MAINTENANCE MANUAL - Rotax Aircraft Engines

462 Pages·2010·10.64 MB·English

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MAINTENANCE MANUAL
(HEAVY MAINTENANCE) FOR ROTAX® ENGINE TYPES
picture 914 UL 3 DCDI with options
picture 912 ULS 3 DCDI with options
ROTAX® 912 AND 914 SERIES
part no.: 899603
WARNING
Before starting any maintenance work, please read the Maintenance Manual completely
as it contains important safety relevant information.
These technical data and the information embodied therein are the property of BRP-
Powertrain GmbH & Co KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior
written permission of BRP-Powertrain GmbH & Co KG, be disclosed in whole or in part to
third parties. This legend shall be included on any reproduction of these data, in whole or
in part.
Copyright 2009 © - all rights reserved.
ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG. In the following document
®
the short form of BRP-Powertrain GmbH & Co KG = BRP-Powertrain is used.
Other product names in this documentation are used purely for ease of identification and
may be trademarks of the respective company or owner.
Approval of translation has been done to best knowledge and judgement - in any case
the original text in German language is authoritative.
BRP-Rotax
Maintenance Manual
SECTION 00
INTRODUCTION
1) Table of contents
SECTION 00
INTRODUCTION
1) Table of contents....................................................................................00-00-00 / 3
2) List of chapters.......................................................................................00-00-00 / 5
3) Index.......................................................................................................00-00-00 / 7
4) List of the valid pages.............................................................................00-00-00 / 11
5) Table of amendments.............................................................................00-00-00 / 19
6) General note ..........................................................................................00-00-00 / 23
7) Safety notice...........................................................................................00-00-00 / 25
7.1) Repeating symbols........................................................................00-00-00 / 25
8) Technical documentation........................................................................00-00-00 / 27
8.1) Filling in the dimension sheets ......................................................00-00-00 / 27
8.2) List of abbreviations ......................................................................00-00-00 / 28
9) Classification of parts for maintenance/repair ........................................00-00-00 / 29
9.1) Determination of actual wear [%]..................................................00-00-00 / 32
10)Maintenance...........................................................................................00-00-00 / 35
10.1) Trouble shooting............................................................................00-00-00 / 35
10.2) Tightening torques ........................................................................00-00-00 / 35
10.3) Consumable materials...................................................................00-00-00 / 36
10.4) Auxiliary tools ................................................................................00-00-00 / 39
10.5) Measuring tools.............................................................................00-00-00 / 41
10.6) Special tools and devices..............................................................00-00-00 / 42
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Maintenance Manual
2) List of chapters
INTRODUCTION...............................................00
POWER PLANT................................................71
ENGINE ............................................................72
FUEL SYSTEM .................................................73
IGNITION SYSTEM ..........................................74
COOLING SYSTEM..........................................75
ENGINE CONTROL..........................................76
EXHAUST SYSTEM AND TURBOCHARGER ..78
LUBRICATION SYSTEM ..................................79
ELECTRIC STARTER .......................................80
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Maintenance Manual
3) Index
A E
Airbox temperature 76-00-00 / 9 Electric starter 80-00-00 / 3
Alternators 74-00-00 / 3 Electric starter installation 80-00-00 / 12
Auxiliary tools 00-00-00 / 37 Electric starter dismantling 80-00-00 / 5
Electric starter inspection 80-00-00 / 9
B
Electric starter diassembly 80-00-00 / 11
Boost pressure display 73-00-00 / 16
Electronic module 74-00-00 / 14
Bowden cable 78-00-00 / 19
Engine components 71-00-00 / 12
C Engine views 71-00-00 / 5
Carburetor assembly 73-00-00 / 53 Exhaust gas temperature display 78-00-00 / 5
Carburetor disassembly 73-00-00 / 19 Exhaust system assembly 78-00-00 / 15
Carburetor heat systems 73-00-00 / 16 Exhaust system inspection 78-00-00 / 11
Carburetor individual components 73-00-00 / Exhaust system disassembly 78-00-00 / 7
23, 73-00-00 / 24 Exhaust turbocharger 78-00-00 / 3
Carburetor socket assembly 73-00-00 / 53
F
Carburetor socket disassembly 73-00-00 /
Filter oil 00-00-00 / 36
17, 73-00-00 / 19
Float bracket 73-00-00 / 28
Carburetor synchronization 73-00-00 / 33
Float housing 73-00-00 / 27
Caution lamps inspection 76-00-00 / 34
Float needle valve inspection 73-00-00 / 30
Charging coil 74-00-00 / 14
Floats 73-00-00 / 27
Choke 73-00-00 / 31
Fly wheel hub 72-00-00 / 9, 74-00-00 / 49
Classification of parts 00-00-00 / 29
Fuel filter 73-00-00 / 7
Cleaning agents 00-00-00 / 38
Fuel handling 73-00-00 / 15
Communication program 76-00-00 / 13
Fuel lines 73-00-00 / 40, 73-00-00 / 43
Components 71-00-00 / 5
Fuel lines assembly 73-00-00 / 55, 73-00-00 / 58
Compressor pressure ratio 76-00-00 / 10
Fuel lines disassembly 73-00-00 / 17, 73-00-00 /
Constant depression carburetor 73-00-00 /
19
12, 73-00-00 / 21
Fuel pressure 73-00-00 / 35, 37
Consumable materials 00-00-00 / 36
Fuel pressure regulator 73-00-00 / 44
Coolant hoses fitting 75-00-00 / 14
Fuel pump 73-00-00 / 45, 73-00-00 / 47
Cooling air duct 75-00-00 / 14
G
Cut-in speed 74-00-00 / 18
Cyl. head assembly 72-00-00 / 73, 72-00-00 Gear set inspection 72-00-00 / 44
Cyl. head temperature sensor 75-00-00 / 15 Gearbox configurations 72-00-00 / 5
Cylinder designation 71-00-00 / 5 Gearbox parts inspection 72-00-00 / 39
Cylinder head disassembly 72-00-00 / 57 Governor 72-00-00 / 7
Cylinder head fitting 72-00-00 / 92 Governor drive removal 72-00-00 / 33
Cylinder head removal 72-00-00 / 55 H
Cylinders assembly 72-00-00 / 86
Heat conduction compound 00-00-00 / 37
Cylinders inspection 72-00-00 / 81
Hose clamps 75-00-00 / 14
Cylinders removal 72-00-00 / 75
Hourmeter 72-00-00 / 8
D Hydraulic valve tappets 72-00-00 / 83
Description of design 71-00-00 / 3 I
Diaphragms 73-00-00 / 25
Idle speed adjustment 73-00-00 / 33
Disc spring pretension 72-00-00 / 51
Ignition 74-00-00 / 3, 74-00-00 / 6
Drain plug 79-00-00 / 10
Ignition cables 74-00-00 / 9
Drip tray disassembly 73-00-00 / 17
Ignition check 74-00-00 / 21
Dual ignition coil 74-00-00 / 17
4 Ignition circuits inspection 74-00-00 / 21
7
47 Ignition electric set reassembly 74-00-00 / 41
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Ignition electric set fitting 74-00-00 / 43 P
Ignition electric set removal 74-00-00 / 35 PC interface 76-00-00 / 12
Ignition housing 72-00-00 / 14 Piston rings inspection 72-00-00 / 79
Ignition housing inspection 72-00-00 / 11 Pistons fitting 72-00-00 / 86
Ignition housing removal 72-00-00 / 11 Pistons inspection 72-00-00 / 77
Ignition timing 74-00-00 / 19 Pistons removal 72-00-00 / 75
Instruments 79-00-00 / 10 Pitting 72-00-00 / 45, 72-00-00 / 47
Intake air temperature sensor inspection 76- Position finding 78-00-00 / 20
00-00 / 42 Preservation 71-00-00 / 18, 71-00-00 / 19
Intake manifold fitting 73-00-00 / 60 Preservation oil 00-00-00 / 37
Intermediate gear 72-00-00 / 20 Pressure connecting lines 73-00-00 / 10, 73-00-00 /
L 49
Pressure measurement system 71-00-00 / 22, 79-
List of valid pages 00-00-00 / 11
00-00 / 26
Lithiumbase grease 00-00-00 / 34
Pressure sensors inspection 76-00-00 / 44
Loctite 00-00-00 / 36
Propeller gearbox 72-00-00 / 5, 72-00-00 / 22, 80-
Lubrication system purging 79-00-00 / 26
00-00 / 3
M
Propeller gearbox diassembly 72-00-00 / 28
Magnetic plug 79-00-00 / 10 Propeller gearbox reassembly 72-00-00 / 49
Main oil pump 79-00-00 / 3, 79-00-00 / 5 Propeller gearbox installation 72-00-00 / 53
Measuring tools 00-00-00 / 39 Propeller shaft removal 72-00-00 / 30
Molycote 00-00-00 / 36 Pushrods 72-00-00 / 85
Multimeter 00-00-00 / 41
R
Multipurpose grease 00-00-00 / 35
Red boost lamp 76-00-00 / 11
O
Return to service 71-00-00 / 18
Oil circuit 79-00-00 / 5 Rev counter inspection 74-00-00 / 55
Oil cooler 79-00-00 / 25 Rev counter drive 72-00-00 / 21
Oil lines 79-00-00 / 25 Rev counter, mechanical 72-00-00 / 8
Oil pressure sensor 79-00-00 / 27 Roller bearings for F2 removal 72-00-00 / 24
Oil pump disassembly 79-00-00 / 14 Roller bearings for F3 removal 72-00-00 / 26
Oil pump 79-00-00 / 11 Roller bearings for F4 removal 72-00-00 / 27
Oil pump checking 79-00-00 / 15 Rotary seal 75-00-00 / 10
Oil pump reassembly 79-00-00 / 18, 79-00-00
S
/ 19
Servo motor 78-00-00 / 20
Oil pump removal 79-00-00 / 11
Silastic 00-00-00 / 36
Oil sump 79-00-00 / 21
Special tools 00-00-00 / 40
Oil tank 79-00-00 / 22
Sprag clutch 72-00-00 / 15
Oil temperature display 79-00-00 / 10
Sprag clutch dismantling 72-00-00 / 17
Oil temperature sensor 79-00-00 / 26
Sprag clutch installation 72-00-00 / 18
Operating fluids 71-00-00 / 11
Sprag clutch removal 72-00-00 / 16
Operating limits 71-00-00 / 11
Spring, wastegate 78-00-00 / 19
Orange caution lamp 76-00-00 / 11
Starting carburetor 73-00-00 / 31
Oscilloscope 00-00-00 / 41
Stator removal and refitting 74-00-00 / 48
Output connections on the TCU for lamps 76-
Stroboscope 00-00-00 / 41
00-00 / 11
Suction pump 79-00-00 / 8
Overspeeding 76-00-00 / 8
Surface damage 71-00-00 / 15
Return to service 00-00-00 / 25, 71-00-00 / 17, 71-
00-00 / 18
Rev counter inspection 74-00-00 / 53
4
Rev counter drive 72-00-00 / 21 77
4
Rev counter, mechanical 72-00-00 / 8 d0
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T
Table of amendments 00-00-00 / 19
Target pressure reduction 76-00-00 / 8
TCU inspection 76-00-00 / 32
Technical data 71-00-00 / 11, 71-00-00 / 15
Temperature measuring system 71-00-00 / 22, 75-
00-00 / 15, 79-00-00 / 26
Three-way solenoid valve 76-00-00 / 53
Throttle potentiometer calibration 76-00-00 / 31
Throttle potentiometer inspection 76-00-00 / 37
Tightening torques 00-00-00 / 35
Trigger coil kit 74-00-00 / 13
Trigger coil kit replacement 74-00-00 / 46
Trigger coils arrangement 74-00-00 / 8
Turbocharger assembly 78-00-00 / 15
Turbocharger disassembly 78-00-00 / 7
Turbocharger inspection 78-00-00 / 11
Turbo control unit 76-00-00 / 32
Type description 71-00-00 / 4
V
Vacuum pump 72-00-00 / 7, 72-00-00 / 10
Vacuum pump drive removal 72-00-00 / 32
Valve guide 72-00-00 / 62
Valve lapping paste 00-00-00 / 36
Valve seats 72-00-00 / 63
Valves 72-00-00 / 64
W
Water pump removal 75-00-00 / 6
Water pump housing 75-00-00 / 7, 75-00-00 / 13
Water pump housing inspection 75-00-00 / 7
Water pump shaft 75-00-00 / 9
Weights 71-00-00 / 11, 71-00-00 / 12
Wiring diagrams 74-00-00 / 24
Wiring harness inspection 76-00-00 / 35
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