Rotax 912 Series User manual

MAINTENANCE MANUAL
(HEAVY MAINTENANCE) FOR ROTAX® ENGINE TYPES
part no.: 899603
ROTAX® 912 AND 914 SERIES

picture 914 UL 3 DCDI with options
picture 912 ULS 3 DCDI with options

These technical data and the information embodied therein are the property of BRP-
Rotax GmbH&Co. KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior
written permission of BRP-Rotax 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 2007 © - all rights reserved.
ROTAX®is a trade mark of BRP-Rotax GmbH&Co. KG. In the following document the
short form of BRP-Rotax GmbH&Co. KG = BRP-Rotax 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.
Before starting any maintenance work, please read the Maintenance Manual completely
as it contains important safety relevant information.
WARNING

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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 / 21
7) Safety notice ...........................................................................................00-00-00 / 23
7.1) Repeating symbols ........................................................................00-00-00 / 23
8) Technical documentation .........................................................................00-00-00 / 25
8.1) Filling in the dimension sheets .......................................................00-00-00 / 25
8.2) List of abbreviations .......................................................................00-00-00 / 26
9) Classification of parts for maintenance/repair ..........................................00-00-00 / 27
9.1) Determination of actual wear [%] ....................................................00-00-00 / 30
10) Maintenance ...........................................................................................00-00-00 / 33
10.1) Trouble shooting ............................................................................00-00-00 / 33
10.2) Tightening torques..........................................................................00-00-00 / 33
10.3) Consumable materials ...................................................................00-00-00 / 34
10.4) Auxiliary tools .................................................................................00-00-00 / 37
10.5) Measuring tools .............................................................................00-00-00 / 39
10.6) Special tools and devices ..............................................................00-00-00 / 40

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NOTES

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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
ELECTRICSTARTER ....................................... 80

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3) Index
3
3way solenoid valve inspection 76-00-00 / 53
A
Abrasives 00-00-00 / 34
Airbox temperature 76-00-00 / 9
Alternator coil 74-00-00 / 15
Alternators 74-00-00 / 3
Auxiliary tools 00-00-00 / 35
B
Boost pressure display 73-00-00 / 16, 78-00-00
/ 5
Bowden cable 78-00-00 / 19
C
Capacities 71-00-00 / 11
Carburetor assembly 73-00-00 / 52
Carburetor disassembly 73-00-00 / 17, 73-00-
00 / 19
Carburetor heat systems 73-00-00 / 16
Carburetor individual components 73-00-00 /
23, 73-00-00 / 24
Carburetor flange 73-00-00 / 38
Carburetor socket assembly 73-00-00 / 52
Carburetor socket disassembly 73-00-00 / 17,
73-00-00 / 19
Carburetor synchronization 73-00-00 / 33
Caution lamps inspection 76-00-00 / 34
Charging coil 74-00-00 / 14
Choke 73-00-00 / 31
Classification of parts 00-00-00 / 25
Cleaning agents 00-00-00 / 34
Communication program 76-00-00 / 13
Components 71-00-00 / 5
Compressor pressure ratio 76-00-00 / 10
Constant depression carburetor 73-00-00 / 12,
73-00-00 / 21
Consumable materials 00-00-00 / 32
Coolant hoses assembly 75-00-00 / 14
Cooling air duct 75-00-00 / 14
Cut-in speed 74-00-00 / 17
Cyl. head assembly 72-00-00 / 70, 72-00-00 /
73
Cyl. head temperature sensor 75-00-00 / 15
Cylinder designation 71-00-00 / 5
Cylinder head dismantling 72-00-00 / 57
Cylinder head fitting 72-00-00 / 92
Cylinder head removal 72-00-00 / 55
Cylinders assembly 72-00-00 / 90
Cylinders inspection 72-00-00 / 81
Cylinders removal 72-00-00 / 75
D
Description of design 71-00-00 / 3
Devices 00-00-00 / 38
Diaphragms 73-00-00 / 25
Disc spring pretension 72-00-00 / 51
Disconnectors inspection 76-00-00 / 52
Displacement chamber parts assembly 72-00-00 /
86
Drain plug 79-00-00 / 10
Drip tray disassembly 73-00-00 / 17
Dual ignition coil 74-00-00 / 16
E
Electric starter 72-00-00 / 20
Electric starter 80-00-00 / 5
Electric starter assembly 80-00-00 / 12
Electric starter dismantling 80-00-00 / 7
Electric starter inspection 80-00-00 / 9
Electric starter reassembly 80-00-00 / 11
Electronic module 74-00-00 / 13
Engine components 71-00-00 / 12
Engine views 71-00-00 / 5
Exhaust gas temperature gauge 78-00-00 / 5
Exhaust system assembly 78-00-00 / 15
Exhaust system inspection 78-00-00 / 11
Exhaust system disassembly 78-00-00 / 7
Exhaust turbocharger 78-00-00 / 3
F
Filter oil 00-00-00 / 32
Float bracket 73-00-00 / 28
Float housing 73-00-00 / 27
Float needle valve inspection 73-00-00 / 29, 73-00-
00 / 30
Float needle valve inspection 73-00-00 / 29, 73-00-
00 / 30
Floats 73-00-00 / 27
Fly wheel hub 72-00-00 / 9, 74-00-00 / 47
Fuel filter 73-00-00 / 7
Fuel handling 73-00-00 / 15
Fuel lines 73-00-00 / 40, 73-00-00 / 42
Fuel lines assembly 73-00-00 / 54, 73-00-00 / 57
Fuel lines disassembly 73-00-00 / 17, 73-00-00 / 19
Fuel pressure 73-00-00 / 37
Fuel pressure regulator 73-00-00 / 43
Fuel pressure regulator 73-00-00 / 8
Fuel pump 73-00-00 / 44, 73-00-00 / 46
Fuel pumps 73-00-00 / 7
Fuels 73-00-00 / 34

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G
Gas bowden cable inspection 73-00-00 / 33
Gas bowden cable inspection 73-00-00 / 33
Gear set inspection 72-00-00 / 44
Gearbox configurations 72-00-00 / 5
Gearbox parts inspection 72-00-00 / 39
Gearing inspection 72-00-00 / 44
Governor 72-00-00 / 7
Governor drive fitting 72-00-00 / 35
Governor drive removal 72-00-00 / 33
H
Heat conduction compound 00-00-00 / 33
Hose clamps 75-00-00 / 14
Hourmeter 72-00-00 / 8
Hydraulic valve tappets 72-00-00 / 83
Hydraulic valve tappets assembly 72-00-00 /
86
Idle speed adjustment 73-00-00 / 33
Ignition 74-00-00 / 3, 74-00-00 / 6
Ignition cable 74-00-00 / 11
Ignition cables 74-00-00 / 9
Ignition check 74-00-00 / 20
Ignition circuit arrangement 74-00-00 / 8
Ignition circuits inspection 74-00-00 / 20
Ignition circuits inspection 74-00-00 / 20
Ignition electric set assembly 74-00-00 / 39
Ignition electric set dismantling 74-00-00 / 35
Ignition electric set fitting 74-00-00 / 41
Ignition electric set removal 74-00-00 / 33
Ignition housing 72-00-00 / 14
Ignition housing inspection 72-00-00 / 11
Ignition housing removal 72-00-00 / 11
Ignition pickup inspection 74-00-00 / 53
Ignition timing 74-00-00 / 18
Instruments 72-00-00 / 8, 73-00-00 / 16, 74-00-
00 / 9, 75-00-00 / 4, 78-00-00 / 5, 79-00-00 / 10
Intake air temperature sensor inspection 76-
00-00 / 42
Intake manifold assembly 73-00-00 / 59
Intermediate gear 72-00-00 / 20
L
List of valid pages 00-00-00 / 9
Lithiumbase grease 00-00-00 / 32
Loctite 00-00-00 / 32
Lubrication system purging 79-00-00 / 26
M
Magnetic plug 79-00-00 / 10
Main oil pump 79-00-00 / 3, 79-00-00 / 5
Measuring tools 00-00-00 / 37
Molycote 00-00-00 / 32
Multimeter 00-00-00 / 37
Multipurpose grease 00-00-00 / 33
O
Oil circuit 79-00-00 / 5, 79-00-00 / 8
Oil cooler 79-00-00 / 25
Oil lines 79-00-00 / 23
Oil pressure sensor 79-00-00 / 27
Oil pump disassembly 79-00-00 / 14
Oil pump 79-00-00 / 11
Oil pump inspection 79-00-00 / 15
Oil pump inspection 79-00-00 / 15
Oil pump reassembly 79-00-00 / 18, 79-00-00 / 19
Oil pump removal 79-00-00 / 11
Oil sump 79-00-00 / 21
Oil tank 79-00-00 / 22
Oil temperature display 79-00-00 / 10
Oil temperature sensor 79-00-00 / 26
Operating fluids 71-00-00 / 11
Operating limits 71-00-00 / 11
Orange caution lamp 76-00-00 / 11
Oscilloscope 00-00-00 / 37
Output connections on the TCU for lamps 76-00-00 /
11
Overspeeding 76-00-00 / 8
P
PC interface 76-00-00 / 12
Piston rings inspection 72-00-00 / 79
Pistons fitting 72-00-00 / 86
Pistons inspection 72-00-00 / 77
Pistons removal 72-00-00 / 75
Pitting 72-00-00 / 45, 72-00-00 / 47
Position finding 78-00-00 / 20
Preservation 71-00-00 / 17, 71-00-00 / 19
Preservation oil 00-00-00 / 33
Pressure connecting lines 73-00-00 / 10, 73-00-00 /
48
Pressure measurement system 71-00-00 / 22, 79-00-
00 / 26
Pressure sensors inspection 76-00-00 / 44
Propeller gearbox 72-00-00 / 5, 72-00-00 / 22, 80-00-
00 / 3
Propeller gearbox dismantling 72-00-00 / 28
Propeller gearbox reassembly 72-00-00 / 49
Propeller gearbox installation 72-00-00 / 53
Propeller shaft removal 72-00-00 / 30
Pushrods 72-00-00 / 85

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R
Red boost lamp 76-00-00 / 11
Return to service 00-00-00 / 25, 71-00-00 / 17, 71-
00-00 / 18
Rev counter inspection 74-00-00 / 53
Rev counter drive 72-00-00 / 21
Rev counter, mechanical 72-00-00 / 8
Rod linkage inspection 73-00-00 / 33
Rod linkage inspection 73-00-00 / 33
Roller bearings for F2 removal 72-00-00 / 24
Roller bearings for F3 removal 72-00-00 / 26
Roller bearings for F4 removal 72-00-00 / 27
Rope sheave 78-00-00 / 19
Rotary seal 75-00-00 / 10
Rust damage 74-00-00 / 10
S
Servo motor 78-00-00 / 20
Silastic 00-00-00 / 32
Solenoid valve (3way) 76-00-00 / 12
Special tools 00-00-00 / 38
Special tools and devices 00-00-00 / 38
Sprag clutch 72-00-00 / 15
Sprag clutch dismantling 72-00-00 / 17
Sprag clutch reassembly 72-00-00 / 18
Sprag clutch removal 72-00-00 / 16
Spring, wastegate 78-00-00 / 19
Starting carburetor 73-00-00 / 31
Stator removal and refitting 74-00-00 / 46
Stroboscope 00-00-00 / 37
Suction pump 79-00-00 / 8
Surface damage 71-00-00 / 15, 74-00-00 / 10
T
Table of amendments 00-00-00 / 17
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
Throttle potentiometer calibration 76-00-00 / 31
Throttle potentiometer inspection 76-00-00 / 37
Throttle valve position inspection 76-00-00 / 29, 76-
00-00 / 31
Tightening torques 00-00-00 / 31
Trigger coil kit 74-00-00 / 13
Trigger coil kit replacement 74-00-00 / 44
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
turbocharger control 76-00-00 / 28
Turbocharger control system 76-00-00 / 13, 78-00-00
/ 3
Turbocharger control unit 76-00-00 / 3
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 / 34
Valve seats 72-00-00 / 63
Valves 72-00-00 / 64
Very fine emery cloth 00-00-00 / 33
W
Water pump disassembly 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
Winter operation 73-00-00 / 16
Wiring diagrams 74-00-00 / 22
Wiring harness inspection 76-00-00 / 35

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Rear page

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NOTES

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Ser. Date Sign Date of Date of Sign/
No. Section Pages of of accept. of implemen- Signature
correction acceptance resp. authority tation
08215
*Approval
The technical content of this document is approved under
the authority of
DOA Nr. EASA.21J.048.
5) Table of amendments
0 00-00-00 all 05 01 2007 DOA*
0 71-00-00 all 05 01 2007 DOA*
0 72-00-00 all 05 01 2007 DOA*
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0 76-00-00 all 05 01 2007 DOA*
0 78-00-00 all 05 01 2007 DOA*
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page 20
May 01/2007
Effectivity 912/914 Series
Edition 1 / Rev. 0
d02620
BRP-Rotax
Maintenance Manual
NOTES