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Rotax MMH-912 Series, Maintenance Manual

The Rotax MMH-912 Series Maintenance Manual is essential for keeping your engine in top condition. This comprehensive manual covers all aspects of maintenance and is available for free download from manualshive.com. Ensure your engine performs at its best by referring to this manual for guidance.

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Effectivity 912/914 Series
Edition 1 / Rev. 0

79-00-00

page 29

May 01/2007

d02628

BRP-Rotax

Maintenance Manual

Description

 Co

de

 Reading new

wear 

limit

wear 

limit

Readings

min

max

100%

50%

Oil pump

Clearance main 
pump (pump cover/
rotor)

OP01

0,00

0,0000

0,05

0,0020

0,20

0,0079

0,13

0,0049

actual

renewed

Clearance suction 
pump (pump cover / 
rotor)

OP01

0,00

0,0000

0,05

0,0020

0,20

0,0079

0,13

0,0049

actual

renewed

0

10

20

30

40

50

60

70

80

90

0.01mm

1

2

3

4 5 6

7

8

9

0

OP01

07429

07204

4) Wear limits

Summary of Contents for MMH-912 Series

Page 1: ...MAINTENANCE MANUAL HEAVY MAINTENANCE FOR ROTAX ENGINE TYPES part no 899603 ROTAX 912 AND 914 SERIES picture 914 UL 3 DCDI with options picture 912 ULS 3 DCDI with options Ref No MMH 912 MMH 914...

Page 2: ...erved ROTAX is a trade mark of BRP Powertrain GmbH Co KG In the following document the short form of BRP Powertrain GmbH Co KG BRP Powertrain is used Other product names in this documentation are used...

Page 3: ...00 00 23 7 Safety notice 00 00 00 25 7 1 Repeating symbols 00 00 00 25 8 Technical documentation 00 00 00 27 8 1 Filling in the dimension sheets 00 00 00 27 8 2 List of abbreviations 00 00 00 28 9 Cla...

Page 4: ...00 00 00 page 4 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02620 BRP Rotax Maintenance Manual NOTES...

Page 5: ...5 May 01 2007 d02620 BRP Rotax Maintenance Manual 2 List of chapters INTRODUCTION 00 POWER PLANT 71 ENGINE 72 FUEL SYSTEM 73 IGNITION SYSTEM 74 COOLING SYSTEM 75 ENGINE CONTROL 76 EXHAUST SYSTEM AND...

Page 6: ...00 00 00 page 6 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02620 BRP Rotax Maintenance Manual NOTES...

Page 7: ...73 00 00 25 Disc spring pretension 72 00 00 51 Drain plug 79 00 00 10 Drip tray disassembly 73 00 00 17 Dual ignition coil 74 00 00 17 E Electric starter 80 00 00 3 Electric starter installation 80 00...

Page 8: ...ing 76 00 00 8 P PC interface 76 00 00 12 Piston rings inspection 72 00 00 79 Pistons fitting 72 00 00 86 Pistons inspection 72 00 00 77 Pistons removal 72 00 00 75 Pitting 72 00 00 45 72 00 00 47 Pos...

Page 9: ...er coil kit 74 00 00 13 Trigger coil kit replacement 74 00 00 46 Trigger coils arrangement 74 00 00 8 Turbocharger assembly 78 00 00 15 Turbocharger disassembly 78 00 00 7 Turbocharger inspection 78 0...

Page 10: ...00 00 00 page 10 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02620 BRP Rotax Maintenance Manual NOTES...

Page 11: ...01 2010 30 10 01 2010 31 10 01 2010 32 10 01 2010 33 10 01 2010 34 10 01 2010 35 10 01 2010 36 10 01 2010 37 10 01 2010 38 10 01 2010 39 10 01 2010 40 10 01 2010 41 10 01 2010 42 10 01 2010 43 10 01 2...

Page 12: ...01 2008 45 07 01 2008 46 07 01 2008 47 05 01 2007 48 05 01 2007 49 07 01 2008 50 07 01 2008 51 07 01 2008 52 10 01 2010 53 10 01 2010 54 10 01 2010 55 10 01 2010 56 05 01 2007 57 07 01 2008 58 10 01...

Page 13: ...7 12 05 01 2007 13 05 01 2007 14 05 01 2007 15 10 01 2010 16 10 01 2010 17 10 01 2010 18 10 01 2010 19 10 01 2010 20 07 01 2008 21 07 01 2008 22 07 01 2008 23 10 01 2010 24 10 01 2010 25 07 01 2008 26...

Page 14: ...1 2007 39 05 01 2007 40 05 01 2007 41 05 01 2007 42 05 01 2007 43 05 01 2007 44 05 01 2007 45 05 01 2007 46 07 01 2008 47 07 01 2008 48 05 01 2007 49 07 01 2008 50 07 01 2008 51 05 01 2007 52 05 01 20...

Page 15: ...01 2007 41 05 01 2007 42 05 01 2007 43 05 01 2007 44 05 01 2007 45 05 01 2007 46 05 01 2007 47 05 01 2007 48 05 01 2007 49 05 01 2007 50 05 01 2007 51 05 01 2007 52 05 01 2007 53 07 01 2008 54 07 01 2...

Page 16: ...5 01 2007 17 05 01 2007 18 07 01 2008 19 10 01 2010 20 10 01 2010 21 10 01 2010 22 05 01 2007 23 05 01 2007 24 05 01 2007 25 05 01 2007 26 05 01 2007 27 10 01 2010 28 05 01 2007 29 05 01 2007 30 05 01...

Page 17: ...00 00 00 Effectivity 912 914 Series Edition 1 Rev 0 page 17 May 01 2007 d02620 BRP Rotax Maintenance Manual NOTES...

Page 18: ...00 00 00 page 18 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02620 BRP Rotax Maintenance Manual NOTES...

Page 19: ...00 all 05 01 2007 DOA 0 80 00 00 all 05 01 2007 DOA 1 00 00 00 11 13 15 19 34 36 01 01 2008 DOA 1 72 00 00 22 23 28 01 01 2008 DOA 51 54 66 01 01 2008 DOA 1 73 00 00 1 2 17 18 25 26 01 01 2008 DOA 53...

Page 20: ...authority tation 3 72 00 00 1 8 10 12 14 18 19 10 01 2010 DOA 22 24 30 32 35 40 42 52 55 58 59 63 69 80 81 83 84 86 88 92 93 98 106 108 111 3 73 00 00 1 6 7 15 19 23 24 10 01 2010 DOA 27 29 30 45 46 5...

Page 21: ...00 00 00 Effectivity 912 914 Series Edition 1 Rev 3 page21 October01 2010 d04774 BRP Powertrain Maintenance Manual NOTES...

Page 22: ...00 00 00 page22 October01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04774 BRP Powertrain Maintenance Manual NOTES...

Page 23: ...s the following engines 912 A 912 F 912 S 912 UL 912 ULS 912 ULSFR 914 F 914 UL Before carrying out maintenance work on the engine please read the Maintenance Manual HeavyMaintenance carefully Seealso...

Page 24: ...00 00 00 page 24 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02620 BRP Rotax Maintenance Manual NOTES...

Page 25: ...ch have the same or similar function Specifications are given in the SI metric system with the USA equivalent in parenthesis 7 1 Repeating symbols This Manual uses the following symbols to emphasize p...

Page 26: ...00 00 00 page26 October01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04774 BRP Powertrain Maintenance Manual NOTES...

Page 27: ...the engine is overhauled repaired before the end of the TBO the 50 specified values 3 for wear limits do not apply and must be calculated separately in accordance with Section 9 Classification of par...

Page 28: ...are taken in hundredths of a millimeter or more precisely the temperature of the part must be 20 to 25 C 68 to 77 F 07437 Fig 00 2 8 2 Listofabbreviations The following table shows the abbreviations u...

Page 29: ...tion is made on the basis of the following criteria Hours of operation decisive are the total operating hours of the part engine or hours since the last overhaul Determined measured actual dimension o...

Page 30: ...450 451 500 501 550 551 600 601 700 701 800 801 900 901 1000 1001 1100 1101 1200 1201 1300 1301 1400 1401 1500 1501 1600 1601 1700 1701 1800 1801 1900 1901 2000 93 36 12 18 24 30 42 46 52 TSN h Time...

Page 31: ...401 450 451 500 501 550 551 600 601 700 701 800 801 900 901 1000 1001 1100 1101 1200 1201 1300 1301 1400 1401 1500 1501 1600 1601 1700 1701 1800 1801 1900 1901 2000 98 98 99 100 90 92 94 96 76 80 83...

Page 32: ...7 Determine actual dimension F of the part in question Fornewdimension max BandwearlimitC seethecorrespondingsection Wear limits e g 74 00 00 sec 4 The actual wear in is determined with the following...

Page 33: ...E A negative result means that the actual dimension F is within the new dimension tolerance D Example for engines of Series 914 Hours of operation indicated 300 h The determined percentage of maximum...

Page 34: ...00 00 00 page34 October01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04774 BRP Powertrain Maintenance Manual NOTES...

Page 35: ...ation at the beginning of this chapter 10 1 Trouble shooting In the Operators Manual possible problems as well as feasible remedies are listed At the same time brief reference is made to the necessary...

Page 36: ...t light duty screw locking agent 10 ml 2 897651 LOCTITE 243 blue medium duty screw locking agent 10 ml 3 898441 LOCTITE 2701 heavy duty screw locking agent 5 ml 4 899789 LOCTITE 603 green oil tolerant...

Page 37: ...stant and highly adherent Usable for tempera tures from 35 C to 120 C 31 F to 248 F and can be subjected to high mechanical loads 19 n a Preservation oil This special oil has excellent penetrating cap...

Page 38: ...a solvent cold cleaner free of halogen on the basis of selected fuel fractions and is biodegradable Never use caustic or corrosive cleaning agents 24 n a Valve lapping paste This paste produced by var...

Page 39: ...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 indication of cracks...

Page 40: ...assembly device for propeller gearbox Fig 00 8 shows one possible tensioning device for the disassembly of the propeller gearbox The dimensions given are only intended for easier orientation and are n...

Page 41: ...100 308 or equivalent Supply voltage 8 to 15 V Flash triggering via inductive clampon pickup Flashing frequency 4500 rpm Multimeter FLUKE series 70 series 80 or equivalent Electronic 3 1 2 digit indi...

Page 42: ...ide sleeve 1 for O ring idle mixture screw and idle jet 6 876510 insertion jig 1 for oil seal 12x30x7 water pump shaft 7 877258 insertion jig for rotary seal 1 8 877270 insertion jig assy 1 for oil se...

Page 43: ...tion mushroom 1 for crankshaft magneto side 24 877377 puller assy 1 narrow configuration for fly wheel hub 25 27 877765 crankcase splitting tool Z 28 877387 valve spring mounting device assy 1 29 8773...

Page 44: ...45 874230 fuel pressure gauge 1 46 877240 trestle adapter assy 1 for fixation of engine Type 912 47 877930 trestle support assy 1 48 877840 hose clamp pliers 1 for spring band hose clip 28 49 976140 d...

Page 45: ...1 for roller bearing 25x52x15 oil seal 30x52x7 and oil inlet cover 66 242091 hex nut M10 1 for roller bearing 25x52x15 oil seal 30x52x7 and oil feed line cover 67 876885 mounting yoke 1 to compress d...

Page 46: ...October01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04774 BRP Powertrain Maintenance Manual Fig 00 9 08201 4 3 2 1 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 25 26 27 28 29 30 31 32 33 33 34 35...

Page 47: ...00 00 00 Effectivity 912 914 Series Edition 1 Rev 3 page47 October01 2010 d04774 BRP Powertrain Maintenance Manual 08202 Fig 00 10 38 40 39 48 49 50 51 41 42 43 44 45 46 47 37...

Page 48: ...00 00 page48 October01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04774 BRP Powertrain Maintenance Manual 08203 Fig 00 11 54 55 56 57 59 60 58 68 69 70 72 61 62 63 64 65 66 67 73 74 75 53 52 71...

Page 49: ...0 11 3 3 Weights 71 00 00 11 3 4 Engine Components 71 00 00 12 4 Treatment of corrosion and surface damage 71 00 00 15 4 1 Propeller shaft 71 00 00 15 4 2 Electric system 71 00 00 15 5 Preservation an...

Page 50: ...71 00 00 page 2 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02621 BRP Rotax Maintenance Manual NOTES...

Page 51: ...rge ignition 2 constant depression carburetors On the 912 Series 1 mechanical fuel pump On the 914 Series 2 electric fuel pumps 12V DC Propeller drive via reduction gearbox with integrated mechanical...

Page 52: ...FAR JAR E TW10 ACG UL noncertified aircraft engines Series 2 Propeller shaft with flange for fixed pitch propeller 3 Propeller shaft with flange for variable pitch propeller and drive for hydraulic c...

Page 53: ...4 for engines of the 912 Series See Figs 71 5 to 71 9 for engines of the 914 Series AS power take off side MS magneto side A points of attachment for engine transport center of gravity P zero referenc...

Page 54: ...rbox optional 9 Engine suspension frame optional 10 Coolant pump 11 Expansion tank 12 Oil pump 13 Connection for oil return line engine 14 Oil filter 15 Electric starter 16 Electronic module 17 Compen...

Page 55: ...71 00 00 page 7 May 01 2007 d02621 BRP Rotax Maintenance Manual Cyl 1 Cyl 3 Cyl 4 Cyl 2 00124 00503 07902 912Series 912Series Fig 71 3 Fig 71 4 P z1 y1 y1 z1 z z y y Fig 71 2 5 8 9 11 12 14 16 17 18...

Page 56: ...ansion tank 20 2 separate oil pumps 21 Connection for oil return line engine 22 Connection for oil return line turbo 23 Oil filter 24 Electric starter 25 Electronic module 26 Compensation tube 27 Conn...

Page 57: ...tax Maintenance Manual A A x x y y P x1 y1 y1 x1 z1 y1 y1 z1 z z y y P 00124 00121 00122 00123 914Series 914Series Fig 71 6 Fig 71 9 Fig 71 8 Cyl 1 Cyl 3 Cyl 4 Cyl 2 13 15 16 17 11 12 26 37 29 30 31 4...

Page 58: ...71 00 00 page 10 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02621 BRP Rotax Maintenance Manual NOTES...

Page 59: ...d must be observed 3 1 Operating limits See latest version of valid Operators Manual for the engine in question 912 Series or 914 Series Operating instructions 3 2 Operating fluids Capacity See latest...

Page 60: ...nsation of clearance by hydraulic valve tappets VALVE TRAIN OHV hydraulic valve tappets pushrods and rocker arms CAMSHAFT steel annealed liquid nitriding CONTROL TIME 1 3 lo 0 T D C Oo 48 before B D C...

Page 61: ...on carburetors 32 mm Type 64 FUEL PUMP 2 electric fuel pumps 3 1 mechanically driven fuel pump 1 2 STARTER electric starter 12 V 0 6 kW optionally 0 9 kW PROPELLER GEARBOX integrated spur gear with to...

Page 62: ...R PITCH drive via the gearbox GOVERNOR optional TURBOCHARGER Exhaust gas turbine with wastegate radial flow com pressor T25 3 TURBOCHARGER electronic proportional plus integral plus derivative CONTROL...

Page 63: ...surface damage In the case of long standstill times a rust film may form on various metal parts Severely or heavily corroded screws nuts washers bearings bushes etc must be replaced 4 1 Propeller sha...

Page 64: ...71 00 00 page 16 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02621 BRP Rotax Maintenance Manual NOTES...

Page 65: ...otective covers must not be removed The engine must be stored in a suitable place closed area clean and dry If the engine is stored longer than 12 months the following inspections must be carried out...

Page 66: ...n oil into the cylinders through the spark plug bores Turn the crankshaft several times Fit spark plugs and spark plug connectors Drain carburetor float chambers Apply engine oil to all linkages on ca...

Page 67: ...ptions of the function of the various systems 6 1 Engine suspension frame 6 1 1 Engine suspension frame disassembly See Figs 71 10 and 71 11 WARNING Perform tasks only on the cold engine Danger of bur...

Page 68: ...lar pipe 1 and the struts 6 NOTE If necessary the engine may be flown to a repair facility as long as not more than 50 of the tube or the strut are severed If they are completely severed they must be...

Page 69: ...Effectivity 912 914 Series Edition 1 Rev 0 71 00 00 page 21 May 01 2007 d02621 BRP Rotax Maintenance Manual 00164 Fig 71 10 1 2 03080 Fig 71 11 3 4 1 6 6 6 6 5 5 5 5...

Page 70: ...es and 914 Series are equipped with two tempera ture control points on the cylinder heads for the coolant one temperature control point for the oil temperature and a pressure control point for the oil...

Page 71: ...entation 72 00 00 8 2 4 1 Mechanical rev counter and hourmeter optional 72 00 00 8 3 Maintenance 72 00 00 9 3 1 Vacuum pump removal and inspection 72 00 00 9 3 2 Governor removal and inspection 72 00...

Page 72: ...pre tension adjustment with overload clutch 72 00 00 51 3 9 15 Disc spring pre tension adjustment with dog hub 72 00 00 51 3 9 16 Propeller gearbox installation 72 00 00 53 3 10 Cylinder head removal...

Page 73: ...3 16 2 Pistons fitting 72 00 00 86 3 16 3 Cylinders fitting 72 00 00 90 3 16 4 Cylinder head fitting 72 00 00 92 3 17 Intake manifold and compensation tube assembly 72 00 00 95 3 18 Crankshaft inspect...

Page 74: ...BRP Rotax Maintenance Manual 72 00 00 page4 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 NOTES...

Page 75: ...includes a friction damped free rotation at the dogs to ensure smooth engine idling Due to this free rotation a distinct torsional impact arises at engine start and stop and in the event of sudden lo...

Page 76: ...BRP Rotax Maintenance Manual 72 00 00 page6 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 Configuration 3 with overload clutch 08204 Fig 72 1 1 2 3 4...

Page 77: ...ler shaft must also be exchanged for the correct one On configuration 912 914 4 the propeller shaft can remain It is the same designasforconfiguration912 914 3 withtheexceptionthattheinsidebore is plu...

Page 78: ...and hourmeter optional These are driven from the camshaft via a bevel gear to the rev counter shaft A flexible shaft allows connection of a combined instrument rev counter or hourmeter Subsequent inst...

Page 79: ...r the respective engine type 912 Series or 914 Series and the systems descriptions given hitherto The description is divided into subsections and descriptions of the function of the various systems 3...

Page 80: ...0 and the 1 allen screw 17 M8x35 and remove together with the lock washers Remove the governor with the gasket NOTE The screwing can be different depending on the type of gover nor See SB 912 052 and...

Page 81: ...he stator Remove the woodruff key 1 from the crankshaft CAUTION Cover the groove for the woodruff key 1 with a protective tape to avoid damage to the oil seal see Fig 72 3 Remove the electric starter...

Page 82: ...cating bore 10 are machined after pressing in the bushing if the bearing bushing 11 is worn the complete ignition cover with pressed in and machined bushing must be replaced Check the shaft seal 13 32...

Page 83: ...BRP Rotax Maintenance Manual Effectivity 912 914 Series Edition 1 Rev 0 72 00 00 page13 May 01 2007 d02622 00383 magnetseitig magneto side 00084 Fig 72 7 Fig 72 8 10 17 13 15 16 11 14 18 IH01 CS05...

Page 84: ...r oil seal onto the crankshaft Apply LOCTITE 518 or 5910 surface sealing compound to the sealing surface 6 of the pre assembled ignition cover apply multi purpose grease LZ or equivalent grease to the...

Page 85: ...d 72 12 After removing the fly wheel hub and the ignition housing see 72 00 00 sec 3 1 and 72 00 00 sec 3 4 measure the axial clearance ES10 of the free wheel gear 6 See 72 00 00 sec 4 NOTE If there i...

Page 86: ...t be heated Use a hot air gun to heat up hex nut 4 M34x1 5 to about 100 to 120 C 212 to 248 F Unscrew the hex nut 4 M34x1 5 from the crankshaft using socket wrench a f 46 part no 877450 NOTE The hex n...

Page 87: ...lutch housing Clean all parts thoroughly The circumferential helical spring 15 must not be loose or distorted to a wavy form Replace sprag clutch as required The cams 16 of the sprag clutch must move...

Page 88: ...irclip 70 part no 845245 NOTE Circlip 68 and circlip 70 can be distinguished by the different outside dimension before they are installed See Fig 72 15 Lock the crankshaft Degrease taper and threads o...

Page 89: ...rning 00239 Fig 72 14 Secure degreased hex nut M34x1 5 with LOCTITE 648 and tighten to 120 Nm 88 5 ft lb NOTE Hex nut has lefthanded thread CAUTION Check axial clearance of free wheel gear see Fig 72...

Page 90: ...kcase Place interme diate gear 2 in position oil intermediate gear shaft 3 and push into position Place thrust washer 4 12 5 21 5 1 on top Check the geartooth system of the intermediate gear 5 If the...

Page 91: ...shaft See Fig 72 18 NOTE Onnewengineversions theignitioncovermustalsobereplaced and the worm gear 9 pressed into the camshaft using special tool part no 877190 Remove allen screw M5x16 2 and the lock...

Page 92: ...er 6 without damaging the ball bearing and the propeller shaft NOTE Alternatively the optimized special tool part no 877540 can be used to remove the propeller gearbox See Fig 72 20 1 Insert dowel pin...

Page 93: ...Rotax Maintenance Manual Effectivity 912 914 Series Edition 1 Rev 1 72 00 00 page23 January01 2008 d04231 00244 00247 2 3 4 5 6 12 13 14 Fig 72 20 Fig 72 21 1 LOCTITE 648 7 9 10 11 8 8 9 Fig 72 20 1 0...

Page 94: ...y mount holder 1 for protractor 2 part no 877520 onto the crankshaft CAUTION Do not damage the crankshaft B Install the metal sheet 3 with allen screw M6x20 4 between drive sleeve and roller bearing N...

Page 95: ...ible accumulations on the piston s surface E Turn the protractor 2 on the holder 1 until the pointer of the metal sheet 3 points to 0 then tighten with screw 5 NOTE From this point onwards until the m...

Page 96: ...he value can be positive or negative L Repeat this procedure for cylinder 4 The piston will be stopped at 180 M Read the difference to 180 from the protractor CAUTION The value can be positive or nega...

Page 97: ...can be replaced if necessary Remove the retaining ring 1 with the circlip pliers Attach extractor 2 partno 877615with8allenscrewsM6x25tothecrankcase Screwstud 3 M10x45 20 part no 941180 into the pull...

Page 98: ...ring for Series 3 See Fig 72 23 After the propeller gearbox is removed the crankcase side propeller shaft bearing and oil inlet flange can be replaced if necessary Before disassembly the governor flan...

Page 99: ...ess and must be replaced before installation CAUTION Grease the grooves of the drill slightly to ensure that the majority of the metal chips adhere to the drill Remove metal chips carefully after dril...

Page 100: ...e the mounting yoke and the gearbox from the fixture Remove the drive gear 5 the thrust washer and the dog gear Force bearing bushing 6 apart with circlip pliers and withdraw from the propeller shaft...

Page 101: ...intenance Manual Effectivity 912 914 Series Edition 1 Rev 3 72 00 00 page29 October01 2010 d04776 00260 00261 Fig 72 25 Fig 72 26 1 2 3 4 5 6 07704 Fig 72 27 Dog hub Overload clutch 13 14 15 11 17 8 9...

Page 102: ...r 1 andscrew hex nut 10 M24x1 5 onto the spindle 8 from the inside Keep nut in position with a wrench By turning the spindle clockwise the propeller shaft is pressed out of the gearbox housing CAUTION...

Page 103: ...aintenance Manual Effectivity 912 914 Series Edition 1 Rev 0 72 00 00 page31 May 01 2007 d02622 Fig 72 28 Fig 72 29 00263 for configuration 2 for configuration 3 and 4 00264 13 14 15 11 12 8 9 10 1 2...

Page 104: ...ws Lock the drive sleeve 5 with the holder part no 242660 remove the allen screw 6 M8x14 and remove the vacuum pump gear 4 with the drive sleeve 5 Remove the countersunk screw 7 M5x12 with the washer...

Page 105: ...ngefixation RemovegovernorflangewithO ringanddistance sleeve item 9 of fig 72 34 behind After removal of propeller gearbox the drive can be disassembled Fix the drive sleeve 9 with holder part no 2426...

Page 106: ...he cylindrical roller bearing 16 CAUTION The attachment screw 7 M8 of the vacuum pump gear for hydraulic governor drive is 16 mm long 0 63 in and with a low profile screw head For vacuum pump drive ho...

Page 107: ...Do not torque screw only tighten enough to keep flange aligned Screw extractor 3 part no 877615 onto the crankcase place press in insert 4 part no 877590 into roller bearing 5 place on the centering...

Page 108: ...vernors latest issue Fit the pressure oil line 18 to the governor flange and the oil pump housing and secure with a clamp The screw plugs 19 and 20 normally remain closed A pressure gauge for governor...

Page 109: ...BRP Rotax Maintenance Manual Effectivity 912 914 Series Edition 1 Rev 0 72 00 00 page37 May 01 2007 d02622 Fig 72 34 00259 18 16 17 18 19 20 13 14 15 11 12 8 9 10...

Page 110: ...with the same procedure but the puller cap 10 part no 876489 is fitted on the pump flange side and the press in insert 14 part no 877595 is used Then the new oil seal 9 in pressed in using insertion j...

Page 111: ...y and measure dimension GB01 See 72 00 00 sec 4 Measure both bearing seats 2 and 3 on the propeller shaft See dimension GB02 and dimension GB03 Check oil seal running surface 4 and 5 Roll propeller sh...

Page 112: ...n damage and the material has been affected the propeller shaft must be replaced Whencarryingoutanyofthesesteps themanufacturersinstructionsmust be observed The ball bearing 6 must be an interference...

Page 113: ...he ramp valley see dimension GB07 See 72 00 00 sec 4 Light to medium traces of wear and pitting on the dogs are permissible Check the gear tooth system 14 of the gear set Check the eccenter for the fu...

Page 114: ...914 Series Edition 1 Rev 3 d04776 If there is visible wear to the disc springs 18 in the contact area 19 they must be replaced Check dimension GB13 of the uncompressed disc spring See 72 00 00 sec 4...

Page 115: ...ons in the gearbox crankshaft to drive gear propeller shaft to clutch hub of the overload clutch Carry out a visual inspection of all toothed shaft profiles for damage and wear To check the toothed sh...

Page 116: ...nd contact area external alternator wear exhaust system wear crankcase mating surfaces NOTE This vibration can be detected with dynamic propeller analysis equipment Normal vibration level for the engi...

Page 117: ...structure the surface treatment and the lubricant viscosity at operating temperature and the additives used are also important Pitting can be divided into the following categories according to the si...

Page 118: ...150 Fig 72 45 Magn approx 75 00149 00148 Fig 72 44 Magn approx 100 NOTE Because of the small size of the pitting shown and the copying process the pictures may not show the pitting clearly enough If y...

Page 119: ...ombination of the mechanical load factors pressure and friction It is triggered by exceeding the material to excess loads at certain points Decisive factors for the formation of pitting are Oil viscos...

Page 120: ...om the main area In some areas the damage reaches the tip area of the tooth resulting in tooth tip fracture Causes This type of damage is usually the result of using oil of low viscosity or of high oi...

Page 121: ...face 8 Apply LOCTITE Anti Seize to the bearing seat 10 of the propeller shaft 9 Fit a sleeve 12 which is approx 30 mm 1 18 in longer than the propeller shaft The inner diameter should be selected so t...

Page 122: ...prings are not well centered the dog gear cannot be depressed sufficiently to allow insertion of ring halves Do not increase the pressure but remove the clutch again and center the disc springs more a...

Page 123: ...f the dog hub in free rotation see the corresponding Maintenance Manual Line Maintenance for the respective engine type 912 Series or 914 Series 3 9 15 Disc spring pre tension adjustment with dog hub...

Page 124: ...912 914 Series Edition 1 Rev 3 d04776 Version with dog hub Version with overload clutch 06296 16 17 18 19 20 15 13 14 15 26 13 14 15 26 16 20 25 27 24 23 22 21 25 27 24 23 22 21 24 25 13 0 2 mm 0 008...

Page 125: ...position Don t use tools don t press or strike the drivegear onto the crankshaft CAUTION Before installing clean hex screw 4 with LOCTITE 7063 Make sure to have an appropriate installation position of...

Page 126: ...iously coated with a thin layer of sealing compound LOCTITE 5910 Turn propeller shaft slightly to allow the dog gear to engage By gently tapping on the gearbox housing not on the propeller shaft with...

Page 127: ...screw on magneto side 3 10 Cylinder head removal See Figs 72 57 and 72 58 If components of several cylinders are disassembled they must be marked to ensure correct coordination at refitting Remove al...

Page 128: ...n such a way that the sealing surface and oil return tubes are not damaged Lift out oil filled push rods stop oil from dripping by sealing with finger Coordinate push rods with cylinder heads to preve...

Page 129: ...ushings must be laid aside in an ordered manner to prevent any mixup Compress the valve springs using valve spring mounting device 1 part no 877380 valve spring mounting pliers 2 or similar tool and l...

Page 130: ...he sealing face is level In the case of slight wear valve and valve seat may be seal lapped using emery paste Clean cylinder head and individual components with suitable cleaning agents See 00 00 00 s...

Page 131: ...r thread 23 mm 0 91 in is screwed into the cylinder head Secure studs with LOCTITE 648 Tightening torque 8 Nm 70 in lb CAUTION If the engine has been overheated the hardness of the cylinder head must...

Page 132: ...ay 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 NOTE Iftherockerarmshaftbearing CH05 isworn itcanbereworked up to a certain limit The cylinder head must be sent to a ROTAX authorized over...

Page 133: ...4351 3 11 2 Reworking of the sealing surface to the exhaust manifold See Fig 72 63 Reworking is permissible if there is a leak at the sealing surface 1 to the exhaust manifold If a rework is necessary...

Page 134: ...nd 72 65 Check diameter of valve stem 1 and inner diameter of valve guide 2 see dimension VT01 and dimension CH01 If wear limit is reached replace valve guide See 72 00 00 sec 4 For this procedure the...

Page 135: ...e pressure to produce a clear imprint of the sealing surface on the valve seat ring Ensure that the sealing surface of the valve seats 1 is clean and if necessary regrind with valve lapping paste CAUT...

Page 136: ...mage and wear Clean valves measure valve stem diameter and check valve disk for wear The valve stem diameter VT01 is measured at the edge of the moving path 1 of the valve stem See Fig 72 67 See 72 00...

Page 137: ...of the 3 retaining grooves 3 on the valve stem for damage or wear To check the wear fit a new valve cotter It must fit without perceptible clearance Place the valve on roller blocks 4 roll it and mea...

Page 138: ...seat surface and must be measured as shown in Fig 72 70 See 72 00 00 sec 4 CAUTION The valve seat at the valve disk is surface hardened For this reason the valve disk must not be reworked If necessar...

Page 139: ...figurations are planned However dual and single valve springs must not be used on the same engine NOTE The valve springs can be distinguished by the different wire thickness and the different spring s...

Page 140: ...72 72 Test load for dual valve spring configuration Test load F for inner spring 53 N 11 91 lbf Test load F for outer 133 N 29 80 lbf Test load for single valve spring configuration Single valve sprin...

Page 141: ...If the dimension exceeds this limit the valve the valve spring support the valve spring retainer the valve cotters and the hydraulic valve tappet or any other damaged components must be replaced on t...

Page 142: ...t are different Check surface of rocker arm shaft and inner diameter of the rocker arm bearing bush 6 for signs of friction Carry out a visual inspection of the valve stem contact area 7 and ball join...

Page 143: ...d with oil The bushing can be installed in any position See 72 00 00 sec 4 The plastic bushing must be adequately oiled before installation CAUTION When installing the rocker arm it is impor tant to e...

Page 144: ...er arm is worn it must be replaced with a rocker arm with a plastic bushing NOTE When doing so check whether an oversize rocker arm shaft is fitted VT05 07496 Fig 72 82 VT07 07497 3 11 8 3 Rocker arm...

Page 145: ...the valve cotters 7 and relieve the valve springs see also Fig 72 59 in 72 00 00 sec 3 11 Carry out the same procedure on the exhaust valve 8 NOTE Ensure correct positioning and equal spacing of the v...

Page 146: ...ax Maintenance Manual 72 00 00 page74 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 Fig 72 83 07707 12 16 17 13 14 11 8 9 10 1 4 4 1 1 1 2 2 3 11 4 4 5 5 6 6 6 7 7 9 10 12 12 13 15 15...

Page 147: ...r is offset from piston center Move the piston to T D C position and mark with an arrow pointing towards the gearbox When the piston is cleaned the arrow 1 becomes visible This arrow faces towards the...

Page 148: ...sing the piston pin extraction tool 4 part no 877090 see 00 00 00 sec 10 6 Insert the pullout spindle 5 into the piston pin 6 and screw on the nut 7 By turning the spindle clockwise the piston pin is...

Page 149: ...00 00 sec 9 If the determined installation clearance is greater than the permissible installation clearance the piston and or the cylinder must be replaced See 72 00 00 sec 4 and 00 00 00 sec 9 Check...

Page 150: ...BRP Rotax Maintenance Manual 72 00 00 page78 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 PI01 PI02 PI02 PI02 13mm 07435 1 2 2 Fig 72 87 Fig 72 86 07412 3 4 Pl04 Pl05 Pl06 0 51 in...

Page 151: ...r to align piston squarely in cylinder and approx 10 mm 0 395 in from the top edge The end clearance is measured using the feeler gauge 4 see dimension PI07 See 72 00 00 4 By closely inspecting the ri...

Page 152: ...Fig 72 90 Measure piston pin and check for traces of seizure in area of con rod seat In case of distinct traces of seizure replace piston pin even if dimensions are correct Measure dimension PI03 See...

Page 153: ...er the readings CY01 CY02 CY03 in the corresponding form sheet See 72 00 00 sec 4 Measure the installation clearance see 72 00 00 sec 3 13 1 If the wear limit for the cylinder has been reached the cyl...

Page 154: ...tenance Manual 72 00 00 page82 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 A A CY04 07413 0 5mm 40mm 76mm CY03 CY01 CY02 07485 00297 1 2 3 4 Fig 72 92 Fig 72 93 Fig 72 91 0 197 in 2...

Page 155: ...e are irregular bright areas fretting pitting the tappet must be replaced See Fig 72 97 CAUTION The cams of the camshaft can be visually inspected for damage after removing the hydraulic valves In the...

Page 156: ...BRP Powertrain Maintenance Manual 72 00 00 page84 October 01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04776 00301 00300 00299 1 2 3 4 5 6 3 Fig 72 94 Fig 72 96 Fig 72 95 Fig 72 97 07580 1 2...

Page 157: ...Make sure that the two ball heads 2 pressed into the rod fit tightly Excessive engine speed may have caused bending of the pushrods Roll push rods and check for run out dimension VT09 Lube oil from th...

Page 158: ...o turn in the crankcase without resistance 3 16 2 Pistons fitting See Figs 72 99 72 100 72 101 72 102 72 103 72 104 and 72 105 The piston pin center is offset from the piston center During installatio...

Page 159: ...iston pin can be pulled in with the piston pin tool 7 part no 877091 Insert piston pin into one side of the piston bore insert spindle of installation tool 8 and fit nut 9 Turning the spindle clockwis...

Page 160: ...tion of the mono hook circlips is dictated by the recess on the piston When assembled the open side of the mono hook circlip must be positioned opposite the piston crown See Fig 72 100 Push installati...

Page 161: ...BRP Rotax Maintenance Manual Effectivity 912 914 Series Edition 1 Rev 0 72 00 00 page89 May 01 2007 d02622 02038 Fig 72 104 16 4 2 mm 2 mm Fig 72 105 08206 17 0 166 in 0 079 in 0 92 in 0 92 in...

Page 162: ...kage to the piston rings the appropri ate piston ring retainer part no 876978 or 876967 must be used The gaps in the rings 2 and 3 must be positioned in the prescribed angle range See Fig 72 106 Pay a...

Page 163: ...BRP Rotax Maintenance Manual Effectivity 912 914 Series Edition 1 Rev 0 72 00 00 page91 May 01 2007 d02622 25 30 25 30 25 30 25 30 05766 1 2 3 Fig 72 106...

Page 164: ...e the flat surfaces of the collar cap nuts 11 to ensure a constant tightening torque Fit cylinder head and cylinder together on crankcase First slightly tighten the cylinder head with 2 collar cap nut...

Page 165: ...mm 0 008 in between the valve covers The valve covers must not touch each other CAUTION Never change the length of the valve cover screw Check whether threads are damaged If this screw is loose or if...

Page 166: ...P Rotax Maintenance Manual 72 00 00 page94 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 Fig 72 110 00312 07709 Fig 72 108 16 17 13 14 15 1 2 3 4 5 6 7 8 Fig 72 109 08340 9 11 12 8 10...

Page 167: ...e angular tube Clean threads apply MOLYKOTE G N to both angular tubes and fit them into position with at least 5 turns Attach compensation tube 2 and the resonator hoses 3 long hose on cylinder side 2...

Page 168: ...BRP Rotax Maintenance Manual 72 00 00 page96 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 NOTES...

Page 169: ...912 914 Series Edition 1 Rev 0 72 00 00 page97 May 01 2007 d02622 1 3 1 3 4 2 0 10 20 30 40 50 60 70 80 90 0 01mm 1 2 3 4 5 6 7 8 9 0 Kurbelwelle crankshaft CS07 1 07517 07507 07710 CS05 CS04 Kurbelwe...

Page 170: ...BRP Powertrain Maintenance Manual 72 00 00 page98 October 01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04776 08748 08748...

Page 171: ...BRP Rotax Maintenance Manual Effectivity 912 914 Series Edition 1 Rev 0 72 00 00 page99 May 01 2007 d02622 PI01 PI02 PI02 PI02 13mm PI03 07403 07435 0 51 in...

Page 172: ...BRP Rotax Maintenance Manual 72 00 00 page100 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 PI07 PI08 PI09 07432 07412 Pl04 Pl05 Pl06...

Page 173: ...renewed Piston red 84mm 3 3 in PI01 83 988 3 3066 84 002 3 3072 83 890 3 3027 83 939 3 3047 actual renewed Piston green 84mm 3 3 in PI01 83 998 3 3070 84 012 3 3075 83 890 3 3027 83 944 3 3049 actual...

Page 174: ...tual renewed Piston ring groove clearance tapered compression ring 2 PI05 0 030 0 0012 0 062 0 0024 0 100 0 0039 0 081 0 0032 actual renewed Piston ring groove clearance oil scraper ring 3 PI06 0 020...

Page 175: ...Rotax Maintenance Manual Effectivity 912 914 Series Edition 1 Rev 0 72 00 00 page103 May 01 2007 d02622 0 5mm 40mm 76mm CY03 CY01 CY02 5 mm 5 mm CH01 07485 07427 07831 0 197 in 2 99 in 1 57 in 0 197...

Page 176: ...1 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 3 mm max 20 3 mm VT01 VT01 3 1 2 5 07443 0 10 20 30 40 50 60 70 80 90 0 0 1m m 1 2 3 4 5 6 7 8 9 0 45 mm 25 mm VT02 5 4 4 07482 V T 0 3 V T 0 3...

Page 177: ...ance Manual Effectivity 912 914 Series Edition 1 Rev 0 72 00 00 page105 May 01 2007 d02622 VT05 VT07 VT06 07497 07409 07496 07498 VT08 0 10 20 30 40 50 60 70 80 90 0 01mm 1 2 3 4 5 6 7 8 9 0 160 mm VT...

Page 178: ...BRP Powertrain Maintenance Manual 72 00 00 page106 October 01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04776 08207 07488...

Page 179: ...ylinder bore A 84mm 3 3 in D1 CY01 84 000 3 3071 84 012 3 3075 84 080 3 3102 84 046 3 3089 actual renewed D2 CY02 CY01 0 015 CY01 0 0006 CY01 0 015 0 008 CY01 0 0006 0 0003 actual renewed D3 CY03 CY01...

Page 180: ...3 0 0010 0 0021 0 102 0 0040 7 006 7 018 0 2758 0 2763 0 2815 0 2789 7 150 7 084 1 90 0 0748 1 40 0 0551 2 40 0 0945 2 15 0 0846 Int V Exh V Valve seat width Int V Exh V VT01 VT01 Valve stem diameter...

Page 181: ...wed Spring length at test load SINGLE Int V VT04 32 4 1 276 33 6 1 323 32 0 1 260 32 2 1 268 actual renewed Exh V VT04 32 4 1 276 33 6 1 323 32 0 1 260 32 2 1 268 actual renewed Rocker arm shaft sup p...

Page 182: ...28 0 6310 actual renewed Rocker arm bore with bronze bushing Int V VT07 12 000 0 4724 12 027 0 4735 12 150 0 4783 12 089 0 4759 actual renewed Exh V VT07 12 000 0 4724 12 027 0 4735 12 150 0 4783 12 0...

Page 183: ...Exh V actual actual renewed actual Cyl 1 Cyl 2 Cyl 3 Cyl 4 renewed actual renewed renewed actual renewed Idle gear bore Idle gear bore Radial clearance VT09 Int V VT09 0 000 0 0000 0 100 0 0039 0 150...

Page 184: ...07 Effectivity 912 914 Series Edition 1 Rev 0 d02622 GB01 0 10 20 30 40 50 60 70 80 90 0 01mm 1 2 3 4 5 6 7 8 9 0 XXX GB04 GB02 GB03 1 1 3 2 GB03 GB05 GB06 Ausf hrung 3 1 7 GB08 GB07 GB11 3 m m GB13 C...

Page 185: ...BRP Rotax Maintenance Manual Effectivity 912 914 Series Edition 1 Rev 0 72 00 00 page113 May 01 2007 d02622 IH01 07456 ES10 07506 0 10 20 30 40 50 60 70 80 90 0 01mm 1 2 3 4 5 6 7 8 9 0 GB18 07508...

Page 186: ...ed Out of true on prop shaft flange dia 122 mm GB04 0 00 0 0000 0 05 0 0020 0 06 0 0024 0 06 0 0022 actual renewed Bore at back end of prop shaft on ver sion 3 only GB05 11 00 0 4331 11 02 0 4339 actu...

Page 187: ...0 0 0 5 0 2 5 actual renewed Dog gear pitting up to 5 of flank area 0 0 0 0 5 0 2 5 actual renewed Backlash of teeth GB18 0 07 0 0028 0 15 0 0059 0 20 0 0079 0 18 0 0069 actual renewed 6 Overload clu...

Page 188: ...BRP Rotax Maintenance Manual 72 00 00 page116 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 NOTES...

Page 189: ...hub Propeller shaft dog gear dog hub drive gear Description Code Readings view min Actual readings Remarks Checked Camshaft CA05 630 HV10 CA04 900 N mm2 Cyl 1 Cyl 2 Cyl 3 Cyl 4 Cylinder head CH08 85...

Page 190: ...BRP Rotax Maintenance Manual 72 00 00 page118 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02622 NOTES...

Page 191: ...x air temperature display only on 914 Series 73 00 00 15 2 10 2 Boost pressure display 73 00 00 15 2 11 Carb heat system and winter operation 73 00 00 16 3 Maintenance 73 00 00 16 3 1 Disassembling fu...

Page 192: ...ion tube 73 00 00 40 3 4 3 1 Carburetor sockets 73 00 00 40 3 4 3 2 Compensation tube 73 00 00 40 3 4 4 Fuel pressure regulator only on 914 Series 73 00 00 42 3 4 5 Fuel pump on 912 Series 73 00 00 43...

Page 193: ...d fuel piping and connections The fuel passes from the tank 1 with the coarse filter 2 via the fire cock 3 the water drain cock 4 and the fine filter 5 to the mechanical fuel pump 6 The latter then pu...

Page 194: ...23 BRP Rotax Maintenance Manual Legend 1 inlet from the tank 2 coarse filter 3 fire cock 4 water drain cock 5 fine filter 6 mechanical fuel pump 7 carburetors 8 return line to tank zum Manometer to fu...

Page 195: ...essure regulator 5 and further on to the individual carburetors A separate check valve 4 is installed parallel to each fuel pump NOTE The arrangement of the two fuel pumps connected in series yields b...

Page 196: ...777 BRP Powertrain Maintenance Manual Legend 1 fine filter water trap 2 main fuel pump MAIN 3 auxiliary fuel pump AUX 4 check valve 5 fuel pressure regulator 6 inlet from the tank 7 return line to tan...

Page 197: ...with a mechanical fuel pump It is driven via an eccenter in the propeller gearbox 2 5 Fuel pump on 914 Series To warrant safe and adequate operation of the fuel system two independent selfpriming van...

Page 198: ...ator into the top fuel chamber 3 and the air chamber 4 The force of the pressure spring which is set by the adjusting screw 5 establishes an equilibrium of forces on the diaphragm at a fuel pressure 0...

Page 199: ...ing values will arise at take off performance Fuel pressure 1370 250 1620 hPa Therefore the required delivery pressure of the fuel pump will be 1620 900 720 hPa Rising airbox pressure will press the d...

Page 200: ...ure is approx 0 25 bar 3 6 p s i above the pressure at air intake airbox For this reason the fuel pressure regulator only on 914 Series is connected to the airbox via a pressure connecting line 1 Enri...

Page 201: ...shorter takeoff phase and to provide added protection against knocking combustion detonation WARNING The pressure connecting lines must function properly to ensure correct engine running Otherwise eng...

Page 202: ...uretor and must correspond with the air pressure at entry into the carburetor Too high pressure en riches the mixture too low pressure leans down the mixture possibly leading to engine stop The float...

Page 203: ...nd in the diffuser tube 8 is pre mixed with air which is brought in from the air filter via the air duct 9 and the atomizer in an annular flow around the needle jet This air flow assists the atomizing...

Page 204: ...he intake air is then effected via the idling system which consists of the idle jet 5 and the idling air jet 6 As an aid for starting a cold engine the BING constant depression carburetor is provided...

Page 205: ...uel in well ventilated places Never fill fuel in enclosed spaces Gasoline is highly inflammable and explosive Do not smoke do not allow open flames or sparks in the vicinity Do not fill the tank to th...

Page 206: ...r for air intake from the engine compart ment is recommended as for instance the filter could be blocked by icing Preheating of the intake air will result in loss of engine perform ance because of the...

Page 207: ...ls produced from the year 2007 onwards have a flexible fuel line 5 See Fig 73 9 3 NOTE Usually it is not necessary to remove the clamp block 6 However if it should become necessary to remove it ensure...

Page 208: ...73 00 00 page18 October01 2010 Effectivity 912 Series Edition 1 Rev 3 d04777 BRP Powertrain Maintenance Manual 11 28 28 28 11 7 29 Fig 73 9 1 32 31 30 29 34 33 7 08667...

Page 209: ...d sealing rings 18 After unscrewing the banjo bolt 19 take off the fuel lines All fuel lines lead to the fuel manifold Unscrew the banjo bolts 20 Remove the fuel line 21 hose line Nowthefuellines 5or7...

Page 210: ...olt has been overstretched and must be replaced See Fig 73 9 2 CAUTION In the event of leaks the max permissible torque must never be exceeded If the engine is equipped with a ROTAX Original Airbox th...

Page 211: ...be pulled off the carburetors towards the back NOTE If required remove 2 pin plug connection of temperature sensor 11 and or loosen air intake hose 12 Remove 3 pin plug connection of the throttle pot...

Page 212: ...ly 01 2008 Effectivity 914 Series Edition 1 Rev 2 d04352 BRP Rotax Maintenance Manual XXX X X X XXX A A Loctite 221 07712 07713 8 9 19 13 14 13 14 16 17 10 11 12 4 5 7 2 3 8 7 4 17 6 5 3 15 20 19 18 F...

Page 213: ...Level Only aeronautical personnel or authorized testers act ing on our instructions may carry out modifications to BRP Rotax specifications CAUTION To avoid contamination in the fuel system proceed wi...

Page 214: ...to the float valve with the viton tip and the carburetor housing Turn the carburetor upside down as the float needle valve is only closed in this position Connect pump 1 to the fuel supply line 2 and...

Page 215: ...ax Maintenance Manual 3 3 3 Individual components of the carburetor on the 912 Series See Illustrated Parts Catalog Rotax 912 914 A A A A Nadelposition needle position 1 4 3 2 07088 18 25 26 27 28 29...

Page 216: ...nce Manual 3 3 4 Individual components of the carburetor on the 914 Series See Illustrated Parts Catalog Rotax 912 914 A A Zyl cyl 1 3 Zyl cyl 2 4 Nadelposition needle position 1 4 3 2 07087 18 25 26...

Page 217: ...cess in the slider piston and nose 10 must engage in the recess in the carburetor housing Check diaphragm for cracks or brittleness replace if necessary 3 3 6 Needle See Fig 73 16 The needle 12 contro...

Page 218: ...SI 914 013 and SI 914 015 latest version 4 On configuration with air filter See SB 912 044 latest version Carburetor calibration 912 A F UL Target Carburetor 1 3 Carburetor 2 4 Needle 2 72 2 72 Idle j...

Page 219: ...ve and clean the float housing 11 with the seal 12 Check both floats 9 for free movement on the guide pin 3 When the float is at its lowest position it still must have radial clearance and must not st...

Page 220: ...14 When the needle valve is closed the two arms 15 of the float bracket must be evenly spaced Spacing On the 912 Series 0 4 to 0 5 mm 016 to 02 in measure withouth washer 20 On the 914 Series 5 4 to...

Page 221: ...and the idle mixture screw 19 Clean carburetor and jets with gasoline Carefully blow through all jets channels in the carburetor housing with compressed air and check for free passage Check oval form...

Page 222: ...or visible wear to the beaded edge 2 of the sprung pin 3 the valve must be replaced If the distance becomes less than 0 5 mm 02 in the float level will be affected leading even to interruption of the...

Page 223: ...shows the positions of the markings on the choke shaft Remove hex nut and pull the complete rotary disc valve from the housing Clean all parts and check NOTE The choke shaft 1 is marked with a dot 2...

Page 224: ...73 00 00 page 34 July 01 2008 Effectivity 912 914 Series Edition 1 Rev 2 d04352 BRP Rotax Maintenance Manual 00362 the drawings show the carburetor for cyl 2 4 00363 Fig 73 27 1 2 3 4 1 Fig 73 26...

Page 225: ...enance Manual Line Maintenance for the engine type 912 Series or 914 Series 3 3 14 Idle speed adjustment See the corresponding section in the respective Maintenance Manual Line Maintenance for the eng...

Page 226: ...uel pumps float housing and fuel lines CAUTION Unsuitable routing of fuel lines may cause engine failure After repair work the fuel system must be checked for leaks Always use clean and non translucen...

Page 227: ...se will get drawn into the propeller airstream If necessary secure with tie wraps If the nominal fuel pressure values are not met during the test run stop the engine and start with the trouble shootin...

Page 228: ...73 00 00 page 38 July 01 2008 Effectivity 912 Series Edition 1 Rev 2 d04352 BRP Rotax Maintenance Manual 00365 1 2 3 Fig 73 28...

Page 229: ...e fuel pressure must be approx 250 hPa above the constantly varying boost pressure in the air box Otherwise the perfect functioning of the carburetors is not assured See 73 00 00 sec 2 Fit the pressur...

Page 230: ...e 3 Tightening torque 2 5 Nm 22 in lb Compress carburetor socket in the area of the carburetor connection to allow easier detection of existing cracks 4 and 5 Also pay particular attention to the area...

Page 231: ...912 914 Series Edition 1 Rev 2 page 41 July 01 2008 d04352 73 00 00 BRP Rotax Maintenance Manual 05792 05794 Fig 73 32 Fig 73 31 00366 05793 4 6 5 5 5 4 5 5 2 3 Fig 73 30 Fig 73 29 Fig 73 29 1 7 1 8...

Page 232: ...ignition circuits to OFF position Switch on the electric fuel pump set to the correct fuel pressure approx 250 hPa above the airbox pressure using the adjuster screw 4 and tighten with the cap nut 5...

Page 233: ...plunger 2 shows scuff marks the pump must be replaced and the eccenter in the propeller gearbox inspected Check the connections 3 of the fuel lines Pumps working at reduced power for example as a resu...

Page 234: ...0 00 page 44 July 01 2008 Effectivity 912 Series Edition 1 Rev 2 d04352 BRP Rotax Maintenance Manual 00367 5 2 6 3 4 1 3 Fig 73 34 00368 or 04962 Fig 73 35 from tank to carburetor from tank to carbure...

Page 235: ...UTION Always follow the safety regulations when handling fuel Use fuel to clean pre filter CAUTION Make sure that no material gets into the fuel pump Carefully accommodate the clean filter in the inta...

Page 236: ...73 00 00 page46 October01 2010 Effectivity 914 Series Edition 1 Rev 3 d04777 BRP Rotax Maintenance Manual 38 13 3 12 9 20 0 5 30 141 5 3 22 8 11 75 8 11 M5 M4 P1 P2 00045 Fig 73 36 2...

Page 237: ...ng 3 to the fuel pressure regulator 4 T fitting 3 to the condensation trap 5 on older engine configura tions condensation trap 5 to the airbox pressure sensor on older engine configurations hose nippl...

Page 238: ...lengthisusedforallpressure connectinglinesandthattheclampsarefixedsecurely In addition all lines must be routed in such a way that scuffing and kinks are avoided See 73 00 00 sec 3 4 5 and 73 00 00 se...

Page 239: ...00 00 BRP Rotax Maintenance Manual 200mm 7 88in 310mm 12 6in 110mm 4 34in 40mm 1 57in 75mm 82 95in 130mm 5 12in 00048 Fig 73 37 00049 Length of tubes depending on installationconditions Fig 73 38 2 3...

Page 240: ...73 00 00 page 50 July 01 2008 Effectivity 912 914 Series Edition 1 Rev 2 d04352 BRP Rotax Maintenance Manual NOTES...

Page 241: ...rs and carburetor sockets See Figs 73 39 1 73 40 and 76 41 Attach carburetor socket 4 and new O ring 5 with hex screws 6 M8x25 and M8x30 7 with washers NOTE On intake manifolds without an O ring groov...

Page 242: ...01 2008 Effectivity 912 914 Series Edition 1 Rev 2 d04352 BRP Rotax Maintenance Manual 02727 05794 4 10 11 4 6 7 12 4 8 5 08390 6 Fig 73 39 1 Fig 73 41 Fig 73 40 Fig 73 39 2 3 1 08389 B LOCTITE 243 A...

Page 243: ...m fuel pump to carburetor 5 9 Fig 73 42 08476 1 NOTE Foreasierassemblyofthefuelline observetheoriginal position of the clamp block The lines from the fuel pump 3 and the lines to the carburetors are a...

Page 244: ...ealing ring 10 Tighten ing torque 15 Nm 133 in lb screw secured with LOCTITE 221 See Fig 73 44 NOTE When converting to a double hose nipple for measure ment of the fuel pressure the jet must be remove...

Page 245: ...remaining sealant residues in a way that they do not get into the carburetor or the fuel system For installation on an old style intake manifold perform the following Remove the intake manifold and m...

Page 246: ...ance Manual Fig 73 45 08180 1 Fig 73 46 08180 1 3 2 2 3 4 4 5 5 6 6 A LOCTITE 221 A A CAUTION While tightening hex nut 5 hold hex screw 2 with a wrench to prevent it from loosening Always fix the flex...

Page 247: ...UTION Use the complete slip on length on the connection pieces Ensure that the airbox 6 is fitted horizontally and torsion free There must be no additional load on the carburetor fixations Now the scr...

Page 248: ...73 00 00 page 58 July 01 2008 Effectivity 914 Series Edition 1 Rev 2 d04352 BRP Rotax Maintenance Manual XXX X X X XXX A A Loctite 221 07713 Fig 73 47 7 8 9 12 4 6 2 3 10 1 13 11 7 7 12 14 2 12 5 1...

Page 249: ...ON To ensure efficient carburetor suspension a distance of 40 mm 1 57 in between the allen screw 2 and the engagement latch 3 must be respected If a counter sunk screw is fitted instead of the allen s...

Page 250: ...from the tank to the fuel pump from the fuel pump to the two carburetors and the return line to the fuel tank must be installed as per the aircraft manufacturer s instructions when installing the eng...

Page 251: ...Checking the ignition unit trouble shooting 74 00 00 11 3 3 Spark plugs 74 00 00 12 3 4 Spark plug connectors and ignition cables 74 00 00 12 3 5 Electronic module trigger coil kit 74 00 00 14 3 6 Ch...

Page 252: ...g diagram 74 00 00 53 3 21 3 Interference suppression box assembly 74 00 00 54 3 21 4 Interference suppression box fitting 74 00 00 54 3 22 Rev counter and ignition trigger coils 74 00 00 55 3 23 Exte...

Page 253: ...wer supply Each of the two independent charging coils 1 located on the generator stator supplies one of the two ignition circuits The energy is stored in capacitors of the electronic modules 2 At the...

Page 254: ...the electronic boxes and the 4 double ignition coils Internal generator See Fig 74 2 Consisting of stator with 8 generator coils 1 and the 2 independent ignition charging coils 2 and the tenpole magne...

Page 255: ...tivity 912 914 Series Edition 1 Rev 0 74 00 00 page 5 May 01 2007 d02624 BRP Rotax Maintenance Manual 4T 2T 4B 2B 1T 3T 1B 3B XXX I A A A S B A A 07723 A O I A XXX I 07722 Fig 74 2 Fig 74 3 6 1 2 3 4...

Page 256: ...ed with an automatic ignition timing controlled by the edge of trigger cams on the fly wheel hub and the electronic modules NOTE For easy engine start the ignition timing at start is 4 B T D C for ign...

Page 257: ...on points only on 914 Series for the top spark plugs and the bottom spark plugs takes into account the differing ignition delays preventing pre ignition and detonation The difference in the ignition p...

Page 258: ...r trigger coils A1 2 and A3 4 raised approx 5 mm 0 20 in control the top electronic module i e Ignition circuit A top trigger coil top electronic module Ignition circuit B bottom trigger coil bottom e...

Page 259: ...between the cylinder heads NOTE The bottom ignition cables can only be routed into position without spark plug connector The ignition cables are screwed into the dual ignition coil and the spark plug...

Page 260: ...74 00 00 page 10 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02624 BRP Rotax Maintenance Manual NOTES...

Page 261: ...trigger coils is harmless Replace attachment screws and lock washers if there is heavy oxidation or rust formation Before reassembly clean all contact surfaces of the screws removed and apply LITHIUM...

Page 262: ...rk plugs as shown in the maintenance overview Assure security of the spark plug connector Resistance spark plug connectors which are seated too loosely must be replaced Check minimum pull off force of...

Page 263: ...ng diagram See 74 00 00 sec 3 13 Check all plug and screwed connections for oxidation and tight fit Checkshortingcablesandignitionswitch Ifignitionswitchfailureissuspected the shorting cable can be pu...

Page 264: ...t full throttle NOTE The ignition unit of the 912 Series and 914 Series have been standardized See SI 912 013 and SI 914 016 Standardiza tion of the ignition unit latest issue The modules 2 are interc...

Page 265: ...re remains on the same ignition circuit the electronic module is the cause and the respective module must be replaced see 74 00 00 sec 3 5 If the failure passes on with the ignition circuit the chargi...

Page 266: ...unit Checking the integrated alternator in operation The check of the internal alternator is carried out at idle speed and under load on a 150 W 0 201 hp consumer Establish check circuit as shown on w...

Page 267: ...ive dual ignition coil see 74 00 00 sec 3 12 The iron core 1 must not be loose If required replace the dual ignition coil In this case the following dismantling work must be performed see 74 00 00 sec...

Page 268: ...tive pliers see 00 00 00 sec 10 5 For this procedure connect stroboscope 1 to battery 2 and clamp inductive pliers 3 to the ignition cable of cylinder 1 top or cylinder 2 top These two spark plugs are...

Page 269: ...he 912 Series Trigger coil A1 2 serves the top spark plug of cylinder 1 and 2 Trigger coil A3 4 serves the bottom spark plug of cylinder 3 and 4 Trigger coil B1 2 serves the bottom spark plug of cylin...

Page 270: ...01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02624 BRP Rotax Maintenance Manual A1 2 A3 4 B3 4 B1 2 1 3 2 4 A1 2 A3 4 B3 4 B1 2 4 5 07486 07487 Start ignition timing Operating ignition timing...

Page 271: ...peed of approx 4000 rpm approx 1700 propeller speed Switch off ignition circuit A with ignition switch This causes only 1 spark plug per cylinder to fire The speed drop with only one spark plug per cy...

Page 272: ...gger coil green white blue yellow 115 0 to 123 0 Trigger coil new with clamps white yellow blue yellow 220 0 to 250 0 Primary ignition coil connection contact ground 0 1 to 0 4 Secondary ignition coil...

Page 273: ...Effectivity 912 914 Series Edition 1 Rev 0 74 00 00 page 23 May 01 2007 d02624 BRP Rotax Maintenance Manual NOTES...

Page 274: ...18 1 ignition magneto generator 2 trigger coil for ignition circuit A 3 trigger coil for ignition circuit B 4 trigger coil for rev counter 5 plug receptacle 2 pin 6 electronic rev counter 7 grounding...

Page 275: ...sw 0 75 ws 0 75 ge 0 75 br 0 75 or 0 75 ro 1 5 ge 0 75 ro 0 5 ws ge 0 5 bl ge 0 75 br 0 75 sw 0 75 sw 0 5 bl ge 0 5 ws ge 0 5 bl ge 0 5 ws ge 0 75 br 1 5 B 1 2 A 3 4 B 3 4 A 1 2 1 5 ge 1 sw 1 sw 1 sw...

Page 276: ...er coil for ignition circuit B 4 trigger coil for rev counter 5 plug receptacle 2 pin 6 electronic rev counter 7 grounding switch for ignition circuit A and B 8 plug receptacle 1 pin 9 plug receptacle...

Page 277: ...r 1 sw 1 sw 1 sw 1 sw ws ge bl ge ws ge bl ge O ro O bl o ro O bl 0 5 bl ge 0 5 ws ge 0 5 bl ge 0 5 ws ge 0 75 ro 0 75 br 7 8 2 3 7 6 5 0 5 ws ge 0 5 bl ge 1 5 1 5 O gn o bl o ro 1 5 ge 0 75 sw 0 75 s...

Page 278: ...er coil for ignition circuit B 4 trigger coil for rev counter 5 plug receptacle 2 pin 6 electronic rev counter 7 grounding switch for ignition circuit A and B 8 plug receptacle 1 pin 9 plug receptacle...

Page 279: ...l 0 75 bl 16 12 1 3 4 2 3T 3B 1T 1B 4B 13 4T 2T 2B 14 0 75 ws 0 75 ws 1T 2T 1 sw 10 0 75 ge 0 75 bl 0 75 ge 0 75 br 0 75 or 0 75 sw 3 4 T 1 2 B 3 4 T 1 2 B 3 4 B 1 2 T 3 4 B 1 2 T A 1 2 A 3 4 B 3 4 ws...

Page 280: ...il for ignition circuit A 3 trigger coil for ignition circuit B 4 trigger coil for rev counter 5 plug receptacle 2 pin 6 electronic rev counter 7 grounding switch for ignition circuit A and B 8 plug r...

Page 281: ...5 bl ge 15 0 75 br 0 75 sw 0 75 sw 0 5 bl ge 0 5 ws ge 0 5 bl ge 0 5 ws ge 0 75 br B 1 2 A 3 4 B 3 4 A 1 2 1 5 ge 1 sw 1 sw 1 sw 1 sw 0 75 sw 0 75 ws 0 75 ws 0 75 gn 0 75 bl 0 75 ge 0 75 ws 0 75 sw 0...

Page 282: ...er coil for ignition circuit B 4 trigger coil for rev counter 5 plug receptacle 2 pin 6 electronic rev counter 7 grounding switch for ignition circuit A and B 8 plug receptacle 1 pin 9 plug receptacle...

Page 283: ...75 bl 0 75 or 0 75 bl 0 75 bl 16 12 1 3 4 2 3T 3B 1T 1B 4B 13 4T 2T 2B 14 0 75 ws 0 75 ws 1T 2T 1 sw 10 0 75 ge 0 75 bl 0 75 ge 0 75 br 0 75 or 0 75 sw 3 4 T 1 2 T 3 4 T 1 2 T 3 4 B 1 2 B 3 4 B 1 2 B...

Page 284: ...4 May 01 2007 Effectivity 914 Series Edition 1 Rev 0 d02624 BRP Rotax Maintenance Manual 3 13 3 Engine external on the 914 Series See latest Installation Manual for engines of the 914 Series and 76 00...

Page 285: ...lso remove the resistance spark plug connectors of the 2 upper spark plugs of cylinders 2 and 4 to allow easy removal of the ignition cables Cut all tie wraps 2 for ignition cable attachment and the p...

Page 286: ...74 00 00 page 36 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02624 BRP Rotax Maintenance Manual 6 8 9 10 3 4 5 00334 7 1 2 2 1 7 4 8 7 6 Fig 74 23...

Page 287: ...ensor cable assembly 26 Pay attention to the correct connection between electronic modules and ignition coils 3 15 1 Dual ignition coils replacement On older engine versions electronic module with 1 4...

Page 288: ...16 and ignition coil holder 17 as well as the rubber buffer 18 together with the bracket 19 Remove both allen screws M6x30 20 at the distance nut M6 21 and remove the connector holder 42 After detachi...

Page 289: ...tion 1 Rev 0 74 00 00 page 39 May 01 2007 d02624 BRP Rotax Maintenance Manual For older engine models Fig 74 24 00406 6 7 2 4 28 5 14 38 2 25 39 4 25 40 13 37 12 20 16 19 18 36 22 23 17 21 16 24 20 15...

Page 290: ...P Rotax Maintenance Manual 4 For new engine models A LOCTITE221 I LITHIUMSEIFENFETT LITHIUM BASE GREASE S SILIKON W RMELEITPASTE SILICONE HEAT COMPOUND 07727 14 15 17 18 19 20 8 9 11 12 1 2 3 5 7 27 2...

Page 291: ...le 27 into the ignition coil holder 28 and fit the dual ignition coils on rubber buffer 15 with the allen screw 14 M6x16 and lock washer NOTE When replacing the rubber buffer 15 secure it on the intak...

Page 292: ...bber buffer 15 secure it on the intake manifold with LOCTITE 221 The connectors of the white blue primary cables from the dual ignition coils must be connected up as shown in the wiring diagram CAUTIO...

Page 293: ...r Attach both 4 pin plug connections electronic module to trigger coil kit and secure with tie wrap NOTE The pick up cable of ignition circuit A top module is marked at the end of the isolating hose w...

Page 294: ...receptacles for the electronic modules NOTE The pick up cable of ignition circuit A top module is marked at the end of the isolating hose with the colors blue and red Those of ignition circuit B bott...

Page 295: ...Effectivity 912 914 Series Edition 1 Rev 0 74 00 00 page 45 May 01 2007 d02624 BRP Rotax Maintenance Manual 00408 35 33 34 34 33 41 Fig 74 26 Fig 74 27 05820 35 33 34 34 33 41...

Page 296: ...on IH03 NOTE The trigger coil kit for older engine versions is no longer available However there is a new trigger coil kit with new trigger coils which will fit older engines For easier adjustment on...

Page 297: ...47 July 01 2008 d04353 BRP Rotax Maintenance Manual 07728 00089 IH03 IH02 Fig 74 28 On older engine models discontinued 4 3 2 1 08450 07139 23 22 21 Trigger coil alignment Fig 74 29 Fig 74 30 Fig 74...

Page 298: ...ide so that no foreign objects can be attracted by the magnet NOTE For removal of stator the ignition housing need not be removed Remove four allen screws 13 and the cable clamp Remove stator ass y 9...

Page 299: ...t can be assembled in any position Check woodruff key in crankshaft for tight fit Degrease tapers of crankshaft and fly wheel hub and apply LOCTITE 221 sparingly Fit fly wheel on assy Apply grease on...

Page 300: ...74 00 00 page 50 July 01 2008 Effectivity 912 914 Series Edition 1 Rev 2 d04353 BRP Rotax Maintenance Manual 07729 Older engine models 6 5 13 14 15 16 17 18 19 20 7 8 9 10 11 12 5 7 7 Fig 74 32 21 20...

Page 301: ...Effectivity 912 914 Series Edition 1 Rev 0 74 00 00 page 51 May 01 2007 d02624 BRP Rotax Maintenance Manual New engine models O I 07730 07731 6 5 7 7 5 9 21 7 Fig 74 33 Fig 74 34...

Page 302: ...event of inquiries Before removal all eight ignition cables must be marked as shown on the cover to ensure correct reassembly Remove the 3 countersunk screws M4x12 and take off the top terminal strip...

Page 303: ...Z ndab schaltung Kondensator oben Z ndkreis A Kondensator unten Z ndkreis B B1 2 A3 4 6 9 10 1 4 5 B A zum Kondensator wei wei rot wei wei rot wei wei rot wei wei rot rot rot wei wei Generatorleitunge...

Page 304: ...suppres sion box cover and attach with 3 countersunk screws M4x8 Assemble complete retaining strip in the interference suppression box with two allen screws M4x12 Secure all screws in the box with LOC...

Page 305: ...ls are of equal design Therefore this checking procedure is valid for the ignition trigger coils too The rev counter trigger coil 3 is fitted on the ignition housing Inspect for physical damage Inspec...

Page 306: ...360 0 V V 1 1 2 3 2 3 4 0 V V 5 5 10 15 10 15 0 V V 5 5 10 10 1 Umdr rev 360 1 Umdr rev 360 1 Umdr rev 360 0 V V 50 50 100 100 150 00219 Speed 500 rpm load 100 Speed 500 rpm load 100 k speed 6000 rpm...

Page 307: ...the lock washers 11 and take off the alternator bracket 9 The alternator support 12 is attached to the gearbox housing with 2 allen screws M6x50 13 lock washers 6 4 14 After removal of the attachment...

Page 308: ...74 00 00 page 58 July 01 2008 Effectivity 912 914 Series Edition 1 Rev 2 d04353 BRP Rotax Maintenance Manual Fig 74 38 07491 1 2 3 4 8 7 18 12 13 14 21 22 20 23 10 11 17 26 25 24 9 15 6 5 19 16...

Page 309: ...er respectively 3 23 4 2 Mechanical check CAUTION Disconnect the cable from the negative battery terminal Remove hex nut 1 from terminal B 2 also remove the three hex screws 3 Remove the rear bearing...

Page 310: ...nator bracket distance with the washer 17 10 1 20 0 5 and loosely attach the alternator with the hex screw 18 M10x45 Now the two allen screws 10 M8 can be tightened to 22 Nm 195 in lb and the two alle...

Page 311: ...Effectivity 912 914 Series Edition 1 Rev 0 74 00 00 page 61 May 01 2007 d02624 BRP Rotax Maintenance Manual IH03 IH02 07510 00086 SP01 AL01 07515 4 Wear limits...

Page 312: ...e gap 912 0 6 0 022 0 9 0 035 0 7 0 028 actual renewed SP01 electrode gap 914 0 7 0 027 0 9 0 035 0 8 0 031 actual renewed actual renewed Ignition housing actual renewed IH02 trigger coil gap old type...

Page 313: ...ound 3 2 4 5 Lichtspulen 8 Stk Lighting coils 8 pieces in Serie gelb gelb in series yel yel 0 1 0 8 gegen Masse against ground Pr flauf mit Fremdregler und 12V 36 Ah Batterie geladen test run with ext...

Page 314: ...74 00 00 page 64 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02624 BRP Rotax Maintenance Manual NOTES...

Page 315: ...ly wheel hub removal 75 00 00 9 3 4 Ignition housing removal 75 00 00 9 3 5 Water pump shaft removal 75 00 00 9 3 6 Rotary seal removal 75 00 00 10 3 7 Rotary seal installation 75 00 00 10 3 8 Axial p...

Page 316: ...75 00 00 page 2 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02625 BRP Rotax Maintenance Manual NOTES...

Page 317: ...k is closed by a pressure cap 3 with pressure relief valve and return valve As the temperature of the coolant rises the pressure relief valve opens and the coolant will flow via a hose at atmospheric...

Page 318: ...tions for instru mentation in the latest Installation Manual 2 2 1 Cylinder head temperature display There are temperature sensors screwed in to the cylinder heads of cylinders 2 and 3 They monitor th...

Page 319: ...on is subdivided into subsections and descriptions of the function of the various systems NOTE When installing the radiator above engine level see the latest respec tive Installation Manual CAUTION Ch...

Page 320: ...r repair work fly wheel hub 1 and the ignition housing 2 must be removed On some engine installations this requires removal or partial lifting of engine after loosening the engine suspension To remove...

Page 321: ...edwiththesealingring 7 Check inside for traces of possible contact with impeller 8 The necessary clearance can be achieved by axial spacing of the water pump shaft The washer 9 fitted behind the impel...

Page 322: ...75 00 00 page 8 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02625 BRP Rotax Maintenance Manual 00377 Fig 75 3 243 6 7 8 9 1 2 3 4 5 3 11 243 Cyl 1 Cyl 2 Cyl 3 Cyl 4 10...

Page 323: ...e lock water pump drive gear 1 with a suitable tool Unscrew impeller using socket part no 877295 to avoid damage to the impeller blades Place ignition cover on a suitable flat surface and press water...

Page 324: ...collar pointing towards the crankcase sealing surface see Fig 75 10 Turn punch 4 around and push the water pump shaft 5 with the press fitted rotary seal 3 into the ignition housing As you do so posit...

Page 325: ...Effectivity 912 914 Series Edition 1 Rev 2 75 00 00 page 11 July 01 2008 d04354 BRP Rotax Maintenance Manual Fig 75 7 Fig 75 6 00386 00387 Fig 75 8 1 2 2 1 Fig 75 9 08451 08448 3 4 5 4 3...

Page 326: ...aft is flush with the sealing surface 11 of the ignition cover 12 If necessary turn the ignition cover around and lay it on a planed hardened sheet with an 8 mm 0 32 in bore Press the water pump shaft...

Page 327: ...t is of stainless steel and fitted with a sealing ring 6 Carry out a visual inspection to see whether the impeller scuffs in the pump housing This can be recognized by scuffing traces in the pump hous...

Page 328: ...ing coolant hoses Use tool part no 877840 spring clamp pliers or equivalent to mount the spring type hose clips On old engine designs the spring type of hose clips are not installed CAUTION It is nece...

Page 329: ...ooling air duct to the individual cylinders Carry out visual inspection for damage cracks chafing marks burnt spots etc In the event of noticeable damage replace the cooling air duct 3 15 Expansiontan...

Page 330: ...75 00 00 page16 October01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04779 BRP Powertrain Maintenance Manual 1 3 4 1 3 2 1 1 3 3 4 4 7 7 7 7 6 5 5 4 Fig 75 13 04555 8 LOCTITE 480...

Page 331: ...e of the proper length of the hose and of its overlapping length with the connectors 3 16 Overflow bottle See latest Maintenance Manual Line Maintenance for the respective engine type CAUTION Check wh...

Page 332: ...60 40 20 140 160 1200 1000 C 800 600 400 200 0 00327 Fig 75 15 NOTE Grounding connection of the temp sensor directly via the cylinder head For sensor resistance see following graph of sensor resistanc...

Page 333: ...ntenance Manual WP01 WP02 Description Code Reading new wear limit wear limit Readings min max 100 50 Water pump reference dim WP01 8 55 0 3366 8 85 0 3484 8 85 0 3484 actual renewed impeller clearance...

Page 334: ...75 00 00 page 20 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02625 BRP Rotax Maintenance Manual NOTES...

Page 335: ...by limiting the compressor pressure ratio 76 00 00 10 2 1 3 Lamp output connections on the TCU 76 00 00 11 2 1 4 Three way solenoid valve 76 00 00 12 2 1 5 PC interface 76 00 00 12 3 Maintenance 76 00...

Page 336: ...00 00 34 3 1 2 3 Wiring harness 76 00 00 35 3 1 2 4 Throttle potentiometer 76 00 00 37 3 1 2 5 Resistance thermometer Intake air temperature sensor 76 00 00 42 3 1 2 6 Pressure sensors 76 00 00 44 3 1...

Page 337: ...n into target pressure in the airbox NOTE The positions of the throttle valve are divided into a linear progression from 0 to 115 After comparison of the actual airbox pressure with the target pressur...

Page 338: ...E The target boost pressure is determined from the inputs of the sensors 5 7 Position of the wastegate supplied indirectly from position of servo motor Rev counter signal 8 transmits the actual engine...

Page 339: ...en the throttle valve position and the nominal airbox pressure for older TCU versions TCU part no 966470 966473 engine performance throttle potentiometer Airbox nominal pressure idle 0 1500 hPa 44 3 i...

Page 340: ...pidly between these throttle positions 108 to 110 and attempts should not be made to remain in this phase but instead to move speedily through this range in both directions to prevent control fluctuat...

Page 341: ...1 12 4 5 6 7 1 2 3 Fig 76 5 1 Turbocharger 2 wastegate 3 Servo motor 4 TCU 5 Ambient pressure sensor 6 Airbox pressure sensor 7 Throttle potentiometer 8 to the rev pickup 9 Resistance thermometer Airb...

Page 342: ...l the TCU lower the target pressure when engine speed exceeds 5900 rpm and open the wastegate thus reducing boost pressure See relevant dia gram CAUTION The automatic opening of the wastegate by the T...

Page 343: ...ke air is heated To reduce the risk of detonation at high boost pressure with high intake air temperature lowering of the target pressure starts at 88 C 190 F airbox tempera ture see diagram Fig 76 7...

Page 344: ...y altitude of 5500 m ambient pressure approx 500 hPa max permitted airbox pressure regarding deactivation 500 x 2 6 1300 hPa i e no reduction of the target pressure since this boost pressure cannot be...

Page 345: ...the default values are effective monitoring of the respective channel e g overspeeding is not possible The monitoring function is inactive Red boost lamp Exceeding the admissible boost pressure will...

Page 346: ...ded Thisprogramallowsquickandefficienterrordiagnosticswithouthaving to dismantle the complete control unit This program can monitor and record the operation of many elements including the 2 pressure s...

Page 347: ...means of a communication program 3 1 1 1 Functions of the communication program For trouble free engine operation the pilot must be able to locate the exact throttle position for the max continuous p...

Page 348: ...ecoding unit Dongle with data cable to connect with computer NOTE The Dongle is only required for the TCU part no 966470 to 966473 On the TCU part no 966741 the computer must be connected directly to...

Page 349: ...pin port of the wiring harness On the TCU part no 966741 connect the computer direct on the RS 232 the 9 pin port of the wiring harness Connect the data cable of the decoding unit Dongle respectively...

Page 350: ...Effectivity 914 Series Edition 1 Rev 0 d02626 BRP Rotax Maintenance Manual 00209 Kommunikationsprogramm communicationprogram PC Laptop zur TCU to TCU zur Dekodiereinheit to Dongle Dekodereinheit Dongl...

Page 351: ...ram Establish connections PC dongle for TCU part no 966470 or directly with the RS232 plug connection for TCU part no 966741 TCU switch on TCU WARNING Ensure engine ignition OFF and secured against un...

Page 352: ...6 12 shows the program version TLR V4 3A c Description of the sub programs On line display See Figs 76 13 76 14 76 15 76 16 76 17 and 76 18 NOTE If when starting the on line sub programs MONITOR 1_SCO...

Page 353: ...Effectivity 912 914 Series Edition 1 Rev 0 76 00 00 page 19 May 01 2007 d02626 BRP Rotax Maintenance Manual NOTES...

Page 354: ...ctivity 914 Series Edition 1 Rev 0 d02626 BRP Rotax Maintenance Manual Fig 76 14 03066 TCU part no 966741 15 17 18 19 9 10 11 6 3 5 2 00444 TCU part no 966470 up to 966473 13 13 14 16 20 23 22 21 8 12...

Page 355: ...sure ratio between 9 and 10 8 effective target pressure input possibly reduced e g by overspeeding airbox temperature or too high pressure ratio 9 Airbox pressure 10 Ambient pressure 11 Servo position...

Page 356: ...facilitates recording of current operational data on the hard disk of the connected PC Logging is activated and stopped by pressing the key L The logging status is indicated by ON for on line recordin...

Page 357: ...ntenance Manual Subsequent to recording the data can be stored on a diskette or printed for evaluation The created LOG files are text files which can be used for further data editing in text and table...

Page 358: ...1100 977 978 100 521 27 6 20 3 80 0 16 53 05 2368 3 3 122 1100 978 978 100 520 27 6 20 3 80 0 16 53 05 2396 3 3 122 1100 978 978 100 517 27 6 20 3 80 0 16 53 05 2384 3 3 122 1100 978 978 100 516 27 6...

Page 359: ...x Maintenance Manual 2_SCOPE For on line display of the control action be tween target pressure and effective airbox pressure in the range of 1000 to 1400 hPa mbar The program is for graphic evaluatio...

Page 360: ...meters are displayed The recording takes place at 6 minute intervals whereby the highest value of each period will be stored 00200 00199 READ_DATA Reads data such as serial number time of operation an...

Page 361: ...May 01 2007 d02626 BRP Rotax Maintenance Manual VIEW_DATA ShowsthefiledatadeducedfromREAD_DATA on the screen The keys page up and page down enable paging on the screen 00205 00201 PRINT_DATA Option t...

Page 362: ...r QUIT Turn off the TCU Disconnect store dongle properly Switch off PC 3 1 1 5 Checking the components of the turbocharger control The communication program allows quick detection of short comings of...

Page 363: ...letely open Visually check whether both throttle valves can be fully opened and closed If necessary correct the installation setting Check the display with throttle valve completely closed nominal 0 m...

Page 364: ...e if idle and full throttle position are within the permissible tolerances If the throttle position for idle and full throttle are not within the permissible tolerances or if not proceeding linearly t...

Page 365: ...fully opened and closed Verify that the Bowden cables allow the complete travel from stop to stop Follow the instructions on the display i e Close the throttle valve completely carb 2 4 and confirm w...

Page 366: ...be carried out NOTE Visual inspection of all components 3 1 2 1 Turbo control unit TCU See Fig 76 29 Location of installation may vary depending on aircraft model and is limited by the length of the w...

Page 367: ...aid is not at your disposal a trial run of the engine is required Engine operation is only allowed for transfer to the nearest maintenance facility where this check has to be conducted afterwards Test...

Page 368: ...e TCU the function of the two lamps is automatically tested Both lamps light up for 1 to 2 seconds and then go out If this does not happen check the following Inspection for physical damage Check conn...

Page 369: ...physical damage or incorrect operation replace part without delay Repair on your own authority is not permitted NOTE Fig 76 31 contains a lot of information Be sides the wiring designations plug allo...

Page 370: ...76 00 00 page 36 July 01 2008 Effectivity 914 Series Edition 1 Rev 2 d04355 BRP Rotax Maintenance Manual 08472 Fig 76 31...

Page 371: ...connection with wiring harness but reconnect immediately after completion of the check and verify tight fit and engagement of catch If the throttle potentiometer was removed from the carburetor for c...

Page 372: ...the adapter flange ensure that it is the appropriate model for the respec tive throttle potentiometer and that it is in stalled in the correct position with the cut off edge upwards See Fig 76 34 When...

Page 373: ...e NOTE Small installation tolerances can be compen sated by turning the throttle potentiometer For tolerances see 76 00 00 sec 3 1 1 6 otherwise recalibration is necessary Inspection for physical dama...

Page 374: ...nections 6 and 7 Throttle valve closed throttle lever pos 0 3 4 to 4 6 k Throttle valve open throttle lever pos 115 0 8 to 2 0 k NOTE Check complete operating range as shown in the following diagram F...

Page 375: ...pos 115 2 4 to 3 2 k Throttle valve closed throttle lever pos 0 100 to 300 NOTE Check complete operating range as shown in the following diagram Fig 76 39 for linear resistance progress CAUTION In th...

Page 376: ...f the resistance Detachplugconnectionwithwiringharnessbutre establish immediately after completion of the check and verify tight fit and engagement of catch Measure resistance between the two terminal...

Page 377: ...ion 1 Rev 0 76 00 00 page 43 May 01 2007 d02626 BRP Rotax Maintenance Manual 80 90 100 110 120 130 30 20 10 0 10 20 30 40 50 Temperatur C temperature 00055 1 00056 Fig 76 40 Fig 76 41 00223 Fig 76 42...

Page 378: ...connection 1 ambient pressure sensor Black plug connection 2 airbox pressure sensor If a pressure sensor must be replaced it is necessary to check the current values via communication program Monitor...

Page 379: ...Effectivity 914 Series Edition 1 Rev 0 76 00 00 page 45 May 01 2007 d02626 BRP Rotax Maintenance Manual static pressure sensors 00057 airboxpressure 1 2 Fig 76 43...

Page 380: ...pressure must not exceed 3500 hPa If the max pressure is exceeded during the course of measur ing the sensor must be replaced When taking the following readings the plug connection to the wiring harn...

Page 381: ...Calculation of this pressure ratio is required since the diagram is effective over a whole voltage range and not just for a single voltage Enter this value in the table Ua Us A pressure can be read o...

Page 382: ...aced When taking the following readings the plug connection to the wiring harness has to be disconnected and reestablished immediately after completion of checks The same applies for the air pressure...

Page 383: ...voltage Us NOTE Calculation of this pressure ratio is required since the diagram is effective over a whole voltage range and not just for a single voltage Enter this value in the table Ua Us A pressu...

Page 384: ...connection with the wiring harness must be disconnected and reestablished immediately after completion of the check CAUTION In the event of physical damage or resistance readings outside allowance rep...

Page 385: ...is not at your disposal an engine test run must be performed See corresponding Maintenance Manual Line Maintenance for the respective engine type 914 Series WARNING If a check reveals shortcomings the...

Page 386: ...nal test of circuit breaker 1 circuit breaker closed switch on TCU The servo motor self test is performed 2 circuit breaker open switch on TCU No self test of servo motor is performed With the circuit...

Page 387: ...e possible variants of the airbox If the 3 way solenoid valve is fastened to the engine suspen sion frame then not all parts of the retro fitting kit are needed In addition the following parts are nee...

Page 388: ...lines Remove 3 way solenoid valve Connect adapter cable 2 to wiring harness Install bracket 3 onto airbox Tighten 3 way solenoid valve with allen screw 4 and lock nut 5 Tightening torque 8 Nm 70 in l...

Page 389: ...kit are not necessary for Variant 2 2x bracket 3 2x allen screw M6x14 4 2x lock nut M6 5 not yet available Disassembly and assembly Variant 2 Remove connection wiring harness 11 of 3 way solenoid valv...

Page 390: ...BRP Rotax Maintenance Manual Fit the push lines onto the 3 way solenoid valve and secure with clamp 6 Positionpushlinesandadaptercable 2 andsecurewithclamps 6 CAUTION Always obey the additional instr...

Page 391: ...do so fit a T fitting into line between solenoid valve and float chamber to facilitate the measuring by pressure gauge of the pressure at airbox pressure exceeding 1250 hPa The T fitting may remain in...

Page 392: ...01 2008 Effectivity 914 Series Edition 1 Rev 2 d04355 BRP Rotax Maintenance Manual 3 2 Wiring diagrams 3 2 1 Engine external on the 914 Series See Installation Manual for the respective engine type 91...

Page 393: ...spection protocol for turbo charger control unit Plausibilt ts Kontrolle plausibility control MONITOR Oberfl che MONITOR menu LOAD 1 idle 0 Sollwert target value _________ LOAD 1 full 115 Sollwert tar...

Page 394: ...76 00 00 page 60 July 01 2008 Effectivity 912 914 Series Edition 1 Rev 2 d04355 BRP Rotax Maintenance Manual NOTES...

Page 395: ...isassembly of the complete exhaust system on the 912 Series 78 00 00 7 3 2 Disassembly of the complete exhaust system incl turbocharger and engine suspension frame on the 914 Series 78 00 00 7 3 3 Ins...

Page 396: ...78 00 00 page 2 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02627 BRP Rotax Maintenance Manual NOTES...

Page 397: ...r compared with muffler part no 978482 The exact measuring of the actual noise emission can be conducted only when the muffler is installed in the aircraft 2 2 Exhaust system on the 914 Series The exh...

Page 398: ...r precompression of the intake air The boost pressure in the airbox is controlled by means of an electronically controlled flap wastegate on the exhaust gas turbine The wastegate is actuated by an ele...

Page 399: ...With the wastegate completely open the engine per formance can reach up to approx 70 kW since not all of the exhaust gases bypass the turbine 2 4 Connectionsforinstrumentation CAUTION Consult also th...

Page 400: ...78 00 00 page 6 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02627 BRP Rotax Maintenance Manual NOTES...

Page 401: ...ee Figs 78 2 and 78 3 CAUTION Work must be carried out on a cold engine Danger of burns Exhaust manifold exhaust system assembly Unhook the Bowden cable for the wastegate control see 78 00 00 sec 3 6...

Page 402: ...3 M8x16 with the washer After removing the 5 nuts 16 with the washer and support plate 15 the muffler can be taken off Turbocharger bracket The suction oil line 5 must also be attached to the turbocha...

Page 403: ...g by means of allen screws 23 M8x25 and nuts 24 and to the holder 26 by means of allen screw M8x50 25 Exhaust bracket NOTE There is no need to disassemble the complete unit of exhaust turbocharger exh...

Page 404: ...vity 912 914 Series Edition 1 Rev 0 d02627 BRP Rotax Maintenance Manual XXX Zyl Cyl 1 Zyl Cyl 3 XXX Zyl Cyl 2 Zyl Cyl 4 08001 Fig 78 3 1 2 3 3 3 3 7 4 5 8 9 10 11 12 6 13 14 15 16 17 18 19 20 21 24 22...

Page 405: ...s the EGT connections have been displaced so that the new drip trays can be assembled screwed to the airbox CAUTION The flanges of the exhaust bends 3 must not touch the cylinder heads On engines of o...

Page 406: ...distortion of max 0 1 mm 0 004 inch is allowed If the max allowed distortion is exceeded then it is possible to rework the surface up to 0 5 mm 0 02 inch The amount of the rework has to be recorded in...

Page 407: ...htly a radial pressure onto the shaft whereby it must not contact the compressor housing Check the complete circumference of 360 e Check wastegate lever See Fig 78 7 Check the wastegate lever for free...

Page 408: ...peller shaft See Fig 78 9 The bearings are tested by means of the pressure drop measuring method CAUTION For this test compressed air at approx 2 bar 29 p s i and a testing device are needed Consistin...

Page 409: ...ressure of 2 bar 29 p s i to the connection cable The pressure drop must not exceed 50 From 2 bar 29 p s i to max 1 bar 14 5 p s i NOTE For optimum results the position of the shaft should always be c...

Page 410: ...screws Fit 4 studs 32 M8x19 5 13 with the longer threaded end 19 5 mm 76 in into turbine housing and tighten to 6 Nm 53 in lb Screw stud 31 M8x30 13 into the top threaded bore 30 and tighten to 6 Nm...

Page 411: ...27 M10x50 Re establish attachment 28 exhaust bracket engine suspension frame not supplied with engine Tightening torque as specified by the fuselage manufac turer Place distance sleeve 10 10 5 17 15 i...

Page 412: ...tion of the oil line connection does not correspond with oil pump housing correction can be achieved by slightly turning the turbocharger center section 34 Fit the 4 exhaust bends 3 NOTE To make assem...

Page 413: ...x50 exhaust bracket 40 Nm 30 ft lb hex screw 6 M10 tension clamp 20Nm 177in lb hex nuts 1 M8 exhaust bend flange 12Nm 106in lb When tightening the exhaust bend flanges ensure equal distance between fl...

Page 414: ...e Bowden cable Loosen set screw of nipple 3 and pull Bowden cable out of the cable retainer 4 Do not lose the pressure spring 5 5 5 1 2 16 9 Remove spring and store in a safe place Remove cotter pin 6...

Page 415: ...the servo motor position power up the TCU NOTE After the automatic self test of the servo motor 12 put the throttle lever into idle position to make sure that the servomotorwillremainalwaysinpositionw...

Page 416: ...ope sheave and fix with a screw nipple 3 with a tightening torque of 2 5 Nm 22 1 in lb Adjust Bowden cable with M6 hex nuts 15 so that no clearance is perceptible on wastegate lever With this adjustme...

Page 417: ...ev 3 78 00 00 page23 October01 2010 d04781 BRP Powertrain Maintenance Manual 4 Wear limits TC01 0 0010 0 0016 0 0020 TC02 TC03 Axial clearance Radial clearance Rework turbine housing flange 0 0033 0 0...

Page 418: ...78 00 00 page 24 July 01 2008 Effectivity 912 914 Series Edition 1 Rev 2 d04356 BRP Rotax Maintenance Manual NOTES...

Page 419: ...00 10 2 6 2 Oil temperature indication 79 00 00 10 3 Maintenance 79 00 00 11 3 1 Oil pump 79 00 00 11 3 1 1 Oil pump removal main and suction pump 79 00 00 11 3 1 2 Oil pump disassembly 79 00 00 14 3...

Page 420: ...79 00 00 page 2 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02628 BRP Rotax Maintenance Manual NOTES...

Page 421: ...gh the oil filter to the individual points of lubrication lubricates also the bearings of the turbocharger and the propeller governor The surplus engine oil emerging from the points of lubrication acc...

Page 422: ...79 00 00 page 4 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02628 BRP Rotax Maintenance Manual 05017 09160 912 Series 914 Series Fig 79 1 Fig 79 2 1 2 3 4 5 6 1 2 3 4 5 6...

Page 423: ...h the oil duct 11 in the left side of the housing The 4 hydraulic valve tappets 12 for cylinders 2 and 4 are supplied with oil via this channel Oil flows to the rocker arm bearing via the hollow push...

Page 424: ...er or drained into the crankcase through channel 39 thus changing pitch accordingly The surplus oil returns back to the crankcase via the duct The engine oil emerging from all lubrication points flows...

Page 425: ...Rev 0 79 00 00 page 7 May 01 2007 d02628 BRP Rotax Maintenance Manual 3 1 2 4 5 7 8 6 11 18 16 15 14 17 12 19 21 20 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 38 39 40 41 42 43 44 9 10 13 37 45 46...

Page 426: ...ger 1 with engine oil by gravity after engine stop Operation of the pressure valve Oil pressure min 0 8 bar 11 6 p s i keeps the ball valve open against the low spring pressure and the oil flows almos...

Page 427: ...Legend to Fig 79 4 1 Turbocharger 2 Pressure oil line turbocharger 3 Pressure valve 4 Valve housing 5 Pressure spring 6 Ball 5 5 mm 0 22 in 7 Banjo bolt 8 Oil sump 9 Suction line turbocharger 10 Ring...

Page 428: ...manual 2 5 Drain plug See the corresponding Maintenance Manual Line Maintenance for the respec tive engine type 912 Series or 914 Series 2 6 Connections for instrumentation CAUTION Consult also the re...

Page 429: ...uction pump See Figs 79 5 and 79 6 Drain oil Remove oil line from screw socket 1 feed Remove both banjo bolts 2 from the suction pump and remove sealing rings 3 NOTE The suction oil line 4 and the rin...

Page 430: ...page 12 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d02628 BRP Rotax Maintenance Manual B B B B B B B 912 Series 07062 13 31 1 17 11 21 12 22 23 24 25 26 14 6 7 9 7 20 19 18 15 30 13 16 16 Fig...

Page 431: ...Edition 1 Rev 0 79 00 00 page 13 May 01 2007 d02628 BRP Rotax Maintenance Manual 914 Series Fig 79 6 B B B B B B Loctite 243 07734 13 27 31 17 11 21 3 5 24 10 12 22 23 28 29 26 14 6 7 8 9 7 20 19 18...

Page 432: ...quired to reach the specified oil pressure On the 912 Series Remove the oil pump cover 22 needle pins 23 pressure inner and outer rotor 24 and O ring 46x3 25 Take out needle pin 26 and pull out oil pu...

Page 433: ...p rotor Also check the gap dimension OP01 main oil pump between crankcase flange surface 5 revolving piston 6 crankcase flange surface 5 pump rotor 7 See 79 00 00 sec 4 A bigger gap greatly reduces pu...

Page 434: ...Effectivity 912 914 Series Edition 1 Rev 0 d02628 BRP Rotax Maintenance Manual 05156 05152 00073 00076 914 Series On new engine models On older engine models Fig 79 8 Fig 79 7 1 2 8 8 8 912 Series 91...

Page 435: ...tion 1 Rev 0 79 00 00 page 17 May 01 2007 d02628 BRP Rotax Maintenance Manual 00076 00071 0 10 20 30 40 50 60 70 80 90 0 01mm 1 2 3 4 5 6 7 8 9 0 00074 OP01 Fig 79 11 Fig 79 12 Fig 79 13 14 15 6 7 3 4...

Page 436: ...ith allen screws 12 M6x50 and lock washers After this tighten allen screws 12 crosswise Tightening torque 10 Nm 90 in lb Fit ball 8 5 mm 0 33 in 21 pressure spring 20 39 5 mm 1 55 in andscrewplug 18 M...

Page 437: ...3 11 2 7 and O ring 14 30 2 5 in the oil pump housing and fit it to the crankcase NOTE Turn oil pump shaft until the drive pin 31 engages in the camshaft Tighten oil pump cover 22 crosswise and by han...

Page 438: ...housing 3 is only removed in the event of damage or for cleaning Remove ball 4 5 5 and pressure spring 5 22 mm long from the valve housing NOTE The banjo bolt together with the ball and spring serve a...

Page 439: ...ump only on 914 Series See Fig 79 15 NOTE The oil sump 1 is only removed in the event of damage or for cleaning Remove tension spring from wastegate flap with a suitable tool Release collar nut 2 of t...

Page 440: ...RP Rotax Maintenance Manual 00077 Fig 79 16 3 4 Oiltank See Fig 79 19 Detach oil lines Remove banjo bolt 1 M10 and remove ring hose nipple 2 with sealing rings 10x14 See latest Maintenance Manual Line...

Page 441: ...sealing rings Turbo pressure oil line 5 only on 914 Series disassembly NOTE The turbo pressure and the suction oil line are attached together by means of two cable clamps 6 8 M5 and 2 cable lamps 7 5...

Page 442: ...part no 847224 is fitted between the cable clamp 14 and the gearbox housing Tightening torques banjo bolts M10 17 Nm 150 in lb banjo bolts M8 10 Nm 90 in lb collar nuts 13 20 Nm 180 in lb hex screws...

Page 443: ...hose clamps or crimp connections CAUTION Use oil lines and tube clamps as specified in the aircraft manufacturers manual 3 7 Oil cooler CAUTION The oil cooler is not supplied with the engine Maintenan...

Page 444: ...efer to wiring diagram in Opera tors Manual 3 9 1 Oil temperature sensor See Fig 79 19 The sensor 1 for oil temperature measurement is screwed into the oil pump housing The sensor is an NTC resistor a...

Page 445: ...splayed Due to further develepment a new oil pressure sensor has been introduced See therefore the latest issue of Service Instruction Running Modifications SI 912 020 and SI 914 022 respectively 0722...

Page 446: ...or resistance over pressure Compare pressure gauge with a calibrated instrument CAUTION The graph resistance over pressure has been deter mined and is effective at the following conditions only ambien...

Page 447: ...t wear limit Readings min max 100 50 Oil pump Clearance main pump pump cover rotor OP01 0 00 0 0000 0 05 0 0020 0 20 0 0079 0 13 0 0049 actual renewed Clearance suction pump pump cover rotor OP01 0 00...

Page 448: ...79 00 00 page 30 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02628 BRP Rotax Maintenance Manual NOTES...

Page 449: ...3 Maintenance 80 00 00 5 3 1 Electric starter dismantling 80 00 00 5 3 1 1 Standard starter 80 00 00 5 3 1 2 HD starter 80 00 00 6 3 2 Electric starter disassembly 80 00 00 7 3 2 1 Standard starter 80...

Page 450: ...80 00 00 page 2 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02629 BRP Rotax Maintenance Manual NOTES...

Page 451: ...intermediate gear During the startup process the sprag clutch establishes a connection to the crankshaft via the intermediate gear and the free wheel gear As soon as the engine speed is higher than th...

Page 452: ...80 00 00 page 4 May 01 2007 Effectivity 912 914 Series Edition 1 Rev 0 d02629 BRP Rotax Maintenance Manual NOTES...

Page 453: ...ivided into subsections and descriptions of the function of the various systems 3 1 Electric starter dismantling 3 1 1 Standard starter See Fig 80 1 Remove the 2 hex nuts M5 1 with lock washers 2 and...

Page 454: ...d02629 BRP Rotax Maintenance Manual 3 1 2 HD starter See Fig 80 2 Remove the 2 hex nuts M5 1 with lock washers 2 and washers 3 from the rear side of the ignition cover 6 The electric starter 4 can be...

Page 455: ...ng flange 1 off the starter housing 2 Carefully pull rotor bearing 3 a short way off the starter housing and press the positive carbon brush 23 with the connector sheath 17 out of the rotor bearing Re...

Page 456: ...ll bearing flange 1 off the starter housing 2 Carefully pull rotor bearing 3 a short way off the starter housing and press the positive carbon brush 23 out of the rotor bearing Remove brush holder 4 w...

Page 457: ...cess material particles are released and could possibly be inhaled Check rotor at 12 or 24 Volts with test lamp between commutator 8 and iron core 9 for connection to ground If the lamp lights up repl...

Page 458: ...ly in their guides 15 Replace too short brushes min length 8 mm 0 32 Check spring pressure replace hot run brush springs 16 Check connector sheaths 17 of the positive pole carbon brush 18 replace as r...

Page 459: ...e ball bearing 10 and the bearing bushing 13 Insert rotor 5 into the bearing flange 1 fit new O ring 62x1 5 18 and put starter housing 2 over rotor Fit the brush holder 4 with the carbon brushes 14 on...

Page 460: ...n housing with a tension clamp 7 Tighten combined nut of the plus terminal connection to a tightening torque of 4 Nm 35 in lb 3 5 2 HD starter See Fig 80 2 Lightly grease the centering bore 9 in the i...

Page 461: ...13 July 01 2008 d04358 BRP Rotax Maintenance Manual 07449 08474 07555 07556 4 Wear limits NOTE The wear limits apply to both configurations of the electric starter standard and HD standard configurati...

Page 462: ...80 00 00 page14 October01 2010 Effectivity 912 914 Series Edition 1 Rev 3 d04798 BRP Powertrain Maintenance Manual 08585...

Page 463: ......

Page 464: ...Flugzeugtype Type of aircraft Flugzeugkennzeichen Aircraft registration no ROTAX Vertriebspartner ROTAX authorized distributor and TM are trademarks of BRP Powertrain GmbH Co KG 2006 BRP Powertrain Gm...

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