advertisement
ref. no.: MMH-912 / MMH-914 | part no.: 899603
AIRCRAFT ENGINES
WARNING
Before starting any maintenance work, please read the Maintenance Manual completely as it contains important safety relevant information.
These technical data and the information embodied therein are the property of BRP-
Powertrain GmbH & Co KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior written permission of BRP-Powertrain GmbH & Co KG, be disclosed in whole or in part to third parties. This legend shall be included on any reproduction of these data, in whole or in part.
Copyright
201 7
© - all rights reserved.
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 purely for ease of identification and may be trademarks of the respective company or owner.
Approval of translation has been done to best knowledge and judgement - in any case the original text in German language is authoritative.
BRP-Rotax
Maintenance Manual
SECTION 00
INTRODUCTION
1) Table of contents
SECTION 00
INTRODUCTION
1) Table of contents .................................................................................... 00-00-00 / 3
2) List of chapters ....................................................................................... 00-00-00 / 5
3) Index ....................................................................................................... 00-00-00 / 7
4) List of the valid pages............................................................................. 00-00-00 / 11
5) Table of amendments ............................................................................. 00-00-00 / 19
6) General note .......................................................................................... 00-00-00 / 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) Classification of parts for maintenance/repair ........................................ 00-00-00 / 29
9.1) Determination of actual wear [%] .................................................. 00-00-00 / 32
10) Maintenance ........................................................................................... 00-00-00 / 35
10.1) Trouble shooting ............................................................................ 00-00-00 / 35
10.2) Tightening torques ........................................................................ 00-00-00 / 35
10.3) Consumable materials................................................................... 00-00-00 / 36
10.4) Auxiliary tools ................................................................................ 00-00-00 / 39
10.5) Measuring tools ............................................................................. 00-00-00 / 41
10.6) Special tools and devices .............................................................. 00-00-00 / 42
Effectivity 912/914 Series
Edition 1 / Rev. 0
00-00-00 page 3
May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
00-00-00 page 4
May 01/2007
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 TURBOCHARGER .. 78
LUBRICATION SYSTEM .................................. 79
ELECTRIC STARTER ....................................... 80
Effectivity 912/914 Series
Edition 1 / Rev. 0
00-00-00 page 5
May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
00-00-00 page 6
May 01/2007
BRP-Powertrain
Maintenance Manual
3) Index
A
Airbox temperature 76-00-00 / 9
Alternators 74-00-00 / 3
Auxiliary tools 00-00-00 / 37
B
Boost pressure display 73-00-00 / 16
Bowden cable 78-00-00 / 19
C
Carburetor assembly 73-00-00 / 53
Carburetor disassembly 73-00-00 / 19
Carburetor heat systems 73-00-00 / 16
Carburetor individual components 73-00-00 /
23, 73-00-00 / 24
Carburetor socket assembly 73-00-00 / 53
Carburetor socket disassembly 73-00-00 /
17, 73-00-00 / 19
Carburetor synchronization 73-00-00 / 33
Caution lamps inspection 76-00-00 / 34
Charging coil 74-00-00 / 14
Choke 73-00-00 / 31
Classification of parts 00-00-00 / 29
Cleaning agents 00-00-00 / 38
Communication program 76-00-00 / 13
Components 71-00-00 / 5
Compressor pressure ratio 76-00-00 / 10
Constant depression carburetor 73-00-00 /
12, 73-00-00 / 21
Consumable materials 00-00-00 / 36
Coolant hoses fitting 75-00-00 / 14
Cooling air duct 75-00-00 / 14
Cut-in speed 74-00-00 / 18
Cyl. head assembly 72-00-00 / 73, 72-00-00
Cyl. head temperature sensor 75-00-00 / 15
Cylinder designation 71-00-00 / 5
Cylinder head disassembly 72-00-00 / 57
Cylinder head fitting 72-00-00 / 92
Cylinder head removal 72-00-00 / 55
Cylinders assembly 72-00-00 / 86
Cylinders inspection 72-00-00 / 81
Cylinders removal 72-00-00 / 75
D
Description of design 71-00-00 / 3
Diaphragms 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
Effectivity 912/914 Series
Edition 1 / Rev. 3
E
Electric starter 80-00-00 / 3
Electric starter installation 80-00-00 / 12
Electric starter dismantling 80-00-00 / 5
Electric starter inspection 80-00-00 / 9
Electric starter diassembly 80-00-00 / 11
Electronic module 74-00-00 / 14
Engine components 71-00-00 / 12
Engine views 71-00-00 / 5
Exhaust gas temperature display 78-00-00 / 5
Exhaust system assembly 78-00-00 / 15
Exhaust system inspection 78-00-00 / 11
Exhaust system disassembly 78-00-00 / 7
Exhaust turbocharger 78-00-00 / 3
F
Filter oil 00-00-00 / 36
Float bracket 73-00-00 / 28
Float housing 73-00-00 / 27
Float needle valve inspection 73-00-00 / 30
Floats 73-00-00 / 27
Fly wheel hub 72-00-00 / 9, 74-00-00 / 49
Fuel filter 73-00-00 / 7
Fuel handling 73-00-00 / 15
Fuel lines 73-00-00 / 40, 73-00-00 / 43
Fuel lines assembly 73-00-00 / 55, 73-00-00 / 58
Fuel lines disassembly 73-00-00 / 17, 73-00-00 /
19
Fuel pressure 73-00-00 / 35, 37
Fuel pressure regulator 73-00-00 / 44
Fuel pump 73-00-00 / 45, 73-00-00 / 47
G
Gear set inspection 72-00-00 / 44
Gearbox configurations 72-00-00 / 5
Gearbox parts inspection 72-00-00 / 39
Governor 72-00-00 / 7
Governor drive removal 72-00-00 / 33
H
Heat conduction compound 00-00-00 / 37
Hose clamps 75-00-00 / 14
Hourmeter 72-00-00 / 8
Hydraulic valve tappets 72-00-00 / 83
I
Idle speed adjustment 73-00-00 / 33
Ignition 74-00-00 / 3, 74-00-00 / 6
Ignition cables 74-00-00 / 9
Ignition check 74-00-00 / 21
Ignition circuits inspection 74-00-00 / 21
Ignition electric set reassembly 74-00-00 / 41
00-00-00 page 7
October 01/2010
Ignition electric set fitting 74-00-00 / 43
Ignition electric set removal 74-00-00 / 35
Ignition housing 72-00-00 / 14
Ignition housing inspection 72-00-00 / 11
Ignition housing removal 72-00-00 / 11
Ignition timing 74-00-00 / 19
Instruments 79-00-00 / 10
Intake air temperature sensor inspection 76-
00-00 / 42
Intake manifold fitting 73-00-00 / 60
Intermediate gear 72-00-00 / 20
L
List of valid pages 00-00-00 / 11
Lithiumbase grease 00-00-00 / 34
Loctite 00-00-00 / 36
Lubrication system purging 79-00-00 / 26
M
Magnetic plug 79-00-00 / 10
Main oil pump 79-00-00 / 3, 79-00-00 / 5
Measuring tools 00-00-00 / 39
Molycote 00-00-00 / 36
Multimeter 00-00-00 / 41
Multipurpose grease 00-00-00 / 35
O
Oil circuit 79-00-00 / 5
Oil cooler 79-00-00 / 25
Oil lines 79-00-00 / 25
Oil pressure sensor 79-00-00 / 27
Oil pump disassembly 79-00-00 / 14
Oil pump 79-00-00 / 11
Oil pump checking 79-00-00 / 15
Oil pump reassembly 79-00-00 / 18, 79-00-00
/ 19
Oil pump removal 79-00-00 / 11
Oil sump 79-00-00 / 21
Oil tank 79-00-00 / 22
Oil temperature display 79-00-00 / 10
Oil temperature sensor 79-00-00 / 26
Operating fluids 71-00-00 / 11
Operating limits 71-00-00 / 11
Orange caution lamp 76-00-00 / 11
Oscilloscope 00-00-00 / 41
Output connections on the TCU for lamps 76-
00-00 / 11
Overspeeding 76-00-00 / 8
Effectivity 912/914 Series
Edition 1 / Rev. 3
BRP-Powertrain
Maintenance Manual
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
Position finding 78-00-00 / 20
Preservation 71-00-00 / 18, 71-00-00 / 19
Preservation oil 00-00-00 / 37
Pressure connecting lines 73-00-00 / 10, 73-00-00 /
49
Pressure measurement system 71-00-00 / 22, 79-
00-00 / 26
Pressure sensors inspection 76-00-00 / 44
Propeller gearbox 72-00-00 / 5, 72-00-00 / 22, 80-
00-00 / 3
Propeller gearbox diassembly 72-00-00 / 28
Propeller gearbox reassembly 72-00-00 / 49
Propeller gearbox installation 72-00-00 / 53
Propeller shaft removal 72-00-00 / 30
Pushrods 72-00-00 / 85
R
Red boost lamp 76-00-00 / 11
Return to service 71-00-00 / 18
Rev counter inspection 74-00-00 / 55
Rev counter drive 72-00-00 / 21
Rev counter, mechanical 72-00-00 / 8
Roller bearings for F2 removal 72-00-00 / 24
Roller bearings for F3 removal 72-00-00 / 26
Roller bearings for F4 removal 72-00-00 / 27
Rotary seal 75-00-00 / 10
S
Servo motor 78-00-00 / 20
Silastic 00-00-00 / 36
Special tools 00-00-00 / 40
Sprag clutch 72-00-00 / 15
Sprag clutch dismantling 72-00-00 / 17
Sprag clutch installation 72-00-00 / 18
Sprag clutch removal 72-00-00 / 16
Spring, wastegate 78-00-00 / 19
Starting carburetor 73-00-00 / 31
Stator removal and refitting 74-00-00 / 48
Stroboscope 00-00-00 / 41
Suction pump 79-00-00 / 8
Surface damage 71-00-00 / 15
Return to service 00-00-00 / 25, 71-00-00 / 17, 71-
00-00 / 18
Rev counter inspection 74-00-00 / 53
Rev counter drive 72-00-00 / 21
Rev counter, mechanical 72-00-00 / 8
00-00-00 page 8
October 01/2010
BRP-Powertrain
Maintenance Manual
T
Table of amendments 00-00-00 / 19
Target pressure reduction 76-00-00 / 8
TCU inspection 76-00-00 / 32
Technical data 71-00-00 / 11, 71-00-00 / 15
Temperature measuring system 71-00-00 / 22, 75-
00-00 / 15, 79-00-00 / 26
Three-way solenoid valve 76-00-00 / 53
Throttle potentiometer calibration 76-00-00 / 31
Throttle potentiometer inspection 76-00-00 / 37
Tightening torques 00-00-00 / 35
Trigger 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 78-00-00 / 11
Turbo control unit 76-00-00 / 32
Type description 71-00-00 / 4
V
Vacuum pump 72-00-00 / 7, 72-00-00 / 10
Vacuum pump drive removal 72-00-00 / 32
Valve guide 72-00-00 / 62
Valve lapping paste 00-00-00 / 36
Valve seats 72-00-00 / 63
Valves 72-00-00 / 64
W
Water pump removal 75-00-00 / 6
Water pump housing 75-00-00 / 7, 75-00-00 / 13
Water pump housing inspection 75-00-00 / 7
Water pump shaft 75-00-00 / 9
Weights 71-00-00 / 11, 71-00-00 / 12
Wiring diagrams 74-00-00 / 24
Wiring harness inspection 76-00-00 / 35
Effectivity 912/914 Series
Edition 1 / Rev. 3
00-00-00 page 9
October 01/2010
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
00-00-00 page 10
May 01/2007
BRP-Rotax
Maintenance Manual
4) List of the valid pages
00-00-00
Cover page
1 05 01 2007
2 05 01 2007
3 05 01 2007
4 05 01 2007
5 05 01 2007
6 05 01 2007
7 10 01 2010
8 10 01 2010
9 10 01 2010
10 05 01 2007
11 07 01 2018
12 07 01 2018
13 07 01 2018
14 07 01 2018
15 07 01 2018
16 07 01 2018
17 05 01 2007
18 05 01 2007
19 03 01 2017
20 07 01 2018
21 07 01 2018
22 07 01 2018
23 10 01 2010
24 10 01 2010
25 10 01 2010
26 10 01 2010
27 10 01 2010
28 10 01 2010
29 10 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 02 01 2015
37 02 01 2015
38 03 01 2017
39 10 01 2010
40 10 01 2010
41 10 01 2010
42 03 01 2017
71-00-00
72-00-00
Effectivity 912/914 Series
Edition 1 / Rev. 6
18 10 01 2010
19 05 01 2007
20 10 01 2010
21 05 01 2007
22 05 01 2007
1 10 01 2010
2 07 01 2008
3 07 01 2008
4 05 01 2007
5 05 01 2007
6 07 01 2018
7 05 01 2007
8 02 01 2015
9 10 01 2010
10 10 01 2010
11 05 01 2007
12 10 01 2010
13 05 01 2007
14 10 01 2010
15 05 01 2007
43 03 01 2017
44 03 01 2017
45 03 01 2017
46 03 01 2017
47 03 01 2017
48 03 01 2017
1 05 01 2007
2 05 01 2007
3 05 01 2007
4 05 01 2007
5 05 01 2007
6 05 01 2007
7 05 01 2007
8 05 01 2007
9 05 01 2007
10 05 01 2007
11 05 01 2007
12 03 01 2017
13 03 01 2017
14 10 01 2010
15 05 01 2007
16 05 01 2007
17 02 01 2015
00-00-00 page 11
July 01/2018
BRP-Rotax
Maintenance Manual
Effectivity 912/914 Series
Edition 1 / Rev. 6
16 07 01 2008
17 05 01 2007
18 02 01 2015
19 02 01 2015
20 02 01 2015
21 05 01 2007
22 02 01 2015
23 01 01 2008
24 10 01 2010
24A 10 01 2010
24B 10 01 2010
25 10 01 2010
26 10 01 2010
27 10 01 2010
28 07 01 2018
29 07 01 2018
30 10 01 2010
31 05 01 2007
32 10 01 2010
33 10 01 2010
34 10 01 2010
35 07 01 2018
36 03 01 2017
37 05 01 2007
38 07 01 2018
39 07 01 2018
40 10 01 2010
41 05 01 2007
42 07 01 2018
43 05 01 2007
44 07 01 2008
45 07 01 2008
46 07 01 2008
47 05 01 2007
48 05 01 2007
49 07 01 2018
50 07 01 2018
51 07 01 2018
52 02 01 2015
53 02 01 2015
54 10 01 2010
55 10 01 2010
56 05 01 2007
57 07 01 2008
58 07 01 2018
59 10 01 2010
60 05 01 2007
61 07 01 2008
62 05 01 2007
63 10 01 2010
64 05 01 2007
65 05 01 2007
66 01 01 2008
67 02 01 2015
68 02 01 2015
69 02 01 2015
70 05 01 2007
71 05 01 2007
72 05 01 2007
73 05 01 2007
74 05 01 2007
75 05 01 2007
76 05 01 2007
77 05 01 2007
78 05 01 2007
79 07 01 2008
80 10 01 2010
81 02 01 2015
82 02 01 2015
83 03 01 2017
84 10 01 2010
85 05 01 2007
86 10 01 2010
87 05 01 2007
88 10 01 2010
89 05 01 2007
90 07 01 2008
91 05 01 2007
92 02 01 2015
93 02 01 2015
94 05 01 2007
95 07 01 2008
96 05 01 2007
97 02 01 2015
98 10 01 2010
99 05 01 2007
00-00-00 page 12
July 01/2018
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Maintenance Manual
73-00-00
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Edition 1 / Rev. 6
100 05 01 2007
101 02 01 2015
102 07 01 2008
103 02 01 2015
104 05 01 2007
105 05 01 2007
106 10 01 2010
107 03 01 2017
108 10 01 2010
109 05 01 2007
110 05 01 2007
111 02 01 2015
112 07 01 2018
113 05 01 2007
114 02 01 2015
115 02 01 2015
116 05 01 2007
117 02 01 2015
118 05 01 2007
1 10 01 2010
2 07 01 2008
3 05 01 2007
4 05 01 2007
5 05 01 2007
6 10 01 2010
7 10 01 2010
8 05 01 2007
9 05 01 2007
10 05 01 2007
11 05 01 2007
12 05 01 2007
13 05 01 2007
14 05 01 2007
15 10 01 2010
16 10 01 2010
17 02 01 2015
18 10 01 2010
19 03 01 2017
20 03 01 2017
21 07 01 2008
22 02 01 2015
23 02 01 2015
24 10 01 2010
46 03 01 2017
47 07 01 2008
48 07 01 2008
49 07 01 2008
50 07 01 2008
51 02 01 2015
52 02 01 2015
53 07 01 2008
54 10 01 2010
55 07 01 2008
56 07 01 2008
57 07 01 2008
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59 07 01 2008
60 03 01 2017
61 03 01 2017
62 02 01 2015
63 02 01 2015
64 07 01 2008
65 07 01 2008
66 02 01 2015
25 07 01 2008
26 07 01 2008
27 02 01 2015
28 07 01 2008
29 10 01 2010
30 02 01 2015
31 02 01 2015
32 07 01 2008
33 07 01 2008
34 07 01 2008
35 07 01 2008
36 07 01 2008
37 07 01 2008
38 02 01 2015
39 07 01 2008
40 07 01 2008
41 07 01 2008
42 07 01 2008
43 02 01 2015
44 02 01 2015
45 02 01 2015
00-00-00 page 13
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Maintenance Manual
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Edition 1 / Rev. 5
1 10 01 2010
2 07 01 2008
3 03 01 2017
4 05 01 2007
5 05 01 2007
6 03 01 2017
7 05 01 2007
8 05 01 2007
9 05 01 2007
10 05 01 2007
11 05 01 2007
12 02 01 2015
13 05 01 2007
14 05 01 2007
15 05 01 2007
16 07 01 2008
17 10 01 2010
18 07 01 2008
19 05 01 2007
20 05 01 2007
21 05 01 2007
22 02 01 2015
23 05 01 2007
24 05 01 2007
25 10 01 2010
26 05 01 2007
27 10 01 2010
28 03 01 2017
29 03 01 2017
30 03 01 2017
31 10 01 2010
32 03 01 2017
33 03 01 2017
34 05 01 2007
35 05 01 2007
36 05 01 2007
37 05 01 2007
38 05 01 2007
39 05 01 2007
40 02 01 2015
41 02 01 2015
42 02 01 2015
75-00-00
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1 07 01 2008
2 05 01 2007
3 05 01 2007
4 02 01 2015
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6 05 01 2007
7 05 01 2007
8 05 01 2007
9 05 01 2007
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11 07 01 2008
12 05 01 2007
13 05 01 2007
14 10 01 2010
15 10 01 2010
16 10 01 2010
17 02 01 2015
18 02 01 2015
19 05 01 2007
20 05 01 2007
43 05 01 2007
44 02 01 2015
45 05 01 2007
46 02 01 2015
47 02 01 2015
48 05 01 2007
49 02 01 2015
50 07 01 2008
51 02 01 2015
52 05 01 2007
53 05 01 2007
54 02 01 2015
55 02 01 2015
56 03 01 2017
57 07 01 2008
58 07 01 2008
59 07 01 2008
60 07 01 2008
61 03 01 2017
62 03 01 2017
63 02 01 2015
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BRP-Rotax
Maintenance Manual
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Edition 1 / Rev. 5
1 05 01 2007
2 07 01 2008
3 05 01 2007
4 05 01 2007
5 05 01 2007
6 05 01 2007
7 05 01 2007
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37 05 01 2007
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40 05 01 2007
41 05 01 2007
42 02 01 2015
43 05 01 2007
78-00-00
79-00-00
4 10 01 2010
5 10 01 2010
6 05 01 2007
7 05 01 2007
8 05 01 2007
9 05 01 2007
10 02 01 2015
11 02 01 2015
12 07 01 2008
13 07 01 2008
14 07 01 2008
15 07 01 2008
16 07 01 2008
17 07 01 2008
18 07 01 2008
19 10 01 2010
20 02 01 2015
21 07 01 2008
22 07 01 2008
23 02 01 2015
24 07 01 2008
1 02 01 2015
2 05 01 2007
44 05 01 2007
45 05 01 2007
46 05 01 2007
47 03 01 2017
48 05 01 2007
49 03 01 2017
50 05 01 2007
51 05 01 2007
52 05 01 2007
53 07 01 2008
54 07 01 2008
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58 07 01 2008
59 03 01 2017
60 07 01 2008
1 10 01 2010
2 05 01 2007
3 02 01 2015
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March 01/2017
BRP-Rotax
Maintenance Manual
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Effectivity 912/914 Series
Edition 1 / Rev. 5
3 05 01 2007
4 05 01 2007
5 05 01 2007
6 10 01 2010
7 05 01 2007
8 10 01 2010
9 02 01 2015
10 10 01 2010
11 02 01 2015
12 02 01 2015
13 02 01 2015
14 02 01 2015
15 05 01 2007
16 05 01 2007
17 05 01 2007
18 02 01 2015
19 02 01 2015
20 02 01 2015
21 10 01 2010
22 05 01 2007
23 05 01 2007
24 05 01 2007
25 05 01 2007
26 02 01 2015
27 02 01 2015
28 02 01 2015
29 02 01 2015
30 02 01 2015
31 02 01 2015
32 02 01 2015
1 07 01 2008
2 05 01 2007
3 05 01 2007
4 05 01 2007
5 02 01 2015
6 02 01 2015
7 05 01 2007
8 05 01 2007
9 05 01 2007
10 05 01 2007
11 10 01 2010
12 02 01 2015
13 03 01 2017
14 03 01 2017
Rear page
00-00-00 page 16
March 01/2017
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
00-00-00 page 17
May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
00-00-00 page 18
May 01/2007
BRP-Rotax
Maintenance Manual
5) Table of amendments
*Approval
The technical content of this document is approved under the authority of
DOA Nr. EASA.21J.048.
08215
0 00-00-00
0 71-00-00
0 72-00-00
0 73-00-00
0 74-00-00 all all all all all
05 01 2007
05 01 2007
05 01 2007
05 01 2007
05 01 2007
0 75-00-00
0 76-00-00
0 78-00-00 all all all
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05 01 2007
05 01 2007
0 79-00-00
0 80-00-00 all all
05 01 2007
05 01 2007
1 00-00-00 11-13, 15,19, 34-36 01 01 2008
1 72-00-00 22, 23, 28,
51-54, 66
01 01 2008
01 01 2008
1 73-00-00 1, 2, 17, 18, 25, 26, 01 01 2008
53, 54, 55, 58 01 01 2008
1 76-00-00 39 01 01 2008
2 00-00-00 7-9,11-16, 19,33 07 01 2008
2 72-00-00 2, 3,8,16, 24-27,35 07 01 2008
38, 40,44-46, 07 01 2008
49-53, 57, 58, 61, 07 01 2008
79, 83,90,95,102 07 01 2008
2 73-00-00
111,114,115
1,2,16-60
07 01 2008
07 01 2008
2 74-00-00 2, 16,46, 47, 49, 07 01 2008
50, 57-60,62 07 01 2008
2 75-00-00 1,11,14,15,17,18 07 01 2008
2 76-00-00 2,35,36,53-60
2 78-00-00 1,11-24
2 79-00-00
2 80-00-00
18,19,27
1,13,14
07 01 2008
07 01 2008
07 01 2008
07 01 2008
3 00-00-00 7-9, 11-16,19-48 10 01 2010
3 71-00-00 12-14,18, 20 10 01 2010
3 72-00-00 1,8-10,14,18-19,22 10 01 2010
34-30,33-34,42,52-
55,59,63,69,81,83-
84,86,92-93,98,106
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BRP-Rotax
Maintenance Manual
3 73-00-00 1,6-7,15-19,23,27, 10 01 2010
29-30,45-46,51,54
3 74-00-00 6,25,27,29,31,33,62 10 01 2010
3 75-00-00
3 76-00-00
1,14-18
59
10 01 2010
10 01 2010
3 78-00-00 1,3-5,19,23 10 01 2010
3 79-00-00 6,8,10,19-21,27 10 01 2010
3 80-00-00 11,14 10 01 2010
4 00-00-00 11-16,20-21,36-38 10 01 2010
43
4 71-00-00 13,17 10 01 2010
4 72-00-00 8,18-22,36,38,49,50 10 01 2010
53,67-69,81,82,92,
93,97,101,103,107,
111,114,115,117
4 73-00-00 17,22,23,27,30,31, 10 01 2010
38,43-63,66
4 74-00-00 3,6,12,22,29,33, 10 01 2010
4 75-00-00
40-42,44,46,47,49
51,54,55,61-63
4,17,18 10 01 2010
4 76-00-00 42,59
4 78-00-00 3,10,11,20,23
10 01 2010
10 01 2010
4 79-00-00 1,9,11-14,18-20, 10 01 2010
26-32
4 80-00-00 5,6,12-14 10 01 2010
5 00-00-00 11-16,19,20,21,38, 03 01 2017
42-48
5 71-00-00 13, 14 03 01 2017
5 72-00-00 35,36,49,50,51,
83,107
03 01 2017
5 73-00-00 19, 20,46,60,61 03 01 2017
5 74-00-00 3,6,28-30,32,33,56, 03 01 2017
61,62
5 76-00-00
5 80-00-00
47,49,59
13,14
03 01 2017
03 01 2017
Effectivity 912/914 Series
Edition 1 / Rev. 6
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Maintenance Manual
6 00-00-00 11-16, 20-22 07 01 2018
6 72-00-00 6, 28,29,35,38,39,42,
DOA*
49-51,58,112 07 01 2018 DOA*
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Edition 1 / Rev. 6
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BRP-Rotax
Maintenance Manual
5.1) Summary of amendments
Summary of the relevant amendments in this context, but without requirement on completness.
4 00-00-00 11-16,20,21,36-38, 02 01 2015 effective pages selected, consumable materials
43 changed/deleted/added.
4 71-00-00 13,17 02 01 2015 information about the ignition timing changed.
4 72-00-00 8,18-20,22,36,38, 02 01 2015 correction of text, LOCTITE from 221 to 603
49,50,53,67-69,81,
82,92,93,97,101,
changed, Dowel pin from 8x20 to 6x20 changed,
Reference to inspection tool changed, Fig 72-75
103,107,111,114
115,117
changed, NOTICE at cylinder head fitting,
Change of tightening angle from 180° to 120°,
38,43-63,66
piston/cylinder/intermediate gear of electric starter
/sprag clutch: wear limits changed.
4 73-00-00 17,22,23,27,30,31, 02 01 2015 information to Fig 73-15/2, float brackets-spacing:
change of text, Fig73-28 changed, fuel pump
(912+914): change of text+graphics, NOTICE+
+NOTES added.
4 74-00-00 3,6,12,22,29,33,40- 02 01 2015 Fig 74-1+20+22+25+28+29+33 changed, wording
42,44,46,47,51,54,
55, 61-63
from “resistance spark plug..” to “spark plug..“
changed, wear limits+form sheet changed.
4 75-00-00
4 76-00-00
4,17,18
42,59
02 01 2015 cylinder head temperature sensor: additional text.
02 01 2015 form sheets changed.
4 78-00-00 3,10,11,20,23
26-32
02 01 2015 exhaust system (912): change of text, Fig 78-3+
13 changed, wear limit (TC03) corrected.
4 79-00-00 1,9,11-14,18-20 02 01 2015 LOC.515 changed to LOC.5910, tightening torque
at oil pump cover changed (from 133 to 90 in.lb
-oiled thread), Fig 79-19 changed.
4 80-00-00 5,6,12- 14 02 01 2015 graphic+wear limits changed.
5 00-00-00 11-16,38,42-48 03 01 2017 changed text and CAUTION to MICRONORM,
effektive pages selected, tool changed
5 71-00-00 13,14
5 72-00-00 35,36,49,51,83
03 01 2017 correction of text
03 01 2017 correction of text
5 73-00-00 20,60-62 03 01 2017 correction of text and graphics
5 74-00-00 5,29,31,33,56,61 03 01 2017 change of text and graphics
5 76-00-00
5 80-00-00
47,49,59
13,14
03 01 2017 change of text and form sheet
03 01 2017 change of text and graphics
6 00-00-00 11-13,20-22
6 72-00-00 6,39,49,50,112
07 01 2018 change of text
07 01 2018 new gear cover assy. with oil spray nozzle
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Edition 1 / Rev. 6
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BRP-Powertrain
Maintenance Manual
6) General note
We are pleased you decided to purchase a ROTAX aircraft engine.
This section describes the maintenance of all engines in the 912/914 Series.
◆ NOTE: The 912/914 Series includes 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 (Heavy Maintenance) carefully. See also the latest revision of the corresponding
Maintenance Manual (Line Maintenance) for the respective engine type 912 Series or
914 Series.
If any passages of this Manual are not clearly understood or if you have any questions, please contact an authorized distributor or Service Center for ROTAX aircraft engines.
Effectivity 912/914 Series
Edition 1 / Rev. 3
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Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
00-00-00 page 24
May 01/2007
BRP-Powertrain
Maintenance Manual
7) Safety notice
Although the mere reading of such information does not eliminate the hazard, your understanding and application of the information will promote correct use.
The information and components/system descriptions contained in this Maintenance
Manual are correct at the time of publication. BRP-Rotax maintains a policy of continuous improvement of its products, without, however, incurring any obligation to install them on its products previously manufactured.
BRP-Rotax reserves the right to discontinue or alter any specification, design, detail, model or equipment, at any time and without incurring obligation.
The illustrations in this Maintenance Manual show the typical construction. They may not correspond to every detail or the exact shape of the actual parts, but show parts which 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 particular information.
These indications are important and must be respected.
▲ WARNING: identifies an instruction which, if not followed, may cause serious injury including the possibility of death.
■ CAUTION: Denotes an instruction which, if not followed, may severely damage the engine or other component.
◆ NOTE: Indicates supplementary information which may be needed to fully complete or understand an instruction.
A revision bar outside of the page margin indicates a change to text or graphic.
XXX
4
VT06
In various illustrations, this symbol indicates the location of the serial number on a component.
In the illustrations concerned, this symbol indicates the position of the serial component number (e.g. on crankshafts, camshafts).
In the illustrations concerned, a fourdigit combination of letters and numbers indicates a control point which needs to be checked. See the corresponding dimension sheets for the correct value.
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Edition 1 / Rev. 3
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Maintenance Manual
NOTES
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Edition 1 / Rev. 3
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Maintenance Manual
8) Technical documentation
See also the corresponding Maintenance Manual (Line Maintenance) for the respective engine type 912 Series or 914 Series.
8.1) Filling in the dimension sheets
See Fig. 00-1
All measurements must be entered in the corresponding dimension sheets as shown.
Fig. 00-1 shows the correct procedure for filling in the dimension sheets attached after each section.
■
CAUTION: If 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 parts for maintenance”.
Look up the desired control point code (1) in the illustration in the specified section.
Fig. 00-1
07538
The maximum limits for wear are divided into two columns, maximum wear
100% (2) and 50% wear (3).
Field (4) gives the maximum permissible values in [mm], field (5) in
[inches].
The respective actual value must be entered in the corresponding box (6) in [mm] or [inches].
The actual value for any part which has been replaced is entered in the corresponding field (7) in [mm] or [inches].
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Edition 1 / Rev. 3
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Maintenance Manual
Dimensional check of parts
See Fig. 00-2
Take readings of all parts listed in the dimension sheets.
Enter the respective actual value in the dimension sheets attached directly after each section.
■ CAUTION: Where measurement values 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).
Fig. 00-2
07437
8.2) List of abbreviations
The following table shows the abbreviations used for the control points.
Abbreviations for control points
Abbreviation Description
AL al ternator
CA
CC
CH
CR
CS
CY
EL
ES
EX
GB
GO
OP
PI
PP
ST
TC
VT
WP ca mshaft c rank c ase c ylinder c on r od c rank s haft cy linder el ectric h ead e lectric s tarter ex haust g ear b ox go o il p ump pi ston p iston p in st t urbo c harger v vernor ator alve t rain w ater p ump
08216
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9) Classification of parts for maintenance/repair
See Figs. 00-3 and 00-4.
As for an overhaul, parts for maintenance/repair must be classified. They are classified either as “parts usable” or as “parts to be replaced” .
The classification 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 of the respective parts.
– See Figs. 00-3 and 00-4 for the classification of such parts.
Proceed as follows:
– Determine wear as a percentage of the wear tolerance
(see the dimension sheets attached directly after each section for the wear limit
(100%) of the part in question).
– Determine the hours of operation for the part in question (see Log book etc.)
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Edition 1 / Rev. 3
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For engines of Series 912:
Fig . 00-3
08677
451
501
551
601
701
201
251
301
351
401 from
0
51
101
151
1301
1401
1501
1601
1701
801
901
1001
1101
1201
1801
1901
500
550
600
700
800
250
300
350
400
450 to
50
100
150
200
1400
1500
1600
1700
1800
900
1000
1100
1200
1300
1900
2000
TSN [h]
(Time Since New) max. permissible wear for repair [%] max. permissible wear for repair [%]
TBO 1500 - 912 Series
4
12
18
24
56
60
62
68
73
30
36
42
46
52
78
82
87
90
93
96
100
TBO 2000 - 912 Series
4
12
18
24
56
60
62
67
72
30
36
42
46
52
92
94
96
98
98
76
80
83
87
90
99
100
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For engines of Series 914:
Fig . 00-4
08679
1201
1301
1401
1501
1601
1701
1801
1901
501
551
601
701
801
901
1001
1101 from
0
51
101
151
201
251
301
351
401
451
1300
1400
1500
1600
1700
1800
1900
2000
550
600
700
800
900
1000
1100
1200 to
50
100
150
200
250
300
350
400
450
500
TSN [h]
(Time Since New) max. permissible wear for repair [%] max. permissible wear for repair [%]
TBO 1200 - 914 Series
68
72
76
82
50
54
60
64
87
91
95
100
6
14
24
30
36
44
TBO 2000 - 914 Series
60
62
67
72
76
80
83
87
90
92
94
96
98
98
99
100
4
12
18
24
30
36
42
46
52
56
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9.1) Determination of actual wear [%]
See Figs. 00-5, 00-6 and 00-7.
Determine actual dimension F of the part in question.
For new dimension (max) B and wear limit C, see the corresponding section´Wear limits“ (e. g. 74-00-00 sec. 4).
Fig. 00-5
08217
Fig. 00-6
07531
A
D
B
F
E
C
The actual wear in [%] is determined with the following formula:
Legend:
A New dimension (min)
B New dimension (max)
C Wear limit
D New dimension tolerance
E Wear tolerance
F Actual dimension
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■ CAUTION: New dimension (max) B is always the dimension which is closest to wear limit C .
Fig. 00-7
08219
Procedure for classification of “On Condition Parts” at maintenance/ repair:
◆ NOTE: A negative result means that the actual dimension new dimension tolerance D .
F is within the
Example for engines of Series 914:
Hours of operation indicated 300 h.
The determined percentage of maximum permissible wear calculated is 46.6 % .
New dimension (max) B = 28.03 mm (1.1035 in.)
Wear limit C = 28.10 mm (1.1062 in.)
Actual dimension
Actual wear
F = 28.07 mm (1.1051 in.)
57.1 %
▲ WARNING: The part must be replaced (i.e. this part is excessively worn for only 300 hours of operation).
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NOTES
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Edition 1 / Rev. 3
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Maintenance Manual
10) Maintenance
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see corresponding
Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or
914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.
Some overlapping maintenance instructions are treated as generally valid information 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 remedial action.
See the respective sections in the Operators Manual for the corresponding engine type in the 912/914 Series.
10.2) Tightening torques
In general, all screw connections on ROTAX engines must be tightened using a torque wrench.
If not specified otherwise for a component, tighten screw connections to the following torque:
M4 : 4 Nm (35 in.lb)
M5 : 6 Nm (55 in.lb)
M6 : 10 Nm (90 in.lb)
M8 : 24 Nm (17.7 ft.lb)
M10 : 35 Nm (25.8 ft.lb)
■ CAUTION: If not specified otherwise, the threads are not lubricated when fastened.
◆ NOTE: Adhere to the tightening torques specified see also indications in the Illustrated Parts Catalog.
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10.3) Consumable materials
▲ WARNING: Use only the specified or technically equivalent materials for all maintenance work.
The materials listed have undergone longterm testing and are suitable for all operating conditions indicated by the manufacturer.
▲ WARNING: When handling chemicals, comply with all the customary regulations and specifications of the producer, including the expiry date.
◆
NOTE: Consider the curing time of the sealing surface compound as stated by the manufacturers’ instructions.
No. part no.
description, application ................................................ Qty.
1 897651 LOCTITE 243 blue, medium duty screw locking agent ................................. 10 ml
2 899789 LOCTITE 603 green, oil tolerant retaining compound, heavy-duty ................. 10 ml
3 297434 LOCTITE Anti-Seize 8151, for the prevention of fretting corrosion ............................ 50 g
4 297433 MOLYKOTE G-N, lubricant ....................................................................... 100 g
5 897330 Lithium-base grease, to avoid leakage current ............................................... 250 g
6 897870 Filter oil, for optimum filter efficiency and moisture protection
................................................................................... 14.8 ml
7 297368 SILASTIC 732 multipurpose onecomponent siliconbased sealing compound ....................................................... 310 ml
8 899788 LOCTITE 648 green, high temperature screw locking agent ............................ 5 ml
9 898351 KLUEBER Isoflex Topas 5910
Long-term grease ......................................................... 0.5 kg
10 899791 LOCTITE 5910 flange sealant provides flexibility and adhesion ........... 50 ml
11 n.a.
LOCTITE 7063 for degreasing and cleaning surfaces.................as required
12 897186 SILICONE HEAT CONDUCTION COMPOUND .........
150 g
Application of the heat conduction compound will reduce heat transfer resistance. The greaselike, temperature-
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13
14
15 n.a.
n.a.
n.a.
resistant silicon compound fills cavities between components and cooling elements (e.g: spark plug - cylinder head), which otherwise do not contribute to heat conduction.
Multipurpose grease LZ
Generally usable, neutrally colored multipurpose grease, water resistant and highly adherent. Usable for temperatures from -35 °C to +120 °C (-31 °F to 248 °F) and can be subjected to high mechanical loads.
Preservation oil
This special oil has excellent penetrating capabilities and reaches even tiny gaps, it’s highly effective additives protect against corrosion of metal surfaces.
Flexible web for surface finishing 3M Scotch-Brite Multi .
Flex - very fine or ultra fine
Is sold by the meter and used for manual removal of smaller rust spots or oxidation, especially for optimum ground connections. It is particularly suitable for removing
LOCTITE from surfaces or threads to make them metallic clean. Before re-applying LOCTITE, clean surfaces with nitrothinner or degreasing agent (CASTROL ZA 30 or OMV
- SOFT SOL). When using solvents, observe the safety regulations for persons and the environment.
16 n.a.
MS4 / DC4 Dow Corning # 4
Electrical insulating compound for protection of electrical connections.
17 898570 Locking paint seals screws ................................................................. 20 ml
18 n.a.
Cleaning agent
▲ WARNING: Use only approved cleaning agents (e.g. varsol, etc.) for cleaning metal parts.
Do not use lyebased cold cleaners or degreasing agents. Do not clean coolant and oil hoses with aggressive solutions.
Clean off residues of sealing compound with sealant remover.
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Edition 1 / Rev. 4
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Maintenance Manual
Soak combustion chamber, piston and cylinder head with cleaning agent and remove combustion residues with a bronze brush. CASTROL “Clenvex 2000” has proved very effective. It is a solvent - cold cleaner, free of halogen, on the basis of selected fuel fractions and is biodegradable.
Never use caustic or corrosive cleaning agents.
19 n.a.
Valve lapping paste
This paste, produced by various manufacturers, is a fine granulate lapping paste for manual lapping of valve seats and valves. The paste is usually available in 3 different granulate sizes. Use as per manufacturer’s instructions.
Compressed air blasting using a solid blasting agent 20 n.a.
This abrasive is suitable for local and gradual very fine treatment of steel parts with rust film (propeller shaft). The
Compressed air blasting contains no harmful substances, is approved by the competent authorities and guarantees optimum cleaning. The granulates used are of sizes 40 to 60
µ . The achievable surface roughness is between 0.5 and 1
µ, which corresponds to ultrafine machining of surfaces.
■ CAUTION: Exhaust valves and intake valves may NOT undergo a compressed air plasting treatment with solid blasting, strong abrasive material. Due to this surface treatment one does gain a microscopic surface grass which does allow as a consequence the adhesion of fuel residues. These deposits are then involved in a chemical reaction (especially of the sulfur and lead content of AVGAS) with the valve material.
This effect may cause hot-gas corrosion on the affected parts.
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10.4) Auxiliary tools
– compression tester or 2 pressure gauges with calibrated orifice, adapter for dial gauge in spark plug thread
– valve spring mounting pliers
– step punch for valve guide
– adjustable reamer 6.5 to 7.5 mm (0.256 to 0.295 in.)
– valve seat machining device, valve lapping paste,
– gearbox support plate
– stud extraction tool
– scraper, very fine emery cloth, grinding tool, cover sheet, adhesive tape
– cleaning agent, approved cleaners, funnel, graphite marker.
– magnetic particle tester DEUTROFLUX, series UHW, or equivalent.
See 72-00-00 sec. 5.1.1.
These testers are suitable for complete combined magnetic particle crack inspection of all ferromagnetic materials. For this purpose an A.C. field circulation can be combined with a shifted phase A.C. circulation . The two magnetizing methods are independent from each other and can be applied separately.
To achieve the direction changes of the magnetic field vector necessary for indication of cracks in any direction, the alternating currents serving as the current supply for the different methods of magnetizing are dephased by
120° to each other: a) current circulation for indication of longitudinal cracks b) field circulation for indication of transverse cracks c) auxiliary circulation for indication of axial and radial cracks on parts with bores right through by using an electric auxiliary conductor (copper bar).
Measure tangential field intensity with field intensity tester Deutrometer 3870 or with an equivalent field intensity tester. The target value is 10 - 50 A/cm.
If cracks are detected then the affected part must be replaced. Clean and demagnetize the part. The maximum remaining magnetism must not exceed
1.2 A/cm.
The inner bore of the propeller shaft is excluded from magnetic particle crack inspection.
■ CAUTION: Observe the manufacturers instructions.
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Disassembly 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 not binding.
Fig. 00-8
(0.2 in.)
07525
(3.15 in.)
(1.89 in.)
(1 in.)
(8.27 in.)
(0.31 in.)
(0.2 in.)
(3.94 in.)
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10.5) Measuring tools
Calliper rule, dial gauge indicator, micrometer, inner micrometer, inner fine measuring device, feeler gauge, spring scale up to 50 kp (500 N)(112.5 lbf).
Stroboscope:
Multimeter:
BOSCH 0 684 100 308 or equivalent. Supply voltage 8 to 15
V. Flash triggering via inductive clampon pickup. Flashing frequency 4500 rpm.
FLUKE series 70, series 80 or equivalent.
Electronic, 3 1/2 digit indication.
Current range 10 A.
Direct voltage range 200 V minimum.
Resistance range 200 Ω to 2 M Ω
Acoustic continuity tester.
Oscilloscope: TEKTRONIX 2225 or equivalent
2 channels
Analog
Sensitivity 5 mV to 5V/div
Frequency limit 50 MHz
■ CAUTION: When using these instruments, observe the manufacturer’s instructions.
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10.6) Special tools and devices
See Figs. 00-9, 00-10 and 00-11.
The following tools and devices are also listed in the Illustrated Parts Catalog.
Fig. No. Part No. Description, application Number
4
5
2
3
1 - 4 877615 Extractor assy. ....................................................... 1 for roller bearing, oil seal
877580
276155
Pull-in spindle M24x1.5 ......................................... 1
Bolt 12x250 ........................................................... 1
6
842585 Hex. screw M24x1.5 - 19 MM ................................. 1
877605 Press-out mushroom .............................................. 1 for propeller shaft F2
877600 Press-out mushroom .............................................. 1 for propeller shaft F3
7
8
9
10
877594 Press-in jig ............................................................. 1 for roller bearing 25x52x15 and oil seal 30x52x7, for F2
877590 Press-in mushroom. ............................................... 1 for roller bearing 25x52x15 and oil inlet flange, for F3
941180 Stud M10x45/20 .................................................... 1 for roller bearing 25x52x15 and oil seal 30x52x7
877561 Pull-out plate ......................................................... 1 for roller bearing 25x52x15, oil seal 30x52x7 and oil inlet cover
11
12
13
14
242091 Hex. Nut M10 ......................................................... 1
240880 extracting nut M6 assy., ......................................... 1 for crankshaft locking screw M8x50
877660 Puller assy. ............................................................ 1 for gearbox
877540 Pushing jig assy. ................................................... 1 for gearbox
15 - 18 876489 Puller assy. ............................................................ 1 for ball bearing 15x32x8, oil inlet flange, oil inlet cover
19 877597 Press-in mushroom ................................................ 1 for needle bearing 22x28x12-vacuum pump
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Fig. No. Part No. Description, application
20
21
877595
Number
Press-in mushroom... ............................................. 1 for ball bearing 15x32x8-vacuum pump
876885 Mounting yoke ....................................................... 1 to compress dog gear
22
23
24
876470 Ring spanner 10/13 ............................................... 1
242661 Distance nut M8x33 ............................................... 1 for fixture for vacuum pump drive
276332 Insertion jig assy. ................................................... 1 for ball bearing 15x32x8, needle sleeve vacuum pump
25
26
27
28
877276 Insertion jig assy. ................................................... 1 for oil seal 22x32x7 vacuum pump
876518 Insertion jig ............................................................ 1 for oil seal 40x55x7 gear box cover
877650 Handle for insertion jig. .......................................... 1 stamp
877320 Press-in ring. ......................................................... 1 for ball bearing 35-72-17, propeller shaft handle with part no. 876518
29 877445 Socket wrench assy. 41x12.5 ................................ 1 for hext nut A/F 41
877440 Socket wrench A/F 41x20 ...................................... 1 30
31
32
877460 Reducing socket 3/4” - 1/2” .................................... 1
877802 Circlip installation tool ........................................... 1 for fitting of piston pin circlips
33 -34 877091 Piston pin extractor assy. ....................................... 1 for fitting and removal of piston pin
34
35
36
36
877155 Extracting nut assy. ................................................ 1
976380 Monohook circlip remover ..................................... 1 for monohook clips puller
876967 Piston ring spanner 84 mm .................................... 1 for piston diameter 84 mm/3.13 in.
876978 Piston ring spanner 79.5 mm ................................. 1 for piston diameter 79.5 mm/3.1 in.
37 - 38 877375 Puller assy. ............................................................ 1 for puller magneto hub
38 940755 Hex. screw M16x1.5x150 ...................................... 1
Effectivity 912/914 Series
Edition 1 / Rev. 5
00-00-00 page 43
March 01/2017
BRP-Rotax
Maintenance Manual
Fig. No. Part No. Description, application
39
40
877417
Number
Protection mushroom. ............................................ 1 for crankshaft magneto side
877790 Adapter ring assy. .................................................. 1 for valve sring mounting device
41
42
43
877380 Valve spring mounting device ............................... 1 for removal of the valve springs
877387 Valve spring loading jig ......................................... 1
877620 Oil filter wrench 80-110 .......................................... 1 for oil filter removal
44 877295 Impeller wrench assy. ............................................ 1 for waterpump impeller
45
46
47
877258 Insertion jig ............................................................ 1 for rotary seal crankcase
876510 Insertion jig ............................................................ 1 for oil seal 12x30x7 water pump shaft
877840 Spring clamp pliers ................................................ 1 for spring type hose clip 28
48
49
50
51
52
53
54
877390 Nut spanner A90 .................................................... 1 for overload clutch
877766 Crankcase splitting tool assy. ................................ 1 for crankcase
877570 Tapping drill M18x1 ............................................... 1 for thread bent socket
877670 Cutting tool ............................................................ 1 for oil filter
877110 Guide sleeve ......................................................... 1 for O-ring 3.2x1.8 idle mixture screw and idle jet 35
877270 Insertion jig assy. ................................................... 1 for oil seal 32x52x7 crankshaft magneto side (ms)
877360 Guide sleeve ......................................................... 1 for oil seal 32x52x7 crankshaft (ms)
55 - 56 877730 Float level gauge assy. .......................................... 1
56 240381 Hex. screw M6x12 ................................................. 1 for float level gauge
57 877690 Check lever ........................................................... 1 for checking of hydraulic valve tappet and valve spring force
Effectivity 912/914 Series
Edition 1 / Rev. 5
00-00-00 page 44
March 01/2017
BRP-Rotax
Maintenance Manual
Fig. No. Part No. Description, application
58
59
877316
Number
Graduated straightedge assy. ................................ 1 for checking plain bearing protrusion
877710 Dial gauge adapter assy. ....................................... 1
60
61
62
876950 Precision dial gauge .............................................. 1
877300 Aligning plate ........................................................ 1 for checking plain bearing position
976140 Dial gauge adapter assy. ....................................... 1 for dial gauge adapter for valve seat inspect
63
64
65
66
67
70
71
72
73
877263 Cylinder aligning tool ............................................. 1 for aligning cylinders
877680 Insertion jig with sleeve ......................................... 1 for oil seal 6x11x3/4.5 of rev counter housing
877500 Pin release tool ...................................................... 1 to release the cable on electr. connectors
877190 Press-in tool .......................................................... 1 for press in of worm gear, mech. rev counter
877520 Protractor crankshaft distortion insp. ...................... 1 see Maintenance Manual Line chap. 05-50-00
877377 Puller assy. ............................................................ 1 for slim edition for magneto hub
877930 Trestle support ....................................................... 1 for engine support
877245 Trestle adapter assy. ............................................. 1 for engine fixation (912 with engine suspension frame on the gearbox /914)
877240 Trestle adapter assy. ............................................. 1 for engine fixation (912/914) without engine suspension frame
74 877890 Torx-bit T40 ........................................................... 1 for magnetic drain plug (old version)
75
76
877450 Socket wrench 46x20 ............................................ 1 for hex. nut, crankshaft magneto side
877465 Reducing socket 1”-3/4” ......................................... 1 for 1” to 3/4”, for socket wrench
77 874234 Fuel pressure gauge .............................................. 1 for measuring fuel pressure
Effectivity 912/914 Series
Edition 1 / Rev. 5
00-00-00 page 45
March 01/2017
BRP-Rotax
Maintenance Manual
Fig. 00-9
7
8
NON-CERTIFIED PARTS / NOT ASTM-COMPLIANT
2
3
4 12
5
6
9
10
11
1
14
13
15
16
23
21
22
28
20
19
17
18
Effectivity 912/914 Series
Edition 1 / Rev. 5
24 25
27
26
AE 2iS_0676
00-00-00 page 46
March 01/2017
BRP-Rotax
Maintenance Manual
Fig. 00-10
41
40
42
NON-CERTIFIED PARTS / NOT ASTM-COMPLIANT
38
36
33
39
37
32
31
30
29
34
35
43
51
47
52
50
Effectivity 912/914 Series
Edition 1 / Rev. 5
44
56
55
48
54
53
46
45
49
AE 2_0163
00-00-00 page 47
March 01/2017
BRP-Rotax
Maintenance Manual
Fig. 00-11
61
62
NON-CERTIFIED PARTS / NOT ASTM-COMPLIANT
66
57
59
60
58
63
70
64
65
74
76
75
72
77
67
71 73
Effectivity 912/914 Series
Edition 1 / Rev. 5
AE 2_0163
00-00-00 page 48
March 01/2017
BRP-Rotax
Maintenance Manual
SECTION 71
POWER PLANT
1) Table of contents
SECTION 71
POWER PLANT
5.1) Storage and preservation directives for a new engine .................. 71-00-00 / 17
5.2) Preservation of an engine which has been in operation ............... 71-00-00 / 18
6.1.1) Engine suspension frame disassembly ................................ 71-00-00 / 19
6.1.2) Engine suspension frame inspection ................................... 71-00-00 / 20
6.1.3) Engine suspension frame assembly .................................... 71-00-00 / 20
6.2) Temperature- and pressure observation ....................................... 71-00-00 / 22
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 1
May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 2
May 01/2007
BRP-Rotax
Maintenance Manual
2) System description
2.1) Description of design
All ROTAX engines of the 912/914 Series consist of several main components and additional aggregates which are described in the following sections.
On the 912 Series : 4-cylinder horizontally opposed 4 stroke engine with a central camshaft pushrods OHV.
On the 914 Series : 4-cylinder horizontally opposed 4 stroke engine with turbocharger and electronic control of boost pressure control
(TCU = turbocharge control unit) and a central camshaft push-rods OHV
Liquid cooled cylinder heads
Ram air cooled cylinders
Dry sump forced lubrication
Dual breakerless capacitor discharge 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 shock absorber and overload clutch
◆ NOTE: The overload clutch is fitted in serial production on both certified aircraft and uncertified aircraft engines of configuration 3.
On the 914 Series : Stainless steel exhaust system
On the 912 Series : Individual parts of the exhaust system (optional), usually fitted by aircraft manufacturer
On the 912 Series : engine suspension frame, optional
On the 914 Series : engine suspension frame in serial production
Electric starter (12 V 0,6 kW / optional : 12 V 0.9 kW )
Integrated AC generator with ext. rectifier-regulator (12V 20A DC)
External alternator (12V 40A DC), optional
Vacuum pump: (only possible for Type 2 and Type 4), optional
Hydraulic constant speed propeller governor: (only for Type 3), optional
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 3
May 01/2007
BRP-Rotax
Maintenance Manual
2.2) Type description
e.g. ROTAX 914 F 2
◆ NOTE: The type description is composed as follows:
ROTAX
02091
914 4-cylinder horizontally opposed turbo engine Type:
Certification: F certified in accordance with FAR/ JAR-E (TW10 - ACG)
UL noncertified aircraft engines
Series 2: Propeller shaft with flange for fixed pitch propeller
◆
◆
NOTE:
NOTE:
3 : Propeller shaft with flange for variable pitch propeller and drive for hydraulic controlled constant speed propeller governor.
4 : Propeller shaft with flange for fixed pitch propeller but prepared for retro-fitting of hydraulic controlled constant speed propeller.
The propeller flange and hub are the same on all three gearbox versions.
For the exact type description, see the latest Operators Manual for your specific engine.
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 4
May 01/2007
BRP-Rotax
Maintenance Manual
2.3) Engine components, engine views, cylinder designation and description of main axes
See Figs. 71-1 to 71-4 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 reference point for all dimensions
◆
NOTE: Allow ±1 mm (0.04 in.) on all stated dimensions as manufacturing tolerance x,y,z axes for system of coordinates
Cyl. 1 cylinder 1 Cyl. 3 cylinder 3
Cyl. 2 cylinder 2 Cyl. 4 cylinder 4
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 5
May 01/2007
BRP-Rotax
Maintenance Manual
912 Series
Fig . 71-1
+z 4
A
7
+x
P
AS
2
+x1
+z1
-x1
x
MS
1
15
-z
3
Side view Cyl. 2-4
-z1
00502
13
(1) Engine number
(2) Propeller flange
(3) Propeller gearbox
(4) Vacuum pump or hydraulically controlled constant speed propeller governor
(5) Intake manifold
(6) Ignition housing
(7) Constant depression carburetor
(8) Airbox (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) Compensation tube
( 18) Oil pressure sensor
( 19) Oil temperature sensor
(20) 2x sensor for cylinder head temperature
(21) Connection for mechanical rev counter
(22) Oil tank
( 23) External alternator
(24) Magnetic plug
(25) Fuel pump
6
21
10
Effectivity 912 Series
Edition 1 / Rev. 0
71-00-00 page 6
May 01/2007
912 Series
Fig. 71-2
25
-y
Front view
912 Series
Fig. 71-3
8
9
18
5
Cyl. 3
Cyl. 1
Top view
07902
Effectivity 912 Series
Edition 1 / Rev. 0
16
BRP-Rotax
Maintenance Manual
17
+z
-y1
P
+z1
+y1
-z1
-z
+y
24
12
19
14
22
00503
20
Fig. 71-4
11
23
Cyl. 4
Cyl. 2
00124
71-00-00 page 7
May 01/2007
914 Series
+z
2 2
AS
+x
P
3
BRP-Rotax
Maintenance Manual
19
4
A
42
MS
-
40
+x1
+z1
-x1
34
24
-z
32
-z1
7
18
35
6
Side view Cyl. 2-4
00120
Fig. 71-5
20
21
10
(1) Engine number
(2) Propeller flange
(3) Propeller gearbox
(4) Vacuum pump or hydraulically controlled constant speed propeller governor
(5) Intake manifold
(6) Ignition housing
(7) Ignition cover
(8) Constant depression carburetor
(9) Airbox
(10) Engine suspension frame
(11) Stainless steel exhaust system
(12) Turbocharger
(13) Electronic turbo control unit (TCU)
(14) Fuel pressure regulator
(15) Servo motor
(16) Bowden cable
( 17) Wiring harness
(18) Coolant pump
(19) Expansion tank
(20) 2 separate oil pumps
(21) Connection for oil return line (engine)
(22) Connection for oil return line (turbo)
(23) Oil filter
Effectivity 914 Series
Edition 1 / Rev. 0
(24) Electric starter
(25) Electronic module
(26) Compensation tube
(27) Connection for boost pressure display
(28) Oil pressure sensor
( 29) Oil temperature sensor
(30) 2x sensor for cylinder head temperature
(31) 2x pressure sensor
(32) Connection for mechanical rev counter
(33) Connection for additional temperature sensor (Airbox)
(34) Drip tray
(35) Condensation water trap
(only on older engine versions)
(36) Solenoid valve
(37) 2x electric fuel pump
(38) Oil tank
( 39) External alternator
(40) Magnetic plug
(41) Connection for additional temperature sensor
(42) Carburetor
71-00-00 page 8
May 01/2007
BRP-Rotax
Maintenance Manual
914 Series
Fig. 71-6
26
+z
31
Top view
-y
Front view
12
914 Series
9
Fig. 71-7
36
30
Cyl. 3
5
A
Cyl. 1
00122
Effectivity 914 Series
Edition 1 / Rev. 0
28
-y
-y1
P
+z1
+y1
+y
14
-z1
40
22
29
-z
-x
33 41 31
11
17
13
30
00121
25
-y1
-x1
+y1
+x1
P
+x
A
15
16
37
1
5
27
Cyl. 4
Cyl. 2
00123
Fig. 71-8
Fig. 71-9
+y
23
39
19
38
00124
71-00-00 page 9
May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 10
May 01/2007
BRP-Rotax
Maintenance Manual
3) Technical data
■
CAUTION: The technical data relevant for engine operation are listed in detail in the respective Operators Manual and 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 version of valid Operators Manual for the engine in question 912 Series or 914 Series, ¨Operating fluids“.
3.3) Weights
See latest version of valid Operators Manual for the engine in question 912 Series or 914 Series, ¨Technical data“.
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 11
May 01/2007
BRP-Powertrain
Maintenance Manual
3.4) Engine / Components
DESIGN:
BORE:
STROKE:
DISPLACEMENT:
CYLINDER:
4-cylinder horizontally opposed 4-stroke-engine
79.5 mm (3.13 in.) 1) 3) 84 mm (3.31 in.) 2)
61.0mm (2.40in.)
1211.2 cm³ 1) 3) 1352 cm³ 2)
Lightweight metal cylinder with Nikasil coated running surface
PISTON:
CYLINDER HEAD:
COMPRESSION:
INTAKE VALVE:
Lightweight cast metal piston with 3 piston rings
4 individual cylinder heads
9 : 1 1) 3) 11.1 : 1 2)
38 mm (1.49 in.), valve seat surface hardened
EXHAUST VALVE: 32 mm (1.26 in.) NIMONIC, armor welding at valve seat
VALVE CLEARANCE: automatic compensation of clearance by hydraulic valve tappets
VALVE TRAIN: OHV, hydraulic valve tappets, pushrods and rocker arms
CAMSHAFT:
CONTROL TIME:
(at 1 mm valve stroke): steel, annealed, liquid nitriding
1) 3) lo. 0° T.D.C.
Oo. 48° before B.D.C.
Ic. 48° after B.D.C.
Oc. 0° T.D.C.
2) Io. 2° before T.D.C. Oo. 48° before B.D.C.
Ic. 48° after B.D.C.
Oc. 2° after T.D.C.
supported in 5 plain bearings, case hardened liquid cooled cylinder heads, ram air cooled cylinders
CRANKSHAFT:
COOLING:
LUBRICATION: 1) Main oil pump circuit:
Dry sump forced lubrication system, trochoid pump driven by the camshaft, oil return by the blow-by gases
2) Suction pump circuit : 3)
Extra trochoid pump driven by the camshaft returns oil from the lower oil sump of the turbocharger to the oil tank
OIL DELIVERY RATE: 1) Main oil pump: approx. 16 l/min. at 5500 rpm
1) 912 A, F, UL
2) 912 S, ULS, ULSFR
3) 914 F, UL
2) Suction pump circuit: 3) approx. 4 l/min. at 5500 rpm
Effectivity 912/914 Series
Edition 1 / Rev. 3
71-00-00 page 12
October 01/2010
BRP-Powertrain
Maintenance Manual
IGNITION UNIT:
IGNITION POINT:
ROTAX DCDI, interference suppressed
Differences between electronic modules: witho u t a dv a nced s t a rt electronic mod u le with a dv a nced s t a rt fly wheel h ub ignition point a t s t a rt 966 8 71
966 8 72 time del a y for ignition a t s t a rt: s witching to a dv a nced ignition: ignition timing in norm a l oper a tion:
4° Before T.D.C.
3 ° After T.D.C.
4° Before T.D.C.
3 ° After T.D.C.
none 3 - 8 s ec.
from 650 to 1000 RPM depending on trigger g a p a fter the expir a tion of the time del a y ( 3 8 s ec.)
Circ u it A: 26° b efore T.D.C.
Circ u it B: 26° b efore T.D.C.
1) 2)
Circ u it B: 22° b efore T.D.C.
3 )
Circ u it A: 26° b ef ore T. D. C.
Circ u it B: 26° b ef ore T. D. C.
1) 2)
Circ u it B: 22° b ef ore T. D.
3 )
FIRING ORDER:
SPARK PLUGS:
1- 4 - 2 - 3
12 mm (0.47 in.), DCPR7 1) , DCPR8 2) , X27EPR-U9 3)
ROTAX part no. 297656 1) 2) 3)
ELECTRODE GAP: see Fig. 74-6 and dimension (SPO1) in 74-00-00
INTEGRATED
ALTERNATOR: Permanent magnet-singlephase alternator
(approx. 250 W AC)
RECTIFIER-
REGULATOR:
EXTERNAL
ALTERNATOR:
(optional)
CARBURETOR:
12 V 20 A DC
12 V 40 A DC with full-wave rectifier-regulator
FUEL PUMP:
2x Bing-constant depression carburetors 32 mm,
Type 64
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:
GEAR TRANSMISSION: integrated spur gear with torsional shock absorbing, overload clutch, on UL optionally without overload clutch
2.27 1) , 2.43 2) 3)
06301
1) 2) 912 A, F, S, UL, ULS
3) 914 F, UL
Effectivity 912/914 Series
Edition 1 / Rev. 5
71-00-00 page 13
March 01/2017
DIRECTION OF
ROTATION:
BRP-Powertrain
Maintenance Manual counterclockwise, seen from the front in the direction of the propeller flange
OVERLOAD CLUTCH: multi-disk clutch
VACUUM PUMP
(optional): drive via the gearbox
PROPELLER PITCH drive via the gearbox
GOVERNOR (optional):
TURBOCHARGER: Exhaust gas turbine with wastegate, radial-flow compressor T25 3)
TURBOCHARGER electronic, proportional plus integral plus derivative
CONTROL UNIT (TCU):regulator with 2 external indicating lamps 3)
CERTIFICATION: 912 A: in acc. with JAR 22 Subpart H
(Type Certificate EASA.E.121)
912 F: in acc. with FAR 33
(Type Certificate EASA.E.121)
912 S: in acc. with FAR 33
(Type Certificate EASA.E.121)
914 F: in acc. with FAR 33 and JAR-E
(Type Certificate EASA.E.121)
Effectivity 912/914 Series
Edition 1 / Rev. 5
71-00-00 page 14
March 01/2017
BRP-Rotax
Maintenance Manual
4) Treatment of corrosion and 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 shaft
The flange should be lightly greased to prevent surface rust forming, see 72-00-00 / sec. 3.9.10.
4.2
Electric system
See 74-00-00 / sec. 3.1.
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 15
May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 16
May 01/2007
BRP-Powertrain
Maintenance Manual
5) Preservation and returning to service
5.1) Storage and preservation directives for a new engine
The engine is preserved at BRP-Powertrain thus guaranteeing proper protection against corrosion damage for at least 12 months after the date of delivery from
BRP-Powertrain.
This warranty confirmation is subject to the following conditions:
The engine must be stored in the original packing as supplied by BRP-Rotax.
The protective 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 every 3 months:
Remove one spark plug on each cylinder and turn crankshaft by hand 2 full turns. Refit spark plug.
Visual inspection for corrosion (e.g. on propeller shaft). If corrosion is detected, the engine must be sent immediately to an authorized overhaul facility for inspection.
▲
WARNING: The engine must not be taken into operation.
◆ NOTE: The maximum possible storage period of the engine is limited to
24 months.
If this storage period is exceeded, inspect following steel components for corrosion:
camshaft, crankshaft, gear set and propeller shaft
If corrosion is detected, the engine must be sent immediately to an authorized overhaul facility for inspection.
Effectivity 912/914 Series
Edition 1 / Rev. 4
71-00-00 page 17
February 01/2015
BRP-Powertrain
Maintenance Manual
5.2) Preservation of an engine which has been in operation
Due to the special coating of the cylinder wall, the ROTAX aircraft engine normally needs no extra protection against corrosion.
■ CAUTION: Maximum storage period 12 months if the listed precautions are taken!
– Oil change see latest issue Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series.
– On the ROTAX 912 Series: Run the engine to allow it to warm up, leave it running at increased idle speed, remove the air filters and inject approx. 30 cm 3 of preservation oil into the carburetors, shut down the engine.
– On the ROTAX 914 Series: Remove the top spark plugs from all four cylinders and spray preservation 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 carburetors.
– Close all openings on the cold engine, such as the exhaust pipe, venting tube and air filter intake against entry of dirt and humidity.
– Spray all external engine steel parts with preservation oil.
– In the event of longer out of service periods repeat the whole preservation procedure annually.
5.3) Returning the engine to service
– Remove all plugs and fasteners.
– Clean spark plugs with solvent and a plastic brush.
– If preservation including oil change took place not longer than a year ago, oil replacement will not be necessary.
– Complete 100 hour inspection if engine has been out of service for more than one year.
▲ WARNING: Work on the engine may only be carried out and approved by authorized persons. See the latest issue Maintenance Manual
(Line Maintenance) for the respective engine type, 912 Series or
914 Series.
Effectivity 912/914 Series
Edition 1 / Rev. 3
71-00-00 page 18
October 01/2010
BRP-Rotax
Maintenance Manual
6) Maintenance
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see latest issue
Maintenance Manual (Line Maintenance) for 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.
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 burns!
◆ NOTE: Prior to detachment of the engine suspension frame
(1), remove the water pump housing (2), as the coolant sockets, which protrude outwards, would hinder removal of the engine suspension frame.
See 75-00-00 sec. 3.
After removal of the two allen screws M10x110 (3) and M10x35 (4) together with the lock washers, the engine suspension frame can be taken off.
◆ NOTE: On engines of the 914 Series, it will also be necessary to remove the muffler and the turbocharger.
See 78-00-00 sec. 3.
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 19
May 01/2007
BRP-Powertrain
Maintenance Manual
6.1.2) Engine suspension frame inspection
See Fig. 71-11
– All components must be subjected to a visual inspection.
■ CAUTION: If the engine is fitted with engine suspension frame part no. 886567, inspection in accordance with SB-912-028 or SB-914-016,“Checking or replacement of engine suspension frame“, latest issue must be performed.
◆ NOTE: A detailed visual inspection of the engine suspension frame in the area of all welded joints between the circular 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 replaced immediately.
6.1.3) Engine suspension frame assembly
See Figs. 71-10 and 71-11.
Screw the engine suspension frame (1) to the engine housing with the lock washers and the allen screw M10x110 (3) and M10x35 (4), tightening to 40 Nm (29.5 ft.lb) in each case.
◆ NOTE: Ensure that the engine suspension frame is attached free of stress. If necessary, fit the shims as needed (5).
◆
NOTE: The allen screws (4) must be of strength 10.9. See SI-
25-1997,“Running modifications“, latest issue.
– On engines of the 914 Series, reattach the muffler and the turbocharger. See 78-00-00 sec. 3.5.
Effectivity 912/914 Series
Edition 1 / Rev. 3
71-00-00 page 20
October 01/2010
BRP-Rotax
Maintenance Manual
Fig. 71-10
00164
2
1
4
03080
*
5
6
Fig. 71-11
5
5
6
3
6
6
5
1
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 21
May 01/2007
BRP-Rotax
Maintenance Manual
6.2) Temperature- and pressure observation
Engines of the 912 Series and 914 Series are equipped with two temperature 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 pressure.
On engines of the 914 Series: The engine is also equipped with control points for measurement of the airbox pressure, airbox temperature and the ambient pressure.
Effectivity 912/914 Series
Edition 1 / Rev. 0
71-00-00 page 22
May 01/2007
BRP-Powertrain
Maintenance Manual
SECTION 72
ENGINE
1) Table of contents
SECTION 72
ENGINE
2.4.1) Mechanical rev counter and hourmeter (optional) ................ 72-00-00 / 8
3.1) Vacuum pump removal and inspection ......................................... 72-00-00 / 9
3.2) Governor removal and inspection ................................................. 72-00-00 / 10
3.4) Ignition housing removal and inspection ...................................... 72-00-00 / 11
3.6.2) Sprag clutch dismantling ...................................................... 72-00-00 / 17
Effectivity 912/914 Series
Edition 1 / Rev. 3
72-00-00 page 1
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3.9.1) Removal of roller bearing for - Series 2 ................................ 72-00-00 / 24
3.9.2) Removal of roller bearing for - Series 3 ................................ 72-00-00 / 26
3.9.3) Removal of roller bearing for - Series 4 ................................ 72-00-00 / 27
3.9.4) Propeller gearbox disassembly ............................................ 72-00-00 / 28
3.9.5) Propeller shaft removal........................................................ 72-00-00 / 30
3.9.6) Vacuum pump drive removal ............................................... 72-00-00 / 32
3.9.7) Propeller governor drive removal .......................................... 72-00-00 / 33
3.9.8) Drive of the propeller governor installation .......................... 72-00-00 / 35
3.9.9) Vacuum pump drive installation ............................................ 72-00-00 / 38
3.9.10) Gearbox components inspection .......................................... 72-00-00 / 39
3.9.11) Toothed shaft profiles´inspection .......................................... 72-00-00 / 43
3.9.12) Gear set (gear wheels) inspection ........................................ 72-00-00 / 44
3.9.13) Propeller gearbox reassembly ............................................. 72-00-00 / 49
3.9.14) Disc spring 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
3.11.2) Reworking of the sealing surface to the exhaust manifold .... 72-00-00 / 61
3.11.8) Rocker arm and rocker arm shaft ........................................ 72-00-00 / 70
3.11.8.1) Rocker arm with plastic bushing ............................ 72-00-00 / 71
3.11.8.2) Rocker arm with pressed sinter bushing ............... 72-00-00 / 72
3.11.8.3) Rocker arm shaft ................................................... 72-00-00 / 72
Effectivity 912/914 Series
Edition 1 / Rev. 2
72-00-00 page 2
July 01/2008
BRP-Rotax
Maintenance Manual
3.16.1) Hydraulic valve tappets fitting .............................................. 72-00-00 / 86
3.17) Intake manifold and compensation tube assembly ...................... 72-00-00 / 95
3.18) Crankshaft inspection................................................................... 72-00-00 / 95
5) Form Sheets ........................................................................................... 72-00-00 / 117
5.1) Form sheet for material testing ROTAX 912/914 Series ............... 72-00-00 / 117
Effectivity 912/914 Series
Edition 1 / Rev. 2
72-00-00 page 3
July 01/2008
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 4
May 01/2007
BRP-Rotax
Maintenance Manual
2) Systems description
2.1) Propeller gearbox
See Fig. 72 -1
Transmission gear ratio crankshaft: propeller shaft 2.43 : 1 2), 3), 4) ; 2.27 : 1 1)
The propeller shaft is driven by the crankshaft via a straight toothed spur gear
(1).
The propeller gearbox incorporates a torsional shock absorbing device. This consists of a torsional shock absorber with dogs (2) and axial springloading by means of disc springs (3).
The design also 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 load changes, but due to the integrated overload clutch it will remain harmless.
◆ NOTE: This overload clutch (4) will also prevent any undue load on the crankshaft in the event of the propeller having ground contact.
◆ NOTE: The overload clutch is fitted in serial production on both certified aircraft and uncertified aircraft engines of configuration 3.
2.1.1) Gearbox version
See Fig. 72 -1
There are 3 gearbox configurations for the 912/914 Series. See 71-00-00 sec. 2.2
1) 912 A, F, UL
2) 912 S, ULS, ULSFR
3) 914 F, UL
4) 912 A, F, UL - optional
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 5
May 01/2007
Fig. 72-1
AE_912_0207
BRP-Rotax
Maintenance Manual
1
Effectivity 912/914 Series
Edition 1 / Rev. 6
3 4
Configuration 3 with overload clutch
2
72-00-00 page 6
July 01/2018
2.2) Hydraulic governor
See Fig. 72 -2
◆ NOTE: Not included in the range of delivery.
A hydraulic governor can be fitted on engines of the 912/914 Series configuration 3 to control a hydraulic constant speed propeller. Engines of the 912/
914 Series configurations 2 and 4 can be retrofitted for this purpose.
i.e., the drive for the governor in the propeller gearbox and the crankcase, its connection cable and the oil feed line to the propeller shaft must be retrofitted.
– On configuration 912/914 - 2, the hollow propeller shaft must also be exchanged for the correct one.
– On configuration 912/914 - 4, the propeller shaft can remain. It is the same design as for configuration 912/914 - 3, with the exception that the inside bore is plugged. After removal of the plug cover the propeller shaft is suitable for use with a governor.
Gear ratio (i) crankshaft : propeller shaft propeller shaft : governor
Total
* optional 2.429 possible
912 A/F/UL
50 : 22
22 : 29
1.722
2.273*
0.759
912 S/ULS/ULSFR
914 Series
51 : 21
22 : 29
1.842
2.429
0.759
08218
Fig. 72-2
BRP-Rotax
Maintenance Manual
◆
◆
NOTE:
NOTE:
Installation of both the hydraulic governor and vacuum pump is not possible.
The gear ratio crankshaft to vacuum pump or propeller governor is 1.722 or 1.842, depending on engine type.
Direction of rotation of the governor ........................... counterclockwise
(CC), looking from the magneto side above onto the governor flange.
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 7
May 01/2007
BRP-Powertrain
Maintenance Manual
2.3) Vacuum pump
It is possible to install a vacuum pump for employment of an inertial navigation system. To do this, the drive kit for the vacuum pump must be retrofitted on propeller gearbox and crankcase.
◆ NOTE: Installation of both the vacuum pump and hydraulic governor is not possible.
Gear ratio: Vacuum pump and hydraulic governor are driven the same way and therefore have an equivalent gear ratio. See hydraulic governor.
2.4) Connections for instrumentation
■ CAUTION: Consult also the relevant section on connections for instrumentation in the Installation Manual.
2.4.1) Mechanical rev counter 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 installation of a flex. rev counter shaft is possible after removal of the rev counter cover on the ignition housing. On engines produced from the year 2007 onwards, it is also necessary to replace the ignition cover and press the worm gear into the camshaft using the tool with part no. 877190.
For connection of a rev counter, see 71-00-00 sec. 2.3 item no. 21 (on
912 Series) or item no. 32 (on 914 Series).
The total transmission ratio from crankshaft to rev counter shaft i = 4
◆ NOTE: As the mechanical hourmeter is directly coupled to the engine speed, the readings may deviate considerably from those given by electronic hourmeters (e.g. TCU,
FlyDat). Maintenance and overhaul intervals are always dictated by the operation period.
Effectivity 912/914 Series
Edition 1 / Rev. 4
72-00-00 page 8
February 01/2015
BRP-Powertrain
Maintenance Manual
3) Maintenance
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see latest issue
Maintenance Manual (Line Maintenance) for 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.
3.1) Vacuum pump removal and inspection
See Fig. 72-3.
■ CAUTION : Observe the vacuum pump manufacturers specifications for maintenance, inspection and repairs!
Unscrew the 4 hex. nuts (1) M6 and remove the lock washers. Remove the vacuum pump (2) from the crankcase (4) together with the gasket and the retaining flange (3).
1
4
3
2
Fig. 72-3
00251
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Edition 1 / Rev. 3
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October 01/2010
BRP-Powertrain
Maintenance Manual
3.2) Governor removal and inspection
See Fig. 72-34 in 72-00-00.
■ CAUTION : Observe the governor manufacturers specifications for maintenance and repairs!
Unscrew the 3 allen screws (16) M8x40 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 governor. See SB-912-052 and/or SB-914-035, “ Installation / Use of governor“, latest issue.
3.3) Removal of the fly wheel hub
See Fig. 72-4
Remove hex. screw M16x1.5 (1). Place protection piece part no. 877410 on the crankshaft, screw puller part no. 877375 down fully and press off the fly wheel hub (2) with the hex. screw.
Fig. 72-4 1
2
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3.4) Ignition housing removal and inspection
See Figs. 72-5, 72-6, 72-7 and 72-8.
Cut the tie wraps and remove the cable clamp from the electronic module.
Detach the plug connections of the two pickup cables and the plug connections of the charging cable. Detach both plug connectors of the alternator cable and the control wiring for the electronic rev counter. See 74-00-00 sec. 3.15.
Decide whether the stator may remain in the ignition housing. Otherwise remove the cable clamps and remove the 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. See 80-00-00 sec. 3.1.
Remove the 7 allen screws M6 from the ignition cover on the bottom side of the ignition cover from the crankcase. A smart blow with a mallet will separate the ignition cover (3) from the crankcase so that it can be taken off.
Remove the O-ring (2).
◆ NOTE: The crankshaft bearings in the ignition housing are lubricated via the oil duct (4). The oil duct at the joining face between the crankcase and the ignition housing is sealed by the O-ring (2)
5x2.
◆ NOTE: The thrust washer of the intermediate starter gear may be stuck on the rear side of the ignition housing.
Fig. 72-5
1
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BRP-Powertrain
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Fig. 72-6
3
4
3
2
00381
00382
Carry out a visual inspection of the sealing surfaces.
Clean oil duct (10) with compressed air and check for free passage. Measure the bearing bore Ø32 (1.26“) mm of the bearing bushing (11) (dimension
(IH01)) for the crankshaft bearing (dimension (CS05)) and determine the clearance. See 72-00-00 sec. 4.
The bearing bushing (11) can not be replaced, as the internal bore and the lubricating 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) 32x52x7 for the crankshaft, if necessary, press new shaft seal into the block with an insertion jig, part no. 877270.
Check whether oil or water emerge from the outside of the leakage bore (14).
Check the rotary seal (15) for the water pump sealing. If liquid is leaking, replace the rotary seal and the shaft seal (16).
Carry out a visual inspection of the bearing (17) for the electric starter.
◆ NOTE: Fig. 72-8 item 18 is the drive shaft for the mechanical rev counter.
Effectivity 912/914 Series
Edition 1 / Rev. 3
72-00-00 page 12
October 01/2010
Fig. 72-7
BRP-Rotax
Maintenance Manual
00084
Effectivity 912/914 Series
Edition 1 / Rev. 0
Fig. 72-8
10
17
18
11
16
15
13
14 00383
72-00-00 page 13
May 01/2007
BRP-Powertrain
Maintenance Manual
3.5) Ignition housing fitting
See Fig. 72-9.
Install the intermediate gear. See 72-00-00 sec. 3.7.
■ CAUTION: If the mounting sleeve, part no. 877360, is not used, the oil seal will be damaged by the sharp edge of the keyway in the crankshaft.
Place O-ring 5x2 into the crankcase and fit mounting sleeve, part no. 877360, for 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 oil seal (7), fit it and turn the water pump shaft to engage it in the geartooth system. Tighten ignition cover with 7 allen screws M6x30 (8) and lock washers evenly to 10 Nm (90 in.lb.).
◆ NOTE: Allen screw (9) M6x30 extends into the oil compartment and must therefore be sealed with LOCTITE 243.
◆ NOTE:
◆ NOTE:
Fig. 72-9 item 10 is the drive shaft for the mechanical rev counter.
For fly wheel installation see 74-00-00 sec. 3.20.
Fig. 72-9
6
10
06302
Effectivity 912/914 Series
Edition 1 / Rev. 3
8
7
9
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BRP-Rotax
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3.6) Sprag clutch
See Figs. 72-10 and 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 is no or too little axial clearance, the sprag clutch may not disengage and the electric starter may be damaged.
Fig. 72-10
00235
Effectivity 912/914 Series
Edition 1 / Rev. 0
Maß dim.
6
72-00-00 page 15
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BRP-Rotax
Maintenance Manual
3.6.1) Sprag clutch removal
See Fig. 72-11.
Lock the crankshaft. See the latest issue Maintenance Manual (Line
Maintenance) for the respective engine type, 912 Series or 914 Series.
Pull out the intermediate gear shaft (1) and remove the intermediate starter gear (2) with the thrust washers 12.5/21.5/1 (3) on both sides of the intermediate gear.
■ CAUTION : Use of impact wrench is not permitted, lock nut (4) must 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. nut (4) has a lefthanded thread!
Insert protection piece, part no. 877410, into the crankshaft and remove the sprag clutch housing (5) from the crankshaft with puller, part no.
877375.
The free wheel gear (6), the pump gear (10) pressed onto the camshaft and the timing gear (8) underneath it can be removed only after splitting the crankcase.
◆
NOTE: The mechanical rev counter is driven via the worm gear
(7) pressed into the camshaft.
◆
NOTE: The worm gear (7) is optional on newer engine versions.
Fig. 72-11
9
8
7
10
4
5
3
1
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6
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3.6.2) Sprag clutch dismantling
See Figs. 72-12 and 72-13.
Carry out a visual inspection to check whether oil sludge has been deposited in the sprag clutch housing (5) and in in the lock (16). For inspection/cleaning purposes, remove the circlip (14). Compress the circlip (19) in the sprag clutch (17) slightly with circlip pliers and twist the sprag unit out of the sprag clutch 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 freely and the surface must be free of damage. Inspect the engaging surfaces of the sprag clutch in the sprag clutch housing.
If wear can be measured on the internal contact surfaces of the sprag clutch housing, the affected parts must be replaced. Check the tapered surface (18). Check the geartooth system (12), the engaging surface of the sprag clutch (11) on the free wheel gear and the bearing bushing
(13).
Fig. 72-12
13
14
17 5
6
18
Fig. 72-13
00237
11
12
15
15 16
19
20
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3.6.3) Sprag clutch installation
See Figs. 72-10, 72-11, 72-12, 72-13, 72-14 and 72-15.
Place the sprag clutch into the sprag clutch housing so that the circlip
(19) is visible. To fit the circlip, compress it slightly using circlip pliers and ensure that clip remains in position and engages fully on the catches in the sprag unit (20).
■ CAUTION : The circlip must be fitted as shown in Fig. 72-15.
Otherwise, it may not fit tightly.
Fit the circlip (14) with the sloping edge pointing towards the sprag clutch.
■
CAUTION : If there is a circlip 68 (14) part no. 845420 still fitted, it must be replaced with a circlip 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 of the crankshaft and taper of the sprag clutch housing.
■ CAUTION : Approx. 2 - 3 mm (0.079 - 0.12 in.) on the bottom side of the sprag clutch housing must be kept free of
LOCTITE 603. If this instruction is not observed, the bearing bushing and the free wheel gear can adhere to the crankshaft, which would cause friction wear on the sprag clutch.
Coat taper of the sprag clutch housing thinly with LOCTITE 603 and fit on crankshaft. As you do so, turn the free wheel gear so that the sprag lobes (16) can be aligned.
◆
NOTE: When turned to the left, looking towards the magneto side of the engine, the free wheel gear (6) must engage in the crankshaft, and when turned to the right, it must move freely!
See Fig. 72-14.
Effectivity 912/914 Series
Edition 1 / Rev. 4
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February 01/2015
BRP-Powertrain
Maintenance Manual
Secure degreased hex. nut M34x1.5 with LOCTITE 603 and tighten to
150 Nm (110.6 ft.lb).
◆ NOTE: Hex. nut has lefthanded thread!
■ CAUTION : Check axial clearance of free wheel gear, see
Fig. 72-10 and dimension (ES10) in 72-00-00 sec. 4.
im Eingriff / engaged frei drehbar / freely turning
Fig. 72-14
00239 circlip part no. 845420
minimum 70,3 mm
(2.77 in.)
Effectivity 912/914 Series
Edition 1 / Rev. 4
04695
Fig. 72-15
1 circlip part no. 845425
08559 minimum 72,3 mm
(2.85 in.)
72-00-00 page 19
February 01/2015
BRP-Powertrain
Maintenance Manual
3.7) Reduction gear for electric starter
See Fig. 72-16.
Place thrust washer (1) 12.5/21.5/1 on the crankcase. Place intermediate 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 geartooth system is deformed, the intermediate gear must be replaced.
◆ NOTE: If the teeth of the intermediate gear are deformed, a noise will be produced when the engine is started.
■ CAUTION : It is important to ensure that both thrust washer are correctly positioned on the shaft.
Fig. 72-16
4
3
1
2
5
00240
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Edition 1 / Rev. 4
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February 01/2015
BRP-Rotax
Maintenance Manual
3.8) Rev counter drive
See Figs. 72-17, 72-18 and 72-19.
The optional mechanical rev counter (1) is driven via the worm gear pressed into the camshaft.
◆
NOTE: On older engine versions without a mechanical rev counter, a cover plate is fitted in place of the rev counter housing. The engine can be retrofitted with a rev counter drive by installation of the drive shaft. See Fig. 72-18.
◆ NOTE: On new engine versions, the ignition cover must also be replaced and the worm gear (9) pressed into the camshaft using special tool, part no. 877190.
Remove allen screw M5x16 (2) and the lock washer, and pull the rev counter housing (3) along with the O-ring (4) and the rev counter shaft (5) out of the ignition housing (see 72-00-00 sec. 3.4).
Gear-tooth system (6) and square end (7) of the rev counter shaft must be inspected for damage. If there is oil leakage, replace the shaft seal (8) 6x11x3 and O-ring (4). Press new shaft seal fully home in the rev counter housing (3) using punch, part no. 877680 .
1
Fig. 72-17
Fig. 72-19
9
00241
2
8
Fig. 72-18
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4
3
7 5
6
00243
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3.9) Propeller gearbox
See Figs. 72-20, 72-20/1 and 72-21.
Before removing the gearbox, it is advisable to check the friction torque. See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series.
■ CAUTION : When removing the gearbox, take care not to damage the bearing seat and the oil seal running surface of the propeller shaft.
Lock crankshaft. See chapter 12-00-00 of the maintenance manual (line maintenance) of the corresponding engine type (912 Series or 914 Series).
Remove 8 allen screws (1) M6 and 2 allen screws (2) M8 together with the lock washers crosswise from the gear cover (3). The gear cover is kept in position by 2 dowel pins. Screw puller (4), part no. 877660, into the two M8 mounting lugs
(5) of the gear cover (3). Now the complete gearbox can be pulled off with the slide hammer puller (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 6x20 (7) into the right (8) and left (8) bore of the gearbox housing.
Screw hex. screw M6 x 40 into the release mechanism. Center the release mechanism (10) and tighten with hex. screw M10x20 (11). Turn left and right hex.
screws (9) evenly to press the gearbox housing off the crankcase.
▲
WARNING: Heated up components - Risk of scalds and burns. Wear safety gloves!
Use a hot air gun to heat up hex. nut M30x1.5 to about 100 to 120 °C ( 212 to 248
°F).
Release hex. nut M30x1.5 (12) with wrench 41 a/f, part no. 877445 and remove the drive gear with friction washer (13) from the crankshaft. If required, lever drive gear gently off with 2 screwdrivers.
◆ NOTE: Hex. nut has lefthanded thread!
Make sure that both dowel sleeves remain in the crankcase and not in the gearbox housing.
■ CAUTION : The gear set has a continuous 6-digit serial number which is shown on the front side of the drive gear (14) and on the dog gear. The gears are paired as a set and must not be exchanged individually.
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4
5
3
00244
Fig. 72-20
08388
Fig. 72-20/1
6
8
7
8
11
9
10
1
2
13
12
LOCTITE 648
Effectivity 912/914 Series
Edition 1 / Rev. 1
14
Fig. 72-21
00247
9
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Propeller shock load - Inspection of crankshaft distortion on installed crankshaft
See Figs. 72-21/1 to 72-21/3
◆ NOTE: The inspection of the crankshaft only makes sense if the shaft runout of the crankshaft AS or MS is less than 0.080 mm (0.0031
inch)
( A ) Carefully mount holder (1) for protractor (2) part no. 877520 onto the crankshaft .
3 Fig. 72-21/1
08477
4
2
1
5
■ CAUTION: Do not damage the crankshaft.
( B ) Install the metal sheet (3) with allen screw M6x20 (4) between drive sleeve and roller bearing.
◆ NOTE: Make sure that the upper spark plugs have been removed.
( C ) Starting with cylinder 1 screw in piston stopper (7) completely.
◆ NOTE: On all 4 cylinders the piston stopper has to be installed in the upper spark plug thread.
◆ NOTE: Make sure that the piston stopper has been screwed in completely - so that it is bottomed out in with the spark plug hole.
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Fig. 72-21/2
08582
7
( D ) Turn the crankshaft carefully in direction of engine rotation until the piston touches the piston stoppers.
◆ NOTE: Allways turn the crankshaft in direction of engine rotation, to move the piston towards the piston stopper.
◆ NOTE: The force applied should be strong enough to break-through possible 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 measurement procedure has ended the protractor must not be turned on the metal sheet.
◆ NOTE: In this position the piston of cylinder 1 touches the piston stopper.
( F ) For a smoother removal of the piston stopper turn the piston slightely away from the piston stopper.
( G ) Now install the piston stopper at cylinder 2 and procede like at cylinder 1.
( H ) Read the difference to 0° from the protractor.
Effectivity 912/914 Series
Edition 1 / Rev. 3
72-00-00 page 24A
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BRP-Powertrain
Maintenance Manual
■ CAUTION: The value can be positive or negative.
( I ) For smoother removal of the piston stopper turn the piston slightely away from the piston stopper.
( J ) Repeat this procedure for cylinder 3. The piston will be stopped at 180°.
(K) Read the difference to 180° from the protractor.
■ CAUTION: The 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 negative.
■ CAUTION: If a value exceeds the GB20 limit, then the engine needs to be overhauled by a ROTAX-authorised service partner.
■ CAUTION: The deviation of the crank pin (as a whole) must not exceed the
GB20 value. For GB20 see also Chapter 4 “wear limits”.
Example showing the results from meassuring a crankshaft, where the GB20 threshold is not exceeded:
Cylinder
1
2
3
4 deviation
0°
+ 2°
0°
+1°
Fig. 72-21/3
08690
Effectivity 912/914 Series
Edition 1 / Rev. 3
72-00-00 page 24B
October 01/2010
BRP-Powertrain
Maintenance Manual
Example showing the results from meassuring a crankshaft, where the
GB20 threshold is exceeded:
Cylinder
1
2
3
4 deviation
0°
+ 2°
0°
-1°
Fig. 72-21/4
08691
3.9.1) Removal of roller bearing for - Series 2
See Fig. 72-22.
After the propeller gearbox is removed, the crankcase side propeller shaft bearing and oil seal can be replaced if necessary.
Remove the retaining ring (1) with the circlip pliers. Attach extractor (2) part no. 877615 with 8 allen screws M6x25 to the crankcase. Screw stud
(3) M10x45/20, part no. 941180, into the pull-in spindle (4), part no.
877580 and fit hex. nut (5) M24x1.5 onto the pull-in spindle.
For better guidance, place the press-in insert (6), part no. 877592, into the roller bearing (7). Place the pull-in spindle (4) into the extractor (2) and through the crankcase.
On the rear side of the crankcase, push the pullout plate (8), part no.
877560, onto the stud and attach with the hex. nut M10 (9), part no.
242091.
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Maintenance Manual
Keep pull-in spindle in position with the handle lever and turn the hex.
nut clockwise until the roller bearing (7) with oil seal (10) is pulled out of the housing. Unscrew hex. nut, remove pullout plate with roller bearing and oil seal and withdraw spindle (11). Unscrew extractor from housing.
■ CAUTION : During this procedure, the oil seal (10) is destroyed and must be replaced.
5
4
Fig. 72-22
00248
11
6
2
1
7
10
8
9 3
3.9.2) Removal of roller bearing 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 flange must be removed. On configuration 912 Series 3 with hydraulic governor, the procedure for pressing out varies from that for Series 2 and 4. On Series 3, the roller bearing is pressed out together with the oil inlet flange.
Remove the retaining ring (1) with circlip pliers. Fit puller cap (2), part no. 876489, and push hex. screw (3) through the cap, roller bearing (4) and oil inlet flange (5). Fit washer (6) and nut (7) on the back end. By turning the hex. screw clockwise, the roller bearing is pulled out together with the oil inlet flange. Take out O-ring (8) and both O-rings (9).
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Edition 1 / Rev. 3
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BRP-Powertrain
Maintenance Manual
3.9.3) Removal of roller bearing for - Series 4
See Fig. 72-24.
After the propeller gearbox is removed, the crankcase side propeller shaft bearing can be replaced if necessary.
For the extracting procedure it is necessary to drill a bore (2) of at least
6.2 mm dia., (1/4") into the center of the oil inlet cover (1).
■
CAUTION : The oil inlet cover is thus rendered useless 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 drilling.
The roller bearing is pulled out together with the oil inlet cover. Remove the retaining ring (3) with circlip pliers. On the gearbox side, fit puller cap
(4), part no. 876489, and push hex. screw (5) through the cap, roller bearing (6) and the hole drilled in the oil inlet cover (1). Fit the pullout plate (7) with the nut (9) and washer (8) on the back end. By turning the hex. screw clockwise, the roller bearing is pulled out together with the oil inlet cover. Remove the O-ring (10).
Fig. 72-24
00250
2
Fig. 72-23
00249
3
5
2
1
4
5
4
3
6
6
7
1
10
7
8
9
8 9
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BRP-Rotax
Maintenance Manual
3.9.4) Propeller gearbox disassembly
See Figs. 72-25, 72-26 and 72-27.
■ CAUTION : Only push the dog gear down until it is possible to remove the two ring halves, otherwise the gearbox housing could be destroyed. The gear cover should be rotated back and forth during this step!
Place the complete gearbox in a suitable fixture (1) and press down the gear wheel with the mounting yoke (2), part no. 876885, until the ring halves (3) can be removed, see 00-00-00 section 10.4
Now relieve the pressure on the gear by turning spindle (4) back and remove 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.
■ CAUTION: Do not overstress bearing bushing (6), as otherwise it will become unusable.
Remove the complete overload clutch (7) or dog hub (8), disc springs
(9) 80x35x3, step collar (10) 6 mm (0.236 in.) or step collar (11) (for gearbox with oil spray nozzle), distance sleeve (12), compensating shim (13), eccenter (14) (for fuel pump on the ROTAX 912 Series, of no significance on the 914 Series) and 8 mm (0.31in.) distance sleeve
(15).
■ CAUTION: The overload clutch is fitted in serial production on all certified aircraft engines and on all noncertified aircraft engines of configuration 3. All other engine versions are equipped with a dog hub, but available with an optional overload clutch or can be retrofitted to accommodate one.
◆ NOTE: Propeller gearbox with oil spray nozzle has a step collar with execution in bore.
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Edition 1 / Rev. 6
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Maintenance Manual
4
Fig. 72-26
Fig. 72-25
1
3
5
00260
Fig. 72-27
15
14
13
2
00261
11
12
10
9
10
8
6
Dog hub
07704_a
Effectivity 912/914 Series
Edition 1 / Rev. 6
11
10
9
7
Overload clutch
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BRP-Powertrain
Maintenance Manual
3.9.5) Propeller shaft removal
See Figs. 72-28 and 72-29.
Place gearbox housing on a suitable surface and press out the propeller shaft with a hand press. Alternatively, the extractor (1), part no.
877615, can be used to press out the propeller shaft.
Fit the extractor onto the gearbox housing (3) with 6 x M6 screws (2) and place press-out insert (4), part no. 877605 (for engine configuration 2), or press-out insert (5), part no. 877600, (for configurations 3 and 4) on the end (6) of the propeller shaft (7).
Insert pull-in spindle (8) into the support (9) of the extractor (1) and screw 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 : The protection piece (press-out insert (4) - part no. 877605 or press-out insert - part no. 877600) must be used without fail, as otherwise the machined inner diameter of propeller shaft would be damaged. If the propeller shaft is removed, the ball bearing (11) must be replaced!
To remove the ball bearing (11), unscrew the 4 hex. screws (12) M7x16 with the washers (13) from the gearbox housing (3).
■ CAUTION : During this procedure, the shaft seal (14) will be damaged and must be replaced.
Heat the gearbox housing to 80 to 100 ° C (176 to 212 °F) and knock the ball bearing (11) out, together with the oil seal (14) and the radius ring
(15), using a suitable punch and from the outside towards the inside.
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BRP-Rotax
Maintenance Manual
7
6
10
Fig. 72-28
8
9
3
Effectivity 912/914 Series
Edition 1 / Rev. 0
00263
4
2
5
1
Fig. 72-29
13
15
11
12
00264
14
3
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BRP-Powertrain
Maintenance Manual
3.9.6) Vacuum pump drive removal
See Fig. 72-30.
The vacuum pump is driven via the drive gear (1) fitted on the propeller shaft.
Check the ball bearing (2) and the needle sleeve (3). Check the geartooth system of drive gear (1), the vacuum pump gear (4), the drive sleeve (5) and the drive shaft of the vacuum pump.
If the ball bearing or needle sleeve are to be replaced, remove the vacuum pump as follows:
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 (8) for ball bearing fixation.
Lift out the oil seal (9) and press out the needle sleeve and ball bearing with a suitable step punch towards the propeller flange. Clean and inspect bearing seat.
◆ NOTE: During this procedure, the needle sleeve (3), the oil seal (9) and the ball bearing (2) are damaged and must be replaced.
■ CAUTION : The attachment screw (6) 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
Fig. 72-30 vacuum pump drive, however, it is only 14 mm long
(0.55 in.) with standard screw head.
4
6
2
7
8
3
00252
9
5
1
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Edition 1 / Rev. 3
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Maintenance Manual
3.9.7) Propeller governor drive removal
See Figs. 72-31 and 72-32.
Remove banjo bolts (1) M10x1 and both sealing rings (2) from the governor flange (3) and the oil pump housing and remove the oil line.
Remove the 4 allen screws (4) M6x20 and 2 allen screws (5) M6x16 for oil inlet flange fixation. Remove governor flange with O-ring and distance sleeve (item 9 of fig. 72-34) behind.
Fig. 72-31
1
2
4
3
4
4
4
5
00256
5
After removal of propeller gearbox the drive can be disassembled. Fix the drive sleeve (9) with holder, part no. 242660. Unscrew allen screw
M8x16 (7) and remove the governor gear (8) with the drive sleeve (9).
Remove the countersunk screw (10) M5x12 with the washer for ball bearing fixation.
Press out the needle sleeve (11) and the ball bearing (12) with a suitable step punch towards the gearbox.
◆ NOTE: Needle sleeve and ball bearing will be damaged by this procedure and must be replaced.
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BRP-Powertrain
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Fig. 72-32
7
8
10
12
11
9
16
14
13
15
00257
Measure the inner diameter (13) of the propeller shaft and the bearing neck (14) of the oil inlet flange (GB05 and GB06). Any wear will probably appear as a flat area on the journal. Check the gear-tooth system of the drive gear (15) and the vacuum pump gear (8). Carry out a visual inspection of the ball bearing (12) and the 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, however, it is only
14 mm long (0.55 in.) with standard screw head.
Clean parts carefully and remove sealant residues. Check the sealing surface and all oil bores in the governor flange (3) for free passage. Carry out a visual inspection of the needle sleeve (11) and the gear-tooth system and bearing surface of the drive sleeve (9). Ensure that the connecting face for the oil pressure line is clean.
The governor must be sent to the manufacturer if any repair work becomes necessary.
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Edition 1 / Rev. 3
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BRP-Rotax
Maintenance Manual
3.9.8) Propeller governor drive installation
See Figs. 72-32, 72-33 and 72-34.
■ CAUTION : The oil inlet flange must be properly aligned and the Oring must not be squeezed.
Install needle sleeve and ball bearing as described in 72-00-00 sec.
3.9.9.
Grease new O-ring (1) and insert it together with the oil inlet flange (2) into the crankcase. Take care that both M6 threads are horizontal and the oil gallery is in a position to let the oil pass. For better positioning, temporarily attach governor flange with 2 allen screws M6x20 (12) and oil inlet flange with 2 allen screws M6x16 (13). Do not torque screw, only tighten enough to keep flange aligned.
Screw extractor (3), part no. 877615, onto the crankcase, place pressin insert (4), part no. 877590, into roller bearing (5), place on the centering (6) and press it fully home into the crankcase with the spindle
(7). Fit circlip in groove with its sharp edge towards the outside.
Align drive gear lip (8) Fig. 72-32 into drive sleeve notch (9) Fig. 72-32 with holder, part no. 242660. Apply LOCTITE 648 to the allen screw
M8x16 and tighten. Torque to 25 Nm (19 ft. lb).
Fit the governor flange (8) again. Fit distance sleeve (9) and new O-ring
(10) 32x4 into the crankcase. Place one O-ring (11) 7x2 into the oil inlet flange and one into the governor flange and keep them in position with some grease. Fit the governor flange and attach it to the crankcase with
4 allen screws (12) M6x20 and to the oil inlet flange with 2 allen screws
(13) M6x16.
Fig. 72-33
7
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00258
3
6
4
2
1
5
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Maintenance Manual
■ CAUTION : Longer screws will damage the oil inlet flange.
◆ NOTE: Tightening torque 10 Nm (90 in.lb). The allen screws
(12) and (13) are secured with LOCTITE 243.
Fit the governor (14) and the new gasket (15). Make sure that the toothing is engaged and the toothed shaft of the governor move easily into the drive sleeve (5). Do not use any tools (such as a hammer) for insertion.
Depending on governor type different screws and nuts are needed.
See SB-912-052 and SB-914-035, “Installation / Use of governors“, 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 pressure inspection can be connected at position (19) if necessary. The maximum governor pressure is between 21.5 bar (312 p.s.i) and 24.5 bar
(355 p.s.i), depending on governor type. The governor starts regulating at 3400 to 4150 rpm.
Malfunction of the propeller governing may be caused by the following:
— incorrect adjustment of governor actuation
— malfunction of propeller governor
— insufficient oil pressure, oil pressure fluctuations
— propeller pitch control.
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Edition 1 / Rev. 5
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BRP-Rotax
Maintenance Manual
Fig. 72-34
Effectivity 912/914 Series
Edition 1 / Rev. 0
18
9
10 8
18
19
12
14
11
20
13
15
16
00259
17
72-00-00 page 37
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BRP-Rotax
Maintenance Manual
3.9.9) Vacuum pump drive installation
See Figs. 72-34, 72-35 and 72-36.
Lubricate new needle sleeve (3). Position puller cap (10), part no.
876489, on crankcase side, place press-in insert, part no. 877579, (11) onto the needle sleeve and fix with the hex. nut (12). Turning the hex.
screw (13) clockwise presses the needle sleeve in completely.
The ball bearing is pressed in 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 jig, part no.
877276, and greased. Apply LOCTITE 243 to the sunk screw (7)
M5x12 and the washer (8) for ball bearing fixation and tighten.
■ CAUTION : The length of allen screw (6) M8x14 must never be altered, as otherwise the screw will collide with the drive shaft of the vacuum pump.
Fit vacuum pump gear (4) and fix drive sleeve (5) with holder, part no.
242660. Apply LOCTITE 648 to allen screw (6) M8x14 and turn it in.
13
10
Fig. 72-35
00253_a
3
11
12
13
4
10
2
14
12
6
7
8 9
5
Effectivity 912/914 Series
Edition 1 / Rev. 6
Fig. 72-36
00252
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3.9.10) Gearbox components inspection
See Figs. 72-37, 72-38, 72-39, 72-40, 72-41 and 72-42.
Clean disassembled gearbox with suitable cleaning agents and check the following parts:
— Check that the bearing bushing (1) for crankshaft support bearing in the gear cover fits tightly 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 shaft and check for run out. Check the run out of the propeller flange, see dimension (GB04).
See 72-00-00 sec. 4.
Fig. 72-38
AE_912_206
Fig. 72-37
4
6
1.1
1.2
1
5
00266
3 2
7
— Check oil spray nozzle (1.1) for blockage and if it is bended. In case of disassembly loosen the banjo bolt (1.2) with Torx T40.
■ CAUTION: The entire propeller shaft with attachment bores must be free of corrosion, and there must be no fretting corrosion at bearing points
((2) and (3)).
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BRP-Powertrain
Maintenance Manual
Treatment of corrosion damage and surface damage to the propeller flange
The flange of the propeller shaft is subject to corrosion. After wrapping the propeller shaft (2) in plastic tape or covering it with plastic tubing, the propeller flange can be treated with an abrasive.
■ CAUTION: Before applying the protective coating, carefully cover the flange face (3), the attachment bores and the propeller shaft in this area (2).
To prevent corrosion damage, the back of the propeller flange should be coated with a corrosioninhibiting agent.
Where there is greater corrosion damage and the material has been affected, the propeller shaft must be replaced.
When carrying out any of these steps, the manufacturers instructions must be observed.
— The ball bearing (6) must be an interference fit on its outer race in the gearbox housing and on its inner race on the propeller shaft.
Check groove (7) for the retaining rings and the gear-tooth system
(8) for wear or damage.
On configuration 3, the inner diameter (9) of the propeller shaft must be checked in the area of the oil inlet flange (10), dimension (GB05/
GB06). See 72-00-00 sec. 4.
◆
NOTE: The dimension GB05 or GB06 by itself is not as important as the radial clearance between GB05/GB06.
Inspect the propeller shaft for cracks. See 00-00-00 sec.10.4.
Register the results of the magnetic particle inspection in the respective form sheet. See 72-00-00 sec. 5.
Fig. 72-39
8
1
9
10
07454
7
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Edition 1 / Rev. 3
72-00-00 page 40
October 01/2010
BRP-Rotax
Maintenance Manual
— Carry out a visual inspection of the dog gear (11) and the dog hub
(12) to establish whether pitting is visible on the gear-tooth system and/or the sliding ramps (GB08) of the dogs. Ensure that the ramp tops of the dog gear are clearing the ramp valleys of the dog hub.
Check the gap between the ramp top and the ramp valley, see dimension (GB07). See 72-00-00 sec. 4. Light to medium traces of wear and pitting on the dogs are permissible.
11
Fig. 72-40
12
GB08
GB11
13
GB07
07420
— Check the gear-tooth system (14) of the gear set.
— Check the eccenter for the fuel pump and the fuel pump tappet for wear, see 72-00-00 sec. 3.9.4 and 73-00-00 sec. 3.4.8
— Check the step collar for wear in the area of the disc spring support, see 72-00-00 sec. 3.9.4.
— Measure the thickness of the plastic thrust washer (13) between the dog gear (11) and the drive gear (15), see dimension (GB11).
See 72-00-00 sec. 4.
— Check the hardened steel dog gear bush (16) for wear.
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BRP-Rotax
Maintenance Manual
Fig. 72-41
14
11
13 15
15
00269
17
16
— 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.
Fig. 72-42
00271
19
19
18
GB13
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Maintenance Manual
3.9.11) Toothed shaft profiles inspection
See Fig. 72-43.
There are two important toothed shaft connections 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 shaft profiles, the tooth width at the head of the respective inner and outer gear-tooth system must be measured. The lowest value is decisive in each case.
See 72-00-00 sec. 4.
CS07,
GB15
Fig. 72-43
GB14,
GB16
07471
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BRP-Rotax
Maintenance Manual
3.9.12) Gear set inspection
The gear set is inspected to detect any damage to the gear-tooth system.
◆
NOTE: The gear set can be inspected with the gearbox installed by using an endoscope with flexible shaft. This must be done in such a way that the condition of the gear flanks can be precisely evaluated - which requires experience.
■ CAUTION: Inspect all gear tooth contact surface for signs of damage and pitting.
Gear set pitting can cause high frequency vibration. This vibration may result in severe problems. As it is transmitted throughout the engine and its attached components:
– fuel pump damage
– gearbox wear (splines and 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 engine is approx 0.5 to 1.0 inch per seconds or ask the aircraft manufacturer for the figures for the particular installation.
Pitting can take many forms, from tolerable break-in pitting to spallation . To assist your judgement, please read the following.
General note on pitting:
Pitting is the breaking off of smaller or larger material particles from the active gear tooth contact surface. Whereas the fracture of a tooth results in gearbox failure, pitting will not normally influence the running of the gearbox. There are different degrees of pitting.
◆
NOTE: Fine pitting or areas of pitting hardly influence the operation of the gear-tooth system.
However, pitting will normally increase with the period of operation.
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The speed at which the pitting increases depends on the lubricant used and the load. The pitted area can become so large that the remaining, unaffected tooth flank can no longer transmit the load safely. Further operation of the components in this condition will result in the total destruction of the gear-tooth system.
◆ NOTE: The most common area where pitting forms is on the base of the gear tooth on the drive gear. For this reason, inspect the drive gear first.
Pitting is damage caused by material fatigue. The latest insights reveal that its formation is influenced by exceeding the permissible Hertzian stress for the material, tangential stress on the surface (friction) and temperature strain. This means that in addition to the material and heat treatment of the material, the surface quality and 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 size of the pitted area, the type of pitting involved and the number of areas affected.
– minor pitting (breakin pitting)
– advanced pitting
– spallation (large zones of the tooth surfaces have broken off)
Minor Pitting: See Figs. 72-44, 72-45 and 72-46.
Characteristics:
Isolated small areas of pitting (up to approx. 0.5 % of the flank area) or porelike zones of pitting, usually only found at the root of the flank.
The formation of this type of pitting may stop once the gearbox wearin period is over.
Causes:
High local pressure on new gears which have not yet been broken in can cause isolated pitting. With increased wear, the stress on these areas is relieved and the pitting may stop. In the same way, changes in the operating conditions can stop the progress of pitting formation.
Conclusion:
This type of pitting does not prevent safe operation. The gear set can remain in use.
◆ NOTE: Figs. 72-44 to 72-46 show gear flanks with minor pitting.
Effectivity 912/914 Series
Edition 1 / Rev. 2
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July 01/2008
◆ NOTE:
BRP-Rotax
Maintenance Manual
Because of the small size of the pitting shown and the copying process, the pictures may not show the pitting clearly enough. If you are in any doubt, seek assistance by studying technical publications or consult your authorized ROTAX distributor or Service Center.
Fig. 72-44
Magn.: approx. 100%
00148
Fig. 72-45
Magn.: approx. 75%
00149
Effectivity 912/914 Series
Edition 1 / Rev. 2
Fig. 72-46
Magn.: approx. 75%
00150
72-00-00 page 46
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Maintenance Manual
Advanced pitting:
See Figs. 72-47 and 72-48.
Characteristics:
Larger areas of breakoff, normally appearing as pitting zones. The breakoff surface usually has a shelllike structure. The total pitting zone may reach a size where it impairs smooth engine running noticeably or the remaining flank surface wears rapidly and is destroyed.
Causes:
The pitting can be attributed to material fatigue due to a combination 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 viscosity and oil temperature.
Conclusion:
Pitting of up to approx. 5 % of the flank surface is permissible if the size of the pitting (at its widest point) does not exceed 0.5 mm (0.02 in). If this value is exceeded, the gear set must be replaced!
▲
WARNING: Gears must always be replaced as a set. Replacement of individual dog gears or drive gears is not permissible.
Effectivity 912/914 Series
Edition 1 / Rev. 0
Pitting in the area of the root flank of a spur gear.
Fig. 72-47
Magn.: approx. 75%
00151
00152
Pitting formation at the foot of spur toothing
Fig. 72-48
Magn.: approx. 75%
72-00-00 page 47
May 01/2007
BRP-Rotax
Maintenance Manual
Spallation (large zones of the tooth flank have broken off)
See Figs. 72-49 and 72-50.
Characteristics:
Large triangular areas of the tooth flank have broken off, starting in a grey zone or area of minor pitting on the root of the tooth. The spalling area is of relatively constant depth. Additional cracks may stretch across the flank from 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 oil temperatures. Otherwise, the causes are the same as for other types of pitting.
Conclusion:
■ CAUTION: If spallation is detected, the gear set must be replaced.
Max. permissible pitting or spallation. See section on advanced pitting.
◆ NOTE: Figs. 72-49 and 72-50. show triangular spallation.
▲ WARNING: Gears must always be replaced as a set. Replacement of individual gears is not permissible.
Fig. 72-49
Magn.: approx. 75%
Fig. 72-50
Magn.: approx. 100%
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3.9.13) Propeller gearbox reassembly
See Figs. 72-51, 72-52 and 72-53.
◆ NOTE: At the modification of the gearbox (e.g. reduction ratio, retro-fit of overload clutch) the part number on the gearbox housing must be corrected. See Fig. 72-51/1.
Install the oil spray nozzle (1.1) with the banjo bolt M8x1 (1.2) into the gearbox housing. Torque to 20 Nm (170 in lbs).
Heat gearbox housing (1) with hot air (or in an oven) to approx 100 ° C
(212 °F). Press shaft seal (2) into the gearbox housing from the inside, using insertion jig, part no. 876518, and grease sealing lips (3). Add radius ring (4) 36/50/ 5.5 with rounded side towards shaft seal. The weight of the ball bearing (5) must cause it to fall into the bearing point of the heated gearbox housing. Apply small amount of LOCTITE 243 into tapped holes and install 4 hex. screws with hardened washers.
Torque to 15 Nm (130 in lbs).
◆ NOTE: “Closed” plastic cage of bearing must be placed towards the propeller flange.
Slide the propeller shaft into the gearbox housing and place on a suitable flat surface (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 that the sleeve presses against the inner ring (11). Press on the gearbox housing, turning it slightly (left-right).
■ CAUTION : Do not tap!
It is an advantage if the gearbox housing is still warm at this stage.
Place distance sleeve (13) 35.2/42/8 and eccenter (14) for the fuel pump onto the propshaft.
Place these components on horizontally and in this order: step collar
(15) with the ø40.8 mm ( 1.60“) towards the disc spring, then two disc springs (16) facing each other and the third disc spring (17) with its back to the second disc spring. Make sure that the disc springs lie against the centering rib (18) of the clutch hub. Apply LOCTITE Anti-Seize to the tooth profile of the slipper clutch (19) and place it onto the propeller shaft.
Effectivity 912/914 Series
Edition 1 / Rev. 6
72-00-00 page 49
July 01/2018
Fig. 72-51/1
12
Fig. 72-51
BRP-Rotax
Maintenance Manual
Carefully fit pre-oiled bearing bushing (20) onto the propeller shaft using circlip pliers. Push on dog gear (21), apply LOCTITE Anti-Seize to both sides of the plastic thrust washer (22) 33.2/51/1.2 and place it on together with drive gear (23).
■ CAUTION : The contact surface of the plastic thrust washer must be level (flat). Risk of breakage!
◆ NOTE: Gearboxes without an overload clutch have no third disc spring (17), centering rib or slipper clutch. Instead, they are fitted with a second step collar (15) and spacer
35.2/42/6, 35.2/42/8 (13), see Figs. 72-52 and 72-53.
■ CAUTION : If the disc springs 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 accurately.
◆ NOTE: Coat contact surfaces of disc springs and dogs as well as the tooth profile of propeller shaft with LOCTITE
Anti-Seize.
gear cover p/n XXXXXX gearbox p/n XXXXXX gearbox s/n XXXXX
1.2
1.1
part no. (6 digit)
1
5
2
10
11
3
4
7
6
Fig. 72-52
AE_912_208
Effectivity 912/914 Series
Edition 1 / Rev. 6
9 8
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■ CAUTION : Danger of material damage! Always install a new thrust washer.
3.9.14) Disc spring pre-tension adjustment (with overload clutch)
See Figs. 72-53 and 72-25 (see Section 72-00-00 / 3.9.4).
When the propeller shaft assembly is uncompressed, the contact surface (24) for the ring halves must lie in the groove of the propeller shaft 1 mm (0.039 in.) over the upper edge (25). The difference must be compensated for by placing shims (26) between eccenter (14) and step collar (15).
◆ NOTE: To facilitate adjustment, they can first be pushed apart until the top edge (25) of the contact surface (24) for the ring halves slips into the groove in the propeller shaft and a 1mm (0.039 in.) compensating shim (26) can be inserted between step collar (15) and eccenter (14).
◆ NOTE: To check the friction torque of 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)
See Fig. 72-53
Completely compress disk springs utilizing mounting yoke part no.
876885. The lower edge of the groove (25) in the propeller shaft must align with the top edge of the retaining ring (24) (distance must not be more than 0.2 mm (0.008 in)). Set distance by shims to max. 0.2 mm
(0.008 in).
After completing the adjustment of the disk spring travel, depress dog gear (2) with mounting yoke, part no. 876885, until both ring halves can be inserted.
■ CAUTION : Always use new ring halves.
Insert ring halves and release pressure, see 72-00-00 sec. 3.9.4.
■ CAUTION : If the spacing is insufficient, never overpress the springs, as this will cause the dog gear to collide with the gear cover.
■ CAUTION : The ring halves must be completely inserted in the groove on propeller shaft!
Check that the ring halves are positioned correctly.
Effectivity 912/914 Series
Edition 1 / Rev. 6
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Fig. 72-53
Version with dog hub
25
24
25
27
20
24
23
22
21
BRP-Powertrain
Maintenance Manual
Version with overload clutch
24
25
27
20
25
24
23
22
21
15
15
13
26
14
13
18
16 disk springs compressed
17
19
15
26
14
13
16 disk springs unloaded
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3.9.16) Propeller gearbox — installation
See Figs. 72-54, 72-55 and 72-56.
Carry out a visual inspection of the crankshaft (1) on the power take off side. Slide drive gear (2) onto the crankshaft (3).
◆ NOTE: Due to the restricted tolerances it can occur that it is difficult to slide the drive gear onto the crankshaft. In such a case try to slide on the drive gear in a different 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 the friction washer (5).
Apply LOCTITE 648 to hex. nut (4) M30x1.5 and screw the nut onto the crankshaft together with the friction washer (5) VS30. Tightening torque
200 Nm (147.5 ft.lb). Then measure the run out (CS24).
See 72-00-00 sec. 4.
Fig. 72-54 Fig. 72-55
1
5
2
4
3
6
08188 07507
◆ NOTE: If there is slight radial run out, reinstall nut (4) and measure again.
■ CAUTION : Dog gear and drive gear are paired and are marked with a consecutive serial number (6). Use only parts with the same serial number!
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Clean sealing surface of gearbox housing and crankcase. Oil which drains onto the sealing surface will eventually create a leak. Insert both dowel pins
6x20 into crankcase. Grease oil seal for propeller shaft in crankcase.
Lubricate bearing bore for propeller shaft.
◆ NOTE: Engines of the 912/914 Series configuration 3 and configuration 4 have no oil seal.
Keep the rollers of the roller bearing in position with grease to facilitate assembly of propeller shaft.
Position gearbox housing with completely pre-assembled gear unit, previously 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 a plastic mallet, the gearbox is fitted on the crankcase.
◆ NOTE: If there is resistance with a gap of approx. 10 mm (0.4
in.), the alignment of the rollers may need readjusting.
Fix the rollers in position again with grease, press them outwards and / or turn the vacuum pump /governor gear slightly to allow engagement.
■ CAUTION : If excessive force is applied at assembly, the roller bearing or the vacuum pump drive can be damaged.
If the sealing surface becomes oily during the assembly process, clean it and reapply surface sealing compound LOCTITE 5910 or 574.
Tighten gearbox evenly with 2 allen screws M8x45 and 8 allen screws
(7) M6x45 and lock washers in a crosswise pattern.
Fig. 72-56
GB18
7 8
9
8
7
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Check the radial gear backlash at the propeller flange (9) with the dial gauge (8), dimension (GB18). See 72-00-00 sec. 4.
Check the friction torque. See the relevant Manual (Line Maintenance)
12.00.00 chapter 7 of the corresponding engine type 912 Series and
914 Series.
Remove crankshaft locking screw and fit crankshaft plug screw M8 x
20 with new Cu gasket ring and tighten to 15 Nm (133 in.lb). For verification turn crankshaft with spanner 24 a/f on hex. 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 allen screw M6x25 (1) and washer from valve cover (2) and lift off valve cover and large and small O-ring. Remove crosswise 2 flanged nuts (3) with washers (4) and two collar cap nuts M8. The collar cap nut is inside the valve cover and has a sealing edge.
◆ NOTE: There is no washer required under the collar cap nut.
On newer engine versions, no washers (4) are fitted. They can be left out during assembly on all engine versions.
■ CAUTION: Do not damage the sealing surface!
Using both hands, carefully pull the complete cylinder head off the cylinder (5).
1
Fig. 72-57
00277
2
3
4
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Edition 1 / Rev. 3
5
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BRP-Rotax
Maintenance Manual
Keep both push rods (6) in position in the oil return tubes (7), seal oil bore of push rods with finger and remove cylinder head (8). The oil return tubes remain with the cylinder head. Remove O-rings (9) 16x15 from the oil return tubes or from the crankcase (10).
Store cylinder head in 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 prevent any mix-up.
Mark the installation position of the push-rod with a suitable pen (e.g. touchup pen) (e.g. ¨IV1“ for intake valve cylinder 1). If the parts are refitted in exactly the same position and assignment as before, the push-rods can be used again. This is because the parts have become broken in to each other in the course of operation before disassembly.
Fig. 72-58
8
7
00278
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9
6
10
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BRP-Rotax
Maintenance Manual
3.11) Cylinder head - disassembly
See Fig. 72-59.
If the rocker arms are to be dismantled without removing the cylinder head, turn the crankshaft to set the piston of the respective cylinder to ignition T.D.C. so that only little pressure remains on the rocker arm. Depress rocker arm with check lever part no. 877690 towards the hydraulic valve tappet. Now the rocker arm is completely released and the rocker arm shaft can be removed.
◆ NOTE: Never use force to press out the rocker arm shaft. The hexagon of the collar cap nut may be in an unfavorable position and prevent removal of the rocker arm shaft. In this case, loosen the nut.
Withdraw rocker arm shaft and remove both rocker arms.
◆ NOTE: Newer engine versions have plastic bushings as bearings.
These plastic bushings 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 lift out valve cotters.
Release valve spring. Remove valve spring retainer and both springs and withdraw valve.
◆ NOTE: Prior to removal of valves, clear burrs which may be present on valve stems to prevent damage to valve stem seal and valve guide. Mark valves coordinately.
Repeat procedure for the second valve. Clean cylinder head.
Check oil return tubes for leaks (visual inspection). If there is leakage in area (3), the respective oil return tubes must be replaced. For this procedure, heat the return tubes with a hot air gun to max. 120 °C (248 °F). Extract the oil return tubes and remove any glue residues from the bore. Apply LOCTITE 648 on the new oil return tubes in the area of the two grooves and twist and push tube into position in the preheated cylinder head. After that heat the cylinder head 10 to 15 minutes to 100 °C (212 °F) so that the LOCTITE hardens.
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When replacing the coolant elbow, mark its position, heat the area with a hot air gun to max. 120 °C (248 °F) and unscrew the fitting. Remove residues of
LOCTITE means and check threads. Apply LOCTITE 648 to the thread on the cylinder head and to the new coolant fitting and screw the fitting into the cold cylinder head. Leave cylinder head to harden for approx. 10 minutes at 100 °C
(212 °F).
If there are oil carbon residues on the sealing face with the cylinder, remove them carefully. Check that the 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 sec. 10.3.
■ CAUTION: For valves sandblasting is not allowed (as cleaning method).
Check cylinder head sealing surface and if necessary, blue it and the cylinder.
The flat surface of the cylinder and the cylinder head may only be slightly machined.
◆ NOTE: In the event of more serious leakage, cylinder and cylinder head can be reworked as described in the Overhaul Manual by a
ROTAX authorized overhaul facility.
If the engine has been "run hot", the hardness of the cylinder head and the cylinder material must be checked.
See 72-00-00 sec. 5 and the corresponding Maintenance Manual (Line Maintenance) for the respective engine type 912 or 914 Series.
Fig. 72-59
2
1
3
00280
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Maintenance Manual
3.11.1) Cylinder head and exhaust manifold studs
See Figs. 72-60, 72-61 and 72-62.
Studs M8 x 20/23 (1) are for attaching the exhaust manifold. Check for tight fit and any damage.
When replacing a stud, it is fitted so that the longer 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 be checked. See the corresponding
Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series. Hardness is tested at control point CH08 as shown in Fig.
72-61.
Procedure for hardness test:
CH08: HB2.5/62.5 DIN EN ISO 6506-2
■ CAUTION: The results of the hardness test must be entered in
72-00-00 sec. 5.
Fig. 72-60 Fig. 72-61
CH08
1
07447
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1
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◆ NOTE:
BRP-Rotax
Maintenance Manual
If the rocker arm shaft bearing (CH05) is worn, it can be reworked up to a certain limit. The cylinder head must be sent to a ROTAX authorized overhaul facility for this purpose.
Fig. 72-62
CH05
CH05
07831
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Edition 1 / Rev. 0
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Maintenance Manual
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, the cylinder head must be sent to a ROTAX authorized overhaul facility for overhaul.
Fig. 72-63
1
08244
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Edition 1 / Rev. 2
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BRP-Rotax
Maintenance Manual
3.11.3) Valve guides
See Figs. 72-64 and 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 cylinder head must be sent to a ROTAX authorized overhaul facility for maintenance.
Fig. 72-64
Maß dim.
CH01
2
Fig. 72-65
1
Maß / dim.
VT01
00279
00281
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Maintenance Manual
3.11.4) Valve seats
See Fig. 72-66.
Carry out a visual inspection of the valve faces for damage and wear.
Apply engineers blue evenly to the valve faces and fit the valves into the respective valve guides. Turn the valve under gentle 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.
■
CAUTION: The annular imprint on the valve face must be a continuous, unbroken ring.
The width of the imprint corresponds to the width of the valve seat CH02.
■
CAUTION: If burned spots or deformation are detected, send the cylinder head to a ROTAX for overhaul or repair.
authorized overhaul facility
See 72-00-00 sec. 4.
Effectivity 912/914 Series
Edition 1 / Rev. 3
1
45°
CH02
00285
Fig. 72-66
72-00-00 page 63
October 01/2010
BRP-Rotax
Maintenance Manual
3.11.5) Valves
See Figs. 72-67, 72-68, 72-69 and 72-70.
Intake valves are checked as follows:
Carry out a visual inspection of the valves for damage 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 72-00-00 sec. 4.
Check valve front surface (5) for pitting.
Check valve stem for possible deposits. Heavy oil carbon residues (2) on the valve stem indicate increased wear on the valve guide.
5
3
Fig. 72-67
3 mm
(0.12 in.)
1
2
3 mm
(0.12 in.)
07443 max 20%
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Oil carbon residue on up to max 20% of the moving path is permissible.
See Fig. 72-67.
■
CAUTION: If there are heavier deposits, the valve may already have overheated and must be replaced. There is a danger of valve fracture at the weld.
Carry out a visual inspection 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 measure the max.
permissible out of true value VT02 on the valve disk using a dial gauge.
See Fig. 72-68.
◆ NOTE: The out of true value can also be measured with the dial gauge adapter assembly part no. 976140 (7). See
Fig. 72-69.
See 72-00-00 sec. 4.
VT02
90
80
0
10
20
30
70
1
2
0
9
8
3 4 5
7
60
0.01mm
40
50
5
Fig. 72-68
07482
4
~45 mm
(1.77 in.)
4
~25 mm
(0.98 in.)
7
Fig. 72-69
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Check the valve face for wear caused by pounding VT03.
Pounding may occur on the inside and the outside edge of the 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 necessary, the valve must be replaced.
However, lapping with valve lapping paste is possible.
Seal-lap both valves and check for leakage.
■ CAUTION: The end of the valve stem (5) must not be ground.
See Fig. 72-68.
Fig. 72-70
VT03 VT03
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3.11.6) Valve springs
See Figs. 72-71 and 72-72.
Carry out a visual inspection of the valve springs for damage and wear.
Depending on engine version, dual or single valve spring configurations 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 strength.
The springs for inlet and outlet are equivalent and symmetrical.
Dual valve spring configuration:
– Inner valve spring (1)
– Outer valve spring (2)
Single valve spring configuration:
– Single valve spring (3)
2.3 mm (0.09 in)
3.5 mm (0.14 in)
3.85 mm (0.15 in)
Valve spring support (4)
Valve cotter (5)
4
3
Fig. 72-71
5
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2
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To check the spring force, apply a test load ( F ) and measure the remaining spring length VT04. For the measurement necessary tools are available on the free market. See Fig. 72-72.
Test load for dual valve spring configuration:
– Test load ( F ) for inner spring
– Test load ( F ) for outer
53 N (11.91 lbf)
133 N (29.80 lbf)
Test load for single valve spring configuration:
– Single valve spring 200 N (45 lbf)
■
CAUTION: Replace valves shorter than the minimum length.
◆ NOTE: The spring length should be as equal as possible on the inlet and outlet sides (max 0.4 mm (0.016 in.) in difference), otherwise replace the springs.
See 72-00-00 sec. 4.
Fig 72-72
F
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3.11.7) Washers
See Figs. 72-73, 72-74 and 72-75.
Carry out a visual inspection of the washers for damage and wear.
The wear must be measured radially with a dial gauge, starting from the reference area (on the inner part of the valve spring support) in measuring range radius (1) and working towards the outside. Dimension t=max. 0.04 mm (0.0016 in.). see Fig. 72-75. Pounding (wear) of more than 0.04 mm (0.0016 in.) is not permissible. 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 the affected valve.
◆
NOTE: The valve spring support can indicate a malfunction of the valve train as a result of badly or insufficiently vented hydraulic valve tappets. Under normal conditions, no measurable wear will be seen, even after longer periods of operation. If a visual inspection reveals pounding wear on the contact surface, the current wear must be tested using a dial gauge.
See SI-912-018 / SI-914-020, “Purging of lubrication system”, latest issue.
Fig. 72-73
„magnified image“ Fig. 72-75
Fig. 72-74
„magnified image“
05450
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1
09864
09864
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3.11.8) Rocker arm and rocker arm shaft
See Figs. 72-76 and 72-77.
The rocker arm bearing (1) is lubricated via the hollow pushrod (2) to the ball joint (female) (3). The oil flows through the oil ducts (4) in the rocker arm to lubricate the rocker arm bearing. The oil exit and thus the splash oil lubrication of the complete valve mechanism is via bore (5) The rocker arms for the inlet and outlet 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 joint (female) (3) of the rocker arm.
Excessive signs of wear indicate lack of oil. Slight reworking of contact area (7) for the valve stem is permissible. Check oil bores (4) in the rocker arm for free passage.
◆ NOTE: Oversize rocker arm shafts and rocker arm bushings are available for repairing the rocker arm bearing in the cylinder head.
The bronze colored fitted bearing bushing (6) cannot be replaced. If necessary, replace the whole rocker arm.
3.11.8.1) Rocker arm with plastic bushing
See Figs. 72-78, 72-79 and 72-80.
In the case of plastic rocker arm bushings (2), it must be ensured that the bushing is of slide fit design. After installation, it must still be possible to rotate it against the rocker arm bore.
Fig. 72-76
00286
5
3
7
6
1
Effectivity 912/914 Series
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Fig. 72-77
00287
4
6
Maß dim.
VT07
72-00-00 page 70
May 01/2007
2
Fig. 72-78
05122
Fig. 72-79
07409
VT08
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Edition 1 / Rev. 0
2
3
1
BRP-Rotax
Maintenance Manual
To allow this, the plastic bushing is equipped with a circular groove (1) on its circumference via which it is supplied 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 important to ensure that the bushing (2) is fitted together with the rocker arm.
See SI-912-009 /SI-914-010,“Introduction of a new rocker arm bushing“, latest issue.
◆
NOTE: Oversize rocker arm shafts and rocker arm bushings are available for repairing the rocker arm bearing in the cylinder head.
Ensure that the correct rocker arm bushing is fitted. For easy identification, the oversize rocker arm bushing, part no. 933397, has two opposed bores (3).
Fig. 72-80
07498
VT06
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3.11.8.2) Rocker arm with pressed sinter bushing
See Fig. 72-81.
See 72-00-00 sec. 4.
The bearing bush cannot be replaced. If the rocker 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.
Fig. 72-81
07497
VT07
3.11.8.3) Rocker arm shaft
See Fig. 72-82.
See 72-00-00 sec. 4.
Check the surface of the rocker arm for signs of friction.
◆ NOTE: Oversize rocker arm shafts and rocker arm bushings are available for repairing the rocker arm bearing in the cylinder head.
Fig. 72-82
Effectivity 912/914 Series
Edition 1 / Rev. 0
07496
VT05
72-00-00 page 72
May 01/2007
BRP-Rotax
Maintenance Manual
3.12) Cylinder head reassembly
See Fig. 72-83.
Place valve spring support (1) in position on the valve guide and fit new valve stem seal (2) on inlet side only. Push oiled intake valve (3) into the valve guide from the outside, slide on both valve springs (outside (4) and inside (5)) or single valve spring (17) and the valve spring retainer (6). Press the valve springs together with the mounting device and pliers, insert 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 valve cotters.
Apply MOLYKOTE G-N to the rocker arm bore (9), the pushrod head (10) and the valve contact area (11). Position inlet rocker arm (12) and outlet rocker arm (13) with bushing (15, 16), depending on the specific configuration, apply MOLYKOTE
G-N to the rocker arm shafts (14) on both sides, see 00-00-00 sec. 10.3, and push into the bearing support.
◆ NOTE:
◆
NOTE:
The rocker arm bearing support is a slide fit. Do not exert force!
Fig. 72-83 shows the configurations with single and dual valve springs.
Lubricate all movable internal parts with engine oil.
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 73
May 01/2007
BRP-Rotax
Maintenance Manual
15
Fig. 72-83
9
16
12
12
7
6
6
12
14
17
2
1
2
1
3
11
4
5
6
10 7
6
5
13
16
10
9
13
15
07707
4
8
17
1
11
1
4
4
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 74
May 01/2007
BRP-Rotax
Maintenance Manual
3.13) Cylinder and piston - removal
See Figs. 72-84 and 72-85.
◆ NOTE: Prior to removal, mark cylinders and pistons in pairs to ensure correct coordination on re-assembly. The cylinders are all identical in design. The piston pin center 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 gearbox on all 4 cylinders and serves to ensure correct assembly of the pistons with offset centers.
Carefully pull off the cylinder. Support the piston by hand to avoid damaging piston and piston rings. Lift out the piston pin circlip (2) with a mono hook circlip puller (3), part no. 976380, see 00-00-00 sec. 10.6.
Fig. 72-84
1
--->
2
3
07708
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 75
May 01/2007
BRP-Rotax
Maintenance Manual
Push out piston pin using installation tool, part no. 877016. If the piston pin is fitted too tightly, it can be pulled out using 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 pulled from the conrod (8) into the extraction sleeve (9) until the piston (10) can be removed.
Remove nut (7) and extraction tool. Remove piston. Coordinate piston pin and piston with the respective cylinder.
Fig. 72-85
4
9
5 6
10
8
00291
7
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 76
May 01/2007
BRP-Rotax
Maintenance Manual
3.13.1) Checking pistons
See Figs. 72-86 and 72-87.
On engines of the 912/914 Series, light alloy full skirt cast pistons are used. The piston axis is offset by 1 mm (0.039 in.).
Remove piston rings using a pair of piston ring pliers. Make absolutely sure to re-fit rings in their initial position. Remove any oil carbon residue from piston rings and ring grooves. The best way to clean the groove root is by using a piece of a broken piston ring. Increased deposit is to be expected when using AVGAS 100LL. Remove carbon deposits from the piston crown.
Inspect and measure piston. Measure the cylinder and determine the permissible installation clearance in accordance with 00-00-00 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 the groove (2) for the piston pin circlip. If any burrs are detected, carefully remove them. If the groove is excessively worn (> 0.3 mm =
0.012 in. than the retaining ring), replace piston.
There are 2 tolerance groups, red and green (piston marked with a red or greencolored dot). The difference between them is 0.01mm (0.0004
in.). The "red" piston is the smaller one. The nominal piston size is stamped on the piston crown. Oversize pistons are not available. The piston is supplied only complete with 3 rings.
Determine the diameter of the piston pin.
See 72-00-00 sec. 4.
With the rings (3) fitted on the piston, measure the flank clearance with a feeler gauge (4). See Fig. 72-87. Increased deposits in the tubular spring (see Fig. 72-89 (3)) of the oil scraper ring indicate that AVGAS
100LL has been used.
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 77
May 01/2007
BRP-Rotax
Maintenance Manual
PI01
Fig. 72-86
PI02
PI02
07435
1
13mm
(0.51 in)
2
Fig. 72-87
3
Pl04
Pl05
Pl06
4
07412
Effectivity 912/914 Series
Edition 1 / Rev. 0
2
72-00-00 page 78
May 01/2007
BRP-Rotax
Maintenance Manual
3.13.2) Checking the piston ring
See Figs. 72-88 and 72-89.
Check the end clearance of the cleaned piston rings.
To determine the end clearance (4), remove the piston rings from the piston using piston ring pliers, clean them and insert into the cylinder.
Use a piston as pusher 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 ring surface (5), the portion of surface contact can be seen and indicates the wear. Install piston rings using piston ring pliers with the marking (6) "TOP" or the dot mark pointing upwards towards the piston crown.
Fig. 72-88
4
00294
Fig. 72-89
Rechteckring/rectangular ring
3
Minutenring/tapered compression ring
PI07/
PI08/
PI09 top top
6
5
5
00296
Effectivity 912/914 Series
Edition 1 / Rev. 2
72-00-00 page 79
July 01/2008
BRP-Powertrain
Maintenance Manual
3.13.3) Piston pin
See 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 72-00-00 sec. 4.
◆ NOTE: The circlips for axial piston pin retention must be used only once and must therefore be replaced.
Fig. 72-90
PI03
07403
Effectivity 912/914 Series
Edition 1 / Rev. 3
72-00-00 page 80
October 01/2010
BRP-Powertrain
Maintenance Manual
3.13.4) Cylinders inspection
See Figs. 72-91, 72-92 and 72-93.
The running surface of the cylinder is "NICKEL-SILICON"coated. All 4 cylinders are identical. Clean the cooling fins (1) of the cylinder.
Remove oil carbon deposits from the top end (2) of the cylinder bore.
Clean sealing surfaces on top (3) and bottom sides (4) and inspect cylinder.
Measure cylinder as shown in the following diagrams and enter 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 cylinder and/or the piston must be replaced.
◆ NOTE: Slight oil carbon residues on the cylinder sealing surface (3) indicate leakage. True up the cylinder along with the cylinder head.
■ CAUTION : If the engine has been overheated, the hardness of the cylinder must be checked. The hardness is measured at control point CY04. See Fig. 72-93. See 72-00-00 sec. 5.1.
Procedure for hardness test:
CH08: HB2.5/62.5 DIN EN ISO 6506-2
Effectivity 912/914 Series
Edition 1 / Rev. 4
72-00-00 page 81
February 01/2015
BRP-Powertrain
Maintenance Manual
Fig. 72-91
3 2
1
Fig. 72-92
07485
Effectivity 912/914 Series
Edition 1 / Rev. 4
4
00297
15
(0.59 in.)
(1.57 in.)
(2.99 in.)
A
Fig. 72-93
A
CY04
07413
72-00-00 page 82
February 01/2015
BRP-Rotax
Maintenance Manual
3.14) Hydraulic valve tappets
See Figs. 72-94, 72-95, 72-96 and 72-97.
Pull hydraulic valve tappets (1) out of the housing using the mono hook circlip puller (2), part no. 976380.
■
CAUTION : Never insert the puller into the retainer (3), but always into the groove in the hydraulic valve tappet. Inserting it into the retainer could cause the hydraulic valve tappet to fall apart. See Fig 72-
94.
Lay hydraulic valve tappets aside, arranging them in a manner that ensures they will be refitted in their original place.
Carry out a visual inspection of the hydraulic valve tappets for damage and wear.
◆ NOTE: The hydraulic valve tappets rotate during engine operation, so the camshaft lobes (4) should be worn evenly.
Failure of a hydraulic valve tappet to rotate will result in uneven wear (2) on the contact surface (1). If there 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 event of damage of the camshaft, the assy. engine block must be sent to a ROTAX authorized overhaul facility.
■ CAUTION : Taking apart hydraulic valve tappets is not allowed and not necessary.
■ CAUTION : In the event of malfunctions such as operation with un-purged hydraulic valve tappets, the components in the tappet (plate) are worn down.
■ CAUTION : If it is necessary to replace a hydraulic valve tappet, make sure that a tappet with a polished cam running surface (ROTAX part no. 881832) is used.
Depending on storage conditions, new hydraulic valve tappets are partially emptied and pump full of oil during engine startup. Oil enters the hydraulic valve tappet through the bore (5). The retaining ring (3) keeps the piston (6) in position when the hydraulic valve tappet is removed. See Fig. 72-95 and 72-96.
◆ NOTE: When putting into operation, observe SI-912-018 / SI-914-020
"Purging of lubrication system“, latest issue.
See 72-00-00 sec. 4.
Effectivity 912/914 Series
Edition 1 / Rev. 5
72-00-00 page 83
March 01/2017
Fig. 72-94
BRP-Powertrain
Maintenance Manual
3
2
Fig. 72-95
4
5
00299
1
Fig. 72-96
3
00300
6
Fig. 72-97
1
2
00301
07580
Effectivity 912/914 Series
Edition 1 / Rev. 3
72-00-00 page 84
October 01/2010
BRP-Rotax
Maintenance Manual
3.15) Pushrods
See Fig. 72-98.
Clean push-rods (1) and carry out a visual inspection. 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 the hydraulic valve tappet passes to the rocker arm through the bore (3).
See 72-00-00 sec. 4.
2
Fig. 72-98
1
80
90
0
10
20
70
60
2
1 0
9
3
4 5 6
8
7
50
0.01mm
40
30
07417
2
3
~160 mm
(6.30 in.)
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 85
May 01/2007
BRP-Powertrain
Maintenance Manual
3.16) Piston and cylinder assembly fitting
3.16.1) Hydraulic valve tappets fitting
Lubricate bearing bore for hydraulic valve tappets in crankcase. Apply
LOCTITE Anti-Seize to the contact surfaces of the hydraulic valve tappets, lubricate their circumference and insert them into the crankcase according to the recorded position . The hydraulic valve tappet must be able to 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 installation of the piston, the arrow (1) on the piston crown must point toward the propeller shaft. This means that on cylinders 1 and 3 , the offset (narrower side (2)) faces downwards, while on cylinders 2 and 4 , the offset
(narrower side (3)) faces upwards.
Install the piston as shown on Fig. adjacent the offset of the piston pin bore is 1 mm (0.039 in.).
If the arrow (1) on the piston crown is no longer visible, the piston must be measured to determine the correct pin offset. See fig. 72-99/72-100.
Fig. 72-99
1
Fig. 72-100
00303
Effectivity 912/914 Series
Edition 1 / Rev. 3
04709
72-00-00 page 86
October 01/2010
BRP-Rotax
Maintenance Manual
Fig. 72-101
Zylinder 1 und 3 /
Cylinder 1 and 3 auf den Propellerflansch gesehen / looking at propeller flange
3
Zylinder 2 und 4 /
Cylinder 2 and 4
Bolzenachse / piston pin axis
Bolzenachse / piston pin axis
00305
2
Oil the entire length of the piston pin (4). The connecting rod eye (5) and the piston pin bore (6) are also oiled. Insert piston pin with guide punch, part no. 877802 (slide fit).
If this is not possible, the piston 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 clockwise draws the piston pin in completely, up to the retaining groove (10).
Fig. 72-102
8
4
00306
9
7
10 6
5
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 87
May 01/2007
BRP-Powertrain
Maintenance Manual
■ CAUTION: Always use new mono hook circlips! Used retaining rings or retaining rings which have already been fitted have too little tangential tension, can twist and thus wear the groove in the piston.
Fit piston pin circlip with installation tool, part no. 877802. To do so, press the mono hook circlip (11) into the groove (14) of the mounting sleeve (13) and push guide punch (12) into the mounting sleeve. Slide mounting sleeve onto the installation tool.
■ CAUTION : The position 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 installation tool (15) into the positioning gauge and press the ring towards the front as far as the stop. Now position the complete installation tool (15) on the piston. Support piston with hand and exert strong pressure on the installation tool to push the mono hook circlip
(11) into the groove (16) of the piston. Apply same procedure on the opposite side of the piston.
◆ NOTE: Old style pistons (17) are made for hookless circlips, the mono hook circlip must be reworked as described in SI-21-1997 “Introduction of the mono hook circlip“, latest issue. See Fig. 72-105.
Fig. 72-103
13
12
14 11
04706
15
Effectivity 912/914 Series
Edition 1 / Rev. 3
72-00-00 page 88
October 01/2010
Fig. 72-104
BRP-Rotax
Maintenance Manual
02038
16
Fig. 72-105
17
(0.166 in)
4,2 mm
(0.079 in)
2 mm
(0.92 in) (0.92 in)
08206
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 89
May 01/2007
BRP-Rotax
Maintenance Manual
3.16.3) Cylinders fitting
See Fig. 72-106.
Place O-ring 87x2 on the cylinder skirt and oil the cylinder wall.
◆ NOTE: On engines with crankcases bearing serial numbers up to S/N 27811, there is an O-ring 87x2 fitted to depress stud bolt M8x297. This O-ring is not fitted on housing with serial numbers above S/N 06.0010.
◆ NOTE: In case of oil leakages in the area of the cylinder barrel a repair solution from crankcase S/N 06.0010 was created. See SI-912-019/SI-914-021 “Oil leakages in the area of the cylinder barrel”, latest issue.
■ CAUTION : To prevent breakage to the piston rings, the appropriate 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 attention to the position of the piston ring gaps (4). The gap in the first piston ring (1) should be positioned in the center of the bottom piston skirt. The ring gap in the second piston ring (2) and the gap in the oil scraper ring (3) should be inclined away from the center of the top piston skirt at an angle of between 25° and max. 30°. See Fig. 72-
106.
■ CAUTION : The ring gap should never be in the area of the piston pin bore.
■ CAUTION : Check twice whether the piston pin circlips are installed as prescribed.
Lubricate piston, compress piston rings with piston ring retainer and carefully fit the coordinated cylinder. Proceed in the same way for the other cylinders.
Effectivity 912/914 Series
Edition 1 / Rev. 2
72-00-00 page 90
July 01/2008
BRP-Rotax
Maintenance Manual
Fig. 72-106
25
° -
30°
25
°-
30°
25
° -
30°
25
° -
30°
05766
1
2
3
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 91
May 01/2007
BRP-Powertrain
Maintenance Manual
3.16.4) Cylinder head fitting
See Figs. 72-107, 72-108, 72-109 and 72-110.
Install respective pushrods (1) in both oil return tubes on the preassembled cylinder head and place pre-oiled O-ring (2) 16x5 on oil return tube (3).
■ CAUTION : Adjust the piston of the cylinder head that should be assembled on OT. This avoids that the valves are
“open” and due to the valve springs the cylinder head rises back up and the O-rings of the oil return lines slip out and are clamped.
Fit cylinder head until the O-rings (2) on both oil return tubes rest in the crankcase (4). Now lift cylinder (5) until the centering (6) of the cylinder engages in the cylinder head recess.
◆ NOTE: This is a safety measure to prevent jamming of cylinder head resulting in leakage.
◆ NOTE: On engines of older design, washers (12) are fitted on the hex. nuts M8. Recent findings show that it is no longer necessary to fit these washers. These washers are therefore not necessary when fitting a new cylinder head.
Fit cylinder head and cylinder together on crankcase. First, slightly tighten the cylinder head with 2 collar cap nuts M8 and 2 hex. nuts M8 crosswise. Ensure that the O-rings (2) are squeezed evenly into the crankcase.
Repeat this procedure on the other cylinder heads.
Attach cylinder aligning tool (8), part no. 877262, to the intake flange of the cylinder heads (10) with 4 allen screws (9) M6x25. Align cylinder heads, thus warranting a flat support for intake manifold. Screw on collar cap nut and flanged nut (11) with washer (12) and tighten cylinder heads in the order shown in Fig.72-108. Tighten to 10 Nm (90 in.lb) and then in addition tighten further by applying a 120° rotation. Remove 4 allen screws (9) and cylinder aligning tool.
◆ NOTE: If cylinder stud heads are damaged or if the cylinder baffle clearance is too tight then the cylinder head studs have to be replaced.
Effectivity 912/914 Series
Edition 1 / Rev. 4
72-00-00 page 92
February 01/2015
BRP-Powertrain
Maintenance Manual
Lubricate all moving parts in rocker arm compartment. Place O-ring (13)
105x2.5 and O-ring (14) 6.4x1.8 in the valve cover (15).
Fit valve cover and tighten with allen screw (16) M6x30 and washer (17) to a tightening torque of 10 Nm (90 in.lb).
■
CAUTION : On the outer contour, there must be a gap of at least 0.2
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 the valve cover is leaking, the oil return to the oil tank by "blow-by gas" will not work at all or only insufficiently.
Screw in spark plugs and tighten to 20 Nm (180 in.lb). Fit spark plug connectors on spark plugs according to the coding sleeves, see 74-00-
00 sec. 3.4.
◆ NOTE: Proceed as per Wiring Diagram. See 74-00-00 sec. 3.13.
Fig. 72-107
7
6
3
5
1
2
4
Effectivity 912/914 Series
Edition 1 / Rev. 4
00278
72-00-00 page 93
February 01/2015
Fig. 72-108 1
BRP-Rotax
Maintenance Manual
7 6
4
8
Fig. 72-109
12
10
11
07709
2 3
9
8
5
10
08340
Fig. 72-110
15
Effectivity 912/914 Series
Edition 1 / Rev. 0
16
17
13
14
00312
72-00-00 page 94
May 01/2007
BRP-Rotax
Maintenance Manual
3.17) Intake manifold inspection and compensation tube assembly
See Fig. 72-111
Check the angular tube (1) screwed into the intake manifold for cracks and tight fit, replace if necessary.
◆
NOTES: Mark the position of the angular tube with a suitable pen (touchup pen).
Remove the 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 2/4) on both ends with screw hose clamps (4). The clip (5) serves to hook in the carburetor support spring. See 73-00-00 sec. 3.5.
Fig. 72-111
5
4
3
2
1
MOLYKOTE G-N
08453
3.18) Crankshaft inspection
Measure the crankshaft (CS04, CS05, CS07 und CS24). See 72-00-00 sec. 4.
In the case of deviation, the whole assy. engine block must be sent to an ROTAX authorized overhaul facility.
Effectivity 912/914 Series
Edition 1 / Rev. 2
72-00-00 page 95
July 01/2008
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 96
May 01/2007
4) Wear limits
Kurbelwelle
(crankshaft)
CS04
BRP-Powertrain
Maintenance Manual
1 3
2 4
07710
CS05
1
2 3 4
CS07
Kurbelwelle
(crankshaft)
1 3
2 4
07517
Effectivity 912/914 Series
Edition 1 / Rev. 4
07507
72-00-00 page 97
February 01/2015
BRP-Powertrain
Maintenance Manual
08748
08748
Effectivity 912/914 Series
Edition 1 / Rev. 3
72-00-00 page 98
October 01/2010
BRP-Rotax
Maintenance Manual
PI01
07435
PI02
PI02
13mm
(0.51 in.)
PI03
Effectivity 912/914 Series
Edition 1 / Rev. 0
07403
72-00-00 page 99
May 01/2007
07412
BRP-Rotax
Maintenance Manual
Pl04
Pl05
Pl06
Effectivity 912/914 Series
Edition 1 / Rev. 0
07432
PI07 /
PI08 /
PI09
72-00-00 page 100
May 01/2007
BRP-Powertrain
Maintenance Manual
07221
Pi
s
ton
Pi ton red
79,5 mm /
Pi
79,5 mm /
Pi
8 ton red
4mm /
Pi
8 s s s s
Cle a r a with Pi
3 , 3
3
3
,1 in.
ton green
in.
ton green
4mm / 3 , 3
,1in.
in.
nce cyl. A s ton “ red ”
Cle a r a nce cyl. B with Pi s ton “ green ”
Pi
Pi s s ton pin ton pin b ore
Pl01
Pl01
Pl01
Pl01
CY01/
Pl01
CY01/
Pl01
Pl02
Pl0 3
79,4 88
3 ,1294
79,502
3 ,1 3 00
79,49 8 79,512
3 ,129 8 3 ,1 3 04
83 ,9 88
3 , 3 066
8
3 ,
4,002
3 072
83 ,99 8 8 4,012
3 , 3 070 3 , 3 075
0,002 0,024
0,0001 0,0009
0,002 0,026
0,0001 0,0010
20,001
0,7 8 74
20,005
0,7 8 76
19,992 19,995
0,7 8 71 0,7 8 72
79, 3 90
3 ,1256
79,4
3
3
,1275
9
79, 3 90 79,444
3 ,1256 3 ,1277
83
3 , 3
, 8 90
027
83 ,9 3 9
3 , 3 047
83 , 8 90
3 , 3 027
83 ,944
3 , 3 049
0,076 0,1 3 0
0,0051 0,00 3 0
0,1 3 0 0,077
0,0051 0,00 3 1
20,040
0,7 8 90
20,02
0,7 883
3
19,970 19,9 8 1
0,7 8 62 0,7 8 67
Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4
Effectivity 912/914 Series
Edition 1 / Rev. 4
72-00-00 page 101
February 01/2015
BRP-Rotax
Maintenance Manual
Description
Reading new min max wear limit
100% wear limit
50%
Piston
Pison pin clearance in piston pin bore
PI02/
PI03
0,006
0,0002
0,013
0,0005
0,050
0,0020
0,032
0,0012
Piston pin clearance in con rod
CS06/
PI03
0,015
0,0006
Piston ring groove clearance rectangular ring 1
PI04
Piston ring groove clearance tapered compression ring 2
PI05
Piston ring groove clearance oil scraper ring 3
PI06
Piston ring end gap rectangular ring 1
PI07
Piston ring end gap tapered compression ring 2
PI08
Piston ring end gap oil scraper ring 3
PI09
0,030
0,0012
0,030
0,0012
0,020
0,0008
0,15
0,0059
0,
15
0,0
059
0,15
0,0059
0,035
0,0014
0,062
0,0024
0,062
0,0024
0,055
0,0022
0,35
0,0138
0,
35
0,01
0,40
38
0,0157
0,050
0,0020
0,100
0,0039
0,100
0,0039
0,100
0,0039
1,00
0,0394
1,000
0,0394
1,00
0,0394
0,043
0,0017
0,081
0,0032
0,081
0,0032
0,078
0,0031
0,68
0,0266
0,
68
0,02
66
0,70
0,0276 actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed
Cyl. 1
Readings
07221
Cyl. 2 Cyl. 3 Cyl. 4
Effectivity 912/914 Series
Edition 1 / Rev. 2
72-00-00 page 102
July 01/2008
BRP-Powertrain
Maintenance Manual
15
(0.197 in.)
(1.57 in.)
(2.99 in.)
CH05
CH05
07485
07831
Effectivity 912/914 Series
Edition 1 / Rev. 4
07427
72-00-00 page 103
February 01/2015
5
3
BRP-Rotax
Maintenance Manual
3 mm (0.12 in.)
1
2
3 mm
(0.12 in.)
07443 max 20%
VT02
90
80
0
10 20
30
70
1
2
0
9 8
7
3 4 5
6
60
0.01mm
40
50
5
07482
4
~45 mm
(1.77 in.)
4
~25 mm
(0.98 in.)
F
VT03
07425
Effectivity 912/914 Series
Edition 1 / Rev. 0
VT03
07483
72-00-00 page 104
May 01/2007
BRP-Rotax
Maintenance Manual
07496
VT05
VT08
07409
80
90
0
10
20
70
60
2
3
1 0
9
4 5 6
8
50
0.01mm
40
30
07417
Effectivity 912/914 Series
Edition 1 / Rev. 0
~160 mm
(6.30 in.)
VT06
07498
VT07
07497
72-00-00 page 105
May 01/2007
BRP-Powertrain
Maintenance Manual
08207
Effectivity 912/914 Series
Edition 1 / Rev. 3
07488
72-00-00 page 106
October 01/2010
BRP-Rotax
Maintenance Manual
07222
Cylinder
(D1) CY01
79,500 79,512
3,1299 3,1304
79,580
3,1331
79,546
3,1317
Cylinderbore
A 79,5 mm /
3,1 in.
Cylinderbore
B 79,5 mm /
3,1 in.
Cylinderbore
A 84 mm /
3,3 in.
Cylinderbore
B 84 mm /
3,3 in.
Cylinderovality
Rework surf
of sealin ace Cylinder/
Cylinder head
(D2)
(D3)
(D1)
(D2)
(D3)
(D1)
(D2)
(D3)
CY02
CY03
CY02
CY01
CY02
(D1) CY01
(D2)
(D3) g
CY01
CY03
CY03
CY02
CY03
CY01 + 0,015
CY01 +0,0006
CY01 +/- 0,008
CY01 +/-0,0003
CY01 +0,015/-0,008
CY01 +0,0006/
-0,0003
CY01 +/- 0,008
CY01 +/- 0,0003
79,512 79,524
CY01 +0,020/-0,008
CY01 +0,0008/
-0,0003
79,590 79,566
3,1304 3,1316 3,1335 3,1325
CY01 + 0,015
CY01 +0,0006
CY01 +0,015/-0,008
CY01 +0,0006/
-0,0003
CY01 +0,020/-0,008
CY01 +0,0008/
-0,0003
84,000 84,012
3,3071 3,3075
CY01 + 0,015
CY01 +0,0006
CY01 +/- 0,008
CY01 +/-0,0003
84,080
3,3102
84,046
3,3089
CY01 +0,020/-0,008
CY01 +0,0006/
-0,0003
CY01 +0,020/-0,008
CY01 +0,0008/
-0,0003
84,012 84,024
3,3075 3,3080
CY01 + 0,015
CY01 +0,0006
CY01 +/- 0,008
CY01 +/-0,0003
0,0000
0,0000
0,0000
0,0000
0,007
0,0003
0,0000
0,0000
84,090
3,3106
84,057
3,3093
CY01 +0,015/-0,008
CY01 +0,0006/
-0,0003
CY01 +0,020/-0,008
CY01 +0,0008/
-0,0003
0,050 0,029
0,0011 0,0020
0,10
0,0039
Effectivity 912/914 Series
Edition 1 / Rev. 5
Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4
72-00-00 page 107
March 01/2017
BRP-Powertrain
Maintenance Manual
09475
Cylinder head
Int. V.
CH01
Valve guide bore inner diameter
Exh. V.
CH01
7,006
0,2758
7,006
0,2758
Valve seat width
Int. V.
CH02
1,40
0,0551
Valve stem diameter
Exh. V.
Int. V.
Exh. V.
CH02
VT01
VT01
7,018
0,2763
7,018
0,2763
1,90
0,0748
1,50 2,00
0,0591 0,0787
6,965 6,980
0,2742 0,2748
6,965 6,980
0,2742 0,2748
7,150
0,2815
7,150
0,2815
7,084
0,2789
7,084
0,2789
2,40
0,0945
2,50
0,0984
6,940
0,2732
2,15
0,0846
2,25
0,0886
6,953
0,2737
6,940
0,2732
6,953
0,2737
Valve stem clearance
Int. V.
CH01/
VT01
Exh. V.
CH01/
VT01
0,026 0,053
0,0010 0,0021
0,026 0,053
0,0010 0,0021
0,00 0,03
0,0000 0,0012
Int. V.
VT02
Out of round of valve head
Exh. V. VT02
0,00
0,0000
0,03
0,0012
0,150
0,0059
0,150
0,0059
0,102
0,0040
0,102
0,0040
0,04 0,035
0,0016 0,0014
0,04 0,035
0,0016 0,0014
Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4
Effectivity 912/914 Series
Edition 1 / Rev. 3
72-00-00 page 108
October 01/2010
BRP-Rotax
Maintenance Manual
Description
Reading new min max wear limit
100% wear limit
50%
Cylinder head
Wear on valve head
Spring length at test load, outer
Int. V.
VT03
0,0
0,000
Exh. V. VT03
Spring length at test load, inner
Int. V.
VT04
Exh. V. VT04
Int. V.
VT04
Exh. V. VT04
0,0
0,000
30,4
1,197
30,4
1,197
32,4
1,276
32,4
1,276
Spring length at test load,
SINGLE
Int. V.
VT04
Exh. V. VT04
32,4
1,276
32,4
1,276
0,0
0,000
0,0
0,000
31,6
1,244
31,6
1,244
33,6
1,323
33,6
1,323
33,6
1,323
33,6
1,323
0,2
0,008
0,2
0,008
30,0
1,181
30,0
1,181
32,0
1,260
32,0
1,260
32,0
1,260
32,0
1,260
0,1
0,004
0,1
0,004
30,2
1,189
30,2
1,189
32,2
1,268
32,2
1,268
32,2
1,268
32,2
1,268
Rocker arm shaft support bore
Int. V.
CH05
Exh. V. CH05
12,000
0,4724
12,000
0,4724
12,018
0,4731
12,018
0,4731
12,090
0,4760
12,054
0,4746
12,090
0,4760
12,054
0,4746
Rocker arm shaft support bore
"oversize"
Rocker arm shaft
Int. V.
Exh. V. CH05
Int. V.
CH05
VT05
Exh. V. VT05
12,200
0,4803
12,200
0,4803
11,983
0,4718
11,983
0,4718
12,218
0,4810
12,218
0,4810
11,994
0,4722
11,994
0,4722
12,290
0,4839
12,290
0,4839
11,950
0,4705
11,950
0,4705
12,254
0,4824
12,254
0,4824
11,967
0,4711
11,967
0,4711 actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed
Cyl. 1 Cyl. 2
Readings
07223
Cyl. 3 Cyl. 4
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 109
May 01/2007
BRP-Rotax
Maintenance Manual
Description
Reading new min max wear limit
100% wear limit
50%
Cylinder head
Rocker arm shaft "oversize"
Int. V.
VT05
Exh. V. VT05
12,183
0,4796
12,183
0,4796
12,194
0,4801
12,150
0,4783
12,167
0,4790
12,194
0,4801
12,150
0,4783
12,167
0,4790
Rocker arm shaft radial clearance suppurt bore
Int. V.
Exh. V.
CH05/
VT05
CH05/
VT05
Rocker arm bore (for plastic bushing)
Int. V.
VT06
Exh. V. VT06
Rocker arm bore (with bronze bushing)
Int. V.
VT07
Exh. V. VT07
Rocker arm bore (with bronze bushing)
"oversize"
Int. V.
VT07
Exh. V. VT07
Rocker arm radial clearance (in the bronze bushing)
Int. V.
Exh. V.
VT07/
VT05
VT07/
VT05
Wall thickness of rocker arm plastic bushing
Int. V.
VT08
Exh. V. VT08
0,006
0,0002
0,006
0,0002
16,000
0,6299
16,000
0,6299
12,000
0,4724
12,000
0,4724
12,200
0,4803
12,200
0,4803
0,006
0,0002
0,006
0,0002
1,95
0,0768
1,95
0,0768
0,035
0,0014
0,150
0,0059
0,035
0,0014
16,018
0,6306
16,038
0,6314
16,018
0,6306
12,027
0,4735
12,150
0,4783
12,027
0,4735
12,227
0,4814
12,350
0,4862
12,227
0,4814
0,044
0,0017
0,150
0,0059
16,038
0,6314
12,150
0,4783
12,350
0,4862
0,160
0,0063
0,044
0,0017
0,160
0,0063
0,102
0,0040
1,98
0,0780
1,90
0,0748
1,98
0,0780
1,90
0,0748
0,093
0,0036
0,093
0,0036
16,028
0,6310
16,028
0,6310
12,089
0,4759
12,089
0,4759
12,289
0,4838
12,289
0,4838
0,102
0,0040
1,93
0,0758
1,93
0,0758 actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed
Cyl. 1
Readings
07223
Cyl. 2 Cyl. 3 Cyl. 4
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 110
May 01/2007
BRP-Powertrain
Maintenance Manual
07582
Description
Reading new min max wear limit
100% wear limit
50%
Cylinder head
Push rod deflection
Int. V VT09
Exh. V VT09
0,000
0,0000
0,000
0,0000
0,100
0,0039
0,100
0,0039
0,200
0,0079
0,200
0,0079
0,150
0,0059
0,150
0,0059 actual renewed actual renewed
Cyl. 1 Cyl. 2
Readings
Cyl. 3 Cyl. 4
Intermediate gear of electric starter
Idle gear bore
Idle gear SHAFT
Radial clearance
ES01
ES02
ES01/
ES02
12,000 12,035 12,057
0,4724 0,4738 0,4747
11,973
0,4714
0,016
0,0006
11,984
0,4718
0,0
0,00
11,9 0
0,470
0,10
0,00
12,046
0,4743
11,96
0,47
0,0
0,00 actual renewed actual renewed actual renewed
Effectivity 912/914 Series
Edition 1 / Rev. 4
72-00-00 page 111
February 01/2015
BRP-Rotax
Maintenance Manual
07453
AE_912_206
07436
Effectivity 912/914 Series
Edition 1 / Rev. 6
07420
07471
72-00-00 page 112
July 01/2018
07508
BRP-Rotax
Maintenance Manual
GB18
7 8
07456
07506
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 113
May 01/2007
BRP-Powertrain
Maintenance Manual
Reading new
Description
Propeller gear box
1) Bearing bush in gear cover min max
Bore GB01
28,03
1,1035
28,04
1,1039 wear limit
100%
28,10
1,1063 wear limit
50%
28,07
1,1051
Radial clearance
GB01/
CS04
0,03
0,0012
2) Propeller shaft
Propeller shaft dia.
35 mm
GB02
35,009
1,3783
0,05
0,0020
35,020
1,3787
0,12
0,0047
35,003
1,3781
0,0
0,0033
35,006
1,3782 actual renewed actual renewed
Propeller shaft dia.
31,5 mm
GB03
31,470
1,2390
Out of true on prop shaft flange, dia. 122 mm
GB04
Bore at back end of prop shaft (on version 3 only)
GB05
0,00
0,0000
11,00
0,4331
Spigot dia. On oil inlet flange, (on version 3 only)
GB06
10,935
0,4305
Radial clearance of spigot
GB05/
GB06
0,040
0,0016
3) Dog gear, Thrust washer
Thickness of thrust washer
GB11
1,075
0,0423
Free height of disk spring
GB13
5,20
0,2047
31,481
1,2394
0,05
0,0020
11,02
0,4339
10,960
0,4315
0,085
0,0033
1,325
0,0522
5,40
0,2126
31,460
1,2386
0,06
0,0024
0,160
0,0063
1,000
0,0394
4, 8
0,1
889
31,465
1,2388
0,0
0,0022
0,123
0,0048
1,038
0,0408
5
,
00
0,19
68 actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed actual renewed
Readings
08471
Effectivity 912/914 Series
Edition 1 / Rev. 4
08486
Reading new wear limit
Description min max
Crankshaft
Crankshaft angle of twist
GB 20
0
(degrees)
2
(degrees)
100% wear limit
50% actual renewed
Cyl. 1
Readings
Cyl. 2 Cyl. 3 Cyl. 4
72-00-00 page 114
February 01/2015
BRP-Powertrain
Maintenance Manual
4) Tooth profile
Crankshaft
Drive Gear
Propeller shaft
Clutch / Dog Hub
CS07
GB14
0,95
0,0374
0,95
0,0374
1,00
0,0374
1,00
0,0374
GB15
GB16
1,50
0,0591
1,50
0,0591
1,60
0,0630
1,60
0,0630
0,80 0,88
0,0315 0,0344
0,80 0,88
0,0315 0,0344
1,10 1,30
0,0433 0,0512
1,10 1,30
0,0433 0,0512
5) gear set, Backlash on gear set
Drive gear pitting up to 5% of flank area
0,0 0,0 5,0% 2,5%
Dog gear pitting up to 5% of flank area
0,0 0,0
Backlash of teeth GB18
6) Overload clutch
Axial gap GB07
0,07 0,15
0,0028 0,0059
Wear on dog hub GB08
1,0
0,039
0,0
0,000
1,2
0,047
0,0
0,000
5,0% 2,5%
0,20 0,18
0,0079 0,0069
0,5
0,020
0,2
0,008
0,8
0,030
0,1
0,004
Ignition housing
Bearing bush in ignition housing
IH01
32,03 32,04
1,2610 1,2614
Radial clearance
IH01/
CS05
0,03 0,05
0,0012 0,0020
Sprag clutch
Axial clearance ES10
0,5
0,020
1,1
0,043
32,10 32,07
1,2638 1,2626
0,12 0,09
0,0047 0,0033
0,2
0,008
0,35
0,014
Effectivity 912/914 Series
Edition 1 / Rev. 4
07241
72-00-00 page 115
February 01/2015
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 116
May 01/2007
BRP-Powertrain
Maintenance Manual
5) Form Sheets
5.1) Form sheet for material testing ROTAX 912/914 Series
5.1.1) Inspection on cracks (see also 00-00-00, section 10.4)
Description
Findings
Remarks
07207
Checked yes no
Flywheel hub
Propeller shaft dog gear dog hub drive gear
5.1.2) Hardness test according to DIN EN ISO 6506-2 HB 2.5/62.5
CY04
CH08
A
A
07413
07424
Description Actual readings
Camshaft
CA05 630 HV10
CA04 900 N/mm2
Cyl. 1 Cyl. 2 Cyl. 3 Cyl. 4
Cylinder head CH08 85 HB
Cylinder CY04 90 HB
Effectivity 912/914 Series
Edition 1 / Rev. 4
Remarks
07206
Checked
72-00-00 page 117
February 01/2015
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
72-00-00 page 118
May 01/2007
BRP-Powertrain
Maintenance Manual
SECTION 73
FUEL SYSTEM
1) Table of contents
SECTION 73
FUEL SYSTEM
2.6) Fuel pressure regulator (only on 914 Series) ................................ 73-00-00 / 8
2.7) Pressure connecting lines (only on 914 Series) ............................ 73-00-00 / 10
2.8) BING constant depression carburetor type 64-3 .......................... 73-00-00 / 12
2.10.1) Airbox air temperature display (only on 914 Series) ............. 73-00-00 / 15
2.11) Carb heat system and winter operation ........................................ 73-00-00 / 16
3.3) BING-constant depression carburetor inspection ........................ 73-00-00 / 23
3.3.2) Float needle valve leakage test ........................................... 73-00-00 / 24
3.3.3) Individual components of the carburetor (on the 912 Series)73-00-00 / 25
3.3.4) Individual components of the carburetor (on the 914 Series)73-00-00 / 26
3.3.10) Float needle valve inspection ............................................... 73-00-00 / 32
Effectivity 912/914 Series
Edition 1 / Rev. 3
73-00-00 page 1
October 01/2010
BRP-Rotax
Maintenance Manual
3.3.11) Starting carburetor (choke) .................................................. 73-00-00 / 33
3.3.13) Carburetor synchronization................................................... 73-00-00 / 35
3.4) General information on the fuel system ........................................ 73-00-00 / 36
3.4.1) Fuel pressure (on 912 Series) .............................................. 73-00-00 / 37
3.4.2) Fuel pressure (on 914 Series) .............................................. 73-00-00 / 39
3.4.3) Carburetor sockets and compensation 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
3.4.6) Fuel pump (on 914 Series) ................................................... 73-00-00 / 45
3.4.7) Pressure connecting lines (only on 914 Series).................... 73-00-00 / 47
3.5) Assembly of carburetor sockets, carburetor and fuel lines ........... 73-00-00 / 51
3.5.1) Fuel pump ............................................................................. 73-00-00 / 51
3.5.2) Carburetors and carburetor sockets ..................................... 73-00-00 / 51
3.5.3) Assembly of the fuel lines (on 912 Series) ........................... 73-00-00 / 53
3.5.4) Assembly of the fuel lines (on 914 Series) ........................... 73-00-00 / 57
3.6) Intake manifolds fitting ................................................................. 73-00-00 / 59
3.7) Engaging the carburetor support .................................................. 73-00-00 / 59
3.8) Connecting fuel lines (tank) ........................................................... 73-00-00 / 60
Effectivity 912/914 Series
Edition 1 / Rev. 2
73-00-00 page 2
July 01/2008
BRP-Rotax
Maintenance Manual
2) Systems description
2.1) Fuel system (on 912 Series)
See Fig. 73-1.
The fuel system comprises the following items:
fuel tank
coarse filter
fine filter
water drain cock
fire cock
1 mechanical fuel pump
2 carburetors
and the required 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 pumps the fuel to the two carburetors (7).
The surplus fuel passes back to the tank or to the suction side of the fuel system via the return line (8).
◆ NOTE: The return line prevents malfunctions caused by the formation of vapor lock. The return line must be restricted to allow circulation of surplus fuel and air without loosing pressure.
Effectivity 912 Series
Edition 1 / Rev. 0
73-00-00 page 3
May 01/2007
BRP-Rotax
Maintenance Manual
Fig. 73-1
1
2
3 4
5
6
00535 zum Tank to fuel tank
8 zum Manometer / to fuel pressure gauge
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
Effectivity 912 Series
Edition 1 / Rev. 0
73-00-00 page 4
May 01/2007
7
BRP-Rotax
Maintenance Manual
2.2) Fuel system (on 914 Series)
See Fig. 73-2.
The fuel system comprises the following items:
fuel tank
coarse filter
fine filter / water trap
fire cock
2 electric fuel pumps
2 check valves
and the required fuel piping and connections
The fuel flows from the tank via a combination of filter and water trap (1) to the two electric fuel pumps ((2) and (3)), connected in series, passes on to the fuel pressure 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 better reserves against vapor lock at high altitudes and temperatures.
The two check valves in the system are necessary to ensure trouble free operation of the fuel system with one pump only.
The surplus fuel passes from the fuel pressure regulator back to the tank via the return line (7).
◆ NOTE: The fuel pressure regulator serves to maintain the fuel pressure at always approx. 0.25 bar (3.6 p.s.i.) above the changing boost pressure in the airbox, thus ensuring proper operation of the carburetors.
Effectivity 914 Series
Edition 1 / Rev. 0
73-00-00 page 5
May 01/2007
BRP-Powertrain
Maintenance Manual
Fig. 73-2a
5
00103
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 tank
(8) fuel filter
3
AUX
4
8
7
2
MAIN
4
8
1
6
Fig. 73-2b
00157
Effectivity 912/914 Series
Edition 1 / Rev. 3
73-00-00 page 6
October 01/2010
BRP-Powertrain
Maintenance Manual
2.3) Fuel filter
A fine filter in the fuel supply line between tank and inlet to the two fuel pumps must have been installed by the aircraft manufacturer.
◆
NOTE: At the suction side the fuel pumps are equipped with a filter.
2.4) Fuel pump (on 912 Series)
The engines of the 912 Series are equipped 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 vane pumps are used. The voltage supply to the two pumps must be established completely independently.
◆ NOTE: Voltage supply to main pump (MAIN) directly from internal alternator and supply to the supplementary pump (AUX) from bus bar or battery.
For engine operation, the rate of delivery of one pump alone is entirely sufficient.
■ CAUTION: Use only genuine ROTAX fuel pumps, as the pump must meet certain requirements.
Effectivity 912/914 Series
Edition 1 / Rev. 3
73-00-00 page 7
October 01/2010
BRP-Rotax
Maintenance Manual
2.6) Fuel pressure regulator (only on 914 Series)
See Figs. 73-3 and 73-4.
The fuel pressure regulator (1) is mounted on the airbox.
Fuel pressure control is essential for flawless engine operation because it keeps the fuel pressure permanently at approx. 0.25 bar (3.6 p.s.i.) above the varying boost pressure in the airbox.
Design and function of the fuel pressure regulator:
The diaphragm (2) divides the pressure regulator 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 0.25 bar (3.6 p.s.i.) above the actual airbox pressure on the other side.
■
CAUTION: All fuel pressure regulators are calibrated by the engine manufacturer and need no further adjustment or maintenance.
◆ NOTE: The arrows cast into the top side of the fuel pressure regulator are of no significance for the usage, as inlet (6) and outlet (7) are directly connected via the chamber.
◆ NOTE: Ensure that the cap nut (8) is securely tightened, as otherwise the fuel pressure may drop.
Fig. 73-3 7 7
00117
6 fuel return fuel feed
1
Effectivity 914 Series
Edition 1 / Rev. 0
00104
2 fuel return
3 8
Fig. 73-4 carburetor airbox
8
5
4
73-00-00 page 8
May 01/2007
BRP-Rotax
Maintenance Manual
Part of the fuel flow from the pumps (approx. 100 l/h) is routed back to the fuel tank via the diaphragm controlled cone valve (8), thus establishing a pressure 0.25
bar (3.6 p.s.i.) higher in the top chamber (fuel side) than in the lower chamber (air side).
Since the lower chamber is connected with the airbox via the pressure line, the pressure of the fuel entering the carburetor will also be 0.25 bar (3.6 p.s.i.) above airbox/float chamber pressure.
Fuel pressure = airbox pressure + 250 hPa
At 1000 m altitude with the prevailing ambient pressure of approx. 900 hPa, the following 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 diaphragm upwards, thus preventing fuel flow back to the tank, i.e. fuel pressure rises until equilibrium is reached again.
■ CAUTION: Correct excess fuel pressure is essential for proper functioning of the carburetor.
too low fuel pressure (wrong calibration, malfunction of regulator or fuel pumps...) leads to a leaner mixture and can result in engine faults or engine failure as not enough fuel or no fuel at all reaches the float chamber.
too high fuel pressure (wrong calibration, malfunction of regulator, increased flow resistance, blockage of return line,...) leads to a richer mixture till flooding of carburetors occurs, causing engine faults or engine stoppage.
Effectivity 914 Series
Edition 1 / Rev. 0
73-00-00 page 9
May 01/2007
BRP-Rotax
Maintenance Manual
2.7) Pressure connecting lines (only on 914 Series)
See Fig. 73-5.
The engines of the 912/914 Series are equipped with constant depression carburetors. For the operation of the carburetors it is necessary that a) the atmospheric pressure in the float chamber corresponds with atmospheric pressure at carburetor air intake (airbox)
With varying airbox pressure (carb air intake) this changing pressure must also act upon the float chamber.
For this reason, the float chamber venting is connected to the airbox via a pressure connecting line (1).
b) the fuel pressure 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).
Enriching of the fuel air mixture at take-off performance
The airbox is furnished with 2 separately located pressure connections connected with the 3-way solenoid valve (2) via pressure connecting lines (1).
Up to maximum continuous performance (approx. 1190 hPa airbox pressure), the float chambers of the carburetors are vented with the static airbox pressure via connection (3). At an airbox pressure above 1270 hPa, the pressure in the float chambers will be raised by the ram air pressure at airbox (connection (4)) initiated by the TCU via an electric solenoid valve (2).
As a result, the effective pressure in the fuel bowl will be increased by the same amount.
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Edition 1 / Rev. 0
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BRP-Rotax
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The purpose of enriching the mixture is to reduce the thermal load on the engine during the 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 engine stoppage can be expected. The lines must therefore be in serviceable condition and free of kinks, secured with clamps and seated securely on their connections.
Fig. 73-5
1 1 2 1
1
3 1
1
4
00048
1
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Edition 1 / Rev. 0
73-00-00 page 11
May 01/2007
BRP-Rotax
Maintenance Manual
2.8) BING constant depression carburetor type 64-3
See Figs. 73-6, 73-7 and 73-8.
The BING constant depression carburetor type 64-3 is a cross-draft butterfly valve carburetor with variable venturi, double float system arranged centrally below the venturi, and a rotary disc valve type starting carburetor. Its particular feature is the carburetor piston (2), which is suspended on a rubber diaphragm
(3) and protrudes into the venturi. It adjusts the smallest crosssection (“air funnel”) of the venturi depending on the vacuum prevailing there. The vacuum is influenced by actuation of the throttle valve (1) and the carburetor piston moves accordingly. The throttle valve diameter is 36 mm (1.42 in.).
When the fuel has reached the specified level in the float chamber, the floats close the needle valve (4) via the float bracket, thus preventing any further supply of fuel.
◆ NOTE: The atmospheric pressure in the float chamber is decisive for the function of the carburetor and must correspond with the air pressure at entry into the carburetor. Too high pressure enriches the mixture, too low pressure leans down the mixture, possibly leading to engine stop.
The float chamber airspace is connected by a channel with the venting nipple
(18). The channel must be clear. With a hose connected on the venting nipple, the correct pressure in the float chamber is established.
The amount of mixture drawn in by the engine and thus its performance are determined by the cross-sectional area in the venturi, which is opened by the throttle valve (1). If the throttle valve is opened while the engine is running, the increased airflow in the venturi results in a vacuum building up at the outlet of the needle jet (16), which draws fuel from the float chamber through the jet system.
The vacuum in the venturi acts on the top side of the diaphragm via the bore (12) in the carburetor piston and attempts to lift the piston against its own weight and the spring. The reference pressure prevailing between air filter and carburetor
(e.g. ambient air pressure) is applied to the bottom side of the diaphragm via channel (13). The space in the cover above the piston guide is vented through bore (14). The bore diameter determines the piston damping.
Effectivity 912/914 Series
Edition 1 / Rev. 0
73-00-00 page 12
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BRP-Rotax
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On its way from the float chamber to the venturi, the fuel passes through the main jet (7), the mixing tube and the needle jet and 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 process and favors fuel distribution in the manifold.
The jet needle (10), which is responsible for part load, is kept in the defined position by the retaining clip (11).
14
3
Effectivity 912/914 Series
Edition 1 / Rev. 0
1
12
10
8
15
5
7
11
6
2
13
4
16
9
02931
Fig. 73-6
73-00-00 page 13
May 01/2007
BRP-Rotax
Maintenance Manual
During idling and low-load operation of the engine, the throttle valve is closed to such an extent that the airflow underneath the carburetor piston (2) no longer forms a sufficient vacuum. The supply of fuel to the 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 with a rotary disc valve starting carburetor (17) using a Bowden cable.
▲ WARNING: With the throttle lever not connected, the carburetor will remain in full throttle position . See Fig. 73-7.
For this reason, never start the engine without first connecting the throttle lever.
Fig. 73-7 full throttle
00128
17
Fig. 73-8
18
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Edition 1 / Rev. 0
00035
17
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BRP-Powertrain
Maintenance Manual
2.9) Handling of fuel
Use only clean gasoline of a registered brand.
Unleaded fuels contain alcohol. Alcohol binds up to 50 % of its own volume in water. Water enters the system mainly in the form of condensation. For this reason, avoid extreme differences in temperature, long period storage, direct sun and plastic containers. When handling fuel, observe the directives without fail.
When refuelling, observe the relevant regulations of the competent aviation authorities.
▲ WARNING: Before refueling, switch off ignition and remove ignition key!
▲
WARNING: Filter fuel (using filter funnel) when filling the tank. Use only clean, non-translucent safety approved fuel containers.
▲
WARNING: Only handle fuel 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 the brim, allow for expansion of the fuel.
Never refuel while engine is running.
For further information, see SI-912-016 and SI-914-019 “Operating fluids“, latest issue.
2.10) Connections for instrumentation
■ CAUTION: Also consult the instructions regarding the connection for instrumentation in the Installation Manual.
2.10.1) Airbox air temperature display (only on 914 Series)
A connection is provided in the airbox for measurement of the air temperature . On the standard engines, this connection is closed by a plug screw.
2.10.2) Boost pressure display
A connection is provided for an absolute pressure gauge in the compensation tube for the indication of the boost pressure.
■ CAUTION: If no manifold pressure gauge is installed make sure that the connector is sealed so that no external air can be drawn in.
Effectivity 912/914 Series
Edition 1 / Rev. 3
73-00-00 page 15
October 01/2010
◆ NOTE:
BRP-Powertrain
Maintenance Manual
On newer engines the manifold pressure fitting is plugged with a M 3.5 screw. Remove this screw before attaching a manifold pressure hose. See therefore SI-912-020 and SI-914-022 “running modifications” respectively.
2.11) Carb heat system and winter operation
The risks of carburetor icing are commonly known. The icing of air humidity in the carburetor may be avoided by preheating the air.
◆ NOTE: An airbox with a carburetor preheating flap is available for engines of the 912 Series.
◆ NOTE: Engines of the 914 Series normally do not require any preheating device as the intake air is preheated by the turbocharger.
◆ WARNING: Carburetor icing is a common cause of engine faults.
Because of the heating up of intake air due to the boost process, preheating of the intake air might not be necessary. But the option of a change over for air intake from the engine compartment is recommended as, for instance, the filter could be blocked by icing.
Preheating of the intake air will result in loss of engine performance because of the reduction in air density.
A further measure to reduce the risk of carburetor icing is to keep the water content of the fuel low by proper handling. Also, install a generously dimensioned water trap in the fuel system of the aircraft to prevent the formation of ice in the fuel lines, filters etc.
3) Maintenance
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see corresponding
Maintenance Manual (Line Maintenance) for 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.
3.1) Disassembling fuel pump, carburetors, carburetor sockets, fuel lines and drip tray (on the 912 Series)
See Fig. 73-9, 73-9/1 and 73-9/2.
■ CAUTION: When disassembling the fuel lines support them so that tension or additional strain is avoided.
Effectivity 912/914 Series
Edition 1 / Rev. 3
73-00-00 page 16
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BRP-Rotax
Maintenance Manual
■ CAUTION: Replace the insulating flange each time when the fuel pump is removed.
To remove the fuel pump (1) remove feed line (2) and hex nuts (3), then remove the fuel pump together with the insulating flange (4).
◆
NOTE: See SI-912-020 “Running modification”, latest issue.
The carburetors must be removed for inspection or maintenance.
◆ NOTE: Models produced from the year 2007 onwards have a flexible fuel line (5). See Fig. 73-9/2.
◆ NOTE: Usually it is not necessary to remove the clamp block (6).
However, if it should become necessary to remove it, ensure that it is refitted in the same position.
Rigid fuel line
The fuel line (7) is supported by a cable clamp (8) on the carburetors. These clamps are attached with allen screws M5x12 (9) and lock nuts (10), which must be removed. Unscrew the collar nut (11) from the carburetor. Unscrew the banjo bolts (12) from the clamp block (6).
◆
NOTE: Airboxes of older build have drainage conncectors in vertical alignment.
1
3
4
2
6
10
7
8
9
11
10
7
12
8 9
Fig. 73-9
09888
Effectivity 912 Series
Edition 1 / Rev. 4
73-00-00 page 17
February 01/2015
BRP-Powertrain
Maintenance Manual
29
32
31
30
29
33
34
7
11
28
Fig. 73-9/1
7
11
28
28
08667
Effectivity 912 Series
Edition 1 / Rev. 3
73-00-00 page 18
October 01/2010
BRP-Powertrain
Maintenance Manual
Flexible fuel line
See Fig. 73-9/2
Each fuel line (5) is supported by a cable clamp (13) on the intake manifold. Each of these clamps is attached with an allen nut M8 (14), which must be removed.
Further the fuel line is attached with 2 cable straps (15) to the compensation tube
(16).
At the carburetors the ring hose nipple of the fuel line is installed with a distance sleeve (17) and sealing rings (18). After unscrewing the banjo bolt (19) take off the fuel lines.
◆ NOTE: The flexible fuel line (5) part no. 874911 (STRATOFLEX) must not be changed every 5 years.
21
15
14
13
20
6
16
26
23
22 15
25
24
20
Fig. 73-9/2
08180
5
19
18
17
18
5
19
All fuel lines lead to the fuel manifold. Unscrew the banjo bolts (20). Remove the fuel line (21) (hose line).
Now the fuel lines (5 or 7), the ring hose nipple (22) (connection for return line and pressure gauge) and 5 sealing rings (23) can be removed.
Unscrew allen screw M10x1x8 (24) with the sealing ring (25).
Carry out a visual inspection of all fuel lines for damage and wear. Pay particular attention to the formation of any cracks in the area of the connections.
Check the lines for free passage with compressed air and inspect the lines for scuffing marks.
Effectivity 912/914 Series
Edition 1 / Rev. 5
73-00-00 page 19
March 01/2017
BRP-Rotax
Maintenance Manual
Carry out a visual inspection of the clamp block (6) of the fuel manifold, the two banjo bolts (20) and the ring hose nipple (22).
◆
NOTE: It is not normally necessary to remove the clamp block (6).
However, if it should become necessary to remove it, it must be reattached with an allen screw M5x16 (26) (tightening torque 6
Nm (53 in.lb). Ensure that it is refitted in the same position.
Inspect banjo bolts (20) for hairline cracks, deformation or tears in the area of the hole (27). If the hole is visibly ovalshaped, the banjo bolt 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, the screw hose clamps
(28) must be released before the carburetors can be removed. See Fig.73-9/
1. Remove the tension spring (29) for carburetor suspension.
Losen the clamp (30) on the carburetor socket (31) and remove the carburetor with twisty motions. Close off the intake openings of the carburetor sockets with appropriate covers.
Remove the hex. screws (31) M8x25, M8x30 (33) and washers to disassemble the carburetor sockets (12). Then the carburetor socket (31) and the O-Ring
(32) can be taken off.
◆ NOTE: See SB-912-030, ”Cracks, wear and distortion on the carburetor flange”, latest issue.
Fig. 73-9/3
20
Fig. 73-9/4
6
27
08212
20 08211
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Edition 1 / Rev. 5
73-00-00 page 20
March 01/2017
BRP-Rotax
Maintenance Manual
3.2) Disassembling carburetors, carburetor sockets, fuel lines and drip tray
(on the 914 Series)
See Figs. 73-10 and 73-11.
To remove the carburetors, loosen the screw hose clamps (3). Remove the fuel line (4) by removing banjo bolts M10 (5) with sealing rings (6).
Remove the clamps (7) of the pressure connecting lines (8) on the carburetor
(float chamber venting) and the fuel pressure regulator (17) (only on 914 Series) and pull off the lines.
Remove the tension spring (9) for carburetor suspension with a suitable tool.
Now the airbox (10) can 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 potentiometer.
Release the clamp (13) of the carburetor socket (14), remove the carburetor with the fuel lines with slight turning and swiveling movements and close off the intake openings.
Remove cable clamp (16), release collar nut (17) and take off the fuel lines.
Remove the hex. screws (15) 2 M8x25 and washers to disassemble the carburetor sockets (14). Then the carburetor socket (14) and the O-Ring (18) can be taken off.
◆ NOTE: See SB-914-019,”Cracks, wear and distortion on the carburetor flange”, latest issue.
◆ NOTE: On older engine versions, the drip tray (19) is not fitted on the airbox but directly on the intake manifold (20), see Fig. 73-10.
Effectivity 914 Series
Edition 1 / Rev. 2
73-00-00 page 21
July 01/2008
BRP-Rotax
Maintenance Manual
Fig. 73-10
20
18
19
07712 14
13
Fig. 73-11
14 9 8
7
XXX
13
8
15
A
7
5
2
16
4
17
3
A Loctite 243
3
19
11
07713
10
XXX 6
5
XXX
4
17
12
Effectivity 914 Series
Edition 1 / Rev. 4
73-00-00 page 22
February 01/2015
BRP-Powertrain
Maintenance Manual
3.3) BING-constant depression carburetor inspection
3.3.1) General note
See Figs. 73-12, 73-13 and 73-14.
■ CAUTION: The determination of the main jet is carried out by the manufacturer on a test bed at 300 m (1000 ft) above
Mean Sea Level.
Only aeronautical personnel or authorized testers acting on our instructions may carry out modifications to
BRP-Powertrain specifications.
◆ NOTE:
Values must be recorded in the engine logbook.
■ CAUTION: To avoid contamination in the fuel system, proceed with great care and cleanliness. It is essential to store carburetors and dismantled parts on clean surfaces.
See SI-912-012 or SI-914-014, ”Routine modification of the Bing constant depression carburetor”, latest issue.
The fuel supply must be closed off before the carburetors are removed for closer inspection. Collect any fuel spilt during disassembly and dispose of it in an ecological manner.
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 23
February 01/2015
BRP-Rotax
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3.3.2) Float needle valve leakage test
See Fig. 73-12.
This check is carried out to ensure that the float valve seat is not leaking.
If the pressure is not maintained, pay particular attention during disassembly 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 apply approx. 0.4 bar
(5.8 p.s.i.) of pressure.
The pressure must be maintained for about 5 seconds.
■ CAUTION: If pressure drops, this indicates leakage which may cause fuel overflow and in consequence engine damage due to hydraulic shock.
Replacement of the float valve seat is not permissible.
Fig. 73-12
1
2
08245
Effectivity 914 Series
Edition 1 / Rev. 3
73-00-00 page 24
October 01/2010
BRP-Rotax
Maintenance Manual
3.3.3) Individual components of the carburetor (on the 912 Series)
See Illustrated Parts Catalog Rotax 912/914
6
Fig. 73-13 A
17
8 5
38
1
3
2
4
15
3
7
11
12
10
4
14
A
13
1
2
A
26
24
27
28
37
36
35
16
29
30
34
23
25
22
07088
Effectivity 912 Series
Edition 1 / Rev. 2
39
A
73-00-00 page 25
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BRP-Rotax
Maintenance Manual
3.3.4) Individual components of the carburetor (on the 914 Series)
See Illustrated Parts Catalog Rotax 912/914
Fig. 73-14
6
A
1
2
3
4
17
38
18
15
3
11
7
12
10
4
14
A
13
1
2 26
24
27
Zyl
. (c yl.)
2/4
Zyl
. (c yl.)
1/3
28
36
37
35
16 29
34
30
23
25
22
21
20
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3.3.5) Diaphragm
See Figs. 73-15 and 73-16.
The plunger (carburetor piston) (8) is attached to the diaphragm (6).
Depending on the pressure prevailing, the plunger is moved up or down. For inspection, remove the two counter sunk screws (1) M5x12, take off the chamber top (2) and remove the plunger spring (3). Check that the cover plate (4) on the chamber top is tightly seated. Wash chamber top with cleaning agent and blowclean the inside venting bore with compressed air Then carry out a visual inspection.
Pull carburetor piston out of the carburetor housing and remove the 4 allen screws (5) M4x12. The diaphragm (6) is held by the retaining ring
(7) on the carburetor piston (8). The position of the carburetor piston is controlled via the diaphragm. There are 2 indexing tabs on the diaphragm (5). Tab (9) fits exactly into the recess 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) controls the fuel consumption at part load. It can be regulated by selecting a needle position between 1 and 4.
Unscrew the retaining screw (11), check needle (12) with shaft securing
(13) and O-Ring (20) for signs of wear.
Pay especial attention to the grooves and the taper of the needle. If there is visible wear, the needle must be replaced and a new one refitted in the same position. The needle jet must be replaced along with the needle as it will also be worn.
◆
NOTE: The needle must move freely when fitted.
Carry out a visual inspection of the outer diameter of the carburetor piston (8) and the two inside compensation bores.
◆ NOTE: The needle is damped by the O-ring (38).
See Figs. 73-13 and 73-14.
Fig. 73-15/2 shows the factory-setting of carburetor jetting and jet needle position. The jet needle position depends on the emmision and specific fuel consumption.
All other settings must be recorded in the engine logbook.
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 27
February 01/2015
1
4
BRP-Rotax
Maintenance Manual
2
Fig. 73-15
1
2
3
4
Nadelposition (needle position)
Fig. 73-15/1
3
5
07229
7
I
9 1 2 A / F / U L
N e e d l e
I d l e j e t
M a i n j e t 4 )
S t a r t j e t 1 )
N e e d l e p o s i t i o n 3 )
C a r b u r e t o r c a l i b r a t i o n
C a r b u r e t o r 1 /
T a r g e t
3 C a r b u r e t o r 2 / 4
2 , 7 2
3 5
2 , 7 2
3 5
1 5 5 o r 1 5 8
8 5
3
T a r g e t
1 5 5 o r 1 5 8
8 5
3
9 1 2 S / U L S / U L S F R
N
S t e d l e
M a a
N e e d r t j i n l j j e e t e t e t e d l e
1 ) p o s i t i o n
9 1 4 F / U L
3 )
C a r b u r e t o r 1 / 3
2 , 7 0
3 5
1 5 5
8 5
3
T a r g e t
C a r b u r e t o r 2 / 4
2 , 7 0
3 5
1 5 5
8 5
3
N e e
I d l e d
S t a r t l e j e t
M a i n j e t 2 ) j e t 1 )
N e e d l e p o s i t i o n 3 )
C a r b u r e t o r 1 / 3
2 , 7 2
3 5
1 5 6 o r 1 6 0
8 5
1 o r 2
C a r b u r e t o r 2 / 4
2 , 7 2
3 5
1 5 8 o r 1 6 4
8 5
2
1)
2)
3)
4)
Fig. 73-15/2
20
6
10
Fig. 73-16
12
07230
11
9
13
8
See SI-03-1998, latest version.
Depending on the airbox version. See SI-914-013 and
SI-914-015, latest version.
Depending on CO measurement value and specific fuel consumption. See SI-914-013 and SI-914-015, latest version.
On configuration with air filter. See SB-912-044, latest version.
Effectivity 912/914 Series
Edition 1 / Rev. 2
73-00-00 page 28
July 01/2008
BRP-Powertrain
Maintenance Manual
3.3.7) Float chamber, floats
See Figs. 73-17, 73-18, 73-19 and 73-20.
On the 912 Series: Release the spring clip (39). See Fig. 73-13.
On the 914 Series: Remove the safety wiring and the end screw (1) with the sealing ring (2) 16x22x1. Tightening torque 5.5 Nm (48.7 in.lb)
Remove 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 stick on the float chamber wall (10).
■ CAUTION: A stuck float causes the carburetor to flood.
Check the wear on the guide sleeves (5) inserted in the float. Check the pins (6) for the float support (7) for wear caused by excessive vibration.
If there is noticeable wear, replace both floats and if necessary also the float brackets (8).
11
Fig. 73-17
12
07715
2
1
Effectivity 912/914 Series
Edition 1 / Rev. 3
3
Fig. 73-18
7
6
5
8
9
07716
10
73-00-00 page 29
October 01/2010
BRP-Powertrain
Maintenance Manual
3.3.8) Float brackets
See Figs. 73-18, 73-19 and 73-20.
Check that the float suspension brackets (8) are parallel. To do so, remove main jet and attach the gauge (13) to the mixing tube with a hex.
screw (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.)
On the 914 Series: 5.4 to 5.5 mm (.21 to .22 in.)
Always replace float brackets together with the float needle valve.
If there is a noticeable fault, the float bracket can be bent for correction or be replaced. After the check, remove the gauge and refit the main jet.
3.3.9) Carburetor jets
Fig. 73-19 14
13
15
04927
Fig. 73-20
14
13
Effectivity 912/914 Series
Edition 1 / Rev. 4
08209
15
73-00-00 page 30
February 01/2015
BRP-Powertrain
Maintenance Manual
See Figs. 73-21 and 73-22.
■ CAUTION: Always maintain high standards of cleanliness when performing any work on the carburetor.
Remove the float chamber. Unscrew the main jet (14), the mixing tube
(15), the needle jet (16), the idle jet (17), the starting jet (18) 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 of inner diameter of needle jet (16), replace if necessary.
Check for correct jetting. See corresponding Illustrated Parts Catalog.
▲ WARNING: Any adjustments to the main and idle jets may only be
performed in accordance with BRP-Rotax instructions,
by an aviation facility or an authorized tester.
LD30. Alle changes must be recorded in the engine
15
15
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 31
February 01/2015
BRP-Rotax
Maintenance Manual
3.3.10) Float needle valve inspection
Check fuel inlet for free passage.
Inspect the viton tip (1). Inspect clip end for 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 fuel flow.
Insert float valve into the valve seat.
Engage float valve clip into float bracket, place it in position and fix float bracket with pin.
Replace the float chamber and fix with spring clip.
◆ NOTE: In addition to this information, also observe the Service
Bulletins SB-912-048 and SB-914-033, ”Replacement of pin in carburetor”, latest issue.
Fig. 73-23
1
04928 gut good
3
2 schlecht bad
Fig. 73-24
2
Effectivity 912/914 Series
Edition 1 / Rev. 2
00026
5
4
73-00-00 page 32
July 01/2008
BRP-Rotax
Maintenance Manual
3.3.11) Starting carburetor (choke)
See Figs. 73-25, 73-26 and 73-27.
Remove 4 countersunk screws M4x14 and remove the complete rotary disc valve housing.
◆ NOTE: The shafts for the rotary disc valve have two markings,
L and R. The shaft marked R is for the carburetors for cylinders 2/4, the shaft marked L for the carburetor for cylinders 1/3. Fig. 73-25 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). This mark must point towards the cable engagement (3) or to bore (4).
Clean all parts and blow out all bores and ducts with compressed air.
Check all parts and replace any defective ones.
◆
NOTE: SI-03-1998 ”Engine start at low temperatures”, latest issue can be carried out to improve cold starting performance.
Fig. 73-25
L carburetor 1/3
07404 carburetor 2/4
R
3.3.12) Carburetor assembly
The carburetor with new O-rings and gaskets is assembled in reverse order.
Effectivity 912/914 Series
Edition 1 / Rev. 2
73-00-00 page 33
July 01/2008
Fig. 73-26
BRP-Rotax
Maintenance Manual the drawings show the carburetor for cyl. 2/4
00362
Fig. 73-27
2
3
1
Effectivity 912/914 Series
Edition 1 / Rev. 2
4
00363
1
73-00-00 page 34
July 01/2008
BRP-Rotax
Maintenance Manual
3.3.13) Carburetor synchronization
See the corresponding section in the respective Maintenance 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 engine type, 912 Series or 914 Series.
3.3.15) Throttle cable and linkage
See the corresponding section in the respective Maintenance Manual
(Line Maintenance) for the engine type, 912 Series or 914 Series.
Effectivity 912/914 Series
Edition 1 / Rev. 2
73-00-00 page 35
July 01/2008
BRP-Rotax
Maintenance Manual
3.4) General information on the fuel system
The most common reason for engine failure is a fault in the fuel system. Many problems can be prevented by regular checks. Contamination and formation of condensate can lead to erratic engine running or misfiring.
Check float chamber for dirt and water.
- In the event of serious contamination or water, drain, clean and flush the whole fuel system thoroughly, including the tank, filter, fuel 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-translucent, safety approved fuel containers. Do not smoke, do not allow open flames or sparks in the vicinity.
Never refuel with engine running.
Do not fill the tank to the brim, allow for expansion of the fuel.
Remove spilt fuel immediately, dispose of it respecting environmental regulations.
Gasoline is highly inflammable and under certain conditions explosive.
Handling of fuel in well ventilated places only.
Close fuel cock, as the float needle valve may not retain the fuel pressure over a longer period or during transport of the aircraft.
Effectivity 912/914 Series
Edition 1 / Rev. 2
73-00-00 page 36
July 01/2008
BRP-Rotax
Maintenance Manual
3.4.1) Fuel pressure (on 912 Series)
See Fig. 73-28.
The pressure inside the fuel system must not exceed 0.4 bar (5.80
p.s.i). Normally, it will lie between 0.15 (2.18 p.s.i) and 0.3 bar (4.4
p.s.i). The fuel pressure tester, part no. 874230, can be used to measure the pressure and check the correct functioning of the fuel system.
Installation of the fuel pressure testing device
Connect the pressure gauge (1) with the hose (2) to the 4-fold nipple
(3) instead of the fuel return line. Fit the pressure gauge where it can be easily observed by the operator of the ground test run.
■ CAUTION: Make sure there is no danger that the pressure gauge and hose 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 shooting procedure.
▲
WARNING: No aircraft take-off before an obvious fault has been found and eliminated!
■ CAUTION:
Fault free operation of the carburetors cannot be guaranteed if the fuel pressure is below 0.15 bar (2.18 p.s.i)or above 0.4 bar (5.80
p.s.i) l. If the minimum required fuel pressure cannot be achieved, it is necessary to use an additional electric fuel pump.
There must be a suitable fuel filter with 0.1 mm (0.004 in.) mesh size between the fuel tank and the fuel pump. Do not use paper filters.
Select fuel lines in accordance with national aviation regulations.
They should have a minimum crosssection of 5 mm (0.2 in.).
The tank must be fitted with a fuel cock (with a screen) to allow immediate interruption of the fuel supply at any time.
Effectivity 912 Series
Edition 1 / Rev. 2
73-00-00 page 37
July 01/2008
BRP-Rotax
Maintenance Manual
Fig. 73-28
09887
3
2
1
Effectivity 912 Series
Edition 1 / Rev. 4
73-00-00 page 38
February 01/2015
BRP-Rotax
Maintenance Manual
3.4.2) Fuel pressure (on 914 Series)
There is no specific connection on the engine for reading the fuel pressure. However, it makes sense to take fuel pressure readings for monitoring purposes and for troubleshooting.
See latest installation manual for the respective engine type.
All the necessary items are available as spare parts.
■ CAUTION: The fuel pressure must be approx. 250 hPa above the constantly varying boost pressure in the “airbox”.
Otherwise the perfect functioning of the carburetors is not assured. See 73-00-00 sec. 2.
Fit the pressure gauge where it can be easily observed by the operator of the ground test run.
■ CAUTION: Make sure there is no danger that the pressure gauge and hoses will get drawn into the propeller airstream. If necessary, secure with tie wraps.
▲ WARNING: No aircraft take-off before an obvious fault has been found and eliminated!
If during the test run the nominal fuel pressure values are not met, shut down engine and start with the trouble shooting procedure.
Effectivity 912 Series
Edition 1 / Rev. 2
73-00-00 page 39
July 01/2008
BRP-Rotax
Maintenance Manual
3.4.3) Carburetor sockets and compensation tube
See Figs. 73-29/1, 73-30, 73-31 and 73-32.
3.4.3.1) Carburetor socket
The carburetor attachment on the engine is designed to ensure that it can be securely fixed to the intake manifold with carburetor sockets (1). See 73-00-00 sec. 3.1.
In addition to chemical strain due to fuel and UV radiation, the carburetor socket is also subject to stress as a result of vibration. Tightening the attachment clamp (2) too firmly can also cause damage to the sockets and distance sleeve (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 of the inner diameter (6).
▲ WARNING: If cracks are suspected, fit a new carburetor socket. See SB-912-030 and SB-914-
019,”Cracks, wear and distortion on the carburetor flange”, latest issue.
3.4.3.2) Compensation tube
See Fig. 73-29.
To simplify carburetor synchronisation a new compensation tube (7) has been introduced. See therefore the latest issue of
SI-912-020 and SI-914-022 “running modifications” respectively.
Normally it is not necessary to unmount the compensation tube, should this however be necessary, then the springs (8) have to be unhinged and the hose clips (9) have to be loosened. The hoses (10) have to be cut for removal.
Effectivity 912/914 Series
Edition 1 / Rev. 2
73-00-00 page 40
July 01/2008
Fig. 73-29
08469
8
Fig. 73-30
BRP-Rotax
Maintenance Manual
10
7
10
1
5
Fig. 73-29/1
5
5
6
5
5
00366
4
4
Fig. 73-31
05793
Fig. 73-32
05792
Effectivity 912/914 Series
Edition 1 / Rev. 2
2
3
05794
73-00-00 page 41
July 01/2008
BRP-Rotax
Maintenance Manual
3.4.4) Fuel pressure regulator (only on 914 Series)
See Fig. 73-33.
Carry out a visual inspection of the fuel pressure regulator (2).
◆ NOTE: All new fuel pressure regulators are calibrated by the engine manufacturer and should not need further adjustment.
However, if this should become necessary, there is an adjustment screw (4) on the bottom side of the regulator.
Set ignition switch for both 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) to a tightening torque of 5 Nm (45 in.lb).
◆
NOTE: Apply LOCTITE 243 to the thread.
■ CAUTION: The fuel pressure regulator must not be disassembled, as there are no spare parts available. If necessary, replace the complete regulator.
The fuel pressure regulator is attached to the airbox with hex. screws
M6x16 and lock washers. Tightening torque 8 Nm (70 in.lb).
■ CAUTION: Failure to tighten the cap nut will result in a pressure drop in the fuel system, which can cause engine damage.
Fig. 73-33
2
00044
4
5
Effectivity 912 Series
Edition 1 / Rev. 2
73-00-00 page 42
July 01/2008
BRP-Rotax
Maintenance Manual
3.4.5) Fuel pump (on 912 Series)
See Figs. 73-34/1,2,3 and 73-35.
Depending on the engine configuration, it may already have been fitted with a pump with fuel hoses, see Fig. 73-9.
On engines without fuel hoses, observe the aircraft manufacturer’s instructions.
Check fuel hoses for scuffing marks and kinks.
3.4.5.1) “AC” fuel pump
In the event of damage of the old pump part no. 892546, the complete pump with all the hoses must be replaced, as the hoses are pressed in one piece with the pump.
Check pump flange (1) for planeness. If the pump 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 result of contaminated valves or leaking diaphragms, must be replaced.
◆ NOTE: A leaking diaphragm can be detected by the fuel emerging from the ventilation holes (4).
◆ NOTE: A slight leakage on the venting line (7) fuel pump part no. 893110 can be attributed to a slight “sweating”. For a period of 1 minute after the engine has been stopped, no liquid must drip down.
In case of uncertainty determine the oil amount. An oil leak is when after 20 min engine run more than 0.5 ml of oil loss is detected.
The fuel sucked in is filtered by a fine screen integrated in the pump. It is not possible to dismantle the fuel pump . If contamination of the fuel pump is suspected, the pump must be inspected on the intake side (5) using an endoscope.
◆ NOTE: The consecutive (6digit) serial number is displayed on the pump housing (6).
◆ NOTE: Service Bulletins SB-912-049 “Checking eccenters and fuel pump plungers”, latest issue must be observed.
Effectivity 912 Series
Edition 1 / Rev. 4
73-00-00 page 43
February 01/2015
Fig. 73-35
00368
Fig. 73-34/1
BRP-Rotax
Maintenance Manual part no. 892542
3
5
1
6
00367
2 from tank or
4
3 from tank
04962 to carburetor to carburetor
3.4.5.2) “BCD“ fuel pump
In the course of continuous development a new fuel pump part no. 893115 has been introduced . The fuel pumps part no.
893110 (without hoses) and part no. 893114 (with hoses) can be configured with corresponding hose nipples and fuel hoses.
See table 1 and table 2 below.
Table 1
Effectivity 912 Series
Edition 1 / Rev. 4
F u e l p u m p p a r t n o .
8 9 3 1 1 0 i n c l u d e s t h e f o l l o w i n g p a r t s : p a r t n o .
q u a n t i t y d e s c r i p t i o n
8
9
6
8
8
2
9
5
3
4
4
5
3
0
1
0
0
0
1
2
8
7
7
4
1
2
7
4
4
2
5
8
0
0
5
5
1
1
1
1
1
2
I
F n
O
N i
N
G i u s
r e u i l l n p p l p p l a s k p a g e e t u e t i m n
7
9 g p
/ 3
/ 5 r i f l a a
, 8
, 7 n g s n s g y e
.
( p r e s
( s u c
1 0 , s u r e t i o n l i n
2 / 1 5 / 1 , 5 l i n e ) e )
73-00-00 page 44
February 01/2015
BRP-Rotax
Maintenance Manual
Table 2 p a r t n o .
8 9 3 1 1 5
F u e l p u m p p a r t n o .
8 9 3 1 1 4 i n c l u d e s t h e f o l l o w i n g p a r t s : q u a n t i t y d e s c r i p t i o n
1 F u e l p u m p a s s y .
9 5 0 2 2 8
6 3 1 8 7 0
8 7 4 3 3 7
8 7 4 3 4 7
2 5 0 4 2 5
8 4 0 7 7 0
8 4 0 7 7 5
1
1
1
1
2
1
1
I n
O s
-
F u
F u
G a r u i e l e l l n a g t i h o h o s k e t
S c r e w n g s e s e f l r i n g a n s o c k e t g e
1 0 , 2 / 1 5 / 1 , 5
S c r e w s o c k e t 9 / 1 6 1 8 U N F / M 1 0 x 1
1 / 2 2 0 U N F / M 1 0 x 1
( p r e s s u r e l i n e )
( s u c t i o n l i n e )
Retrofitting of fuel pump assy. part no. 893110 to 893115
See Fig. 73-35/1.
Connections to the fuel pump:
Fuel inlet (3):
Hose nipple.............. 9/5,7
Tightening torque: 10 Nm (88 in.lb.)
Fuel outlet (2)
Hose nipple.............. 7/3,8
Tightening torque: 10 Nm (88 in.lb.)
3 B
4
B LOCTITE 243
1 Fuel pump assy.
2 Hose nipple 7/3,8
3 Hose nipple 9/5,7
4 Gasket ring 10,2/15/1,5
2
B 4
09875
Fig. 73-35/1
1
Effectivity 914 Series
Edition 1 / Rev. 4
73-00-00 page 45
February 01/2015
BRP-Rotax
Maintenance Manual
Retrofitting of fuel pump assy. part no. 893114 to 893115
See Fig. 73-35/2 and Fig. 73-35/3.
Connections to the fuel pump:
Fuel inlet (3):
Screw socket..............1/2-20 UNF/M10x1
Tightening torque: 10 Nm (88 in.lb.)
Fuel outlet (2)
Screw socket..............9/16-18 UNF/M10x1
Tightening torque: 10 Nm (88 in.lb.)
Connection fuel hoses to screw sockets:
Fuel inlet(4):
Fuel hose assy. ..............AN6 connection
Tightening torque: 32 Nm (283 in.lb.)
Fuel outlet (5)
Fuel hose assy. .............AN5 connection
Tightening torque: 27 Nm (239 in.lb.)
■ CAUTION: Counter the screw socket when screwing!
◆
NOTE: The fuel lines part no. 874337 and 874347 (STRATOFLEX) must not be changed every 5 years.
6
4
3
1
5
2
4
5
6
1
2
3
Fuel pump assy.
Fuel hose assy. (outlet)
Fuel hose assy. (inlet)
Screw socket 1/2-20 UNF/M10x1 (inlet)
Screw socket 9/16-18 UNF/M10x1 (outlet)
Gasket ring 10,2/15/1,5
6
Effectivity 914 Series
Edition 1 / Rev. 5
Fig. 73-35/2
09874
73-00-00 page 46
March 01/2017
Specific:
Greasing the screw socket thread
BRP-Rotax
Maintenance Manual
G r e a s e
(rotating)
09876
Fig. 73-35/3
G r e a s e
(rotating)
◆ NOTE: These fuel hoses are not subject of the 5-year replacement interval and must not be changed.
Installation relevant modifications
See Fig. 73-35/4 and Fig. 73-35/5.
Operating limits
See latest Operators Manual.
Fuel pressure: max..................0,5 bar* min....................0,15 bar
* applicable only for fuel pump part no. 893110, 893114 and
893115.
◆ NOTE: In case of an engine exchange or upgrade is has to be noted that also the operating limits must be adapted to the instrument.
Certification to the latest requirements such as FAR or
EASA has to be conducted by the aircraft manufacturer.
For more informations and related instructions, contact the aircraft manufacturer.
Effectivity 914 Series
Edition 1 / Rev. 4
73-00-00 page 47
February 01/2015
Effectivity 914 Series
Edition 1 / Rev. 4
BRP-Rotax
Maintenance Manual
Version 1
Connections to the fuel pump part no. 893110 .
See Fig. 73-35/4.
Fuel inlet (2):
ø Outside dia...............
Slip-on length:......
Fuel oulet (3)
ø Outside dia...............
8 mm (0.315 in.) max. 22 mm (0.87 in.)
6 mm (0.236 in.)
Slip-on length:.....
Drainage (4): max. 22 mm (0.87 in.)
ø Outside dia.................
6 mm (0.236 in.)
Slip-on length:.....
max. 22 mm (0.87 in.)
■
CAUTION: Ensure at installation of the supply line to fuel pump (1) that no additional moments or load will rest on the pump!
■ CAUTION: Utilize max. slip-on length. Secure hoses with suitable screw clamps or crimp. Route all lines without kinks and avoid tight bends.
Version 2
Connections to the fuel pump part no. 893114 using a screw socket on the fuel hose .
See Fig. 73-35/5.
Fuel inlet (2):
Thread (5)................
Tightening torque:
Fuel oulet (3)
9/16-18 UNF
15 Nm
Ring hose nipple (6) 3/4 DIN7642
Tightening torque: 15 Nm
Drainage (4):
ø Outside dia........................6 mm
Slip-on length:.............
max. 22 mm
■ CAUTION: Route the lines without kinks and avoid tight bends.
73-00-00 page 48
February 01/2015
BRP-Rotax
Maintenance Manual
-
-
■ CAUTION: Drainage line have to be routed into a ram-air and vacuum free zone, according to the requirements and release of BRP-Powertrain. The drainage line must not be routed into the slipstream. Ram pressure or vacuum impair the fuel pressure.
The lines have to be routed so that in case of damage the surplus of fuel/oil is drained off suitably.
Route the lines in a continous decline.
The lines have to protected against any kind of blockage e.g. by formation of ice.
■ CAUTION: When using an additional electric fuel pump, then a check valve (part no. 874532) with easy opening should be used and installed according to the Installation
Manual 912/914.
■ CAUTION: Use the pilot jet (part no. 963820) from the fuel pressure line to the fuel return line (see latest Installation Manual
912/914 Series).
Version 1
08829
Fig. 73-35/4
4
3 fuel inlet
5 fuel outlet
2 6
Version 2
11
08831
Fig. 73-35/5
4
11
2
3
Effectivity 914 Series
Edition 1 / Rev. 4
73-00-00 page 49
February 01/2015
BRP-Rotax
Maintenance Manual
3.4.6) Fuel pump (on 914 Series)
See Fig. 73-36/1 and 73-36/2.
Check the filter in the pumps, see Line Maintenance 12-00-00 sec. 2.10.
If the installation specific fine filter shows a lot of dirt then the filter (1) of the fuel pump also have to be inspected.
Cleaning of the fuel pump integrated filter
■ CAUTION: Don’t damage intake connection or filter.
Use a forceps to carefully pull out pre-filter from the intake connection.
■ CAUTION: 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 intake connetion.
Perform visual check on fuel pump.
■
CAUTION : It is not possible to disassemble the fuel pump, there are no spare parts available. If necessary the fuel pump has to be replaced.
In the event of a malfunction in the fuel system, the pump performance and/or the current input of the fuel pump can be checked.
With a pressure difference of approx. 250 hPa (3,63 PSI), the fuel pump is pumping at approx. 100 l/h.
The current input at this quantity is approx. 2 A.
◆ NOTE: These figures are reference values.
Fig. 73-36/1
00157
Effectivity 914 Series
Edition 1 / Rev. 4
1
73-00-00 page 50
February 01/2015
Fig. 73-36/2
BRP-Rotax
Maintenance Manual
11,75 8
M5
M4
P1
ø38
ø13,3
ø12
ø8
00045
P2
ø9
3.4.7) Pressure connecting lines (only on 914 Series)
See Figs. 73-37 and 73-38.
The pressure connecting lines are of essential importance for safe operation of the engine. See also 73-00-00 sec. 2 and the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 or 914 Series.
Check all lines and T-fittings for damage (mechanical, thermal, etc.) and leakage.
■ CAUTION: All lines are secured with clamps. Check them for safety reasons.
Effectivity 914 Series
Edition 1 / Rev. 3
73-00-00 page 51
October 01/2010
BRP-Powertrain
Maintenance Manual
If the lines have been detached or replaced, connect them correctly:
hose nipple (2) to the T-fitting (3)
T-fitting (3) to the fuel pressure regulator (4)
T-fitting (3) to the condensation trap (5) (on older engine configurations)
condensation trap (5) to the airbox pressure sensor (on older engine configurations)
hose nipple (6) to solenoid valve (7) ((towards 2-pin electric connector (8))
◆ NOTE: On newer engines the solenoid valve (7) is mounted on the airbox (1). See 76-00-00 sec. 3.1.2.9.
hose nipple (9) to solenoid valve (7) ((towards electric connector (8) on the opposite side))
solenoid valve (7) (top connection) to T-fitting (10)
T-fitting (10) to float chamber venting of carburetor 1/3
T-fitting (10) to float chamber venting of carburetor 2/4
Secure all lines with clamps 8 (11).
An exception are the 3 lines on the solenoid valve which, due to the shape of the valve, must be secured with clamps 6.8 (12).
The lines to the float chamber venting must be fixed to the fuel lines with tie wraps (13). Do not constrict!
■
CAUTION: Ensure that the total slip-on length is used for all pressure connecting lines and that the clamps are fixed securely.
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 sec. 3.4.6.
Reconnect plug connections to temperature sensors and throttle potentiometer.
Check that the plug connections are attached securely.
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 52
February 01/2015
Fig. 73-37
BRP-Powertrain
Maintenance Manual
13 3 7
13
4
10 9
6 2 1
00048
Fig. 73-38
10
200 mm
(7.88 in.)
11 11
310 mm
(12.6 in.)
110 mm (4.34 in.)
4
3
40 mm (1.57 in.)
6
*
11
130 mm
(5.12 in.)
2
75 mm
(82.95
11
9
130 mm
(5.12 in.)
12
1
5
12
7
00049
* Length of tubes depending on
* installation conditions
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 53
February 01/2015
BRP-Powertrain
Maintenance Manual
3.5) Assembly of fuel pump, carburetor sockets, carburetor and fuel lines
3.5.1) Fuel pump
See Fig. 73-39/1 and 73-39/2.
In addition to the inspection of all fuel lines, if used, the drainage line
(12) must be checked for damage, leaks, hardening from heat, porosity, loose connections, secure attachment and routing without kinks and tight bends.
3.5.1.1) Removal of the fuel pump
Loosen hex. nut (9) with lock washer (10) and remove the fuel pump.
3.5.1.2) Inspection of the fuel pump
See Fig. 73-39/1 and 73-39/2.
■ CAUTION: The pump cover (11) must not be opened for inspection. The markings (locking compound) must be inspected.
■ CAUTION: The hose nipples (2,3) must be checked for tightness and leakage. If necessary, the nipples and fuel hoses assy. (13,14) must be removed, cleaned and tightened with a new sealing ring
(15) using LOCTITE 243. Tightening torque
10 Nm.
Fuel pressure
The pressure within the fuel system must be max. 0.5 bar. With the new fuel pressure gauge part no. 874234, the pressure and the efficiency of the fuel supply can be inspected.
◆ NOTE: The fuel pressure gauges part no. 874231 and/or 874233 are marked with the usual fuel pressure limit (max. 0.4 bar). At the new fuel pressure gauge part no. 874234 this limit was adjusted accordingly to 0.5 bar.
In coordination with the aircraft manufacturer or national registration authority, a subsequent correction of the limit mark should be possible.
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 54
February 01/2015
BRP-Powertrain
Maintenance Manual
3.5.1.3) Montage der Kraftstoffpumpe
See Fig. 73-39/1 and Fig. 73-39/2.
■ CAUTION: In addition to the new insulating flange a new O-ring (4) must be used. Do not use the old insulating flange and
O-ring!
◆ NOTE: If a new pump was installed,it may occur that during the first time (about 30 minutes) oil leaks from the air vent nipple. This is no leakage of the pump.
◆ NOTE: No sealant is necessary at the sealing surfaces on the gearbox housing and fuel pump flange.
Install fuel pump with new insulating flange (1) and O-ring (4). Secure hex. nut M8 (2) with lock washer A8 (3) with LOCTITE 243 and tighten evenly. Tightening torque 15 Nm.
◆ NOTE: The additional fastening with LOCTITE 243 should be applied to any appointment or re-assembly of the fuel pump and insulating flange.
Re-install fuel lines.
Version 1
08829
4
3 fuel inlet
5 fuel outlet
2 6
Version 2
11
08831
Fig. 73-39/1
4
11
2
3
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 55
February 01/2015
B LOCTITE 243
BRP-Powertrain
Maintenance Manual
S/N (6-digit)
10
XX.XXXX
9
XXXXXX part no.
(6-digit)
B
1
7
8
12
08830
Fig. 73-39/2
3
4
1
2
5
6
Fuel pump
Nipple (fuel inlet)
Nipple (fuel outlet)
Drainage
Thread
Ring hose nipple
7
8
9
Insulating flange
O-ring
Hex. nut M8
10 Lock washer A8
11 Pump cover
12 Drain line
13 Fuel hose assy. (outlet)
14 Fuel hose assy. (inlet)
3.5.2) Carburetors 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 groove, a gasket
(8) (see Illustrated Parts Catalog) must be fitted.
The screws are locked with LOCTITE 221. Tightening torque 15 Nm
(133 in.lb).
Fit carburetor into carburetor socket, which should be free of grease and oil , align and fix with hose clamp (9). Tightening torque 2.5 Nm
(22 in.lb).
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 56
February 01/2015
B LOCTITE 243
1
B
BRP-Powertrain
Maintenance Manual
◆ NOTE: If hose clamp (9) does not have a spacer leave a 7-8 mm
(0.27 - 0.31 in.) gap. Do not overtighten as this will damage the socket.
Check distance of 5 to 6 mm (0.2 in. to 0.24 in.) on allen screw (10) as this is important to allow free movement of the tension spring (11).
Engage tension spring in the bracket (12) using a suitable tool.
■ CAUTION: To ensure efficient carburetor suspension, a distance of 40 mm (1.57 in.) between allen screw and engagement latch must be respected.
2
4
Fig. 73-40
09886
Fig. 73-41
02727
13
11
40 mm
12
5-6 mm
5 7,8
Fig. 73-40/1
05794
5
9
9
Effectivity 912/914 Series
Edition 1 / Rev. 4
Fig. 73-41/1
08390
A LOCTITE 221
6
5
7
A
8
A
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BRP-Powertrain
Maintenance Manual
3.5.3) Assembly of the fuel lines (on 912 Series)
See Figs. 73-42, 73-43, 73-44
■ CAUTION: To prevent locked up stresses, all components should first be screwed on loosely and then tightened to the prescribed tightening torque.
If the clamp block (1) has been removed, it must now be reattached with an allen screw M5x16 and a tightening torque of 6 Nm (53 in.lb).
◆ NOTE: For easier assembly of the fuel line, observe the original position of the clamp block.
The lines from the fuel pump (3) and the lines to the carburetors are attached to the bottom side of the clamp block, each between a sealing
Fig. 73-42
5 to fuel pressure gauge
2
5
6
1
9 to fuel tank to fuel tank
9
2
1
2 to carburetor to carburetor to carburetor from fuel pump
2
3 from fuel pump
5
09192
08476 ring (2) and the banjo bolt (5) (tightening torque 10 Nm
(90 in.lb)).
The ring hose nipple (6) is attached to the top side of the clamp block between a sealing ring (2) and the banjo bolt (5) (tightening torque 10
Nm (90 in.lb)).
– connection for return line to the tank (Ø outside 7mm (0.28 in.)) slip-on length: max. 17 mm (0.67 in.)
– connection to the pressure gauge (Ø outside 6 mm (0.24 in.)) slip-on length: max. 17 mm (0.67 in.)
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 58
February 01/2015
Effectivity 912 Series
Edition 1 / Rev. 4
BRP-Rotax
Maintenance Manual
The double hose nipple (6) is optional.
◆ NOTE: The double hose nipple (6) contains an integrated restrictor (9) (0.35 mm (.0138 in.)) which plays a decisive role in ensuring correct functioning of the fuel system.
◆ NOTE: If no pressure gauge is connected, a single ring hose nipple is fitted. The restrictor (9) is then in the top banjo bolt (5). For recognition the banjo bolt is either marked with yellow color or with the label “FUEL”.
■ CAUTION: Do not get the connections mixed up.
Unscrew allen screw M10x1x8 (11) with the sealing ring (10). Tightening torque 15 Nm (133 in.lb) - screw secured with LOCTITE 221. See
Fig. 73-44.
◆ NOTE: When converting to a double hose nipple for measurement of the fuel pressure, the jet must be removed from the banjo bolt (5).
Screw the fuel lines to the carburetors.
Rigid line
◆ NOTE: Do not tighten the clamp block until all lines have been connected.
▲ WARNING: The lines must be fitted without tension and with all the standard in serial supports to prevent breaks caused by vibration during operation.
■ CAUTION: When assembling the fuel lines, ensure that they are adequately supported to prevent strain on the connections. See Fig. 73-43.
◆ NOTE: An optional double hose nipple (6) is available for measurement of the fuel pressure.
Assembly at the carburetor should be carried out analogously the disassembly. See sec. 3.4.4.
73-00-00 page 59
February 01/2015
BRP-Rotax
Maintenance Manual
Fig. 73-43 Fig. 73-44
5
2
1
3
5
10
11
4
07513
07514
9
8
7
Flexible lines
See Fig. 73-45
See SI-912-020, ”Running modifications”, latest issue.
◆ NOTE: The flexible line must not be changed every 5 years.
From 2007 on, all new models will have a flexible line instead of the present rigid fuel line.
Assembly at the carburetor should be carried out analogously the diassembly. See sec. 3.4.4.
◆
NOTE: In case of a retrofit on configurations with steel fuel lines remove the screw connectors (1) and remove 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 machine the nut/clamp contact area until the surface is parallel with the sealing surface of the carb socket. The thickness of the material must not be dressed down less than 10,5 mm (0.413 in.) and should be smooth and flat so that the nut/clamp assembly has an even contact surface (see Fig. 73-46).
Effectivity 914 Series
Edition 1 / Rev. 5
Ensure proper support of the flexible fuel line. Install Hex. screw (2) and washer (3) with 15 Nm (133 in. lb.). Install the cable clamp (4) at the hex. screw (2) of the carburetor socket with the hex. nut (5).
Tightening torque of hex. nut (5) 24 Nm (18 ft. lb.)
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BRP-Rotax
Maintenance Manual
■ CAUTION: While tightening hex. nut (5), hold hex. screw (2) with a wrench to prevent it from loosening.
Always fix the flexible fuel line at the compensation tube with clamps
(6) in such a way that no wear is possible.
08180
6
5
4
3
A
2
A LOCTITE 221
1
6
3
2
A
Fig. 73-46
07313
1
Effectivity 914 Series
Edition 1 / Rev. 5
73-00-00 page 61
March 01/2017
BRP-Rotax
Maintenance Manual
3.5.4) Assembly of the fuel lines (on 914 Series)
See Fig. 73-47.
Attach fuel line (1) to carburetor (fuel inlet) with collar nut (2). Support the line on the carburetor bracket with a cable clamp (3). The cable clamps are attached with allen screws (4) M5x12 and lock nuts (5). The tighten collar nut to 10 Nm (90 in.lb).
Now the airbox (6) can be refitted on the connections of the carburetors.
Do not damage the previously fitted fuel lines and pressure connecting lines.
Ensure that all clamping locations are free of grease .
■
CAUTION: 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 screw hose clamps (7) can be tightened on the connecting hose (8) and, if necessary, on air intake hose (9).
Fit the pressure connecting lines (10) (float chamber venting) on both carburetors and fuel pressure regulator (11) with clamps (12) 8. See 73-
00-00 sec. 3.4.9.
Attach the 2 fuel lines (1) to the fuel pressure regulator (11) with banjo bolts (13) M10 and sealing rings (14) 10x14 on both sides.
Tightening torque: 15 Nm (133 in.lb).
■ CAUTION: When fitting fuel lines, support them adequately to avoid strain or additional load.
Reconnect plug connection to temperature sensors and throttle potentiometer.
Check plug connections for security.
Effectivity 914 Series
Edition 1 / Rev. 4
73-00-00 page 62
February 01/2015
BRP-Rotax
Maintenance Manual
Fig. 73-47
1
2
8
A Loctite 243
XXX
12
10
12
A
14
13
7
7
5
12
3
4
1
XXX
11
XXX
2
07713
6
9
7
Effectivity 914 Series
Edition 1 / Rev. 4
73-00-00 page 63
February 01/2015
BRP-Rotax
Maintenance Manual
See 72-00-00 sec. 3.17.
3.7) Engaging the carburetor support
See Figs. 73-48 and 73-49.
Check that the tension spring (1) moves freely in the allen screw (2) and in the distance sleeve (5) and engage the tension spring in the engagement latch (3) using a suitable tool. Ensure that the two arms (4) of the tension clamp with the engagement latch point upwards. If necessary, correct the position of the tension clamp.
■ CAUTION: 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 screw and the distance sleeve, support set part no. 887730, see Fig. 73-54, must be used.
Repeat procedure for second carburetor.
◆ NOTE: Only on 912 Series: On engine models from the year 96 onwards, the carburetor support is already fitted in serial production. We recommend installing it on all engines older than this. See
Service Bulletin SB-912-010,”Fitting of a carburetor support”, latest issue.
Engines 912 S, 912 ULS, 914 UL and 914 F have been equipped with the carburetor support since the beginning of production.
3
Fig. 73-48
2
4
(1.57 in.)
1
5
2
Fig. 73-49
Effectivity 914 Series
Edition 1 / Rev. 2
04730
03884
73-00-00 page 64
July 01/2008
BRP-Rotax
Maintenance Manual
3.8) Connecting fuel lines (tank)
The fuel lines 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 engine in the aircraft.
■ CAUTION: When tightening the fuel lines, no force or torque may be applied to the fuel pump connections or the fuel pressure regulator.
Effectivity 912/914 Series
Edition 1 / Rev. 2
73-00-00 page 65
July 01/2008
BRP-Powertrain
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 4
73-00-00 page 66
February 01/2015
BRP-Powertrain
Maintenance Manual
SECTION 74
IGNITION SYSTEM
1) Table of contents
SECTION 74
IGNITION SYSTEM
1) Table of contents .................................................................................... 74-00-00 / 1
2) Systems description ................................................................................. 74-00-00 / 3
2.1.) Electric system (alternators, ignition) ............................................ 74-00-00 / 3
2.1.1) Ignition .................................................................................. 74-00-00 / 6
2.1.2) Allocation of trigger coils and ignition circuits ....................... 74-00-00 / 8
2.1.3) Firing order ........................................................................... 74-00-00 / 9
2.1.4) Ignition cables ....................................................................... 74-00-00 / 9
2.2) Connections for instrumentation ................................................... 74-00-00 / 9
2.2.1) Electronic rev counter ........................................................... 74-00-00 / 9
3) Maintenance / troubleshooting ............................................................... 74-00-00 / 11
3.1) Treatment of corrosion and surface damage ................................ 74-00-00 / 11
3.1.1) Electric system...................................................................... 74-00-00 / 11
3.2) 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) Charging coil ................................................................................. 74-00-00 / 15
3.7) Generator coils .............................................................................. 74-00-00 / 16
3.8) Dual ignition coil ............................................................................ 74-00-00 / 17
3.9) Cut-in speed of ignition ................................................................. 74-00-00 / 18
3.10) Ignition timing control .................................................................... 74-00-00 / 19
3.11) Ignition circuits inspection (ignition check) .................................... 74-00-00 / 21
3.12) Measurement values for the ignition unit ...................................... 74-00-00 / 22
3.13) Wiring diagrams ............................................................................ 74-00-00 / 24
3.13.1) Engine internal (on the 912 Series) ...................................... 74-00-00 / 24
3.13.2) Engine internal (on the 914 Series) ...................................... 74-00-00 / 30
3.13.3) Engine external (on the 914 Series) ..................................... 74-00-00 / 34
3.14) Ignition electric set removal ........................................................... 74-00-00 / 35
3.15) Ignition electric set dismantling ..................................................... 74-00-00 / 37
3.15.1) Dual ignition coils replacement ............................................. 74-00-00 / 37
3.16) Ignition electric set reassembly .................................................... 74-00-00 / 41
Effectivity 912/914 Series
Edition 1 / Rev. 3
74-00-00 page 1
October 01/2010
BRP-Rotax
Maintenance Manual
3.17) Ignition electric set refitting ............................................................ 74-00-00 / 43
3.18) Trigger coil kit replacement ........................................................... 74-00-00 / 46
3.19) Stator removal and refitting.......................................................... 74-00-00 / 48
3.20) Fly wheel hub' ............................................................................... 74-00-00 / 49
3.21) Interference suppression box (only on the 912 Series) ................. 74-00-00 / 52
3.21.1) Interference suppression box dismantling ............................ 74-00-00 / 52
3.21.2) Interference suppression box wiring 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) External alternator (optional on 912/914 Series) ........................... 74-00-00 / 57
3.23.1) V-belt pulley removal ............................................................. 74-00-00 / 57
3.23.2) Alternator removal ................................................................ 74-00-00 / 57
3.23.3) V-belt assembly .................................................................... 74-00-00 / 57
3.23.4) Checking of the external generator....................................... 74-00-00 / 59
3.23.4.1) Check of the power output of the generator ......... 74-00-00 / 59
3.23.4.2) Mechanical check .................................................. 74-00-00 / 59
3.23.5) Alternator assembly .............................................................. 74-00-00 / 59
3.23.6) V-belt tension ........................................................................ 74-00-00 / 59
4) Wear limits .............................................................................................. 74-00-00 / 61
5) Form Sheets ........................................................................................... 74-00-00 / 63
Effectivity 912/914 Series
Edition 1 / Rev. 2
74-00-00 page 2
July 01/2008
BRP-Rotax
Maintenance Manual
2) Systems description
2.1.) Electric system (alternators, ignition)
See Fig. 74-1.
ROTAX engines of the 912/914 Series are equipped with a breakerless dual ignition system (DCDI-Dual Capacitor Discharge Ignition).
The ignition unit needs no external power 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 moment of ignition, 2 each of the 4 external trigger coils (3) actuate the discharge of the capacitors via the primary circuit of the dual ignition transformers (4).
◆ NOTE: The 5th trigger coil (5) is provided for the rev counter signal.
Fig. 74-1
Firing order: 1 - 4 - 2 - 3
6
Ignition circuit A
2
4
5
3
B3/4
6
A1/2
3
4
3
A3/4
B1/2
3
1
2
4
10040
Effectivity 912/914 Series
Edition 1 / Rev. 5
4
Ignition circuit B
74-00-00 page 3
March 01/2017
BRP-Rotax
Maintenance Manual
The standard equipment also includes an integrated AC generator (pos. 6, Fig
74-1) with an external rectifier-regulator (12V DC 250 W).
For higher power requirements, it is possible to install an external alternator (12V
DC 600W).
◆
NOTE: A rectifier-regulator is already integrated in the external alternator.
The electric system comprises the internal generator with the charging coils for the ignition and the ignition electrics with 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 magneto ring (3)
The fly wheel hub (4) (ignition triggering) is attached to the magneto ring.
The 4 trigger coils (5) are fitted externally on the alternator.
Ignition electrics: See Fig. 74-3.
Consists of 4 dual ignition coils (1) connected together by their magnetic cores and two electronic modules (2) positioned above.
The 3-point suspension is with one each support on crankcase, ignition housing and intake manifold.
For safety reasons, the ignition electrics must not be exposed to ambient temperatures higher than 80 °C (176 °F).
Effectivity 912/914 Series
Edition 1 / Rev. 5
74-00-00 page 4
March 01/2017
BRP-Rotax
Maintenance Manual
Fig. 74-2
2
O
1
I
6 A
3
Fig. 74-3
2
5
A
XXX
4
A
A
XXX
1T
3T
1B
3B
07722
I
I
2T
4T
A
B
A
A
07723
2B
4B
Effectivity 912/914 Series
Edition 1 / Rev. 0
S
1
74-00-00 page 5
May 01/2007
BRP-Rotax
Maintenance Manual
2.1.1) Ignition
See Fig. 74-4.
As already stated, the engine is equipped with dual ignition of a breakerless capacitor discharge design (DCDI). That means that the ignition unit comprises two independently working ignition circuits
(separate trigger coil, electronic module, charging coils etc.).
◆ NOTE: The ignition unit cannot be disassembled and needs no adjustment.
Each ignition circuit consists of two ignition branches. Ignition occurs on cylinder 1 and 2 simultaneously every 360° as well as on cylinder 3 and
4 but 180° offset.
◆ NOTE: Due to engine design, ignition occurs also at "the TDC of the exhaust stroke", but this has no effect on engine operation.
The engine is furnished 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 ignition circuit A and B.
As soon as the engine runs, the ignition point will change over automatically to operation ignition.
On the 912 Series:
Differences between electronic modules: without advanced start electronic module with advanced start fly wheel hub ignition point at start 966871
966872 time delay for ignition at start: switching to advanced ignition: ignition timing in normal operation:
4° Before T.D.C.
3° After T.D.C.
none from 650 to 1000 RPM depending on trigger gap
Circuit A: 26° before T.D.C.
Circuit B: 26° before T.D.C.
Circuit B: 22° before T.D.C.
1) 2)
3)
4° Before T.D.C.
3° After T.D.C.
3 - 8 sec.
after the expiration of the time delay (3-8 sec.)
Circuit A: 26° bef ore T. D. C.
Circuit B: 26° bef ore T. D. C.
1) 2)
3)
1) 2) 912 A, F, S, UL, ULS
3) 914 F, UL
On the 914 Series: ignition circuit A ignition circuit B
26°
22°
The transition from start ignition timing to the timing for operation takes place between 650 and 1000 rpm.
See Installation Manual, chapter 24-00-00 and SI-912-020 of the relevant engine type.
Effectivity 912/914 Series
Edition 1 / Rev. 5
74-00-00 page 6
March 01/2017
◆ NOTE:
BRP-Rotax
Maintenance Manual
The different ignition points (only on 914 Series) for the top spark plugs and the bottom spark plugs takes into account the differing ignition delays, preventing preignition and detonation.
The difference in the ignition points is achieved by different lengths of the trigger cam (1) on the fly wheel hub.
Trigger cam for ignition circuit A (raised position) is approx. 4 mm (0.16") longer.
Fig. 74-4
1
B3/4
A1/2
00135
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 7
May 01/2007
BRP-Rotax
Maintenance Manual
2.1.2) Allocation of trigger coils and ignition circuits
See Fig. 74-5.
The upper 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 electronic module
◆ NOTE: The spark plugs are supplied differently on the 912
Series and the 914 Series. See 74-00-00 sec. 3.10.
Fig. 74-5
Drehzahlmesser rev. counter
B3/4
A1/2
A3/4
B1/2
00135
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 8
May 01/2007
BRP-Rotax
Maintenance Manual
2.1.3) Firing order
The firing order is 1 - 4 - 2 - 3 .
2.1.4) Ignition cables
The 8 ignition cables of the spark plug connectors are marked with number 1 through 4 for cylinder assignment. 2 cables each for the bottom spark plugs are routed together in a protection hose 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 connector, thus enabling easy replacement.
2.2) Connections for instrumentation
■ CAUTION: Consult also the relevant section in the Installation Manual.
2.2.1) Electronic rev counter
On the ignition housing there is an inductive pick-up triggering one each positive or negative impulse at every turn of the crankshaft. The optional rev counter is a specially adapted AC device.
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 9
May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 10
May 01/2007
BRP-Rotax
Maintenance Manual
3) Maintenance / troubleshooting
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see corresponding
Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or
914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.
3.1) Treatment of corrosion and surface damage
See 71-00-00 sec. 4.
3.1.1
Electric system
Formation of a rust film on the permanent magnets in the magneto ring and on the metal cores of the 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 grease. Take care that no foreign objects fall into the magneto ring. Clean ring terminals and apply LITHIUM grease to the contact surfaces to assure lasting contact.
Check contact between electrical contacts and ground connections
(ring terminals) by removal, if necessary apply contact spray to increase conductivity.
3.2) Checking the ignition unit, trouble shooting
Components can only be replaced but not repaired. If there is no ignition spark, systematically trace possible causes.
▲ WARNING: For safety’s sake, switch off ignition, if possible, and withdraw ignition key!
▲
WARNING: Danger of fatal injury due to high voltage! Always take all appropriate protective measures and use all safety equipment when working on the ignition unit!
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 11
May 01/2007
BRP-Powertrain
Maintenance Manual
3.3) Spark plugs
See Figs. 74-6 and 74-7.
Inspection of the spark plugs:
check electrode gap, dimension (SP01 ), see 74-00-00 sec. 4.
check heat range, see 71-00-00 sec. 3.4.
See the latest Maintenance Manual "Line Maintenance“ for the respective engine type.
Fig. 74-6
SP01
00086
3.4) Spark plug connectors and ignition cables
See Fig. 74-7.
Carry out visual inspection of spark plug connectors (1) for corrosion and damage, replace if necessary.
Check tight fit of spark plug connectors on the spark plugs as shown in the maintenance overview. Assure security of the spark plug connector. Spark plug connectors which are seated too loosely must be replaced.
Check minimum pull-off force of 30 N (265 in.lb) .
Check screw connection with the ignition cable (2) and the tie wrap clip (3).
If there is visible damage, replace spark plug connector.
Check correct connection of the ignition cables (2) against the wiring diagram. See 74-00-00 sec. 3.13.
The cable ends are equipped with identification rings (4). The ignition cables for the bottom spark plugs are protected by a glass fiber/silicone protection hose (5) All ignition cables are covered by a protection hose (6) — replace if there is visible damage.
For measurement values of the spark plug connectors, see 74-00-00 sec.
3.13
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 12
February 01/2015
BRP-Rotax
Maintenance Manual
Check all cables and their plug connections for damage and correct connection as per wiring diagram. See 74-00-00 sec. 3.13.
Check all plug- and screwed connections for oxidation and tight fit.
Check shorting cables and ignition switch. If ignition switch failure is suspected, the shorting cable can be pulled off the ignition switch.
▲ WARNING: Proceed with particular care, because the ignition is not switched off.
Assure sufficient grounding between engine, battery and fuselage. Observe the fuselage manufacturer's wiring diagram.
Fig. 74-7 1
4
6
3
2
00397
5
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 13
May 01/2007
BRP-Rotax
Maintenance Manual
3.5) Electronic module, trigger coil kit
See Figs. 74-8, 74-9, 74-10 and 74-11.
■ CAUTION: On the 914 Series, the ignition points for circuit A and B differ from that on ROTAX engine 912 ! In the event of failure of an ignition circuit on the 914 Series, the two 6-pin plug connectors
(1) of the pick-up cables may be swapped over for localization of the fault, only for the purpose of testing and at low throttle, never at full throttle .
◆ NOTE: The ignition unit of the 912 Series and 914 Series have been standardized. See SI-912-013 and SI-914-016,“Standardization of the ignition unit“, latest issue.
The modules (2) are interchangeable as they are of the same design.
If the affected electronic module is replaced without success, there is a fault in the charging coil or the trigger coils for this ignition circuit. Dismantling is described here for both cases. See 74-00-00 sec. 3.19.
If the malfunction in the ignition circuit then appears again when the modules have been interchanged, there is a fault in the electronic module.
Older engine models
Fig. 74-8
2
2
A
New engine models
Fig. 74-9
2
2
00399
1
Effectivity 912/914 Series
Edition 1 / Rev. 0
00398
Fig. 74-10
1
07724
Fig. 74-11
07725
74-00-00 page 14
May 01/2007
BRP-Rotax
Maintenance Manual
3.6) Charging coil
See Fig. 74-12.
In case of malfunction of one ignition circuit, the 2 single-pin plugs of the red charging cables may be interchanged for localization of the problem.
If the failure 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 charging coil (1) for ignition circuit " A " or (2) for circuit " B " is the cause. In this case the stator must be removed see 74-00-00 sec. 3.19
Check charging cable for damage. Measure resistance with a multimeter see
74-00-00 sec. 5, if necessary, replace the complete stator. See 74-00-00 sec.
3.12.
Fig. 74-12
1
2
Effectivity 912/914 Series
Edition 1 / Rev. 0
3
00400
74-00-00 page 15
May 01/2007
BRP-Rotax
Maintenance Manual
3.7) Generator coils
See Fig. 74-12.
If the generator does not work, the reason may be a defective or damaged yellow alternator cable or a defective winding on the 8 alternator coils (3). Disconnect alternator cables (yellow) and check resistance values.
Measure the resistance with a multimeter. See 74-00-00 sec. 3.12 and
74-00-00 sec. 5.
◆ NOTE: If the value measured corresponds with the values specified, the cause may be a defective rectifier-regulator.
■ CAUTION : When performing any of the work described here, ensure that no foreign objects can enter the ignition 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 wiring diagram Fig. 74-12.
– Set engine speed to 4000 rpm.
– Check that charge indicating lamp goes out.
– Read off the idle voltage on the voltmeter (8) and record it in the 74-00-00 sec. 5 „Form sheets“.
– Close circuit-breaker (7), read off voltage under load on the voltmeter (8) and record it in the 74-00-00 sec. 5 „Form sheets“ .
2
4 5 8
Fig. 74-12
07539
G G R +B L C
-
1
6
G 3W
+
V
150W
3
A
7
(1) Magneto-generator
(2)
(3)
Recitfier regulator part no. 965345
Charge indicating lamp 3W (0.004 hp)
(4) Battery 12 V charged
(5) Capacitor 22 000 µF/25 V
(6) Consumer (lamps) 150 W (0.201 hp)
(7) Circuit breaker
(8) Voltmeter
Testing is carried out at 4000 rpm with and without consumer.
Effectivity 912/914 Series
Edition 1 / Rev. 2
74-00-00 page 16
July 01/2008
BRP-Powertrain
Maintenance Manual
3.8) Dual ignition coil
See Figs. 74-13 and 74-14.
If the failure of a single resistance spark plug or 2 resistance spark plugs is noticed, check the connections and the resistance values of the respective 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.
3.15 and 3.16. See SI-912-013 and SI-914-016,“Standardization of the ignition unit“, latest issue.
Measure the resistance with a multimeter.
See 74-00-00 sec. 3.12 and 74-00-00 sec. 5.
Older engine models
Fig. 74-13 to electronic module to ground
00401
New engine models
Fig. 74-14 to ground
1
1 to electronic module
07726
Effectivity 912/914 Series
Edition 1 / Rev. 3
74-00-00 page 17
October 01/2010
BRP-Rotax
Maintenance Manual
3.9) Cut-in speed of ignition
See Fig. 74-15
Ignition must cut-in between 150 rpm. and max. 220 rpm. of crankshaft speed.
To be checked with stroboscope and inductive 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 actuated by the trigger coil A1/2.
Start engine, aim stroboscope towards trigger coil A1/2 and observe flashing light.
This procedure should be performed on all ignition cables.
◆ NOTE: A precise inspection is only possible on an ignition test bed.
3
Fig. 74-15
1
2
00402
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 18
May 01/2007
BRP-Rotax
Maintenance Manual
3.10) Ignition timing control
See Figs. 74-16 and 74-17.
The automatic ignition timing is actuated by the trigger cam (1) of ignition circuit
A or trigger cam (2) of ignition circuit B . Transition from start ignition timing to operating ignition timing takes place from 650 rpm upwards.
Inspection is carried out with a stroboscope and induction pliers.
For this procedure, connect stroboscope to battery and clamp inductive pliers to the ignition cable of cylinder "1 top" . This spark plug is actuated by the trigger coil A1/2 .
At an engine speed of 150 to max. 1000 rpm,. the trailing edge of the trigger cam
(3) aligns with the core (4) of the trigger coil.
Trigger coil assignation (on the 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 cylinder 1 and 2
Trigger coil B3/4 serves the top spark plug of cylinder 3 and 4.
Trigger coil assignation (on the 914 Series)
Trigger coil A1/2 serves the top spark plug of cylinder 1 and 2
Trigger coil A3/4 serves the top spark plug of cylinder 3 and 4
Trigger coil B1/2 serves the bottom spark plug of cylinder 1 and 2
Trigger coil B3/4 serves the bottom spark plug of cylinder 3 and 4.
After transition from start ignition timing to operating ignition timing, the leading edge of the trigger cam (5) aligns with the core (4) of the trigger coil.
See Fig. 74-17.
For wear limits, see 74-00-00 sec. 4.
The readings must be entered in 72-00-00 sec. 5.
The ignition timing control must be carried out on all 4 trigger coils, paying attention to the corresponding ignition cable.
See 72-00-00 sec. 5.
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 19
May 01/2007
Start ignition timing
BRP-Rotax
Maintenance Manual
B3/4
1
A1/2
3
4
Fig. 74-16
A3/4
B1/2
Operating ignition timing
Fig. 74-17
2
07486
B3/4
4
A1/2
5
Effectivity 912/914 Series
Edition 1 / Rev. 0
A3/4
B1/2
07487
74-00-00 page 20
May 01/2007
BRP-Rotax
Maintenance Manual
3.11) Ignition circuits inspection (ignition check)
Let engine warm up. The ignition check is performed at an engine speed 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 cylinder must not exceed 300 rpm. Then perform the same inspection with ignition circuit " B" switched off. Here, too, the speed drop must not exceed 300 rpm. The difference in speed using only circuit A or B must not exceed 115 rpm.
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 21
May 01/2007
BRP-Powertrain
Maintenance Manual
3.12) Measurement values for the ignition unit
The following measurement values can be checked at the appropriate point after detaching the plug connections.
Generator coil
(on stator)
Generator coil
Charging coil
(on stator)
Trigger coil
Trigger coil new *
(with clamps)
Primary ignition coil connection contact
Secondary ignition coil high voltage
Spark plug connector yellow yellow red green/white -
white/yellow -
-
-
-
yellow 0.1
to 0.8 Ω ground
∞
ground 3.2
to 4.5 Ω blue/yellow 115.0 to 123.0
Ω blue/yellow 220.0 to 250.0 Ω ground 0.1
to 0.4 Ω
High v.
6.1
to 6.7 k Ω
4.4
to 6.0 k
Ω
◆ NOTE:
◆ NOTE:
* Fitted in serial production from year 1995.
A check of the complete ignition unit is only possible on an ignition test bench with an oscilloscope. This is especially important if failure occurs only intermittently. In this case, send the complete ignition unit to an authorized overhaul facility.
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 22
February 01/2015
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 23
May 01/2007
BRP-Rotax
Maintenance Manual
3.13) Wiring diagrams
3.13.1) Engine internal (on the 912 Series)
Wiring diagram of the ignition unit ("individual plug"), 912 Series
See Figs. 74-18, 74-19 and 74-20.
Legend to wiring diagram (Fig. 74-18)
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 switch for ignition circuit ”A” and ”B”
8 plug receptacle 1-pin
9 plug receptacle 4-pin
10 electronic module for ignition circuit ”A”
11 electronic module for ignition circuit ”B”
12 double ignition coil
13 engine
14 cylinder 1-4
15 spark plugs
16 charging coils
V consumer connection o color code
Effectivity 912 Series
Edition 1 / Rev. 0
74-00-00 page 24
May 01/2007
T = top = oben
B = bottom = unten
Fig. 74-18
BRP-Powertrain
Maintenance Manual
2
4
Engine version 912 A/F/
UL older model
◆ NOTE:
Fig. 74-18 shows the wiring diagram for electronic modules with 1-pin and
4-pin plugs.
ignition circuit A: 1 - 2 TOP
3 - 4 BOTTOM ignition circuit B: 1 - 2 BOTTOM
3 - 4 TOP
0,75 ws
0,75 ws
0,75 ws
0,75 sw
0,75 ws
Propellerseite
Magnetseite bl blue br brown ge yellow gn green ro red rs pink sw black ws white or orange
Effectivity 912 Series
Edition 1 / Rev. 3
O ge mit A
0,75 br
B3/4
A1/2
O ws mit B
0,75 br
0,75 sw
0,75 sw
0,5 ws/ge
0,5 bl/ge
1,5
1,5
0,5 bl/ge
0,5 ws/ge
B1/2
3/4
A
00403
74-00-00 page 25
October 01/2010
BRP-Rotax
Maintenance Manual
Legend to wiring diagram (Fig. 74-19)
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 switch for ignition circuit ”A” and ”B”
8 plug receptacle 1-pin
9 plug receptacle 4-pin
10 electronic module for ignition circuit ”A”
11 electronic module for ignition circuit ”B”
12 double ignition coil
13 engine
14 cylinder 1 - 4
15 spark plugs
16 charging coils
V consumer connection o color code
Effectivity 912 Series
Edition 1 / Rev. 0
74-00-00 page 26
May 01/2007
T = top
B = bottom
Fig. 74-19
BRP-Powertrain
Maintenance Manual
2
4
B 1/2
B ge ws
B 3/4
B ws ws
A 1/2
A ge ws
A 3/4
A ws ws
3/4B ws
Engine version 912 ULS/S older model
◆
NOTE:
Fig. 74-19 shows the wiring diagram for electronic modules with 1-pin, 4-pin and 6-pin plugs.
ignition circuit A: 1 - 2 TOP
3 - 4 BOTTOM ignition circuit B: 1 - 2 BOTTOM
3 - 4 TOP
0,75 ws
0,75 ws
0,75 sw
0,75 sw
0,75 bl
0,75 sw bl blue br brown ge yellow gn green ro red rs pink sw black ws white or orange
0,75 br
B3/4
A1/2
0,75 sw
0,75 sw
0,5 ws/ge
0,5 bl/ge
Magnetseite
0,75 sw
0,75 ws
0,75 sw
0,75 ws
Propellerseite
3/4T ws
0,75 bl
0,75 bl
0,75 ge
0,75 ws
0,75 sw
0,75 or
Effectivity 912 Series
Edition 1 / Rev. 3
1,5
1,5
0,5 bl/ge
0,5 ws/ge
A3/4
B1/2
04702
74-00-00 page 27
October 01/2010
BRP-Rotax
Maintenance Manual
Legend to wiring diagram (Fig. 74-20)
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 switch for ignition circuit ”A” and ”B”
8 plug receptacle 1-pin
9 plug receptacle 6-pin
10 electronic module for ignition circuit ”A”
11 electronic module for ignition circuit ”B”
12 double ignition coil
13 engine
14 cylinder 1 - 4
15 spark plugs
16 charging coils
V consumer connection o color code
Effectivity 912/914 Series
Edition 1 / Rev. 5
74-00-00 page 28
March 01/2017
Fig. 74-20
BRP-Rotax
Maintenance Manual
T = top
B = bottom
Engine version 912
A / F / U L / U L S / S new model
◆
NOTE:
Fig. 74-20 shows the wiring diagram for electronic modules with 6-pin and
6-pin plugs.
ignition circuit A: 1 - 2 TOP
3 - 4 BOTTOM ignition circuit B: 1 - 2 BOTTOM
3 - 4 TOP bl blue br brown ge yellow gn green ro red rs pink sw black ws white or orange vi violet
Effectivity 912/914 Series
Edition 1 / Rev. 5
AE 2_0166
74-00-00 page 29
March 01/2017
BRP-Rotax
Maintenance Manual
3.13.2 Engine internal (on the 914 Series)
See Figs. 74-21 and 74-22.
Legend to wiring diagram (Fig. 74-21)
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 switch for ignition circuit ”A” and ”B”
8 plug receptacle 1-pin
9 plug receptacle 4-pin
10 electronic module for ignition circuit ”A”
11 electronic module for ignition circuit ”B”
12 double ignition coil
13 engine
14 cylinder 1 - 4
15 spark plugs
16 charging coils
V consumer connection o color code
Effectivity 914 Series
Edition 1 / Rev. 0
74-00-00 page 30
May 01/2007
T = top
B = bottom
Fig. 74-21
BRP-Powertrain
Maintenance Manual
Engine version 914 UL/F older model
◆
NOTE:
Fig. 74-21 shows the wiring diagram for electronic modules with 1-pin and 4-pin plugs.
ignition circuit A: 1 - 4 TOP ignition circuit B: 1 - 4 BOTTOM bl blue br brown ge yellow gn green ro red rs pink sw black ws white
Effectivity 914 Series
Edition 1 / Rev. 3
00218
74-00-00 page 31
October 01/2010
BRP-Rotax
Maintenance Manual
Legend to wiring diagram (Fig. 74-22)
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 switch for ignition circuit ”A” and ”B”
8 plug receptacle 1-pin
9 plug receptacle 6-pin
10 electronic module for ignition circuit ”A”
11 electronic module for ignition circuit ”B”
12 double ignition coil
13 engine
14 cylinder 1 - 4
15 spark plugs
16 charging coils
V consumer connection o color code
Effectivity 912/914 Series
Edition 1 / Rev. 5
74-00-00 page 32
March 01/2017
T = top
B = bottom
Engine version 914
UL/F new model
Fig. 74-22
BRP-Rotax
Maintenance Manual
◆
NOTE:
Fig. 74-22 shows the wiring diagram for electronic modules with 6-pin and 6-pin plugs.
0,75 vi ignition circuit A: 1 - 4 TOP ignition circuit B: 1 - 4 BOTTOM bl blue br brown ge yellow gn green ro red rs pink sw black ws white vi violet
0,75 vi
Effectivity 912/914 Series
Edition 1 / Rev. 5
AE 2_0167
74-00-00 page 33
March 01/2017
BRP-Rotax
Maintenance Manual
3.13.3
Engine external (on the 914 Series)
See latest Installation Manual for engines of the 914 Series and
76-00-00 sec. 3.1.2.3.
Effectivity 914 Series
Edition 1 / Rev. 0
74-00-00 page 34
May 01/2007
BRP-Rotax
Maintenance Manual
3.14) Ignition electric set removal
See Fig. 74-23
The ignition electric set, consisting of 2 electronic modules and 4 dual ignition coils, is fitted to the engine on 3 rubber buffers. For removal, detach all 8 spark plug connectors (1) from the spark plugs. Cut the tie wraps for the 4 lower spark plug connectors, unscrew the resistance spark plug connectors and draw the ignition cables with protection hose through the cylinder heads. Take care not to lose the ignition cable identification rings.
◆ NOTE: On engines with hydraulic propeller governor, it is necessary to also 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 plug connectors.
Remove cable clamp (3) and grounding cable (10) after removal of allen screw
M5x25 (4) at the electronic module. Mark the two plug connections (5) of the pickup cables and the plug connection of the red charging cable and remove them (see 74-00-00 sec. 3.13 respective wiring diagram for ignition unit). Detach both attachments (6) of the ignition electric set (1 x M6 on ignition housing and
1 x M8 on crankcase).
Remove 4 allen screws M6 (7) from each of the two intake manifolds (8). Now the 2 intake manifolds (8) with O-rings, resonator line (9) and ignition electric set can be removed, proceeding with great care. Plug all 4 intake apertures to avoid entry of foreign objects
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 35
May 01/2007
BRP-Rotax
Maintenance Manual
1
7
7
8
Fig. 74-23
2
6
00334
9
5
6 3
2
10
4
1
8
7
4
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 36
May 01/2007
BRP-Rotax
Maintenance Manual
3.15) Ignition electric set dismantling
See Figs. 74-24 and 74-25.
◆ NOTE: Before removal, mark all 8 ignition cables resp. check the correct application of the identification rings (1)-(2)-(3 )-(4) of cylinders no. 1 through 4 to avoid mix-up at reassembly.
Cut the remaining tie wraps (25) of the spark plug connectors and unscrew the spark plug connectors.
Remove allen screw M5x25 (6) for the electronic modules (7) and tilt modules sideways from the engine. Remove hex. screw M6x16 (8) and lock washer from the intake manifold and the grounding cables (9) of both electronic modules and
(10) from the 4 ignition coils as well as the grounding cable of the sensor 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 pin plug):
See Fig. 74-24.
For replacement of a dual ignition coil, the following dismantling procedure is required:
Remove hex. nut M6 (11) and rubber buffer (12) with bracket (13).
Remove the allen screw M6x16 (14) from the rubber buffer (15) with an allen key. Remove both hexagon socket screws (16) and ignition coil holder (17) as well as the 3 rubber buffers (18) together with the bracket
(19).
Remove both allen screws M6x30 (20) from the distance nut M6 (21).
After detaching the double grounding cables (10), the dual ignition coils
(22) can be replaced individually. The ignition cables are screwed in and therefore are replaceable.
◆ NOTE: With the exception of the dual ignition coil (23) for spark plug 3 and 4 bottom, all are fitted in the same position, with boss (24) upwards.
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 37
May 01/2007
BRP-Rotax
Maintenance Manual
On newer engine versions (electronic module with 6+ 4 pin plug):
See Fig. 74-25.
When replacing a dual ignition coil, the following dismantling procedure is required:
Remove hex. nut M6 (11) and rubber buffer (12) with bracket (13).
Using an allen key, remove the allen screw M6x16 (14) on the rubber buffer (15) and remove the ignition coil holder (28). Remove both allen screws (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 detaching the dual ignition coils
(22) with the fixation latch (37), the dual ignition coils (22) can be replaced individually. To do so, release the corresponding cables
(white/blue) from the connector housing using special pin release tool part no. 877500.
The ignition cables are screwed into the dual ignition coil and thus also replaceable.
◆ NOTE: With the exception of the dual ignition coil (23) for spark plug 3 and 4 bottom, all are fitted in the same position, with boss (24) upwards.
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 38
May 01/2007
2
4
Fig. 74-24
7
BRP-Rotax
Maintenance Manual
For older engine models
6
1
3
5
1
3
8 26
9
10
28
5
14
11
27
39
15
20
24
16
25
2
39
40
4
25
38
13
37
12
20
16
19
18
36
21
23 17
22
00406
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 39
May 01/2007
Fig. 74-25
A LOCTITE 243
I: LITHIUMSEIFENFETT
LITHIUM BASE GREASE
S SILIKON
WÄRMELEITPASTE
SILICONE
HEAT COMPOUND
7
BRP-Powertrain
Maintenance Manual
6
6
For new engine models
26
1
3
5
1
8
3
2
28
4
27
39
9
15
11
14
5
21
23
37
24
20
16
17
25
40
2
39
4
4
25
38
13
12
16
20
19
18
42
36
22
Effectivity 912/914 Series
Edition 1 / Rev. 4
07777
74-00-00 page 40
February 01/2015
BRP-Powertrain
Maintenance Manual
3.16) Ignition electric set reassembly
On older engine versions (electronic module with 1+ 4 pin plug):
See Figs. 74-18, 74-19, 74-21 and 74-24.
Re-assembly of dual ignition coils in reverse order.
Attach the dual ignition coils offset and in the correct position as per drawing, with the two allen screws M6x30 (20) and lock washers A6 with distance nut M6 (21).
Pay attention to the dual ignition coil (23) for spark plugs 3B and 4B. It must be fitted turned by 180° compared with the 3 other dual ignition coils, see Fig. 74-
24.
With the two allen screws M6x20 (16), lock washer A 6 and hex. nut M6 reassemble, first only slightly tightening, the ignition coil holder (17), the ignition coil bracket (19), and the dual ignition coils.
Insert ignition cable (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 intake manifold with LOCTITE 243.
The connections of the white cables and the black grounding cables of the dual ignition coils must be placed as per wiring diagram. Route the grounding cables
(9) and (10) towards the outside. To achieve the correct distance, fit the two electronic modules (7) on the ignition coil holders with allen screws (6) M5x25.
Now all attachment screws for dual ignition coils can be tightened. Tighten ignition coil bracket (13) and rubber buffer (12) with hex. nut M6 and lock washer.
On newer engine versions (electronic module with 6+ 4 pin plug):
See Figs. 74-20, 74-22 and 74-25.
Re-assembly of dual ignition coils in reverse order.
Screw corresponding ignition cables with protection hose onto the dual ignition coils.
◆ NOTE: The correct cable lengths and assignations can be seen in the latest Illustrated Parts Catalog.
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 41
February 01/2015
BRP-Powertrain
Maintenance Manual
Attach the dual ignition coils offset and in the correct position with fixation latch
(37) and connector holder (42) as per drawing, with the two allen screws M6x30
(20) and lock washers A6 with distance nut M6 (21). Pay attention to the dual ignition coil (23) for spark plugs 3B and 4B. It must be fitted turned by 180° compared with the 3 other dual ignition coils, see Fig. 74-25.
With the two allen screws M6x20 (16), lock washer A 6 and hex. nut M6, reassemble, first only slightly tightening, the ignition coil holder (17), the ignition coil bracket (19), and the dual ignition coils.
Insert ignition cable (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 intake manifold with LOCTITE 243.
The connectors of the white/blue primary cables from the dual ignition coils must be connected up as shown in the wiring diagram.
■ CAUTION : The different ignition distribution of engine types 912/914 is achieved by means of the different plug assignation on the 6-pin connector housing, see Fig. 74-20 and 74-22, item. (16).
Route the grounding cables (9) towards the outside. To achieve the correct distance, fit the two electronic modules (7) on the ignition coil holders with allen screws (6) M5x25.
Now all attachment screws for the dual ignition coils can be tightened. Tighten ignition coil bracket (13) and rubber buffer (12) with hex. nut M6 and lock washer.
Now engage the two 6-pin connector receptacles of the electronic modules in the connector holder (42) and fit the connector housing of the dual ignition coils.
■ CAUTION : Pay attention to the correct attachment position A/B and the position on the connector holder!
Plug connection A ---> magneto side position
Plug connection B ---> power take off side position
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 42
February 01/2015
BRP-Rotax
Maintenance Manual
3.17) Ignition electric set refitting
On older engine versions (electronic module with 1+ 4 pin plug):
See Figs. 74-24 and 74-26.
Insert O-rings (33) 34x2 in the groove (34) of the cylinder heads and remove the plugs from the intake openings. Fit both intake manifolds (35) with preassembled ignition electric set and tighten crosswise with 4 allen screws M6x25/
70 and lock washers. Insert rubber buffer (18) into bracket (36) of ignition housing and tighten with hex. nut and lock washer.
Place distance sleeve (37) in position and fix ignition electric set on crankcase with hex. screw (38) M8, washer and lock washer. Now tighten all screws and nuts of the ignition electric set.
Fit grounding cables (9), (10) and (26) on the nubs (41) at the intake manifold with hex. screw (8) M6x16 and lock washer. 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 with the colors blue and red. Those of ignition circuit B (bottom module) are green and colorless
(neutral) respectively.
■
CAUTION : The cable shielding must be fully inserted into the cable clamp to assure optimum grounding.
Connect the two red cables coming from the charging coils with the two pink cables of the SMD electronic modules. Route the whole cable assembly into the cable clamp and attach it to the ignition coil holder (17) together with the electronic module using allen screw (6) M5x25.
Fit two each ignition cables (39) for the lower spark plugs into the glass fiber/ silicone tube (5) and route them between cylinder heads. Screw resistance spark plug connector (40) onto the ignition cables, secure with tie wraps (25) and fit onto the spark plugs as shown on the wiring diagram.
Attach 4 ignition cables each for cylinders 1 - 3 and 2 - 4 to the new coolant hose with a new tie wrap.
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 43
May 01/2007
BRP-Powertrain
Maintenance Manual
On newer engine versions (electronic module with 6+ 4 pin plug):
See Figs. 74-25 and 74-27.
Remove plugs from the intake openings and insert O-rings (33) 34x2 in the groove (34) of the cylinder heads. Fit both intake manifolds (35) with preassembled ignition electric set and tighten crosswise with 4 allen screws M6x25/
70 and lock washers. Insert rubber buffer (18) into bracket (36) of ignition housing and tighten with hex. nut and lock washer.
Place retaining bracket (13) in position and fix ignition electric set on crankcase with allen screw (38) M8, washer and lock washer. Now tighten all screws and nuts of the ignition electric set.
Fit grounding cables (9) and (26) on the nubs (41) at the intake manifold with hex.
screw (8) M6x16 and lock washer. Engage both 6-pin connector receptacles for the trigger coil kit in the connector holder (42) and insert the connector 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 (bottom module) are marked green and colorless (neutral).
◆
NOTE: Ensure that they are plugged in in the correct position on the connector holder!
Plug connection A ---> „"top“
Plug connection B ---> "bottom“
Route the whole cable assembly into the cable clamp and attach it to the ignition coil holder (17) with LOCTITE 243 together with the electronic module using allen screw (6) M5x25.
■ CAUTION : The cable shielding must be fully inserted into the cable clamp to assure optimum grounding.
Fit two ignition cables (39) for each of the lower spark plugs into the glass fiber/ silicone protection hose (5) and route them between the cylinder heads. Thread identification rings (1 - 4) onto the ignition cables as shown on the wiring diagram and screw resistance spark plug connectors (40) onto the ignition cables, secure with tie wraps (25) and fit onto the spark plugs as shown in the wiring diagram.
Attach 4 ignition cables each for cylinders 1 - 3 and 2 - 4 to the coolant hose with a new tie wrap.
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 44
February 01/2015
Fig. 74-26
35
34
33
BRP-Rotax
Maintenance Manual
41
33
34
00408
Effectivity 912/914 Series
Edition 1 / Rev. 0
35
34
33
34
Fig. 74-27
41
33
05820
74-00-00 page 45
May 01/2007
BRP-Powertrain
Maintenance Manual
3.18) Trigger coil kit replacement
See Figs. 74-28, 74-29, 74-30, 74-31, 74-32 and 74-33.
Because of the shielding (6), the trigger coil kit (5) can be exchanged only as a complete set. Remove the attachment screws (7) with the distance sleeves (8) and cable clamps and fit new trigger coil kit. The stator (9) need not be removed in this case.
The trigger coils (1) are only adjustable to a limited extent. The gap (2) between trigger coil and trigger cam (3) is equal to dimension (IH02).
◆ 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 the new trigger coils ("clip on pick up“), the attachment has been changed from a cylindrical hole with centering (21) to a elongated hole
(22).
The gap (IH02) between the trigger coil and the trigger cam must be adjusted using a feeler gauge. On trigger coil with oblong hole, 5 washers, part no. 827800
(23) are also needed for the fastening.
■ CAUTION : As the trigger coils are no longer centered and the screw has clearance in the oblong hole, during adjustment of the gap
(IH02), all trigger coils must be pressed clockwise up to the limit stop.
■ CAUTION : Fit the cable clamps in such a way that there is adequate grounding between the shielding and the ignition housing.
See 74-00-00 sec. 4 and sec. 5 forms.
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 46
February 01/2015
Fig. 74-28
4
BRP-Powertrain
Maintenance Manual
IH03
Fig. 74-29
1
On older engine models
(discontinued)
IH02
3
2
On new engine models
(„clip on pickup“)
00089
Fig. 74-30
21
08450
„Old“
22
„New“
23
07728
Trigger coil alignment
Fig. 74-31
07139
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 47
February 01/2015
BRP-Rotax
Maintenance Manual
3.19) Stator removal and refitting
See Figs. 74-32, 74-33 and 74-34.
Lock crankshaft with the thread bolt, part no. 240880 See also 75-00-00.
Remove hex. screw (10) M16x1.5 together with lock washer and washers. Place protection piece, part no. 877410, on crankshaft, screw puller, part no. 877375, fully onto the thread (11) and press off fly wheel hub (12) together with magneto ring with the hex. screw of the puller. Store fly wheel hub assy. aside 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) from the centering (14) and carry out a visual inspection. Check cable assembly for damage. The contact faces (15) between stator and ignition housing must be clean to assure good grounding. Check the resistance values of the components, see 74-00-00 sec. 4.
Repair of the stator is not planned. When replacing the stator, pay attention to correct routing of the cable assembly. One each charging coil grounding cable is screwed with the stator fixation. At assembly, apply Lithium grease to the contact areas (20) of the stator and the screw heads.
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 48
May 01/2007
BRP-Powertrain
Maintenance Manual
3.20) Fly wheel hub'
See Fig. 74-32.
Carry out visual inspection of magneto inner side (16) and the taper surface (17).
Under normal circumstances, dismantling of fly wheel hub is not necessary.
If it has been dismantled, clean the contact faces (18) Apply LOCTITE 243 to all
10 allen screws (19) (alternating 5 screws M6x30 and 5 screws M6x25) and screw together.
◆ NOTE: The hole pattern in the magneto ring is symmetrical and therefore it 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 243 sparingly.
Fit fly wheel on assy. Apply grease on the contact face of the washer 17/36/5 (20) and of the lock washer 16 (21). Screw in hex. screw M16x1.5 (10) with washer
17/36/5 and lock washer 16 and immediately tighten to 45 Nm (33.2 ft.lb) +180° angle to rotation.
■ CAUTION : The woodruff key must remain in the groove.
Adjust the air gap of the external triggers with feeler gauge to dimension (1H02).
Check external trigger coils for correct axial position with reference to the trigger cam of the fly wheel hub. Offset must not exceed dimension (IH03), see
74-00-00 sec. 3.18.
See 74-00-00 sec. 4.
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 49
February 01/2015
Fig. 74-32
BRP-Rotax
Maintenance Manual
Older engine models
15
6
5
14
9
7
19
20
13
16
8
7
5
7 07729
18
17
12
11
20
21
10
Effectivity 912/914 Series
Edition 1 / Rev. 2
74-00-00 page 50
July 01/2008
Fig. 74-33
09890
BRP-Powertrain
Maintenance Manual
New engine models
O
5
9
I
6
7
5
7
21
7
Bild 74-34
07731
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 51
February 01/2015
BRP-Rotax
Maintenance Manual
3.21) Interference suppression box (only on the 912 Series)
See Fig. 74-35.
◆ NOTE: Fitted in serial production up to 1995!
3.21.1) Interference suppression box dismantling
The interference suppression box contains two electronic boxes, four dual ignition coils and two capacitors. Each interference suppression box bears a consecutive serial number on the cover. Always quote this serial number in the 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. Now the individual ignition cables can be replaced as necessary.
Mark and pull off all connections for the ignition coils. Remove the four countersunk screws M4x12 on the bottom side of the electronic box.
Unscrew the grounding cable at the ignition coil. Now the complete ignition coil group can be taken out. If necessary, the electronic boxes can also be removed after closing the shorting cables on the capacitors.
Check the capacitors and replace if necessary. Now all individual parts can be inspected.
Effectivity 912 Series
Edition 1 / Rev. 0
74-00-00 page 52
May 01/2007
BRP-Rotax
Maintenance Manual
3.21.2) Interference suppression box wiring diagram
1T
A1/2 zum
Kondensator weiß weiß
3B
2T
A3/4
4B
3T
B3/4
1B
B1/2
4T 2B
A
4
5
1
2
3
B
6
7
8
9
10
Zündabschaltung:
Kondensator oben:
Zündkreis A
Kondensator unten:
Zündkreis B
IGNITION CIRCUIT A
(1) alternator cable, red shorting cable, white
(2) pick-up cable white, for ignition circuit A-Cyl. 3 white/red, for ignition circuit A-Cyl. 4
(3) pick-up cable white, for ignition circuit A-Cyl. 1 white/red, for ignition circuit A-Cyl. 2
(4) primary cable for ignition coil, ignition circuit A, Cyl. 3/4, black (ground) ignition circuit A, Cyl. 3/4, white
(5) primary cable for ignition coil, ignition circuit A, Cyl. 1/2, black (ground) ignition circuit A, Cyl. 1/2, white
04787
Fig. 74-35
IGNITION CIRCUIT B
(6) alternator cable, red (from stator) shorting cable, white (to capacitor)
(7) pick-up cable white, for ignition circuit B-Cyl. 1 white/red, for ignition circuit B-Cyl. 2
(8) pick-up cable white, for ignition circuit B-Cyl. 3 white/red, for ignition circuit B-Cyl. 4
(9) primary cable for ignition coil, ignition circuit B, Cyl. 1/2, black (ground) ignition circuit B, Cyl. 1/2, white
(10)primary cable for ignition coil, ignition circuit B, Cyl. 3/4, black (ground) ignition circuit B, Cyl. 3/4, white
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 53
May 01/2007
BRP-Powertrain
Maintenance Manual
3.21.3) Interference suppression box assembly
The interference suppression box is assembled in reverse order.
Always observe the wiring diagram for the interference suppression box. Lithiumbase grease must be applied to all cable connections to prevent leakage current.
Push both electronic boxes into the suppression box housing and position the pads. Connect grounding cables and primary cables to the ignition coils. Attach ignition coil set in the suppression housing with 4 countersunk screws M4x12. Secure countersunk screws with LOCTITE
243.
Arrange ignition cables on the bottom part of the terminal strip as shown in the wiring diagram and the description on the interference suppression 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 LOCTITE 221.
Attach ignition cables 1T and 3B to the ignition cable support with tie wraps.
3.21.4) Interference suppression box fitting
For safety reasons, the interference suppression box must not be exposed to ambient temperatures higher than 60 °C (140 °F), and due to vibration, it should be installed in the cockpit. If the box has to be installed on the engine due to lack of space, vibration damping elements must be fitted. Check all grounding from the interference suppression box to the engine and if necessary, clean the contact faces and assemble with toothed lock washers. See Service Instruction SI
25-1994.
◆ NOTE: On models from the year 92 onwards, resistance spark plug 12mm (.47 in.) DCPR7E is fitted, see SB-912-
001,“Engine type 912 A, Ignition unit with resistor spark plug“, latest issue.
Effectivity 912/914 Series
Edition 1 / Rev. 4
74-00-00 page 54
February 01/2015
BRP-Powertrain
Maintenance Manual
3.22) Rev counter and ignition trigger coils
See Figs. 74-36 and 74-37.
◆ NOTE: All 5 trigger coils 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.
- Inspect all connections
■
CAUTION: Any parts which have suffered physical damage or are not functioning correctly must be replaced without delay. For measurement values, see 74-00-00 sec. 3.12.
Fig. 74-36
Effectivity 912/914 Series
Edition 1 / Rev. 4
3
09889
74-00-00 page 55
February 01/2015
BRP-Rotax
Maintenance Manual
Fig. 74-37
Fig. 74-37 shows oscilloscope images of the rev counter signal.
Trigger
Coil
100
Ohm
V
0,0
-4,0
-8,0
-12,0
-16,0
-20,0
0,0 ms
20,0
V
DC
16,0
12,0
8,0
4,0
AE 2_0169
Trigger coil OLD (without clips – line colors: GNWH; BUYE) @500 rpm
0,0
-4,0
-8,0
-12,0
-16,0
-20,0
0,0 ms
20,0
V
DC
16,0
12,0
8,0
4,0
2,0 4,0 6,0 8,0 10,0 12,0
1 turn (360º)
14,0 16,0
Trigger coil NEW (with clips – line colors: WHYE; BUYE) @500 rpm
18,0
2,0 4,0 6,0 8,0 10,0 12,0
1 turn (360º)
14,0 16,0
Effectivity 912/914 Series
Edition 1 / Rev. 5
20,0
18,0 20,0
AE 2_0168
74-00-00 page 56
March 01/2017
BRP-Rotax
Maintenance Manual
3.23) External alternator (optional on 912/914 Series)
3.23.1) V-belt pulley removal
See Fig. 74-38.
After removal of the propeller, the V-belt pulley (3) remains loose on the propeller flange (2).
After removal of the 8 allen screws M5x16 (7) with the lock washers (8), the two pulley carrier plates (4), the V-belt pulley(3) and the narrow Vbelt (1) can be taken off.
3.23.2) Alternator removal
Remove the two hex. screws M8x20 (24) with the lock washers (25) and washers (26) and the tension bar (20) below the external alternator.
Remove the hex. screws M10x45 (18) and take off the alternator (15) with the washer (17).
Remove the two allen screws M8x20 (10) with 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 screws, it can be taken off.
3.23.3) V-belt pulley assembly
See Fig. 74-38.
Slide the pulley (3) fully over the propeller flange (2) and insert the Vbelt 9.5x675 (1) loosely in the V-belt pulley.
Insert the two pulley carriers (4) with the centering (5) facing the inside
(6) of the propeller flange and loosely preassemble the propeller with the two pulley carriers.
Push the V-belt pulley (3) onto the two V-belt pulley carriers (4) and attach with the 8 allen screws M5x16 (7) with lock washer (8).
■
CAUTION: The two pulley carriers must be positioned precisely with the centering exactly on the inside (6) of the propeller flange.
Tighten the propeller with the preassembled pulley to the tightening torque recommended by the propeller manufacturer.
Effectivity 912/914 Series
Edition 1 / Rev. 2
74-00-00 page 57
July 01/2008
BRP-Rotax
Maintenance Manual
8
7
4
Fig. 74-38
1
3
5
19
07491
17
16
18
10
11
24
25
26
13
12
9
20
23
22
21
14
2
6
15
Effectivity 912/914 Series
Edition 1 / Rev. 2
74-00-00 page 58
July 01/2008
BRP-Rotax
Maintenance Manual
3.23.4) Checking of the external generator
See Fig. 74-39
3.23.4.1) Check of the power output of the generator
At an alternator rpm of 5000 rpm the output has to be at least 40 amps (between Terminal B (2) and ground).
◆ NOTE 5000 rpm of the alternator is equivalent to
1680 rpm of the propeller shaft or the propeller 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 plate(4).
After loosening the crosshead screw (5) and removing the cover (3) the brush carrier and the rubber can be taken off.
Messure the length of the brush carrier (6) (AL02) and record the result in the appendix. Check the shaft for grooves. It should not be possible to feel a ridge (9). Turn the shaft by hand. The bearings must be easy to move and must not show any resistance.
Fig. 74-39
3
3
4
2
08481
3
1
5
08482
6
08483
7
5
Effectivity 912/914 Series
Edition 1 / Rev. 2
74-00-00 page 59
July 01/2008
BRP-Rotax
Maintenance Manual
8
6
08484
9
AL02
08485
3.23.5) Alternator assembly
See Fig. 74-38.
Net loose preassemble the alternator bracket (9) on the gearbox housing with the two allen screws (10) M8x20 with high tension lock washer (11) VHZ 8. To attach the alternator support (12), the two allen screws M6x45 (13) with lock washers A6 are unscrewed from the propeller gearbox and then retightened to also hold the alternator support (12).
Push the alternator (15) into the bracket (16) of the alternator 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 allen screws (13) M6 to 10 Nm (90 in.lb) together with the lock washers and washer (14). Insert the V-belt (1) into the pulley of the alternator (19).
Loosely preassemble the tension bar (20) on the side with the oblong hole on the alternator bracket (9) with allen screws (21) M8x16, washer
(23) 8.4 and lock washer A8 (22). Then loosely preassemble tension bar (20) on the alternator (15) with allen screw (24) M8x20, lock washer
(25) and washer (26).
3.23.6) V-belt tension
See latest Maintenance Manual "Line Maintenance“ for the respective engine type.
Effectivity 912/914 Series
Edition 1 / Rev. 2
74-00-00 page 60
July 01/2008
4) Wear limits
BRP-Rotax
Maintenance Manual
07510
Effectivity 912/914 Series
Edition 1 / Rev. 5
74-00-00 page 61
March 01/2017
Ignition housing
trigger coil gap “old type”
IH02
0,4
0,016
0,5
0,020 trigger coil gap (with clamps)
IH02
0,3
0,012
0,4
0,016
BRP-Rotax
Maintenance Manual
08696
A 1/2 A 3/4 B 1/2 B 3/4
Effectivity 912/914 Series
Edition 1 / Rev. 5
74-00-00 page 62
March 01/2017
5) Form Sheets
Fig. 74-39
BRP-Powertrain
Maintenance Manual
08247
Effectivity 912/914 Series
Edition 1 / Rev. 4 new/old old new/
74-00-00 page 63
February 01/2015
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
74-00-00 page 64
May 01/2007
BRP-Rotax
Maintenance Manual
SECTION 75
COOLING SYSTEM
1) Table of contents
SECTION 75
COOLING SYSTEM
2.2.1) Cylinder head temperature display ................................... 75-00-00 / 4
3.1) Water pump removal and inspection ............................................ 75-00-00 / 6
3.2) Water pump housing - dismantling and inspection ........................ 75-00-00 / 7
3.8) Axial position of the water pump shaft .......................................... 75-00-00 / 12
3.10) Water pump housing — reassembly ............................................. 75-00-00 / 13
3.14) Cooling air duct (optional 912/ 914 Series) ................................... 75-00-00 / 14
3.17) Temperature measurement system .............................................. 75-00-00 / 15
3.17.1) Cylinder head temperature sensor ................................... 75-00-00 / 15
Effectivity 912/914 Series
Edition 1 / Rev. 2
75-00-00 page 1
July 01/2008
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
75-00-00 page 2
May 01/2007
BRP-Rotax
Maintenance Manual
2) Systems description
2.1) Cooling system
See Fig. 75-1.
The cooling system of the ROTAX 912/914 Series is designed for liquid cooling of the cylinder heads and ram-air cooling of the cylinders.
The cooling system of the cylinder heads is a closed circuit with an expansion tank.
The coolant flow is forced by a water pump, driven from the camshaft, from the radiator to the cylinder heads. From the top of the cylinder heads, the coolant passes on to the expansion tank (1). Since the standard location of the radiator
(2) is below engine level, the expansion tank located on top of the engine allows for coolant expansion.
◆ NOTE: When installing the radiator above engine level, see the latest respective Installation Manual.
The expansion tank 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 pressure to the transparent overflow bottle (4). When it cools down, the coolant will be sucked back into the cooling circuit. The expansion tank (3) must always be full of coolant, and the coolant level in overflow bottle (4) should be between the two marks.
■ CAUTION : Too high pressure in the cooling system might cause damage.
The hose between the expansion tank and the overflow tank must be free of blockages and the venting bore (5) must not be closed.
On engines of the 914 Series, the coolant hoses (6) for cyl. 1 and 2 are routed very close to the exhaust system and are therefore additionally protected by a heat resistant protection hose.
For winter operation, always use a coolant mixture with a sufficiently low freezing point (pour point). To ensure trouble-free engine start even at low temperatures, observe the special directives in the Operators Manual.
Effectivity 912/914 Series
Edition 1 / Rev. 0
75-00-00 page 3
May 01/2007
BRP-Powertrain
Maintenance Manual
3
1
5
4
6
2
Fig. 75-1
00125
2.2) Connections for instrumentation
■ CAUTION: Consult also the relevant sections on connections for instrumentation in the latest Installation Manual.
2.2.1) Cylinder head / coolant temperature display
There are temperature sensors screwed in to the cylinder heads of cylinders 2 and 3. In the course of further development and standardization, new cylinder heads with modifications in its mold have been introduced. Due to these changes the coolant temperature instead of the cylinder head temperature in the aluminium will be displayed.
See latest Installation Manual and/or SI-912-020/SI-914-022 “Running modifications”.
◆ NOTE: Identifying of new cylinder heads: The electrical connection of the temperature sensor is pointing upwards. New configuration see Fig.
75-1/1. Old configuration see Fig. 75-1/2.
Temperature sensor
Fig. 75-1/2
Effectivity 912/914 Series
Edition 1 / Rev. 4
Temperature sensor
Fig. 75-1/1
09862_2
75-00-00 page 4
February 01/2015
BRP-Rotax
Maintenance Manual
3) Maintenance
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see corresponding
Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or
914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.
◆ NOTE: When installing the radiator above engine level, see the latest respective Installation Manual.
■ CAUTION : Check whether the overflow bottle has been modified in accordance with SB-912-039 and SB-914-025, “Modifications of the overflow bottle“ , latest issue.
◆ NOTE: When filling or replenishing the cooling system, coolant is always added via the expansion tank (3).
To drain the coolant, open the radiator cap and remove the lowest attachment screw
(with sealing ring) of the water pump, as this is the lowest point of the cooling system of the engine assembly.
Effectivity 912/914 Series
Edition 1 / Rev. 0
75-00-00 page 5
May 01/2007
BRP-Rotax
Maintenance Manual
3.1) Water pump removal and inspection
See Fig. 75-2.
The water pump is integrated in the ignition housing. For 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 the hex. screw (3) M16x1.,5 from the fly wheel hub, the crankshaft must be locked. See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series.
3
Fig. 75-2
1
00344
2
Effectivity 912/914 Series
Edition 1 / Rev. 0
75-00-00 page 6
May 01/2007
BRP-Rotax
Maintenance Manual
3.2) Water pump housing - dismantling and inspection
See Fig. 75-3
Remove the 2 allen screws M6x20 (1) of the water inlet elbow (2) and remove the elbow with the O-ring.
◆
NOTE: Mark the position of the water inlet elbow with a suitable pen
(touchup pen).
Release all 4 screw hose clamps or spring band hose clamps of the water drainage hoses and pull them off water pump housing. The water pump housing
(4) with gasket (5) can be taken off by removing 5 more allen screws M6 (3).
■ CAUTION: The allen screw (6) protrudes into the water compartment and is therefore of stainless steel and sealed with the sealing ring (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 impeller is of stainless steel.
Remove the impeller (8) with special tool, part no 877295, with crankshaft locked, turning counter-clockwise.
Check the coolant fitting (10) screwed into the water pump housing for leakage, cracks and tight fit, replace if necessary. Mark the position of the bent socket.
Warm up water pump housing to approx. 80 °C (180 °F) and remove the socket.
Clean threads (11) carefully of LOCTITE residue, apply LOCTITE 243 to the new coolant fitting and fit it into position with at least 5 turns.
Normally, fittings with a bend angle of 45° are fitted. On the 914 engine and engines with ROTAX engine suspension frame, there is a fitting with a bend angle of 80° fitted at cylinder 2.
Effectivity 912/914 Series
Edition 1 / Rev. 0
75-00-00 page 7
May 01/2007
BRP-Rotax
Maintenance Manual
Fig. 75-3
9
8
5
243
4
Cyl. 3
Cyl. 1
Cyl. 4
243
Cyl. 2
00377
10
11
3
2
7
6
1
3
Effectivity 912/914 Series
Edition 1 / Rev. 0
75-00-00 page 8
May 01/2007
BRP-Rotax
Maintenance Manual
3.3) Fly wheel hub removal
See 72-00-00 sec. 3.1.
3.4) Ignition housing removal
See 72-00-00 sec. 3.3.
3.5) Water pump shaft - removal
See Figs. 75-4 and 75-5.
It is an advantage to loosen the impeller when dismantling the engine (with crankshaft locked). Otherwise, 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 pump shaft out with a suitable punch (2). Pull out the drive gear (1).
Inspect water pump shaft (3) for wear. Pay attention to possible corrosion at the thread end (4). If engine is run without coolant, formation of corrosion is possible in this position.
If corroded, replace the water pump shaft.
◆ NOTE: The shaft has a conical end (5).
Fig. 75-4
2
1
Effectivity 912/914 Series
Edition 1 / Rev. 0
00384
Fig. 75-5 3
00385
4
5
75-00-00 page 9
May 01/2007
BRP-Rotax
Maintenance Manual
3.6) Rotary seal - removal
See Fig. 75-6.
Remove old shaft seal and rotary seal using 2 pins (1) of 5 mm (0.2 in.) diameter and a suitable punch (2). Shaft seal and rotary seal will be destroyed during removal and must be replaced.
3.7) Rotary seal - installation
See Figs. 75-7, 75-8, 75-9 and 75-10.
Press new shaft seal (1) 12x30x7, pre-oiled sealing lip showing inwards, into ignition housing using insertion jig (2), part no. 876510.
Carefully press rotary seal (3) on punch (4), part no 877258, and press the water pump shaft (5) carefully into the positive stop of the punch, conical end first.
Insert the pump gear (6) into the ignition housing with the wide 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, position the drive gear so that it is flush with the pump shaft.
Now place the ignition housing on a flat surface and, using a hand press, press the water pump shaft in to the stop with max. 20 kN with punch (4), part no.
877258. Then turn ignition housing and press water pump shaft back using a 10 mm (3/16 inch) bolt until the collar of the water pump shaft is flush with the sealing surface of the water pump housing. Turn water pump shaft to check for clearance and free movement.
◆ NOTE: The spring of the rotary seal presses the water pump shaft outwards towards the sealing surface (11), depending on the axial clearance (14), see Fig. 75-10.
See also SI-912-001 and SI-914-001, “Installation of rotary water pump seal and water pump impeller“, latest issue.
Effectivity 912/914 Series
Edition 1 / Rev. 0
75-00-00 page 10
May 01/2007
1
Fig. 75-6
2
BRP-Rotax
Maintenance Manual
Fig. 75-7
2
00386
Fig. 75-8
08448
Effectivity 912/914 Series
Edition 1 / Rev. 2
4
5
3
08451
00387
Fig. 75-9
4
3
75-00-00 page 11
July 01/2008
1
BRP-Rotax
Maintenance Manual
3.8) Axial position of the water pump shaft
See Fig. 75-10
Check axial position of water pump shaft and pump gear. The step (6) of the gear points inward towards the crankcase.
◆
NOTE: To ensure the correct gap (8) (dimension WP02) between the impeller (9) and the water pump housing (10), make sure that the collar (7) of the water pump shaft 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 back as required with a ø10 mm (0.40 in.) bolt. Trial spin the installed pump shaft.
Place stainless steel shim (13) on the shaft, fit impeller (9), turning clockwise, and tighten with special tool, part no. 877295. Tightening torque 15 Nm (133 in.lb).
◆ NOTE: Check impeller (9) for out-of-round. If it is noticeably out-ofround, replace impeller or if necessary also the pump shaft.
See 75-00-00 sec. 4.
Fig. 75-10
WP01
12
6
14
00085
Effectivity 912/914 Series
Edition 1 / Rev. 0
13
7
9
10
11
WP02
8
75-00-00 page 12
May 01/2007
BRP-Rotax
Maintenance Manual
3.9) Ignition housing assembly
See 72-00-00 sec. 3.5.
3.10) Water pump housing — reassembly
See Fig. 75-11.
Position gasket (1), attach water pump housing (2) to the ignition housing with
2 allen screws (3) M6x90 and 3 allen screws (4) M6x35 together with lock washers, torque to 10 Nm (90 in.lb).
■ CAUTION : The bottom allen screw (5) M6x35 protrudes into the water chamber, so it 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 housing or on the impeller. If necessary, the axial position of the water pump impeller can be corrected to achieve an optimum gap, see 75-00-00 sec. 3.8.
Insert O-ring (7) into water pump housing, fit the water inlet elbow (8) in the position marked before disassembly with 2 allen screws (9) M6x20 with lock washers. Tightening torque 10 Nm (90 in.lb).
◆ NOTE: The water inlet elbow is symmetrical and can, if required, be fitted in other positions.
1
Fig. 75-11
4
7
00392
Effectivity 912/914 Series
Edition 1 / Rev. 0
2
3
8
6
9
3
5
75-00-00 page 13
May 01/2007
BRP-Powertrain
Maintenance Manual
3.11) Coolant hoses fitting
See Fig. 75-13
■ CAUTION: The spring band hose clamps must be installed in the drawn origin position. (See sketch)
08341
Fit all coolant hoses (1) coming from the expansion tank to the coolant exit on the cylinder heads (3) with spring band hose clamps (4). Also fit the coolant hoses between the water pump (6) and the coolant entry (7) into the cylinder heads with spring band hose clamps.
◆ NOTE: Position spring band hose clamps so that they cannot damage neighboring 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 necessary to look out for a proper overlapping of the coolant hose and of the connecting tube.
Check the clips and hoses for tight fit and leaks. The spring type hose clips have to be mounted in such a way, so that chafing can not occur. If a governor is used then for the water tube at cylinder
1 a protection hose (8) has to be installed and secured with
LOCTITE 480 or an equivalent adhesive.
3.12) Spring band hose clamps
Carry out visual inspection. Position the clamps so as to avoid contact and friction with neighboring parts.
Use a suitable tool for assembly. See 00-00-00 sec. 10.6.
Effectivity 912/914 Series
Edition 1 / Rev. 3
75-00-00 page 14
October 01/2010
BRP-Powertrain
Maintenance Manual
3.13) Radiator (optional 912/ 914 Series)
Clean radiator elements and check for damage, straighten fins if necessary. In particular, check the hose connections and the support plates. Check for tightness if leaks are suspected.
3.14) Cooling air duct (optional 912/ 914 Series)
The cylinders are ram-air cooled. The cooling air is pushed during flight and by the propeller into the engine compartment and is distributed evenly by the cooling 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) Expansion tank
See Fig. 75-12
See latest valid Maintenance Manual “Line Maintenance“ of the corresponding engine type. On newer engines the expansion tank is in a different position. See therefore the latest issue of the Service Information “Running modification” SI-
912-020 and SI-914-022 respectively.
◆ NOTE: On engines with the old expansion tank, the old hose locations and the old coolant hoses don’t have to be upgraded and can be continued to be used.
-x
200± 10 mm
51° alt (o
27° neu (n ld) ew
)
60°±3° neu (ne
90°±3° alt (o ld) w)
Effectivity 912/914 Series
Edition 1 / Rev. 3
-y
P
+x
252± 5 mm
+y
Fig. 75-12
04557
75-00-00 page 15
October 01/2010
3
Fig. 75-13
1
8
4
1
3
BRP-Powertrain
Maintenance Manual
1
3
7
2
1
4
4
3
7
7
7
5
6
4
5
04555
: LOCTITE 480
Effectivity 912/914 Series
Edition 1 / Rev. 3
75-00-00 page 16
October 01/2010
BRP-Powertrain
Maintenance Manual
In the case of repair/overhaul it has to be considered that the old expansion tank part no. 922398 does not offer the space to install the spring hose type clamps this is due to limited space between the tube (cylinder 1 and cylinder 3).
Due to different positions for the supply/drain hoses leading to and from the expansion tank, it is necessary to have different hose lengths. Take care 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 whether the overflow bottle has been modified in accordance with SB-912-039 and SB-914-025, “Modifications of the overflow bottle”, latest issue.
3.17) Temperature measurement system
◆ NOTE: There are several temperature control points on ROTAX engines of the 912/914 Series. Refer to wiring diagram in Operators Manual.
3.17.1) Cylinder head / coolant temperature sensor
See Figs. 75-14, 75-14/1 and 75-15.
In the course of further development, the cylinder heads are made from new casting mold. At these, the temperature sensor is screwed on the top side. See latest SI-912-020/SI-914-022, “Running modifications“.
Bild 75-14
Temperature sensor „with
Suffix -01“
Effectivity 912/914 Series
Edition 1 / Rev. 4
Temperature sensor
„without Suffix -01“
9862_2
Bild 75-14/1
75-00-00 page 17
February 01/2015
BRP-Powertrain
Maintenance Manual
On assembly, tighten the temperature sensor to 7 Nm (62 in. lb). Secure screws with LOCTITE 243.
Fig. 75-15
( Ω )
1200
1000
800
600
400
200
0
00327
20 40 60 80 100 120 140 160
(°C)
◆ NOTE: Grounding connection of the temp. sensor directly via the cylinder head.
For sensor resistance, see following graph of sensor resistance overtemperature.
deviation: max ± 10%
◆ NOTE: The different versions of the cylinder heads can be mixed installed, but make sure, if and at which position the cylinder head temperature and coolant temperature is measured. This also defines the naming of the indicating instrument with the appropriate temperature limit. See latest Installation Manual and/or SI-912-020/
SI-914-022 “Running modifications”.
Effectivity 912/914 Series
Edition 1 / Rev. 4
75-00-00 page 18
February 01/2015
4) Wear limits
BRP-Rotax
Maintenance Manual
WP01
07509
WP02
07511
Reading new
Description min
Water pump
reference dim.
WP01
8,55
0,3366 max
8,85
0,3484 wear limit
100%
8,85
0,3484 impeller clearance WP02
0,3
0,012
0,5
0,020
0,7
0,028 wear limit
50%
0,6
0,024 actual renewed actual renewed
Effectivity 912/914 Series
Edition 1 / Rev. 0
Readings
07202
75-00-00 page 19
May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
75-00-00 page 20
May 01/2007
BRP-Rotax
Maintenance Manual
SECTION 76
ENGINE CONTROL
1) Table of contents
SECTION 76
ENGINE CONTROL
2.1) Turbocharger control (only on 914 Series) .................................... 76-00-00 / 3
2.1.1) Control of boost pressure in the airbox ............................. 76-00-00 / 3
2.1.2) Target pressure reduction ................................................ 76-00-00 / 8
2.1.2.1) Target pressure reduction at overspeeding ................ 76-00-00 / 8
2.1.2.2) Target pressure reduction at excessive airbox
temperature ................................................................ 76-00-00 / 9
2.1.2.3) Target pressure reduction 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
3.1) Control system of the turbocharger (only on 914 Series) ............... 76-00-00 / 13
3.1.1.1) Functions of the communication program .................. 76-00-00 / 13
3.1.1.2) Required items ........................................................... 76-00-00 / 13
3.1.1.3) Scope of the communication program ........................ 76-00-00 / 15
3.1.1.4) Application of the communication program ................ 76-00-00 / 17
3.1.1.5) Checking the components of the turbocharger control76-00-00 / 28
3.1.1.6) Checking the throttle valve position ............................ 76-00-00 / 29
3.1.1.7) Recalibration of the throttle position ........................... 76-00-00 / 31
Effectivity 912/914 Series
Edition 1 / Rev. 0
76-00-00 page 1
May 01/2007
BRP-Rotax
Maintenance Manual
3.1.2) Static check of the turbocharger control .......................... 76-00-00 / 32
3.1.2.1) Turbo control unit (TCU) ............................................. 76-00-00 / 32
3.1.2.2) Caution lamps ............................................................. 76-00-00 / 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
3.1.2.7) Servo motor ................................................................ 76-00-00 / 50
3.1.2.8) Circuit breaker for servo motor ................................... 76-00-00 / 52
3.1.2.9) Three-way solenoid valve ............................................ 76-00-00 / 53
Engine external (on the 914 Series) ................................. 76-00-00 / 58
4) Form Sheets ............................................................................................ 76-00-00 / 59
Effectivity 912/914 Series
Edition 1 / Rev. 2
76-00-00 page 2
July 01/2008
BRP-Rotax
Maintenance Manual
2) Systems description
2.1) Turbocharger control (only on 914 Series)
2.1.1) Control of boost pressure in the airbox
See Figs. 76-1, 76-2, 76-3, 76, -4 and 76-5.
The position of the carburetor throttle valves is signalled by a potentiometer to the TCU, where it is transformed in a chosen pattern 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 pressure, the position of the wastegate will be varied by a servo motor until the pressures are equal.
◆ NOTE: With carb throttle valve closed, a high boost pressure is specified although hardly any exhaust gas energy is available. The wastegate will then be completely closed and the length of the Bowden cable between the servo motor and the wastegate can be verified or adjusted.
Fig. 76-1
115%
100% 0%
00137
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 3
May 01/2007
Effectivity 914 Series
Edition 1 / Rev. 0
BRP-Rotax
Maintenance Manual
The electronic regulator (4) TCU (Turbo Control Unit) is the “central processing unit” as the junction of all engine parameter inputs. For functioning of the TCU, the following sensors e.g. trigger coils are required.
Airbox pressure sensor (5) provides the actual boost pressure in the airbox
Ambient pressure sensor (6) conveys the prevailing ambient pressure
Throttle valve position sensor (7) supplies actual position of carburetor throttle valve.
◆ NOTE: 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 speed via the 5 th sensors on the ignition housing
Airbox temperature sensor (9) conveys the prevailing intake air temperature in the airbox
All the sensors are connected with the TCU via a common wiring harness (10). In addition to the voltage supply (11) for the TCU, the following connections are provided on the wiring harness:
- plug connections (12), each for one warning and one boost lamp
plug connection (13) for the three-way solenoid valve
2 wires for an additional electronic rev counter (14)
- PC interface (15) for reading the TCU data via computer.
76-00-00 page 4
May 01/2007
BRP-Rotax
Maintenance Manual
The following diagram shows the pressure regulating sequence for the newer TCU versions (TCU No. 966741 or higher) (Fig. 76-2).
Fig. 76-2
Fig. 76-3
1400
1300
1200
1100
1000
900
0 hPa
1500
10 20 30 40 50 60 7 0 80 90 100
00170
36
34
32
30
28
46 in. HG
44
42
40
38
110 115 %
The airbox target pressures for engine operation with newer TCU versions:
00952 engine performance throttle potentiometer Airbox-nominal pressure idle continuous output take-off performance
~ 0 %
100 - 108 %
110 - 115 %
1500 hPa (44,3 in. HG)
1220 hPa (36,0 in. HG)
1370 hPa (40,5 in.HG)
The following diagram (Fig. 76-4) illustrates the relationship between the throttle valve position and the nominal airbox pressure for older
TCU versions (TCU part no. 966470 - 966473).
Fig. 76-4 hPa
1400
1300
1200
1100
1000
900
0 10 20 30 40 50 60 7 0 80 90 100
04813
40 in. HG
38
36
34
32
30
28
110 115 %
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 5
May 01/2007
BRP-Rotax
Maintenance Manual
■ CAUTION: Prolonged engine operation is not allowed between max. continuous performance (100 %) and take-off performance (115 %). The target pressure rises rapidly 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 fluctuations.
◆ NOTE:
This range must be passed swiftly in both directions to avoid problems such as pressure fluctuations.
In the course of model refinement, some parameters have been changed slightly. Diagram and table show the presently valid state of software.
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 6
May 01/2007
Fig. 76-5
BRP-Rotax
Maintenance Manual
13
8
9
7
7
12
11
14
15
6
5
1
1
(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
Effectivity 914 Series
Edition 1 / Rev. 0
10
3
4
00139
2
2
(9) Resistance thermometer, Airbox temp.
(10) Wiring harness
(11) Voltage supply
(12) Lamps
(13) Three-way solenoid valve
(14) external rev counter (to tach)
(15) Rs232 interface
76-00-00 page 7
May 01/2007
BRP-Rotax
Maintenance Manual
2.1.2) Target pressure reduction
Provision for target pressure reduction is made depending on various effects as a protective measure against overstressing the engine.
2.1.2.1) Target pressure reduction at overspeeding
See Fig. 76-6
It is the responsibility of the pilot to prevent engine speeds in excess of 5800 rpm, and during fast flight and descent when using a fixed pitch propeller, the pilot must therefore reduce the engine performance.
Only if the pilot fails to do this will the TCU lower the target pressure when engine speed exceeds 5900 rpm and open the wastegate, thus reducing boost pressure. See relevant diagram.
■ CAUTION: The automatic opening of the wastegate by the TCU is an emergency measure in the event of a pilot error, but does not release the pilot from responsibility to reduce the engine performance.
00177
900
800
700
600
500
400
300
200
100
0
-100
5000
Fig. 76-6
5900 6000 6100 6200 6300 6400 6500
Motordrehzahl [1/min]
(engine speed) e.g. at take-off performance (throttle valve position 115 %)
- target pressure 1370 hPa (without limitation)
- at an engine speed of 6100 rpm - target pressure reduction by approx. 265 hPa (according to diagram).
- current target pressure 1105 hPa - corresponds to 70 kW power instead of 84.5 kW .
Effectivity 912/914 Series
Edition 1 / Rev. 0
76-00-00 page 8
May 01/2007
180
160
140
120
100
80
60
40
20
0
-20
70
BRP-Rotax
Maintenance Manual
2.1.2.2) Target pressure reduction at excessive airbox temperature
See Figs. 76-7 and 76-8.
During the compression process in the turbocharger, the intake 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 temperature, see diagram (Fig. 76-7).
220
200
180
160
140
120
100
80
60
40
20
0
-20
Fig. 76-7
00178
50 54 58 62 66 70 74 78 82 86 90 94 98 Airbox Temperatur [°C]
(airbox temperature)
Target pressure reduction will result in a drop in maximum performance e.g. the power drop can reach up to 10 kW at
80 °C (176 °F) airbox temperature.
◆ NOTE: On TCU part no. 966470 to 966473, the airbox target pressure reduction starts at 72 °C
(162 °F). See Fig. 76-8.
72 74 76 78 80
Fig. 76-8
00902
82 Airbox Temperatur [°C]
(airbox temperature)
Effectivity 912/914 Series
Edition 1 / Rev. 0
76-00-00 page 9
May 01/2007
BRP-Rotax
Maintenance Manual
2.1.2.3) Target pressure reduction by limiting the compressor pressure ratio
To prevent vibration resonance, the max. turbo charger speed of approx. 165 000 rpm must not be exceeded. Since the turbo charger speed can be deduced exactly enough from the pressure ratio, this ratio is limited to max. 2.6.
Example: e.g. at density 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 reached at all at this altitude.
Explanation:
The critical flying altitude for max. continuous power is reached at 4500 m. Because of the low density at this altitude, the actual boost pressure is only approx. 1140 hPa, although the wastegate is completely closed.
Deactivation would not start until airbox pressure of 1300 hPa is reached.
◆ NOTE: Deactivation happens very rarely and only under certain climatic conditions and at certain altitudes.
Effectivity 912/914 Series
Edition 1 / Rev. 0
76-00-00 page 10
May 01/2007
BRP-Rotax
Maintenance Manual
2.1.3) Lamp output connections on the TCU
The TCU is furnished with output connections for an external „red“ boost lamp and an „orange“ caution lamp.
When the TCU is switched on, the two lamps are automatically subjected to a function test. Both lamps light up for 1 to 2 seconds and then go out.
Orange caution lamp:
All sensor inputs are monitored by the TCU via this caution lamp.
When the lamp goes out, this indicates that the TCU is ready for operation. A lamp which flashes continuously indicates a malfunction of the TCU or its periphery.
In the event of a malfunction, for instance if a circuit is interrupted, the
TCU switches over to pre-programmed default values to ensure engine operation.
■ CAUTION : While 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 activate the red boost lamp, and it will light up continuously until boost pressure falls below the threshold.
Threshold......................... 1550 hPa (actual boost pressure)
The TCU registers the time of full engine operation with boost pressure. Full throttle operation for longer than 5 minutes will cause the red warning lamp to flash.
■ CAUTION : The red boost lamp helps the pilot to avoid full power operation with too high boost pressure for longer than
5 minutes as otherwise the engine would be thermally overstressed.
◆ NOTE: The time observation starts at actual boost pressure of
1250 hPa. After 5 minutes the warning is issued via the boost lamp.
The warning is deactivated again as soon as the boost pressure falls below 1250 hPa. If the pressure limit is exceeded again, for example after 30 seconds, the boost lamp lights up again.
Effectivity 912/914 Series
Edition 1 / Rev. 0
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May 01/2007
BRP-Rotax
Maintenance Manual
2.1.4) Three-way solenoid valve 3
The TCU also controls the 3-way solenoid valve, which causes various pressures to become active on the float chamber of the carburetors.
For further information, see 73-00-00 sec. 2.8.
◆ NOTE: The solenoid valve is inactive below the threshold.
2.1.5) PC interface
The TCU incorporates a serial interface. By using a specially developed program, all input and exit signals of the TCU can by monitored, checked and if necessary recorded.
This program allows quick and efficient error diagnostics without having to dismantle the complete control unit.
This program can monitor and record the operation of many elements, including the 2 pressure sensors, temperature sensors, rev pickup, throttle valve and wastegate position.
◆ NOTE: This system works “ real time during engine operation.
” i.e. if necessary also
It allows the engineering staff to check and record TCU data during flight.
These recordings can then be evaluated on a graph and facilitate troubleshooting.
In addition, these recordings can be used as documentation for engine repair and overhaul.
◆ NOTE: This communication program is not included in the delivery range of the engine, but is readily available as a spare part from the respective dealer.
Effectivity 912/914 Series
Edition 1 / Rev. 0
76-00-00 page 12
May 01/2007
BRP-Rotax
Maintenance Manual
3) Maintenance
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see corresponding
Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or
914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.
3.1) Control system of the turbocharger (only on 914 Series)
3.1.1) Checking the turbocharger control unit (TCU) by 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 performance.
function test of all sensors
checking the throttle potentiometer (throttle position, throttle valve position) on-line data recording of the turbocharger control
quick fault analysis
This program allows prompt analysis of defects and irregularities in the TCU components.
3.1.1.2) Required items
See Fig. 76-9.
- PC with processor 80 286 or higher, with main frame memory min. 640 KB RAM graphic adapter EGA, CGA or VGA serial interface COM 1 or COM 2 operating system MS-DOS 5.0 or higher disk drive 3.5 inch
◆ NOTE: We recommend a laptop or notebook computer, since these units can also be used directly on the engine or aircraft.
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 13
May 01/2007
BRP-Rotax
Maintenance Manual
- Communication program:
Software between TCU and computer tlr V4.3a for TCU part no. 966470 and 966471 tlr V4.5a for TCU part no. 966472 and 966473 tlr V4.6a for TCU part no. 966741
◆ NOTE:
- Decoding 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 the RS 232 plug connection, the 9pin port of the wiring harness.
All the required components, except the computer, are available in the form of a monitoring set (1) or as a floppy disk (2).
Fig. 76-9
00427
1
Communicationprogram tlr V4.3a
00210
Communicationprogram tlr V4.6a
00210
2
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 14
May 01/2007
Effectivity 914 Series
Edition 1 / Rev. 0
BRP-Rotax
Maintenance Manual
3.1.1.3) Scope of the communication program a) Software
The software is the property of BRP-Rotax. Duplication is only permissible for the purpose of copying onto the hard disk or for the creation of backup copies or for filing.
b) Necessary connections
See Figs. 76-10 and 76-11.
- On the TCU part no. 966470 to 966473, the decoding unit
(Dongle) must be connected to the RS 232 plug connection, the 9-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 the wiring harness, with the COM1 interface of computer (COM1 or COM2).
◆ NOTE: The computer is normally provided with two serial interfaces (1) and (2).
Normally a serial interface (usually a 9-pin port) is used for connection of a mouse.
Since there is no need for a mouse to control the communication program, the Dongle can be connected with the interface for the mouse, best known as COM 1.
◆ NOTE: On the TCU part no. 966741, there is no decoding unit and the connection is direct.
Fig. 76-10 1
00197
00198
2
76-00-00 page 15
May 01/2007
BRP-Rotax
Maintenance Manual
Fig. 76-11 Dekodereinheit
(Dongle) zur TCU
(to TCU) zur Dekodiereinheit
(to Dongle) zum PC
(to PC)
PC
Laptop
Kommunikationsprogramm
(communicationprogram)
TCU
Effectivity 914 Series
Edition 1 / Rev. 0
00209
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May 01/2007
Effectivity 914 Series
Edition 1 / Rev. 0
BRP-Rotax
Maintenance Manual c) Procedure for installation of the communication program on the PC
- Check which TCU part no. and thus which program version is applicable.
TCU part no.
966470
966471
966472
966473
966741
Program version
TLR43A.exe
TLR45A.exe
TLR45A.exe
TLR45A.exe
TLR46A.exe
Insert the floppy disk into the disk drive and copy the corresponding communication program onto the hard disk.
◆ NOTE: Copy the communication program into a directory with a corresponding name.
08220
3.1.1.4) Application of the communication program a) Start of the program:
- 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 unintentional “ON”.
switch on PC (if not active already)
- start the program by double-clicking on the program symbol.
◆ NOTE: The first time the program is started, it will ask for the graphic adapter and the interface.
Normally, “V“ is entered for VGA and “1“ for COM1. After entering these parameters, the configuration file TLR.cfg will be created and stored in the communication program.
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BRP-Rotax
Maintenance Manual
◆ NOTE: If the wrong interface is entered, this file can be deleted and the program start repeated.
b) Starting the subprograms:
See Fig. 76-12
The subprograms are listed in the bottom line and are started by keying in first letter of the program name, e.g. “M” for
MONITOR (monitor program)
◆
NOTE: The key “ESC” will always return you to the main menu.
Fig. 76-12 program information line main menu
Fig. 76-13
1
Effectivity 914 Series
Edition 1 / Rev. 0 sub programs 00443
◆ NOTE: Fig. 76 -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_SCOPE and 2_SCOPE) the failure message
“/ERROR: Serial I/O Continue with any key...” appears in the last line (1), a connection between TCU and computer has been interrupted. Checking of all plug connections between TCU and computer is necessary. In addition, verify voltage supply to TCU.
Rectify any detected interruption between TCU and computer and switch TCU voltage supply
“OFF” and “ON”.
00191
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May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
76-00-00 page 19
May 01/2007
20
19
23
22
21
Fig. 76-14
2
3
10
9
6
11
15
19
2
18 17
3
BRP-Rotax
Maintenance Manual
TCU part no. 966741
5
03066
4
5
TCU part no. 966470 up to 966473
00444
6
7
8
10
9
11
12
14
13
18 17
16
15
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 20
May 01/2007
BRP-Rotax
Maintenance Manual
Legend to monitor display
(2) Rev counter display
(3) Throttle valve position
(4) Pressure difference between (8) and (9)
(5) LOG status ON/OFF
(6) Target pressure on basis of throttle valve position
(7) Target pressure on basis of pressure 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
(12) not activated
(13) Target pressure reduction by exceeding of the max. airbox temperature
(14) Target pressure reduction by exceeding max. engine speed
(15) Airbox temperature
(16) Knocking signal (not activated)
(17) LOG actuation ON/OFF
(18) Software status
(19) Program identification
(20) Servo output %
(21) D factor
(22) I factor
(23) P factor
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 21
May 01/2007
Effectivity 914 Series
Edition 1 / Rev. 0
BRP-Rotax
Maintenance Manual
◆ NOTE:
MONITOR: Serves for the on-line display of operational engine data such as airbox pressure, ambient pressure, servo position, airbox temperature etc.
LOG:
Because of the multitude of displays, parameters important for the user are printed in bold type and underlined.
Is a submenu (18) of the MONITOR program and 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 recording and “OFF” respectively for non-recording (see Fig. 76-14, item
(5)).
A so-called Log file will be loaded onto the hard disk stating date and starting time of the recording.
Example:
Fig. 76-15 11061014.LOG
Minute (minute)
Stunde (hour)
Tag (day)
Monat (month) 00193
◆ NOTE: Verify this date and starting time when booting the PC.
If more than 4000 data lines are recorded, the current LOG file will be closed automatically and a new one opened.
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BRP-Rotax
Maintenance 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 calculation programs.
Fig. 76-16, for instance, shows usage of data on an EXCEL spreadsheet.
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 23
May 01/2007
BRP-Rotax
Maintenance Manual time PC
(hh:mm:ss)
16:53:04
16:53:04
16:53:05
16:53:05
16:53:05
16:53:05
16:53:05
16:53:05
16:53:06
16:53:06
16:53:06
16:53:06
16:53:06
16:53:06
16:53:07
16:53:07
16:53:01
16:53:01
16:53:02
16:53:02
16:53:02
16:53:02
16:53:02
16:53:03
16:53:03
16:53:03
16:53:03
16:53:03
16:53:03
16:53:04
16:53:04
16:53:04
16:53:07
16:53:07
16:53:08
16:53:08
16:53:08
16:53:08
16:53:08
00475 load throttle (0-
115%)
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3
3,3 speed
(1/min)
2387
2384
2391
2380
2391
2373
2376
2392
2394
2371
2373
2368
2396
2384
2384
2386
2372
2371
2365
2368
2369
2362
2382
2375
2376
2385
2375
2369
2386
2391
2386
2388
2384
2386
2369
2387
2388
2387
2377
2 3
-122
-122
-123
-123
-122
-122
-123
-123
-123
-123
-123
-122
-123
-123
-123
-122
-123
-122
-123
-123
-122
-122
-122
-123
-123
-123
-122 pressure difference
(mbar)
-123
-123
-123
-122
-122
-122
-123
-123
-122
-122
-122
-123
4
978
978
977
977
978
978
977
977
977
977
978
978
977
977
977
978
977
978
977
977
978
978
978
977
977
978
978 actual pressure
(mbar)
977
977
977
978
978
977
977
977
978
978
978
977
9
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100 nominal pressure
(mbar)
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
1100
6
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978
978 ambient pressure
(mbar)
978
978
978
978
978
978
978
978
978
978
978
978
10 servo position (0
- 100 zu) knocking airbox (°C)
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
100
527
504
523
518
517
513
512
533
524
523
521
520
517
516
510
511
524
502
501
520
520
503
502
516
518
521
517
516
497
497
530
500
495
495
528
526
526
521
522
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
27,6
11 16 15
For above numbering see also monitor display.
P-factor
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
20
23
Fig. 76-16
I-factor D-factor output servo
(+/-100)
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
0
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
3
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
80
100
80
80
80
80
80
80
22 21 20
◆ NOTE: Fig. 76-16 shows an EXCEL spreadsheet of program version TLR V4.3A.
Effectivity 914 Series
Edition 1 / Rev. 0
1_SCOPE: For on-line display of the control action with regard to pressure deviation (airbox pressure to target pressure) in the range of ±100 hPa
(mPa).
The program is for graphic evaluation of the parameters (8) and (9) in the monitor program.
76-00-00 page 24
May 01/2007
BRP-Rotax
Maintenance Manual
Fig. 76-17
00194
2_SCOPE: For on-line display of the control action between target pressure and effective airbox pressure in the range of 1000 to 1400 hPa
(mbar).
The program is for graphic evaluation of the parameters (8) and (9) in the monitor program.
Fig. 76-18
Effectivity 914 Series
Edition 1 / Rev. 0
00195
76-00-00 page 25
May 01/2007
BRP-Rotax
Maintenance Manual
- Data display
See Figs. 76-19, 76-20, 76-21, 76, -22 and 76-23.
HISTORY_BUFFER: A subprogram for reading, displaying and printing of the data stored in the TCU.
Fig. 76-21 shows that 8 control parameters are displayed. The recording takes place at 6 minute intervals, whereby the highest value of each period will be stored.
Fig. 76-19
00199
READ_DATA: Reads data such as serial number, time of operation and the latest transmitted engine data from the storage in the TCU. When 100
% is reached, the reading is complete.
◆ NOTE: If this command is carried out during creation of a LOG file, the failure message “SERIAL
ACCESS DENIED” will appear. In this case, repeat the reading procedure.
Fig. 76-20
Effectivity 914 Series
Edition 1 / Rev. 0
00200
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May 01/2007
BRP-Rotax
Maintenance Manual
VIEW_DATA: Shows the file data deduced from READ_DATA on the screen. The keys “page up” and “page down” enable paging on the screen.
Fig. 76-21
00201
PRINT_DATA: Option to print data deduced from
READ_DATA.
Fig. 76-22
Effectivity 914 Series
Edition 1 / Rev. 0
00205
76-00-00 page 27
May 01/2007
Effectivity 914 Series
Edition 1 / Rev. 0
BRP-Rotax
Maintenance Manual
◆ NOTE:
◆
NOTE:
Figs. 76-21 and 76-22 show program version
TLR V4.3A.
The printer must be connected with the PC via the parallel interface (1).
Fig. 76-23
00196 d) End of program
Stop communication program with “ Q ” for 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 shortcomings of the components via the sub program „MONITOR“.
◆ NOTE: A corresponding trouble shooting chart is available on request from authorized distributors and service centers. See latest Operators
Manual for the respective engine type or the official Homepage www.rotax-aircraftengines.com.
76-00-00 page 28
May 01/2007
Fig. 76-25
BRP-Rotax
Maintenance Manual
3.1.1.6) Checking the throttle valve position
See Figs. 76-24 and 76-25.
- Start-up of the subprogram MONITOR.
At the top in the center (1) is the position display for the throttle valve (carburetor 2/4)
1
1
Program version TLR V4.3A
00445 Program version TLR V4.6A
03066
0 %
115 % throttle valve completely closed throttle valve completely 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° max. deviation +3%
- Check the display with throttle valve completely open: nominal: 115 % max. deviation -2%
■ CAUTION: Check whether indication is linear over the complete range from 0% to 115% i.e. the
115% position is not indicated before throttle valve is fully open.
Fig. 76-25
Effectivity 914 Series
Edition 1 / Rev. 0
00214
00215
76-00-00 page 29
May 01/2007
BRP-Rotax
Maintenance Manual
- Check the display at max. continuous performance.
■ CAUTION: Throttle lever must be in positive stop position.
nominal: 100 % max. deviation +3%.
▲ WARNING: This check of position is only meaningful and permissible 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, then a new calibration of the throttle position is absolutely necessary.
Recalibration to be carried out only by an authorized ROTAX-
Dealer or Service Center if the TCU is of part no. 966470 to
966473 .
If TCU part no. 966741 or higher is used, proceed with calibration as described in the following section.
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 30
May 01/2007
BRP-Rotax
Maintenance Manual
3.1.1.7) Recalibration of the throttle position
See Figs. 76-26, 76-27 and 76-28.
- Start up of the sub program THROTTLE.
- Check whether the throttle valve (carburetor 2/4) can be 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 with ENTER.
03072
Fig. 76-26
Fig. 76-27
- Fully open the throttle valve (carb 2/4) and confirm with
ENTER.
03073
Fig. 76-28
- Calibration data will be transferred automatically and the calibration takes place.
03071
Effectivity 914 Series
Edition 1 / Rev. 0
- Verification of the throttle position as per section 76-00-00
/ 3.1.1.6 .
76-00-00 page 31
May 01/2007
BRP-Rotax
Maintenance Manual
3.1.2) Static check of the turbocharger control
The easiest way to check function of turbocharger control components is by the communication program. If this program is not at your disposal, the following static checks can 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 wiring harness.
- Inspection for physical damage.
- Inspection of the 4 rubber buffers (1) for damage, which is detrimental for vibration damping.
- Inspection of the 36-pin plug receptacle (2).
▲ WARNING: The TCU must never be opened.
■ CAUTION: Replace TCU without delay in the event of physical damage or incorrect operation.
Fig. 76-29
1
Effectivity 914 Series
Edition 1 / Rev. 0
2
00092
76-00-00 page 32
May 01/2007
BRP-Rotax
Maintenance Manual
Further shortcomings can only be detected in correlation with the respective component of the turbo control unit.
■
CAUTION: The following checks are necessary if the TCU is to be replaced.
- Inspection of the throttle valve position using the communication program. See 76-00-00 sec. 3.1.
■
CAUTION: If this 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 run engine. See the corresponding Maintenance
Manual (Line Maintenance) for the respective engine type,
912 Series or 914 Series.
- When switching on the TCU, observe self test of the servo motor, see 76-00-00 sec. 3.1.2.7 and the caution lamps, see 76-00-00 sec. 3.1.2.2.
▲ WARNING: If an inspection reveals irregularities, then the engine must not be taken in operation until the cause is found and rectified.
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 33
May 01/2007
BRP-Rotax
Maintenance Manual
3.1.2.2) Caution lamps
See Fig. 76-30
The TCU is furnished with output terminals for an external red boost lamp (WARNING LAMP) and an orange caution lamp.
Location of the lamps depends on type of aircraft and is limited by the length of the wiring harness. Standard location is on the instrument panel in the cockpit.
When switching on the voltage supply of the 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 connections of wiring harness
Check lamps for correct functioning
◆ NOTE: The two caution lamps are not included in the delivery range of the engine.
■ CAUTION: In the event of physical damage or incorrect operation, replace part without delay.
■
CAUTION: The negative poles (10, 11) must not be attached directly to the battery potential. A potentialfree 2-pin lamp socket must be used, as the lamps are triggered via the negative pole.
Fig. 76-30
Effectivity 914 Series
Edition 1 / Rev. 0
00211
+12V
øV
øV
+12V
CAUTION LAMP
76-00-00 page 34
May 01/2007
Effectivity 914 Series
Edition 1 / Rev. 2
BRP-Rotax
Maintenance Manual
3.1.2.3) Wiring harness
See Fig. 76-31
The sensors are connected with the TCU via the wiring harness.
▲ WARNING: If an inspection reveals irregularities, then the engine must not be taken in operation until the cause is found and rectified.
The easiest way to check function of turbo control components is by the communication program. If this program is not at your disposal, the following static checks can be carried out.
- For verification and troubleshooting, check all connections for passage and physical damage. See Fig. 76-31.
- Verify that all plug connections fit tightly.
■ CAUTION: In the event of 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. Besides the wiring designations, plug allocation, cable length, the polarity of the voltage supply to the single components are also stated.
■ CAUTION: Due to a modification a three-way solenoid valve was introduced. If the engine is equipped with an old 3-way solenoid valve then, if the wiring harness needs to be replaced, the 3way solenoid valve also has to be changed.
See 76-00-00 sec. 3.1.2.9.
If the wiring harness is replaced, the throttle valve position must be recalibrated (see 76-00-00 sec. 3.1.1.7) and the turbocharger control checked in accordance with 76-00-00 sec. 4
If this aid is not at your disposal, an engine test run has to be performed. See corresponding Maintenance Manual (Line
Maintenance) for the respective engine type 914 Series.
76-00-00 page 35
July 01/2008
Fig. 76-31
BRP-Rotax
Maintenance Manual
08472
Effectivity 914 Series
Edition 1 / Rev. 2
76-00-00 page 36
July 01/2008
BRP-Rotax
Maintenance Manual
3.1.2.4) Throttle potentiometer
See Figs. 76-32, 76-33, 76-34, 76-35, 76-36, 76-37, 76-38 and
76-39.
The throttle potentiometer (1) is installed on constant depression carburetor 2/4.
The turning range when installed is from 0% - 115%.
◆ NOTE: The throttle potentiometer is fitted on older and newer versions. See Figs. 76-34, 76-36 and 76-37.
See Figs. 76-37, 76-00 and 2-00.
1
115%
100% open closed
0%
Fig. 76-32
Fig. 76-33
00056
For the following measurements, unplug 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 checking, then verification of the throttle valve position via the communication program will be necessary. See 76-00-00 sec. 3.1.
If this aid is not at your disposal, an engine test run has to be performed. See the corresponding Maintenance Manual (Line
Maintenance) for the respective engine type, 912 Series or
914 Series. Engine operation is only permissible for transfer to the nearest maintenance facility , where this check has to be performed afterwards.
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 37
May 01/2007
Fig. 76-34 sloping edge
2
BRP-Rotax
Maintenance Manual
When reassembling the original throttle potentiometer, it is not necessary to dismantle the adapter flange (2). This would increase the installation tolerance unnecessarily.
When replacing the throttle potentiometer, pay attention to the version used and if necessary, also remove the adapter flange.
◆
NOTE: When assembling the adapter flange, ensure that it is the appropriate model for the respective throttle potentiometer and that it is installed in the correct position (with the cut off edge upwards). See Fig. 76-34
Fig. 76-35
5 6
5 6 7
7
(5) = minus
(6) = loop closed
(7) = positive
3
1
4
07717
00052
Effectivity 914 Series
Edition 1 / Rev. 0
When installing the throttle potentiometer, check the version, see Figs. 76-36 and 76-37 and ensure that it engages with free movement in the flat surface of the throttle valve shaft. Secure the allen screws M4x7 (3) and the combined screws M4x22 (4) with LOCTITE 221. In addition, witness paint marking must be applied to the screws.
76-00-00 page 38
May 01/2007
adapter flange
BRP-Rotax
Maintenance Manual older model version part no. 861930 newer model version part no. 861931 cut off edge
Fig. 76-36
2 potentiometer
05378 older model version part no. 966480 newer model version part no. 966481
Fig. 76-37
1
05379 distinguishing feature
Effectivity 914 Series
Edition 1 / Rev. 1
◆ NOTE: Small installation tolerances can be compensated by turning the throttle potentiometer.
For tolerances, see 76-00-00 sec. 3.1.1.6, otherwise, recalibration is necessary.
- Inspection for physical damage.
- Measurement of the nominal resistance:
Measure resistance between connections (5) and (7).
Nominal resistance: 3.2 to 4.8 k
- Measurement of resistance across turning range of fitted throttle.
To check the function of the throttle potentiometer over the operating range, take the following readings:
76-00-00 page 39
January 01/2008
Effectivity 914 Series
Edition 1 / Rev. 0
BRP-Rotax
Maintenance Manual
Resistance between the connections (6) and (7):
Throttle valve closed
(throttle lever pos. 0%): 3.4 to 4.6 k
Ω
Throttle valve open
(throttle lever pos. 115%): 0.8 to 2.0 k Ω
◆ NOTE: Check complete operating range as shown in the following diagram (Fig. 76-38) for linear resistance progress.
Fig. 76-38
5
4,5
4
3,5
3
2,5
2
1,5
1
0,5
0 open throttle position
00221 closed
76-00-00 page 40
May 01/2007
3,5
Fig. 76-39
3
2,5
2
1,5
1
0,5
0 closed
BRP-Rotax
Maintenance Manual
Resistance between the connections (5) and (6):
Throttle valve open
(throttle lever pos. 115%): 2.4 to 3.2 k
Ω
Throttle valve closed
(throttle lever pos. 0%): 100 to 300 Ω
◆ NOTE: Check complete operating range as shown in the following diagram (Fig. 76-39) for linear resistance progress.
■ CAUTION: In the event of physical damage or resistance readings outside allowance, replace the part without delay.
throttle position
00222 open
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 41
May 01/2007
Effectivity 914 Series
Edition 1 / Rev. 4
BRP-Powertrain
Maintenance Manual
3.1.2.5) Resistance thermometer (Intake air temperature sensor)
See Figs. 76-40, 76-41 and 76-42.
The sensors (1) for measuring intake air temperature is screwed into the airbox.
■ CAUTION: In the event of physical damage or resistance readings outside allowance, replace part without delay.
- Inspection for physical damage.
- Measurement of the resistance:
Detach plug connection with wiring harness but re-establish immediately after completion of the check and verify tight fit and engagement of catch.
Measure resistance between the two terminals (2) and compare with relevant resistance/temperature chart below.
Allowance for resistance: max ±1%
When assembling the resistance thermometer, secure with
LOCTITE 243 and tighten to 15 Nm (135 in.lb).
◆ NOTE: On engines equipped with the older TCU version, part no. 966470 to 966473, resistance thermometer part no. 966430 must be used. See SB-914-013, “Turbocharger control unit (TCU) with software level according to
RTCA DO 178 B“, latest issue.
76-00-00 page 42
February 01/2015
BRP-Rotax
Maintenance Manual
Fig. 76-40
1
1
Fig. 76-41
1 00056
00055
2
Effectivity 914 Series
Edition 1 / Rev. 0
130
120 Fig. 76-42
00223
110
100
90
80
-30 -20 -10 0 10 20 30 40 50
Temperatur [°C] temperature
76-00-00 page 43
May 01/2007
BRP-Rotax
Maintenance Manual
3.1.2.6) Pressure sensors
See Fig. 76-43.
To prevent mixup of the two pressure sensor inputs, the plug connections are in different colors. In addition, the airbox pressure sensor cable set of the wiring harness is labeled.
Gray plug 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 (Monitoring).
See 76-00-00 sec. 3.1.
If this aid is not at your disposal, an engine test run has to be performed. See corresponding Maintenance Manual (Line
Maintenance) for the respective engine type 914 Series.
▲ WARNING: If an inspection reveals irregularities, then the engine must not be taken in operation until the cause is found and rectified.
Effectivity 914 Series
Edition 1 / Rev. 0
76-00-00 page 44
May 01/2007
BRP-Rotax
Maintenance Manual
Effectivity 914 Series
Edition 1 / Rev. 0
00057 static pressure sensors
1 2 airbox pressure
Fig. 76-43
76-00-00 page 45
May 01/2007
BRP-Rotax
Maintenance Manual a) Airbox pressure sensor:
See Figs. 76-44 and 76-45.
On engines with an airbox of older configuration, the installation location of the airbox pressure sensor (2) depends on the aircraft type and is limited by the length of the wiring harness.
On engines with an airbox of newer configuration, the airbox pressure sensor (2) is integrated in the airbox. See SI-914-013 and SI-914-015, “Introduction of a new airbox“, latest issue.
■ CAUTION: The sensor is designed for a pressure range of
500 hPa to 2500 hPa and max. pressure must not exceed 3500 hPa.
If the max. pressure is exceeded during the course of measuring, the sensor must be replaced.
When taking the following readings, the plug connection to the wiring harness must be disconnected and reestablished immediately after completion of the checks. The same applies for the air pressure hose.
The easiest way to check the function of the two pressure sensors is to use the communication program. If this program is not at your disposal, the following static checks can be carried out.
Inspect for physical damage.
Static check for function of airbox pressure sensor:
Allocation of connections for test set-up / legend to Fig. 76-44
(3) Measuring voltage output Ua
(4) Ground (øV)
(5) Voltage supply Us min. + 3 V, max. + 15 V
(6) Pressure connection
Effectivity 914 Series
Edition 1 / Rev. 0
Fig. 76-44
966 502 airbox pressure
2
5 4 3
00058
6
76-00-00 page 46
May 01/2007
Ua/Us
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0,0
Fig. 76-45
00442
Effectivity 914 Series
Edition 1 / Rev. 5
BRP-Rotax
Maintenance Manual
Test set-up
Connect pin (3) to ground and connect pin (4) to positive side of voltage supply Us . Apply test pressure to sensor (input 6)
Take reading of output voltage between pin (3) and pin (2).
Divide the measured output voltage (Ua) by the supply 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 pressure can be read off at the intersection of the straight lines.
Max. deviation ± 40 hPa
■ CAUTION: In the event of physical damage or resistance readings outside allowance, replace the part without delay.
hPa pressure absolute
76-00-00 page 47
March 01/2017
BRP-Rotax
Maintenance Manual b) Static pressure sensor:
See Figs. 76-46 and 76-47.
The location of the ambient pressure sensor (1) depends on the aircraft type, but is limited by the length of the wiring harness.
■ CAUTION: The sensor is designed for a pressure range of
100 hPa to 1200 hPa and the max. pressure must not exceed 3500 hPa.
If the max. pressure is exceeded during the course of measuring, the sensor must be replaced.
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 hose.
The easiest way to check function of the two pressure sensors is by use of the communication program. If this program is not at your disposal, the following static checks can be carried out.
Inspection for physical damage.
Static check for function of airbox pressure sensor:
Allocation of connections for test set-up / legend to Fig. 76-46
(2) Measuring voltage output Ua
(3) Ground (øV)
(4) Voltage supply Us min. + 3 V, max. + 15 V
(6) Pressure connection
Effectivity 914 Series
Edition 1 / Rev. 0
Fig. 76-46
00058
966 507 ambient pressure
1
4 3 2
6
76-00-00 page 48
May 01/2007
Ua/Us
0,9
0,8
0,7
0,6
0,5
0,4
0,3
0,2
0,1
0,0
00441
Effectivity 914 Series
Edition 1 / Rev. 5
Fig. 76-47
BRP-Rotax
Maintenance Manual
Test set-up
Connect pin (3) to ground and connect pin (4) to positive side of voltage supply Us . Apply test pressure to sensor (input 6)
Take reading of output voltage between pin (2) and pin (3).
Divide the measured out put voltage (Ua) by the supply 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 pressure can be read off at the intersection of the straight lines.
Max. allowance ± 60 hPa
■ CAUTION: In the event of physical damage or resistance readings outside allowance, replace the part without delay.
hPa pressure absolute
76-00-00 page 49
March 01/2017
Effectivity 914 Series
Edition 1 / Rev. 0
BRP-Rotax
Maintenance Manual
3.1.2.7) Servo motor
See Fig. 76-48
The installation location of the servo motor (1) depends on the aircraft type but is limited by the length of the wiring harness and bowden cable length to wastegate.
- After switching on the TCU, ensure that the automatic self check of the servo motor is performed. During this auto test the complete operating range is traversed and afterwards the engine remains in position corresponding to throttle lever position.
- Inspection for physical damage.
When taking the following readings, the plug 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, replace the part without delay.
- Measurement of the nominal resistance :
Measure resistance between connections (2) and (4).
Nominal resistance: 4.4 to 5.5 k Ω
- Measuring the resistance with wastegate closed:
Check the following values with the throttle in 0% position:
Resistance between the terminals (2) and (3):
Resistance value: 0 to 70 Ω
Resistance between the terminals (4) and (3):
Resistance value: 4.6 to 5.4 Ω
- Checking between terminals (5) and (6) for power supply:
Resistance value: 5.0 to 20.0 Ω
■ CAUTION: When replacing the servo motor, verification of the relevant values using of the communication program (monitoring) is required. See
76-00-00 sec. 3.1.
76-00-00 page 50
May 01/2007
BRP-Rotax
Maintenance Manual
If this aid 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 engine must not be taken into operation until the cause is found and rectified.
Fig. 76-48
1
Effectivity 914 Series
Edition 1 / Rev. 0
3 2
4
2 3 4 5
M
6
00059
76-00-00 page 51
May 01/2007
Effectivity 914 Series
Edition 1 / Rev. 0
BRP-Rotax
Maintenance Manual
3.1.2.8) Circuit breaker for servo motor
See Fig. 76-49.
The location of the circuit breaker (1) depends on the aircraft type, but is limited by the length of the wiring harness.
■ CAUTION: The circuit breaker is not included in the delivery range of the engine. Check circuit breaker according to the aircraft manufacturers instructions.
- Operational 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 breaker open, the servo motor must not start turning. The orange caution lamp starts flashing.
■
CAUTION: If the required boost pressure cannot be reached or if the circuit breaker does not act correctly, locate the cause. Until the cause has been found and rectified, engine operation is only permitted for ground testing.
■ CAUTION: In the event of physical damage or incorrect operation, replace the part without delay.
Fig. 76-49
M
1
14
TCU
2
00217
76-00-00 page 52
May 01/2007
BRP-Rotax
Maintenance Manual
3.1.2.9) Three-way solenoid valve
See Fig. 76-50
The 3-way solenoid valve (1) is installed on the engine suspension frame or directly on airbox on newer engines.
Due to a modification a new 3-way solenoid valve has been introduced. See SI-914-022, „Running Modifications“, latest issue.
Accessories and attachment of the 3-way solenoid valve could differ because of the possible variants of the airbox.
08494
If the 3-way solenoid valve is fastened to the engine suspension frame, then not all parts of the retro-fitting kit are needed.
In addition the following parts are needed:
Variant 1: for airbox part no. 667167
◆ NOTE: all parts for variant 1 are included in retrofit kit part no. 881040
Fig New Qty/
No..
p/n engine parts requirement - retrofit kit part no. 881040
Description Old part no.
Application
1 874313
2 666010
3 951040
4 840391
5 842040
6 866710
1
1
2
2
2
4
3-way solenoid valve 874310 airbox adapter cable bracket allen screw M6x14 lock nut M6 tie wraps
-
-
-
-
wiring harness
3-way solenoid valve bracket bracket
3-way solenoid valve
Effectivity 914 Series
Edition 1 / Rev. 2
76-00-00 page 53
July 01/2008
07233
Effectivity 914 Series
Edition 1 / Rev. 2
Variant 1
BRP-Rotax
Maintenance Manual
Disassembly and assembly - Variant 1
Remove connection wiring harness (11) of 3-way solenoid valve (1).
Cut off tie wraps (6).
Loosen 3x clamps (12) from 3-way solenoid valve and remove 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. lb).
■ CAUTION: Route all pressure connections such that there will be no sharp bends or chafing.
Push lines onto fittings as far as they will go and secure with clamps (12).
Position lines and adapter cable (2) and secure with clamps (6).
6
11 12
12
1
07234
Fig. 76-50
2
4
12
3
12
5
76-00-00 page 54
July 01/2008
BRP-Rotax
Maintenance Manual
Variant 2 for airbox part no. 867753
(attachment of the 3-way solenoid valve on the engine suspension frame)
Fig New parts requirement:
Qty/
No. part no. engine
Description
881040* 1
7 n.a** 1 retrofit kit bracket
8 241841
9 927571
10 842030
2
2
2 allen screw M5x12 washer 5,3 lock nut M5
Old Application part no.
-
airbox
3-way solenoid valve
-
-
bracket bracket bracket
* following parts of the retrofit 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 valve (1).
Cut off tie wraps (6).
Loosen 3x clamps (12) from 3-way solenoid valve and remove lines.
Loosen clamps (13) from engine suspension frame (14) and remove 3-way solenoid valve.
Connect adapter cable (2) to wiring harness.
Tighten the new 3-way solenoid valve with allen screw (8), washer (9) and lock nut (10) onto bracket (7). Tightening torque 8 Nm (70 in. lb).
Install 3-way solenoid valve with clamp (13) onto engine suspension frame.
■ CAUTION: Route all pressure connections such that there will be no sharp bends or chafing.
Effectivity 914 Series
Edition 1 / Rev. 2
76-00-00 page 55
July 01/2008
Effectivity 914 Series
Edition 1 / Rev. 2
BRP-Rotax
Maintenance Manual
Fit the push lines onto the 3-way solenoid valve and secure with clamp (6).
Position push lines and adapter cable (2) and secure with clamps
(6).
■ CAUTION: Always obey the additional instruction.
Variant 2
12
1
07231
Fig. 76-51
12
14
13
07232
6
2
8
12
12
13
9
10
7
76-00-00 page 56
July 01/2008
Effectivity 914 Series
Edition 1 / Rev. 2
BRP-Rotax
Maintenance Manual
■ CAUTION: In the event of physical damage, mechanical defects or readings outside tolerance, replace the part without delay.
- Inspection for physical damage
- check for pneumatic passage
Disconnect the pressure connection lines. See 73-00-00 sec. 2.7.
- check the mixture enrichment (dynamic)
To 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 place, but for standard operation it must be securely closed.
- Measure the resistance between the two terminals (2):
Disconnect plug connection with wiring harness but reestablish immediately after completion of check and verify tight fit and engagement of catch.
- resistance at 20 °C (68 °F):
(older model version)
28.3 to 31.1 Ω
- resistance at 20 °C (68 °F):
(newer model version)
22 to 25 Ω
Fig. 76-52
08489
7
76-00-00 page 57
July 01/2008
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 914 Series, latest issue.
Effectivity 914 Series
Edition 1 / Rev. 2
76-00-00 page 58
July 01/2008
4) Form Sheets
Fig. 76-53
BRP-Rotax
Maintenance Manual
10265
Effectivity 914 Series
Edition 1 / Rev. 5
76-00-00 page 59
March 01/2017
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 2
76-00-00 page 60
July 01/2008
BRP-Powertrain
Maintenance Manual
SECTION 78
EXHAUST SYSTEM AND TURBOCHARGER
1) Table of contents
SECTION 78
EXHAUST SYSTEM AND TURBOCHARGER
2.1) Exhaust system (on the 912 Series) ............................................. 78-00-00 / 3
2.2) Exhaust system (on the 914 Series) ............................................. 78-00-00 / 3
2.3) Turbocharger (only on the 914 Series) .......................................... 78-00-00 / 3
2.3.1) Exhaust turbocharger ....................................................... 78-00-00 / 4
2.4.1) Exhaust gas temperature display (optional) ..................... 78-00-00 / 5
3.1) Disassembly of the complete exhaust system
3.3) Inspection of the exhaust system and turbocharger components
3.3.1) Exhaust bend and exhaust manifold ................................. 78-00-00 / 11
Turbocharger .................................................................... 78-00-00 / 12
3.4) Assembly of the complete exhaust system (on the 912 Series) ... 78-00-00 / 16
3.5) Assembly of the complete exhaust system incl. turbocharger
3.6) Bowden cable, rope sheave and spring for wastegate control
3.6.2) Checking of the components ............................................ 78-00-00 / 21
3.6.3) Assembly and adjustment ................................................ 78-00-00 / 21
4) Wear limits .............................................................................................. 78-00-00 / 23
Effectivity 912/914 Series
Edition 1 / Rev. 3
78-00-00 page 1
October 01/2010
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
78-00-00 page 2
May 01/2007
BRP-Powertrain
Maintenance Manual
2.) Systems description
2.1) Exhaust system (on the 912 Series)
On ROTAX engines of the 912 Series, the exhaust system assy. is not included in the ROTAX scope of delivery, but it is available optionally. The engine is supplied only with the 4 exhaust sockets on the cylinder head.
The exhaust system must be configured or manufactured by the aircraft or fuselage manufacturer.
For disassembly, inspection and assembly of the exhaust system, observe the aircraft manufacturers instructions.
The exhaust muffler especially designed for the ROTAX engines 912 S / ULS can be used also on the ROTAX engines 912 UL / A / F. Engine performance and specific fuel consumption remain unchanged or are slightly better when using this muffler.
The muffler is 0.3 kg lighter than the muffler which is usable only for the 912 A/
F/UL Series.
By optimizing the design of the muffler the noise emission may seem subjectively higher compared with muffler for 912 A/F/UL Series. 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 exhaust system on ROTAX engines of the 914 Series collects all gases which accumulate in the combustion chamber of the cylinders and routes them via exhaust bends and exhaust manifold to the exhaust turbocharger. There, the combustion gases drive the exhaust gas turbine to achieve a power increase.
See 78-00-00 sec. 2.3. From the exhaust turbocharger, the combustion gases are routed to the muffler, which is fitted for noise reduction.
The exhaust system is made of stainless steel. The exhaust bend is connected to the exhaust manifold by means of slide sleeves to ensure that expansion due to heat can be compensated for.
The exhaust bends are sealed to the cylinder head by the ridge on the exhaust bends. The muffler is supported via the exhaust bracket on the engine suspension frame.
Owing to continuous further development, the exhaust bends were slightly reworked. The couplings were optimized for their position.
Position of the EGT connections to the exhaust bends for cylinders 3 and 4 were routed such that installation of the new drip trays is possible.
Effectivity 912/914 Series
Edition 1 / Rev. 4
78-00-00 page 3
February 01/2015
◆ NOTE:
BRP-Powertrain
Maintenance Manual
If replacement of any single old part number is necessary, you must replace it with the same old part number. If the old part number is not available, the entire assembly including all 4 pipes and manifold must be replaced with new part numbers. New style pipes and manifold are not interchangeable with old style.
2.3) Turbocharger (only on the 914 Series)
ROTAX engines of the 914 Series are equipped with an exhaust turbocharger which makes use of the energy in the exhaust gas for 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 electric servo motor via a bowden cable.
2.3.1) Exhaust turbocharger
See Fig. 78-1
The exhaust turbocharger is basically an arrangement of two turbo machines, a turbine and a blower, on a common shaft.
The turbine transforms the energy of the hot exhaust gases and drives a blower which aspirates ambient air and transfers it precompressed via the carburetors into the cylinders.
The sole operational connection between engine and turbo is the air and exhaust stream. The speed of the turbo depends mainly on the pressure ratio at the turbine impeller but not directly on engine speed.
Fig. 78-1
3
1
2
Effectivity 912/914 Series
Edition 1 / Rev. 3
00136
78-00-00 page 4
October 01/2010
BRP-Powertrain
Maintenance Manual
◆ NOTE: Fig. 78 -1 shows a schematic arrangement of a boost pressure control with the wastegate in the exhaust stream
(1) engine
(2) exhaust turbocharger
(3) boost pressure regulating valve (wastegate)
Because of the large speed range of the engine and the varying power requirement, control of the exhaust turbocharger is necessary to achieve the respective nominal pressure in the airbox.
The waste gate directs part of the engine exhaust gases so that they bypass the turbine and flow directly into the exhaust (by-pass).
◆ NOTE: With the wastegate completely open, the engine performance can reach up to approx. 70 kW since not all of the exhaust gases bypass the turbine.
2.4) Connections for instrumentation
■ CAUTION: Consult also the relevant sections on connections for instrumentation in the latest Installation Manual.
2.4.1) Exhaust gas temperature display (optional)
The exhaust gas temperature is monitored by means of 4 sensors on the exhaust manifold. The temperature display device is connected via
NiCrNi control lines.
On 912 Series: The manufacturer of the exhaust system must attach or provide the connections M8x1 for installation of the metalsheathed thermocouples, part no. 966370, in the exhaust bends.
On 914 Series: The connection thread M8x1 for attachment of the metalsheathed thermocouples, part no. 966370, are already provided in the exhaust bends.
Effectivity 912/914 Series
Edition 1 / Rev. 3
78-00-00 page 5
October 01/2010
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
78-00-00 page 6
May 01/2007
BRP-Rotax
Maintenance Manual
3) Maintenance
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see corresponding
Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or
914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.
3.1) Disassembly of the complete exhaust system (on the 912 Series)
▲
WARNING: For disassembly, observe the aircraft manufacturers instructions.
3.2) Disassembly of the complete exhaust system incl. turbocharger and engine suspension frame (on the 914 Series)
See 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. 3.6.1.
Remove lock nuts M8 (1) on exhaust bend flanges.
◆ NOTE: If one of the studs M8x23/20 (2) should also become loose, refit and tighten to 8 Nm (71 in.lb). The longer threaded end (23 mm)
(0.9 in.) to be screwed into cylinder head.
Withdraw exhaust bends (3) by pulling and swiveling them slightly.
Detach turbo pressure (4) and suction oil lines (5) from the oil pump. See Fig.
78-2. For further details on “Turbocharger oil circuit”, see 79-00-00.
Slacken tension clamp (6) but do not detach or remove it from the exhaust bracket (7).
Remove the allen screw M10x50 (8) (attachment of the turbocharger bracket) together with the lock washer and washer and allen screw M6x50 (25) with the compensating shim.
Also detach connection (9) turbocharger bracket - engine suspension frame (not supplied with the engine).
Effectivity 912/914 Series
Edition 1 / Rev. 0
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May 01/2007
BRP-Rotax
Maintenance Manual
Support the complete unit of exhaust - turbocharger - manifold, remove the tension clamp and take off the complete unit. Remove the distance sleeve (10)
10.5/17/15 from the engine suspension frame attachment.
◆ NOTE: If necessary, remove the Bowden cable (11) for wastegate control. See 78-00-00 sec. 3.6. This is normally not necessary.
Muffler:
◆
NOTE: There is no need to disassemble the complete unit of muffler turbocharger - exhaust manifold for the removal of the muffler bracket.
To disassemble the muffler (12), remove the hex. screw (13) 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 turbocharger bracket (16) by means of a cable clamp (18), allen screw (18) M5x12 and lock nut (19).
Remove these items first.
The turbocharger bracket is attached on the turbine housing by 3 hex. screws
(20) M8x16.
Unscrew these 3 screws as far as possible.
◆ NOTE: These screws cannot be removed completely straight away as they touch the bearing housing. For complete removal, it is necessary to slacken the fourth attachment screw slightly.
■ CAUTION: To prevent any damage to the turbine impeller, fit the attachment screws (20) again. This will ensure that the turbine housing will not separate from the impeller.
Ensure that the two retaining ring halves are in position.
Effectivity 912/914 Series
Edition 1 / Rev. 0
78-00-00 page 8
May 01/2007
BRP-Rotax
Maintenance Manual
Exhaust manifold:
◆ NOTE: There is no need to disassemble the complete unit of muffler turbocharger - exhaust manifold for the removal of the muffler bracket.
The exhaust manifold (22) is directly attached to the turbine housing 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 - exhaust manifold for the removal of the muffler bracket.
Remove allen screw (27) M10x50 along with the lock washer and washer.
Also, detach connection (28) of exhaust bracket with engine suspension frame
(not supplied with the engine).
Remove distance sleeve (29) 10.5/17/15 from the arm of the engine suspension frame.
Fig. 78-2
4
5
11
00160
Effectivity 912/914 Series
Edition 1 / Rev. 0
78-00-00 page 9
May 01/2007
Fig. 78-3
1
BRP-Powertrain
Maintenance Manual
2
C
Zyl.
Cyl.
1
3
C
2
1
C .... LOCTITE 648
E .... LOCTITE ANTI SEIZE 15378
Zyl.
Cyl.
2
3
29
E
3
6
12
27
Effectivity 912/914 Series
Edition 1 / Rev. 4
7
28
32
E
14
15
XXX
14
31
E
E
13
E 3
E
E
Zyl.
Cyl.
4
21
Zyl.
Cyl.
3
22
E
4
24
E
25
10
19
26
23
18
5
17
8
20
E
9
16
XXX
5
11
34
10049
78-00-00 page 10
February 01/2015
BRP-Rotax
Maintenance Manual
3.3) Inspection of the exhaust system and turbocharger components
(only on the 914 Series)
See Fig. 78-3
Visual inspection of all components.
■ CAUTION: Because of the high thermal stress, inspect the complete exhaust system especially for crack formation.
3.3.1) Exhaust bend and exhaust manifold
Visual inspection of all components.
The wear on the walls of the slide seats on the exhaust bend and the exhaust manifold must not exceed approx. 0.3 mm (0.01 in.). See
Fig. 78-7
■ CAUTION: On older engine versions, observe SB-914-017.
On newer versions, 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 older design, it is not possible to replace individual parts.
If it becomes necessary to replace one exhaust bend or exhaust manifold, all 4 exhaust bends including exhaust manifolds must be replaced. See SI-914-022, “Running modifications”, latest issue.
3.3.2) Muffler:
■ CAUTION: When inspecting the muffler, also observe SB-914-
006, “Employment of a muffler of reduced noise emission“, latest issue. SB-914-015, “Checking or replacement of the exhaust muffler of reduced noise emission“, latest issue. SB-914-017, “Checking or replacement of exhaust bend“, latest issue and SB-914-028,
“Inspection of exhaust muffler“, latest issue.
Effectivity 914 Series
Edition 1 / Rev. 4
78-00-00 page 11
February 01/2015
BRP-Rotax
Maintenance Manual
3.3.3) Turbocharger
See Fig. 78-4 up to Fig. 78-14
Visual inspection of the turbocharger.
◆ NOTE: The turbocharger is handled as a complete unit, i.e. no spare parts are available from BRP-Rotax. In the event of damage, the complete unit has to be replaced.
a) Check plan surface of the tubine opening
See Fig. 78-4
Use a straight edge to test for distortion. A 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 the appendix.
TC03
Fig. 78-4
08463
1
2
Effectivity 914 Series
Edition 1 / Rev. 2 b) Check threaded hole for damage
See Fig. 78-4
■ CAUTION: It is not allowed to repair any of the threads (2) inside of the turbine housing with thread inserts.
c) Check rotor turbine for clearance
See Fig. 78-5
Apply slightly a radial pressure onto the shaft to minimize the gap between the compressor casing and the compressor wheel. The gap must never be less than 0.1 mm (0.004 inch). Check the complete circumference of 360°.
78-00-00 page 12
July 01/2008
BRP-Rotax
Maintenance Manual
Fig. 78-5 Fig. 78-6
08467
08468 d) Check compressor wheel for clearance
See Fig. 78-6
Apply slightly 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 movement. If it does not move freely, lubricate the axle of the wastegate with LOCTITE Anti-Seize 8151,
ROTAX part no. 297434.
Effectivity 914 Series
Edition 1 / Rev. 2
Fig. 78-7
08463
78-00-00 page 13
July 01/2008
BRP-Rotax
Maintenance Manual
■ CAUTION: On older engine versions, also observe SB-914-005,
“Introduction of a turbo charger with a modified wastegate“, latest issue.
e) Axial- and Radial- clearance charger shaft
See Fig. 78-8
Record the readings in the appendix.
TC01
TC02
Fig. 78-8
08465
08466
Effectivity 914 Series
Edition 1 / Rev. 2 f) Testing the impeller 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.
Consisting of:
2 pressure gauges
1 orifice jet (inner diameter = 1 mm (.039 in.) / length = 3 mm
(.12 in.)
1 connecting nipple M12x1.5
for the thread in the middle section of the turbocharger
1 cover plate for the oil outlet n.B. connecting hoses
Procedure:
Screw in the connecting nipple and close the oil outlet with the cover plate.
Connect the pressure gauges together with the regulating valves.
78-00-00 page 14
July 01/2008
Fig. 78-9
08462
BRP-Rotax
Maintenance Manual
Apply a constant pressure 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 changed slightly during the check, i.e. the shaft should be moved backwards and forwards in axial and radial directions.
Effectivity 914 Series
Edition 1 / Rev. 2
78-00-00 page 15
July 01/2008
BRP-Rotax
Maintenance Manual
3.4) Assembly of the complete exhaust system (on the 912 Series)
■ CAUTION: For assembly, observe the exhaust system and aircraft manufacturers´ instructions.
3.5) Assembly of the complete exhaust system incl. turbocharger (on the
914 Series)
See Figs. 78-3, 78-10 and 78-11.
Turbocharger / turbocharger bracket / exhaust manifold
Release and remove the 3 upper hex. screws (20) M8x16 on the turbine housing, but only slacken the lower screw.
Place the turbocharger bracket (16) on the outer side of the retaining ring in position and loosely attach with the allen 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
(53 in.lb).
Attach muffler (12) with washers and M8 nuts (14) on turbine housing. Screw the support plate (15) onto the turbine housing with the washer and nut (14) M8.
Attach turbocharger bracket (16) to the support plate with washer and hex. screw
(13) M8x16 and tighten screw slightly.
Tighten muffler attachment nuts M8 to 25 Nm (18.5 ft.lb).
Fit the exhaust manifold (21) onto turbine housing using allen screws (22)
M8x25 and tighten slightly with M8 nuts (23).
■ CAUTION: The attachment screws for exhaust manifold and turbocharger bracket are not tightened until installation on the engine is complete to prevent locking up of stresses.
Installation of the check valve. See 79-00-00.
Effectivity 912/914 Series
Edition 1 / Rev. 2
78-00-00 page 16
July 01/2008
BRP-Rotax
Maintenance Manual
Engine suspension frame / exhaust system assembly / exhaust bends
Screw the engine suspension frame (1) to the engine housing with the lock washers and the allen screw M10x110 (3) and M10x35 (4). See Fig. 71-10 and
71-11 in 71-00-00.
Place distance sleeve (29) 10.5/17/15 into left arm of engine suspension frame and attach exhaust bracket on engine housing (7) with washer, lock washer and allen screw (27) M10x50.
Re-establish attachment (28) exhaust bracket engine suspension frame (not supplied with engine). Tightening torque as specified by the fuselage manufacturer.
Place distance sleeve (10) 10.5/17/15 into right arm of engine suspension frame.
Screw turbocharger assembly to the holder (26) on the engine housing, complete with muffler and turbocharger bracket with washer, lock washer and allen screw
(8) M10x50 and allen screw M8x50 (25). The muffler is attached to the exhaust bracket with the tension clamp (6) tightened to a torque of 15 Nm (133 in.lb).
■
CAUTION: Position tension clamp so that the tension free zone (33) comes to rest on the edge of the exhaust bracket. See Fig. 78-10.
Re-establish attachment (9) turbocharger bracket engine suspension frame (not supplied with engine). Tightening torque as specified by the aircraft manufacturer.
Fig. 78-10
Effectivity 914 Series
Edition 1 / Rev. 2
00095
33
6
78-00-00 page 17
July 01/2008
BRP-Rotax
Maintenance Manual
Tightening torque of the M10 screws = 40 Nm (30 ft.lb).
Reconnect the two oil lines for turbocharger on the oil pump.
See 79-00-00.
◆ NOTE: If the location 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 assembly easier, LOCTITE Anti-Seize can be applied on the labyrinth end (36). See Fig. 78-11
The connecting ends (35) of the exhaust manifold must overlap the pleat of the labyrinth end by at least 5 mm (.197 in.) at each of the 4 exhaust bends. See
Fig. 78-11
■ CAUTION: All 4 exhaust bends must be fitted free of stress and must not be damaged during installation.
After completion of installation as described, all the screw connections on the turbocharger bracket, exhaust manifold, exhaust bends
Fig. 78-11
35 min. 5 mm (min. 0.179 in.)
00163
36
Effectivity 914 Series
Edition 1 / Rev. 2
78-00-00 page 18
July 01/2008
BRP-Powertrain
Maintenance Manual and the tension clamp must be tightened to the specified torques.
See Fig. 78-3
Tightening torque:
Allen screws (8) M10x50 turbocharger bracket 40 Nm/ 30 ft.lb
Allen screws hex. screw
(27) M10x50
(6) M10 exhaust bracket tension clamp
40 Nm/ 30 ft.lb
20 Nm / 177 in.lb
hex. nuts (1) M8 exhaust bend flange 12 Nm / 106 in.lb
When tightening the exhaust bend flanges, ensure equal distance between flange and cylinder head from top to bottom. The flanges (2) of the exhaust bends (3) must not touch the cylinder heads. See Fig.
78-12
■ CAUTION: If the exhaust flange is deformed, it must be replaced.
After each disassembly, the lock nuts (1) must be replaced with new lock nuts M8.
■ CAUTION: In the high temperature zone of the turbocharger and exhaust system, use exclusively high grade, stainless steel screws.
3.6) Bowden cable, rope sheave and spring for wastegate control (on the 914
Series)
Fig. 78-12
1
3
00165
2
Effectivity 914 Series
Edition 1 / Rev. 3
78-00-00 page 19
October 01/2010
16
1
11
BRP-Rotax
Maintenance Manual
See Fig. 78-13
3.6.1) Disassembly
Remove tension spring (1) with a suitable tool and cut wire (2) of the
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) and pin (7) from wastegate lever (8).
Now the Bowden cable can be pulled out from the conduit.
If required, remove rope sheave (9) after removal of the allen screw (10)
M5 x 20 along with lock washer and washer.
3.6.2) Checking of the components
Fig. 78-13
1
2
17
6
10
9
11
7
8
7
08248
Effectivity 914 Series
Edition 1 / Rev. 4
6
15
15
14
18
5
4
12
3
13
78-00-00 page 20
February 01/2015
BRP-Rotax
Maintenance Manual
Visual inspection of all components. Check bowden cable for free movement.
■
CAUTION: Renew bowden cable if damaged. See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series.
Check spring engagement holes (11) for wear.
■
CAUTION: On older engine versions, observe SB-914-008.
3.6.3) Assembly and adjustment
Ascertaining the position of the servo motor:
See Figs. 78-13 and 78-14.
To ascertain 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 servo motor will remain always in position with wastegate
„closed“ . The servo motor is self locking.
Position finding is absolutely necessary for correct adjustment of the Bowden cable.
While assembling the rope sheave, interrupt the voltage supply to the TCU or unplug the 2-pin plug connection (13). Risk of destroying the servo motor if it is activated by the TCU during assembly.
Fit rope sheave as per detail A , Fig. 78-9 and secure with washer, lock washer and allen screw M5x20 (10). The rope sheave has to be fixed to prevent rotating of the output shaft when the rope sheave is tightened. Tightening torque to 6 Nm (53 in.lb).
If the cable retainer has been removed at disassembly, apply LOCTITE
648 on cable retainer (4) and press it into servo motor housing.
Effectivity 914 Series
Edition 1 / Rev. 2
78-00-00 page 21
July 01/2008
Effectivity 914 Series
Edition 1 / Rev. 2
BRP-Rotax
Maintenance Manual
Fit Bowden cable to wastegate lever with pin (7) and cotter pin (6).
Feed Bowden cable through flexible conduit (and integrated adjusting screw) (14). Using a suitable tool, fit suitable clamp (e.g. crimp clamp
(18)) for traction relief as shown in Fig. 78-13. Insert pressure spring
(5) in cable retainer (4), thread Bowden cable through and around the rope 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 adjustment set, pre-tension the pressure spring by 1 to 2 mm
(0.04 - 0.08 in.) at straightened cable with the adjustment screw at support.
Insert silicon hose 5x8 (17), length approx. 125 mm (4.92 in.), into the spring.
Engage return spring on support and spring pin (16).
■
CAUTION: To minimize wear on spring engagement holes, engage spring on spring pin, twist it by approx. one turn and engage other end of spring on support.
Secure safety wiring (2) between servo motor and traction relief so that the Bowden cable cannot escape from the cable retainer and consequently change the setting during operation.
25 mm
+5m m
Fig. 78-14
02618
78-00-00 page 22
July 01/2008
BRP-Rotax
Maintenance Manual
4.) Wear limits
Turbochar
g
er
Axi a l cle a r a nce TC01
R a di a l cle a r a nce TC02
Rework t u r b ine ho us ing fl a nge
TC0 3
0,025 0,040
0,0010 0,0016 to
0,0 8 4
0,00 33 to
0,070
0,002 8
0,056 0,074
0,0022 0,0029 to
0,127
0,0050 to
0,109
0,004 3
0,5
0,0200
08473
Effectivity 914 Series
Edition 1 / Rev. 4
78-00-00 page 23
February 01/2015
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 2
78-00-00 page 24
July 01/2008
BRP-Powertrain
Maintenance Manual
SECTION 79
LUBRICATION SYSTEM
1) Table of contents
SECTION 79
LUBRICATION SYSTEM
2.2) Main oil pump (Engine lubrication circuit) ...................................... 79-00-00 / 5
2.3) Suction pump (turbocharger oil circuit, only on 914 Series) .......... 79-00-00 / 8
2.6.1) Oil pressure indication ...................................................... 79-00-00 / 10
2.6.2) Oil temperature indication ................................................ 79-00-00 / 10
3.1.1) Oil pump removal (main and suction pump) .................... 79-00-00 / 11
3.1.2) Oil pump disassembly ...................................................... 79-00-00 / 14
3.1.3) Oil pump checking ............................................................ 79-00-00 / 15
3.1.4) Oil pump assembly (on 912 Series) ................................. 79-00-00 / 18
3.1.5) Oil pump assembly (on 914 Series) ................................. 79-00-00 / 19
3.2) Pressure check valve (only on 914 Series) ................................... 79-00-00 / 20
3.9) Temperature- and pressure observation ....................................... 79-00-00 / 26
3.9.1) Oil temperature sensor ..................................................... 79-00-00 / 26
3.9.2) Oil pressure sensor .......................................................... 79-00-00 / 27
Effectivity 912/914 Series
Edition 1 / Rev. 4
79-00-00 page 1
February 01/2015
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
79-00-00 page 2
May 01/2007
BRP-Rotax
Maintenance Manual
2) Systems description
2.1) Lubrication system
See Figs. 79-1 and 79-2.
ROTAX engine types of the 912/914 Series are equipped with a dry sump forced lubrication and a main oil pump with integrated pressure regulator. The ROTAX
914 Series has an additional suction pump for the turbocharger oil circuit.
◆
NOTE: The oil pumps are driven by the camshaft.
The main oil pump sucks the engine oil from the oil tank (1) via the oil cooler
(2) and forces it through 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 accumulates on the bottom of the crankcase and is forced back to the oil tank by the blow-by gases.
◆ NOTE: The oil temperature sensor (6) is located on the oil pump flange and measures the oil feed temperature.
The oil circuit is vented via bore (5) in the oil tank, where the blow-by gases leave the system.
On engines of the 914 Series, the turbocharger is lubricated via a separate oil line (3) from the main oil pump.
The oil emerging from the turbocharger collects in the oil sump and is pumped back to the oil tank by a separate suction pump via the oil line (4).
Effectivity 912/914 Series
Edition 1 / Rev. 0
79-00-00 page 3
May 01/2007
1
912 Series
Fig. 79-1
BRP-Rotax
Maintenance Manual
4
5
1
3
2
914 Series
Fig. 79-2
6
09160
4 3
5 6
2
Effectivity 912/914 Series
Edition 1 / Rev. 0
05017
79-00-00 page 4
May 01/2007
BRP-Rotax
Maintenance Manual
2.2) Main oil pump (Engine lubrication circuit)
See Fig. 79-3
The trochoid oil pump sucks the engine oil out of the oil tank (1) via line (2). The oil passes through the oil cooler (3) fitted on the suction side via the oil line (4) to the oil pump rotor (5) (main oil pump) , which is driven by the oil pump shaft
(6).
The pump forces the oil through the filter mat from the outside to the inside of the oil filter (7). The oil pressure from 1.5 to 5 bar (22 to 72 p.s.i.) is controlled by the pressure relief valve (8). The surplus oil returns to the oil pump rotor via the channel (9).
If the filter mat in the oil filter is completely clogged up, the pressure relief valve
(10) will open and lube oil will flow unfiltered to the individual lubrication points.
Prevent this situation by all means, using lube oil and filter as specified and carrying out punctual replacement of oil filter.
The oil will then be pumped through 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-rod (13) and the oil duct (14). The oil emerging from bore (15) lubricates the valve mechanism and flows through the oil return line (16), into the channel (17) and back to the crankcase.
Forced oil supply from oil duct (11) is also supplied to camshaft bearing (18)
CC23, main bearing (19) CC13, the conrod bearing (20) of cylinder 4 and the bronze bush (21) of the backing bearing IH01 in the ignition housing.
In the crankcase sealing surface (22), the oil enters the right crankcase half. As a result, the camshaft bearing (24) CC22, the middle main bearing (25) CC12 and the two conrod bearings (26) and (27) of cylinders 3 and 2 are lubricated via the oil duct (23). This oil duct supplies the hydraulic valve tappets and the valve mechanism of cylinders 1 and 3.
The forced oil supply then reaches the camshaft bearing (28) CC21, the main bearing (29) CC11, the conrod bearing (30) of cylinder 1 and the backing bearing
(31) GB01 in the gearbox housing. The electrical connection of the oil pressure gauge is at the oil pressure sensor (32) .
Effectivity 912/914 Series
Edition 1 / Rev. 0
79-00-00 page 5
May 01/2007
BRP-Powertrain
Maintenance Manual
On the ROTAX 912/914 Series, which is equipped with a hydraulic governor, the governor (35) is supplied with the required forced oil via oil line (33). From the governor flange (34), the oil flows to the gear pump in the governor, which raises the pressure to approx. 23 bar (330 p.s.i.). According to the lever position of the governor, oil is pumped via oil duct (36) and through oil inlet flange (37) and into the hollow propeller shaft (38) to the variable pitch propeller 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 to the bottom of the crankcase (40) and is pressed back into the oil tank by the crankcase gases
(blow-by – gases) via the ring hose nipple (41) and the oil return line (42). The tangential feed of the returned oil effects separation of oil from air via the screen
(43). As a result, the intake system (2) is supplied with oil which is to a large extent free of air.
The oil tank is vented via the connection (44) into a suitable container or to the outside.
For oil change, the oil is drained by removing drain plug (45).
◆
NOTE: Only on 914 Series: Oil pump rotor (46) of the pump.
suction oil
Effectivity 912/914 Series
Edition 1 / Rev. 3
79-00-00 page 6
October 01/2010
912 Series
914 Series
Fig . 79-3
38
BRP-Rotax
Maintenance Manual
34 35
39
36
37
33
3
2
31
29
30
25
20
4
44 9
8
10 7
42
5
46
32
28
27
24
26 19
23
6
11
40
41
12
13
18
17
16
00130
14 15
21
22
45
1
43
Effectivity 912/914 Series
Edition 1 / Rev. 0
79-00-00 page 7
May 01/2007
BRP-Powertrain
Maintenance Manual
2.3) Suction pump (turbocharger oil circuit, only on 914 Series)
See Fig. 79-4
The suction pump (11) is of the same design as the main oil pump (12) and sits on the extended common pump shaft (15).
The lubrication of the turbocharger shaft, which is supported on plain bearings, is via a separate oil line (2) from the main oil pump.
The choke valve (3) on the entry into the turbocharger housing prevents flooding of the turbocharger (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 almost unhindered to the bearing bore. Without oil pressure the valve closes and stops the oil flow.
■ CAUTION: Oil loss combined with heavy smoke emission at engine start is a strong indication of a defective check valve.
The oil emerging from the bearing bore collects in the oil sump (8). From there, it is sucked off by the suction pump (11) via a separate line (9) and pumped back to the oil tank via the ring hose nipple (10).
◆
NOTE: The suction pump is also a trochoid pump and, like the main oil pump (12), is driven by the common oil pump shaft.
Effectivity 912/914 Series
Edition 1 / Rev. 3
79-00-00 page 8
October 01/2010
BRP-Powertrain
Maintenance Manual
Fig . 79-4
11
9
10
TO O
ZUM
12
2
Legend to Fig. 79-4:
(1) Turbocharger
(2) Pressure oil line (turbocharger)
(3) Pressure valve
(4) Valve housing
18
(5) Pressure spring
(6) Ball ø 5.5 mm (0.22 in.)
(7) Banjo bolt
(8) Oil sump
(9) Suction line (turbocharger)
(10) Ring hose nipple
(11) Suction pump
(12) Main oil pump (pressure oil pump)
(13) Oil pump housing (main oil pump)
(14) Oil pump housing (suction oil pump)
(15) Oil pump shaft
(16) Oil feed line
(17) Oil pressure sensor
(18) Oil filter
(19) Pressure relief valve
Effectivity 912/914 Series
Edition 1 / Rev. 4
19 zum hydr. Verstellregler
(optional) to hydr. governor
17
912 Serie
914 Serie
912 Series
914 Series
UF
OELZULA
OIL INLET
16
15
13
1
2
7
6
5
3
4
00131
9
8
10052
79-00-00 page 9
February 01/2015
BRP-Powertrain
Maintenance Manual
2.4) Magnetic plug
See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series.
◆
NOTE: It is possible to repair the thread of the magnet plug of the crankcase with a helicoil. See section 8.7 of the overhaul manual.
2.5) Drain plug
See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series.
2.6) Connections for instrumentation
■ CAUTION: Consult also the relevant section in the Installation Manual.
2.6.1) Oil pressure indication
Via an electric resistance pick-up attached on oil pump housing with connection to indicating instrument.
2.6.2) Oil temperature indication
The sensor for the oil temperature is fitted in the oil pump housing. The sensor is a thermo switch with changing internal resistance according to oil temperature.
Effectivity 912/914 Series
Edition 1 / Rev. 3
79-00-00 page 10
October 01/2010
BRP-Powertrain
Maintenance Manual
3) Maintenance
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see corresponding
Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or
914 Series, and the systems descriptions given hitherto. The description is subdivided into subsections and descriptions of the function of the various systems.
3.1) Oil pump
3.1.1) Oil pump removal (main and suction pump)
See Figs. 79-5 and 79-6.
Drain oil.
Remove oil line from screw socket (11,13,14) (feed). Remove both banjo bolts (36) from the suction pump and remove sealing rings (28).
◆ NOTE: The suction oil line (34) and the ring hose nipple (35) need not be removed.
Remove banjo bolt (36) and take off sealing rings (28). Also remove the distance sleeve (31) (configuration 2 / 4). On configuration 3, the pressure oil line (30) to the governor should be removed for easier disassembly. Same procedure on pressure oil line (32) to the turbocharger.
Remove oil filter (8) with oil filter wrench, part no. 877620
Release 4 allen screws (27) (on 912 Series: M6x50 on 914 Series:
M6x65) with lock washers and take off complete oil pump unit with
2x O-rings (25) 11x2.7 and (24) 1 x 30x2.5.
◆ NOTE: Suction pump only on ROTAX 914 Series!
Effectivity 912/914 Series
Edition 1 / Rev. 4
79-00-00 page 11
February 01/2015
BRP-Powertrain
Maintenance Manual
Fig. 79-5
912 Serie
912 series
OEL ZULAUF
OIL INLET
ZUM HYDR. REGLER
TO HYDR. GOVERNOR
Effectivity 912/914 Series
Edition 1 / Rev. 4
B .... LOCTITE 243
C .... LOCTITE 648
L .... KLUEBER ISOFLEX TOPAS Nb5051
O .... ENGINE OIL
79-00-00 page 12
February 01/2015
Fig. 79-6
914 Serie
914 series
BRP-Powertrain
Maintenance Manual
OEL ZULAUF
OIL INLET
ZUM HYDR. REGLER
TO HYDR. GOVERNOR
TURBO
DRUCK /
PRESSURE
Effectivity 912/914 Series
Edition 1 / Rev. 4
TANK
TANK
TURBO
RÜCKLAUF / RETURN LINE
B .... LOCTITE 243
C .... LOCTITE 648
L .... KLUEBER ISOFLEX TOPAS Nb5051
O .... ENGINE OIL
79-00-00 page 13
February 01/2015
BRP-Powertrain
Maintenance Manual
3.1.2) Oil pump disassembly
See Figs. 79-5 and 79-6.
◆ NOTE: The oil filter nipple (7), screw socket M18x1.5/M14x1.5
(11,13,14), oil temperature sensor (37) and oil pressure sensor (8) are only removed if required, e.g. in the event of damage or for cleaning.
Remove screw plug (6), adjusting shim (5), pressure spring (4) and ball
8.5 mm (0.33 in.) (2) of oil pressure release valve.
◆
NOTE: The adjusting shim is only fitted if required to reach the specified oil pressure.
On the 912 Series :
Remove the oil pump cover (23), needle pins (22), pressure inner and outer rotor (17) and O-ring 46x3 (18). Take out needle pin (16) and pull out oil pump shaft (15) with pressed in drive pin.
On the 914 Series :
Remove the suction pump cover (23), needle pins (22), suction inner and outer rotor (20) and O-ring 46x3 (21). Take out needle pin (16) .
Remove oil pump housing (19) of the suction pump, pressure inner and outer rotor (17) and O-ring 57x3 25G (18) of main oil pump.
Take out last needle pin (16) and pull out oil pump shaft (15) with pressed in drive pin.
◆ NOTE: Only on 914 Series:
Suction inner and outer rotor (20), O-ring (21) 46x3, needle pin (18) and oil pump housing (19).
Effectivity 912/914 Series
Edition 1 / Rev. 4
79-00-00 page 14
February 01/2015
BRP-Rotax
Maintenance Manual
3.1.3) Oil pump checking
See Figs. 79-7, 79-8, 3179-9, 79-10, 79-11, 79-12 and 79-13.
Visually check all components of oil pump.
Check inside (1) of oil pump cover with a straightedge (2) for wear.
Check all revolving rotors of pump. If there are noticeable furrows on mating faces of rotor inside (3) and revolving piston outside (4), replace both components.
Insert revolving pistons and rotors into their respective housings.
Only on 914 Series:
Check the gap dimension (OP01) ( suction oil pump ) between crankcase flange surface — revolving piston crankcase flange surface — pump 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 pump capacity.
Check sealing surfaces of both oil pump housings and pump cover, resurface on an even surface plate if necessary.
Check pump shaft at the bearing bores (8).
◆ NOTE: If there is still an older model oil pump shaft fitted on engines 912 A and 912 UL (identifiable by the roll pin on the pump shaft) the shaft must be replaced in accordance with SB-912-032 “Replacement of oil pump assy. or oil pump shaft assy“, latest issue.
Remove screw plug (9), pressure spring (10) and ball (11), clean and check ball seat (12) in pump housing. The compensating shim (13) is only fitted if required to reach specified oil pressure.
Clean all parts and clear oil bores with compressed air.
Effectivity 912/914 Series
Edition 1 / Rev. 0
79-00-00 page 15
May 01/2007
912 Series
On new engine models
Fig. 79-7
BRP-Rotax
Maintenance Manual
912 Series
On older engine models
Fig. 79-8
Effectivity 912/914 Series
Edition 1 / Rev. 0
05156
00073
2
1
Fig. 79-9
05152
8
8
914 Series
8
00076
Fig. 79-10
79-00-00 page 16
May 01/2007
BRP-Rotax
Maintenance Manual
Fig. 79-11
14
15
4
3
4
3
6
7
00076
Fig. 79-12
00071
11
10
13
9
12
Fig. 79-13
80
90
0
10
20
70
60
2
1 0
9
8
7
50
0.01mm
30
40
5
00074
15
7 6
14
Effectivity 912/914 Series
Edition 1 / Rev. 0
79-00-00 page 17
May 01/2007
BRP-Rotax
Maintenance Manual
3.1.4) Oil pump assembly (on 912 Series)
See Fig. 79-5
Lubricate bearing bore for pump shaft in oil pump housing with engine oil and install pump shaft (15). Push needle pin (16) 4x15.8 into the pump shaft (15), insert suction inner and outer rotor (17) and turn the pump shaft to check it. Fit the 2 outer O-rings (25) 11-2.7 and O-ring (24)
30-2.5 in the oil pump housing and fit it to the crankcase.
◆
NOTE: Turn oil pump shaft so that the drive pin engages in the groove of the camshaft.
◆ NOTE: Models from the year 1995 onwards have a suction inner and outer rotor of height 16 mm (0.63 in.) instead of 13 mm (0.51 in.).
◆ NOTE: Apply LOCTITE 5910 to the crankcase in the area of the split line between the two crankcase halves.
Push both needle pins (22) 4x15.8 into the pump housing, insert O-ring
(18) 57-3 and tighten oil pump cover (23) crosswise by hand evenly with allen screws (27) M6x50 and lock washers. After this tighten allen screws (27) crosswise. Tightening torque 10 Nm (90 in.lb).
Fit ball 8.5 mm (0.33 in.) (2), pressure spring (4) 39.5 mm (1.55 in.) and screw plug (6) M12x1 and secure with wire. Tightening torque with oiled thread 15 Nm (133 in.lb).
◆ NOTE: The adjusting shim (5) is not supplied as standard equipment. It is only fitted if a test run reveals that the oil pressure is too low.
If the oil filter nipple (7) has been removed, retighten to 60 Nm (44.3 ft.lb).
Slightly lubricate the rubber seal for oil filter (8) with engine oil. Screw oil filter on by hand until it touches the oil filter housing. Then tighten by an extra 3/4 turn.
◆ NOTE: Depending on the model, a hose nipple or a screw socket for either a metric connection or a UNF thread is installed.
Tighten the ring hose nipple with 15 Nm (133 in.lb). In the case of a model with a screw socket tighten with 25 Nm (18.5 ft.lb). Tighten oil temperature sensor (37) with LOCTITE 243 and a torque of 7 Nm (62 in.lb). Grease the thread of the banjo bolt (36) and tighten with 12 Nm
(105 in.lb). Apply LOCTITE 243 on plug screw (29) and tighten with a torque of 10 Nm (90 in.lb).
Effectivity 912 Series
Edition 1 / Rev. 4
79-00-00 page 18
February 01/2015
BRP-Powertrain
Maintenance Manual
3.1.5) Oil pump assembly (on 914 Series)
See Fig. 79-6
Lubricate bearing bore for pump shaft in oil pump housing with engine oil and install pump shaft (15).
Push needle pin (16) 4x15.8 into the pump shaft, insert oil pump piston with rotor (17) in main oil pump and turn pump shaft to check it.
Insert O-ring (18) 57-3 and push on oil pump housing (19), push second needle pin (16) 4x15.8 into the pump shaft, insert suction inner and outer rotor (28) of the suction pump. Rotate the pump shaft again to check it.
◆ NOTE: Apply LOCTITE 5910 to the crankcase in the area of the split line between the two crankcase halves.
Push both needle pins (22) 4x29.8 through the two pump housings and insert O-ring (21) 46-3. Fit the 2 outer O-rings (25) 11-2.7 and O-ring (24)
30-2.5 in the oil pump housing and fit it to the crankcase.
◆ NOTE: Turn oil pump shaft until the drive pin engages in the camshaft. Tighten oil pump cover (23) crosswise and by hand evenly with allen screws (27) M6x65 and lock washers. After this tighten allen screws (27) crosswise.
Tightening torque with oiled thread 10 Nm (90 in.lb).
Fit ball 8.5 mm (0.33 in.) (2), pressure spring (4) 39.5 mm (1.55 in.) long and screw plug (6) M12x1. Tighten oiled thread with a torque of 15 Nm
(133 in.lb).
■ CAUTION: The adjusting shim (5) is not supplied as standard equipment. It is only fitted if a test run reveals that the oil pressure is too low.
If the oil filter nipple (7) has been removed, retighten it to 60 Nm (44.3
ft.lb). Slightly lubricate the rubber seal for oil filter (8) with engine oil.
Screw on oil filter by hand until it touches the oil filter housing. Then tighten oil filter by an extra 3/4 turn.
◆
NOTE: Depending on the model a hose nipple or a screw socket for either a metric connection or a UNF thread is installed.
Effectivity 914 Series
Edition 1 / Rev. 4
79-00-00 page 19
February 01/2015
BRP-Powertrain
Maintenance Manual
Tighten the ring hose nipple with 15 Nm (133 in.lb). In the case of a model with a screw socket tighten with 25 Nm (18.5 ft.lb). Tighten oil temperature sensor (36) with LOCTITE 243 and a torque of 7 Nm (62 in.lb).
Also fit oil pressure sensor (9) secured with LOCTITE 243. Tightening torque 15 Nm (133 in.lb). Grease the threads of the banjo bolts (33) and
(36) and tighten with 12 Nm (106 in.lb).
3.2) Pressure check valve (only on 914 Series)
See Fig. 79-14.
Remove banjo bolt (1) M8 with sealing rings (2) 8x13.
◆ NOTE: The valve 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 as a pressure check valve. For further information, see 79-00-00 sec. 2.3. At present it is possible to control the pressure check valvue by testing for an opening pressure (via oil) of 0.4 bar (+/
- 0.05)
Clean all components and inspect them visually.
Also check thread and flange surface of turbocharger housing.
If there is leakage at the valve seat (6), it can be reworked with valve lapping paste or other suitable method. If necessary, replace banjo bolt.
Reassembly in reverse order.
Screw valve housing (3) with sealing ring (7) 12x18 into turbocharger housing and tighten to 25 Nm (18.5 ft.lb).
1
8
4
00075
3
7
5
2
6
Fig. 79-14
Effectivity 914 Series
Edition 1 / Rev. 4
79-00-00 page 20
February 01/2015
BRP-Powertrain
Maintenance Manual
■ CAUTION: If the ball (4) installed under the pressure spring (5), the oil circuit is interrupted and the turbocharger will be destroyed.
Insert pressure spring (5) and ball (4).
The pressure oil line (8) is attached with the banjo bolt (1) and sealing rings (2) on both sides. Tightening torque 10 Nm (90 in.lb).
◆ NOTE: For recognition the banjo bolt is either marked with a blue color or reads the label “OIL”.
3.3) Oil sump (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 the turbo oil suction line (3). Remove the 2 allen screws
(4) M6x55 and take off cable support (5), oil sump (1) and O-ring (6) 9x2.3.
Clean all components and check them visually. Also check thread and flange surface of turbo charger housing. In the event of damage, replace oil sump.
Reassembly in reverse order.
The oil sump (1) is attached with the O-ring (6), cable support (5) and 2 allen screws (4) M6x55.
Tighten collar nut (2) of the turbo oil suction line to 20 Nm (180 in.lb).
Secure the allen screws (4) with wire.
Fig. 79-15
00075
5
6
1
2
3
4
Effectivity 914 Series
Edition 1 / Rev. 3
79-00-00 page 21
October 01/2010
BRP-Rotax
Maintenance Manual
3.4) Oil tank
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 Maintenance“ for the respective engine type.
Fig. 79-16
11
9
15
10
12
4
5
13
1
2
6
3
Effectivity 912/914 Series
Edition 1 / Rev. 0
14
8
00077
7
79-00-00 page 22
May 01/2007
BRP-Rotax
Maintenance Manual
3.5) Oil lines (steel lines)
See Figs. 79-17 and 79-18.
The steel oil lines are only removed in the event of damage or for cleaning.
Governor pressure oil line (1) to hydr. governor disassembly
Remove the cable clamp (2) for cable support from the side of the gearbox.
Remove banjo bolt (3) M10 with sealing rings from governor flange. Then release the banjo bolt (4) on the oil pump housing and take off the 3 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) ø 8/M5 and 2 cable lamps (7)
ø5/M5.
Remove banjo bolt (8) with sealing rings.
■ CAUTION: Make sure that the ball (9) and the spring (10) of the pressure check valve are not damaged or lost.
Turbo oil suction line (11) (only on 914 Series ) disassembly
The suction oil line is additionally supported on the turbocharger bracket by a cable clamp. Remove it before disassembly.
Remove banjo bolt (12) M10 with sealing rings from the suction oil pump and the collar nut (13) from the oil sump.
Clean all lines and inspect them visually. Check for free passage.
Effectivity 912/914 Series
Edition 1 / Rev. 0
79-00-00 page 23
May 01/2007
BRP-Rotax
Maintenance Manual
Reassembly of the lines in reverse order.
■ CAUTION: Pay attention that the lines are fitted free of stress and without scouring. Respect minimum distances, e.g. 2 mm (0.08 in.) from housing.
■ CAUTION: On the 914 Series, it is important to ensure that a shim distance ring (part no. 847224) is fitted between the cable clamp (14) and the gearbox housing.
Tightening torques: banjo bolts M10 banjo bolts M8
- 17 Nm (150 in.lb)
- 10 Nm (90 in.lb) collar nuts (13) hex. screws M8x20 (14)
(secure with LOCTITE 243).
- 20 Nm (180 in.lb)
- 15 Nm (135 in.lb) screw plug M12x1 (16)
◆ NOTE:
- 25 Nm (18.5 ft.lb)
On configuration 2 and 3, a distance sleeve (15) 10.5/15/10 is fitted instead of the governor oil line (1).
Fig. 79-17
4 zum hydr. Verstellregler
(optional) to hydr. governor
5
15 1
Fig. 79-18
Ölzulauf oil inlet
0-1 bar
0
11
12 zum Öltank to oil tank
14
2
6
00082
8
1
16
7
9
10
3
00083
13
Effectivity 912/914 Series
Edition 1 / Rev. 0
79-00-00 page 24
May 01/2007
BRP-Rotax
Maintenance Manual
3.6) Oil lines
■ CAUTION: The oil lines not supplied with the engine must be maintained as per aircraft manufacturers specifications.
In addition the following maintenance work should be performed:
Clean oil feed line from oil tank to oil cooler and to oil pump and check visually.
The same applies to the oil return lines. Pay special attention to the line ends.
For replacement, only use genuine, certificated tubes. For attachment of the tubes use suitable screw 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. Maintenance must be performed in accordance with the aircraft manufacturers instructions .
In addition the following maintenance work should be done:
Clean oil cooler fins and straighten them, if necessary. Rinse the oil cooler inside.
■ CAUTION: It is absolutely necessary after an engine damage, swarf in oil filter and on the magnetic plug to replace the oil cooler.
Carry out visual inspection of the oil cooler body and the connections. Pressure test with 3 bar (43.6 p.s.i) in a water bath to check for leaks.
See also latest issue Maintenance Manual "Line Maintenance“ for the respective engine type.
Effectivity 912/914 Series
Edition 1 / Rev. 0
79-00-00 page 25
May 01/2007
BRP-Powertrain
Maintenance Manual
3.8) Purging of lubrication system
See the corresponding section in the respective Maintenance Manual (Line
Maintenance) for the engine type, 912 Series or 914 Series.
3.9) Temperature- and pressure observation
See the corresponding Maintenance Manual (Line Maintenance) for the respective engine type, 912 Series or 914 Series.
◆ NOTE: The engines of the 912 Series and 914 Series have several temperature control points. Refer to wiring diagram in Operators 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 and identical with the two sensors for the cylinder head temperature.
The max. operating temperatures must not be exceeded. In the event of temperature rise above the limit, check the following:
the oil system (see corresponding Maintenance Manual (Line
Maintenance) for the respective engine type, 912 Series or 914
Series.)
temperature sensor
indicating instrument
wiring connections
sensor cable.
◆ NOTE: Grounding connection of the sensors direct via the oil pump housing.
Fit sensor. See 79-00-00 sec. 3.1.
Fig. 79-19
09489
Effectivity 912/914 Series
Edition 1 / Rev. 4
1
79-00-00 page 26
February 01/2015
BRP-Powertrain
Maintenance Manual
3.9.2) Oil pressure sensor
See Figs. 79-20, 79-21, 79-22 and 79-23.
The sensor for measurement of the oil pressure is screwed into the oil pump housing.
The range of the sensor is from 0 to 10 bar (0 to 145 p.s.i) This range (3) is indicated on the wrench flats of the sensor.
■ CAUTION: For this reason, the pressure range of the display instrument must be adjusted to the pressure range of the sensor. If this is not done, an incorrect oil pressure will be displayed.
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.
New oil pressure sensor part no. 456180
Tightening torque: 15 Nm (133 in.lb).
No LOCTITE - seals with gasket ring (1).
Effectivity 912/914 Series
Edition 1 / Rev. 4
79-00-00 page 27
February 01/2015
BRP-Powertrain
Maintenance Manual
Sensor characteristic curve:
Fig. 79-20
08591
Retrofitting of oil pressure sensor part no. 956413 and part no. 956357
location: oil pump housing
wiring connection for instrument.
(see fig. 79-20)
In contrary to the oil pressure sensor part no. 956413 and part no.
956357 the new oil pressure sensor part no. 456180 is equipped with a connector. As output signal the 2-wire version (4 to 20 mA) is available. Oil pressure sensor PIN A (connector housing PIN 1) is not connected and has no function.
■ CAUTION: To prevent the ingress of dampness into the connector housing, the free hole in the connector housing has to be closed with LOCTITE 5910, Silicone adhesive or similar.
Oil pressure sensor PIN B (connector housing PIN 2) has to be connected to the positive bus via a fuse or circuit breaker (the Red lead from the current oil pressure sensor). Oil pressure sensor PIN C
(output signal) (connector housing PIN 3) has to be connected directly to the indicating instrument. For connection to the indicating instrument a connector set or oil pressure sensor wire assy. is available. See
Ilustrated Parts Catalog (IPC).
◆ NOTE: The sensor cable can be modified in its length according to the installation situation, e.g. shortened or extended.
For extension an appropriate cable (Ölflex
â
Heat 260
Effectivity 912/914 Series
Edition 1 / Rev. 4
79-00-00 page 28
February 01/2015
BRP-Powertrain
Maintenance Manual
MC 2x 0.5 mm 2 (AWG 20) or equivalent) can be used. A resistance cable or similar is not necessary.
wire gauge: stranded wire, 0.5 mm
operating temperature range:
2 (AWG 20) min.: - 25 °C (-13 °F) max.: + 125 °C (+ 257 °F)
■
CAUTION: The sensor characteristic has been determined, and is effective at the following conditions only (see fig. 1).
ambient temperature: 20 °C ( 68 °F) tolerance: ± 4%
tightening torque: 15 Nm (98 in.lb) and LOCTITE 243
Replacement of the current oil pressure sensor part non. 956413 and part no. 956357 by part no. 456180
Parts requirement: oil pressure sensor part no. 456180 and oil pressure cable assy. part no. 864250.
■ CAUTION: Take care which oil pump housing is mounted. The part number is shown on the housing.
Oil pump housing part no. 911815 and part no. 911810
1. Remove the oil pressure sensor part no. 956413.
2. Install new oil pressure sensor part no. 456180 with LOCTITE 243.
Tightening torque 15 Nm (98 in.lb)
Oil pump housing part no. 811809
New oil pressure sensor part no. 456180 cannot be installed. Oil pump housing must be replaced or the threads must be recut.
1. Remove the oil pump housing in accordance with the relevant
Maintenance Manual (Heavy).
Option A: Replace oil pump housing
Replace oil pump housing.
Option B: Rework of the oil pump housing
Recut threads with M10x1 thread tap.
■ CAUTION: Clean the thread completely from swarf.
2. Install the oil pump housing in accordance with the relevant
Maintenance Manual (Heavy).
Effectivity 912/914 Series
Edition 1 / Rev. 4
79-00-00 page 29
February 01/2015
(
BRP-Powertrain
Maintenance Manual
3. Install new oil pressure sensor part no. 456180 with LOCTITE 243.
Tightening torque 15 Nm ( 98 in.lb).
▲ WARNING: Certification to the latest requirements such as FAR or
EASA has to be conducted by the aircraft manufacturer.
Old version: part no. 956357
07226
Fig. 79-21
◆
NOTE: Grounding connection of the sensor is direct via the oil pump housing.
For sensor resistance see following graph showing sensor resistance over pressure. Compare pressure gauge with a calibrated instrument.
■
CAUTION: The graph resistance over pressure has been determined, and is effective at the following conditions only.
ambient temperature:
voltage: deviation:
20 °C (68 °F)
12 V max ± 5%
After removal of oil pressure sensor, clean the thread. Apply LOCTITE
243 to thread of sensor and tighten to 15 Nm (133 in.lb).
(
Ω
) 200
150
100
50
0
2 4 6 8 10
(bar)
00229
Fig. 79-22
Effectivity 912/914 Series
Edition 1 / Rev. 4
79-00-00 page 30
February 01/2015
BRP-Powertrain
Maintenance Manual
Old Version: part no. 956413
◆ NOTE: Grounding connection of the sensor is direct via the oil pump housing.
40,4 mm
(1.59 in.)
4,8 mm
(0.19 in.)
1/8” - 27 NPT
L~3 m l~ 118 in.
26,6 mm
(1 1/16”)
Fig. 79-23
08370
L~150 mm l~ 6 in.
In contrary to the oil pressure sensor part no. 956357 offered up to now, the new oil pressure sensor operates on basis of a current variation.
operating temperature range: min.: - 40 °C (-40 °F) max.: + 125 °C (+ 257 °F)
grounding: via engine block/airframe ground
■ CAUTION: The graph current over pressure has been determined, and is effective at the following conditions only.
ambient temperature: 20 °C (68 °F)
tolerance: ± 5%
tightening torque: 15 Nm (98 in.lb) and LOCTITE 234
(mA) 25
20
15
10
5
0
Effectivity 912/914 Series
Edition 1 / Rev. 4
2 4 6 8 10
(bar)
79-00-00 page 31
February 01/2015
BRP-Powertrain
Maintenance Manual
The sensor cable is approx. 3 m long and has 3 leads. The Black lead is not to be connected and has no function. The Red lead from the sensor has to be connected to the positive bus via a fuse or circuit breaker. The White lead
(output signal) has to be connected directly to the instrument. See also the relevant instructions of the instrument supplier/aircraft manufacturer for correct connection and wiring.
4) Wear limits
80
90
0
10
20
70
60
2
3
1 0 9
8
4 5 6
7
50
0.01mm
40
30
Fig. 79-24
00229
Reading new
Description min
Oil pump
Clearance main pump (pump cover/ rotor)
OP01
Clearance suction pump (pump cover / rotor)
OP01
0,00
0,0000
0,00
0,0000 max
0,05
0,0020
0,05
0,0020 wear limit
100%
0,20
0,0079
0,20
0,0079 wear limit
50%
0,13
0,0049
0,13
0,0049 actual renewed actual renewed
07429
Effectivity 912/914 Series
Edition 1 / Rev. 4
Readings
79-00-00 page 32
February 01/2015
BRP-Rotax
Maintenance Manual
SECTION 80
ELECTRIC STARTER
1) Table of contents
SECTION 80
ELECTRIC STARTER
1) Table of contents .................................................................................... 80-00-00 / 1
2) Systems description ................................................................................. 80-00-00 / 3
2.1) Electric starter ............................................................................... 80-00-00 / 3
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 ............................................................... 80-00-00 / 7
3.2.2) HD starter ......................................................................... 80-00-00 / 8
3.3) Electric starter — inspection of individual parts ............................ 80-00-00 / 9
3.4) Electric starter — reassembly ....................................................... 80-00-00 / 11
3.5) Electric starter — installation ........................................................ 80-00-00 / 12
3.5.1) Standard starter ............................................................... 80-00-00 / 12
3.5.2) HD starter ......................................................................... 80-00-00 / 12
4) Wear limits .............................................................................................. 80-00-00 / 13
Effectivity 912/914 Series
Edition 1 / Rev. 2
80-00-00 page 1
July 01/2008
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
80-00-00 page 2
May 01/2007
BRP-Rotax
Maintenance Manual
2) Systems description
2.1) Electric starter
The electric starter is a DC motor with permanent magnets and carbon brushes.
The gear-tooth system on the armature shaft is permanently engaged in the 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 the speed generated by the electric starter, the sprag clutch disengages.
See 72-00-00 sec. 3.6 and 72-00-00 sec. 3.7.
◆
NOTE: To improve startup, there is an optional HD (heavy duty) starter with increased power available. See SB-912-037 and SB-914-023
“Installation of an electric starter with enhanced power“, latest issue.
Effectivity 912/914 Series
Edition 1 / Rev. 0
80-00-00 page 3
May 01/2007
BRP-Rotax
Maintenance Manual
NOTES
Effectivity 912/914 Series
Edition 1 / Rev. 0
80-00-00 page 4
May 01/2007
BRP-Powertrain
Maintenance Manual
3) Maintenance
The following sections describe maintenance procedure for engines of the 912/914
Series above and beyond the maintenance and special checks, see corresponding
Maintenance Manual (Line Maintenance) for 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.
3.1) Electric starter dismantling
Fig. 80-1
3.1.1) Standard starter
See Fig. 80-1
◆ NOTE: In the course of continuous development and standardization the components (1), (2) and (3) in figure 80-1 were replaced by the part (10).
1
Remove the 2 hex. nuts M5 (1) with lock washers (2) and washers (3) or the cap nut (10) from the rear side of the ignition cover (8). The electric starter (6) can be removed by releasing the tension clamp (7). The electric starter is kept in position by 2 distance sleeves (4) and O-rings
(5).
◆ NOTE: When withdrawing the electric starter from the ignition housing, hold the bearing flange with starter housing and rotor bearing together. Otherwise the carbon brushes will jump off the commutator.
2
3 10
8
9
4
5
6
4
5
10050
7
Effectivity 912/914 Series
Edition 1 / Rev. 4
80-00-00 page 5
February 01/2015
BRP-Powertrain
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) or the cap nut (10) from the rear side of the ignition cover (6). The electric starter (4) can be removed by releasing the tension clamp (5).
◆ NOTE: In the course of continuous development and standardization the components (1), (2) and (3) in figure 80-2 were replaced by the part (10).
Fig. 80-2
6
1
2
3
10
9
7
4
8
10051
5
Effectivity 912/914 Series
Edition 1 / Rev. 4
80-00-00 page 6
February 01/2015
BRP-Rotax
Maintenance Manual
3.2) Electric starter — disassembly
3.2.1) Standard starter
See Fig. 80-3
Unscrew combined nut (23) and remove connector sheath (17) with Oring (19). Pull 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) with the connector sheath (17) out of the rotor bearing.
Remove brush holder (4) with the carbon brushes from the rotor (5). Pull rotor out of the starter housing together with compensating shim (6).
Clean all parts thoroughly. See 00-00-00 sec. 10.3.
22
Fig. 80-3
19
1
2
20
14
12
11
5
15
10
18
6
23
19
17
3
13 17
4
21
Effectivity 912/914 Series
Edition 1 / Rev. 0
00231
14
80-00-00 page 7
May 01/2007
21
19
BRP-Rotax
Maintenance Manual
3.2.2) HD starter
See Fig. 80-4
Unscrew combined nut (23) and remove connector sheath (17) with Oring (19). Unscrew allen screw (24) M5 and pull 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) with the carbon brushes from the rotor (5). Pull rotor out of the starter housing together with compensating shim (6).
Clean all parts thoroughly. See 00-00-00 sec. 10.3.
Fig. 80-4
6
12
5
23
17
1 19
20
11
10
18
24
3
13
16
4
17
23
2
14
14
07735
Effectivity 912/914 Series
Edition 1 / Rev. 0
80-00-00 page 8
May 01/2007
BRP-Rotax
Maintenance Manual
3.3) Electric starter — inspection of individual parts
See Figs. 80-3, 80-4, 80-5, 80-6, 80-8 up to 80-11
◆ NOTE: The following work steps apply to both starter models (HD and standard starter).
After disassembly of starter, check the following parts:
See 80-00-00 sec. 4
Rotor
Clean commutator, check for run out, carry out visual inspection, if necessary fine machine and undercut commutator ribs (7), see Fig. 80-5. The insulation should be 0.5 mm (.02 in.) lower than the ribs.
▲ WARNING: During this machining process, 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, replace rotor.
Check rotor coils for interruption at 2 or 4 Volts and an interposed ammeter
(measuring range 60 A), see Fig. 80-6. If there are great differences between the individual ribs, the rotor must be replaced. If the rotor shows clear signs of overheating, replace it.
Check ball bearing (10) 6002 Z. When replacing the rotor, fit it with the closed side facing towards the middle of the rotor (open side (11) facing outward) to prevent abraded particles penetrating the ball bearing. Inspect gear-tooth system (12) and radial clearance of the rotor in the rotor bearing (3).
Fig. 80-5
Fig. 80-6
9
7
8
00232
00233
Effectivity 912/914 Series
Edition 1 / Rev. 2
80-00-00 page 9
July 01/2008
BRP-Rotax
Maintenance Manual
Bearings
Check bearing socket (13) and if necessary, replace the complete rotor bearing.
Carbon brushes
Carbon brushes (14) must move freely 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 required.
O-rings
Replace all O-rings (19) and oil seal (20) when repairing the electric starter.
Starter housing
Carry out visual inspection of the inner magnets (21) for cracks.
Studs
Carry out visual inspection of both studs (22) or allen screws (24).
Effectivity 912/914 Series
Edition 1 / Rev. 0
80-00-00 page 10
May 01/2007
BRP-Powertrain
Maintenance Manual
3.4) Electric starter — reassembly
See Figs. 80-3, 80-4, 80-5, 80-6 and 80-7.
◆ NOTE: The following work steps apply to both starter models (HD and standard starter).
Determine the required number of compensating shims (6) for the axial clearance, see dimension (ES08) of the rotor (5).
See 80-00-00 sec. 4.
Grease oil seal (20), the 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) onto the rotor. Push compensating shims (6) onto the rotor shaft, insert the positive-pole carbon brush (23) into the rotor bearing and then fit the complete rotor bearing (3) with new O-ring 62x1.5 onto the starter housing.
◆ NOTE: Ensure correct positioning and engagement of the positioning noses.
The HD starter is screwed together with the allen screws (24) M5x180, tightened to a torque of 6 Nm (53 in.lb).
Fig. 80-7
ES08
6
Effectivity 912/914 Series
Edition 1 / Rev. 3
00234
80-00-00 page 11
October 01/2010
BRP-Powertrain
Maintenance Manual
3.5) Electric starter — installation
3.5.1) Standard starter
See Fig. 80-1
Lightly grease the centering bore (9) in the ignition housing (8). Push complete electric starter (6) with new O-rings (5) 4.7x1.4 and distance sleeves (4) into the ignition housing (8).
◆ NOTE: Take care that the electric starter is not pushed apart as you do so.
Attach electric starter with lock washer (2) A5 and hex. nut (1) M5 or only with cap nut M5 (10) to the crankcase, fix to ignition 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 ignition housing (6). Push complete electric starter (4) into the ignition housing (6). Tighten evenly with washer (3), spring (2) and hex. nut (1) or only with cap nut M5 (10) and then attach to the ignition housing with the tension clamp (5).
■ CAUTION: The allen screw (7) M5x180 is only for "internal“ attachment of the starter components. During assembly on the ignition housing, the allen screw (7) must not be turned, as the position of the rotor bearing (8) could be changed. The marks on the rotor bearing and on the starter housing must correspond.
Effectivity 912/914 Series
Edition 1 / Rev. 4
80-00-00 page 12
February 01/2015
BRP-Rotax
Maintenance Manual
4) Wear limits
◆
NOTE: The wear limits apply to both configurations of the electric starter, standard and HD.
Fig. 80-8
07449
Fig. 80-9
08474
standard configuration
07555
Fig. 80-10
ES09
ES09
Effectivity 912/914 Series
Edition 1 / Rev. 5
Fig. 80-11
07556
HD configuration
ES09
ES09
80-00-00 page 13
March 01/2017
BRP-Rotax
Maintenance Manual
Description
Reading new min max wear limit
100% wear limit
50%
Electric starter
Commutator
Armature shaft
Armature bushing
Bearing seat on shield
Axial clearance
ES03
ES04
ES05
ES07
ES08
Length of plus brush ES09
Length of minus brush
Radial clearance armature shaft/ armature bushing
Bearing seat on shaft
ES09
ES05/
ES04
ES06
12,0
0,472
12,0
0,47
0,03
0,001
14,991
0,590
27,5
1,083
9,77
0,385
9,82
0,387
32,000
1,2598
0,1
0,004
28,0
1,102
9,79
0,385
9,84
0,387
32,036
1,2613
0,4
0,016
12,5
0,492
12,5
0,49
0,07
0,003
27,0
1,063
9,75
0,384
27,3
1,075
9,76
0,384 actual renewed actual renewed
9,86
0,388
32,069
1,2626
0,4
0,016
8,5
0,335
8,5
0,33
0,11
0,0043
9,84
0,387
32,035
1,2619 actual renewed actual renewed
10,00
0,394 actual renewed actual renewed actual
10,00
0,394
0,09
0,0035 renewed actual renewed
15,005
0,591
14,987
0,5900 actual renewed
Readings
08249
Effectivity 912/914 Series
Edition 1 / Rev. 5
80-00-00 page 14
March 01/2017
® and TM trademarks of BRP-Rotax GmbH & Co KG. © 201 8 BRP-Rotax GmbH & Co KG. All rights reserved
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