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MAINTENANCE MANUAL (LINE MAINTENANCE) FOR ROTAX® ENGINE TYPE 914 SERIES
ROTAX® 914 UL 3 WITH OPTIONS
part no.: 899608 WARNING Before starting any maintenance work, please read the Maintenance Manual, as it contains important safety relevant onformation. Failure to do so may result in personal injuries including death. Consult the original equipment manufacturer´s handbook for additional instructions!
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 2010 © - 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. d04855.fm Edition 2/Rev. 1 Effectivity: 914Series Chapter structure Foreword ture oftheATA(Air The structureoftheManualfollowswh ROTAX-aircraft engines. questions, pleasecontactanauthorized If anypassagesofthe nance Manual(LineMa Before carryingoutmaintenancework Manual issubdividedinto Introduction Scheduled maintenance Replenishing operating fluids systems of the Maintenance Unscheduled maintenance checks Scheduled maintenance checks Time limits Maintenance Limitations Airworthiness General note ofamendments Table List of effective pages MAINTENANCE MANUAL MAINTENANCE GENERAL NOTE Chapter: INTRO BRP-Powertrain Subject Transport Association) Manual arenotclearlyunde intenance) carefully. thefollowingchapters: ontheengine,readMainte- enever itisapplicablethestruc- Distribution orServiceCenterfor standards. TheMaintenance Chapter LEP Chapter INTRO Chapter 12-20-00 Chapter 12-10-00 Chapter 12-00-00 Chapter 05-50-00 Chapter 05-20-00 Chapter 05-10-00 Chapter 05-00-00 Chapter 04-00-00 Chapter 00-00-00 Chapter TOA rstood orifyouhave Chapter INTRO July 01/2010 page 1 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES INTRO January 01/2010 page 2 page
d04520.fm BRP-Powertrain MAINTENANCE MANUAL
Chapter: LEP LIST OF EFFECTIVE PAGES
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Title page 05-10-00 1 01 01 2010 INTRO 1 07 01 2010 2 01 01 2010 2 01 01 2010 3 01 01 2010 4 01 01 2010 LEP 1 07 01 2010 5 01 01 2010 2 07 01 2010 6 01 01 2010 3 07 01 2010 7 01 01 2010 4 07 01 2010 8 01 01 2010
TOA 1 07 01 2010 05-20-00 1 01 01 2010 2 01 01 2010 2 01 01 2010 00-00-00 1 01 01 2010 3 01 01 2010 2 01 01 2010 4 01 01 2010 3 01 01 2010 5 01 01 2010 4 01 01 2010 6 01 01 2010 5 01 01 2010 7 01 01 2010 6 01 01 2010 8 01 01 2010 7 01 01 2010 9 01 01 2010 8 01 01 2010 10 01 01 2010 9 01 01 2010 11 01 01 2010 10 01 01 2010 12 01 01 2010 11 01 01 2010 13 01 01 2010 12 01 01 2010 14 01 01 2010 13 01 01 2010 15 01 01 2010 14 01 01 2010 16 01 01 2010 15 01 01 2010 17 01 01 2010 16 01 01 2010 18 01 01 2010
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chapter page date
12-20-00 49 01 01 2010 50 01 01 2010 51 01 01 2010 52 01 01 2010 53 01 01 2010 54 01 01 2010 55 01 01 2010 56 01 01 2010 57 01 01 2010 58 01 01 2010 59 01 01 2010 60 01 01 2010 61 01 01 2010 62 01 01 2010 63 01 01 2010 64 01 01 2010 65 01 01 2010 66 01 01 2010 67 01 01 2010 68 01 01 2010 69 01 01 2010 70 01 01 2010 71 01 01 2010 72 01 01 2010 73 01 01 2010 74 01 01 2010 75 01 01 2010 76 01 01 2010 Rear page d04856.fm Effectivity: 914 Series Edition 2 / Rev. 1 LEP page 3 July 01/2010 Edition 2/Rev. 1 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES July 01/2010 LEP page 4 page
d04856.fm d04857.fm Edition 2/Rev. 1 Effectivity: 914Series 40-0al07 all 04-00-00 1 1 1 1 0 0 0 0 0 0 0 0 0 0 0 no. TOA LEP INTRO 12-20-00 12-10-00 12-00-00 05-50-00 05-20-00 05-10-00 05-00-00 00-00-00 TOA LEP INTRO chapter all all all all all all all all all all all 1 1-4 1 Note: THEAPPROVAL ISGIVENTO CHAPTERS ALL page The technicalcontentof EXCEPT THEAIRWORTHINESS LIMITATIONS under the authority of under theauthority SECTION 04-00-00 WHI 04-00-00 SECTION SPECIFIC APPROVAL OFTHEEASA. 01 012010 01 012010 01 012010 01 012010 01 012010 01 012010 01 012010 01 012010 01 012010 01 012010 01 012010 07 012010 07 012010 07 012010 change date of TABLE OFAMENDMENTS 121 EASAapproved 01 2010 MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain Chapter: TOA DOA* DOA* DOA* DOA* DOA* DOA* DOA* DOA* DOA* DOA* DOA* DOA* DOA* DOA* *Approval remark for approval DOA No. EASA.21J.048. this documentisapproved CH ISSUBJECTTO proval from authorities dateap- of date of issue signature July 01/2010 TOA page 1 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES January 01/2010 TOA page 2 page
d04522.fm d04523.fm Edition 2/Rev. 0 Effectivity: 914Series Table ofcontents Introduction information concerning theoper information concerning This chapteroftheMaintenanceMa TheROTAX incl 914Series NOTES: Series. thismain This sectiondescribes Abbreviations and terms used inthis Manual General note Safety Conversion table Use for intended purpose Technical documentation Maintenance concept Instruction notice Safety 1 n 1 UL. Fand914 914 MAINTENANCE MANUAL MAINTENANCE Chapter: 00-00-00 GENERAL NOTE BRP-Powertrain Subject ation oftheaircraft engine. tenance ofenginetypeROTAX 914 nual containsgeneral andsafety udes allenginessuchasthe ae3 page ae7 page 5 page ae16 page 14 page 13 page 12 page 10 page 9 page 00-00-00 Page January 01/2010 page 1 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 00-00-00 January 01/2010 page 2 page
d04523.fm d04523.fm Edition 2/Rev. 0 Effectivity: 914Series number Engine serial Distributors ROTAX Documentation Purpose Generalnote 1) Fig. 1 starter.the left,oppositeelectric See product improvement. The number,serial asthemanufacturer ororderi When makinginquiries www.rotax-aircraft-engines.com. See latestOperators Manual oront ROTAX Authorized Distributors for Aircraft Engines. also contactyour nearestauthoriz For additionalinformati turer and/ordealer. operation, consultthedocumentation For moredetailedinformation regarding, tenance andsafety information for work. service vice staffapproved by thelocalaviati ofthisMaintenanceManual The purpose MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain on on engines, maintenance or parts, youon engines, can maintenanceorparts, Cyl. 1 Cyl. 2 engine number (1)ison ng parts, alwaysng parts, indicatetheengine Cyl. 3 ed ROTAX-aircraft enginedistributor. Cyl. 4 makes modifications totheenginefor he Internet atthe he Internet on authorities with on authorities provided by theaircraft manufac- maintenance, safety- orflight istoacquaintmaintenanceser- Fig. 1 . the ignitioncover, on official Homepage 00-00-00 somebasicmain- 1 January 01/2010 page 3 page 03645 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 00-00-00 January 01/2010 page 4 page
d04523.fm d04523.fm Edition 2/Rev. 0 Effectivity: 914Series Abbreviations Abbreviations andterm 2) M Engine Management System Introduction GasTemperature Exhaust Unit Control Engine Manual Installation EMS EuropeanAviati Design Organisation Approval INTRO Department of Transport EGT ECU Ignition Discharge DualCapacitor IM Counter-clockwise Clockwise EASA Actuator Speed Constant DOA DOT Association Transport Air DCDI Canadian GeneralStandards Board CCW American Society forTesting and Materials Institute American Petrol CW Austro Control GmbH CSA AlertServiceBulletin CAN/CGSB Across-flat dimension ATA Aircraft ASTM Ampere API ACG see OM(Type designation) ASB see OM(Type designation) A/F A/C 912 ULS Version France A see OM (Type designation) see OM(Type designation) 914UL see OM(Type designation) 914F see OM(Type designation) 912 ULSFR see OM(Type designation) minute per Revolutions 912ULS Fahrenheit Degrees 912UL (Centigrade) DegreesCelsius 912S 912F 912A rpm °F °C * Reference to another section another to Reference * Abbreviation s usedinthisManual MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain lubricants. (only inthe The drop symbol indicates useof sealing agents, adhesives or center of gravity on Safety Agency on Safety Illustrated Parts Catalog) Illustrated Parts Description 00-00-00 January 01/2010 page 5 page Edition 2/Rev. 0 Effectivity: 914 Series X showsthe serialcomponent number Maintenance Manual ofEffective List Pages Rules Flight Visual Overhaul Since Time XXX MM Time Since New Part LEP Part number Surface MountedDevices VFR Letter Service VVolt ServiceInstruction TSO ServiceBulletin TSNP Serial Number part no. IPC) (only stillvalid SMD RecordofRevisions SL Research OctaneNumber SI SB is a trade mark of BR S/N unit supply power s.v. meter newton RV testing non-destructive RON not available ROTAX asnecessary(only Illustrated PartsCatalog) Revision Rev. Catalog) Parts part(onlyIllustrated new PSU Nm motor octanenumber magneto side NDT Directive Airworthiness n.a. kilograms nB International Standard Atmosphere N Table of Contents MON Operators Manual MS hours AD Overhaul Manual kg Federal Aviation Regulation ISA Federal Aviation Administration TOC Catalog Illustrated Parts OM EuropeanNorm hr. OM FAR FAA IPC EN Abbreviation MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain P-Powertrain GmbH & CoKG Description 00-00-00 January 01/2010 page 6 page
d04523.fm d04523.fm Edition 2/Rev. 0 Effectivity: 914Series .)Conversion table 2.1) Density: volume: of Units Units offorce: Units of length: of Units Units ofpressure: Units of mass: of Units Units ofarea: 1 lbf/in 1 sqin(in 1 cuin(in a U)=3.7854 dm gal1 (US) =4.5461 dm gal1 (UK) 1 g/cm nH =33.8638hPa Hg 1 in 1 lb/ft 1 1 dm 2 1 dm 1 dm 1 cm 1 cm m=0.03937in 1 mm a = 14.5037lbf/in 1 bar = 100 000 Pa (1000 hPa) bar 1 (s)= 0.0689 bar (psi) 1lf= 4.4482 N 1 lbf a= 1N/m 1 Pa g=2.2046 lb kg 1 1i =25.4mm 1in b=0.45359kg 1 lb = 0.224809 lbf 1 N 1 ft = 12 in =12 1 ft 3 2 3 3 3 3 3 3 2 = 16.3871cm ) = 6.4516 cm ) = 0.06102 cu in (in = 0.155in sq (in = 62.43 g/cm = 0.016018 lb/ft = 0.26417gal (US) = 0.21997gal (UK) = 1l = 0.3048 m MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain 2
2 3 3 3 3 (in 2 3 2 (psi) ) 3 3 ) ) W 01 41 820 18 16 14 12 10 8 6 4 AWG mm spec. fuel consumption: Units ofvelocity: Units oftemperature: Units oftorque: AWG-mm Conversion table- Wire Gauge: Cable cross-section: Units ofpower: 2 11 ...... 0.52 0.8 1.3 2.1 3.3 5.3 8.4 13 21 /W = 0.001644 lb/hph g/kWh 1 bhh=608.277g/kWh 1 lb/hph tmn=0.3048 m/min 1 ft/min mh= 0.53996 kn 1 km/h nl =0.113 Nm 1 inlb / = 3.6 km/h 1 m/s tl =1.356 Nm 1 ft lb / = 196.85 ft/min 1 m/s m=0.737 ft lb Nm 1 W=1.3596 PS 1 kW =1.341 hp 1 kW S=0.7355 kW 1 PS 2 p=0.7457 kW 1 hp t=1.852 km/h 1 kt C=(°F -32) /1,8 °C °F = (°C x 1.8) +32 x =(°C °F = °C-273,15 K = 8.848 inlb = 0.00508m/sec 00-00-00 January 01/2010 page 7 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 00-00-00 January 01/2010 page 8 page
d04523.fm d04523.fm Edition 2/Rev. 0 Effectivity: 914Series used Symbols Measure Revision General note Safety 3) NOTES: tion. Thisinformation isim This Manualusesthefollowing symbol in parenthesis. Specifications aregiven ture orotherwise. gation, toremove, replaceordiscont BRP-Powertrain at theright reserves ously manufactured. imposing uponitselfany obligation to maintains apolicyofcontinuous im Manual arecorrectatth The information andcomponents-/system safetycommon workshop practice. understanding theinformat Although thereading ƽ ƽ ƽ ƽ ƽ NOTICE WARNUNG WARNUNGCAUTION WARNUNGWARNING change totext orgraphic. A revision baroutsideof tion. needed tofully complete or informationIndicates supplementary which may be MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain severely damage theengi Denotes aninstructionwhich, ifnotfollowed, may may causeminorormoderateinjury. Identifies aninst of death. may in causeseriousinjury Identifies aninst of suchinformation doesnot e timeofpublication. BRP-Powertrain, however, in the SI metric system in theSImetric portant andmust beobserved. portant ion willpromoteitsco provement ofits inue any design,specification,fea- any time, andwithout ruction which, ifnotfollowed, ruction which, ifnotfollowed, install themonitsproductsprevi- s to emphasize particular informa- s toemphasize particular descriptions containedinthis descriptions the page marginthe page indicatesa understand aninstruc- ne orothercomponent. with theUSAequivalent rrect use. Always use cluding thepossibility eliminatethehazard, products without 00-00-00 incurring obli- incurring January 01/2010 page 9 page Edition 2/Rev. 0 Effectivity: 914 Series Illustration tion Safety instruc- Warning Manual General note .)Safety notice 3.1) of thepossible hazardous advise theuserofallc are notexhaustive It is, however, tounderstand important equipment. lose power inflightwhichcanresult engine cancauseaserious observed, and cautionsadviseofspecificoperat andca including warnings This Manualusestechnicaltermswhich engines. are alreadyfamiliarwith This editionwasprimarilypublishedto tain allROTAX 914aircraft engines. accident preventative measures, legal theinstructi In additiontoobserving It isyour responsibility tobecompletely In theeventofanydiscrepan ones usedintheIllust This Manual has beenprepar resulting fromtheimpro However, BRP-Powertrain disclaimslia engines andhasbeenutilized safely This information relatestothepre product. whether authorized ornot product atitstimeofmanufacture. It and/orproc The contentdepictsparts any authority, themorestrin Where differences exist between this aeronautical authority It isunderstoodthatthis See chap. 05-00-00section skilled professional mechanic becarri recommend thatany service MAINTENANCE MANUAL MAINTENANCE . BRP-Powertrain couldnot BRP-Powertrain rated PartsCatalog. must beobserved. onceivable ways inwhichse per useofthecontents. Manualmaybetransla allserviceproceduresre utions described inthis utions described by BRP-Powertrain, aftermanufacturing the consequences ofeachway. gent regulation 1.2) cy theGermanvers ed asaguidetocorrec paration anduseofROTAX aircraft doesnotincludedealermodifications, inlossoflife, ordamageto injury ons inourManual,general safety and ed outand/orverified by ahighly and effectively by BRP-Powertrain. ing and servicing methodsthat,ifnot ing andservicing Manual andregulationsprovided by edures applicable to the particular edures applicable totheparticular regulations andr be usedbyaircraftmechanicswho malfunction orcausetheengineto bility for alldamageand/orinjuries familiar withthesafety instructions that these warnings andcautions that thesewarnings may beslightlydi should beapplied. possibly know, evaluate and ted intoanotherlanguage. BRP-Powertrain strongly Manual. These warnings Manual. Thesewarnings ion prevails. lating toROTAXaircraft rvice mightbedone or rvice tly service andmain- tly service egulations ofany 00-00-00 fferent fromthe January 01/2010 page 10
d04523.fm d04523.fm Locking devices Edition 2/Rev. 0 Effectivity: 914Series tightening wrench Torque locking device isimpaired, Torque wrenchtightening installed orreplacedwith Locking devices (e.g. locking tab, se ƽ NOTICE WARNUNG MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain ed whenfastened. If notspecifiedotherwise, new ones, wherespecified. specifications must be strictly adheredto.specifications must bestrictly itmust bereplaced. lf-locking fasteners, etc.)must be the threadsarenotlubricat- Iftheefficiencyofa 00-00-00 January 01/2010 page 11 Edition 2/Rev. 0 Effectivity: 914 Series Returning Standstill Tools Spare parts Accessories Safety notice General note .)Instruction 3.2) after consentby the mended andreleasedby BRP-Powertrain. This enginemust onlybeoperated wi marked. Pass onsafety wa In thistechnicalManual passages regarding Engines requireinstructions umentation (logbook, overhaulan authorized orr theengineoritsco When returning against contamination. forinstructions engine After enginestandstill(l engine. advice for operation, maintenance, shouldcoverThese instructions expl theoretical andpractical instructions. elementsformentary personalinstructi Technical documentationanddirections maintenance andrepair. ƽ ƽ NOTICE NOTICE WARNUNG WARNUNG MAINTENANCE MANUAL MAINTENANCE alog. ther citedintheManual or useonlytools In principle used (seelatestWa GENUINE ROTAX parts spare andor void ifspareparts Any warranty by BRP-Po Center.Distribution- andService areavailableSpare parts ROTAX attheauthorized Powertrain vo isnulland er’s opinionotherwise, an (seeIPC)orsuitableries use ofGENUINEROTAX and/oraccesso- spareparts by theenginemanufacturer. Thisisonlywarranted by must meet wi Spare parts BRP-Powertrain engine manufacturer. maintenance records “out ofuse”.Protectf onger than2months)obse epair company, doc- ensurethatthenecessary rnings tootherusers! rnings concerning safetyconcerning areespecially use andoperational safety ofthe mponents (e.g. propellergearbox) to anation ofthetechnicalcontext, th accessories supplied,recom- th accessories their application, on, but canby nomeanssubstitute are useful and necessary comple- areusefulandnecessary rranty Conditions). Modificationsareonlyallowed uel- andcarburetor system id (seeWarranty Conditions). etc.) areenclosed. wertrain becomesnulland wertrain accessories otherthan accessories equivalent inthemanufactur- y limitedwarranty by BRP- and applianceswhichareei- th therequirementsdefined in theIllustrated Cat- Parts and/or accessories are and/or accessories rve withoutfailrve the use, operation, 00-00-00 January 01/2010 page 12
d04523.fm d04523.fm Edition 2/Rev. 0 Effectivity: 914Series nance) (Heavy Mainte- Maintenance II nance) Mainte- (Line Maintenance I General note 3.3) Maintenance Concept Maintenance 3.3) OE:ThisManual can NOTES: Maintenance". consideredbe normally nents orparts Maintenance Manual IIdetailsremova separate Manual Whereapplicable, you willbereferred totheHeavy Main- NOTES: this Manual are tobec adjustment ofengineco The scopeoflinemaintena Chapter 00,05and12 facility. as maintenancefunctionsandmust Repairs beyond thelevels detailedin Maintenance II(H - Maintenance I(LineMaintenance) - ries: The maintenancefunctionsdetailedin tenance Manual I(LineMaintenance nace. tenance Manual for above work andbeyond linemainten- MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain eavy Maintenance) onsidered linemaintenance. mponents (including part wear mponents (includingpart nce consistsofremova only bedoneby an thisManual arenotrecommended be used in combination withMain- incombination beused yond thecapabilities l, installationa this Manual fall intotwo catego- l, installationand authorized overhaulauthorized ), asitbuilds uponit. nd repairofcompo- ). Allproceduresin 00-00-00 ofthe"Line January 01/2010 page 13 Edition 2/Rev. 0 Effectivity: 914 Series Reference pages Replacement Status Documentation General note .)Technical documentation 3.4) ber isgiven onthefooter ofeachpage. pages isgiven inthechapterLEP. BRP-Powertrain, if can bereplacedinsteadofthecomplete theManualisconstruct Furthermore be downloaded freeofcharge. www.rotax-aircraft-engines.com should becomparedwiththerevisi amendments. Thefirstcolumn The statusoftheManual Letter Service - Instruction Service - Bulletin Service - ServiceBulletin Alert - PartsCatalog Illustrated - Manual Overhaul - Manual(Line Maintenance - Manual Operators - Manual Installation - The information contained of ROTAX aircraft engines. These documentsform the Any reference toadocumentrefers ficient. for spec the objectbought,inparticular andoperational regulations structional of thecustomersitmay occurthatex Due tothefast technicalprogress andfu sidered applicable for skilled MAINTENANCE MANUAL MAINTENANCE not statedotherwise. BRP-Powertrain s can be determined withth s canbedetermined is basedondataandexpe instructions ensuring c ensuring instructions mechanics under normal conditions. mechanics undernormal and HeavyMaintenance) indicatestherevisi . Amendmentsandcurrentversions can The particular edition andrevision num- The particular on provided onROTAX-WebSite: tothelatest ed insuchaway thatsinglepages isting laws, safety con- prescriptions, cannot betransferred completelyto ial constructions, ormay notbesuf- lfilment of particular specifications lfilment ofparticular document.Thelistofeffective edition issuedby on state. Thisfigure ontinued airworthiness ontinued airworthiness e aidofthetable of rience thatarecon- rience 00-00-00 January 01/2010 page 14
d04523.fm d04523.fm Illustrations Edition 2/Rev. 0 Effectivity: 914Series OE:TheIllustrations andDocument NOTES: dimensions orotherdetailsfrom whichhavethe parts thesameorsi arrangement. They may notrepresentin The illustrations inthisManual are tent. This number (e.g. 00277)isof with aconsecutive irrelevant number. in adocumentdatafile/gr MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain illustrations mere sketches andshow atypical milar function.Ther full detailortheexact shapeof aphic datafileandareprovided is notpermitted. nosignificancefor thecon- s inthisMan efore deductionof 00-00-00 January 01/2010 ual arestored page 15 Edition 2/Rev. 0 Effectivity: 914 Series ditions and repaircon- Maintenance page Engine stop- gine en- Non certified Certified engine Use General note .)Usefor intendedpurpose 3.5) OE:These enginesaretechnicall NOTES: not compromise safety. tal, uncertificated aircra tal, uncertificated a crucial factor thereliabi a crucial concerning maintenance andrepairconditionsprescrib Use for alsoincl intendedpurpose ofuse,The operator assumesallrisk conform tonoaircraft standards. These any aeronauticalstandardsor ULisnotcertifi Engine ROTAX 914 to thelatesttechnological dards for safety andtimebetween ov aircraft engi Certified federations have tobeobserved. doubt theregulations isintendedfor F us The engineROTAX 914 the durability oftheengine. he/she knows thisengineis ƽ ƽ WARNUNGWARNING ing thesamequalityassurance system. gines andhave beenmanufactured by BRP-Powertrain us- MAINTENANCE MANUAL MAINTENANCE the enginewithoutpropeller. Never injuries. cancauseserious run Bursting offparts Explosion hazard. BRP-Powertrain eRTX94F istested ne ROTAX 914 ofthenational ft andvehicles onlyinwh standards and rigorously tested. standards andrigorously subjectto regulatory safety or regulatory udes observation of udes observation ed. Theseengineshave notreceived authorities ortherespective authorities sportive erhaul. Itwas developed toconform lity oftheengine andacknowledges by sudden stoppage. enginesarefor ed by themanufacturer. Thisis e in certified aircraft. Incaseof e incertified y equivalent to certified en- y equivalent tocertified as peraeronauticalstan- ich anengine durability testing,and theoperational, and canincrease use inexperimen- 00-00-00 thisusethat January 01/2010 failure will page 16
d04523.fm d04858.fm Edition 2/Rev. 1 Effectivity: 914Series worthiness Continued Air- Limitations Airworthiness Introduction 40-0al07 all 04-00-00 1 no. EUROPEAN AVIATION SAFETYAGEN chapter PART 21A.31(a)(3)ANDFAR 33.4. THE AIRWORTHINESS LIMITATIONS PROCEDURE CONTAINED INTHIS REPLACEMENT TIME, INSPECTION worthiness ofROTAXworthiness Regardingenginelimitations NOTES: not applicable. For theROTAX th typeengine 914Series -NONEtions“. This chapter04-00-00provides inform of definedcomponentsare Scheduled inspectionsoftheenginein page SECTION MUST ALSOBEAPPROVED.SECTION MUST AIRWORTHINESS LIMITATIONS change date of 121 EASAapproved 01 2010 See chap. 05-00-00. in ordertoensurethe inchapter05andar descriped ents arerequiredonthisen Maintenance checks andreplac its ofoperation“ inthere MAINTENANCE MANUAL MAINTENANCE Chapter: 04-00-00 BRP-Powertrain EASA approved aircraft engines. remark for Approval approval ANYCHANGETO required inordertoen CY (EASA)INACCO AIRWORTHINESS LIMITATIONS SECTION ISAPPROVED BYTHE INTERVAL, ANDRELATED proval from authorities dateap- of Continued Airworthiness! ation about “Airworthiness Limita- ation about“Airworthiness cluding replacement levant Operators Manual. e airworthiness e airworthiness EACH MANDATORY see therelevant chapter “lim- gine! Theseproceduresare e arequiredby ement ofdefinedcompon- date of sure theContinued Air- RDANCE WITH issue 04-00-00 limitations are andoverhaul the authority signature July 01/2010 page 1 page Edition 2/Rev. 1 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE EASA approved BRP-Powertrain NOTES 04-00-00 July 01/2010 page 2 page
d04858.fm d04524.fm Edition 2/Rev. 0 Effectivity: 914Series Table ofcontents Introduction section. tions aretreatedas function ofthevarious systems. So issubdivid Thedescription described. In thischapterthemaintenance mechanic undernormal experience whichareconsideredto The information given intheMain Maintenance Acceptable methods Consumable materials Trouble shooting notes Procedure personnel Authorized General note MAINTENANCE MANUAL MAINTENANCE Chapter: 05-00-00 MAINTENANCE BRP-Powertrain Subject generally valid information working conditions working of engine ROTAX 914 Series is Series of engineROTAX 914 tenance Manualisbasedondataand me overlapping maintenanceinstruc- be applicablebe for aviation askilled ed into sections and description of ed intosectionsanddescription ae10 page 7 page 6 page 5 page 4 page 3 page 3 page at thebeginningofthis 05-00-00 Page January 01/2010 page 1 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-00-00 January 01/2010 page 2 page
d04524.fm d04524.fm Edition 2/Rev. 0 Effectivity: 914Series tools Special sories Parts andacces- Modifications Instruction limits Procedures and Safety notice Maintenance 1) .)Generalnote 1.1) train whendisassembling special tools. Useonlythespecia Maintenance ofengines manufacturer andaccessories refusesany liability.uine parts oftheengine.characteristics For products may possibly c andthusarenotauthorized forertrain genuine arenot BRP-Powertrain parts emphasize thatparts We particularly exclude any liabilityof components iliary Non-authorized modificationsaswell theoretical andpractical personalinstruction. supplementstotraining. They,sary The guidelinesgiven in official recommendationfor engi The proceduresandlimitsinthisMa ƽ ƽ WARNUNGWARNING MAINTENANCE MANUAL MAINTENANCE
not correspondingtothein BRP-Powertrain dent preventive directives plied, alsorespectthegener Besides ourinstructions Non-compliance canresultin the enginemanufacturer. the MaintenanceManual hange ornegatively influen and systemsrequiress and assembling theengine. ne maintenanceandoperation. damages resulting l toolsrecomme however, cannotsubstitutecompetent nual constitutethemanufacturers and accessories notsuppliedas andaccessories astheuseofcomponentsandaux- use. Installationand/oruseofsuch verified for suitabilityby BRP-Pow- in thedocum stallation instructions stallation instructions andlegalregulations. pecial knowledge and ally valid safety andacci- serious injuries ordeath! injuries serious are usefulandneces- nded by BRP-Power- ce theconstructive from useofnon-gen- 05-00-00 entation sup- January 01/2010 page 3 page Edition 2/Rev. 0 Effectivity: 914 Series Information training Type-specific General note .)Authorized personnel 1.2) Maintenance organizationsandindi Any taskoutlinedhereinmay beperformed if It isarequirementt See chap. 00-00-00 and guidanceonany ofth BRP-Powertrain throughitsworldwide following the has met conditions: lined. required specialtooling, “On-the-job“instruction byaBRP-Powertrain orauthorized BRP-Powertrain Dis- - instruction Formal - Experienceperforming in the task - And the Requirements of the applicable regulatory authority regarding mainte- - andprudent Reasonable mainte - Suitableand toolsfixtures asoutlined intheROTAX Maintenance Manual. - Suitable work environment to prevent cont - Type-specific training (for the applic - approved bythe national aviation authority and/or BRP-Powertrain. tributor representative. nance procedures are met. modules. Requisite knowledgeof the taskresulta as of: MAINTENANCE MANUAL MAINTENANCE from a BRP-Powertrain from aBRP-Powertrain auth hat allorganizationsor BRP-Powertrain section: 3.4). training orexperience e tasksoutlinedherein. nance practices areutilized. Including: and able ROTAXable aircraft engine) whichis or viduals areencour distribution network fordistribution network information amination ordamage to engine parts or individuals possessthe orized training facility training orized theorganization to performalltasksout- aged tocontact 05-00-00 January 01/2010 orindividual or page 4 page
d04524.fm d04524.fm Edition 2/Rev. 0 Effectivity: 914Series Disassembly ating fluids Handling of oper- Ignition “ON“ Ignition “OFF“ General note .)Procedure notes 1.3) the system. fail thatnocontamination,metal chip At maintenanceofcooling-,lubricatin . Secure andobservepropellerzone - Secure thepropelleragainstun - take careof thefollowing: whichrequires At maintenancework avoid any mix-up. Take care of At disassembly oftheengine, mark ƽ ƽ ƽ ƽ ƽ ƽ ƽ ƽ WARNUNGWARNING WARNUNGWARNING WARNUNGWARNING WARNUNGWARNING MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain perature before starting work. perature before starting Allways allow theen Hot engineparts! vere orscalding! burns Failure may tocomplywiththisinstruction causese- connectedtoground.ble (Plead)isnotproperly The ignitionis shock!Risk ofelectric and secureengineagainst - Disconnectbattery - Ignition“ event ensurethefollowingPrincipally at incaseofanunintent ries measurese This precautionary Non-compliance canresultin spect withoutfail the re- work, outmaintenanceandservice When carrying Non-compliance canresultin OFF these marks, don’t ruin them. don’truin thesemarks, switched on intentional turningbyhandand “ andsystemgrounded, the components as necessary to thecomponentsasnecessary ignition “ON“and s, foreign material and/or dirt enters s, foreign and/ordirt material g andfuelsystemta gine tocooldown safety regulations. ional start oftheengine. ional start unintentional operation. , aslongtheground-ca- serious injuries ordeath! injuries serious ordeath! injuries serious rves toavoidrves any inju- each maintenance battery connected, battery 05-00-00 ke carewithout toambienttem- January 01/2010 page 5 page
Edition 2/Rev. 0 Effectivity: 914 Series General notes Re-assembly O-rings Sealing rings, Nuts Removed parts parts Cleaning of Safety wiring Tool .)Trouble shooting 1.4) Before re-assembly check components elements, O-ring At reassembly oftheengine, replace Once loosened, Before re-usingdisassembled parts, See chapter12inthe Op ofthenecessa description brief In theOperators Manual, possible proble quence. Ifnot maintenance instructions. use adhesives, lubricants, doubt, usenew screws andnuts. damage. Check thecontactfaces andth Use cleanscrews andnuts instructions. ƽ ƽ ƽ ƽ ƽ NOTICE NOTICE NOTICE WARNUNGWARNING WARNUNG WARNUNG WARNUNG always s andoilseals. MAINTENANCE MANUAL MAINTENANCE cause serious enginedamage. cause serious nuts. ort Overtightening thetighteni Exactly observe Non-compliance canresultin materials. unknown cleaningagentschec with suitable cle aregenerally washed All metallandsyntheticparts by anew one. etc.) shouldbenecessary, it safety item(e.g. safety self-locking wiring, fastener, disassembling/reaIf during specified tools. or tightenscrews andnuts wi In ordertoavoid mechanicaldamages, never loosen BRP-Powertrain replace self-securing nuts.replace self-securing erators Manual for engi cleaningagentsandsolv only andinspectface ry remedialactionisgiven. ry respected, damage aning agents. Before usingnew and clean, check andrefi all sealingrings, whether parts are whether parts reads for damages. Incaseof ms arelisted.At oo looseconnectioncould ssembling theremoval ofa ng torquesfor screws and must bealways replaced th pliersbut onlywiththe ne type914(Series). serious injuries ordeath! injuries serious of nuts andthreadfor k thecompatibilityof ents indicatedinthe may betheconse- gaskets, securing 05-00-00 the sametime, a t themasper missing. Only January 01/2010 page 6 page
d04524.fm d04524.fm Edition 2/Rev. 0 Effectivity: 914Series General note .)Consumable Materials 1.5) for alloperating condi specifiedhaveThe materials beentested themanu Respect NOTES: To someextent productde NOTES: 2897330 12 897166 11 297433 10 297434 9 899791 8 7n.a. 899784 6 898241 5 899789 4 899788 3 897651 2 899785 1 No. ƽ NOTICE WARNUNG part no. ing compound. ing timeandtheexpire date for ROTAXvice partners engines. be obtainedfromthelocalaut thecomparability.cerning In c LOCTITE 222.Ifnecessary equivalent technicalproper MAINTENANCE MANUAL MAINTENANCE to preventto leakage current Lithium-base grease or DowCorning, long-term lubricant forshaft seals MOLYKOTE 44 medium, Lubricating paste MOLYKOTE G-N, for the prevention of frettingcorrosion LOCTITE Anti-Seize 8151, LOCTITE 574 and LOCTITE 518 surface sealing compound, can be used instead LOCTITE 5910 black, LOCTITE 574 surface sealing compound, can be used instead LOCTITE 518 red, surface sealing compound LOCTITE 574 orange, instant adhesiveincreasedflexibility LOCTITE 480 black, oil-tolerant grouting product,high-strength LOCTITE 603 green, high strength screw securing agent LOCTITE 648, medium-dutysecuring screw agent LOCTITE 243 blue, medium-dutysecuring screw agent LOCTITE 221 violet, BRP-Powertrain cluding the expiry cluding theexpiry regulationsandspecificat ary When handlingchemicals, comp fromBRP-Powertrainterials for allmaintenancework. Use onlythespecifiedor tions indicatedby themanufacturer. Description, Application facturers instruction concerning thecur- facturers concerning instruction date andinstruction. for alongtime scriptions deviatescriptions inspiteof ties, i.e.: LOCTITE221and of the particular surface seal- of theparticular ontact themanufacturer con- some casesinformation can technically equivalent horized distributors andser- distributors horized ions oftheproducer, in- ly withallthecustom- 05-00-00 and aresuitable 250 g (0.55 lb) g(0.55 250 lb) g(0.22 100 lb) g(0.22 100 g(0.11 lb) 50 (US)) ml(0.013gal 50 (US)) ml(0.013gal 50 (US)) ml(0.005gal 20 (US)) ml(0.003gal 10 (US)) (0.001 ml gal 5 (US)) ml(0.003gal 10 (US)) ml(0.003gal 10 January 01/2010 Qty. page 7 page ma- Edition 2/Rev. 0 Effectivity: 914 Series 0898570 20 n.a. 19 n.a. 18 n.a. 17 6297710 16 5897186 15 4297368 14 3897870 13 No. part no. MAINTENANCE MANUAL MAINTENANCE seals screws seals Screw securingpaint vironment. serve the safety regulations for persons and en- ob- solvents, using When SOL). OMV-SOFT innerdegreasing or agent (CASTROL ZA30or applyingLOCTITE,clean surfaces with nitroth- re- Before clean. metallic them make to threads able forremoving LOCTITEfrom surfaces or for optimum ground connections. It ishighly suit- alof smaller rust spots oroxidation, especially Issold bythe meter and used for Manual remov- standard Very fine emery cloth SR4600A -very fine against corrosion of metal surfaces. tiny gaps, it’s highly effective additivesprotect lent penetratin excel- has oil preservation The Requirements: Preservation oil edmechanical to loads. +120 °C(-31 °F to +248 °F) and canbe subject- to °C -35 from temperatures for Useable ent. pose grease, water resistant and highly adher- Generally useable, neutrallycolored multi-pur- Multi-purpose grease LZ for shock absorption PU-glue otherwisenot do contribute to heat conduction. which head), plug-cylinder spark (e.g.: element cavitiesbetween components and the cooling like, temperature- heat transfer will reduce Application of the heatconduction compound COMPOUND CONDUCTION HEAT SILICONE sealing compound multi-purpose SILASTIC 732, against moisture against for optimum filter efficiency and protection oil Filter BRP-Powertrain Description, Application g capabilities and reaches even even and reaches g capabilities one-component resistant silicon resistant resistance. Thegrease- silicon-based silicon-based compoundfills 05-00-00 (US)) ml(0.005 gal 20 gal (US)) (0.082 ml 310 150 g (0.33 g lb) 150 gal (US)) (0.082 ml 310 gal (US)) (0.004 ml 14.8 January 01/2010 Qty. page 8 page
d04524.fm d04524.fm Edition 2/Rev. 0 Effectivity: 914Series 3n.a. 23 n.a. 22 n.a. 21 No. part no. MAINTENANCE MANUAL MAINTENANCE cation ofand adhesivessealants. Degreasing fluid. For parts cleaning before appl- LOCTITE 7063 ing of surfaces. ness of 0,5 to 1µ, which represents fine process- possible60 µ. to Itsurface is achievea rough- cleaning. The granulates used are of sizes40 to relevant authorities and guarantees optimum containsnoxious no matter,is approved bythe (propeller shaft). The very fine treatment of steelparts rust withfilm suitable This abrasiveis abrasive MICRONORM agents. cleaning corrosive or caustic use Never is biologicallyand disposable. theselected basisof fuel fractionstensides with Itsolvent-cold isa cleaner,free of halogen,on sults havebeen achieved with “Clenvex 2000“. tion residues with a bronze brush. Very good re- headcleaning with agentremove and combus- Soak combustion chamber, pistonand cylinder pound residue with sealant remover. aggressive solutions. Clean off sealing com- agents. Donotcoolant clean or oilhoses with notDo uselye-basedcold cleaner or degreasing Cleaning agents BRP-Powertrain NOTICE Description, Application parts. etc.)for cleaning allmetal agents (e.g. kerosine, varsol, approved only Use cleaning MICRONORM abrasive MICRONORM abrasive for local and gradual gradual and local for 05-00-00 January 01/2010 Qty. page 9 page Edition 2/Rev. 0 Effectivity: 914 Series Lock washer Nut securing Self-locking lar Advisory Circu- General note .)Acceptable methods,techniques andpractice 1.6) OE:Whenfittinglock washers, ends(1)must thecurved-up NOTES: ing toDIN980ispo nuts elementonnuts accordingtoDIN985aswell accord- asthesecuring When usingaself-locking nut, take ca Respect withoutfail all techniques andpractice. Theseare Circular"ACThis Manual "Advisory All general inspection, ening torques. ing meansandlubrication maintenance andrepairinstructions. tion andrepairsinnon-pressurized ar Ci accordance withAdvisory ƽ NOTICE WARNUNG point towards thescrew headornut. 1 MAINTENANCE MANUAL MAINTENANCE moved. wires must bereplacedeachtimethey have beenre- Self-locking nuts, cotterpi sitioned towards outside. BRP-Powertrain maintenance andrepairhas additional indicationsregar of fixationelements. A rcular AC 43.13fromFAA. 1 describes maintenancemethods, describes recognized andauthor eas for whichtherearenoseparate re thatthepolyam ns, tabwashers andsafety dhere tospecifiedtight- ding securing andseal- ding securing to be carried outin to becarried 05-00-00 ide insert ring on ring ide insert ized for inspec- January 01/2010 page 10 00144
d04524.fm d04525.fm Edition 2/Rev. 0 Effectivity: 914Series Table ofcontents Introduction regarding TBOandtimeli This chapteroftheMaintenanceMan avoid enginetroubles by theus These checks, relatedtolimitedperiods Definition of terms Time limit General Overhaul (TBO) cycle Life Time limit Operating hours Annual inspection Time limit for the coolant parts rubber for limit Time MAINTENANCE MANUAL MAINTENANCE Chapter: 05-10-00 BRP-Powertrain Subject TIME LIMITSTIME mits on rubber components.mits onrubber e ofpreventive maintenance. ual containsgeneral information ofoperation, areplannedtohelp ae4 page 3 page 3 page 3 page 3 page ae8 page 8 page 8 page 5 page 05-10-00 Page January 01/2010 page 1 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-10-00 January 01/2010 page 2 page
d04525.fm d04525.fm Edition 2/Rev. 0 Effectivity: 914Series Definition Definition Definition Definitionofterms 1) .)Life cycle 1.3) Timelimit 1.2) .)Operatinghours 1.1) Theplannedinspectionstobeperform - Amechanical hourmeteris NOTES: of theengine. avoid engine malfunctionsordefects mainte formed. Theseprecautionary replaced for ageneral overhaul, Once thetimelimitsha either oncalendarinterv Time limitsarepredet Thetimeiscountedirresp - All timeduringwhichtheengineis - standings andtoensuresafety: The operating hoursaredefi engine TBO, relateto All ofthemaintenancein NOTES: Parts withalimitedlife Parts NOTES: quoted inflighthours. The life cycleisalways specifiedas continued trouble-freeoper intended asprecautionar on experiencefromlongtestruns as idlingortake-offpower. number ofoper readings oftheel nance andoverhaul ar intervals given by electronicremitters speed, thereadingsmay deviat of flighthoursis tion andoverhauled ifthespecifiedtimespanornumber MAINTENANCE MANUAL MAINTENANCE ating hours. BRP-Powertrain ermined time spans and intervals whicharebased timespansandintervals ermined the number ofoperating ve beenreached,theaffect als orthenumber of tervals, suchasthe y maintenancemeasures ned asfollows inorder ective oftheloadfact ation oftheengine. reached(whichever comesfirst). or maintenance work mustor maintenancework beper- ectronic hourmeter. an exact timespanandisalso andfieldobservations.Theyare nance measuresaredesignedto and ensure continued airworthiness and ensurecontinued airworthiness running iscountedtowardsthetotal cycle must betaken outofopera- ed atcertainintervalsarebased directly coupledtotheengine engineoperating hours. 100 hr. inspectionandthe (e.g. TCU, FlyDat).Mainte- hoursoftheengine. e considerably fromthose e always dictatedby the ed parts must eitherbe ed parts or oftheengine,such toprevent misunder- inordertoensure 05-10-00 January 01/2010 page 3 page Edition 2/Rev. 0 Effectivity: 914 Series keep to Legal obligation operation Maintenance of Definition .)Generaloverhaul (TBO) 1.4) TBO values for theenginearealways valuesmance testsandempirical The TBOvalues approved by therele to sendintheseobj operating conditi operation undernormal component assemblies, add-oncom The timebetween overha The usermust recordtheoper upgrade/expansion programs. TBOvaluestion ofairworthiness. operation oftheenginea fication ofairworthiness. manufacturer's andtheaviation aut operating conditionsarethe Normal MAINTENANCE MANUAL MAINTENANCE ects for anoverhaul. BRP-Powertrain nd arerequiredfor theacceptanceandcertifica- uls (TBO)for allobjects(suchastheengine, ating hoursint can bechangedinresponsetopossible which have beengatheredthrough hority’s recommendations for thecerti- ponents) istheapproved lengthof conditions whichcomplywiththe vant arebasedonperfor- authorities shown inoperating hoursand years. ons before it becomes mandatory ons before itbecomesmandatory he enginelogbook. 05-10-00 January 01/2010 page 4 page
d04525.fm d04525.fm Edition 2/Rev. 0 Effectivity: 914Series this time limit After reaching General Timelimit 2) contaminants. andall cleaned, preserved For anoverhaul, theenginemust be The timelimitfor engi ƽ ƽ NOTICE NOTICE WARNUNG WARNUNG MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain shipped to an authorized ROshipped toanauthorized After reachingthistime A general overhaul of isdueafteradefinedperiod start ofoperation (whicheverstart comesfirst). eration oraftera ne operation willbe s openings tobeclosed removed fromtheaircraft, be specified calendar life calendar specified initial since pecified by theTBO. limit, theenginehastobe TAX overhaul facility. prevent of entering 05-10-00 January 01/2010 page 5 page
op- Edition 2/Rev. 0 Effectivity: 914 Series (1 For theTBOofspecific enginety refer totheengi letin (SB)for therespecti 1 UL 914 1 UL 914 UL 914 F 914 F 914 F 914 ExtensionoftheTBOispossible and scription Type de- Engine and incl. 4,418.103 incl. and from 4,417.501 up to rm67379 2000 hr. oryears, 15 from6,773.779 6,773.778 incl. and from 4,418.104 up to 2000 hr. oryears, 15 from4,420.909 4,420.908 incl. and from 4,420.314 up to 4,420.313 from 4,420.001to ne logbookorre engine affected MAINTENANCE MANUAL MAINTENANCE engine S/N BRP-Powertrain ve enginetype. For ext whichever comes first first comes whichever 1000 hr. oryears, 10 whichever comes first first comes whichever first comes whichever 1200 hr. oryears, 12 first comes whichever first comes whichever 1200 hr. oryears, 12 first comes whichever 1000 hr. oryears, 10 lease certificate. Time BetweenTime Overhaul pe/version refer tothetable below. will bespecified TBO ensions alreadyeffective (1 (1 (1 (1 (1 (1 first whichever comes i.e.toyears, 10 12 hr. hr. to 1200 1000 SB-914-027UL None first whichever comes i.e.toyears, 12 15 hr. hr. to 2000 1200 SB-914-039 first whichever comes i.e.toyears, 10 12 hr. hr. to 1200 1000 SB-914-027 None first whichever comes i.e.toyears, 12 15 hr. hr. to 2000 1200 SB-914-039UL SB tobe carried out 05-10-00 by a Service Bul- by aService to increase TBO (1 (1 (1 (1 January 01/2010 page 6 page (1
d04525.fm d04525.fm Edition 2/Rev. 0 Effectivity: 914Series Shipment ceeding Authorized ex- following: ROTAXThe shipmenttoanauthorized ever comesfirst. Extension orexceeding oftheTBOby Useful remarks and observations concerning the engine. Data about the type of aircraft used. 6 5 Indication of total engine operating hours (TSN) and where applicable, engine 4 The engine assembly asper supply volume. Additionally alladded-on parts as Maintenance records of the engine (i.e. all maintenance check lists, and reports 3 Engine logbook. 2 1 NOTE: This information This must besu NOTE: operating hours since aprevious overhoul (TSO). sensors, ignition unit,electric starter, oiltank. in thevolume supplyassuch carburetors, filters, fuel pump, external generator, ofoperation, of maintenance,findings of and of oilanalyses). MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain tory of componentstotraced. be tory 5%or6monthsisallowed which- overhaul facility pplied to allow the service his- pplied to allow the service 05-10-00 must includethe January 01/2010 page 7 page Edition 2/Rev. 0 Effectivity: 914 Series General note General note Time limit General note .)Annual inspection 2.3) Timelimitfor thecoolant 2.2) Timelimitfor rubberparts 2.1) during overhaulduring orwhent of operation A 100hr. out inspectionistobecarried Coolant must bereplaced diaphragm onbot - carburetor sockets - The following components See chap. 05-10-00 section: -V-belt hosesoncompensatingtube rubber - all rubberhosesofthe - all rubberhosesofthefuel - all rubberhosesof - venting hoseof - ƽ craft manufacturer supply volumeandiftheyarenot NOTICE WARNUNG or every 12 MAINTENANCE MANUAL MAINTENANCE the carburetors This timelimitmust befollowed section: addition BRP-Powertrain h carburetors thecoolingsystem
months he engineisreplaced. lubrication systemwhich andsystemsmust berepl as permanufacturers inst 5.1)) tothevisualinspec 2) system(incl.teflonhoses) . oftherespective components. , whichever comesfirst. inthemaintenanc periodically afterevery periodically 100hours tions (seechap. 05-20-00 are partoftheengine independently ructions, atthelatest aced every 5years: e scheduleofair- 05-10-00 January 01/2010 and page 8 page in
d04525.fm d04526.fm Edition 2/Rev. 0 Effectivity: 914Series Table ofcontents required Documentation Introduction nance workcarriedout worthiness oftheengine, mechanic. Astheparty regarding periodicmaintenanceand This chapteroftheMaintenanceMan It istheresponsibilityof protocol canreplacet This inspectionprotocolisnotinte airworthiness directives. airworthiness oftheen The ownerand/oruseris vious inspectionprotocolsand craft mechanicperformingthework Check list/Maintenance schedule procedures schedule Maintenance Visual inspection Unscheduled maintenance checks Scheduled maintenance checks SCHEDULED MAIN Maintenance schedule MAINTENANCE MANUAL MAINTENANCE Chapter: 05-20-00 BRP-Powertrain Subject he knowledgeandexperienceof gine. Thisincludescompli byqualifiedengineers. primarily responsiblefo theownerand/oruserto primarilyresponsible theownerorusersh TENANCE CHECKS any otherrequireddocuments. nded tobeall-inclus on theenginehasaccesstopre- the maintenancechecklist. ual containsgeneralinformation ae9 page 7 page 5 page 3 page ae13 page 11 page ould onlyhavethemainte- r themaintenanceandair- for themaintenanceand ance withallapplicable make surethattheair- ive, fornosuch acertifiedaircraft 05-20-00 Page January 01/2010 page 1 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-20-00 January 01/2010 page 2 page
d04526.fm d04526.fm Edition 2/Rev. 0 Effectivity: 914Series check 25-hr. hr.Special check check 100 hr. Intervals Definition Scheduled maintenancechecks 1) carried out. hr.additionalchecksaspe and all200 OE:This maintenance NOTES: If before maintenanceisperformed - Fortheintervalsbetweenmaintenance - In ordertodemonstratecontinu - This meansforexamplethat hr.intervalsinaccordance 600 Periodic inspectionsarethosewhich a specifiedperiodofoperation. This sectionliststheperi In ordertodemonstratecontinu - h hcspromda h 5hr.in Thechecks performedatthe25 - 0 hr 600 hr 200 hr 100 will be due at 200 hr. ±10 hr. hr. hr.±10 will bedueat200 hr.checkisactually that ifa100 permissible, butt check must out becarried hr. check isdoneafter87hours 100 maintenance check istobe doneatt inspected afterevery100hoursofoperation. overhauled engines. hr.inspection.Thisappliesboth 100 inspected afterthefirs 5hr 25 XXXXX XXXXXXXX 0 hr 100 operating withleadedAVGAS. but not essential,witht check. Thischeck isrecommendedby themanufacturer MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain hese tolerancesmustnot 0 hr 200 XXX odic inspectionswhichmu t 25hoursofoperation. Intervalshours - 0 hr 300 after 187hoursofoperation). every 100 with chap.05-20- n o t20h.±0hr. hr.±10 and notat210 ed airworthiness, ed airworthiness, ceuecnan ounfra5 hr. schedule containsacolumnfor a50 0 hr 400 carried outat110hr.,thenextcheck must beperformed the prescribed interval, the next interval, the prescribed r maintenancechecklistmustbe to newlydeliveredenginesand foeain h et10hr. of operation, thenext 100 he same interval (e.g.he sameinterval iffirst he exception ofoil changewhen hr. ofoperation spection arethesameasfor 0 hr 500 work, atoleranceof±10hr.is be exceeded.Thismeans 00. section: 0 hr 600 st becarriedoutafter X an enginemustbe an enginemustbe 05-20-00 a10hr.check a100 0 rto hr 700 at 50,100,200, January 01/2010 5.1). page 3 page 2000 hr Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-20-00 January 01/2010 page 4 page
d04526.fm d04526.fm Edition 2/Rev. 0 Effectivity: 914Series spections Recommends in- exceeded Operating limits Unscheduled maintenancechecks 2) engine operation. manufacturer, aspossible malfuncti out maintenance iscarried The manufacturer alsorecommendsth chapter 05-50-00 accordance withtheapplicableun (e.g. lightningstrike).Insuchca etc.), orifunusual the enginehavebeenexceeded(e.g. An inspectionofthe Electr. fuelpump Radiators, Lines Exhaust fixation Engine cowling Fuel filter Fuel Propeller Battery part Oil MAINTENANCE MANUAL MAINTENANCE ). operating conditionshave BRP-Powertrain - carry out dynamically balancing balancing out dynamically carry - undamaged andtrue runs - check for discoloration - and - damage. for - addi- (provides oil the analyse - contamination. oil for - Insufficient fuel supply. tion. instruc- themanufacturers Observe concentration acid for each cell - correct function. - of fuel filter on airframe side (for - o iclrn n apn.Dangerofoverheating re-tighten the exhaustfixation - for discoloring and warping. - engine mustbeperformedif track. including verificationof propeller cracks. tion of the engine). tionalinformation on the condi- and loose fragmented material). foreignbodies, sealing material is hr.operation. of first 2 on the cylinder head after the (wherenotalreadypre inspection ses theenginemustbeinspectedin scheduled maintenancechecks.(See ons couldhave negative effects on overspeed, excessivetemperature e following inspectionswhenever occurred duringoperation theoperati scribed byscribed theairframe vibrations Engine damage, unusual Danger ofoverheating Danger Possible engine wear and damage). lean (Enginemalfunction too running Engine loss. Engine to misfire. Power Starting problems damage). (Engine malfunction and Engine runningto lean Leakage possible danger 05-20-00 January 01/2010 ng limitsof page 5 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-20-00 January 01/2010 page 6 page
d04526.fm d04526.fm Edition 2/Rev. 0 Effectivity: 914Series Filter Nuts Screws and Wiring lines Air-Fuel-, andOil Parts parts Moving General note inspection Visual 3) blockages, cleanedand Filters andscreensmustbeinspect visually evidentdamage. Surface damage,secureseating,lo dent damage. or worninsulation;secureseati General cleanliness;loose,corroded cleanliness, secure Cracks, dents,kinks,requi welding seamsordueto Secure seating,surfacecondition, damage. extreme wear,cracks,corr ness, easeofmovement,adjustment,me Normal operatingcondit limited to,thefollowing. The scopeofavisualins visually evidentdamage. MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain seating andothervisu ion, accuratealignmen replaced asrequired. pection generallyincludes, materialfatigueorst red flexibility,collapse osion, deformationand ng, heatdamageandot cleanliness, deforma ed forcontaminationandpotential cking wire,securi or brokenterminals;chafed, chanical stress,travel,catching, ally evidentdamage. ress, corrosionandother t, leak-tightness,cleanli- d lines/hoses,abrasion, other visuallyevident but isnotnecessarily ng paintandother 05-20-00 her visuallyevi- tion, cracksin January 01/2010 page 7 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-20-00 January 01/2010 page 8 page
d04526.fm d04526.fm Edition 2/Rev. 0 Effectivity: 914Series equipment Replacement of medial action Discrepancies/re- records Maintenance Extra inspections check lists Maintenance Specified period Inspections schedule procedures Maintenance check (maintenance list) 4) date. SB (LTA)mustbeentered Replacement ofequipment to storeandkeep therecords. Itisthere outmaintenancework. carry findings tobegenerat All discrepanciesand book. maintenance records. Themaintenan After maintenance, the All themaintenancework - hr. ch Therespective check (e.g. 100 - Thelistsmustbeph - and volume ofmaintenancework Checks outasperthema arecarried must work listed All erwise stated. All statedchecksarevisualinsp ture" areabytheaircraft each pageofthemain check. MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain be carriedoutwithin ed andmaintainedby th remedial actionmust be otocopied andfilledou completed check listsmu tenance check list. intheenginelogbook, mechanicperformingthetask. (e.g. fuelpump,govern carriedoutmustbein ections fordamageandwear,unlessoth- isoutlinedinkey words. intenance check lists, wheretype ce must beconfir sponsibility oftheaircraft operator eck) must beno the specifiedperiod. t foreachmaintenance e company to authorized recorded in a report of recorded inareport st beenteredinthe or....) andexecutionof stating S/N,TSNand itialled inthe"signa- med inthelog 05-20-00 ted onthetopof January 01/2010 page 9 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-20-00 January 01/2010 page 10
d04526.fm d04526.fm Edition 2/Rev. 0 Effectivity: 914Series Check List/MaintenanceSchedule 5) TSN ( TSN Engine S/N Engine type ENGINE Propeller model and S/N Propeller brand Time sincenew Aircraft modelS/N and Aircraft make Registration number AIRCRAFT TSO ( TSO Telephone/Fax/E-mail Address Contact Name OPERATORAIRCRAFT oil fuel coolant Used operating fluids: t t - mixture ratio ime ime s s ince ince ince n o ew) verhaul) MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain Identification 05-20-00 January 01/2010 page 11 Edition 2/Rev. 0 Effectivity: 914 Series Next check at: due on) is applicable (circle check This Certificate Telephone/Fax/E-mail Address Maintenance workshop FACILITYMAINTENANCE MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain 5h.5 r 0 r 0 r 0 hr. 600 (TS______) (engine hr.) hr. 200 ______hr. hr. 100 hr. 50 hr. 25 Identification 05-20-00 January 01/2010 page 12
d04526.fm d04526.fm Edition 2/Rev. 0 Effectivity: 914Series General note dition. oil pressure sensor.Inspect for tight fit and good con- Visual inspection of the temperaturesensor and the ence. Takenote of changes causedby temperature influ- ders for obstruction, cracks, wear and good condition. Check cooling airduct and coolingof fins thecylin- abnormalities. General visual inspectionofthe engine for damage or passage. Inspect ventingbore in capoverflow of bottle forclear damage, leakage and clearpassage. Inspectfrom line expansion tank to overflow bottle for necessary. as replenish level, coolant Verify ities. Inspect the overflowbottle for damage and abnormal- fit. correct Inspectprotection rubber onexpansion tank basefor Inspect radiator cap. level, Check coolant malities. Inspect the expansiontank fordamage and abnor- basethe ofwater pump forsigns of leakage. Carry out visual inspectionof leakage bore at the kinks and restrictions. tions and secure attachment. Verify routing is free of age, hardeningfrom heat, porosity,loose connec- leak- including damage, for hoses coolant all Inspect .)MaintenanceSchedule 5.1) Points of Inspection OE:Ifthepoints1-3 NOTES: maintenance checklist.See Perform thefollowingmaintenanceta Legend: X = do the the task do = X Legend: replenish as necessary. replenishasnecessary. ln no task required = blank 1.)inspection Visual ofengine the Powertrain for instructions continuedairworthiness. be checked andrepairedin If oneofthepoints1-3isnot with themaint MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain 50 hr. recommended chapter 05-20-00 indicated Operating hours enance schedule. of thechecklist are as Interval Interval sks attheintervalsshownin 12-20-00 X 12-20-00 X 12-20-00 12-20-00 X X 12-20-00 X X 100 hr. fulfilledthentheenginemust accordance withtheBRP- 2 hr.check. 25 sec. 3) sec. 11.5) sec. 11.1) sec. 4) sec. 11.1) Reference Chapter fulfilled thencontinue 05-20-00 January 01/2010 Signature page 13 Edition 2/Rev. 0 Effectivity: 914 Series fit, including damage from heat, deformation, cracks. suspension engine Inspect Check the magnetic plug at every oil change. oil every at plug magnetic the Check Checkingthe airfilter. fit. Inspectsafety wiring, replacenecessary. as tight for parts allexternal of nuts and screws Inspect tions. tachments. Verify routingfree is of kinksand restric- from heat, porosity, security of connectionsand at- hardening leakage, damage, for lines oil all Inspect Engine cleaning uncharacteristicgunpowder burns (leaks). Inspect the exhaust systemfor formation crack and damage and signswear. of Inspect the wiringconnectionsits and for securefit, marks. scuffing and/or cracks any for check also lines, fuel steel of case the In ments. Verifyrouting and isfree restrictions.kinks of from heat, porosity, security connectionsattach- and Inspect allfuellines for damage, leakage, hardening Test pressure______hPa (psi) method. pressure differential the by compression the Check bar/psi y 4 3 2 1 Cyl # Pressure drop (%orfraction) Points of Inspection and fasteners for secure fasteners for and 4.) Checking the engine suspension MAINTENANCE MANUAL MAINTENANCE 7.) Checking the air filter air the Checking 7.) 5.) Engine external parts 3.) Compression check Compression 3.) 6.) Enginecleaning BRP-Powertrain 2.) Magnetic plug vr 0 r 12-20-00 hr. every 200 indicated Operating hours as Interval Interval 12-20-00 X X 12-20-00 X 12-20-00 X 12-20-00 X 12-20-00 X X 12-20-00 X 12-20-00 X 100 hr. sec. 5) sec. 16.1) sec. 4) sec. 4) sec. 2) sec. 1) sec. 3.1) sec. 14) Reference Chapter 05-20-00 January 01/2010 Signature page 14
d04526.fm d04526.fm Edition 2/Rev. 0 Effectivity: 914Series necessary.Replace asrequired. electrodeessary. Check gab and adjust as nation, clean,electrode check gap and adjustnec- if Remove allspark plugs,check the heat rangedesig- Checkingthe idlespeed. (1 (1 ence. Takenote of changes causedby temperature influ- dition. normalities, checking for cracks, wear and good con- Inspect the carburetor sockets for damage and ab- pneumatic synchronization. Check carburetor synchronization.Mechanical or stop. to stop from lever throttle the Check thatthe bowdentheallows cable travel full of (throttle lever and starting carburetor). Check for free movement of the carburetor actuation Minimum pull-off is force 30 N (7 lb). theon spark plugs. Check that resistance spark plug connectors fit tightly Replace spark plugs. corrosion. Inspect the floatchamber assy. for contaminationand inspection. retor Removal/assembly of the twocarburetorsfor carbu- and thatcan arise. nokinks Check that the passage of the ventilation linesisfree avoided. gine and carburetorfunction andmust therefore be troublewith the float chamber ventilationimpairs en- Checkingthe ventilationof the float chambers. Any useof leaded fuel more than 30%of operation. See SB-914-019 - latest edition. Points of Inspection 9.) Inspecting carburetor sockets and drip tray 8.) Checking the carburetor the Checking 8.) 10.) Spark10.) plugconnectors MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain 11.) Spark plugs every 200 hr. 200 every vr 0 hr. every 200 hr. every 200 tion annual inspec- Heavy MM hr. every 200 indicated Operating hours as Interval Interval (1 12-20-00 X 12-20-00 X X 12-20-00 X 12-20-00 X 100 hr. (1 sec. 12.4) 12-20-00 sec. 3.1) 73-00-00 sec. 16.2) 12-20-00 sec. 3.4.3) 73-00-00 Heavy MM sec. 12.6) sec. 12.3.1) sec. 16.2) sec. 12.1) Reference Chapter 05-20-00 January 01/2010 Signature page 15 Edition 2/Rev. 0 Effectivity: 914 Series see OperatorsManual SI-914-019, and latest edition. position. Check the wastegate flap for free running and correct Refill oil tank with approx. 3lit Refill oiltankwithapprox. oiltank. Check ______Findings:______inspect filtermat. Cut oldoilfilterpr without Inspect overloadclutch. Gearboxes (with overload clutch). Actual friction torque______Nm (in.lbs) with overloadclutch. Check the friction torque in free rotation on gearboxes thefuelfilter. Check Lubricate the axle(wastegate flap). damage. and ment Check the wastegate bowdencable forfree move- ter. Remove oldoilfilter from engineinstall andnew oilfil- clutch). Check the propellergearbox (without overload (1 Check the propeller gearbox (with overload clutch). ants are used. Flushing the cooling system where conventional cool- ntecs oeta 0 foeainwt eddfe .. VA 0 L12-20-00 In the case more than 30%of operation with leaded fuel e.g.: AVGAS100 LL Points of Inspection oducing any metal chips oducing anymetal and res of oil.Fo res 15.) Checkingthepropeller gear box 12.)Flushing the cooling system 13.) Checking thewastegate flap 14.) Fuel filter (on airframe side) airframe (on filter Fuel 14.) r oilquality, MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain 16.) Oil change the coolant when replacing 50 hr. 50 hr. 12-20-00 50 hr. 12-20-00 every 600 hr. every 1000 hr. hr. every 600 indicated Operating hours (1 (1 (1 as Interval Interval (1 12-20-00 X 12-20-00 12-20-00 X 12-20-00 X X 12-20-00 X 12-20-00 X 12-20-00 X 12-20-00 X 100 hr. sec. 9) sec. 8) sec. 8) sec. 8) 13.6) sec. 13.2), sec. 13.5) 13.4)) sec. 13.3), sec. 17.1) sec. 11.3) 12-20-00 sec. 17.2) sec. 17.2) SB-914-020 sec. 2) 05-50-00 SI-914-019 sec. 13.2) Reference Chapter 05-20-00 January 01/2010 Signature page 16
d04526.fm d04526.fm Edition 2/Rev. 0 Effectivity: 914Series Checks for Checks leaks. (onlycold at engine). After enginetest run,re-tighten the oilfilterhand by A/B (difference)______rpm B (Off)______rpm A (Off)______rpm Speed drop without ignition circuit: Ignitionat check _____ engine rpm speed. Limits see Operators Manual914series. Start the engine and run to operating temperature. thesafety Observe instructions! Check the electric fuel pumps. Certificate No.______Aircraft mechanic______Inspector______Location, Date______turerand wasrecorded inthe EngineLog book. Check at______hr.(TSN___, TSO___) was carried out accordingtorecommendations of theengine manufac- theOn engineidentified as per pointon 5, the ______the______hr. Returning engineservice to Replace the main fuel pump. attachmentthe and V-belt tension. with aux On configurations complied with. All ServiceInstructions and Service Bulletinsare Points of Inspection iliary generator, check the iliary generator,check 17.) Checking the V-belt tension V-belt the Checking 17.) MAINTENANCE MANUAL MAINTENANCE 18.) Electric fuelpumps 19.) Engine test19.) Engine run BRP-Powertrain General note vr 00h.IM hr. MM II every 1000 hr. every 1000 indicated Operating hours as Interval Interval 12-20-00 X X 12-20-00 X 100 hr. sec. 14.4) sec. 3.4.6) 73-00-00 (Heavy) sec. 6) sec. 8) Reference Chapter 05-20-00 January 01/2010 Signature page 17 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-20-00 January 01/2010 page 18
d04526.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series Table ofcontents Introduction dures. regarding unscheduledmaintenancech This chapteroftheMaintenanceMan impairs theairworthi fault operation asdefi (e.g. abnormal Special checks outim must becarried Reporting Examination after engine failure Checking of the overload clutch Engine check afterpropeller strike incidents UNSCHEDULED MAINTENANCECHECKS ƽ ƽ NOTICE NOTICE WARNUNG WARNUNG Hard to turn over turn to Hard Sparknot plug inaccordancewith specification Oil specificatio minimum value Oil pressurebelow ture Exceeding the max. permissibletempera- oil Exceeding ofcylinder max. head temperature Exceeding ofadmissibleengine max. RPM Inspection in extreme climatic conditions in water Returning engine to serviceaftersubmerging clutch overload integrated without gearbox Propeller clutch Propeller gearboxintegrated with overload MAINTENANCE MANUAL MAINTENANCE Chapter: 05-50-00 n not respected n not BRP-Powertrain Subject run andaleakagecheck out. run must becarried After eachspecialcheck/ plicable. checks Observe withoutfailObserve allt In thecourseofspecialchecks specifyif ness oftheengine. for components(e.g. hydraulic governor) isap- ned intheOperators Manual) which ual containsgeneral information mediately inthe ecks andtheirassociatedproce- he specifiedinstructions. repair work, anenginetest repair work, page 27 page 20 page 19 page 17 page 15 page 13 page 11 page 10 page 9 page 9 page 7 page 5 page 4 page 3 page 3 page event ofanengine 05-50-00 Page January 01/2010 additional page 1 page
Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-50-00 January 01/2010 page 2 page
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series General note Definition check Engine afterpr 1) .)Propeller gearbox withintegratedoverload clutch 1.1) before operation cancontinue. After any propellerstrike thefollo See SL-912-015,SL-914-013,SL Any incidentwhiletheengineisst - strikeis: A propeller Inspect the crankshaft on the power take off side for out-of-roundness. See Observe the manufacturers instructions forthe governor, vacuum pump 7 6 The whole gearboxbe must inspected, repairedoverhauled or inaccor- Remove the gearbox and rollerbearing ofthe propeller shaft. Observe the directives of the aircraft manufacturer. 5 Inspect add-oncomponents. 4 3 2 repair inspect, detected, is damage any If damage. for engine the Inspect 1 necessary toperformre Step opeller strikeincidents chapter 72-00-00the of Heavy Maintenance Manual. propeller. and Inspect drive for governorand vacuum pump (if fitted) - NDTforon gearbox cracks housing, propellershaft and gear set - Carry out detailedinspection of allgearbox components - too but notlimited BRP-Powertra the with dance Inspect allsystems forcorrect functioning. structionsfor continued airworthiness. or overhaul the whole engineaccordancein the with BRP-Powertrainin- MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain pairs ont wing inspectionsmust beperformed -2ST-009, currentedition. in instructions he propeller. ationary orrunni Procedure forcontinued airworthiness - ng whichmakesit 05-50-00 January 01/2010 page 3 page Edition 2/Rev. 0 Effectivity: 914 Series Propeller strike .)Propeller gearbox overload integrated without clutch 1.2) The following inspectionsmust be tinue. Inspectthe engine fordamage. If anydamageis detected, inspect,repair or 1 Inspect the crankshaftthe on power take off sideforout-of-roundness. Observe the manufacturers instructions for the governor, vacuum pump and 7 6 The whole gearbox must be inspected, repaired or overhauled inaccordance Removethe gearboxandroller bearing of the propeller shaft. manufacturer. aircraft the of directives the Observe 5 Inspect add-on components. 4 3 2 Step Inspect all systems fo allsystems Inspect tions for continued airworthiness. overhaul the whole engineaccordance in the with BRP-Powertrain instruc- shaft. See chapter 72-00-00 of the Heavy Maintenance Manual. Maintenance Heavy the of 72-00-00 chapter See shaft. crank- installed on distortion crankshaft of Inspection - load shock Propeller propeller. Inspect drivefor governor andpump vacuum(if fitted). forcracks NDT gearbox on housing, propeller shaftand gear set - Carry out detailed inspection of all gearbox components - limited too with the in BRP-Powertrain MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain r correct functioning. correct r structions for continuedairworthiness -but not performed before ope Procedure 05-50-00 ration cancon- January 01/2010 page 4 page
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series General note Checking theoverload of clutch 2) Fig. 1 for Theengineshouldberun a NOTES: Slippingofoverl NOTES: tocheck th essary In theevent ofleaddeposits Danger of damagethe to engine suspension! Lock the crankshaft. See chap. 12-20-00 section: Remove the propeller asper manufacturers instruction. 3 2 1 Step IRUFH)LQ1 .UDIW)LQ1 OE Because of difficult measurement of the slipping torque NOTE: measuring tool. the propeller flange and the breakaway torque measured with a suitable A specially prepared lever (e.g. length 1.5 m (4.92 ft.), see Fig.1) isfitted on OHQJWK/LQP /lQJH/ P NOTICE resulting inahighertorque. test, otherwisethereistheri rate. rise, thepropellerspeeddoe MAINTENANCE MANUAL MAINTENANCE e overload clutch. BRP-Powertrain the breakawaythe measured. is torque and/or ifslippi a suitable mounting attachment. gearbox must be removed and the test out carried on of extremely lightweight enginesuspension), the Depending onthe engineinstallation (e.g. inthe case oad clutchisapparent Procedure ng issuspected, sk of the clutch „drying out“, sk oftheclutch„drying s notincreaseatthesame short time just prior tothe timejustprior short 7) 05-50-00 if atenginespeed January 01/2010 it willbenec- page 5 page 08054 Edition 2/Rev. 0 Effectivity: 914 Series Obtained value Measurement in m(Nx=Nm). in Nandthelengthof The breakaway torqueiscalculated must beinspected,repairedorover If thevalue isgr ft.lb.). 590 mustThe value determined Repeat themeasurement Powertrain for instructions continuedairworthiness. Release the crankshaft, see chap. 12-20-00 section: 4 ƽ Step NOTICE WARNUNG eater orsmallert MAINTENANCE MANUAL MAINTENANCE damage canoccur. Do notexceed 800Nm( BRP-Powertrain thelever distancefromit (L)usedatthenormal arm several timestogetastable value. be between 600and800Nm(442 han thelimitvalue, theoverload clutch hauled inaccordanc on thebasisofforce (F)measured Procedure 9 ft.lb)otherwisegearbox 590 7) e withtheBRP- 05-50-00 . January 01/2010 page 6 page
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series Engine stoppage Rough running Engine General note Examinationafterenginefailure 3) following enginephenomenatofa to can alsobeofhelp. Itisimportant available ont data.Observations In ordertofindpossible causesofthefa ulsse fuel supply Spark plug electronic module, charging coil) Ignition system (shorting cable, Fuel system nieengine temperature too low supply fuel wiring (assignment fault) Engine Carburetor Ignition i updefect oilpressureto Oil pump Oil system ƽ NOTICE WARNUNG part part part MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain Unintendedstoppage engine byseizing ed. necessary. Thefault needs timethenadetai for ashort Should oneoftheabove m Engine runsEngine erraticallymisfires and Rough running engine wrong spark plug connection defect grounding malfunction icing carburetor falseair intake due to defective carburetorflange float chamber venting contamination vapour locks vailing in intake silencer vailing inintake toocarburetor lean jettingdue to conditions pre- incorrectsynchronization of the carburetor falseair intake due to defective carburetorflange float chamber venting valve contaminationfloat in chamberfloat or needle he aircraft andthe cilitate troubleshooting. incorrect venting contamination oil shortage pay particular attentiontoany pay ofthe particular ilure, itisimporta possible cause possible cause entioned pointsoccureven to belocatedandcorrect- led check oftheengineis o low or noo lowor oilpressure possible cause engine suspension 05-50-00 nt topassonall January 01/2010 page 7 page Edition 2/Rev. 0 Effectivity: 914 Series Cylinder head Operators Manual) isaclearsignal A rise incylinderheadtemperature A rise inspectionof Detailed - allsystemsforcorrectfunctioning. Inspect - The wholeenginemustbeinspect - asatbaig/ordbaig rather consequential damage wear(low oil Camshaft bearings/Conrod bearings ae upmalfunction contaminated leaking malfunction not enough coolant malfunction Water pump valve relief Pressure cap Radiator Radiator notworking is Return valve Cooling system ness. dance withtheBRP-Pow NOTICE part part MAINTENANCE MANUAL MAINTENANCE Unintended engine stoppageseizingby BRP-Powertrain paired. The entire assembly must bedismantled, inspected and re- Cylinder head temperature toohigh affected enginecomponents. ertrain instructionsforcontinuedairworthi- pressure) for afailure inthecoolingsystem. above operating limits(see normal bad venting ed, repairedoroverhauledinaccor- possible cause possible cause possible 05-50-00 January 01/2010 page 8 page
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series General note General note 3.1) Returning engine to service aftersubmerging water in toservice engine Returning 3.1) .)Inspectioninextreme climatic conditions 3.2) rized ROTAXrized distributor. tocontact do this, itisnecessary requires adjustmentofth Flying inareaswithextr arerecommended. intervals increased wear onallcomponents. For orareaswithheav Flying indeserts Carry outdetailed - Inspect allsystemsfo - tions for continuedairworthiness. overhauled or repaired inaccordanc An enginewhichhasbeensubmerged ƽ ƽ NOTICE NOTICE WARNUNG WARNUNG MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain oil coolerarenecessary. Every 25hr. checks ofairf merged inwater“. The enginemust bemark inspection ofaffect eme climaticconditions r correctfunctioning. e carburetor jettingand the aircraft manu ily contaminatedordustyaircauses e with theBRP-Powertrain with e instruc- in water must beinspected, this reason, shorter maintenance this reason,shorter ed enginecomponents. ed clearly “Enginesub- ed clearly ilter, coolantradiator and or inextreme altitudes of thecoolingsystem.To facturer andanautho- 05-50-00 January 01/2010 page 9 page Edition 2/Rev. 0 Effectivity: 914 Series rpm 6200 than more more than 1min. rpm max. 6200 max. 1min. up to 6200 rpm General note .)Exceedingofmax. 3.3) OE:Any exceeding ofthema NOTES: If the speed6200 of exceeded rpmwas If the limit was exceeded for more than 1minute If the limit was exceeded for max. 1minute upto 6200 rpm Detailed inspection of affected engine components. functioning. correct for systems all Inspect crankshaft. the Replace 5 Check that the push-rods are straight. 4 The whole engine mustinspected, be repaired or3 overhauledin accordance 2 1 Detailed inspection of affected engine components. functioning. correct for systems all Inspect Inspect the crankshaft for out-of-roundness.5 See chap. 72-00-00 of the Heavy Check that the push-rods are straight.4 The whole enginemustinspected, be repairedor overhauled 3 inaccordance 2 1 Check that the push-rods are straight. 1 Step Step Step with theBRP-Powertraininstructio Maintenance Manual. Maintenance with theBRP-Powertraininstructio ration extent ofovers be enteredby thepilotinto MAINTENANCE MANUAL MAINTENANCE admissible engineRPM BRP-Powertrain peeding and pertinent detail. peeding andpertinent Procedure Procedure Procedure ns forcontinued airworthiness. ns forcontinued airworthiness. x. admissible theenginelogbookstatingdu- engine RPMmust 05-50-00 January 01/2010 page 10
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series 180 °C(356 °F) Exceeding up to Graphic General note .)Exceedingofmax.cylinder temperature head 3.4) Table 1. Table Fig. 2 Overview andproceed: Any exceeding ofthema NOTES: 2 Inspect all further systems for correct functioning. correct for further systems all Inspect ac- in overhauled or repaired inspected, be must system cooling whole The 2 1 ƽ Step NOTICE WARNUNG Carry out detailed inspection of the affected engine components such as. cordance with the BRP-Powe - Check all coolant fittings (feed/outflow) for secure fit. secure for (feed/outflow) fittings coolant all Check - cylin- the If securely. fitted is attachment head cylinder the that Check - system. cooling onthe Leakage check - Max. temperature exceeded up to 180 °C (356 °F) - briefly (356 °F) 180 °C ture of over°C 180(356 and/or °F) for longer than30 min.“ tempera- “Excess sec. in instructed as proceed loose, is nut head der pertinent detail. pertinent book, statingduration extent perature must beenteredby MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain perature. t Pleaseobserve ed, otherlimitsarealsoof If themaximum cylinderhe 0 instructed intable1 Proceed as Proceed asinstructed in table2 (See OperatorsManual914Series) Operating limit rtrain instructions for continued airworthiness. Procedure x. admissible cylinderheadtem- 30 min. the pilotintoenginelog ten exceeded, of excess temperature and he relevant instructions. ad temperature isexceed- 05-50-00 Time January 01/2010 e.g. oiltem- page 11 07140 Edition 2/Rev. 0 Effectivity: 914 Series (356 °F) over 180 °C Exceeding of Table 2. All cylinder heads and cylinders must be removed and subjected to a detailed Check compression bycarrying outdifferentiala pressurecheck. Carry out detailed inspectionthe of affected enginecomponents. 5 Inspect allfurther systems for correct functioning. 4 The wholecooling system mustinspected, be repaired oroverhauled inac- 3 2 1 Step Excess temperatureover of 180 °C (356°F) and/or forlonger thanmin. 30 See chap.See 72-00-00Maintenance inthe Heavy Manual. check including hardnesstesting. cordancewith the BRP-Powertrain instructions forcontinued airworthiness. MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain Procedure 05-50-00 January 01/2010 page 12
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series (320 °F) max. 160 °C Exceeding up to Graphic General note .)Exceedingthemax.permissible oiltemperature 3.5) Table 3. Table Fig. 3 Overview andproceed; Any exceeding ofthema NOTES: 7 Inspect all further systems for correct functioning. correct for further systems all Inspect oil out change. Carry Cut oil filter housing and inspect filter mat for foreign matter. 7 undamaged. and correctly routed are oil lines that Check 6 cooler Inspectoil for contaminationcheck and the entirecircuitoil forcorrect 5 level intheoiltank. oil Inspect 4 whole The oilsystem mustinspected, be repairedor overhauled in accor- 3 2 1 ƽ Step NOTICE WARNUNG (320 °F) (320 160 °C Excess temperature uptomax.160 °C (320 °F) max.15 min. functioning. dance with theBRP-Powertrain instructions forcontinued airworthiness. 0 detail. ing duration extant of excessive temperature andpertinent must beenteredby thepilot MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain structions. head temperature. Pleaseobs other limitsareoftenexc oil If themax.permissible table 3 instructed in Proceed as in table4 Proceed asinstructed (See OperatorsM Operating limit 15 min. Procedure x. admissible oiltemperature into theenginelogbook,stat- eeded, too, e.g. thecylinder temperature isexceeded, erve therelevanterve in- anual 914Series) Time 05-50-00 January 01/2010 page 13 07140 Edition 2/Rev. 0 Effectivity: 914 Series 160 °C(320 °F) Exceeding over Table 4. Cutoil filter housing and inspect filter mat for foreignmatter. (oilco system oil whole the Inspect Carry out detailed inspectionthe of affected enginecomponents. 5 Inspect allfurther systems for correct functioning. 4 Theengine whole must be inspected, repaired or overhauled inaccordance 3 2 1 Step Excess temperature160 over°C (320 °F) for than longer15 min. with the BRP-Powertrain MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain instructions for continued airworthiness. forcontinued instructions Procedure oler, oillines)mustbeinspected. oler, 05-50-00 January 01/2010 page 14
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series ground sure onthe Minimum oilpres- Graphic General note .)Oilpressurebelow minimum value 3.6) Inspect thecomplete - cause. If noticed Oil pressurebelow minimum oilpressureontheground Fig. 4 Overview andinstruction Any exceeding ofthemin. NOTES: (7.25 psi) 0.5 bar ƽ SI-914-007, latestissue. SI-914-007, NOTICE WARNUNG Oil pressure Oil on ground table 5 instructed in Proceed as instructed intable6 Proceed as tion extent ofexcessive pre entered by thepilotinto MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain Please observe therelevantPlease observe instructions. limits areoftenexceeded, e. If theoilpressurefalls be , immediatelystopthee lubrication system,trace 1 min. Operating limit (See OperatorsManual914Series) admissible oilpressuremust be ssure and pertinent details. ssure andpertinent engine logbook,statingdura- low theminimum value, other ngine and determine the ngine anddetermine Time g. theoiltemperature. cause andrectify.See (minimum value) 05-50-00 January 01/2010 page 15 07188 Edition 2/Rev. 0 Effectivity: 914 Series ating limit below the oper- 0.5 bar (7.25 psi) then more flight in falls pressure Minimum oil min. limit for max. 1 low operating bar (7.25 psi) be- flight upto0.5 in falls pressure Minimum oil Consequent damagecanbeex If theoilpressurefalls below themi minimum value morethan0. psi) andfor max.1min.,thec Inspect allfurther systems for correct functioning. Cutoil filter housing and inspect filter mat for foreignmatter. Carry out detailed inspectionthe of affected enginecomponents. 4 3 The wholecooling system mustinspected, be repaired oroverhauled inac- 2 1 Oil pressure below minimum permissible value more than 0.5 bar (7.25 psi) inflight psi) (7.25 bar 0.5 than more value minimum permissible below pressure Oil Carry out detailedinspection of the affected engine components. Inspect allsystems for correct functioning. 9 andoilchan checks Ifaftertheprevious 8 Ifno causefor the lowoilpressure isfound after the above checks, carryout 7 Inspect crankcasepressure (See InstallationManual 914 Series, latest is- 6 Inspect indicating instrument to specificationsthe of manufacturer, replace Inspect pressure sensor. 5 quantity. oil Verify 4 Inspectfor alloillines restrictions and clear passage. 3 2 1 ƽ Step Step NOTICE Oil pressureminimum permissible below oil pressure 0.5barmax. upto WARNUNG tions forcontinued airworthiness. pairor overhaul the enginein accordance with the BRP-Powertraininstruc- an oilchange. sue.) required. as Replace the crankshaft. - cordancewith the BRP-Powertrain instructions forcontinued airworthiness. MAINTENANCE MANUAL MAINTENANCE (inclusive tank oil lation oftheenginecomp Replace theoilcoolerandoi BRP-Powertrain (7.25 psi) max. 1min. in flight in 1min. max. psi) (7.25 5 bar(7.25psi).Table 6. ause must be determined. Tableause must bedetermined. 5. pected iftheoilpre nimum value uptomax.0.5bar(7.25 ) must beflushed. Procedure Procedure ge the oil pressure is still too low, re- isstilltoolow, ge theoilpressure l lines. Before thereinstal- lete lubrication system lete lubrication ssure falls below the 05-50-00 January 01/2010 page 16
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic less than 5hr. General note 3.7) Oil specification not respected Oilspecificationnot 3.7) Fig. 5 Position oftheplugscrew operation for oil specificationintheOperator by thepilotin Anentry If by errorenginewas se NOTES: Run engine forapprox. 1hour and replaceandoilfilteroil once more, as Purgefrom air oilsystem. Seechap.12-20-00, section: specif as oil Refilloiltankwith 8 Drain oilfromtank. 7 Drain oilcompletely 6 Replace oilfilter. 5 4 3 Remove the lowest positioned banjoscrew (1) (banjo bolt, plugor screw Oil change. 2 1 Step stated above. Tighteningtorque see InstallationManual 914 Series. jo bolt or plug screw. ban- in Screw crankcase. the oilfrom remaining the drain and socket) screw less than5hours details isrequired. MAINTENANCE MANUAL MAINTENANCE 1 plug screw plug 1 Part BRP-Powertrain (pusher config.) Druckpropeller pos. 2 Oil specification not respected rviced withoil,whichdoesnotcorrespond rviced from oil cooler. s Manual andthe , the following, the meas ied, refertoO 1 Procedure (tractor config.) Zugpropeller the enginelogbookofallpertinent pos. 1 Function perators Manual. engine hasbeenin ures must betaken: 05-50-00 13.7) January 01/2010 . page 17 02712 Edition 2/Rev. 0 Effectivity: 914 Series longer thanlonger 5hr. If theenginehasbeenoperated work isrequired. work corresponding withspecificationin 1Runengine for approx. 1hour and replace oiland oil filter once more, as stat- 11 0Purgeair Se from oilsystem. with oilasspecif Refill oiltank tank. oil Drain oilfrom 10 from oilcooler. Drain oilcompletely 9 Replace oilfilter. 8 7 6 or screw plug bolt, (banjo (1) screw banjo positioned lowest the Remove change. Oil Carry out detailed inspectionthe of affected enginecomponents. 5 The gearboxmust be inspected, repairedoverhauled or inaccordance with 4 gearbox. propeller Remove 3 2 1 Step ed above. ed Tightening torque see Installation Manual 914 Series. 914 Manual Installation see torque Tightening bolt or plug screw. screw socket) and drain the remaining oil from the crankcase. Screw inbanjo the BRP-Powertraininstructions MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain Oil specificationnot respected longer than5hourslonger theOperators Manual thefollowing e chap. 12-20-00, section: 12-20-00,section: e chap. ied, referto for continued for airworthiness. Procedure Operators Manual. Operators withengineoilnot 05-50-00 13.7) January 01/2010 . page 18
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series General note 3.8) Spark plug not in accordance Sparkplugnotin withspecification 3.8) parts, thefollowingparts, veri to specificationof If by plugswe errorany of thespark 7 Change oiland oilfilter. Change DifferentialpressureSee check. chap. 12-20-00 section: Inspectspark plug thread fordamage (especially at bad burn off). 7 Detailedinspection of affected enginecomponents. 6 for function. allsystems correct Inspect 5 4 3 Inspect the spark plugs for damage (formation of melt beads, burn off). At Mark position of the spark plugs (e.g. cyl. 1 top) and remove all spark plugs. 2 1 Step tinued airworthiness. tinued con- for instructions BRP-Powertrain the with accordance in overhauled or periscope.by If parts are damaged,theengine must beinspected, repaired heavy melt beads orbad burn off, inspect the piston dome and cylinderwall Spark plugSpark not in accordance with specification MAINTENANCE MANUAL MAINTENANCE the enginemanufacturer BRP-Powertrain fication willbenecessary. re installedwhicharenotaccording Procedure and/or notgenuine ROTAX 05-50-00 5) January 01/2010 . page 19 Edition 2/Rev. 0 Effectivity: 914 Series Graphic Inspection General note .)Hard toturnover 3.9) Measuring torquerequir Measuring outinspecti Carry See Fig. 6 Carry out detailed inspectioncrank of drive. Carry out detailed inspectionthe of affected gearboxcomponents. 4 3 Torque must bedetermined with asuitable jig. Removespark plug connector and remove 1sparkfrom plug eachcylinder. 2 1 ƽ ƽ Step Fig. 6 WARNUNGWARNING . The torque must bemax. 150 Nm(110.64 ft.lb). necessarymove to the crank whole drive. doTo this, determine the maximum occurring torque on the propellershaft rf nN/ N in F Kraft oc nN in F force MAINTENANCE MANUAL MAINTENANCE on onlycold ative ofaircraft battery. terminal Ignition “OFF“andsystem shock!Risk ofelectric eghLi m in L length / (m) L Länge BRP-Powertrain ed to turn crank drive ed toturn Engine runs sluggishly engine andbefore 1 Procedure grounded! Disconnectneg- st start. 05-50-00 January 01/2010 page 20 05694
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series General note General note .0 Sudden drop inboo 3.10) .1 Sudden increasein 3.11) 2 Check wiring. Check See12-20-00 section: 2 Visual inspectionthe ofengine, inparticular 1 2 Check wiring. Check See12-20-00 section: 2 Visual inspectionthe ofengine, inparticular 1 4 Oil level check. See levelcheck. Oil chap. 12-10-00 section: oilconsumption. Check 4 3 ƽ ƽ ƽ ƽ Step Step NOTICE NOTICE WARNUNG WARNUNGWARNING WARNUNG - Air intakesystem Air - Turbocharger - OE If no mechanical damage isdetected the during visual NOTE: - Air intakesystem Air - Turbocharger - OE If no mechanical damage isdetected the during visual NOTE: Sudden increase inboostpressure and speed MAINTENANCE MANUAL MAINTENANCE boostpressureandspeed st pressureandspeed Sudden drop in boost pressure and speed BRP-Powertrain must be also be carried out. must bealsocarried ues fall below theminimum, operatingIf thepermissible cause hasbeenascertained The enginemust notbeput injury! Danger ofserious overbe senttotheauthorized If thereisdamagetothetu 76-00-00of the Heavy Maintenance Manual. inspection, check the boost pressure control.See chap. See chap. 76-00-00 of the Heavy Maintenance Manual inspection, check the boost pressure control. Procedure Procedure 16.1) 16.1) . . rbocharger, theenginemust thecorrespondingchecks limits areexceeded orval- 4.1) into operation untilthe and thefault remedied. haul facility for overhaul. . 05-50-00 January 01/2010 page 21 Edition 2/Rev. 0 Effectivity: 914 Series General note .2 Periodic fallinboost riseand 3.12) turbo control unit) Check wiring.See 12-20-00 section: inspection Visual of the engine,particularin 2 1 ƽ ƽ ƽ Step NOTICE WARNUNG WARNUNGWARNING OE Ifmechanical no damageis detected theduring visual in- NOTE: system intake Air - Turbocharger - Periodic riseand fall boost in pressure andspeed MAINTENANCE MANUAL MAINTENANCE must be also be carried out. must bealsocarried ues fall below theminimu operating limitsareexceededIf thepermissible orval- cause hasbeenascertain The enginemust notbeputin injury! Danger ofserious BRP-Powertrain See chap. 76-00-00 of the Heavy Maintenance Manual chap. HeavySee of the Maintenance 76-00-00 spection, check the boostpressure control. pressure and speed (vibration of speed(vibration pressure and Procedure 16.1) m, thecorrespondingchecks . ed andthefault remedied. to operation untilthe 05-50-00 January 01/2010 page 22
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series Checks up lights Red boostlamp General note .3 Red boostlampofthepr 3.13) ously its have beenexceeded. No immediatechecks are The following checks out: must becarried overloadof thermal canbeexpected at Depending onhow longthelim sure intheairbox hasbeenexceeded. When theredboostlamplightsup, th 1 Inspection of the of Inspection 1 2 Check wiring. Check See12-20-00 section: 2 Visual inspectionthe ofengine, inparticular 1 ƽ ƽ ƽ Step Step NOTICE WARNUNG WARNUNGWARNING is necessary. Cylinder heads - Valves - Cylinders - -Pistons - Air intakesystem Air - Turbocharger - OE If no mechanical damage isdetected the during visual NOTE: If the value was exceeded for more than 1 min. MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain Red boost lamplightsupcontinuously Red boost lamplightsupcontinuously carried out. carried ing limits, thecorrespondi If values have fallen operat- below orexceeded further cause hasbeenascertained The enginemust notbeput injury! Danger ofserious Limit exceeded for upto1min. necessary aslongno necessary See chap. 76-00-00 of the Heavy Maintenance Manual inspection, check the boost pressure control. essure control lightsupcontinu- it isexceeded, increasedwear asaresult Procedure Procedure is indicatesthatthenominalpres- cylinders, valves plugs. andspark 16.1) ng checks must bealso . into operation untilthe and thefault remedied. further operating lim- further 05-50-00 January 01/2010 page 23 Edition 2/Rev. 0 Effectivity: 914 Series Checks General note .4 Red boostlampoftheboos 3.14) The followingThe checks If theredboostlampflashes, thisindi plugs. overloadresult ofthermal canbeexpec Depending onhow longthe minute take-off performan Check wiring.12-20-00 See section: 1 1 Inspection of the of Inspection 1 Visual inspection of the engine.chap. See 12-20-00 section: 1 No immediatearenecessaryno checks aslongfurther as operatinglimits 1 Check compression pressure.See chap. 12-20-00 section: Check the spark plugs.See chap. 12-20-00 section: 3 2 ƽ Step Step Step Step NOTICE WARNUNG is necessary. Cylinder heads - Valves - Cylinders - -Pistons have been exceeded. OE If nomechanicaldamage is detected the during visual in- NOTE: MAINTENANCE MANUAL MAINTENANCE ing limits, theco If values have fallen below carried out. carried BRP-Powertrain must be carried out: must becarried Red boost lamplightsflashingis Red boost lamplightsflashingis Red boost lamplightsflashingis Red boost lamplightsflashingis Limit exceededfor upto 1min. Limit exceeded for over 3 min. Limit exceeded for 1to3min. ce limithasbeenexceeded. 00-00of the Heavy Maintenance Manual chap. See control. 76- pressure check boost the spection, t pressurecontrol isflashing limit hasbeenexceeded, rresponding checks mu cates thatthetime Procedure Procedure Procedure Procedure ted atcylinders, valves andspark 16.1) . or exceeded further operat- orexceeded further increased wear asa 16.2) limitfor the5- 05-50-00 . st bealso 5) January 01/2010 3) . . page 24
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series Checks ues Emergency val- flashes lamp Orange General note 3.15) Orange cautionlampoftheb Orange 3.15) The following checks out: must becarried to ensurecontinued oper tothepreprogrammed “e internally In theevent ofafault, e. of theturbocontroluni If theorange lampflashes, thisi Ifthelampisnotlitup, NOTES: Check wiring.12-20-00 See section: 2 Visual inspection of the engine, inparticular 1 ƽ ƽ ƽ ƽ Step NOTICE NOTICE WARNUNG WARNUNG WARNUNGWARNING - Air intake system intake Air - Turbocharger - NOTE: If no mechanical damage is detected during the visual the during isdetected damage mechanical no If NOTE: for operation. MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain Orange caution lamp lights is flashing is lights lamp caution Orange Monitoring isinactive.Monitoring tive channel,e.g. overspeedi In thisemergencyprogram, sponding checks must be or values have fallen below operatinIf thepermissible cause hasbeenascertained The enginemust notbeput injury! Danger ofserious t orrelatedcomponents. g. asaresultofcirc ation oftheengine. 76-00-00the of HeavyMaintenance Manual. chap. See control. pressure check boost the inspection, oost pressurecontrol isflashing ndicates anoperating orfunctionalfault mergency values“ or(default values), Procedure the boostpressurecontrolisready 16.1) uit break,theTCUswitches g limitshave beenexceeded . also be carried out. also becarried theminimum, thecorre- monitoring of the respec- the of monitoring into operation untilthe ng, isnolongerpossible. and thefault remedied. 05-50-00 January 01/2010 page 25 Edition 2/Rev. 0 Effectivity: 914 Series Checks General note .6 Failure ofthevoltage supply for theturbocontrol unit(TCU) 3.16) The following checks out: must becarried Check wiring.See chap. 12-20-00 section: inspection Visual of the engine,particularin 2 1 ƽ ƽ ƽ Step NOTICE WARNUNG WARNUNGWARNING Failure ofFailure the voltage supply forturbo thecontrol unit(TCU) OE If no mechanical damage isdetected the during visual NOTE: Electric system (voltage supply) - MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain sponding checks must be or values have fallen below operatinIf thepermissible cause hasbeenascertained The enginemust notbeput injury! Danger ofserious 76-00-00 of the Heavy Maintenance Manual. inspection, check the boost pressure control. See chap. Procedure g limitshave beenexceeded also be carried out. also becarried 16.1) theminimum, thecorre- into operation untilthe and thefault remedied. . 05-50-00 January 01/2010 page 26
d04527.fm d04527.fm Edition 2/Rev. 0 Effectivity: 914Series General note Reporting 4) OE:Theform isalsoavailabl NOTES: ROTAXauthorized distributor. form onthenext pageshoul any relevant occurrencesthatmay in turer shallevaluate fieldinformation an According totheregula Register: Register: www.rotax-aircraft-engines.com in CRAFT ENGINESHomepage MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain tion of EASA part 21A.3 tion ofEASApart Document type/Diverses d befilledout volve malfunctionoftheengine, the d report totheauthority.d report In caseof e fromtheofficialROTAX AIR- and senttotheresponsible / FAR 21.3themanufac- electronicversion. 05-50-00 January 01/2010 page 27 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-50-00 January 01/2010 page 28
d04527.fm d04527.fm Form Edition 2/Rev. 0 Effectivity: 914Series
A-Z V R 1. L OPER. Control No. 8. Commentsit occurred. (Describe State probable the malfunction cause and or recommendations defect and the circumstances to prevent recurrence.) under which
ATA Code AIRCRAFT ENGINES OFFICE DISTRICT OPERATOR
CUSTOMER 1. DESIGNATOR SERVICE INFORMATION REPORT A/C Reg. No. MAINTENANCE MANUAL MAINTENANCE Enter pertinent data MANUFACTURER MODEL/SERIES SERIAL NUMBER BRP-Powertrain 2.
AIRCRAFT 3. ROTAX Muster 0 POWERPLANT 4. PROPELLER
5. SPECIFIC PART (of component) CAUSING TROUBLE
Part Name MFG. Model or Part No. Serial No. Part/Defect Location
6. ENGINE COMPONENT (Assembly that includes part)
Engine/Comp. Name Manufacturer Model or Part No. Serial Number MECH AIR TAXI MFG ACG COMMUTER OTHER 05-50-00 OPER January 01/2010 Engine TSN Engine TSO Engine Condition 7. Date Sub. Optional Information: Check a box below, if this report is related to an aircraft
Accident; Date Incident; Date REP. STA TELEPHONE NUMBER: ( ) ——— SUBMITTED BY: page 29 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 05-50-00 January 01/2010 page 30
d04527.fm d04528.fm Edition 2/Rev. 0 Effectivity: 914Series Table ofcontents Introduction maintenance procedures. This chapteroftheMaintenanceMa For reasonsofclarity, NOTES: maintenance check list(See05-20-00). tions. onlyas Itserves The section“Maintenanceofthesystems“ Scheduled maintenance Replenishing operating fluids Introduction MAINTENANCE OFTHESYSTEMS ing tosystem. As far aspossible, thecont following pagesfor furt listed intheMain MAINTENANCE MANUAL MAINTENANCE Chapter: 12-00-00 BRP-Powertrain Subject asupplementtoandfurt tenance Schedule. Ple nual containsthemostcommon her explanation ifneeded. only headlinesandkeywords are isassociatedwithothersec- ent hasbeenarranged accord- 12-20-00 12-10-00 12-00-00 her explanation ofthe 12-00-00 Chapter ase refer tothe January 01/2010 page 1 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-00-00 January 01/2010 page 2 page
d04528.fm d04529.fm Edition 2/Rev. 0 Effectivity: 914Series Table ofcontents Introduction the engineandalsoprovides anov This chaptercovers thestepsrequired fill levels. The engineshouldalways beinahoriz Cooling system Fluid capacities General note Lubrication system Lubrication REPLENISHING OPERATINGFLUIDS Coolant check/replenish Oil level check/replenish Oil level MAINTENANCE MANUAL MAINTENANCE Chapter: 12-10-00 BRP-Powertrain Subject erview ofthefillcapacities.erview to replenishalloperating fluidson ontal positionbefore checking the ae5 page 3 page ae7 page 7 page ae9 page 9 page 12-10-00 Page January 01/2010 page 1 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-10-00 January 01/2010 page 2 page
d04529.fm d04529.fm Edition 2/Rev. 0 Effectivity: 914Series on the engine pointsServicing General 1) Fig. 1 6 5 4 MAINTENANCE MANUAL MAINTENANCE Oil dipstick cover Oil tank Oil tank 6 Oil filter 5 4 tank Expansion 3 2Radiator1 cap Part BRP-Powertrain 1 Function 2 3 12-10-00 January 01/2010 page 3 page 08578 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-10-00 January 01/2010 page 4 page
d04529.fm d04529.fm Edition 2/Rev. 0 Effectivity: 914Series System General note capacities Fluid 2) Overview Oil system MIN mark MIN corresponds 2.5 to l system Oil Cooling system approx. 1.5l approx. system Cooling Fuel system Refer to the relevant specifica- relevant the to Refer system Fuel ƽ System NOTICE WARNUNG gal.) corresponds3.0(0.8 to US l (0.66 USgal.) and MAXmark manufacturer aircraft the by provided tions MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain damage. should beavoided. Theuseof used. Any mixingofdifferent if non-approved orcontaminated The operation oftheengine Fill capacity (0.4 US gal.) Refer to Referto gal.) (0.4 US in the Installation Manual Installation in the Refer to the corresponding chapter in the Installation Manual Installation in the in the Flight Manual Flight in the Refer to the corresponding chapter Details aboutthe operating fluids may beadversely affected manufacturers andtypes the corresponding chapter additives may resultin fuel, oilorcoolantare 12-10-00 January 01/2010 page 5 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-10-00 January 01/2010 page 6 page
d04529.fm d04529.fm Edition 2/Rev. 0 Effectivity: 914Series Engine test run Instruction General note Coolingsystem 3) 3.1) Coolant check/replenish Coolant 3.1) Engine test run isnecessary: Engine testrun To refillthecoolantfo See Check thecoolant leveland topwith up coolantrequired. as Allowtheengine to cool down. Switch the engineOFF. 5 leaks. for Check 4 Engine test run. 3 2 1 2 Check the coolant level. The coolantle thecoolantlevel. Check Openthe radiator cap (1)the onexpansion tank (2). 2 1 Use onlycoolant asrecommended in the currentOperators Inspect coolantwith densimeter glycol or 4 3 Tighten the radiator cap by hand. 5 ƽ ƽ ƽ ƽ Step Step Fig. 2 WARNUNGWARNING WARNUNGWARNING enedcoolant must bereplaced. sketch). OE The radiator cap must be tightened until the stop lug is NOTE: composition. ofsame with coolant replenish If necessary, NOTICE . MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain ing. voke theescapeofboilingcoolantandresultinscald- open slowly. Suddenopening is hot.For safety’s sake, cover capwitharag and Never opentheradiator capwhenthecoolingsystem Risk ofBurns! ofanyature before work. start Always allow enginetocooldown toambienttemper- Hot engineparts! Risk ofBurns! Manual. contacted. llowing stepsarenecessary. Procedure Procedure vel must be filled up befilled vel must tester. Strongly discoloredor thick- of thecapcouldpro- 12-10-00 to the top(see to January 01/2010 page 7 page Edition 2/Rev. 0 Effectivity: 914 Series Graphic Fig. 2 Coolant check/replenish Expansion tank Radiator cap 2 1 MAINTENANCE MANUAL MAINTENANCE Part BRP-Powertrain FRRODQW .KOPLWWHO 2 1 Function 12-10-00 January 01/2010 page 8 page 08523
d04529.fm d04529.fm Edition 2/Rev. 0 Effectivity: 914Series Instruction Preparatory tasks General note system Lubrication 4) .)Oillevel check/Replenish 4.1) oil inthecrankcase. For checking andbefore re See Before checking theoillevel, make su Fit the oil dipstick and tighten the oil tank cover (1) by hand. oil dipstick. the on - Marks oillevel Check 8 7 required. Replenishoilas 6 For oil longer flightsreplenish The oil level in the oil tank should be between the two marks (max./min.) on 5 (2). out theoildipstick Pull 4 Thisprocess completed is whenair flows back to the oiltank.airThis flow 3 Prior tocheck, oillevel turn the propeller several times byhand in direction 2 1 ƽ ƽ ƽ ƽ Step Fig. 3 WARNUNGWARNING WARNUNGWARNING Difference between “max.“ and “min“. - mark =0.45l (0.95 liq.pt) via the venting passage see also SI-27-1997, “oil level check“, latest issue. the max. and min.marks, as During standard engine operation, the oillevelshouldmid-way be between SB-914-026, "Introduction of anewdipstick", oil latest issue. the oil dipstick, but must never fall below the min. mark. See Service Bulletin is removed. oil tank can beperceiveda murmur as (gurgling) whentheoil cover tank (1) of the chap. 10.3.3) inthe Operators ManualSeries. 914 also See oiltank. the to engine the oil from the all pump to rotation of engine . NOTICE NOTICE MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain ative ofaircraft battery. terminal Ignition “OFF“andsystemgrounded! Disconnectneg- shock!Risk ofelectric ofanyture before work. start Always allow enginetocool Hot engineparts! Risk ofBurns! erating fluids“ latest issue. latest fluids“ erating erators Manual and SI-914-019, “Selectionof suitable op- Only usebrandnameoil inaccordance with the latest Op- oil reserve. plenish proceedasfollows. at (ove higher oillevel Procedure re thatthereis down toambienttempera- to max. mark to warrant more r servicing), r servicing), oil will escape not excess residue 12-10-00 January 01/2010 page 9 page Edition 2/Rev. 0 Effectivity: 914 Series Graphic Engine test run Fig. 3 Oil level check/Replenish isnecessary: Engine testrun 1 Operate the engine until th until theengine Operate 1 Check the oilleveland topwith up oilasrequired. Checkleaks. for Allow the engine to cool down. 5 OFF. engine the Switch 4 3 2 Step egn i eprtr ewe 0t 0° 12-10°F). (122 °C -160 (enginetemperature oil betweento 50 70 2 Oil dipstick Oil cover tank Oil 2 1 MAINTENANCE MANUAL MAINTENANCE Part BRP-Powertrain 1 2
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d04529.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Table ofcontents Introduction servicing ontheengine. servicing This chaptercontainsinformation whic detail. more in work the MaintenanceSchedulefor theva to This chapterrelatesinparticular Checking the air filter Engine cleaning Introduction Visual inspection Checking the compression check Leakage Cooling system Test run of engine Inspection of the fuel filter inthe airframe flap wastegate the Checking crankshaft Locking the Checking the V-belt tension Fuel system Replacing theair dry filter Cleaning thedry air filter Corrosion Checking theengine suspension Checking the compression fault-tracing for compression the Checking Accessories bottle Overflow Expansion tank,Radiator cap system cooling the Flushing Replacing the coolant Checking thecoolingsystem Checking the carburetor actuation carburetor the Checking Idle speed adjustment Checking of the float chamber Operating range check Idle speed check Pneumatic synchronization synchronization Mechanical Carburetor synchronization SCHEDULED MAINTENANCE MAINTENANCE MANUAL MAINTENANCE Chapter: 12-20-00 BRP-Powertrain Subject themaintenancewo rious engine systemsandcoversrious the h isrequiredto ae3 page 1 page ae7 page 5 page 5 page ae13 page ae11 page 11 page 9 page ae27 page 25 page 23 page 21 page 19 page ae17 page 15 page ae35 page 35 page 33 page 32 page 30 page 29 page 29 page ae50 page 49 page 47 page 45 page 44 page 40 page 38 page 37 page 37 page perform scheduled 12-20-00 rk mentionedin rk Page January 01/2010 page 1 page Edition 2/Rev. 0 Effectivity: 914 Series Propeller gearbox system Electric oilcircuit the Flushing Inspecting the magnetic plug Lubrication system Checking the propeller gearbox Checking the friction torquein freerotation Installation of spark plug plugs Remove thespark Inspection and replacement of spark plugs ofwiring Check Installation of the magnetic plug Purging the oilsystem Cleaning the oiltank oftheoilfilterinsert Inspection oilfilter Install Oil filter replacement Oil change MAINTENANCE MANUAL MAINTENANCE Subject BRP-Powertrain ae75 page 73 page 73 page 71 page 69 page 69 page 68 page 67 page 64 page 63 page ae65 page ae62 page 60 page 58 page 57 page 56 page 55 page 53 page 12-20-00 Page January 01/2010 page 2 page
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series ing After each clean- Cleaning Cleaning agents General note Enginecleaning 1) required before cleaning. by useofcompressed airto Clamp connectionsetc. - Spark plugconnector - Ignition unit - Battery - After eachcleaningprocedure, dry Always cleanengineincoldstate. If necessary, theengine NOTES: ommended. Seechap. 05-00-00section: Use ofacommerciallyavailable cold
ƽ ƽ ƽ ƽ NOTICE NOTICE NOTICE NOTICE WARNUNG WARNUNG WARNUNG WARNUNG MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain damage! be closedoff. Failure todo water c agents and/ordirty Before cleaning,allopeni their failure aretheconsequence. shaft seals. Oxidationof This isdetrimental Never cleananeng ulations. of itinaccordancewith off.are rinsed Collectthe fuel, oilandotherenviro When cleaningtheengine, t ing agentsfor clea Do notuseeasilyinflammabl must becleanedwithdue prevent leakagecurrent. all electrical componentssuchas all electrical cleaningagentfor ning theengine. to the electrical to theelectrical ine withahighpressurecleaner. 1.5) applicable environmental reg- nment-contaminating agents thevarious componentsand ngs throughwhichcleaning . cleaning water anddispose ould entertheenginemust this may resultinengine he dissolved residuesof e liquidsorcausticclean- care. Repairleaks as installations and 12-20-00 the engineisrec- January 01/2010 page 3 page Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-20-00 January 01/2010 page 4 page
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Cleaning General note General note Checking airfilter 2) .)Cleaningthedryairfilter 2.1) See To filterthefo cleanthedry tenance Manual. airfilterasde Cleandirty interval. outvisualinspectionofdry Carry 3 Rinse air filter with low pressure wate lowpressure air filter with Rinse Spray K&N filter cleaner onto filter su 3 Lightly tap and brush offsurface dirt ( 2 1 ƽ ƽ ƽ ƽ Step NOTICE NOTICE NOTICE NOTICE Fig. 1 WARNUNG WARNUNG WARNUNG WARNUNG dry naturally ( dry naturally ( min. and B ). Fig. 2 MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain with hotairgun. overDo notdry naked flam thisstep.cleaners during cleaning tergents, particle Never usegasoline, steam, the engine. formance but mightalsopr willnot filterinsert A dirty replace airfilter. intervals. spondingly shorter In theevent ofdustformati C . ). llowing stepsarenecessary: air filter after prescribed maintenance air filterafterprescribed scribed inaircraftscribed manufacturers Main- Procedure rface and leaveto soakfor approx.10 r fromto insideoutside let and element A ). onlyreducetheengineper- agents orhighpressure on, cleanairfilteratcorre- omote prematurewear of e, withcompressedairor caustic liquids, strong de- Iffiltermatisdamaged, 12-20-00 January 01/2010 page 5 page Edition 2/Rev. 0 Effectivity: 914 Series After cleaning Graphic Fig. 2 red coloring. OE:Eachfilterpleatmu After 5to10min.thefilt NOTES: Fig. 1 Cleaning ofthefilter ƽ NOTICE WARNUNG A
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d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic General note 2.2) Replacing the dry airfilter dry the Replacing 2.2) Fig. 3 turer andfromROTAX. typeairfilterswhichar Only usedry See ƽ ƽ NOTICE NOTICE Fig. 3 WARNUNG WARNUNG . MAINTENANCE MANUAL MAINTENANCE 2 Safety wire Safety filter Air 3Carburetor2 1 Part BRP-Powertrain es, and wire-secureagainstloss. Attach new airfilter, free tion: elem and awiresecuring Each airfiltermust bese 1.6) . Filterconnection 3 2 e specifiedby theaircraft manufac- Function 1 of grease, atconnectionfac- cured by clampattachment ent. Seechap. 05-00-00sec- must befreeofoil. 12-20-00 January 01/2010 page 7 page 08527 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-20-00 January 01/2010 page 8 page
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series trap Condensation Turbocharger Abnormalities General note inspection Visual 3) Exhaust system andtur - ticular: avisualinspectionyouDuring shouldfo Take noteofchangescausedby temperature influence. definition andscopeofvisualinspec General visualinspectionofthe OE:Onlyfittedonengines sor. Itmust bereplacedwhen There isacondensationtrap between th NOTES: Fuelandoillines- - Heat protectionhoses - Engine suspensionframe-see71- - Cooling airductandcool - Venting hoses(carburetor,oiltank) - harness Wiring - Heat protectionplates - Pressure sensors - Servo motor-see 76-00-00 of - Fuelpumps - Notes onturbocharger: and 2)formechanicaldamage. Check thetwoheatprotectionhos Manual Turbocharger unitsee- 76-00-00 the of Heavy MaintenanceManual. Carry out visual inspection of compressor and turbo housing for cracks. Check compressorimpeller formechanical damagefree and move- 4 a Onlyinspection visual isnecessary. 3 2 1 Step ment. MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain see 73-00-00oftheHea bocharger withattachment ing finsofthecylinder itfillswithcondensation. engine for For damageorabnormalities. theHeavyMa tion (Seechap. 05-20-00section: es (waterpump-cylinderhead1 00-00 oftheHeavyMaintenance Procedure with airbox ofoldermodel. cus onthefollowi e airbox andthepressuresen- vy MaintenanceManual intenance Manual 12-20-00 ng pointsinpar- January 01/2010 page 9 page 3) . Edition 2/Rev. 0 Effectivity: 914 Series necting lines Pressure con- - Reversing valve-2xFl Reversing - -reversingvalve Airbox - -pressuresensor Airbox - -fuelpressureregulator Airbox - See Fig. 4 ƽ ƽ Fig. 4 WARNUNGWARNING . See73-00-00ofthe MAINTENANCE MANUAL MAINTENANCE stoppage, they must beche pressure sensorisalmost tween theairbox, floatcham As afailure ofthepressu 1 BRP-Powertrain 1 oat chamberventilation 1 1 Heavy MaintenanceManual 1 re connectinglines(1)be- certain tocauseengine certain cked withespecialcare. bers, fuelregulatorand 12-20-00 January 01/2010 1 page 10 00048
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Definition gine suspension Checking the en- General note .)Checking theenginesuspension 3.1) .)Corrosion 3.2) See chapter“AC 43.13-1BMaintenanceand Repair“. with corrosionrefer to the F about different typesof metals viaanelectro-chemicalreacti Corrosion isanatural processwh Inspect engine isolatingmounts includingfor heat damage, wearand Inspect the surroundings of engine attachment on crankcase and gearbox. 3 Verifythe engine suspensionpoints onthe crankcase for tight fit and dam- 2 1 ƽ Step NOTICE WARNUNG cracks. attachments. loose be may there ring), (black If there isdiscolorationthe of crankcase aroundtheattachment points cracks. including age MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain cause serious enginedamage.cause serious nuts. or Overtightening thetighteni Exactly observe corrosionandcorrespond AA Advisory CircularACAA Advisory 43.13. ich attacks andpotentiallydamages on. For moredetailedinformation Procedure too looseconnectioncould ng torquesfor screws and ing methodsfor dealing 12-20-00 January 01/2010 page 11 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-20-00 January 01/2010 page 12
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Fuel lines Water pump Leakage General note Leakage check 4) inspection isnecessary. See On steelfuellinesint ing marks. Inspect fuellines, theirconnections mechanical sealmust bereplaced(i replaced. Inthecaseof oil, theoilsealonwater pump If theleakagebore, located Checking water pumpfor leaks. Ifaleakissu NOTES: the causeandremedyfault. Visual inspectionofthew 4 After shut down of engine no liquid must drip down. drip must liquid no engine of down shut After Switch off ignition and secure engineagainst unintentional operation. Se- 4 Operate the engine until th Cleaning the engine. 3 2 1 ƽ ƽ Step NOTICE NOTICE WARNUNG WARNUNG cure aircraft againstunauthorized operation. °F). °C (122 -160 min (engine oiltemperature between 50to 70 MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain engine failure! Leaking connectionscanlead comply withthespecifiedtorque! Avoid overstretching thefi he areaatconnections(fitt coolant drips atthel coolantdrips hole enginefor leaks. Ifle at the base of the ignition housing, is dripping at thebaseofignitionhousing,isdripping spected, thenthefollowing check ispossible: Fig. 5. e temperatures have stab e temperatures shaftmay bedefec and screw fasteners. Lookfor scuff- nspect thequalityofcoolant). Procedure eakage bore, thecoolant xing elements. Always ings) (2)adetailedvisual to engineproblems or aks arevisible, locate tive andmust be ilized foraperiodof5 12-20-00 January 01/2010 page 13 Edition 2/Rev. 0 Effectivity: 914 Series kinks Hose clamps, lines Oil Coolant hoses Fuel pump Graphic cially intheareaof nor andthesuctionoillinefrom the pressureoillinefrompum Also inspecttheoilretu hose immediately. Inspect alloilfeed linesfr Check coolanthose Inspect isolatingflangeof Fig. 5 Connections andfuellines nections, for porosity, dam Check allhoses, the surroundingarea 3 particularly intheareaofhose clampsandhosecon- particularly 3 Fuel filter Fuel Connections (Fittings) lines(Steel) Fuel 3 2 1 MAINTENANCE MANUAL MAINTENANCE XXX Part thefixationscrew). s andconnectionsfitt ** BRP-Powertrain to seeifthereareany leaks! A rn linefromthecrankcase rn 2 XXX om theoiltanktoo fuelpumpfor leaks. age andkinks. Ifdamag A turbocharger totheoilpump(espe- 1 p tothegovernor flangeofthegover- 2 A Functions ings for leakage. Examine A * il coolerandtotheengine. XXX 1 totheoiltank.Check
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d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Value Instruction tools Special General note Checking compression the 5) Detailed inspectionof - thiness. in accordancewiththe BRP-Powertrain If thevalue isover 25%inspection, chap. 12-20-00section: properly.are working The If thepressurelossis Testing outusingthe iscarried equipment arenecessary. To measurethecompressionpressu See (87 psito65psi)( The maximum pressure drop permissible Repeat theseproceeding at all4cylinder heads. 6 Now put constant pressure, between 5.5-6 bar (80-87 psi) on the line and take 5 Screw adaptor (1) into the spark plug thread and connect up the two pressure 4 Remove the upper spark plugs. As a general rule, make sure that no dirt par- Started with cylinderhead 1movepistonposition.to TDC 3 2 Operate the engine un 1 n.a. Connect line. Connect Adapter to spark plug thread. Orifice jet*, of 1mm (0.04 in) inner diameter and 3 mm(0.12 in) gauges. 2pressure n.a. Compressed air approx. 6bar (87 psi). n.a. n.a. n.a. n.a. ƽ ƽ Step Part number Fig. 6 WARNUNGWARNING readingsat pressure gauge( gauges (2)the with orifice jet (3) between them( ticles can enter through the spark plug bore into the combustion chamber ( °F). 160 - (122 °C 70 to 50 between temperature oil (engine . MAINTENANCE MANUAL MAINTENANCE D BRP-Powertrain Ignition “OFF“andsystemgrounded! shock!Risk ofelectric ). 60° degree approach angle according to AC43.13, latest issue. *or equivalent e.g. orifice diameter0.040 in., long 0.0250 in., length. less than25%thenthevalv 16.2) affected enginecomponents. spark plughastobe spark til the temperatures til the . differential pressur C ). repair oroverhaul out must becarried Procedure re thefollowing instructions for instructions continued airwor- Description is 25%,e.g. fr have stabilized for have stabilized installed accordingto e seats and piston rings e seatsandpistonrings B ). e testprocedure special toolsand 12-20-00 om 6to4.5bar a periodof 5 min January 01/2010 page 15 . A ). Edition 2/Rev. 0 Effectivity: 914 Series Graphic Checking thecompression. Fig. 6 D 4 Compressor Manometer/Test gaugesset 4 Adaptor 3Orifice2 1 jet MAINTENANCE MANUAL MAINTENANCE Part / PP LQ ' PP LQ 3 BRP-Powertrain 1 A B Function
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d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic Measurement Instruction General note 5.1) Compression check Compression for fault-tracing 5.1) Fig. 7 Compression check for fault-tracing Detailed inspection of - ued airworthiness. out inaccordancewiththeBRP carried bar If thevalue isbelow 6 psi). (29 Individual readingsfor t Compression check for fault-tracing. sion shouldbebetween 9 A compressiontesteris formed. In thecourseoffault-tracing a 4 Successively take readings on all four cylinders and compare results. compare and cylinders on all four readings take Successively compression Press tester (1) over theplug spark hole and usethe starter to 4 3 Unscrewand remove top spark plugs.As ageneral rule,make sure thatno Operate theengine until th 2 1 Step turn theengine over with openthrottle until maximum pressure isreached. ber. dirt particles can enterthrough the sparkbore pluginto the combustion cham- °F). 160 - (122 °C 70 to 50 between temperature oil (engine MAINTENANCE MANUAL MAINTENANCE 1 Compression tester Compression 1 Part BRP-Powertrain he cylindermust notdiff requiredtocheck co affected enginecomponents. (7psi), inspection, r (87 n 2br(3 n 7 psi). bar(130and174 and 12 e temperatures have stabiliz have e temperatures compression check Procedure -Powertrain for instructions contin- Function A mpression. Thecompres- B epair oroverhaul must be rb oeta bar er by morethan2 canalsobeper- ed for a period of 5min ed foraperiod 12-20-00 1 January 01/2010 page 17 08651 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-20-00 January 01/2010 page 18
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic tension Belt General note Checking V-belt the tension 6) Fig. 8 Checking theV-belt tension To adjustthebelttension: attachment andV-belt tension. In thecaseofconfigurations with See hntgtnhx ce 1 1 ihtgtnn oqe4 m(0ft.lb) and Nm(30 Then tighten hex. screw (1) M10 with tighteningtorque 40 the Press alternator upwards and tightenallen screw(3). Loosen the hex. screw (1)and M10 the two M8allen screw (2) and (3). 3 2 1 2 Step Fig. 8 le ce 8()wt iheigtru 2N 15in.lb). Nm(195 allenscrew(2) M8 with tighteningtorque 22 . MAINTENANCE MANUAL MAINTENANCE 2, 3 Allen screw M8 screw Allen M10 screw Hex. 2, 3 1 Part BRP-Powertrain 1 additional auxiliary generator,additional auxiliary inspect Procedure Function 3 12-20-00 January 01/2010 page 19 00353 Edition 2/Rev. 0 Effectivity: 914 Series belt tension belt Checking the V- Fig. 9 Inspect V-belt tensionasperdrawing below. MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain 12-20-00 January 01/2010 page 20 00354
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series crankshaft Loosen the crankshaft Locking the General note Locking thecrankshaft 7) After completionofwork/check: The following procedure work See OE:Thethreadboltfor crankshaf NOTES: To check,wrench usemm 24 (15/16 inch.)torotate the crankshaftat hex. Remove the thread bolt (2) and refit crankshaft plug screw(1) M8x20along 2 1 Screwthethread bolt (2) into the crankcase. Whiledoingso, movethe crank- 3 Turn crankshaft/propeller shaft untilthepiston ofno. cyl.1 no. and 2are in Remove the plug screw (1) M8x20sealing andring from the crankcase half 2 1 ƽ ƽ Step Step Fig. 10 WARNUNGWARNING screw (7) on the magneto side. in.lb). Nm(133 withsealing anewring with atorque of 15 ntercs 6 ftecakhf,adtgtnt 0N 8.8in.lb). Nm(88.48 in the recess (6) of the crankshaft, and tightento 10 shaftand toslightly fro withthespanner ring untillocking thescrew engages Turn trig- the until indification for position crankshaft the relief NOTES: 240880. no. part TDC positionlock and crankshaft inthis positionwith the threadbolt (2) (cyl. 2/4). . dard toolkitsuppli MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain ture before start anyture before work. start Always allow enginetocool Hot engineparts! Risk ofBurns! with a flash light. aflash with tionally verified by looking through the crankcase recess (6) The requiredpositionrecess of the crankshaft canaddi- be sition. ger boss (3)is between the both coil(4,5) trigger the at po- s aretobeaccomplished: ed witheachengine. Procedure Procedure t locking is part ofthestan- t locking ispart down toambienttempera- 12-20-00 January 01/2010 page 21 Edition 2/Rev. 0 Effectivity: 914 Series Graphic Fig. 10 Locking thecrankshaft 6 Hex. screwM16x1.5x40 Crankshaft 7 Trigger coils Trigger boss 6 Thread bolt 4,5 M8x20 screw Plug 3 2 1 MAINTENANCE MANUAL MAINTENANCE Part BRP-Powertrain $ % Function 1 2 12-20-00 3 January 01/2010 4 08530,08531 page 22 7 & 5
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Checks General note Checking wastegateflap the 8) The following checks out: must becarried See Check the wastegate lever (3) for free movement. 4 flap. wastegate the of adjustment the Check Check thebowden cable suspensionand spring. 3 Check thebowden cable of the wastegateactuation (1)for mechanical dam- 2 1 ƽ Step NOTICE Fig. 11 WARNUNG NOTES: If it does not move not If it does freely, NOTES: Manual. nance Mainte- Heavy of the 78-00-00 See (2). screw adjusting the using readjust necessary, If closed. completely be must flap wastegate the position, this In the Whenengine hasbeen shutdown, themotor servo al- NOTES: or wear. age . MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain Maintenance Manual. ble must bereplaced.S 1 flexible wireofthebow Damage tothebowden cable isnotpermissible. Ifonly part no.part 297434. ROTAX Anti-SeizewastegateLOCTITE 8151, the with of closed position. movesmotor approx.revolution 1/2 in thenremains and This also applies when the TC ways to closed position. runs Procedure ee 78-00-00oftheHeavy lubricate the axle lubricate hole)(lubrication den cable isabraded, theca- U isswitched on.Theservo 12-20-00 January 01/2010 page 23 Edition 2/Rev. 0 Effectivity: 914 Series Graphic Fig. 11 3 4 Lubrication hole Lubrication Wastegate lever Adjusting screw 4 Wastegate actuation 3 2 1 MAINTENANCE MANUAL MAINTENANCE Part BRP-Powertrain 2 4 1 Function 12-20-00 January 01/2010 page 24 00147
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series pump Fine filter fuel General note filterintheairframe fuel ofthe Inspection 9) Heavy Maintenance Manual. grated inthefuel pumpsmust al If thefilterinairf Schedule Thefiltercanbe Inspect thisfinefilter NOTES: (3). gascolater mustbeafilter (2), pumps fuel In thefuelsupplylinebet See ƽ ƽ NOTICE NOTICE Fig. 12 WARNUNG WARNUNG . colator). MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain complete pump. available.no spareparts The fuelpumpmust notbedi selection andthecorrectinsta Theaircraft manufactertrain. The finefilterisnotinclude rame isheavily th soiled, (3)asdescribedin ween thefueltank(1 so beinspected.Seechap. 73-00-00 in aconfiguration as the Aircraft Maintenance e two finefilters (4) inte- If necessary, replacethe d in delivery fromBRP-Pow- delivery d in ) andthefeed tothetwo urer isresponsible for the assembled, asthereare llation ofthefinefilter. filter/water trap (gas- 12-20-00 January 01/2010 page 25 Edition 2/Rev. 0 Effectivity: 914 Series Graphic Fig. 12 Inspection ofthefuelfilter 4 Fine filter (fuel pumps) filter(fuel Fine Gascolater Fuel pumps 4 line supply Fuel 3 2 1 MAINTENANCE MANUAL MAINTENANCE Part BRP-Powertrain AUX 2 Function MAIN 2 12-20-00 3 4 January 01/2010 1 00103,00157 page 26
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series run Test Preparation General note 10)Test runofengine Anchor theaircraftsuitablytoth - Inspect tightfi - Make surethatnoloose - Test asfollows: run Ensure thatalltheoperatingfluids - Preparation of the 3Shut engine down. 13 After full-load run, conduct ashort cooling run to prevent formation of vapour 12 Conduct ashortfull throttle runcheck and that the engine reaches the max. Ignitionper checkthe as current Operators Manual. 11 bar Check temperaturesandpressure:oil Atasteady oilpressure above 2 10 rpm. Then first use the throttle lever 9 min. at2000 Let engine run for approx. 2 within up be built has to Oil pressure oilpressure. observe start, engine After 8 sec.(f 10 max. for switch starter Press “ON“. circuits ignition both for Ignition 7 Master switch“ON“. 6 Throttlelever toposition. idle 5 Activate choke. 4 Establishfuel supply (open fuel cock). 3 2 1 ƽ ƽ Step that thepropeller partment replenished tothespecifiedlevel WARNUNGWARNING OE On switching off the engine switch off ignition and withdraw NOTE: and fuelsystem after shut-down. lock in cylinder heads.This isnecessary to preventsteam locksin the cooling asit depends on the propeller used. full power speed. Consult the pilot’s operating handbook for maximum speed, psi) enginespeed (29 °F). (122 °C 50 reaches temperature oil the until riod, rpm and then run through warming up pe- to bring the engine to approx. 2500 sec. 10 MAINTENANCE MANUAL MAINTENANCE t ofthepropeller engine for testrun: BRP-Powertrain petent operator. Checkrunning. thatthecock Always theenginefrom observe peller, rotatingandstre Danger oflife threateningin zone isclearandsafebe the ignition key. ignition the maybe increased. objects (e.g.tools)ar e groundandfixwheelchocks.Ensure Procedure (engineoil,coolant,fuel)are loe yacoigpro f2min.). ollowed byacooling periodof 2 ssed parts oftheengine! ssed parts fore startingtheengine juries causedbyjuries thepro- pit isoccupiedby acom- e leftintheenginecom- a safe placewhileitis 12-20-00 January 01/2010 page 27 Edition 2/Rev. 0 Effectivity: 914 Series Check of leaks filter Oil coolant Engine oil and down. Inspect theenginefor oil,fuelor Replenish engineoil ƽ ƽ ƽ NOTICE WARNUNG WARNUNGWARNING MAINTENANCE MANUAL MAINTENANCE ter the trial run onacoldengine. run ter thetrial If theoilfilterhasbeenr escape ofboilingcoolant slowly. Sudden openingofth is hot.For safety’s sake Never opentheradiator c Risk ofBurns! BRP-Powertrain and coolantasrequir coolant leaksandr ed onceenginehascooled , cover capwitharag andopen eplaced, re-tightenby handaf- ap whenthecoolingsystem and resultinscalding. e capcouldprovoke the epair asnecessary. 12-20-00 January 01/2010 page 28
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Overview system 11) Cooling 11 Checking thecoolingsystem 11.1) Fig. 13 1 MAINTENANCE MANUAL MAINTENANCE 4 Radiator cap with gasket with cap Radiator tank Expansion pump Water 4 lines Coolant 3 2 1 Part BRP-Powertrain 1 4 Function 2 12-20-00 3 January 01/2010 page 29 08579 Edition 2/Rev. 0 Effectivity: 914 Series Instruction General note Radiator cap tank Expansion Water pump Coolant hoses General note 12 Replacing thecoolant 11.2) the water pump(2). To replace thecoolant See Inspect thegasket oftheradiator c bottom ofthetankfor tight fit. Inspect expansion tank(3)for damage Inspect allconnectionsonthetop hardening asaresult outvisualinspec Carry See See chap. 12-20-00 section: valve valv andreturn 4 Fit attachment Fit screw (stainless steel)alongwith sealing anew ring. Tighten 4 3 Drain the Drain engine coolant. pump water of ring) sealing (with (1) screw attachment bottom the Remove 3 Open the radiator capon the expansion tank. 2 1 ƽ ƽ ƽ ƽ ƽ Step NOTICE Fig. 14 Fig. 13 WARNUNG WARNUNGWARNING WARNUNGWARNING o1 m(0in.lb). Nm (90 to 10 OE:If theradiator located is below the engine, alsodetach the NOTES: (2). . . MAINTENANCE MANUAL MAINTENANCE erators Manual. Use onlycoolantasrecomm escape ofboilingcoolant slowly. Suddenopeningofth is hot.For safety’s sake Never opentheradiator c Risk ofBurns! ofanyture before work. start Always allow enginetocool Hot engineparts! Risk ofBurns! BRP-Powertrain e for properoperation. of heatandporosity. tion ofallcoolanthose lowest positioned coolant hose. following stepsarenecessary: 11.4) . and bottomofthe ap (4)andcheck thepressurerelease Procedure . Inspect protection rubber atthe . Inspectprotectionrubber , cover capwitharag andopen ap whenthecoolingsystem and resultinscalding. s (1)for damage, leaks, down toambienttempera- ended inthecurrentOp- e capcouldprovoke the cylinder headandon 12-20-00 January 01/2010 page 30
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic Fig. 14 Replace thecoolant OE:Run the engine and briefly replenish with clean coolant as NOTES: Fit radiator cap. 8 7 6 Refill newly mixed coolant in coolant mixed Refill newly 6 If the coolant is being replaced with a different type, (conventional coolant, 5 Step system).See chap. 12-10-00 section: section: waterlesscoolant) the cooling systembe must flushed. See chap. 12-20-00 11.3) MAINTENANCE MANUAL MAINTENANCE 2 Water pump Water (stainless steel) screw Attachment 2 1 Part BRP-Powertrain . required. to the expansion tank (hig tank to theexpansion 2 Procedure Function 3.1) . 1 hest point of thecooling hest point 12-20-00 January 01/2010 page 31 08533 Edition 2/Rev. 0 Effectivity: 914 Series Instruction General note 13 Flushing th 11.3) To flushthecoolantfo OE:Run the enginefor aminute and replenish coolant asrequired. NOTES: Fit radiator cap. 4 3 2 Refill newly mixed coolant into the expansion tank (highest point of the cooling cooling the of point (highest tank expansion the into coolant mixed newly Refill 2 h ytmi lse sn uewtra rsueo a 2 psi). bar (29 system Theis flushed using purewater at apressureof 2 1 ƽ ƽ Step WARNUNGWARNING e cooling system e cooling system). See chap. 12-10-00 section: section: 12-10-00 chap. See system). OE:For theflushing, openthe lowest located coolant hose(either NOTES: NOTICE MAINTENANCE MANUAL MAINTENANCE slowly. is hot.For safety’s sake Never opentheradiator c Hot steamcancausescalds BRP-Powertrain by the coolant manufacturer. water must notthemax. exceedpermissible prescribed limit drainedwater of correspondingly after flushing.The residual be must system cooling the isused, coolant water-free Where at water pumpradiator). or llowing stepsarenecessary: Procedure 3.1) , cover capwitharag andopen . ap whenthecoolingsystem in theface andonhands! 12-20-00 January 01/2010 page 32
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic tank Expansion Radiator cap General note 14 Expansion tank,radiatorcap 11.4) Checking Expansiontank,radiator cap. outvisualinspectionof Carry Inspect sealingsurface (7)andtube The radiator capmust NOTES: ing pressure. replace withanew origi intheradiator cap incorporated seal Inspect therubber Onolderengines NOTES: valvedown, thereturn (2)opens can flow intotheexpansio up,the coolantwarms thepressure re required. Ifthepressure See To equalize pressureinthecool Fig. 15 6 8 . tank. ning Modification“,latestissue. psi) canbein (13.0 bar 0.9 MAINTENANCE MANUAL MAINTENANCE Rubber seal valve Return valve relief Pressure 3 2 1 Part BRP-Powertrain nal radiator capwith (3), the pressure spring (3), thepressurespring in the system rises above inthesystemrises n tankviatheline(5). tank for damagea ing system,anexpansion tankis for damageandleaks. Ifnecessary, andthecoolantissucked back. 7 aradiator capwithopeningpressureof connection (8)oftheexpansion tank. 3 1 lief valve (1)opensandthecoolant be tightenedfullyontheexpansion Function 3 stalled. See 1.2 bar (17.4 psi) (6)open- psi) bar(17.4 1.2 Whenthecoolantcools (4) andthetwo valves nd scuffingmarks. 2 12br(74psi) as bar(17.4 1.2 4 12-20-00 SI-914-022 “Run- January 01/2010 5 page 33 Edition 2/Rev. 0 Effectivity: 914 Series Fig. 15 Tube connections Sealing surface Opening pressurethe of radiator cap 8 Connection to overflowbottle 7 Pressure spring 6 5 4 MAINTENANCE MANUAL MAINTENANCE Part BRP-Powertrain Function 12-20-00 January 01/2010 08534,07620 page 34
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series General note Graphic Instruction General note 15 Overflow bottle 11.5) 16 Accessories (including radiat 11.6) cooling airducts) cooling Fig. 16 Overflow bottle bottle. overflow Checking See Check hose connection (3). Inspect bracket(2)for the safety wire. 4 Check the venting bore (1) in the screw cap (see Service Bulletin SB-914-025, 3 Inspect the bottle fordamage. 2 1 ƽ Step NOTICE Fig. 16 WARNUNG “Modificationthe of overflow bottle“, latest issue). . MAINTENANCE MANUAL MAINTENANCE 3 Hose connection Hose Bracket bore Venting 3 2 1 Part BRP-Powertrain Maintenance Manual ofth Equipment istobeinspect 3 or, radiatorhoses,hoseclamps, Procedure Function 1 e aircraft manufacturer. ed inaccordancewiththe 2 12-20-00 January 01/2010 page 35 08536 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-20-00 January 01/2010 page 36
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic Instruction speed Idle 12) Fuelsystem 21 Carburetor synchronization 12.1) Fig. 17 Synchronization atidlespeed Firstthemechanicalsynch NOTES: To synchronize when See Checking thesynchroni close ontheadjustmentscrew). When synchronizing,slacken bothbo For smoothidling,synchronizationof Detach the resonator hose (1) (see option 4) of the compensating tube (2) to 1 Step Fig. 17 engine running shouldnoticeable. be inthe difference aslight condition, In this systems. intake air two the separate . pneumatic synchronization has already been carried out. pneumatic synchronizationhasalreadybeencarried MAINTENANCE MANUAL MAINTENANCE Compensating tube Resonator hose 2 1 Part BRP-Powertrain idling thefollowing zation atidlespeed Procedure wden cables (throttlelever lies the throttlevalves isnecessary. 2 Function steps arenecessary. 1 ronization and 12-20-00 January 01/2010 then onlythe page 37 05491 Edition 2/Rev. 0 Effectivity: 914 Series Synchronization adjustment throttle Basic General note 22 Mechanical synchronization 12.2) of thesynchronizationprocess. lever throttle the ensure that remains position. Itisanadvantage atthispoi You must atthispointplac For synchronousbasicthrottle See Carry outtheaboveCarry proc Asas soonthetwo carburetorbowden cables are installed (throttlein lever Using the cablefixation (4), secure the bowdencable accordingly. 3 2 As soon asthe throttle lever inthe cockpi 1 Gently turn each idlemixture screw(6) Pull out the feeler gaugethen and turn eachidle speed adjustment(2) screw 6 5 Insert a 0.1 mm (0.004 in.) feeler gauge (gap X)between the idle speed adjust- Unscrew idle speed adjustment screw (2) untilis free itof the stop. 4 Returnthe throttle lever (1) tostop itsidle position (3) byhand. There should 3 Remove cable fixation (4)throttle on (1). lever 2 1 Adjustthe twobowdencables for simultaneousopening of the throttle valves. automatically. fully opens valve throttle the that Check 8 7 ƽ ƽ Step Step Fig. 18 WARNUNGWARNING (2) rests fully on the idle on fully (2) rests cockpit in idle position), you must check that the idle speed adjustment screw (3). position idle stop carburetor the (1) to lever valve throttle the check 1.5 turns clockwise. clockwise until contact ismade with the 0.1 mm(0.004in.) feeler gauge. stop idle carburetor the and (2) screw ment procedure. this during resistance no be then reopenby 1.5 turns counter clockwise. . MAINTENANCE MANUAL MAINTENANCE running. Always theenginefromasafe observe placewhileitis peller, oftheengine! rotatingandstressedparts Danger oflife threatening BRP-Powertrain edure onbothcarburetors. e thethrottlelever int stop (3) without pressure. without (3) stop adjustment proceedasfollows. Procedure Procedure nt toenlistthehelp in this position dur thisposition in (clockwise) until it is fullyinsertedand untilitis (clockwise) t remains is in the idle stop position, intheidlestop t remainsis (3), then gently turn the idle screw idle screw gently turnthe (3), then injuries caused by thepro- injuries he cockpit totheidlestop ing thenext steps 12-20-00 of anassistantto January 01/2010 page 38
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic Fig. 18 Mechanical synchronization outtheaboveCarry proc 4 An An idle speedwhichis too lo Check the true running of the engine. If necessary, adjust with the idle mixture 5 4 Step ; 3 5 1 2 4 low, adjust accordingly with idle adjustaccordingly low, Start the engine and verifytheidle speed. If thespeed idleis too high too or See chap.See 12-20-00 section: screw (6). NOTICE MAINTENANCE MANUAL MAINTENANCE 8 Plug screw M3.5x5 Plugscrew Idle adjustment screw mixture Idle 8 spring Return 7 fixation Cable 6 Idle stopposition 5 Adjustment screw 4 Throttle valve lever 3 2 1 Part BRP-Powertrain and if the idle speed is too high, the engine isharder to start. edure onbothcarburetors. 12.5) speed adjustment screw (2). screw speed adjustment Procedure 7 . Function 8 w can result in gearbox wear, gearbox in result w can 6 12-20-00 January 01/2010 page 39 08538 Edition 2/Rev. 0 Effectivity: 914 Series Graphic Connection tool Special General note 23 Pneumatic synchronization 12.3) Fig. 19 Option 1 Possible connectionmethods. flow meterorvacuum gauge(s). The two carburetors areadjus See OE:Perform amechanicalsynch NOTES: 2 Using the push on angular tube (4) and compensating tube (2) install a flexible a flexible install (2) tube compensating and (4) tube angular on push the Using Remove the compensating tube (2) fromthe push onangular tube (4) after re- 2 1 ƽ ƽ Step Fig. 19 WARNUNGWARNING rubber hose(5) leadingto the vacuum gauge(1). themoving twoclamps(3). to Fig. 22 pneumatic synchronization. Rubber hose Angular tube Clamp 5 Compensations tube 4 Vacuum gauge 3 2 1 MAINTENANCE MANUAL MAINTENANCE Part running. Always theenginefromasafe observe placewhileitis peller, oftheengine! rotatingandstressedparts Danger oflife threatening BRP-Powertrain 4 . 3 1 ted toequalflow rate atidlingwithasuitable 5 Option 1 Procedure 2 Function ronization before attemptinga injuries caused by thepro- injuries 5 3 12-20-00 4 January 01/2010 page 40 08652
d04530.fm d04530.fm Graphic Edition 2/Rev. 0 Effectivity: 914Series Fig. 20 Option 2 Using the push on angular tube (5) and compensating tube (2) install aflexible Remove one end of the compensating tube (2) and tube (3) from the push on 2 1 Step rubber hose(6)leading to thegauge vacuum (1). angular tube(5)after removingthe twotension clamp (4). MAINTENANCE MANUAL MAINTENANCE Rubber hose tube Angular Clamp 6 Tube 5 Compensating tube 4 gauge Vacuum 3 2 1 Part BRP-Powertrain 1 5 Option 2 6 Procedure Function 4 2 3 12-20-00 January 01/2010 page 41 08659 Edition 2/Rev. 0 Effectivity: 914 Series Graphic Fig. 21 Option 3 After synchronization tighten theM6x6 screw (1) LOCTITE with 221. Remove thecompensating tube (3) with attached tubes (4)(connection be- 3 Remove hex. screw (1) M6x6 from intake manifold (2) and connect the vacuum 2 1 Step tween intake manifolds) and plug the fittings in the intake manifolds. manifolds. intake the in fittings the plug and manifolds) intake tween gauge. Compensating tube Intake manifold 4Tube screwM6x6 Hex. 3 2 1 MAINTENANCE MANUAL MAINTENANCE Part 2 BRP-Powertrain 1 Option 3 Procedure Function 4 3 2 1 12-20-00 January 01/2010 page 42 08660
d04530.fm d04530.fm Graphic Edition 2/Rev. 0 Effectivity: 914Series Fig. 22 Option 4 5 After synchronization tighten the screw M6x6 (4) with LOCTITE 221. LOCTITE with (4) M6x6 screw the tighten synchronization After Install the hose nipple(5) M6with the sealing ring (6). (4). screw the Unscrew 5 4 Clamp the tube (2) with hose clamping pliers (1).Observe the position! The 3 Install the vacuum gauge. 2 1 Step compensation tube (3) does not have to be removed. be to have not does (3) tube compensation MAINTENANCE MANUAL MAINTENANCE 6 Sealing ring Sealing nipple Hose M6x6 Screw 6 Compensation tube 5 Tube 4 Clampingpliers 3 2 1 Part BRP-Powertrain 3 2 Option 4 Procedure 1 Function 4 5 12-20-00 6 January 01/2010 page 43 08661 Edition 2/Rev. 0 Effectivity: 914 Series result No satisfactory General note 12.3.1) Idlespeedcheck If an unsatisfactory resultisachievedIf anunsatisfactory Before proceeding,secu tion andcleanifnecessary. chap. 12-20-00section: theengineandverify Start and ropes. screw canunscrewe be venthigh tooon a load the idlestops. If theis idlespeed too high, thethe maximumidle If asetting of more than1/2 turnis required, repeat mechanical synchronizationto pre- ƽ ƽ ƽ NOTICE WARNUNG WARNUNGWARNING MAINTENANCE MANUAL MAINTENANCE spect for freepassage. Also check for translucent, jell Secure asafe areaaround Secure thepropellerregion Risk oflife threateningin BRP-Powertrain d is complete turn. complete d is 12.5) Setting ofmore than 1/2 turn re theaircraft onthe theidlespeed . , inspecttheidlejetsfor contamina- . If necessary correctasper . Ifnecessary juries causedbyjuries propeller! ground usingwheelchocks propeller during testrun. propeller during before watch testrun it. y-like contamination.In- 12-20-00 January 01/2010 page 44
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Procedure General note 12.3.2) Operating range check range 12.3.2) Operating sary. See To controltheoperati ing range (idletofullthrottle) whenselectedintheco take-off rpm First establish thattheengineisdeve check the Once theproperidlingspeedhasbeenes 5 Any major Any adjustmentsrequired necessitate replacedverification of allparam- Equal adjustmentbe must made onboth carburetors. 5 Finalidle speed adjustmentbemay required by resetting thespeed idle adjust- 4 3 Once full power has been established on both carburetors, retard the throttle 2 Start and warm up engine (See Operators Manual). Select full power and check 1 Step eters mentioned in this procedure. ment screws (2). Discrepancies mustcompensated be for by adjustingtheoff NOTES: carburetors. both for reading same the and observe the pressure gaugesettings. pressure The gaugesshould show that both pressure gauges are registeringthesame readings. If the same reading isnotmadeon both gauges. If necessary,fit/modify the carburetoractuation asrequired Check thatcarburetor actuation effectstravel full and that 3 Shut down the engine. 2 1 Re-testing the engine. Tightening the locknut. 4 Loosening the locknut on the bowden cable and adjusting the 3 Shut down the engine. 2 1 Fig. 23 operating range aboveoperating range theidlespeed Step Step MAINTENANCE MANUAL MAINTENANCE . to achieve full power on both carburetors. on both power full to achieve startingcarburetors (choke) are inthefull off position. off idle adjustment. BRP-Powertrain ng range above idlingthe idle adjustment(1). canbechecked oradjusted. ckpit. Thenthesettingofoperat- Procedure loping fulltake-off performance or Procedure Procedure tablished, it is necessary to tablished, itisnecessary following stepsareneces- . 12-20-00 January 01/2010 page 45 Edition 2/Rev. 0 Effectivity: 914 Series Graphic Assembly Fig. 23 Inspect operating range/idle speed thescrewplugM3 Refit - compensationtubeassy.on Install - ƽ Fig. 21 sated for. removal. Anyminordifferencesin ; NOTICE WARNUNG 2 ). Idle mixture screw Screw plug M3.5x5 Idle speed adjustment screw 4 Idle adjustment 3 2 1 MAINTENANCE MANUAL MAINTENANCE Part Follow manufacturer. oftheinstrument theinstructions BRP-Powertrain .5 (3)andhex.screwsM6 balance atidlespeedwillbecompen- 1 engine inreversesequenceof Function 3 4 x6 with gasket (pos. 1 gasket(pos. x6 with 12-20-00 January 01/2010 page 46 08682
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Instruction General note 24 Checking ofthefloatchamber 12.4) To check ofthefloat See Inspect the float chamberfor contaminationandcorrosion. Remove both floats (5) fromthe floatchamber. Remove float chamber(3)with gasket (4) and bothfloats. 5 (2). screw attachment Open 4 Remove drip tray (1). 3 2 1 7 Adjust with the idle with Adjust disas- the analogously out be carried should chamber float of the Assembly 7 6 ƽ ƽ ƽ Step Step NOTICE Fig. 24 WARNUNG WARNUNGWARNING See chap.See 12-20-00 section: sembly. . MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain tem includingcarburetor. the problem. Inspectandcl the causeisandtake corr If any contaminatio ofanyture before work. start Always allow enginetocool Hot engineparts! Risk ofBurns! chamberthefollowing stepsarenecessary: speed adjustment. 12.5) Procedure Procedure . n onfloatchambert esponding actiontorectify ean thecompletefuelsys- down toambienttempera- 12-20-00 he findoutwhat January 01/2010 page 47 Edition 2/Rev. 0 Effectivity: 914 Series Graphic Float chamber Fig. 24 Gasket Float chamber 5Float screw Attachment 4 tray Drip 3 2 1 MAINTENANCE MANUAL MAINTENANCE Part BRP-Powertrain 1 2 Function 3 5 4 12-20-00 January 01/2010 page 48 08681
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series gine running Optimizing en- adjustment Idle General note 12.5) Idle speed adjustment Idle speed 12.5) Necessary onlyifnottaken Necessary Basic adjustmentoftheidlespeedis - Always outidlespeedadjus carry See 1 Close idle mixture screw (4)byturnin Closeidlemixturescrew 1 4 Then readjustment of the idle speed is carried out using the idle speed adjust- speed idle the using out is carried speed idle the of readjustment Then The optimum setting isthe middle between the twopositions at whichan rpm. 4 Starting fromthis basic adjustment,theidle mixture (4)is turned screw until 3 2 ƽ Step See chap.12-20-00section: adjustment screw(2)of NOTICE Fig. 23 WARNUNG OE:Turning the idle mixture cont NOTES: again. ment(2) screwandif necessary, byslightlyturning themixture idle screw drop isnoticed. the highest idle speed is reached. opening againby 1.5turns counter clockwise. . MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain See chap.12-20-00section: matic synchronizationwillbenecessary. achieved, inspectionofthe If satisfactory idles a richer mixture.a richer results in a leaner mixture counter clockwiseand turning in the throttle valve. throttle the care ofatsynchronization. 12.2) tment whentheengineiswarm. Procedure . peed adjustment first effectedusingtheidlespeed g clockwise to screw in fully and then then and in fully to screw g clockwise rol screwin clockwise direction idle jetor 12.3) . 12-20-00 cannotbe additional pneu- January 01/2010 page 49 Edition 2/Rev. 0 Effectivity: 914 Series Procedure General note 26 Checking thecarburetor actuation 12.6) To testthecarburetor U See OE:Eachcarburetor isactuatedby two bowden cables. Atpo- NOTES: idle speedsetting Route bowden cables insuchaway t influenced by any movement Inspectreturn springs (3) and inspect engagementholes for wear. Inspectand lubricate linkage oncarburetorandcarburetor jointswith engine 5 Adjustthrottle cables to aclearance1mm of (0.04 in). Bowdencable must allow full travel of lever from stop to stop. 4 Inspectbowden cables and levers forfree movement. 3 2 1 ƽ ƽ ƽ ƽ Step Fig. 25 WARNUNGWARNING WARNUNGWARNING oil. . connection for choke actuation. sition (1)connectionfor throttlevalve, andatposition(2) MAINTENANCE MANUAL MAINTENANCE and synchronization. actuation disconnected. retor is valve isfullyopen.Theinitia With carburetor actuation Risk oflife threateningin jam! opened andclosed.Bowden cabl choke actuationofthestarti Adjust bowden cables sothatthethrottlevalve andthe Risk oflife threateningin BRP-Powertrain actuationthefollowin full throttle of engineorairframe, Procedure hat carburetor ac ! Sonever theenginewith start g stepsarenecessary: juries causedbyjuries propeller! causedbyjuries propeller! not connected,thethrottle ng carburetor canbefully l positionoftheCDcarbu- thus possibly falsifying es andlever must not tuation willnotbe 12-20-00 January 01/2010 page 50
d04530.fm d04530.fm Graphic Edition 2/Rev. 0 Effectivity: 914Series Fig. 25 Checking thecarburetor actuation 1 MAINTENANCE MANUAL MAINTENANCE 3 Return springs Return Connection for chokeactuation valve forthrottle Connection 3 2 1 3 Part BRP-Powertrain Function ~1 mm 3 2 12-20-00 January 01/2010 page 51 02480 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-20-00 January 01/2010 page 52
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Overview 13) Lubrication 31 General 13.1) Fig. 26 2 1 MAINTENANCE MANUAL MAINTENANCE Oil filter Oil cooler (optional) Drain screwM12x12 4 Oil tank 3 2 1 Part
BRP-Powertrain
IN
O
U T 3 Function 12-20-00 back fromengine to oilpump January 01/2010 08238,08580 4 page 53 Edition 2/Rev. 0 Effectivity: 914 Series connections Oil lines, Oil Observe! General note Oil linesandotheroilconnecti thesuctionlines,oilcooler Draining - Fig. 26 For detailedinformation seeSI-914- - Replacement oftheoilfilterand Replacement - Itisadvisable tocheck the NOTES: ƽ ƽ ƽ ƽ ƽ and thehydraulictappets. quickly andwithoutinterruptiontopr must beavoided,asitresults NOTICE WARNUNG WARNUNGWARNING WARNUNGWARNING . See chap. 12-10-00 section: it informs aboutoilconsumption. MAINTENANCE MANUAL MAINTENANCE drive: voiding oftheoilsystem thefollowingObserve topr battery. ofaircraft tive terminal Switch offignitionandremo shock!Risk ofelectric ofanyture before work. start Always allow enginetocool Hot engineparts! Risk ofBurns! BRP-Powertrain ons are not normally removed.ons arenotnormally in airenteringtheoilsystem. the oilchangeshoul 011 “oilchange“,latestissue, and andreturnlineisnotnecessary event adrainingof oil level toanoilchangeas prior and damagetothevalve 4.1) event possible unintentional ve key! Disconnectnega- down toambienttempera- . d beeffected 12-20-00 theoilsystem January 01/2010 page 54
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Procedure 32 Oilchange 13.2) NOTES: Run engine to warm oil Run enginetowarm To changetheoilfollo NOTES: Fit drain screw (M12x12) withsealing anew ring and safety wire. Tightening Disposeof oilfilter accordingenvironmental to regulations. 5 4 Replace oilfilter atchangeoil eachinspect and the filter inserts. Remove safetyand wire oil drain from screw the oiltank, drain the used oil 3 Crank engine by hand to transfer the oil from the crankcase. 2 1 After carrying outchange,oil the the engine shouldhand becranked thein by Pour inapprox.3l(0.8 (US)) galof fresh oil. 7 6 Compressed air must not be used to blow through the oil system (or oil lines, 8 ƽ ƽ Step Step NOTICE NOTICE WARNUNG WARNUNG NOTES: When When installing theoildrain screw one has tolock the nut NOTES: Nm(18.5 ft.lb). torque 25 See chap.See 12-20-00 section: and disposeas ofper environmental regulations. chap.See 12-10-00 section: direction of enginerotation direction oil pump housing, oil bores in the housing). circuit. cedure. MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain after correctventin commissioning (e.g. when is open.Attentionmust also The enginemust notbecr able operating fluids“latestissue. Operators Manual andSI-914- Only usebrand nameoilin of the oil tank floor. isonthefloor of the which wing stepsarenecessary: (approx. 20 turns)tocomp (approx. 4.1). 13.5) Procedure Procedure . g oftheoilsystem). before beginningoilchangepro- oil tank.This anked whentheoilsystem assembling thepropeller accordance withthelatest be paidtothisbefore first 019, “Selectionofsuit- letely refill the entireoil refill letely 12-20-00 will prevent damage January 01/2010 page 55 Edition 2/Rev. 0 Effectivity: 914 Series Procedure Graphic tool Special General note 33 Oilfilterreplacement 13.3) Fig. 27 Special tool To outtheprocedure carry taking carenottoproducechips. At every oilchange, unscr Unscrew theoilfilter. 1 Unscrew the oilfilterwi Unscrew 1 atn.877*(2)Cutting tool (1)filterOil wrench equivalent* or part no. 877670* part no. 877620* ƽ ƽ ƽ Step NOTICE WARNUNG WARNUNGWARNING part number 1 MAINTENANCE MANUAL MAINTENANCE the by-pass valve. only. Onlythesefilterswill forced flow us lubrication, To ensurecorrectfunctioni ofanyture before work. start Always allow enginetocool Hot engineparts! Risk ofBurns! BRP-Powertrain ew theoilfilterandcut th theoil filter wrench.
following stepsarenecessary: Procedure
e genuine ROTAX oilfilter ensure correctpressurein ng oftheoilcircuitand down toambienttempera- open usingspecialtool Description 2 12-20-00 January 01/2010 page 56 02734
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic Procedure General note 34 Install oilfilter 13.4) Fig. 28 Install oilfilter. Inspect allsystemsfor correctfunction. To mounttheoilfilter See Tightenfilteroil with a3/4 turn (270°). 5 4 Screw onoilfilteruntilf Screw Install the oilfilterthe on engine. th film engineoilon thin Apply 4 Clean the contact surface (1) of the o 3 2 1 ƽ Step NOTICE Fig. 28 WARNUNG 4 . MAINTENANCE MANUAL MAINTENANCE Oil filter Gasket Oil pump housing 4 surface Contact 3 2 1 1 Part BRP-Powertrain After test run inspectti After testrun B following stepsarenecessary: ilter gasket is ilter gasket 2 A e gasket (3) of the oil filter (4). oilfilter the of (3) e gasket Procedure 4 Function il pump housing(2) withclean a cloth. seated solidly. ght fitofoilfilter. 3 4 12-20-00 C January 01/2010 page 57 08550 Edition 2/Rev. 0 Effectivity: 914 Series Unclear findings eign matter Increased for- matter Possible foreign Procedure General note 35 Inspection ofthefilterinsert 13.5) bronze chipsorsliver If anincreasedamountofmetalparticl ofsealing compound Remains - ofbearingmaterial Sliver - chips Aluminium - Bronze chips - chips Steel - Possible foreign matter: To outtheprocedure carry asita This inspectionisimportant In thecaseofunclearfindings: pointsunfilter the bearing thiness. Ifthefilterma in accordancewiththeB possible causeofany damage. conditionoftheengi the internal 5 Unroll and inspect it for metal chips, chips, itformetal inspect and Unroll filter Remove mat, foldand uppress remaining oilout. Cut topand bottom off edges the mat with aknife. 5 filter Remove insert. 4 chips. produce not to care taking tool special using open oil filter Cut 3 2 1 Pass over mattwith aclean magnet andfor inspect metal. 6 4 Inspect the oil filter once more. once oil filter the Inspect Engine test run. See chap. 12-20-00section: anew Fit oil filter. 4 circuit. theoil Flush 3 2 1 ƽ Step Step NOTICE WARNUNG sion. MAINTENANCE MANUAL MAINTENANCE chips. must beinspectedcarefullyfor metal The filterinsert BRP-Powertrain from bearing abrasion, r from bearing t iscloggedby foreign ma RP-Powertrain for instructions continuedairwor- ed viatheby-pass valv following stepsarenecessary: ne andprovides information aboutthe llows conclusionstobedrawn regarding Procedure Procedure es isfound, suchasbrass- or foreign matter, contamination and abra- epair oroverhaul theengine 10) tter, thelubeoilreaches e intheoilfilter. . 12-20-00 January 01/2010 page 58
d04530.fm d04530.fm Contaminated Edition 2/Rev. 0 Effectivity: 914Series Graphic Fig. 29 Oil filter ƽ NOTICE WARNUNG 2 MAINTENANCE MANUAL MAINTENANCE 1 Filter mat element Filter Gasket ring 5 Filter cover 4 Filter housing 3 2 1 3 Part BRP-Powertrain repair ofpistonengines. 15) and flushtheoilcircuit. If theoilcircuitiscontami . Properjudgementrequires to bearings Function from oilpump See chap. 12-20-00section: nated, replacetheoilcooler 4 years ofexperience in 5 12-20-00 January 01/2010 08427,00181 5 page 59 Edition 2/Rev. 0 Effectivity: 914 Series Procedure General note 36 Cleaning theoiltank 13.6) Procedure tocle Thisprocedureisoptional NOTES: See 3 Clean oil tank Cleanoil (8) and inner parts (5,6) and for checkdamage. Remove the inner partsofthetankoil thebaffle suchas insert(5)and par- the 3 Detach the profile(2) clampand remove the oiltank cover (3) together with 2 1 Reassemble the oiltank byfollowingthesamereverse stepsin order. Safety wire. 6 Nm to 25 Tighten ring. gasket a new with (1) M12x12 screw drain Fit 5 4 ƽ Step Step NOTICE Fig. 30 WARNUNG tition (6). tition the O-ring (4) and the oillines. 1. ft.lb). (18.5 . if thereisheavy tocleant It isonlynecessary system. Seechap. 12-20-00section: an theoiltank: MAINTENANCE MANUAL MAINTENANCE cause enginefaults orenginedamage. Incorrect assembly ofth BRP-Powertrain oil contamination. Procedure Procedure and requiresvent e oiltankco he oiltankandtheinnerparts 13.7) mponents can 12-20-00 . January 01/2010 ing oftheoil page 60
d04530.fm d04530.fm Graphic Edition 2/Rev. 0 Effectivity: 914Series Cleaning theoiltank Fig. 30 4 8 3 MAINTENANCE MANUAL MAINTENANCE Oil tank Gasket ring Partition 8 7 6 cover Oil tank 5Baffle clamp Profile 4O-ring Drain screw 3 2 1 insert 1 Part BRP-Powertrain 7 Function 6 2 5 12-20-00 January 01/2010 page 61 05556 Edition 2/Rev. 0 Effectivity: 914 Series Procedure General note 37 Purging system oil the 13.7) after maintenanceworkduringwh - (e after reinstallation - before eachfirststartup - Purging theoilsystemisnecessary: ƽ opened andvoided. NOTICE WARNUNG MAINTENANCE MANUAL MAINTENANCE the lubrication syste the lubrication outinaccordanc carried procedure must befollowed meticulously. Itmust be lifeeration andservice of Purging oftheoilsystemis BRP-Powertrain .g. afteroverhaul) ich thelubricationsystemwas m“, latestissue. e withSI-914-020,“Purging theengineand extremely important for extremely op- important 12-20-00 January 01/2010 therefore the page 62
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Contamination Unclear findings numbers larger chips in Steel numbers chips inlow Steel Procedure General note 14) Inspectingthemagnetic plug ertrain instructions for instructions ertrain engine must berepairedoroverhauled Trace thecauseandremedy. caseof In the If therearelargeraccumulations of in). (0.125 mm accumulation isbelow 3 Steel chipsinlow numbersasdepictedin Remove themagneticplugandinspec See about possible damage. conditionof the internal Themagneticplugislo becauseit This inspectionisimportant NOTES: Inspect the oilfilter once more. Engine test run. See chap. 12-20-00 section: oilfilter. anew Fit 4 theoilcircuit. Flush 3 2 1 ƽ Step NOTICE Fig. 31 WARNUNG . unclear findings: cylinder 2andgearbox. MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain of affected enginecomponents. See chap. 12-20-00 section: and flushtheoilcircuit. If theoilcircuitiscontami continued airworthiness. thegearbox and metalchipsonthe Procedure t itfor accumulation ofchips. allows conclusionstobedrawn on in accordancewiththeBRP-Pow- cated onthecrankcase between engineandreveals information Fig. 31 nated, replacetheoilcooler 10) 15) can be tolerated if the the if canbetolerated . . Detailedinspection magnetic plug,the 12-20-00 January 01/2010 page 63 Edition 2/Rev. 0 Effectivity: 914 Series Install Graphic 41 Installation ofthemagnetic plug 14.1) engine components. Inspect allsystems for correctfuncti The following steps Fig. 31 Inspecting themagneticplug. Safetythe wire plug. ft.lb). Nm(18.5 Refit the magnetic plug.Tightening torque 25 Clean the magnetic plug. 3 2 1 Step acceptable MAINTENANCE MANUAL MAINTENANCE arenecessary: BRP-Powertrain on. Detailedinspec Procedure not acceptable magnetic plug tion ofaffected 12-20-00 08565,08566,08564,08563 January 01/2010 page 64
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Equipment Procedure Filling lines Temporary oil tank Oil lines Oil General note 15) Flushingtheoilcircuit Purging oftheoilsystem,se Reconnect negative terminal The following stepshave tobe Fill theoiltankwithapprox. Otherwise, could metalchips NOTES: cle andnotback totheoiltank. is notconnected.Theretu Temporary oillines Clean theoiltank. turer. Dismantle andflusho Control the oilcaptured duringthe ri 2 Turnengine byhand indirectionof engine rotationreturn to thefromoil the 1 Install newoilfilterandrefillwith oil. Install cleaned oillines and oilcooler accordingto the manufacturers instruc- 4 3 ƽ ƽ ƽ ƽ Step NOTICE NOTICE WARNUNG WARNUNG WARNUNGWARNING cedure is complete when no more contamination can be discovered. discovered. be can contamination more no when complete is cedure oil from the oil tank into the engine and into the collection container. The pro- tion. discovered. be can contamination more no when complete tank during flushing. tank during MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain (only for flushing)must befi tenance Manual oftheaircraft manufacturer. Inspect alltheequipmentin suction pipe, otherwise air level oil The mu inthetank tive ofaircraft battery. terminal Switch offignitionand shock!Risk ofelectric il linesasperinstructions rn lineisroutedinto rn 08gal(US))ofengineoil. 3 l(0.8 e chap. 12-20-00 section: ofaircraft battery. carried outaf carried Procedure nsing process. The rinsing process is remove key! Disconnect nega- ter refilling: penetrate theradiator oroil st notdropbelow will besucked inagain. a separate, cleanrecepta- oftheaircraft manufac- tted sothatt accordance withtheMain- 13.7) 12-20-00 January 01/2010 . he oilcooler theendof page 65 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-20-00 January 01/2010 page 66
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Overview 16) Electricsystem Fig. 32 1 4 MAINTENANCE MANUAL MAINTENANCE 7 Protection hose Protection cable Grounding Plug connectors 7 module Electronic 6 Ignition cable 5 Dual ignitioncoil 4 Spark plug connectors 3 2 1 Part BRP-Powertrain 5 6 Function 2 7 12-20-00 6 3 January 01/2010 08552,08553 page 67 Edition 2/Rev. 0 Effectivity: 914 Series Procedure General note 61 Check wiring of 16.1) The following stepsha Inspectplug connections of the wiringharness, of the turbochargercontrol unit Inspect all 8 ignition cables to spark plug connector for corrosion or damage 9 8 Verify shielding of cable assemblies for corrosion or damage, good ground con- Inspectgrounding cablesfor tight fit,corrosion or damagereplace and nec- if 7 6 Verify plug connections of alternator cables with rectifier-regulator and connec- Inspectplug connections between electronic moduleand ignition coilsfor cor- 5 Inspectplug connections between pick-up cable, electronic module, charging 4 Inspectall groundconnections for corrosiondamage,and replace ifnecessary. 3 Inspect all cable connectors and their connections for tight fit, good contact, 2 1 ƽ ƽ ƽ ƽ Step WARNUNGWARNING WARNUNGWARNING lamps forcorrosion or damageandtight fitand replace necessary. as two the and valve control disconnector, motor, servo sensor, temperature airbox potentiometer, throttle tacho-generator, sensors, pressure 2x (TCU), if necessary. replace fitand tight and sary. tact and tightfit, inspect theattachment of the shieldingand replace ifneces- essary. damage and replace if necessary. cablestionsall of onrectifier-regulator forgoodcontact, tight fit,corrosion or rosiondamage or and replaceif necessary. shortingand cables forcorrosion or damageand replace required. as corrosionor damage and replace asnecessary. MAINTENANCE MANUAL MAINTENANCE ture before start ofanyture before work. start Always allow enginetocool Hot engineparts! Risk ofBurns! Switch offignitionandremove key! shock!Risk ofelectric BRP-Powertrain ve out: tobecarried Procedure down toambienttempera- 12-20-00 January 01/2010 page 68
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Remove tool Special Renewal intervals General note 62 Inspection andrepl 16.2) 16.2.1) Remove thesparkplugs change spark plugsbetween cylinders.change spark tion. Always plugs replacebothspark Remove plugsandstore thespark employed andthat thecorrect Ensure thatthefollowing plugs spark Operation with NOTES: See make plugwill surethatthespark In numerous teststhebestpossi specified for eachenginetype. Because ofthediffering 1 eis875 DX7P-91 m(.7in) mm (0.47 12 NDX27EPR-U9 897257 914 Series ƽ NOTICE Fig. 33 WARNUNG Engine . intervals accordingly.intervals sult inincreasedwear oft MAINTENANCE MANUAL MAINTENANCE acement of spark plugs acement ofspark BRP-Powertrain See chap. 05-50-00section: lems andpre-ignitiona plugs Use ofincorrectspark Part no. thermal load,particular thermal spark plugsocketspark isused: leadedfuels(e.g. AVGAS 100LL)canre- ble to heatrange hasbeendetermined burn offdepositsbutburn them accordingto correspondingto ofacylinder Designation he spark plugs. Reduce renewalhe spark nd consequentenginedamage. spark plugshave spark been can resultinignitionprob- 3.8) and donotinter- . cylinderandposi- 12-20-00 engine typeare will notoverheat. Size of socket January 01/2010 page 69 Edition 2/Rev. 0 Effectivity: 914 Series Spark plugface Electrode gap check Visual Heat range 16.2.2) Inspection of sparkplugs of 16.2.2) Inspection engine: plugfaceSpark reveals thefollowi Inspecttheelectrodegapalsoonuseofnew plugs. spark NOTES: plugsforInspect allspark mechanicaldamage. Check heatrange and . . m(.2 .2 n . m(.3 in) (0.035 mm 0.9 in) mm (0.0230.027 - 0.60.7 - melt beads melt white withformation of coating glossy oily, velvet black brown to coloured light Spark plug face New The gapcouldhave beenc MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain adjust electrodegapcorrespondingly. leaking valves - toolean mixture - following: the Indicates worn cylinderpiston and rings - chamber combustion in oil much too - -misfiring damagedvalve stem seal - following: the Indicates engine operating temperature too low - insufficientintake air (clogged airfilter) - rich too mixture - following: the Indicates plug and calibrationthe ofengine are correct Electrode gap ng abouttheoperating hanged by impr Information Wear limit Wear 12-20-00 conditionofthe oper handling. January 01/2010 page 70
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Graphic Installation Cleaning 16.2.3) Installationofsparkplug duction compound). the cylinderheadshould Fig. 33 spark plugs plugto and tightenspark Apply smallamountof Before every installation,thespark ƽ ƽ ƽ ƽ NOTICE NOTICE WARNUNG WARNUNG WARNUNGWARNING 1 2 Electrode gap MAINTENANCE MANUAL MAINTENANCE Head area electrode Ground 2 1 Part BRP-Powertrain apply to the first three threads. firstthree tothe apply ply heatconductioncom or theheadarea(2)canleadtoignitionproblems. Ap- Heat conductioncompoundat pl not interchangespark Always pl replacebothspark skin. May ifswallowed. beharmful Rinse offwithwater intheca Eyes andskinirritation! heat conductioncompound be cleaned(e.g. toremove 0N 17in.lb)onthe Nm(177 20 plug threadandthesp Function ugs between cylinders. pound sparingly pound sparingly se ofcontactwitheyes or ugs ofacylinderanddo the groundelectrode(1) cold to spark plugthread to spark residueofheatcon- 12-20-00 engine. ark plugseatat ark January 01/2010 and donot page 71 00086 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-20-00 January 01/2010 page 72
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series Test procedure General note clutch the overload Engine without General note 17) Propeller gearbox 71 Checking thefrictiontorque infreerotation 17.1) The following stepsarenecessa See without overload clutch. For torq thisreasonthefriction Engines withouttheover Thefollowing “freerotati NOTES: Remove crankshaftpin. locking See chap. 12-20-00 section: 6 Calculate friction torque (Nm) bymultiplyingthe force (N)obtained on the 5 center the from (L) in distance propeller to the scale spring acalibrated Attach 4 consid- into taking ramps, between forth and back hand by propeller the Turn 3 With the crankshaft locked, the propellerturned canbe byhandor 15de- 30 Fit the crankshaft lockingpin. Seechap. 12-20-00section: 2 1 ƽ ƽ Step Fig. 34 WARNUNGWARNING See calculation example. calculation See The friction torque must be between 30 Nm and max. 60 Nm (22 to 44.3 ft.lb). (L). peller springscale by the distancethe is attached scale from the center of the pro- or 30degree range of freerotation. of the propeller. Measure the force required to pull the propeller through the 15 ticeable during this moment. eration the friction torque. Nooddirregular noisesor resistance must beno- sional absorptionunit. shock This isthe maximum amount of movement allowed bythe dog gears inthe tor- grees depending on the profile of the dog gears installed. NOTICE . clutch asoptionalextra. onlyonengineswiththeoverloadcheck“ arenecessary MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain tive ofaircraft battery. terminal Switch offignitionand shock!Risk ofelectric load clutch(slipperclut the ROTAX fo instructions the ROTAX spect,repair or overhaul the gearbox inaccordancewith in- achieved, is not torque friction mentioned above If the ue methodcannot ry forry thetestingprocedure: Procedure on check“ torque and“friction remove key! Disconnectnega- r continued airworthiness. ch) have nofreerotation. be appliedonengines 12-20-00 7). January 01/2010 7). page 73 Edition 2/Rev. 0 Effectivity: 914 Series Graphic Fig. 34 Checking torque. thefriction .UDIW)LQ1 IRUFH)LQ1 MAINTENANCE MANUAL MAINTENANCE OHQJWK/LQP /lQJH/ P BRP-Powertrain 12-20-00 January 01/2010 page 74 05694
d04530.fm d04530.fm Edition 2/Rev. 0 Effectivity: 914Series General note 72 Checking thepropeller gearbox 17.2) carried outifcrackscarried aresuspected. Crack testingofthepr chap. 72-00-00intheHeavy MaintenanceManual. Detailed inspectionoftheaffected with theBRP-Powertrain instructi The gearbox must beinspec MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain opeller shaftisnotnorma ted, repairedorover ons for continued airworthiness. gearbox componentsinaccordance lly planned,but canbe hauled inaccordance 12-20-00 January 01/2010 page 75 Edition 2/Rev. 0 Effectivity: 914 Series MAINTENANCE MANUAL MAINTENANCE BRP-Powertrain NOTES 12-20-00 January 01/2010 page 76
d04530.fm
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Motornummer / Engine serial no.
Flugzeugtype / Type of aircraft
Flugzeugkennzeichen / Aircraft registration no.
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