Rotax 914 series User manual

MAINTENANCE MANUAL
(LINE MAINTENANCE) FOR ROTAX® ENGINE TYPE 914 SERIES
part no.: 899606
ROTAX ® 914 UL 3 WITH OPTIONS


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!
WARNING
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 permis-
sion 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.

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SECTION 00-00
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) Introduction ............................................................................................ 00-00-00 / 9
4.1) Remarks........................................................................................ 00-00-00 / 9
4.2) Engine serial number .................................................................... 00-00-00 / 9
4.3) Conversion table and abbreviations ..............................................00-00-00 / 11
5) Safety notice ...........................................................................................00-00-00 / 13
5.1) Symbols used ................................................................................00-00-00 / 14
5.2) Maintenance Concept ................................................................... 00-00-00 / 15
5.3) Technical documentation ............................................................... 00-00-00 / 16
5.3.1) Use for intended purpose ................................................. 00-00-00 / 17
5.3.2) Instruction .........................................................................00-00-00 / 18
6) List of effective pages ............................................................................. 00-00-00 / 19
7) Table of amendments ............................................................................. 00-00-00 / 21

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2) List of chapters
INTRODUCTION ............................................... 00
TIME LIMITS / MAINTENANCE CHECKS ........ 05
MAINTENANCE ................................................ 12

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3) Index
A
Abbreviations 00-00-00 / 12
Accessories (cooling system) 12-00-00 / 23
Accessories (lubrication system) 12-00-00 / 41
Additional checks 05-50-00 / 1
Advisory Circular 05-00-00 / 13
Air filter 05-20-00 / 9, 12-00-00 / 8
Annual inspection 05-10-00 / 9
Authorized personnel 05-00-00 / 6
Auxiliary generator 05-20-00 / 10, 12-00-00 / 12
AVGAS operation 05-20-00 / 8
B
Boost lamp 05-50-00 / 19, 05-50-00 / 20
Boost pressure 05-50-00 / 18
Boost pressure control 05-50-00 / 19,
05-50-00 / 20, 05-50-00 / 21
C
Calendar life 05-10-00 / 3
Carburetor 05-20-00 / 9
Carburetor actuation 12-00-00 / 31
Carburetor socket 05-20-00 / 9
Caution lamp 05-50-00 / 21
Check list (maintenance) 05-20-00 / 3
Cleaning (air filter) 12-00-00 / 8
Cleaning (engine) 12-00-00 / 4
Cleaning (oil tank) 12-00-00 / 35
Cleaning agents 05-00-00 / 12
Cold cleaning agent 12-00-00 / 4
Compression pressure 05-20-00 / 10,
12-00-00 / 10
Contaminants 05-10-00 / 3
Conversions 00-00-00 / 11
Coolant 05-10-00 / 7, 12-00-00 / 20
Coolant hose 12-00-00 / 19
Cooling system 05-20-00 / 8, 12-00-00 / 19,
12-00-00 / 21
Crankshaft 12-00-00 / 13
Crankshaft locking pin 12-00-00 / 13
Cylinder head temperature 05-50-00 / 8,
05-50-00 / 11
D
Differential pressure 05-20-00 / 10, 12-00-00 / 10
Drip tray 05-20-00 / 9
Dry air filter 12-00-00 / 8
E
Electric system 12-00-00 / 43
Electrode gap 12-00-00 / 44
Engine cleaning 05-20-00 / 4, 12-00-00 / 4
Engine external parts 05-20-00 / 7
Engine failure 05-50-00 / 8
Engine log book 05-10-00 / 4
Engine number 00-00-00 / 9
Engine operation 05-10-00 / 3
Engine running erratically 05-50-00 / 8
Engine running out of round 05-50-00 / 8
Engine sluggish 05-50-00 / 17
Engine stoppage 05-50-00 / 8
Engine suspension 05-20-00 / 6, 12-00-00 / 7
Engine test run 05-20-00 / 11, 12-00-00 / 16
Expansion tank 12-00-00 / 22
Extreme climatic conditions 05-50-00 / 9
F
Filter cleaner 12-00-00 / 9
Filter insert 12-00-00 / 38
Filter oil 05-00-00 / 10, 12-00-00 / 9
Float chamber ventilation 05-20-00 / 9
Free rotation 12-00-00 / 47
Friction torque 12-00-00 / 47
Fuel filter 05-20-00 / 10, 12-00-00 / 15
Fuel system 12-00-00 / 25
G
Ground contact 05-50-00 / 3
H
Heat conduction compound 05-00-00 / 11,
12-00-00 / 44
I
Idle speed adjustment 12-00-00 / 30
Inspections 05-50-00 / 3
Instruction 00-00-00 / 18
Intended purpose 00-00-00 / 17
Introduction 00-00-00 / 9
L
Leakage check 12-00-00 / 6
List of the valid pages 00-00-00 / 19
Lithium-base grease 05-00-00 / 10
Lock washer 05-00-00 / 13
Loctite 05-00-00 / 10
Lubrication system 12-00-00 / 33

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M
Magnetic plug 05-20-00 / 7, 12-00-00 / 40
Maintenance 05-00-00 / 5
Maintenance (periodic) 05-20-00 / 1
Maintenance (systems) 12-00-00 / 1
Maintenance check list 05-20-00 / 2,
05-20-00 / 5. See 05-20-00 Chapter 2.2
Maintenance records 05-10-00 / 4
MICRONORM abrasive 05-00-00 / 12
Molykote 05-00-00 / 10
Multi-purpose grease 05-00-00 / 11
N
Note 00-00-00 / 9
Nut securing 05-00-00 / 13
O
Oil change 05-20-00 / 8, 12-00-00 / 34
Oil circuit 12-00-00 / 41
Oil dipstick 12-00-00 / 33
Oil filter 12-00-00 / 38
Oil level check 05-20-00 / 7, 12-00-00 / 33
Oil pressure (minimum) 05-50-00 / 13
Oil quality 05-20-00 / 8
Oil specification 05-50-00 / 15
Oil system 12-00-00 / 36
Oil tank 12-00-00 / 35
Oil tank cap 12-00-00 / 33
Oil temperature 05-50-00 / 12
Optimizing engine running 12-00-00 / 30
Overflow bottle 12-00-00 / 23
Overload clutch 05-50-00 / 3, 05-50-00 / 4,
05-50-00 / 6
P
Periodic maintenance 05-20-00 / 1
Plug-in connector 12-00-00 / 43
Preservation oil 05-00-00 / 11
Pressure sensor 05-50-00 / 13
Procedure notes 05-00-00 / 7
Propeller gearbox 00-00-00 / 16,
05-20-00 / 7, 05-50-00 / 3, 12-00-00 / 47,
12-00-00 / 48
Propeller stoppage 05-50-00 / 3
R
Radiator cap 12-00-00 / 22
Reporting 05-50-00 / 22
Return to service 05-20-00 / 11, 05-50-00 / 9
Rubber parts 05-10-00 / 5
S
Safety notice 00-00-00 / 13
Seizing 05-50-00 / 8
Silastic 05-00-00 / 10
Slipping torque 05-50-00 / 6
Spark plug 05-20-00 / 10, 05-50-00 / 16,
12-00-00 / 44
Spark plug connectors 05-20-00 / 10
Spark plug wrench 12-00-00 / 44
Speed (engine) 05-50-00 / 10, 05-50-00 / 18
Speed (idle) 05-20-00 / 9, 12-00-00 / 30
Submerging in water 05-50-00 / 9
Synchronization 05-20-00 / 9
Synchronization (mechanical) 12-00-00 / 25
Synchronization (pneumatic) 12-00-00 / 27
Synchroniztion (idle) 12-00-00 / 25
T
Table of amendments 00-00-00 / 21
TBO 05-10-00 / 3
Technical documentation 00-00-00 / 16
Time limit (for rubber parts) 05-10-00 / 5
Time limit (for the coolant) 05-10-00 / 7
Time limits (for engine operation) 05-10-00 / 3
Trouble shooting 05-00-00 / 9
Turbo control unit 05-50-00 / 21
Turbocharger 12-00-00 / 4
U
Unscheduled maintenance checks 05-50-00 / 1
Utilizable materials 05-00-00 / 10
V
V-belt tension 05-20-00 / 10, 12-00-00 / 12
Valve lapping paste 05-00-00 / 12
Very fine emery cloth 05-00-00 / 11
Visual inspection 05-20-00 / 5, 12-00-00 / 4
W
Wastegate flap 05-20-00 / 7, 12-00-00 / 14
Wiring 12-00-00 / 43

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4) Introduction
We are pleased you decided to purchase a ROTAX aircraft engine.
This section describes the maintenance of engine type 914 Series.
◆ NOTE: The 914 Series includes all engines such as the 914 F and 914 UL.
Before carrying out maintenance work on the engine, read the Maintenance Manual
carefully.
If any passages of the Manual are not clearly understood or if you have any questions,
please contact an authorized Distribution or Service Center for ROTAX-aircraft
engines.
4.1) Remarks
The purpose of this Maintenance Manual is to acquaint maintenance service
staff approved by the local aviation authorities with some basic maintenance and
safety information for service work.
To ensure competent maintenance and servicing, please also refer to the
documentation provided in the Operator’s Manual, Installation Manual, techni-
cal directives and Illustrated Parts Catalog.
For additional information on engines, maintenance or parts, you can also
contact your nearest authorized ROTAX-aircraft engine distributor.
4.2) Engine serial number
When making inquiries or ordering parts,
always indicate the engine number (1), as
the manufacturer makes modifications to
the engine for product improvement. The
engine number is on the ignition cover, on
the left, opposite the electric starter.
See Fig. 1.
1
magneto side
03645
power take off
side
Fig. 1

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4.3) Conversion table and abbreviations
Units of length:
1 mm = 0.03937 in
1 in = 25.4 mm
1 ft = 12 in
= 0.3048 m
Units of area:
1 cm2= 0.155 sq in (in2)
1 sq in (in2) = 6.4516 cm2
Units of volume:
1 cm3= 0.06102 cu in (in3)
1 cu in (in3) = 16.3871 cm3(in3)
1 dm3=1l
1 dm3= 0.21997 gal (UK)
1 gal (UK) = 4.5461 dm3
1 dm3= 0.26417 gal (US)
1 gal (US) = 3.7854 dm3
Units of mass:
1 kg = 2.2046 lb
1 lb = 0.45359 kg
Density:
1 g/cm3= 0.016018 lb/ft3
1 lb/ft3= 62.43 g/cm3
Units of force:
1 N = 0.224809 lbf
1 lbf = 4.4482 N
Units of pressure:
1 Pa = 1N/m2
1 bar = 100 000 Pa (1000 hPa)
1 bar = 14.5037 lbf/in2 (psi)
1 lbf/in2 (psi) = 0.0689 bar
1 in HG = 33.8638 hPa
Units of power:
1 kW = 1.341 hp
1 hp = 0.7457 kW
1 kW = 1.3596 PS
1 PS = 0.7355 kW
Units of temperature:
K = °C - 273.15
°C = (°F - 32) / 1.8
°F = (°C x 1.8) + 32
Units of velocity:
1 m/s = 3.6 km/h
1 ft/min = 0.3048 m/min
= 0.00508 m/sec
1 m/s = 196,85 ft/min
1 kn = 1.852 km/h
1 km/h = 0.53996 kn
spec. fuel consumption:
1 g/kWh = 0.001644 lb/hph
1 lb/hph = 608.277 g/kWh
Units of torque:
1 Nm = 0.737 ft lb
= 8.848 in lb
1 ft lb = 1.356 Nm
1 in lb = 0.113 Nm
Cable cross-section: AWG - mm2
04783
Conversion table - Wire Gauge: AWG - mm²
AWG 4 6 8 1012141618 20
mm221,2 13,3 8,35 5,27 3,31 2,08 1,31 0,82 0,519

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Abbreviations and terms used in
this Manual:
* Reference to another section (only
in the illustrated parts catalog)
@at
The drop symbol indicates use of
sealing agents, adhesives or lubri-
cants. (only in the illustrated parts
catalog)
center of gravity
rpm Revolutions per minute
912 A see OM (Type designation)
912 F see OM (Type designation)
912 S see OM (Type designation)
912 UL see OM (Type designation)
912 ULS see OM (Type designation)
912ULSFR ROTAX®912 ULS Version
France
914 F see OM (Type designation)
914 UL see OM (Type designation)
A/C Aircraft
ACG Austro Control GmbH
A/F across-flat dimension
ASB Alert Service Bulletin
CCW counter-clockwise
CW clockwise
DCDI Dual Capacitor Discharge Ignition
DOT Department of Transport
EASA European Aviation Safety Agency
IM Installation Manual
EGT Exhaust Gas Temperature
IPC Illustrated Parts Catalog
FAA Federal Aviation Administration
FAR Federal Aviation Regulations
OM Overhaul Manual
h hours
OM Operator’s Manual
ISA International Standard Atmosphere
JAA Joint Aviation Authorities
JAR Joint Aviation Regulations
AD Airworthiness Directive
MS magneto side
N new part (only illustrated parts
catalog)
nB as necessary (only illustrated parts
catalog)
NDT Non-Destructive Testing
n.a. not available
Rev. Revision
s.v. still valid (only illustrated parts
catalog)
S/N Serial Number
SB Service Bulletin
SI Service Instructions
SL Service Letter
SMD Surface Mounted Devices
TNr. Part No.
TSN Time Since New
TSO Time Since Overhaul
VFR Visual Flight Rules
MM Maintenance Manual
XXX shows the serial component
number

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5) Safety notice
This Manual has been prepared as a guide to correctly service and maintain all ROTAX
914 aircraft engines.
This edition was primarily published to be used by aircraft mechanics who are already
familiar with all service procedures relating to ROTAX made aircraft engines.
Please note that the instructions will apply only if proper hand tools and special service
tools are used.
This Manual uses technical terms which may be slightly different from the ones used
in the Illustrated Parts Catalog.
It is understood that this Manual may be translated into another language. In the event
of any discrepancy the German version is prevail.
The content depicts parts and/or procedures applicable to the particular product at its
time of manufacture. It does not include dealer modifications, whether authorized or not
by BRP-Rotax, after manufacturing the product.
In addition, the sole purpose of the illustrations throughout the Manual, is to assist
identification of the general configuration of the parts. They are not to be interpreted
as technical drawings or exact replicas of the parts.
The use of ROTAX parts is most strongly recommended when considering replacement
of any component. Authorized ROTAX distributor assistance should be sought in case
of doubt.
The engines and the corresponding components identified in this document should not
be utilized on product(s) other than those mentioned in this document.
Torque wrench tightening specifications must be strictly adhered to.
Locking devices (ex.: locking tab, self-locking fasteners, etc.) must be installed or
replaced with new ones, where specified. If the efficiency of a locking device is impaired,
it must be replaced.
It is your responsibility to be completely familiar with the safety instructions including
warnings and cautions described in this Manual. These warnings and cautions advise
of specific operating and servicing methods that, if not observed, can cause a serious
engine malfunction or cause the engine to lose power in flight which can result in loss
of life, injury or damage to equipment.
It is, however, important to understand that these warnings and cautions are not
exhaustive. BRP-Rotax could not possibly know, evaluate and advise the user of all
conceivable ways in which service might be done or of the possible hazardous
consequences of each way.
Although the mere reading of such information does not eliminate the hazard, your
understanding of the information will promote its correct use. Always use common shop
safety practice.

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This information relates to the preparation and use of ROTAX aircraft engines and has
been utilized safely and effectively by BRP-Rotax. However, BRP-Rotax disclaims
liability for all damage and/or injuries resulting from the improper use of the contents.
We strongly recommend that any service be carried out and/or verified by a highly
skilled professional mechanic, see 05-00-00, sec. 2.2.
Specifications are given in the SI metric system with the USA equivalent in parenthesis.
BRP-Rotax reserves the right at any time, and without incuring obligation, to remove,
replace or discontinue any design, specification, feature or otherwise.
5.1) Symbols used
This Manual uses the following symbols to emphasize particular information:
This information is important and must be observed.
▲▲
▲▲
▲WARNING: Identifies an instruction which, if not followed, may cause
serious injury including the possibility of death.
■■
■■
■CAUTION: Denotes an instruction which, if not followed, may severely
damage the engine or other component.
◆◆
◆◆
◆NOTE: Indicates supplementary information which may be needed
to fully complete or understand an instruction.

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5.2) Maintenance Concept
The maintenance functions detailed in this Manual fall into two categories: Line
Maintenance and Heavy Maintenance.
Repairs above and beyond the extent of the work described in these two
Manuals are not considered as maintenance work and may only be carried out
by authorized overhaul companies.
- Line Maintenance (Section 00, 05 and 12):
The scope of line maintenance consists of removal, installation and adjust-
mentof engine components (including part wear). All procedures in this
Manual are to be considered line maintenance.
◆NOTE: Where applicable, you will be referred to the Heavy Mainte-
nance Manual for work above and beyond line maintenance.
- Heavy Maintenance (separate Manual, part No. 899603)
The Heavy Maintenance Manual covers in detail work steps for the removal,
installation and repair of components where such work exceeds the limits of
standard "Line Maintenance".
◆NOTE: This Manual must be used in conjunction with the Line Mainte-
nance Manual on which it is based.

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5.3) Technical documentation
These documents form the instructions ensuring continued airworthiness of
ROTAX aircraft engines:
- Installation Manual 914 Series
- Operator’s Manual
- Maintenance Manual 914 Series (Line+Heavy 912/914 MM)
- Overhaul Manual 912 / 914 Series
- Illustrated Parts Catalog 912 / 914 Series
- Alert Service Bulletins
- Service Bulletins
- Service Instructions
- Service Letters
Any reference to a document refers to the latest edition issued by BRP-Rotax,
if not stated otherwise.
The information contained is based on data and experience that are considered
applicable for skilled mechanics under normal conditions.
Due to the fast technical progress and fulfilment of particular specifications of
the customers it may occur that existing laws, safety prescriptions, construc-
tional and operational regulations cannot be transferred completely to the object
bought, in particular for special constructions, or may not be sufficient.
The illustrations in this Manual are mere sketches and show a typical arrange-
ment. They may not represent in full detail or the exact shape of the parts which
have the same or similar function. Therefore deduction of dimensions or other
details from illustrations is not permitted.
- All necessary documentation is available from the ROTAX Distribution- and
Service Centers.
- For the latest documentation, refer to SB-914-000 and see the official
homepage www.rotax-aircraft-engines.com. Many of the necessary docu-
ments are also available as free downloads in pdf format.
◆NOTE: The Illustrations and Documents in this Manual are stored in a
document data file/graphic data file and are provided with a
consecutive irrelevant number.
This number (e.g. 00277) is of no significance for the content.

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Return shipment:
When returning the engine or its components (e.g. propeller gearbox) to an
authorized overhaul or repair company, ensure that the necessary documenta-
tion (log book, maintenance records etc.) are enclosed.
5.3.1) Use for intended purpose
- The engine ROTAX 914 F is intended for use in certified aircraft. In
case of doubt the regulations of the national authorities or the
respective sportive federations have to be observed.
– Certified aircraft engine 914 F is tested as per aeronautical stand-
ards for safety and time between overhaul. It was developed to
conform to the latest technological standards and rigorously tested.
◆NOTE: Engine 914 UL is not certified. These engines have not
received any aeronautical standards or regulatory
safety or durability testing, and conform to no aircraft
standards. These engines are for use in experimental,
uncertificated aircraft and vehicles only in which an
engine failure will not compromise safety. However
these engines confirm to BRP-Rotaxquality standards.
The operator assumes all risk of use, and acknowl-
edges by this use that he/she knows this engine is
subject to sudden stoppage.
- Use for intended purpose also includes observation of the opera-
tional, maintenance and repair conditions prescribed by the manu-
facturer. This will also increase the service life of the engine.
▲WARNING: Never run the engine without propeller, this inevitably
causes engine damage and is an explosion hazard.

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5.3.2) Instruction
Engines require instructions regarding their application, use, operation,
maintenance and repair.
Technical documentation and directions are useful and necessary
complementary elements for personal instruction, but can by no means
substitute theoretical and practical instructions. These instructions
should cover explanation of the technical context, advice for operation,
maintenance, use and operational safety of the engine.
- This engine must only be operated with accessories supplied,
recommended and released by BRP-Rotax. Modifications are only
allowed after consent by the engine manufacturer.
- After engine standstill (longer than 2 months) observe without fail
the instructions for engine “out of use”. Protect fuel- and carburetor
system against contamination.
■CAUTION: Spare parts must meet with the requirements defined
by the engine manufacturer. This is only warranted by
use of GENUINE ROTAX spare parts and/or accesso-
ries (see IPC) or suitable equivalent in the manufactuer’s
opinion otherwise, any limited warranty by BRP-Rotax
is null and void (see Warranty Conditions).
Spare parts are available at the authorized ROTAX
Distribution- and Service centers.
Any warranty by BRP-Rotax becomes null and void if
spare parts and or accessories other than ORIGINAL-
ROTAX spare parts and/or accessories are used
(see latest Warranty Conditions).

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Kapitel Seite Datum Kapitel Seite Datum
Title page
00-00-00 1 05 01 2007
2 05 01 2007
3 05 01 2007
4 05 01 2007
5 05 01 2007
6 05 01 2007
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05-20-00 1 09 01 2007
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Sept. 01/07
Effectivity 914 Series
Edition 1 / Rev. 1
d02795
BRP-Rotax
MAINTENANCE MANUAL
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