SERVICE BULLETIN Replacement of fuel - Rotax
Contents
1. 00 00 Initial Issue Page 14 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05489 fm2. 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 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 3 4 1 Assembling of the fuel pump part no 893110 without crimped 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 3 4 2 Assembling of the fuel hoses assy with crimped on hose assy supplied by BRP Powertrain See Fig 8 Procedure Remove hose clamp pliers from fuel hose assy Pie d05489 fm XX April 2013 73 00 00 Initial Issue Page 10 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05489 fm SB 912 063 SERVICE BULLETIN NOTE Thereby the fuel contained in the lines flow out and flush the residual con tamination from the fuel line All lines must be laid out without kinks avoid tight angles NOTICE Prevent the hoses from rubbing on components or against each other 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
3. remove fuel pump with lock washer A8 and in sulating flange Graphic Fig 1 XX April 2013 Initial Issue Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05489 fm 09865 73 00 00 Page 5 of 14 d05489 fm SB 912 063 SERVICE BULLETIN 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 Stratoflex Graphic Fuel pump Fig 2 09841 The following work steps are necessary see Fig 3 Do not use any pliers with sharp surfaces NOTICE a See Proce XX April 2013 73 00 00 Initial Issue Page 6 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05489 fm SB 912 063 SERVICE BULLETIN Graphic Cut the band clamp Slide back fire sleeve Band clamp Cutting pliers Hose pinch pliers 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 Step Procedure 4 The cut should be made just after the crimped ferrel to avoid losing any needed length The fuel hose is reduced by approx 20 mm 0 79 in NOTE A clean cut surface is very important Repeat procedure at the second fuel hose assy XX April 2013 73 00 00 Initial Issue Page 7 of 14 Copyright BRP Powertrain GmbH amp
4. the end of the hose 2 Slide all 4 1 ear clamps 1 on the fuel and fire sleeves NOTE Large clamp on fire sleeve small clamp on fuel hose 4 Push the fuel hoses 2 onto nipple completely up to the stop Crimp 1 ear clamp 1 outlet side 10 8 13 3 mm 0 43 0 52 in 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 soace for the 1 ear clamp 1 of the fire sleeve Repeat steps on inlet side with 1 ear clamp 1 12 8 15 3 mm 0 50 0 60 in for fuel hose assy 2 Graphic it Map 11 4 2an amp 14 Lulun tjuta bandibana 100 2 2 Fuel hose assy Mark paint or tape Fig 8 09849 09850 XX April 2013 73 00 00 Initial Issue Page 11 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063 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 3 5 Assembling of fire sleeves with crimp clamp connection See Fig 9 The distance from the 1 ear clamp 2 to the nipple flange 3 has to be me NOTICE asured so that the outer 1 ear clamp 2 can be mounted on the fire sleeve 4 in the correct position ee Measure the distance at fuel hose assy 1 from 1 ear clamp 2 to nippl
5. 92546 from 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 Fuel pumps with part no 892542 and part no 892546 with following serial numbers S N are assembled in the engines spare parts mentioned above and are affected by this replacement Concurrent ASB SB SI and SL Latest SI 912 020 regarding the general notes measurements changes etc Reason The field observation over the years has shown that in isolated cases poor quality of the mechani cal fuel pump part no 892542 and 892546 can occur which may subsequently lead to malfunc tions To prevent possible interference with the fuel system the fuel pumps have to be replaced against the successor type part no 893110 Subject Replacement of fuel pumps for ROTAX engine type 912 Series Compliance Atthe next scheduled maintenance event A replacement 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 _ZAWARNING personal injuries or even fatal injury Approval The technical content of this document is approved under the authority of DOA ref EASA 21J 048 Labor time Es
6. CO KG All rights reserved SB 912 063 3 Accomplishment Instructions SERVICE BULLETIN 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 ROTAXg Distributors or their Service Center Persons approved by the respective Aviation Authority NOTE All work has to be performed in accordance with the relevant Installation Manual and Maintenance Manual Safety notice 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 Proceed with this work only in a non smoking area and not close to sparks _ZA WARNING or open flames Switch off ignition and secure engine against unintentional Should removal of a locking device e g lock tabs self locking fasteners NOTICE etc be required when undergoing disassembly assembly always replace with a new one 3 1 Removal 3 1 1 Removal of fuel pump part no 892542 without crimped hose assembly see Fig 1 The following work steps are necessary Procedure Remove fuel hoses as per aircraft manufacturers instructions 2 Loosen hex nuts 13 mm 0 51 in and
7. CO KG All rights reserved SB 912 063 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 See Fig 5 Graphic Fig 5 09846 XX April 2013 73 00 00 Initial Issue Page 8 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05489 fm d05489 fm SB 912 063 SERVICE BULLETIN 3 2 Assembling of fuel pump assy part no 893110 Graphic XX April 2013 Initial Issue See Fig 6 In addition to the insulating flange also replace the O ring at reassembly NOTICE or assembly of the fuel pump Both parts are included in the set of fuel pump assy Procedure Install fuel pump 5 with new insulating flange 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 NOTE The additional security with LOCTITE 243 is applicable to each reassembly or assembly of the fuel pump af og 146 j Da S LOCTITE 243 Prandin CI St it Insulating flange Lock washer A8 Hex nut M8 Fuel pump assy Fig 6 09847 73 00 00 Page 9 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063 SERVICE BULLETIN 3 3 Inspection of fuel pump assy part no 893110 General See Fig 7 The fuel pump cover 1 must not
8. RP Powertrain GmbH amp CO KG All rights reserved d05489 fm d05489 fm SB 912 063 SERVICE BULLETIN 2 3 Material requirement per engine parts requirement no engine no 8 LL i KIT assy consisting all following parts 81360 fuel pump kit r 1 Fuel pump assy 893110 inclusive insulating flange part no 950227 942674 Hex nut M8 fuel pump assy Lock washer A8 945752 fuel pump assy fuel pump assy inlet O 851453 1 ear clamp 12 8 15 3 mm 0 50 0 60 in 1 851463 1 ear clamp 10 8 13 3 mm 0 43 0 52 in 851663 1 ear clamp 22 4 25 6 mm 0 88 1 01 in 853313 1 ear clamp 17 8 21 0 mm 0 70 0 83 in aa fuel pump assy fuel pump assy outlet fuel pump assy inlet outlet fuel pump assy outlet N 874336 Fuel hose assy 874345 11 Fuel hose assy 1 as required 2 for configuration with fire sleeve fuel pump assy inlet 2 4 Material requirement per spare part none 2 5 Rework of parts none 2 6 Special tooling lubricant adhesives sealing compound XX April 2013 Initial Issue Price and availability will be supplied on request by ROTAX Authorized Distributors or their Service Center Existing ROTAX GENUINE tool can be modified as follows or equivalent When using the special tools please note the information supplied by the NOTICE manufacturer 73 00 00 Page 4 of 14 Copyright BRP Powertrain GmbH amp
9. d05489 fm os BRP SB 912 063 ROTAX AIRCRAFT ENGINES SERVICE BULLETIN Replacement of fuel pumps for ROTAX Engine Type 912 Series ATA System 73 00 00 Fuel system RECOMMENDED Symbols used Please pay attention to the following symbols throughout this document emphasizing particular information General note Identifies an instruction which if not followed may cause serious in jury or even fatal injury moderate injury AXCAUTION Identifies an instruction which if not followed may cause minor or 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 XX April 2013 Current valid documentation see 73 00 00 Initial Issue www FLYROTAX com Page 1 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05489 fm SB 912 063 SERVICE BULLETIN 1 Planning information 1 1 Applicability 1 2 1 3 1 4 1 5 1 6 1 7 XX April 2013 Initial Issue All versions of the engine type 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 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 8
10. e flange sealing surface 3 and mark the fire sleeve 4 correspondingly Graphic Distance measuring Par i Furos ooo Tearen ooo 1 1 ear clamp 3 S Nipple flange Fire sleeve O Fig 9 09851 09856 XX April 2013 73 00 00 Initial Issue Page 12 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved d05489 fm SB 912 063 Graphic XX April 2013 Initial Issue SERVICE BULLETIN 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 routed so that in the event of a internal leak the ex NOTICE cess fuel can flow to a suitable location position See therefore Installation Manual of the relevant engine type and SI 912 020 Modification finished Fire sleeve Fig 10 09853 eed Restore the aircraft to standard operating condition Connect the negative terminal of board battery 73 00 00 Page 13 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063 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 Operators Manual of the 912 Series 3 6 1 Check of fuel pressure Slight short t
11. erm pressure undershoots are allowed But the pressure must stabilize to the operat ing limit within 5 seconds If not the cause should be determined and rectified 3 6 2 Check of float chamber Check float chamber for any debris particles that could get in until the replacement If any debris particles should be found then they must be located If needed remove clean and install again the float chamber 3 6 3 Check venting line NOTE A slight leakage on the venting line may occur For a period of 1 minute after the engine has been stopped no liquid must drip down 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 confirmed in the logbook Approval of translation to 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 XX April 2013 73
12. timated labor time engine installed in the aircraft labor time will depend on installation and therefore no estimate is available from the engine manufacturer 73 00 00 Page 2 of 14 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SB 912 063 SERVICE BULLETIN 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 additon 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 pump with insulating flange lock washers and nuts in accordance with chap 3 1 2 are unserviceable and must be scrapped 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 their Service Center 2 2 Company support information All parts are supplied free of change XX April 2013 73 00 00 Initial Issue Page 3 of 14 Copyright B
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