SERVICE BULLETIN Replacement of fuel pumps for ROTAX
Contents
1. without impeding on the fuel hose clamp Graphic Distance measuring os pa R APM ttt Fab 11 12S 44 ti i a l ce y 1 y a es __ gt Ua Ny Aa Fuel hose assy Nipple flange 1 ear clamp on fire sleeve Fig 9 24 June 2013 Revision 1 Copyright BRP Powertrain GmbH amp CO KG All rights reserved 9 a2 TL eee AA 09851 09856 73 00 00 Page 12 of 14 d05679 fm d05679 fm SB 912 063R1 SERVICE BULLETIN Graphic 24 June 2013 Revision 1 See Fig 10 Procedure Push fire sleeve fuel inlet to stop and mount 1 ear clamp 17 8 21 0 mm 0 70 0 83 in with suitable crimp pliers Repeat steps for fire sleeve fuel outlet 22 4 25 6 mm 0 88 1 01 in NOTICE A drain line must be installed that in the event of a internal leak any fluid NOTICE is drained to a suitable location position See therefore Installation Manual of the relevant engine type and SI 912 020 Modification finished Fuel hose assy Fuel pump assy Fig 10 09853 Restore the aircraft to standard operating condition Connect the negative terminal of the battery 73 00 00 Page 13 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063R1 SERVICE BULLETIN 3 6 Test run Conduct test run including ignition check and leakage test NOTE Due to the replacement with the new fuel pump automatically note the changed operating limit See latest Operators2. GMS Stalling the fuel pump NOTE Also all work has to be carried out in accordance with the aircraft manu facturer s instructions a Install fuel pump 5 with new insulating flange gasket 1 and O ring 2 Secure new hex nuts M8 4 and lock washer A8 3 with LOCTITE 243 and tighten them evenly Tightening torque 15 Nm 133 in Ib Graphic 2 Oem N LOCTITE 243 oo o Fig 6 09847 PE 24 June 2013 73 00 00 Revision 1 Page 9 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063R1 SERVICE BULLETIN 3 3 Inspection of fuel pump assy part no 893110 General See Fig 7 The fuel pump cover 1 must not be opened for inspection Check the security markings witness paint 2 Check the connecting nipples 3 4 for tightness If necessary secure them with LOCTITE 243 Tightening torque 10 Nm 88 5 in Ib Graphic Fuel pump part no 893110 1 Fuel pump cover Security marking witness paint Connecting nipple outlet inner D 3 8 mm 0 15 in Connecting nipple inlet inner D 5 7 mm 0 22 in Fig 7 09848 3 4 Assembling of the fuel hoses assy NOTICE All lines must be installed free of kinks avoid tight bends NOTICE Prevent the hoses from chafing on components or against each other Ensure there is adequate free length in the hose to allow for engine move ment 3 4 1 Assembling of the fuel pump part no 893110 without crimped
3. 08 002984 inclusive O9 000001 up to 09 002805 10 000061 up to 10 005298 inclusive 11 000121 up to 11 000840 inclusive and fuel pumps part no 892546 from S N 06 005914 up to 06 005933 inclusive 07 000259 up to 07 008848 inclusive 08 000511 up to 08 002863 inclusive 09 000211 up to 09 002895 inclusive 10 000001 up to 10 005088 inclusive 11 000001 up to 11 000330 inclusive are affected which has been installed at engine repair general overhaul NOTE The fuel pumps part no 893110 893114 and 893115 are not affected by this replacement 1 2 Concurrent ASB SB SI and SL Latest SI 912 020 regarding the general notes measurements changes etc 1 3 Reason Field observation over the years has shown that in isolated cases failures of the mechanical fuel pump part no 892542 and 892546 can occur which may subsequently lead to malfunctions To prevent possible problems with the fuel system the fuel pumps have to be replaced 1 4 Subject Replacement of fuel pumps for ROTAX engine type 912 Series 1 5 Compliance 24 June 2013 Revision 1 At the next scheduled maintenance event Areplacement of the fuel pumps according to the instructions in section 3 has to be carried out May 01 2014 at the latest Non compliance with these instructions could result in engine damages _Z WARNING personal injuries or even fatal injury 73 00 00 Page 2 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d
4. Manual of the 912 Series Also contact your aircraft manufacturer for further instructions 3 6 1 Check of fuel pressure NOTE The fuel pump part 893110 has different characteristics as the fuel pumps part no 892542 and part no 892546 Low fuel pressure indications are possible and allowed But the pressure must stabilize to the operating limit within 5 seconds If not the cause should be determined and rectified Due to the technical design and installation conditions construction of the return line etc pres sure fluctuations at the fuel pump part no 893110 are possible These pressure fluctuations within the specified operating limits are not considered to a problem 3 6 2 Check of float chamber Check float chamber for any debris particles If any debris particles should be found then their source must be located If necessary remove clean and install again the float chamber 3 6 3 Check drain line NOTE A slight leakage on the drain line can be attributed to a slight sweating and not considered to be a issue For a period of 1 minute after the engine has been stopped no liquid must drip down In case of uncertainty determine the oil amount The maximum leakage is 0 5 ml for a 20 min engine run 3 7 Summary These instructions section 3 have to be conducted in accordance with compliance in section 1 5 The execution of the recommended Service Bulletin must be entered in the engine logbook Approval of translation to
5. S N 06 005914 up to 06 005933 inclusive 07 000259 up to 07 008848 inclusive 08 00051 1 up to 08 002863 inclusive 09 000211 up to 09 002895 inclusive 10 000001 up to 10 005088 inclu sive 11 000001 up to 11 000330 inclusive are affected which has been installed at engine repair general overhaul NOTE The fuel pumps part no 893110 893114 and 893115 are not affected by this replacement For complete instruction and compliance to this Service Bulletin refer to Service Bulletin SB 912 063 latest edition section 1 2 onward NOTE Section 1 6 Approval Is not required for engines of the type UL Series Section 3 Accomplishment In addition persons with adequate type specific training 24 June 2013 73 00 00 Revision 1 Page 2 of 2 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05681 fm SB 912 063R1 ROTAX AIRCRAFT ENGINES s BRP SERVICE BULLETIN Replacement of fuel pumps for ROTAX Engine Type 912 Series This SB revises the initial issue dated 24 June 2013 ATA System 73 00 00 Fuel system RECOMMENDED Symbols used Please pay attention to the following symbols throughout this document emphasizing particular information i AWARNING Identifies an instruction which if not followed may cause serious in jury or even fatal injury Identifies an instruction which if not followed may cause minor or moderate injury Denotes an instruction which if not followed may se
6. best knowledge and judgement in any case the original text in German language and the metric units Sl system are authoritative NOTE The illustrations in this document show the typical construction They may not represent full detail or the exact shape of the parts which have the same or si milar function Exploded views are not technical drawings and are for reference only For specific detail refer to the current documents of the respective engine type 3 8 Enquiries Enquiries regarding this Service Bulletin should be referred to the ROTAX authorized distributor of your area A list of all distributors is provided on www FLYROTAX com 24 June 2013 73 00 00 Revision 1 Page 14 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05679 fm
7. on hose assy supplied by BRP Powertrain Perform assembly according to the service manual of the aircraft manufacturer Instruction and materials are not supplied by BRP Powertrain When connecting the hoses make sure the orientation is correct Procedure Connect the hose from the fuel tank to the connecting nipple identified as 4 in Fig 7 The hose that goes to the carburetors should be connected to the connecting nipple identified as 3 in Fig 7 NOTE After installation of the hoses ensure the fuel tap is turned back ON 24 June 2013 73 00 00 Revision 1 Page 10 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05679 fm d05679 fm SB 912 063R1 SERVICE BULLETIN 3 4 2 Assembling of the fuel pump part no 893110 when replacing fuel pump part no 892546 See Fig 8 a Remove hose clamp pliers from fuel hose assy NOTE Thereby the fuel contained in the lines flow out and flush the residual debris from the fuel line Be prepared with a suitable container and or cloth to catch the outcoming fuel Procedure Before the fuel hose 2 is fitted with a 1 ear clamp 1 the two fuel hoses have to be marked 3 16 mm 0 63 in from the end of the hose 2 Slide all 4 1 ear clamps 1 on the fuel and fire sleeves NOTE Clamps part no 853313 851663 on fire sleeve and clamps part no 851463 851453 on fuel hose Slide the fuel hoses 2 onto nipple completely up to the end stop Cri
8. 05679 fm d05679 fm SB 912 063R1 SERVICE BULLETIN 1 6 Approval The technical content of this document is approved under the authority of DOA ref EASA 21J 048 1 7 Labor time Estimated labor time engine installed in the aircraft labor time will depend on installation and therefore no estimate is available from the engine manufacturer 1 8 Mass data change of weight none moment of inertia unaffected 1 9 Electrical load data no change 1 10 Software accomplishment summary no change 1 11 References In addition to this technical information refer to current issue of Illustrated Parts Catalog IPC Heavy Maintenance Manual HMM NOTE The status of Manuals can be determined by checking the table of amend ments of the Manual The 15t column of this table is the revision status Compare this number to that listed on the ROTAX WebSite www FLYROTAX com Updates and current revisions can be downloaded for free 1 12 Other puplications affected none 1 13 Interchangeability of parts Fuel pumps which are removed along with insulating flange gasket lock washers and nuts in accordance with chap 3 1 are unserviceable and must be returned to your local ROTAX Authorized Distributors or their Service Center 2 Material Information 2 1 Material cost and availability Price and availability and any possible support consideration will be supplied on request by ROTAX Authorized Distributors or th
9. d05681 fm SB 912 063UL R1 ROTAX AIRCRAFT ENGINES A gt ee SERVICE BULLETIN Replacement of fuel pumps for ROTAX Engine Type 912 Series This SB revises the initial issue dated 24 June 2013 ATA System 73 00 00 Fuel system RECOMMENDED Symbols used Please pay attention to the following symbols throughout this document emphasizing particular information i AWARNING Identifies an instruction which if not followed may cause serious in jury or even fatal injury Identifies an instruction which if not followed may cause minor or moderate injury NOTICE Denotes an instruction which if not followed may severely damage NOTICE the engine or could lead to suspension of warranty NOTE Information useful for better handling A revision bar outside of the page margin indicates a change to text or graphic To obtain satisfactory results procedures specified in this publication must be accomplished with accepted methods and prevailing government regulations BRP Powertrain GmbH amp Co KG cannot be responsible for the quality of work performed in accomplishing the requirements of this publication 24 June 2013 Current valid documentation see 73 00 00 Revision 1 www FLYROTAX com Page 1 of 2 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063UL R1 SERVICE BULLETIN 1 Planning information 1 1 Applicability In accordance with the current Maintenance Ma
10. eir Service Center 2 2 Company support information Price and availability and any possible support consideration will be supplied on request by ROTAXg Authorized Distributors or their Service Center 24 June 2013 73 00 00 Revision 1 Page 3 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063R1 SERVICE BULLETIN 2 3 Material requirement per engine parts requirement part no engine part no 945752 Lock washer A8 m fuel pump assy 881360 Fuel pump set Le for fuel pump exchange consists of 893110 1 Fuel pump assy consists of 1x fuel pump part no 893115 2x gasket ring part no 250425 1x nipple part no 840740 1x nipple part no 840745 1x isolating flange part no 950228 1x O ring part no 631870 942674 Hex nut M8 fuel pump assy 851453 1 ear clamp 12 8 15 3 mm 0 50 0 60 in fuel pump assy inlet 851463 1 ear clamp 10 8 13 3 mm 0 43 0 52 in i fuel pump assy outlet 851663 1 ear clamp 22 4 25 6 mm 0 88 1 01 in ae fuel pump assy inlet 853313 1 ear clamp 17 8 21 0 mm 0 70 0 83 in Lo fuel pump assy outlet 2 4 Material requirement per spare part none 2 5 Rework of parts none 2 6 Special tooling lubricant adhesives sealing compound Price and availability will be supplied on request by ROTAX Authorized Distributors or their Service Center Description Application When using the special tools please note the information supplied by the NOTICE t
11. ers Fig 3 09842 09843 09854 NOTE Cut off the fuel hose with a very sharp knife so that no cutting residues are produced See Fig 4 Risk of cut injuries AXCAUTION Knives are sharp and may cause injury Wear protective gloves Procedure length The fuel hose is reduced by approx 20 mm 0 79 in NOTE Make note of orientation of the hoses inlet outlet A clean cut surface is very important 4 The cut should be made adjacent to the crimped ferrel to avoid losing any needed d05679 fm Repeat procedure at the second fuel hose assy 24 June 2013 73 00 00 Revision 1 Page 7 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063R1 SERVICE BULLETIN Graphic 1 Fuel hose Cutting knife Crimped ferrule Fig 4 09844 09845 09855 Procedure Loosen hex nuts 13 mm 0 51 in and remove fuel pump with lock washer A8 and in sulating flange gasket See Fig 5 Graphic X Fig 5 R ig g 09846 S 24 June 2013 73 00 00 Revision 1 Page 8 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05679 fm SB 912 063R1 SERVICE BULLETIN 3 2 Assembling of fuel pump assy part no 893110 See Fig 6 In addition to the insulating flange gasket also replace the O ring at reas NOTICE sembly or assembly of the fuel pump Both parts are included in the set of fuel pump assy Ensure the O ring is located in the recess in the fuel pump before in
12. ithout crimped hose assembly see Fig 1 The following work steps are necessary Procedure Make note of orientation of the hoses inlet outlet Loosen hex nuts 13 mm 0 51 in and remove fuel pump with lock washer A8 and in sulating flange gasket Remove fuel hoses as per aircraft manufacturers instructions 24 June 2013 Revision 1 73 00 00 Page 5 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063R1 SERVICE BULLETIN Graphic Fig 1 09865 3 1 2 Removal of fuel pump part no 892546 with fire sleeve see Fig 2 Figure shows fuel pump part no 892546 with crimped fuel hose assy and fire sleeve Graphic Fuel pump Fig 2 09841 The following work steps are necessary see Fig 3 Do not use any pliers with sharp surfaces NOTICE di j a rowers Cut off the 1 ear clamp 1 of fire sleeve 2 with cutting pliers 3 Slide back the fire sleeve 2 to make fuel hose accessible for cutting Pinch off the fuel hose with hose clamp pliers 4 d05679 fm 24 June 2013 73 00 00 Revision 1 Page 6 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063R1 SERVICE BULLETIN Graphic Cut the band clamp Slide back fire sleeve A a Pinch rubber hose to prevent fuel leakage a k oe NA y gt 7 3 S pi CAI j f lt E gt Y J Band clamp Fire sleeve Cutting pliers Hose pinch pli
13. mp 1 ear clamp 1 outlet side part no 851463 with suitable crimp pliers NOTE The edge of the 1 ear clamp 1 must align with mark 3 from fuel hose 2 because otherwise there is too little space for the 1 ear clamp 1 of the fire sleeve Repeat steps on inlet side with 1 ear clamp 1 part no 851453 for fuel hose assy 2 Graphic wo i 2o 5 te n thus 2 Fuel hose assy Mark paint or tape Fig 8 09849 09850 24 June 2013 73 00 00 Revision 1 Page 11 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063R1 SERVICE BULLETIN 3 4 3 Leakage test Because all fuel hose connections are visible and accessible now inspect the whole fuel system for leaks Therefore pressurize the system for example by an electric fuel pump with the operat ing pressure NOTE Reconnect of battery may be necessary for operating the fuel pump in order to perform this test 3 5 Assembling of fire sleeves with crimp clamp connection See Fig 9 NOTICE 4 in the correct position Procedure The distance from the 1 ear clamp 2 to the nipple flange 3 has to be me asured so that the outer 1 ear clamp 5 can be mounted on the fire sleeve Measure the distance at fuel hose assy 1 from 1 ear clamp 2 to nipple flange sealing surface 3 and mark the fire sleeve 4 correspondingly NOTE The clamp securing the fire sleeve should be as close as possible but
14. nual LINE all mechanical AXCAUTION fuel pumps have a 5 year life Fuel pumps prior to 2008 with S N starting 07 or 06 should have already been replaced in line with the routine main tenance requirements If this 5 year replacement has been omitted the pump should be replaced with immediate effect It is necessary to check the part no amp S N of any pumps previously replaced to ensure that are not in the affected range NOTE Basically all fuel pumps with part no 892542 and part no 892546 are af fected Pumps with following serial numbers S N are originally installed in the engines and or delivered as spare parts and are affected by this replace ment All versions of the engine type 912 UL from S N 4 408 362 up to S N 4 410 000 inclusive 6 770 101 up to 6 770 278 inclusive 6 775 7383 inclusive 6 775 769 up to 6 775 994 inclusive 6 776 094 up to 6 776 099 inclusive 6 776 141 up to 6 778 295 inclusive 912 ULS from S N 5 648 164 up to S N 5 653 000 inclusive 6 374 055 up to S N ULSFR 6 374 205 inclusive 6 775 001 up to 6 775 038 inclusive 6 775 047 up to 6 775 174 inclusive 6 775 268 up to 6 775 390 inclusive 6 775 416 up to In Addition all fuel pumps part no 892542 from S N 06 005924 up to 06 005981 inclusive 07 000529 up to 07 008428 inclusive 08 000001 up to 08 002984 inclusive 09 000001 up to 09 002805 10 000061 up to 10 005298 inclusive 11 000121 up to 11 000840 inclusive and fuel pumps part no 892546 from
15. ool manufacturer 24 June 2013 73 00 00 Revision 1 Page 4 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05679 fm d05679 fm SB 912 063R1 SERVICE BULLETIN 3 Accomplishment Instructions NOTE Before maintenance review the entire documentation to make sure you have a complete understanding of the procedure and requirements Accomplish All the measure must be taken and confirmed by at least one of the following person or facilities ment ROTAX Airworthiness representative ROTAX Distributors or their Service Center Persons approved by the respective Aviation Authority NOTE Safety notice NOTICE 3 1 Removal NOTICE All work has to be performed in accordance with the relevant Installation Manual and Maintenance Manual Proceed with this work only in a non smoking area and not close to sparks or open flames Switch off ignition and secure engine against unintentional operation Secure aircraft against unauthorized operation Disconnect negative terminal of aircraft battery Risk of scalds and burns Allow engine to cool sufficiently and use appro priate safety gear while performing work Should removal of a locking device e g lock tabs self locking fasteners etc be required when undergoing disassembly assembly always replace with new ones Ensure the fuel supply is turned off before disconneting any hoses 3 1 1 Removal of fuel pump part no 892542 w
16. verely damage NOTICE the engine or could lead to suspension of warranty NOTE Information useful for better handling A revision bar outside of the page margin indicates a change to text or graphic X WO S a 24 June 2013 Current valid documentation see 73 00 00 Revision 1 www FLYROTAX com Page 1 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063R1 SERVICE BULLETIN 1 Planning information 1 1 Applicability In accordance with the current Maintenance Manual LINE all mechanical AXCAUTION fuel pumps have a 5 year life Fuel pumps prior to 2008 with S N starting 07 or 06 should have already been replaced in line with the routine main tenance requirements If this 5 year replacement has been omitted the pump should be replaced with immediate effect It is necessary to check the part no amp S N of any pumps previously replaced to ensure that are not in the affected range NOTE Basically all fuel pumps with part no 892542 and part no 892546 are af fected Pumps with following serial numbers S N are originally installed in the engines and or delivered as spare parts and are affected by this replace ment The part no and S N can be found on the edge of the mounting flange All versions of the engine type Serial number In Addition all fuel pumps part no 892542 from S N 06 005924 up to 06 005981 inclusive 07 000529 up to 07 008428 inclusive 08 000001 up to
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