have a mark The mark must be visible on both rotors Step Procedure 9 Push on the rotor inner rotor 10 Insert the rotary piston outer rotor 1 Rotor inner rotor 2 Rotary piston outer rotor 3 Mark m WARNUNG NOTICE All the o rings must be replaced Step Procedure 1 Insert new o rings in the oil pump housing 1 63x2 5 o rin...

Page 438: ...INTENANCE MANUAL BRP Powertrain 79 00 00 Page 16 July 01 2012 See Fig 21 Fig 21 m WARNUNG NOTICE Make sure the oil pump cover is in the correct position when putting it on Step Procedure 1 Place the oil pump cover on the oil pump housing 1 Oil pump cover ...

Page 439: ...correct installation position 1 Oil pump shaft 2 Oil pump housing 3 O rings Step Procedure 1 Apply LOCTITE 5910 to the support area on the crankcase 1 Crankcase Step Procedure 2 Install the oil pump housing with M6x50 Allen screws and 6 4 washers crosswise and by hand Then tighten the Allen screws crosswise Tightening torque 10 Nm 88 48 in lb 3 Tighten plug screw Tightening torque 30 Nm 265 44 in ...

Page 440: ...nance Manual Line for the 912 i Series Bleed the oil system See relevant Maintenance Manual Line for the 912 i Series Carry out an engine test run and leakage check NOTE Then check that the oil seal is securely fitted after the test run Step Procedure 5 Install the oil filter See relevant Main tenance Manual Line for the 912 i Series NOTE Oil the gasket of the oil seal 6 Install the oil lines ...

Page 441: ... to cool down to ambient tempe rature before starting any work m WARNUNG mWARNING Danger of electric shock Switch off the ignition and pull out the ignition key Disconnect the ne gative terminal of the battery ENVIRONMENT NOTE Dispose of used oil according to local environ mental regulations m WARNUNG NOTICE Use appropriate protective coverings to prevent the ingress of debris particles into all d...

Page 442: ...n Clean all parts carefully See also section 05 00 00 Procedures Step Procedure 1 Open profile clamp 163 2 Remove the oil tank cover assy and O ring 1 Oil tank 2 Oil tank cover assy 3 O Ring 4 Profile clamp Step Procedure 3 Remove the baffle insert and partition from the oil tank 1 Oil tank 2 Baffle insert 3 Partition Step Procedure 1 General visual inspection See rele vant Maintenance Manual Line...

Page 443: ...only to be removed if necessary and only as far as is necessary m WARNUNG NOTICE The oil cooler is not included in the delivery of the engine Maintenance must be carried out in accordance with the aircraft manufacturer s in structions m WARNUNG mWARNING Danger of severe burns and scalds Always allow the engine to cool down to ambient tempe rature before starting any work ENVIRONMENT NOTE Dispose o...

Page 444: ...ee relevant Maintenance Manual Line for the 912 i Series Carry out an engine test run and leakage check m WARNUNG NOTICE The oil cooler is not included in the delivery of the engine Maintenance must be carried out in accordance with the aircraft manufacturer s in structions Step Procedure 1 Clean the cooling fins of the oil cooler and straighten them out if necessary 2 Rinse out the inside of the ...

Page 445: ...st be maintained according to the aircraft manufacturer s instructions Step Procedure 1 Remove the oil lines and clamps accor ding to the instructions in the aircraft ma nufacturer s manual m WARNUNG NOTICE The steel oil lines which are included in the de livery are only removed if they are damaged or for cleaning Step Procedure 1 Remove the cable clamp for supporting the line on the side of the g...

Page 446: ...temperature sensor the indicating instrument the line connection the measurement line must be checked NOTE The ground connection of the tempera ture sensor is established directly via the housing m WARNUNG NOTICE Ensure that the lines are installed without tensi on and are not scuffed Observe minimum di stances e g 2 mm 0 0787 in from the housing Step Procedure 1 Install the oil lines and clamps a...

Page 447: ...NSOR OIL INSTALLATION Step Procedure 1 To do this see section 76 70 00 Sensors and actuators 2 Clean the thread of the oil temperature sensor Step Procedure 1 To do this see section 76 70 00 Sensors and actuators Step Procedure 1 To do this see section 76 70 00 Sensors and actuators m WARNUNG NOTICE The pressure range of the display device must match the pressure range of the pressure sen sor Othe...

Page 448: ...e with a HeliCoil DRAIN PLUG See relevant Maintenance Manual Line for the 912 i Series engine type FLAT AREAS Flat areas on lubricant supply components up to a maximum of 0 3 mm 0 0118 in The indentations must not have sharp edges Remove sharp edges carefully with a shar pening stone Damage limits must not be exceeded m WARNUNG NOTICE The sealing surfaces on oil pump components must not be repaire...

Page 449: ...eries engine The description is divided into sub sec tions and explanations of system functions Subject Page 1 Introduction 2 Service products 3 System description 4 Safety information Page 1 Page 3 Page 3 Page 5 5 Removal A Preparation B Removal of the electric starter 6 Inspection A Electric starter inspection 7 Installation A Preparation B Electric starter installation 8 Finishing work Page 5 P...

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Page 451: ... MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 80 00 00 Page 3 July 01 2012 Chapter 80 00 00 ELECTRIC STARTER SERVICE PRODUCTS Description Part no KLUEBER ISOFLEX TOPAS Nb5051 898351 ...

Page 452: ...d05359 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 80 00 00 Page 4 July 01 2012 Electric starter ...

Page 453: ...s must be OFF MAINTENANCE As well as the maintenance and special checks see the relevant Maintenance Manual Line for the respective 912 i Series engine type REMOVAL Preparation Switch the ignition key OFF Disconnect the battery negative pole ELECTRIC STARTER REMOVAL Fig 1 Fig 2 m WARNUNG mWARNING Danger of severe burns and scalds Always allow the engine to cool down to ambient temperature before s...

Page 454: ...first press the electric starter gently down with a screwdriver and then pull off the starter by hand INSPECTION ELECTRIC STARTER DISASSEMBLY IN SPECTION ASSEMBLY Fig 3 m WARNUNG NOTICE Do not tap the electric starter with a hammer the adhering magnets can come off m WARNUNG NOTICE Only allowed for HD starters 1 Electric starter 2 Rotor 3 O Ring ...

Page 455: ...FINISHING WORK Connect the negative terminal of the on board battery Carry out an engine test run See relevant Maintenance Manual Line for the 912 i Series engine type m WARNUNG NOTICE Ensure that the electric starter is in the correct installation position See Fig 4 Step Procedure 1 Push the whole electric starter into the ignition housing 2 Tighten the M5 hex nuts equally Tightening torque 6 Nm ...

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Page 457: ......

Page 458: ...ial no __________________________________________________________ Type of aircraft __________________________________________________________ Aircraft registration no ROTAX authorized distributor and TM are trademarks of BRP Rotax GmbH Co KG 2018 BRP Rotax GmbH Co KG All rights reserved ...

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