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INTRO
LEP
TOA
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MAINTENANCE MANUAL
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Effectivity: 914 Series
Edition 2 / Rev. 2
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MAINTENANCE MANUAL
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Effectivity: 914 Series
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LEP page 3
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BRP-Powertrain
MAINTENANCE MANUAL
NOTES
Effectivity: 914 Series
Edition 2 / Rev. 1
LEP page 4
July 01/2010
BRP-Powertrain
MAINTENANCE MANUAL
Chapter: TOA
TABLE OF AMENDMENTS
*Approval
The technical content of this document is approved under the authority of DOA No. EASA.21J.048.
Note: THE APPROVAL IS GIVEN TO ALL CHAPTERS
EXCEPT THE AIRWORTHINESS LIMITATIONS
SECTION 04-00-00 WHICH IS SUBJECT TO
SPECIFIC APPROVAL OF THE EASA.
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INTRO
LEP
TOA
00-00-00
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05-50-00
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12-20-00
INTRO
LEP
TOA
04-00-00
VGS
RV
00-00-00
05-10-00
05-20-00
05-50-00
12-20-00
chapter page date of change remark for approval
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1 all all all all all all all all all all all all
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15-18
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01 01 2010
01 01 2010
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01 01 2010
01 01 2010
01 01 2010
01 01 2010
01 01 2010
01 01 2010
01 01 2010
07 01 2010
07 01 2010
07 01 2010
07 01 2010
2015 02 01
2015 02 01
2015 02 01
2015 02 01
2015 02 01
2015 02 01
2015 02 01
2015 02 01
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
date of approval from authorities date of issue
EASA approved
signature
Effectivity: 914 Series
Edition 2 / Rev. 2
TOA page 1
February 01/2015
BRP-Powertrain
MAINTENANCE MANUAL
NOTES
Effectivity: 914 Series
Edition 2 / Rev. 0
TOA page 2
January 01/2010
BRP-Powertrain
MAINTENANCE MANUAL
1) General note
Purpose
The purpose of this Maintenance Manual is to acquaint maintenance service staff approved by the local aviation authorities with some basic maintenance and safety information for service work.
Documentation
ROTAX
Distributors
Engine serial number
For more detailed information regarding, maintenance, safety- or flight operation, consult the documentation provided by the aircraft manufacturer and/or dealer.
For additional information on engines, maintenance or parts, you can also contact your nearest authorized ROTAX-aircraft engine distributor.
ROTAX Authorized Distributors for Aircraft Engines.
See latest Operators Manual or on the Internet at the official Homepage www.FLYROTAX.com.
When making inquiries or ordering parts, always indicate the engine serial number, as the manufacturer makes modifications to the engine for product improvement. The engine number (1) is on the ignition cover, on the left, opposite the electric starter. See Fig. 1 .
Cyl. 1 Cyl. 3
Fig. 1
Effectivity: 914 Series
Edition 2 / Rev. 2
Cyl. 2 Cyl. 4
1
03645
00-00-00 page 3
February 01/2015
BRP-Powertrain
MAINTENANCE MANUAL
NOTES
Effectivity: 914 Series
Edition 2 / Rev. 0
00-00-00 page 4
January 01/2010
BRP-Powertrain
MAINTENANCE MANUAL
3) Safety
General note
Revision
Measure
Symbols used
Although the reading of such information does not eliminate the hazard, understanding the information will promote its correct use. Always use common workshop safety practice.
The information and components-/system descriptions contained in this
Manual are correct at the time of publication. BRP-Powertrain, however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on its products previously manufactured.
BRP-Powertrain reserves the right at any time, and without incurring obligation, to remove, replace or discontinue any design, specification, feature or otherwise.
Specifications are given in the SI metric system with the USA equivalent in parenthesis.
This Manual uses the following symbols to emphasize particular information. This information is important and must be observed.
m
WARNUNG
Identifies an instruction which, if not followed, may cause serious injury including the possibility of death.
m
WARNUNG
Identifies an instruction which, if not followed, may cause minor or moderate injury.
m
WARNUNG
Denotes an instruction which, if not followed, may severely damage the engine or other component.
NOTES:
Indicates supplementary information which may be needed to fully complete or understand an instruction.
ENVIRONMENT NOTE
Environment note gives you tips on environmental protection.
A revision bar outside of the page margin indicates a change to text or graphic.
Effectivity: 914 Series
Edition 2 / Rev. 2
00-00-00 page 9
February 01/2015
BRP-Powertrain
MAINTENANCE MANUAL
3.1) Safety notice
General note
This information relates to the preparation and use of ROTAX aircraft engines and has been utilized safely and effectively by BRP-Powertrain.
However, BRP-Powertrain disclaims liability for all damage and/or injuries resulting from the improper use of the contents. BRP-Powertrain strongly recommend that any service be carried out and/or verified by a highly skilled professional mechanic
See chap. 05-00-00 section 1.2)
Manual
Warning
Safety instruction
Illustration
This Manual has been prepared as a guide to correctly service and maintain all ROTAX 914 aircraft engines.
This edition was primarily published to be used by aircraft mechanics who are already familiar with all service procedures relating to ROTAX aircraft engines.
This Manual uses technical terms which may be slightly different from the ones used in the Illustrated Parts Catalog.
It is understood that this Manual may be translated into another language.
In the event of any discrepancy the German version prevails.
It is your responsibility to be completely familiar with the safety instructions including warnings and cautions described in this Manual. These warnings and cautions advise of specific operating and servicing methods that, if not observed, can cause a serious engine malfunction or cause the engine to lose power in flight which can result in loss of life, injury or damage to equipment.
It is, however, important to understand that these warnings and cautions are not exhaustive. BRP-Powertrain could not possibly know, evaluate and advise the user of all conceivable ways in which service might be done or of the possible hazardous consequences of each way.
In addition to observing the instructions in our Manual, general safety and accident preventative measures, legal regulations and regulations of any aeronautical authority must be observed.
Where differences exist between this Manual and regulations provided by any authority, the more stringent regulation should be applied.
The content depicts parts and/or procedures applicable to the particular product at its time of manufacture. It does not include dealer modifications, whether authorized or not by BRP-Powertrain, after manufacturing the product.
Effectivity: 914 Series
Edition 2 / Rev. 0
00-00-00 page 10
January 01/2010
BRP-Powertrain
MAINTENANCE MANUAL
3.3) Maintenance Concept
General note
The maintenance functions detailed in this Manual fall into two categories:
- Maintenance I (Line Maintenance)
- Maintenance II (Heavy Maintenance)
Repairs beyond the levels detailed in this Manual are not recommended as maintenance functions and must be done by an authorized overhaul facility.
Maintenance I
(Line Maintenance)
Maintenance II
(Heavy Maintenance)
Chapter 00,05 and 12
The scope of line maintenance consists of removal, installation and adjustment of engine components (including part wear). All procedures in this Manual are to be considered line maintenance.
NOTES: Where applicable, you will be referred to the Heavy Maintenance Manual for work above and beyond line maintennace.
separate Manual
Maintenance Manual II details removal, installation and repair of components or parts normally considered beyond the capabilities of the "Line
Maintenance".
NOTES: This Manual can only be used in combination with Maintenance Manual I (Line Maintenance), as it builds up on it.
Effectivity: 914 Series
Edition 2 / Rev. 0
00-00-00 page 13
January 01/2010
BRP-Powertrain
MAINTENANCE MANUAL
3.4) Technical documentation
General note
These documents form the instructions ensuring continued airworthiness of ROTAX aircraft engines.
The information contained is based on data and experience that are considered applicable for authorized mechanics (iRMT) under normal conditions.
Due to the fast technical progress and fulfilment of particular specifications of the customers it may occur that existing laws, safety prescriptions, constructional and operational regulations cannot be transferred completely to the object bought, in particular for special constructions, or may not be sufficient.
Documentation
Status
Replacement pages
- Installation Manual
- Operators Manual
- Maintenance Manual (Line and Heavy Maintenance)
- Overhaul Manual
- Illustrated Parts Catalog
- Alert Service Bulletin
- Service Bulletin
- Service Instruction
- Service Letter
The status of the Manuals can be determined with the aid of the table of amendments. The first column indicates the revision state. This figure should be compared with the revision provided on ROTAX-WebSite: www.FLYROTAX.com
.
Amendments and current versions can be downloaded free of charge.
Furthermore the Manual is constructed in such a way that single pages can be replaced instead of the complete document. The list of effective pages is given in the chapter LEP. The particular edition and revision number is given on the footer of each page.
Reference
m
WARNUNG
This Manual for maintenance is only part of the Technical Documentation and will be supplemented by the respective Operators Manual, Installation Manual,
Overhaul Manual and Illustrated Parts Catalog.
Any reference to a document refers to the latest edition issued by
BRP-Powertrain, if not stated otherwise.
Effectivity: 914 Series
Edition 2 / Rev. 2
00-00-00 page 14
February 01/2015
Authorized exceeding
Shipment
BRP-Powertrain
MAINTENANCE MANUAL
Extension or exceeding of the TBO by 5 % or 6 months is allowed whichever comes first.
The shipment to an authorized ROTAX overhaul facility must include the following:
5
6
1
2
3
4
Engine log book.
Maintenance records of the engine (i.e. all maintenance check lists, and reports of operation, of maintenance, of findings and of oil analyses).
The engine assembly as per supply volume. Additionally all added-on parts as in the supply volume such as carburetors, filters, fuel pump, external generator, sensors, ignition unit, electric starter, oil tank.
Indication of total engine operating hours (TSN) and where applicable, engine operating hours since a previous overhoul (TSO).
NOTE: This information must be supplied to allow the service history of components to be traced.
Data about the type of aircraft used.
Useful remarks and observations concerning the engine.
Effectivity: 914 Series
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05-10-00 page 7
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BRP-Powertrain
MAINTENANCE MANUAL
2.1) Time limit for rubber parts
General note
m
WARNUNG
This time limit must be followed independently and in
addition to the visual inspections (see chap. 05-20-00 section: 5.1)) of the respective components.
Time limit
The following components and systems must be replaced every 5 years:
- venting hose of the carburetors
- all rubber hoses of the cooling system
- all rubber hoses of the fuel system
- all rubber hoses of the lubrication system which are part of the engine supply volume and if they are not in the maintenance schedule of aircraft manufacturer
- carburetor rubber flange assy.
- Air intake hose (connection between turbocharger and airbox)
- diaphragm on both carburetors
- rubber hoses on compensating tube
- V-belt
2.2) Time limit for the coolant
General note
Coolant must be replaced as per manufacturers instructions, at the latest during overhaul or when the engine is replaced.
2.3) Annual inspection
General note
A 100 hr. inspection is to be carried out periodically after every 100 hours of operation or every 12 months, whichever comes first.
See chap. 05-10-00 section: 2) .
Effectivity: 914 Series
Edition 2 / Rev. 2
05-10-00 page 8
February 01/2015
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MAINTENANCE MANUAL
Points of Inspection
Checking the idle speed.
Interval
Operating hours as indicated
8.) Checking the carburetor
100 hr.
X
Chapter
Reference
12-20-00 sec. 12.3.1)
Checking the ventilation of the float chambers. Any trouble with the float chamber ventilation impairs engine and carburetor function and must therefore be avoided.
Check that the passage of the ventilation lines is free and that no kinks can arise.
every 200 hr.
Check for free movement of the carburetor actuation
(throttle lever and starting carburetor).
Check that the bowden cable allows the full travel of the throttle lever from stop to stop.
Removal/assembly of the two carburetors and carburetor inspection.
every 200 hr.
X 12-20-00 sec. 12.6)
Heavy MM
73-00-00 sec. 3)
Check carburetor synchronization. Mechanical or pneumatic synchronization.
Inspect the float weight every 200 h
(and/or annual inspection
X 12-20-00 sec. 12.1)
12-20-00 sec. 12.4.1)
Inspect the carburetor sockets for damage and abnormalities, checking for cracks, wear and good condition.
Take note of changes caused by temperature influence.
9.) Inspecting carburetor sockets and drip tray
every 200 hr.
(1
Heavy MM
73-00-00 sec. 3.4.3)
(1
See SB-914-019 - latest edition.
10.) Spark plug connectors
Check that resistance spark plug connectors fit tightly on the spark plugs.
Minimum pull-off force is 30 N (7 lb).
every 200 hr.
Replace spark plugs.
11.) Spark plugs
Remove all spark plugs, check the heat range designation, clean, check electrode gap and adjust if necessary. Check electrode gab and adjust as necessary. Replace as required.
every 200 h
X
X
(1
12-20-00 sec. 16.2)
12-20-00 sec. 16.2)
(1 use of leaded fuel more than 30% of operation.
Signature
Effectivity: 914 Series
Edition 2 / Rev. 2
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MAINTENANCE MANUAL
Points of Inspection
Interval
Operating hours as indicated
12.) Flushing the cooling system
100 hr.
Flushing the cooling system where conventional coolants are used.
when replacing the coolant
Check the wastegate flap for free running and correct position.
13.) Checking the wastegate flap
X
X Check the wastegate bowden cable for free movement and damage.
Lubricate the axle (wastegate flap).
X
Chapter
Reference
12-20-00 sec. 11.3)
12-20-00 sec. 8)
12-20-00 sec. 8)
12-20-00 sec. 8)
Check the fuel filter.
14.) Fuel filter (on airframe side)
X 12-20-00 sec. 9)
Check the friction torque in free rotation on gearboxes with overload clutch.
15.) Checking the propeller gear box
X
Actual friction torque________ Nm (in.lbs)
Gearboxes (with overload clutch).
Inspect overload clutch.
every 600 hr.
(1
12-20-00 sec. 17.1)
Check the propeller gearbox (with overload clutch).
Check the propeller gearbox (without overload clutch).
Remove old oil filter from engine and install new oil filter.
16.) Oil change
50 hr.
(1
Cut old oil filter without producing any metal chips and inspect following components for wear and/or missing material every 1000 hr.
every 600 hr.
50 hr.
(1
X
X
05-50-00 sec. 2)
SB-914-020
12-20-00 sec. 17.2)
12-20-00 sec. 17.2)
12-20-00 sec. 13.3),
13.4))
12-20-00 sec. 13.5)
Filter mat
Findings:_________________________________
_______________________________________
Filter cover
Findings:_________________________________
_______________________________________
Sealing lip (wear, cracks, missing material)
Findings:_________________________________
_______________________________________
Signature
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05-20-00 page 16
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MAINTENANCE MANUAL
Points of Inspection
Interval
Operating hours as indicated
100 hr.
Chapter
Reference
Signature
Spring of bypass valve (small)
Findings:_________________________________
_______________________________________
Positioning spring (large)
Findings:_________________________________
_______________________________________
Check oil tank.
Refill oil tank with approx. 3 litres of oil. For oil quality, see Operators Manual and SI-914-019, latest edition.
50 hr.
(1
X 12-20-00 sec. 13.2),
13.6)
(1
In the case more than 30% of operation with leaded fuel e.g.: AVGAS 100 LL 12-20-00 sec. 13.2)
SI-914-019
17.) Checking the V-belt tension
On configurations with auxiliary generator, check the attachment and the V-belt tension.
Check the electric fuel pumps.
18.) Electric fuel pumps
every 1000 hr.
X 12-20-00 sec. 6)
MM II
(Heavy)
73-00-00 sec. 3.4.6)
IM sec. 14.4)
Replace the main fuel pump.
every 1000 hr.
19.) Engine test run
Observe the safety instructions!
Start the engine and run to operating temperature.
Limits see Operators Manual 914 series.
Ignition check at _____ rpm engine speed.
Speed drop without ignition circuit:
A (Off)___________rpm
B (Off)___________rpm
A/B (difference)________rpm
After engine test run, re-tighten the oil filter by hand
(only at cold engine).
Checks for leaks.
General note
All Service Bulletins are complied with.
X
X
12-20-00 sec. 8)
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MAINTENANCE MANUAL
Points of Inspection
Interval
Operating hours as indicated
100 hr.
Chapter
Reference
Signature
Returning engine to service
On the engine identified as per point 5, on the _____________________ the________hr.
Check at______hr. (TSN___, TSO___) was carried out according to recommendations of the engine manufacturer and was recorded in the Engine Log book.
Location, Date_______________________
Inspector___________________________
Aircraft mechanic_____________________
Certificate No.______________________
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05-20-00 page 18
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MAINTENANCE MANUAL
Introduction
Chapter: 05-50-00
UNSCHEDULED MAINTENANCE CHECKS
m
WARNUNG
In the course of special checks specify if additional
checks for components (e.g. hydraulic governor) is applicable.
After each special check/repair work, an engine test run and a leakage check must be carried out.
m
WARNUNG
Observe without fail all the specified instructions.
Special checks must be carried out immediately in the event of an engine fault (e.g. abnormal operation as defined in the Operators Manual) which impairs the airworthiness of the engine.
Table of contents
This chapter of the Maintenance Manual contains general information regarding unscheduled maintenance checks and their associated procedures.
Page Subject
Engine check after propeller strike incidents
Propeller gearbox with integrated overload clutch
Propeller gearbox without integrated overload clutch
Checking of the overload clutch
Examination after engine failure
Returning engine to service after submerging in water
Inspection in extreme climatic conditions
Exceeding of max. admissible engine RPM
Exceeding of max. cylinder head temperature
Exceeding of max. coolant temperature
Exceeding the max. permissible oil temperature
Oil pressure below minimum value
Oil specification not respected
Spark plug not in accordance with specification
Hard to turn over
Reporting page 3 page 3 page 4 page 5 page 7 page 8 page 9 page 10 page 11 page 12 page 13 page 15 page 17 page 19 page 20 page 27
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MAINTENANCE MANUAL
NOTES
Effectivity: 914 Series
Edition 2 / Rev. 0
05-50-00 page 2
January 01/2010
BRP-Powertrain
MAINTENANCE MANUAL
3) Examination after engine failure
General note
In order to find possible causes of the failure, it is important to pass on all available data. Observations on the aircraft and the engine suspension can also be of help. It is important to pay particular attention to any of the following engine phenomena to facilitate troubleshooting.
Engine
Fuel system
part
Ignition system (shorting cable, electronic module, charging coil)
Spark plug
Engine runs erratically and misfires possible cause
fuel supply vapour locks contamination float chamber venting false air intake due to defective carburetor flange carburetor icing malfunction grounding defect wrong spark plug connection
Rough running
Engine stoppage
Ignition
Carburetor
Engine m
part
WARNUNG
Rough running engine possible cause
wiring (assignment fault) fuel supply contamination in float chamber or float needle valve float chamber venting false air intake due to defective carburetor flange incorrect synchronization of the carburetor engine temperature too low too lean carburetor jetting due to conditions prevailing in intake silencer
Should one of the above mentioned points occur even for a short time then a detailed check of the engine is necessary. The fault needs to be located and corrected.
Oil system
Oil pump
part
Unintended engine stoppage by seizing possible cause
oil pressure too low or no oil pressure oil shortage contamination incorrect venting defect
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Edition 2 / Rev. 0
05-50-00 page 7
January 01/2010
BRP-Powertrain
MAINTENANCE MANUAL
Cylinder head part
Unintended engine stoppage by seizing
Camshaft bearings/Conrod bearings rather consequential damage wear (low oil pressure)
possible cause
NOTICE
The entire assembly must be dismantled, inspected and repaired.
- The whole engine must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.
- Inspect all systems for correct functioning.
- Detailed inspection of affected engine components.
A rise in cylinder head temperature or coolant temperature above normal operating limits (see Operators Manual) is a clear signal for a failure in the cooling system.
Cylinder head temperature or coolant temperature too high part possible cause
Cooling system not enough coolant bad venting
Return valve is not working
Radiator
Radiator cap
Pressure relief valve
Water pump malfunction contaminated leaking malfunction malfunction
3.1) Returning engine to service after submerging in water
General note
m
WARNUNG
The engine must be marked clearly “Engine submerged in water“. Define if it was fresh water or salt water.
An engine which has been submerged in water must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness. See latest Maintenance Manual of the relevant engine type.
Inspection
- Inspect all systems for correct functioning.
NOTE: Prior to the detailed inspection, all parts should be cleaned and inspected for corrosion. For accessories (e.g. vacuum pump, fuel filter etc.) the instructions and specifications of the corresponding manufacturer must be followed.
Effectivity: 914 Series
Edition 2 / Rev. 2
05-50-00 page 8
February 01/2015
BRP-Powertrain
MAINTENANCE MANUAL
Complete inspection of these components:
generator gearbox engine suspension frame fuel system ignition system cylinder unit cooling system valve train system exhaust system lubrication system electric starter
In most cases an overhaul is necessary, in this regard send the engine without delay to an authorized ROTAX overhaul facility for inspection.
If an engine was submerged into water, all electrical components (e. g.: ignition coils, stators, spark plugs, spark plug connectors, turbocharger control unit, sensors, wiring harness) must be replaced.
NOTE: Discoloration or corrosion are signs of submerging in water.
3.2) Inspection in extreme climatic conditions
General note
m
WARNUNG
Every 25 hr. checks of air filter, coolant radiator and oil cooler are necessary.
Flying in deserts or areas with heavily contaminated or dusty air causes increased wear on all components. For this reason, shorter maintenance intervals are recommended.
Flying in areas with extreme climatic conditions or in extreme altitudes requires adjustment of the carburetor jetting and of the cooling system. To do this, it is necessary to contact the aircraft manufacturer and an authorized ROTAX distributor.
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3.3) Exceeding of max. admissible engine RPM
General note
NOTES: Any exceeding of the max. admissible engine RPM must be entered by the pilot into the engine log book stating duration extent of overspeeding and pertinent detail.
5800 rpm up to max. 6200 rpm
If the limit was exceeded for max. 1 minute up to 6200 rpm
Step Procedure
1 No action is required.
5800 rpm up to max. 6200 rpm
If the limit was exceeded for more than 1 minute up to 6200 rpm
1
Step Procedure
Check that the push-rods are straight.
6200 rpm up to max. 6500 rpm
If the limit was exceeded for max. 1 minute up to 6500 rpm
1
Step Procedure
Check that the push-rods are straight.
6200 rpm up to max. 6500 rpm
If the limit was exceeded for more than 1 minute up to 6500 rpm
1
2
3
4
5
Step Procedure
The whole engine must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.
Check that the push-rods are straight.
Inspect the crankshaft for out-of-roundness and torsion. See chapter 72-00-
00 of the latest Heavy Maintenance Manual.
Inspect all systems for correct functioning.
Detailed inspection of affected engine components.
more than 6500 rpm
If the speed of 6500 rpm was exceeded
Step
1
2
Procedure
The whole engine must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.
Check that the push-rods are straight.
3
4
5
Check differential pressure.
Replace the crankshaft. Check the drive gear for out-of-roundness and torsion. See chapter 72-00-00 of the Heavy Maintenance Manual.
Check if piston had contact with valve.
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7
8
6
Step
Check roundness of valves.
Procedure
Inspect all systems for correct functioning.
Detailed inspection of affected engine components.
3.4) Cooling system temperature exceeded
General note
m
WARNUNG
NOTES:
If the cooling system temperature is exceeded, other limits are also often exceeded, e.g. oil temperature.
Please observe the relevant instructions.
Any exceeding of the max. admissible cooling system temperature must be entered by the pilot into the engine log book, stating duration extent of excess temperature and pertinent detail.
Graphic
3.4.1)Exceeding of max. cylinder head temperature
(relevant for engine S/N without Suffix -01)
See latest SB-912-068.
Overview and proceed:
180 °C
(356 °F)
Proceed as instructed in table 2
Proceed as instructed in table 1
Operating limit
(See Operators Manual 914 Series)
0
30 min.
Time
Fig. 2
07140
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Exceeding up to
180 °C (356 °F)
Table 1.
1
Step
2
Max. temperature exceeded up to 180 °C (356 °F) - briefly
Procedure
The whole cooling system must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.
Inspect all further systems for correct functioning.
Carry out detailed inspection of the affected engine components such as.
Leakage check on the cooling system.
Check that the cylinder head attachment is fitted securely. If the cylinder head nut is loose, proceed as instructed in sec. “Excess temperature of over 180 °C (356 °F) and/or for longer than 30 min.“
Check all coolant fittings (feed/outflow) for secure fit.
Exceeding of over 180 °C
(356 °F)
Table 2.
1
4
5
2
3
Excess temperature of over 180 °C (356 °F) and/or for longer than 30 min.
Step Procedure
The whole cooling system must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.
Inspect all further systems for correct functioning.
Carry out detailed inspection of the affected engine components.
Check compression by carrying out a differential pressure check.
All cylinder heads and cylinders must be removed and subjected to a detailed check including hardness testing.
See chap. 72-00-00 in the Heavy Maintenance Manual.
3.4.2)Exceeding of max. coolant temperature
(relevant for engine S/N with Suffix -01)
See latest SB-912-068.
General note
m
WARNUNG
If the coolant temperature is exceeded, other limits are also often exceeded, e.g. oil temperature. Please observe the relevant instructions.
NOTES: Any exceeding of the max. admissible coolant temperature must be entered by the pilot into the engine log book, stating duration extent of excess temperature and pertinent detail.
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Grafik
BRP-Powertrain
MAINTENANCE MANUAL
Overview and proceed;:
135 °C
(275 °F)
Proceed as instructed in table 2
Proceed as instructed in table 1
Operating limit
(See Operators Manual 914 Series)
0
30 min.
Zeit
Fig. 3
07140
3.5) Exceeding the max. permissible oil temperature
General note
m
WARNUNG
NOTES:
If the max. permissible oil temperature is exceeded, other limits are often exceeded, too, e.g. the cooling system temperature. Please observe the relevant instructions.
Any exceeding of the max. admissible oil temperature must be entered by the pilot into the engine log book, stating duration extant of excessive temperature and pertinent detail.
Graphic
Overview and proceed;
160 °C
(320 °F)
Proceed as instructed in table 4
Proceed as instructed in table 3
Operating limit
(See Operators Manual 914 Series)
0
15 min.
Fig. 4
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Exceeding up to max. 160 °C
(320 °F)
Table 3.
1
Step
6
7
4
5
2
3
Excess temperature up to max. 160 °C (320 °F) max. 15 min.
Procedure
The whole oil system must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.
Inspect oil level in the oil tank.
Inspect oil cooler for contamination and check the entire oil circuit for correct functioning.
Check that oil lines are routed correctly and undamaged.
Cut oil filter housing and inspect filter mat for foreign matter.
Carry out oil change.
Inspect all further systems for correct functioning.
Exceeding over
160 °C (320 °F)
Table 4.
1
4
5
2
3
Step
Excess temperature over 160 °C (320 °F) for longer than 15 min.
Procedure
The whole engine must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.
Inspect all further systems for correct functioning.
Carry out detailed inspection of the affected engine components.
Inspect the whole oil system (oil cooler, oil lines) must be inspected.
Cut oil filter housing and inspect filter mat for foreign matter.
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4) Reporting
General note
According to the regulation of EASA part 21A.3 / FAR 21.3 the manufacturer shall evaluate field information and report to the authority. In case of any relevant occurrences that may involve malfunction of the engine, the form on the next page should be filled out and sent to the responsible authorized ROTAX distributor.
NOTES: The form is also available from the official ROTAX AIR-
CRAFT ENGINES Homepage in electronic version.
www.FLYROTAX.com
Register: Document type/Diverses
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NOTES
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3) Visual inspection
General note
General visual inspection of the engine for damage or abnormalities. For definition and scope of visual inspection (See chap. 05-20-00 section: 3) .
Abnormalities
Take note of changes caused by temperature influence.
During a visual inspection you should focus on the following points in particular:
- Exhaust system and turbocharger with attachment
Notes on turbocharger:
1
2
3
4
Step Procedure
Only a visual inspection is necessary.
Check compressor impeller for mechanical damage and free movement.
Carry out visual inspection of compressor and turbo housing for cracks.
Turbocharger unit - see 76-00-00 of the Heavy Maintenance Manual.
- Engine suspension frame - see 71-00-00 of the Heavy Maintenance
Manual
- Heat protection hoses
Check the two heat protection hoses (water pump - cylinder head 1 and 2) for mechanical damage.
- Fuel and oil lines - see 73-00-00 of the Heavy Maintenance Manual
- Fuel pumps
- Servo motor - see 76-00-00 of the Heavy Maintenance Manual
- Pressure sensors
- Heat protection plates
- Wiring harness
- Venting hoses (carburetor, oil tank)
- Cooling air duct and cooling fins of the cylinder
- Oil filter
Condensation trap
NOTES: Only fitted on engines with airbox of older model.
There is a condensation trap between the airbox and the pressure sensor. It must be replaced when it fills with condensation.
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Pressure connecting lines
See Fig. 4 . See 73-00-00 of the Heavy Maintenance Manual m
WARNUNG
As a failure of the pressure connecting lines (1) between the airbox, float chambers, fuel regulator and pressure sensor is almost certain to cause engine stoppage, they must be checked with especial care.
- Airbox - fuel pressure regulator
- Airbox - pressure sensor
- Airbox - reversing valve
- Reversing valve - 2x Float chamber ventilation
1
1
1
1
1
1
Fig. 4
00048
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4) Leakage check
General note
m
WARNUNG
Leaking connections can lead to engine problems or engine failure!
Visual inspection of the whole engine for leaks. If leaks are visible, locate the cause and remedy the fault.
Leakage
NOTES:
Step
1
2
3
4
If a leak is suspected, then the following check is possible:
Procedure
Cleaning the engine.
Operate the engine until the temperatures have stabilized for a period of 5 min (engine oil temperature between 50 to 70 °C (122 - 160 °F).
Switch off ignition and secure engine against unintentional operation. Secure aircraft against unauthorized operation.
After shut down of engine no liquid must drip down.
Water pump
Fuel lines
Checking water pump for leaks.
If the leakage bore, located at the base of the ignition housing, is dripping oil, the oil seal on the water pump shaft may be defective and must be replaced. In the case of coolant drips at the leakage bore, the coolant mechanical seal must be replaced (inspect the quality of the coolant).
Inspect fuel lines, their connections and screw fasteners. Look for scuffing marks.
m
WARNUNG
Avoid overstretching the fixing elements. Always comply with the specified torque!
On steel fuel lines in the area at connections (fittings) (2) a detailed visual inspection is necessary. See Fig. 5.
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Graphic
BRP-Powertrain
MAINTENANCE MANUAL
Connections and fuel lines
1
2
1
2
2
3
Fuel pump
Coolant hoses
Oil lines
Hose clamps, kinks
1
2
3
Part Functions
Fuel lines (Steel)
Connections (Fittings)
Fuel filter
Fig. 5
Inspect the fuel pump for leaks.
07069
Check coolant hoses and connections and fittings for leakage. Examine the surrounding area to see if there are any leaks!
Inspect all oil feed lines from the oil tank to the oil cooler and to the engine.
Also inspect the oil return line from the crankcase to the oil tank. Check the pressure oil line from the oil pump to the governor flange of the governor and the suction oil line from the turbocharger to the oil pump (especially in the area of the fixation screw).
Check all hoses, particularly in the area of the hose clamps and hose connections, for porosity, damage and kinks. If damage is detected, replace hose immediately.
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12.4) Checking of the float chamber
General note
See Fig. 24 .
m
WARNUNG
Risk of Burns!
Hot engine parts!
Always allow engine to cool down to ambient temperature before start of any work.
Instruction
3
4
1
2
5
To check of the float chamber the following steps are necessary:
Step Procedure
Remove drip tray (1).
Open attachment screw (2).
Remove float chamber (3) with gasket (4) and both floats.
Remove both floats (5) from the float chamber.
Inspect the float chamber for contamination and corrosion.
m
WARNUNG
If any contamination on float chamber the find out what the cause is and take corresponding action to rectify the problem. Inspect and clean the complete fuel system including carburetor.
6
Step
7
Procedure
Assembly of the float chamber should be carried out analogously the disassembly.
Adjust with the idle speed adjustment.
See chap. 12-20-00 section: 12.5) .
12.4.1) Wiegekontrolle der Schwimmer
Mittels Wiegekontrolle kann festgestellt werden, ob die betroffenen
Schwimmer Kraftstoff aufgenommen haben. Dies ist natürlich nur aussagekräftig, sofern die Schwimmer bereits mit Kraftstoff in Kontakt waren.
HINWEIS: Bei neuen, noch nicht mit Kraftstoff in Verbindung gebrachten Ersatzteilen, muss diese Prüfung nicht durchgeführt werden.
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1
Schritt
2
3
Vorgehen
Schwimmer 1-2 Minuten an der Luft trocknen. Nur im trockenen Zustand wiegen.
Bei sämtlichen betroffenen Schwimmer mittels kalibrierter Waage das
Summengewicht beider Schwimmer ermitteln. Messgenauigkeit der Waage 0,1 g oder besser.
Die Werte der Messung sind in den Wartungsunterlagen zu vermerken.
Das max. zulässige Gesamtgewicht (beider Schwimmer gemeinsam) beträgt 7 Gramm.
m
WARNUNG
Sämtliche Schwimmer, die den Wert überschreiten, sind ausnahmslos zu erneuern.
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Graphic
Float chamber
BRP-Powertrain
MAINTENANCE MANUAL
Fig. 24
1
2
3
4
1
2
5
Part
Drip tray
Attachment screw
Function
Float chamber
Gasket
Float
5
3
4
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12.5) Idle speed adjustment
General note
See Fig. 23 .
m
WARNUNG
If satisfactory idle speed adjustment cannot be achieved, inspection of the idle jet or additional pneumatic synchronization will be necessary.
See chap. 12-20-00 section: 12.3) .
Idle adjustment
Optimizing engine running
Always carry out idle speed adjustment when the engine is warm.
- Basic adjustment of the idle speed is first effected using the idle speed adjustment screw (2) of the throttle valve.
See chap. 12-20-00 section: 12.2) .
Necessary only if not taken care of at synchronization.
1
2
3
4
Step Procedure
Close idle mixture screw (4) by turning clockwise to screw in fully and then opening again by 1.5 turns counter clockwise.
Starting from this basic adjustment, the idle mixture screw (4) is turned until the highest idle speed is reached.
The optimum setting is the middle between the two positions at which an rpm. drop is noticed.
Then readjustment of the idle speed is carried out using the idle speed adjustment screw (2) and if necessary, by slightly turning the idle mixture screw again.
NOTES: Turning the idle mixture control screw in clockwise direction results in a leaner mixture and turning counter clockwise in a richer mixture.
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12.6) Checking the carburetor actuation
General note
See Fig. 25 .
Route bowden cables in such a way that carburetor actuation will not be influenced by any movement of engine or airframe, thus possibly falsifying idle speed setting and synchronization.
NOTES: Each carburetor is actuated by two bowden cables. At position (1) connection for throttle valve, and at position (2) connection for choke actuation.
m
WARNUNG
Risk of life threatening injuries caused by propeller!
Adjust bowden cables so that the throttle valve and the choke actuation of the starting carburetor can be fully opened and closed. Bowden cables and lever must not jam!
m
WARNUNG
Risk of life threatening injuries caused by propeller!
With carburetor actuation not connected, the throttle valve is fully open. The initial position of the CD carburetor is full throttle! So never start the engine with the actuation disconnected.
Procedure
3
4
1
2
U
To test the carburetor actuation the following steps are necessary:
5
Step Procedure
Inspect bowden cables and levers for free movement.
Bowden cable must allow full travel of lever from stop to stop.
Adjust throttle cables to a clearance of 1mm (0.04 in).
Inspect and lubricate linkage on carburetor and carburetor joints with engine oil.
Inspect return springs (3) and inspect engagement holes for wear.
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Graphic
BRP-Powertrain
MAINTENANCE MANUAL
Checking the carburetor actuation
~1 mm
1
Fig. 25
3
1
2
3
Part Function
Connection for throttle valve
Connection for choke actuation
Return springs
3
2
02480
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13.2) Oil change
Procedure
NOTES: Run engine to warm oil before beginning oil change procedure.
To change the oil the following steps are necessary:
Step
1
2
3
4
5
Procedure
Crank engine by hand to transfer the oil from the crankcase.
See chap. 12-10-00 section: 4.1).
Remove safety wire and oil drain screw from the oil tank, drain the used oil and dispose of as per environmental regulations.
Replace oil filter at each oil change and inspect the filter components.
See chap. 12-20-00 section: 13.5) .
After inspection dispose the oil filter components according to environmental regulations.
Fit drain screw (M12x12) with a new sealing ring and safety wire. Tightening torque 25 Nm (18.5 ft.lb).
NOTES: When installing the oil drain screw one has to lock the nut which is on the floor of the oil tank. This will prevent damage of the oil tank floor.
m
WARNUNG
Only use brand name oil in accordance with the latest
Operators Manual and SI-914-019, “Selection of suitable operating fluids“ latest issue.
m
WARNUNG
The engine must not be cranked when the oil system is open. Attention must also be paid to this before first commissioning (e.g. when assembling the propeller after correct venting of the oil system).
6
7
Step
8
Procedure
Pour in approx. 3l (0.8 gal (US)) of fresh oil.
After carrying out the oil change, the engine should be cranked by hand in the direction of engine rotation (approx. 20 turns) to completely refill the entire oil circuit.
Compressed air must not be used to blow through the oil system (or oil lines, oil pump housing, oil bores in the housing).
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13.3) Oil filter replacement
General note
m
WARNUNG
Risk of Burns!
Hot engine parts!
Always allow engine to cool down to ambient temperature before start of any work.
m
WARNUNG
To ensure correct functioning of the oil circuit and the forced flow lubrication, use genuine ROTAX oil filter only. Only these filters will ensure correct pressure in the by-pass valve.
At every oil change, unscrew the oil filter and cut open using special tool taking care not to produce chips.
Special tool
Graphic
To carry out the procedure the following steps are necessary:
part number
part no. 877620* part no. 877670*
* or equivalent
Description
(1) Oil filter wrench
(2) Cutting tool
Special tool
2
1
877 620
Procedure
Fig. 27
Unscrew the oil filter.
1
Step Procedure
Unscrew the oil filter with the oil filter wrench.
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13.4) Install oil filter
General note
See Fig. 28 .
m
WARNUNG
After test run inspect tight fit of oil filter.
Procedure
Graphic
3
4
1
2
5
To mount the oil filter the following steps are necessary:
Step Procedure
Clean the contact surface (1) of the oil pump housing (2) with a clean cloth.
Apply thin film engine oil on the gasket (3) of the oil filter (4).
Install the oil filter on the engine.
Screw on oil filter until oil filter gasket is seated solidly.
Tighten oil filter with a 3/4 turn (270°).
Inspect all systems for correct function.
Install oil filter.
3
A
4
C
4
1
2
B
4
3
4
1
2
Part
Contact surface
Oil pump housing
Function
Gasket
Oil filter
Fig. 28
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13.5) Inspection of the filter components
General note
The filter components must be inspected carefully.
m
WARNUNG
This inspection is important as it allows conclusions to be drawn regarding the internal condition of the engine and provides information about the possible cause of any damage.
Procedure
3
4
1
2
5
8
9
6
7
To carry out the procedure the following steps are necessary:
Step Procedure
Cut oil filter open using special tool taking care not to produce chips.
Remove anti-drain membrane.
Cut top and bottom edges off the mat with a knife.
Remove filter mat, fold up and press remaining oil out.
Unroll and inspect it for metal chips, foreign matter, contamination and abrasion.
Pass over matt with a clean magnet and inspect for metal.
Inspect filter housing at the contact surfaces for increased wear.
Check both springs of oil filter for increased wear.
Check anti-drain membrane for damage in the area of filter contact.
Possible foreign matter
Possible foreign matter:
- Steel chips
- Bronze chips
- Aluminium chips
- Sliver of bearing material
- Remains of sealing compound
Increased foreign matter
If an increased amount of metal particles is found, such as brass- or bronze chips or sliver from bearing abrasion, repair or overhaul the engine in accordance with the BRP-Powertrain instructions for continued airworthiness. If the filter mat is clogged by foreign matter, the lube oil reaches the bearing points unfiltered via the by-pass valve in the oil filter.
Unclear findings
3
4
1
2
In the case of unclear findings:
Step Procedure
Flush the oil circuit.
Fit a new oil filter.
Engine test run. See chap. 12-20-00 section: 10) .
Inspect the oil filter once more.
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Contaminated
Graphic
BRP-Powertrain
MAINTENANCE MANUAL m
WARNUNG
If the oil circuit is contaminated, replace the oil cooler and flush the oil circuit. See chap. 12-20-00 section:
15) . Proper judgement requires years of experience in repair of piston engines.
Oil filter to bearings from oil pump
3
2
4
5
1
5
6
Fig. 29
4
Part
1
2
3
Function
Filter housing
Filter cover
Gasket ring
6
Part
4
5
6
Function
Anti-drain membrane
Filter mat
Springs
08427,00181,10228-10231
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13.6) Cleaning the oil tank
General note
See Fig. 30 .
NOTES: This procedure is optional and requires venting of the oil system. See chap. 12-20-00 section: 13.7) .
It is only necessary to clean the oil tank and the inner parts if there is heavy oil contamination.
Procedure
Procedure to clean the oil tank:
1
2
3
Step Procedure
Detach the profile clamp (2) and remove the oil tank cover (3) together with the O-ring (4) and the oil lines.
Remove the inner parts of the oil tank such as the baffle insert (5) and the partition (6).
Clean oil tank (8) and inner parts (5, 6) and check for damage.
m
WARNUNG
Incorrect assembly of the oil tank components can cause engine faults or engine damage.
5
6
4
Step Procedure
Fit drain screw (1) M12x12 with a new gasket ring. Tighten to 25 Nm
(18.5 ft.lb).
Safety wire.
Reassemble the oil tank by following the same steps in reverse order.
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14) Inspecting the magnetic plug
General note
See Fig. 31 .
NOTES: The magnetic plug is located on the crankcase between cylinder 2 and gearbox.
This inspection is important because it allows conclusions to be drawn on the internal condition of the gearbox and engine and reveals information about possible damage.
Procedure
Remove the magnetic plug and inspect it for accumulation of chips.
Steel chips in low numbers
Steel chips in low numbers as depicted in Fig. 31 can be tolerated if the accumulation is below 3 mm (0.125 in).
Steel chips in larger numbers
Unclear findings
If there are larger accumulations of metal chips on the magnetic plug, the engine must be repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.
3
4
1
2
5
6
In the case of unclear findings:
Step Procedure
Flush the oil circuit.
Fit a new oil filter.
Install magnetic plug.
Engine test run. See chap. 12-20-00 section: 10) .
Check magnetic plug once again.
Check oil filter once again.
Contamination
m
WARNUNG
If the oil circuit is contaminated, replace the oil cooler and flush the oil circuit.
See chap. 12-20-00 section: 15) . Detailed inspection of affected engine components.
Trace the cause and remedy.
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Graphic
BRP-Powertrain
MAINTENANCE MANUAL
Inspecting the magnetic plug.
magnetic plug acceptable not acceptable
Fig. 31
08565,08566,08564,08563
Install
14.1) Installation of the magnetic plug
1
2
3
The following steps are necessary:
Step Procedure
Clean the magnetic plug.
Refit the magnetic plug. Tightening torque 25 Nm (18.5 ft.lb).
Safety wire the plug.
Inspect all systems for correct function. Detailed inspection of affected engine components.
Effectivity: 914 Series
Edition 2 / Rev. 0
12-20-00 page 64
January 01/2010
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