Europa XS Rotax 914 Installation Manual
Contents
1. Fig 3 Detail of pressure sensor mounting bracket This unit is fitted on the engine side of the firewall mark a suitable position note that the cables to the TCU are quite short and drill through the firewall with a 4 8 mm drill Fit two MS21047 3 anchor nuts on the cabin side riveting them with TAPK36BS rivets Fit the bracket to the firewall with two AN3 4A bolts The pressure sensors are fitted to the bracket with AN4 5A bolts and MS21042 4 stiffnuts Connect a length of 4 mm bore PVC tube to each of the pressure sensors The airbox sensor tube connects to the unused leg of a nylon T piece situated forward of the airbox on the port side A water trap is supplied with the engine and it should be fitted in the line The static pressure tube should terminate close to the engine air inlet filter Page 1 5 Europa XS Rotax 914 Engine Manual Issue 6 September 2003 Manifold pressure gauge A manifold pressure gauge calibrated to read between 10 in Hg and 50 in Hg is provided along with all the necessary parts to plumb it into the engine The position of the gauge is suggested to be beside the tachometer Refer to the diagram in figure 4 for all the connections CARBURETTOR BALANCE TUBE 6mm FUEL HOSE FS 02 RESTRICTOR FUEL CONDESATE TRAP 1 8 BSP 6mm HOSE FITTING 1 8 BSP BULKHEAD FITTING 15mm HOLE E d SECURE WITH LOCTITE 243 zeae ZZZZZZZZZ FIREWALL IB 1 8 BSP 1 8 gt HOSE FITTIN2. Europa XS Rotax 914 Installation Manual Europa XS Rotax 914 Engine Manual Issue 7 October 2004 Index of Chapters Chapter Description 1 Engine installation 2 Engine controls 3 Oil tank 4 Cooling duct and coolers 5 Fuel system 6 Engine cowlings 7 Access doors 8 Propeller and spinner 9 Commissioning the engine Annex A Final inspection checklist September 2002 Issue 5 Europa XS Rotax 914 Engine Manual 1 Engine installation Preparation Before starting work on the engine installation read this manual and the Rotax 914 installation manual There are some delicate parts attached to the engine notably the ignition triggers which require care in handling Instead of installing the engine mounting to the aircraft then trying to position a heavy engine onto it the engine mounting should be attached to the engine first This may have already been done at the Rotax factory The exhaust silencer has a slotted outlet stub and requires the tailpipe EX08 to be added to it The tailpipe is designed to be clamped in position See figure 1 Although the tailpipe could be welded to the silencer for tri gear operators this is not recommended as it is often better to remove the tailpipe before fitting or removing the lower cowlings as otherwise the presence of the nose gear can make life difficult EX0B TALPIPE Fig 1 Exhaust tailpipe Engine mount fitting There are two mounting frames associated with fitting the en
3. bolts For ease of installation attach an MS21047 3 anchor nut to the underside of the housing s flange at each end using TLPK 424 BS rivets then using AN525 10R10 bolts secure the housing in place The front mounting will use an AN970 3 washer see figure 2 and an AN970 3 washer can be used temporarily to hold the rear of the mounting until it is substituted by the throttle closed stop Fit the throttle knob parts TH07 using an AN525 10R10 bolt and MS21042 3 nut to the top of the throttle lever to complete the installation Slot the throttle cables through the gap between the firewall and the upper mounting members of the landing gear frame securing them to the frame with tie wraps to prevent chafing Remove and discard the straight cable outer receptacle provided on each carburettor and in its place insert the throttle cable s threaded end Use one check nut each side of the bracket to clamp the cable outer in place The cables may seem excessively long but this is to allow large bend radii in the engine bay to ensure minimum friction Each throttle cable should emerge through the metal firewall on the opposite side to the carburettor that it will control Loop the cable up and aft towards the centre of the firewall then down into the bracket of the appropriate carburettor Loosely secure the two cables where they cross Insert the cable inner into the nipple on the carburettor throttle lever which is sprung to its full open position
4. instrument panel you may have to site them elsewhere Be careful to take into account the length of the already made up cables which connect the various engine related components together before making your final decision on their positions Page 1 2 June 2004 Issue 7 Europa XS Rotax 914 Engine Manual CMY TIP ANI QITA Atheta MS Sy QE2H L2H DNOT WHEL O f O77 MOLLIS Siga IA 7 ESI SAFZSW FZ 2 emmed imod iso moans avo C O Nes 1 TO IMIN fih Z OE Wy LAN E BUS 329225 Qy7215y2 PA 270 GE x onw y zo MHIS dy 8E Ui KONSA AP x qi LAOS DNS IMT Ol x Ol My2p APTLY quo7 4 TAVOG AAS JA E UW IIS 4 aw Linang POL Lnrow LWN 200912 1022302 en ISA GAO X IA INIG DNLNFOW TAW 2HSYM Sho HIB 9 IKVINdd A 9 ININNDAV INIT 9 Ze 3IINSNT 01 q39n933 Sy Q I T9IS 096 NY S2BHSYM v x M N g NG GA IN ex 2108 OIW NG 9 PA PS LIN XN E NG S Luno ON NELJ s uga GOLIN 22H l i MPO HWEING d zz N AN LaVINIGd KA NN sei 200 7 SETT 1 SPV 4 uot owx ov MIDS AY quo 2927705 222M4oa4 17M 2243 1304 2709 ee 97 Pho DNILNIIOW ren 23d 130p dez ONIONI aLON Fig 2 914 engine installation exploded view Page 1 3 March 2006 Issue 7 Europa XS Rotax 914 Engine Manual When cutting the necessary holes through the firewall for the various cables keep them to a minimum size and use a suitable method of sealing around the cables after they are in place Having posit
5. into a housing Installation Drill a 13 mm 4 diameter hole as low as possible in the back face of the Coke kab throttle lever spine of the cockpit moulding for the cable outer assembly to go through See figure 3 Push the threaded p portion of the cable outer housing through the hole and clamp itin place with the lock washer and knurled nut Fig 3 Position of choke control Note As it can be difficult to insert the two cables into their respective outers remove the plastic knob instead leaving the cables installed when mounting the outer to the cockpit module The choke cables should emerge through the metal firewall as do the throttle cables Loop these cables forward over the top of the engine so that they enter the 90 elbow guides mounted on the carburettor from the front Rotate the elbows so that the cables enter them as straight as possible Push the cables into the carburettor cable guides and secure the cables to the choke levers using the solderless nipples Ensure that the choke knob is fully in and the choke levers are fully down at the same time and that full choke movement can be achieved Squeeze silicone RTV around the cables where they come through the firewall and secure them with a cable tie to the engine mounting frame to prevent them from chafing To ensure that the cables don t come out of their guides use locking wire wrapped around the cable outer and also the cable guides Page 2 4 Ap
6. plate against the front bulkhead Tighten these bolts according to the manufacturer s specification Mark both bulkheads and the propeller flange to note their relative positions for later reference Spinner Cut away sufficient of the rear edge of the spinner in the three positions where the propeller blades are to allow the spinner s rear edge to align with the rear bulkhead flange Allow a clearance of about 3 4mm 1 8 around the blades Although it s a good starting point don t rely on the alignment of the flanges of the spinner and rear bulkhead to ensure the spinner is true Page 8 1 Europa XS Rotax 914 Engine Manual Issue 4 September 2001 Hold the spinner in place using adhesive tape or clamps then with some form of reference pointer positioned close to the spinner about 10 15cm 4 6 back from the front carefully with ignition off note that if the ignition leads have not yet been wired to switches the ignition will be live rotate the propeller by hand to check for concentricity Removal of a spark plug from each cylinder will make turning the propeller easier Adjust the spinner as required to achieve concentricity then mark out and drill nine 4 8mm holes three equally spaced between each blade through the spinner and the rear bulkhead flange Remove the spinner and install MS21047 3 anchor nuts onto the inside of the rear bulkhead s flange using TAPK 33 BS countersink rivets Measure accurately the di
7. the door panels in the openings as accurately as possible and tape them temporarily in place from the outside Scuff sand the inside of the cowling around the door panels Cover the door panel with plastic sheeting to act as a release agent Lay up four plies of bid at 45 around the door panels lapping onto the cowling approximately 2 3cm 1 Page 7 1 Europa XS Rotax 914 Engine Manual Issue 4 September 2001 Cover the layups with peel ply and allow to cure before removing the door panels Trim the flange to be 18mm 3 4 wide Drill through this flange on the side opposite to where the hinge will be centred 7mm from the flange edge with an 8mm drill Now drill through the access door to match the above hole with a 6mm 1 4 drill Fit the spring receptacle 82 47 113 20 to the flange Fit the white wear washer 82 46 101 39 to the 14 turn fastener 82 11 200 20 insert the fastener through the door and fit the retainer 82 32 301 12 Hinges Cut a piece of 20001 3 hinge to be 75 mm 3 long for each door and file a clearance cut out for the hinge pivot in both the door panel and cowling Bond and rivet the hinge in place using countersunk TLPK424BS rivets Countersink the cowling and door panel with a drill before riveting Page 7 2 June 2004 Issue 7 Europa XS Rotax 914 Engine Manual 8 Propeller and spinner This chapter relates to the fitting of the Warp Drive ground adjustable propeller If other ground ad
8. the fibreglass Assemble the two cables to the throttle lever according to figure 3 ensuring the end fittings are free to pivot Thread the cables into the cable outers then install the lever into the housing as shown in figure 2 adjusting the lever friction as desired The friction should be sufficient to prevent the carburettor throttle lever spring from opening the throttle automatically and this can be done after final assembly Cover the opening in the side of the housing to keep dirt out a suitably sized rubber grommet would be ideal NOTE T ROTTLE LEVER BEARING FLY INSTALLED USING LOCTITE 638 Zerr HOUSING SECURING BOLT WASHER THOA AN 525 0R 0 ANObO I0L 208F TM T E CABLE EYE CHECKNUT ANZIG AR Sark WASHERS ANITO Zorr ACHR NUTS MS 21047 3 WITH RIVETS TAPK 55 BS AFF WASHERS AN 960 AIGL ZofF NNLDE NUTS ACCESS HOLE CLEVER FRICTION ADTUSTMERT Fig 2 Exploded diagram of throttle lever assembly Page 2 2 N ovember 2004 Issue 8 Europa XS Rotax 914 Engine Manual Installation The throttle lever housing should be positioned such that its front face is 380 mm 15 aft of the firewall For the monowheel aircraft this will ensure clearance with the main wheel top when it is retracted Mark out and cut a slot for the throttle lever in the spine in the centre tunnel then checking that full throttle travel is achievable drill through the flanges for mounting
9. 237724029 134 VH 291123024 VAHA INNS LIV 39NV T4 INNI WELT TNIXIOT 32M i 1 231134034 T O SN NUISITUDI 3199 AIN ACHING 4799 2 71 INIA Fig 2 Propeller and spinner assembly Page 8 5 September 2003 Issue 6 Europa XS Rotax 914 Engine Manual Looking at how the two zeros have misaligned will confirm that the inner scale has moved something like 1 4 but without the vernier it would be difficult to be absolutely sure INTENTIONALLY BLANK Page 8 6 September 2002 Issue 5 Europa XS Rotax 914 Engine Manual 9 Commissioning the engine Overview Before commissioning the engine read the Rotax Installation Manual again to make quite sure that nothing has been omitted At this stage the throttle 100 setting will be established There are several other checks that need to be made as part of commissioning the engine You need to be sure that there are no restrictions in the oil lines or the fuel lines and that the engine oil system is fully primed before first start up You also need to check that both the electric pumps provide sufficient flow to the carburettors Note Refer to the Final Inspection Checklist in appendix A before commencing commissioning A limited amount of test equipment is necessary for commissioning and a kit is available from Europa Aviation on hire to carry it out Throttle setting The engine is fitted with a 9 pole RS232 plug this has to be connected v
10. G PANEL CUT OUT DETAILS BS116 PLASTIC TUBING LOOP TO ALLOW PANEL REMOVAL HFSP 3 2N 1 8NPT 3mm 47 2 1 858 4 3 11164 h a PCD 66 7 2 5 8 58 0 2 1 4 b MANIFOLD PRESSURE GAUGE Fig 4 Manifold pressure gauge connections Propeller drive lugs The engine is normally delivered with the six propeller drive lugs suitable for the ground adjustable Warp Drive propeller supplied loose These are a light interference fit in the propeller flange with a relief on the forward part to assist in starting the insertion of them into the flange To complete the installation it will be necessary to pull them into position using a suitable bolt nut and washer with a spacer tube Ensure that the drive lugs are fitted with no gap between the back of the propeller flange and the drive lug collar Page1 6 February 2005 Issue 7 Europa XS Rotax 914 Engine Manual 2 Engine controls The Rotax 912 has two independent carburettors each one providing a fuel air mixture to one pair of cylinders The only mechanical controls required for the carburettors are throttle and choke There is a computer controlled turbocharger wastegate control which varies the boost pressure in response primarily to demand from throttle position but limited also by other functions such as RPM static pressure airbox pressure and temperature etc The throttle lever will be set to give engine output varying from 0 to 115 full t
11. N JATVA 0382 GP dd INIT nandu Nees x TANI AYYWIHd an Ay omy jo aug NOLIVINSNI YOLLJUNAHYI 408 Olid 3A331S JHH 4304 1303 U3NIVINOO AUaLiv8 eqm ONIBAL poii lang purgag vooeyyp INYHLIUNAT10d HA JOJSID 0 B2IPU 4379 uo seul jeuoBeig 9joN UL TI ul 19487 jang Duneorpul eDner jyBis teal SOH J8n j WWZ mamm SOH 9n WWE sme Sul aN AJA 1N3A 390v9 LHDIS INJA ANYL dV9 u3TIld 71304 eDnex JUBIS uo pieM103 Bupnjoo MAIA i t Fig 2 Fuel system Page 5 4 Europa XS Rotax 914 Engine Manual Issue 8 November 2004 6 Engine cowlings The upper and lower engine cowlings are trimmed to fit together and fit into the joggle at the front of the fuselage for mounting The cowlings are held together using countersunk screws through Tinnerman washers into anchor nuts mounted to the lower cowling Attachment of the cowlings to the fuselage is also by means of similar screws and anchor nuts The trimming required will be 1 Removal of the flat areas at the rear of the air outlet ramp in the lower cowling at the two circular areas at the lower cowling front and at the lower rectangular areas at the front of the lower cowling When doing the first of these jobs leave a small flange about 4 5mm 3 16 around the outlet to give it some stiffness 2 Opening the up the side cooling gills 3 Opening for the NACA scoop in the lower cowling To prevent the end of the inlet ramp contactin
12. Setting the throttle lever in the cockpit back about 2 3 cm 1 from its full forward position screw both nipples tight on the cables Check for full throttle movement making any adjustments as required then seal the open hole in the throttle lever housing to prevent anything thrown up from the wheel from entering Throttle closed stop The addition of a throttle closed stop is important to avoid the possibility of excess tension on the throttle cable causing loss of throttle control Following the method below prepare a plate made from 3 mm 1 8 aluminium 50 mm 2 wide With the throttle closed and the slow running adjustment correctly set at the carburettors measure the distance from the rear of the throttle lever where it protrudes above the top of the tunnel to the centre of the rear 4 8 mm 3 16 mounting hole The plate length will be 6 mm 1 4 more than this measurement Drill the plate 6 mm 1 4 from one end bond with Redux to the tunnel and bolt with an AN525 10R10 bolt Note You should set the throttle closed stop such that a fully warmed engine idles at 1200 1400 rpm Although the engine idles more smoothly at 1600 rpm or more when landing the aircraft you will benefit from minimal residual thrust Page 2 3 Europa XS Rotax 914 Engine Manual Issue 9 April 2006 Choke Control The two choke control cables are swaged together into the choke operating knob but run in separate outer sleeves which are swaged
13. and approximately 30 forwards The hose curves immediately aft and up to go over the rear cylinder s water hose under the starter motor and inside the engine ring mount it then loops up to the tank Radiator The radiator is bolted to the side plates of the cooling duct by two AN4 5A bolts and MS21042 4 nuts each side A short hose C05 leads from one port of the radiator to the engine coolant pump outlet and a longer hose C04 leads to the header tank These hoses are to be secured with 25 35 mm hose clips Air filter The air filter is fitted directly to the end of the compressor and to isolate it from the general environment of the engine a compartment is made using parts CD6 and CD7 the lower cowling closing the bottom see the exploded diagram figure 6 The diagram shows what holes will be required in the compartment Not all the holes are pre cut Photographs figures 7 and 8 illustrate a completed installation First rivet parts CD6 and CD7 together using TAPD46BS rivets Position the assembly against the starboard footwell with the top surface 13 cm below the top surface of the footwell This will allow sufficient room for the oil tank The large hole in the side of the CD6 is for the air filter to pass through This will also help in determining the location of the assembly Drill through the rear face of CD6 and into the footwell with a 4 8 mm drill for the three AN525 10R8 fixing bolts Temporarily attach the assembly
14. as spacing washers Check that the nuts are split pinned Lubrication system Check that the oil outlet banjo bolt underside is wire locked Check that the drain plug port front is wire locked Europa XS Rotax 914 Engine Manual March 2008 Page 10 1 Carburettors Duplicate check that both throttles are working over the full range and that they close together Check that the choke control works correctly and closes fully Check presence of throttle gate for maximum continuous power setting Check throttle lever carburettor position Throttle closed 0 3 throttle full open 113 115 throttle gate 100 104 See chapter 9 for method of checking these positions Exhaust system Ensure that no thermal wrapping is on the exhaust down pipes Electrics Check for chafing of wires through firewall Check that metal p clip is used without insulation to clamp the metal braided sheath around the cables from the ignition boxes Check that an earth wire is connected to the above p clip Operation With throttle fully closed switch on master switch and observe the turbo wastegate lever The lever should cycle open and closed closed is with the cable pulling the lever Check that the wastegate is fully closed Check that the maximum static rpm at 100 throttle is 5200 or higher fixed pitch and ground adjustqable propellers Check also that no more than 5600 rpm is reached at 115 throttle see chapter 8 Ensure that the switc
15. c pump adjusting the pressure into the regulator to remain at 0 5 bar 7 25 psi and measure the flow rate into the measuring container It must be at least 125 of the full power fuel consumption of 33 litres per hour To achieve this the pump must deliver 1 litre innot more than 87 seconds 1 US quart in 82 seconds Do the same check with the other pump and finally with both pumps Repeat these checks with the fuel selector on Reserve and record the fuel flows that were achieved Note Quantity pumped litres time seconds x 3600 litres hour If using quarts use the same formula but don t forget to divide the result by 4 to obtain gallons hour If you cannot achieve sufficient fuel flow there must be a restriction in the lines between the fuel outlets and the engine perhaps a kinked or squashed fuel line Now reconnect the fuel tank return line to the regulator and the pressure line from the airbox to the regulator control diaphragm Fuel pressure check Connect the pressure gauge via a T piece at the fuel inlet and switch on both pumps Check that the pressure does not exceed 0 35 bar 5 1 psi Ifthe fuel pressure does exceed this limit there may be several reasons For example the pressure regulator may be incorrectly adjusted it may be faulty or there could be a restriction in the return line Page 9 3 Europa XS Rotax 914 Engine Manual Issue 7 June 2004 INTENTIONALLY BLANK Page 9 4 September 2002 Issue 5 E
16. e vent from the oil tank allows an oil mist to escape to atmosphere It is not unusual to run the vent line to the bottom of the cowling however if you do this don t position the end of the tube such that it will be in the airstream whilst flying This could cause low pressure at the end of the tube to suck more oil from the tank than it should Another consideration is that the oil mist will tend to coat the fuselage if left to vent freely To avoid this you can run the vent line into a collector bottle before it goes to atmosphere however no bottle is provided Page 3 2 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual 4 Cooling duct and coolers Overview A duct is fabricated from aluminium sheet to direct cooling air to the oil cooler and radiator which are arranged one behind the other with the radiator in front of the oil cooler The duct is open at the bottom and uses the inside of the bottom cowling as the lower seal Duct Figures 1 shows the assembly of the aluminium duct from the individual components 914 ONLY EWR p RUBBER SEAL RVET ar fees TYAGAL DETAIL Fig 1 Assembly of cooling duct Page 4 1 Europa XS Rotax 914 Engine Manual Issue 4 September 2001 Check the fit of the duct in between the footwells and if necessary adjust the width of the duct then rivet the CD1 CD2 and CD3 sections together using TAPD46BS rivets Rivet sealing strip to the bottom sides of the d
17. echanical pump From the electric pumps the fuel lines join again This line is connected to the inlet of the fuel pressure regulator on the top rear of the engine A further line from the regulator takes a small flow of fuel back to the starboard side of the fuel tank The engine connection to this line incorporates an already fitted restrictor to allow a flow of fuel to prevent fuel vapourisation in hot conditions Installation Electric fuel pumps The electric pumps supplied with the engine are to be mounted in the port underfloor chamber situated in the baggage bay floor Refer to the schematic diagram on page 3 and drawing on page 4 for details of the various fuel system fittings Whilst the pump is not installed either solder extension wires to the existing ones or attach connectors for later use Inline filters The in line filters are to be connected between the selector valve and the fuel pumps Before mounting the filters into the fuel system it is necessary to incorporate a safety spring in each Without this spring it is just possible for the knurled nut if it comes loose to cover most of the fuel flow holes area and so limit fuel flow and also allow unifltered fuel to pass through which could result in engine failure Unscrew the end fitting at the end which has the 2 fuel flow holes and the knurled nut the inlet end Fit t he spring part number LC042G 2 over the fuel flow holes and with it butting up against the knu
18. ecommended The vernier scale The vernier scale on the inclinometer supplied with the Warp Drive propeller is designed to allow the accurate measurement of small angles that would otherwise be too small to see using a standard scale The principle of its operation is the alignment of lines on inner and outer scales The outer scale on your inclinometer is in degrees of arc and the inner scale represents minutes of arc As an exercise using the inclinometer align the two zeros of inner and outer scales together If you now look at the alignment of the graduations of both inner and outer scales you will see that they progressively misalign as you move away from the zero and then after the 30 of the inner scale they start to realign until the graduation marked 60 is back in line with a graduation on the outer scale See the first illustration in the figure below If you now look at the graduation mark representing 15 on the inner scale and rotate this scale to align with the nearest adjacent graduation on the outer scale you will have moved the inner scale 15 minutes of arc or 1 4 See the second illustration in the figure below Fig 1 Vernier scales Page 8 4 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual GYATSO PITS NY 4209 cg GI TEU IFES NY 809 ng nx i E LEOUTSW UYELSTQIIS 4109 LAN JOHING Pd f INN JOTAN ei 7 WA F 2 39w73 STTTIAONS GNIS 4 WHY ZINNGE VIHM INH
19. er priming make sure that all oil connections are secure and that the oil tank is still full at least to its mid level Although the engine has been run in by the manufacturers it is prudent to operate it initially at a fairly conservative power rating until you are sure that there are no problems with cooling Once you are happy with the general engine running you can carry out the remaining fuel and oil system checks Oil system check Run the engine at full power and check that the depression in the oil inlet pipe as measured by the gauge already fitted is less than 0 3 bar 4 4 psi If the depression is greater than this check the hoses for kinks or for any other restriction in the system before continuing to operate the engine Page 9 2 September 2002 Issue 5 Europa XS Rotax 914 Engine Manual Fuel system check The next items to check are the electric fuel pumps this operation can be carried out with the engine stopped Disconnect the fuel return line at the fuel pressure regulator and connect atemporary 8mm hose from the return line fitting on the regulator leading to a suitable measuring container of at least 1 litre 1 quart capacity Fuel flow check Disconnect the small bore hose from the control diaphragm at the front of the regulator Connect the syringe pump with integral pressure gauge to the regulator and pressurise the line to 0 5 bar 7 25 psi With the aircraft fuel selector valve on Main switch on one electri
20. fit on top of the footwell T MOINTING BRACKET PIE TANE DIL TANK MOUNTING BRACKET BEACKET INSTALLATION MANUFACTURED Fig 1 Oil tank mounting bracket Bracket installation Arranging the bracket with the upper lug fitting under the oil tank lid fasten the bracket to the tank using the two number 6X size jubilee clips Keep the clamps away from the radius of the bracket With the engine and lower cowling in place position the oil tank and bracket onto the front face of the starboard side footwell Position the tank so that there is reasonable clearance from both the engine and cowling Page 3 1 Europa XS Rotax 914 Engine Manual Issue 4 September 2001 Drill through the bracket into the forward and top surfaces of the starboard footwell and bolt it in place using AN525 10R10 bolts and MS21042 3 nuts with AN970 3 large area washers on the inside to spread the load To oil pump Vent line DUIS Retum from sump To oil cooler ri r 017 Fi Ar Ta JE oak Fig 2 Oil tank connections Oil tank installation Reinstall the oil tank to its mounting bracket and orientate it so that the oil tank return fitting which is identified as the pipe which enters the tank at a tangent is pointing to aft and slightly to starboard Screw the two 90 elbow fittings to the tank fittings arranging the tank return fittings as shown in figure 2 Connect up the hoses to the tank as shown in figure 2 Oil tank vent Th
21. g the air filter it may be necessary to file away the rear of the ramp 4 Cutting the hole in the upper and lower cowlings for the propeller shaft Initially cut a hole in the centre of this front circular area the same size as the propeller shaft This will enable the cowlings to locate on the propeller shaft making subsequent fitting easier For the tri gear version an extra slot must be cut in the rear of the lower cowling to allow for the nose gear leg the size is shown in figure 1 2 75 70mm Fig 1 Slot for nose gear leg Page 6 1 Europa XS Rotax 914 Engine Manual Issue 8 November 2004 Installation Mark a line on the upper cowling 13 mm away from and parallel to the horizontal edge Mark the centres for the holes to join the two cowlings together according to the drawing in figure 2 Note The joint between the cowling halves is not horizontal with the aircraft datum waterline 0 TOP COWLING 6 EQUISPACED HOLES 5 EQUISPACED HOLES EACH SIDE 13mm 1724 a CUT AWAY FLAT S CUT HOLE TO FIT AROUND AREAS ONLY PROPELLER SHAFT E 7 m BOTTOM COWLING 6 EQUISPACED HOLES REMOVE FLAT AREA EACH SIDE OF CENTRELINE Fig 2 Cowling trimming and position of attachment screws Place the two cowlings together and hold them with clamps or adhesive tape then try them in place on the front of the fuselage Trim the bottom edge of the top cowling if necessary so that both cowlings can sit snugly
22. gine to the undercarriage frame the engine itself is already fitted to a ring mount which is a Rotax component and that is fitted to the Europa engine mount which in turn is fitted to the undercarriage mount Page 1 1 Europa XS Rotax 914 Engine Manual Issue 6 September 2003 Fit the engine mounting frame to the Rotax ring mount using M10 x 110 bolts and M10 Binx nuts The upper bolts and the lower port bolt should be fitted with the bolt heads aft and the lower starboard bolt with the head forward The excess length of the bolts will need to be cut off leaving a minimum of two threads emerging from the end of the nut It will be necessary to chamfer the lower starboard bolt s head as shown in figure 2 Engine installation Mount the engine to the landing gear frame using the rubber mountings See figure 2 To check the orientation of the engine set the fuselage level using the port door sill as the reference as usual Check that the propeller flange is truly vertical The engine mounting frame has been designed with the engine offset to starboard by 1 5 To check that this offset is correct clamp a straight edge to the propeller flange horizontally and mark a point 51 cm 20 each side of the engine centre line Measure the distance from these points parallel to the aircraft centre line to the firewall The difference between the two readings should be 26 mm 1 1 16 If any correction is found necessary shim between the landing gea
23. h of the 8mm fuel hose back to the fuel tank generally following the fuel supply line but finishing at the starboard reserve fuel tank outlet Connect a union HFSB 8 2N to the unused port of the F09C fitting and connect the return line to this port If your aircraft is fitted with the optional water drain kit then you will need to fit a T piece HFTP 8 8 8 into the line between the port tank outlet and the drain valve The return line is then fitted to this T piece Fuel sight gauge calibration When the time comes to calibrate the fuel sight gauge you will need to start with the Reserve side full and only unuseable fuel in the Main side Set the aircraft level to simulate level flight then pour in sufficient fuel to ensure that 2 or 3 litres will go over the tank tunnel and into the Main side 15 litres should be sufficient to do this Remember that fuel enters the tank on the Reserve side Now ensure that the fuel selector valve is positioned to take fuel from the port side of the tank which is the Main side and empty the port side of the tank only Next pour in fuel in equal quantities 5 litres at a time for example Mark off the gauge after each 5 litres has been added bearing in mind that due to the tunnel in the tank and the variations in cross section the marks will not be equally spaced Another point to consider is that after the fuel has been used down below the top of the tunnel the sight gauge w
24. h to isolate the Turbo Control Unit TCU is guarded against inadvertent operation A latching or covered switch is recommended Check also that the switch is clearly placarded with TCU ON TCU OFF A warning label close to the switch should also be present marked Warning Engine over boost may be possible with TCU switched off Run the engine at full power for 2 minutes prior to the first flight Mogas Aircraft on U K register Rotax engines are designed to run on Mogas Please note that if you intend to use Mogas in your aircraft it is necessary to apply for permission from the L A A Page 10 2 March 2008 Europa XS Rotax 914 Engine Manual
25. hrottle position This power is available only for 5 minutes normal continuous maximum power being 100 Stops on the carburettors control the 0 and 115 positions but a gate will need to be included in the slotted facia plate through which the throttle lever runs to set the 100 position Special purpose software is used with which to set the throttle stops details of which are to be found in the Rotax s 914 Engine Installation Manual Although there are two independent throttles and chokes there is only one throttle and one choke control in the cockpit Throttle Control A single lever protruding through a slot in the central spine on top of the central tunnel provides the pilot with throttle control The lever is mounted and pivots in a fibreglass housing fixed to the underside of the wheel well and operates two separate cables Throttle Lever Housing Drill the holes in the throttle lever housing as shown in figure 1 19 mm 0 75 Umm 0 45 25 mm 1 89 mm 3 5 TNI 20 mm 0 8 Fig 1 Throttle lever housing drilling dimensions Page 2 1 Europa XS Rotax 914 Engine Manual Issue 9 April 2006 Drill also a 4 8 mm hole in each flange for mounting bolts Open up the hole on the starboard side of the housing to allow a socket spanner through A ssembly Install the cable outers through the two holes in the housing and clamp them in position using the nyloc nut with an AN960 416L washer each side of
26. ia a special cable with a dongle to a PC More recently Rotax have removed the requirement for a special cable and a conventional RS232 connector cable can be used On earlier engines the part number on the TCU will be 966471 966472 or 966473 these engines have a TCU at rev 4 5 and a dongle will be required the appropriate software is 4 5 Newer engines have a TCU part number 966741 a dongle is not required and the TCU and software are at rev 4 6 The software required must be installed in the PC The cable and software are available on hire from Europa With the master switch of the aircraft on run the program detailed instructions are included in the Rotax Installation Manual This will check that the throttle in the closed position corresponds to 0 in the fully open position corresponds to 115 and will enable you to mark the 100 position It is recommended that you make a gate or detent at the 100 position to avoid the possibility of exceeding this power setting in normal flight Coolant system Fill the system with a 50 50 mixture of a good quality antifreeze and water Oil system It is necessary to check that the suction at the oil pump inlet is not excessive Rotax specify a maximum depression of 0 3 bar 4 4 psi below ambient pressure at the oil pump inlet at full throttle To check this a T piece must be inserted into the oil pump suction line Because this test has to be done with the engine running at full th
27. ill indicate the level of the port side of the tank main only The fuel tank is designed to hold approximately 9 litres of reserve fuel However this amount may be reduced in turbulent conditions There will be a small quantity of unusable fuel Page 5 2 November 2004 Issue 8 Europa XS Rotax 914 Engine Manual REDUCER HFRP 8 12 2 PLACES FILTER PRO 805 FH O15 LOOPS PROVIDE ABILITY 12mm HOSE TO SERVICE FILTERS 2 PLACES POSITION ABOVE PUMPS FUEL PUMP No 2 FUEL PUMP No 1 FILLER HETS 8 8 8 AND VENT 4 PLACES E FUEL TANK RESERVE STARBOARD HFSB 8 2 ag HESB 8 2N TU23RM TO SIGHT GAUGE SELECTOR VALVE 6749 HFSB 8 4N 3 OFF RETURN SUPPLY KEY N HFSB 8 2N 1 8 NPT 8mm FIT TING l 1 HFSB 8 4N 1 4 NPT 8mm FIT TING TU23RM 6mm CLEAR PU TUBING HFTP 8 8 8 8mm TEE PIECE e NOTE Bmm FUEL HOSE USED EXCEPT WHERE STATED PRESSURE REGULATOR Fig 1 Schematic diagram of fuel system fittings Page 5 3 Europa XS Rotax 914 Engine Manual Issue 8 November 2004 QUYAV1d JANA 1303 eur aney 34518 uj 340 2054 Jans 39nvb HOLIIHUSIH 3NVHLIHNATOd OHVAUOA 89379 TW 210 JAHISIU 5 gt S NILLI 3SOH Genno pas Nc 88S4H Jenn Hod NIVA SYOLOINNOOD u31NIOd SY G3SN ITONYH 104 jo aug dWNd 1314 8 8 8 3sou AYVONODIS JH JAVA Tan 6429 JAVA YOLDITAS AVM HOLLIHNAHVI JNI NI 1 HOLYINDIY 34N5S34d TANI om jo aug Av
28. in place then drill through the centres with a 3 2 mm 147 drill Use clecos through some of the holes to hold the cowlings together Since the engine has already been set to the correct position relative to the fuselage the cowlings will be set so that the front circular flat area is concentric with the engine propeller flange Trim the rear edge of the cowlings as required to ensure a good fit to the fuselage with the front face concentric with the propeller flange The front face of the cowlings should be set to be 25mm 1 behind the front face of the propeller flange Finally after fitting the cowlings cut out the front circular face of the cowlings to leave a flange 25 mm 1 wide Page 6 2 November 2004 Issue 8 Europa XS Rotax 914 Engine Manual Now mark a line on both cowlings 13 mm from and parallel to their rear edges Mark the hole centres according to figure 2 and drill through with a 1 8 drill and use clecos to hold them in place Enlarge the holes joining the two cowlings together to 4 8 mm 3 16 except for the rearmost hole each side and install MS21047 3 anchor nuts 10 in total to the inside of the lower cowling with TAPK33BS countersink rivets The remaining holes should also be opened to 4 8 mm and MS21047 3 anchor nuts installed to the inside of the fuselage using countersink rivets As the thickness of the fuselage where the anchor nuts are to be located will vary depending on their position a selection
29. ioned the servo motor mark out the mounting holes Fit two MS21047 4 anchor nuts on top of the tunnel using TAPK33BS rivets The unit is mounted with two spacers on each AN4 17A bolt one W14 spacer and one shorter spacer made by cutting a W14 in half TAM 4 TeP of ARNALL Figure 3 Position of servo motor and TCU View looking forward Turbo control unit This unit is mounted vertically on firewall on the cabin side in the position shown in figure 2 The four mounting bolts pass through the firewall with the nuts in front of it Since the thread length of the bolts is rather short it will be necessary to make the appropriate part of the firewall thinner Using a 20 mm 3 4 hole saw carefully drill through the forward skin and foam only Bond NAS1169C10 Tinnerman washers into the recess with flox ensuring that the recessed face of the washers is kept clear of the flox Mount the unit with spring washers and M4 nuts Page 1 4 September 2003 Issue 6 Europa XS Rotax 914 Engine Manual Pressure sensors Two pressure sensors are provided with the engine measuring respectively the static pressure and the airbox pressure These sensors need to be mounted with the pressure connection facing downwards to avoid any possibility of condensate entering them Make up a mounting bracket from the 1 x 1 aluminium angle supplied drilling it as shown in figure 4 20 19 4 8 MM 2 PLACES N25 0 50 20 25 4 PLACES
30. justable propellers are fitted the general instructions in this chapter will apply but details will vary Refer to the figure showing the propeller and spinner arrangement at the end of this chapter Spinner bulkheads Rear bulkhead Carefully mark out and drill with a hole saw six holes in the rear bulkhead concentric with the periphery to allow through the propeller drive lugs which you have installed in the engine propeller shaft flange Cut out also the central hole required for the boss in the propeller flange Make these holes such that the bulkhead is not loose on the lugs and centre boss Front bulkhead Mark out and drill six holes in the front bulkhead concentric with the periphery to allow through the propeller attachment bolts Also make holes in the front bulkhead centred on where each of the propeller blade clamping bolts will be to allow a suitably sized socket through with some clearance Drill through the head of each propeller attachment bolt to allow locking wire to be used Propeller Make up the propeller according to the manufacturer s instructions setting the blade angles only approximately at this stage Fine setting of blade angle is best done on the aircraft Tighten the bolts according to the manufacturers specification File the front bulkhead flange locally to clear each propeller blade then bolt the propeller to the engine propeller flange with the bulkheads either side of the propeller hub and the face
31. nts close to the air filter will cause most of the oil mist to be ingested into the engine and so reduce the amount which would otherwise run down the fuselage Ensure that it doesn t exhaust such that oil can get onto the brake disc The wastegate cable needs to loop through the compartment to avoid sharp bends which would inhibit its operation Page 4 7 Europa XS Rotax 914 Engine Manual Issue 4 September 2001 Europa XS Rotax 914 oil system Schematic view looking down engine removed for clarity 12 mm oil hose 70 cm long 12 mm oil hose 61 cm long 90 elbow straight if Straight unio radiator dropped 2 Oil cooler 12 mm oil hose These hoses route together under the 90 elbow outie 8mm fuel hose over cylinders Oil pump housing C06 90 elbow hose trim short leg of elbow as required FRONT Fig 9 Schematic view of oil cooling system Page 4 8 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual 5 Fuel system The installation of the fuel system described in the fuselage manual takes the fuel line as far as the fuel selector valve After the fuel has passed through the fuel valve the line connects to twin in line filters which are transparent and so aid visual detection of contamination From the filters the lines run to the twin electric pump inlets The electric pumps are pilot activated and are duplicated as the Rotax 914 engine is not fitted with a m
32. of 3 2 mm diameter countersink rivets are provided Use the shortest rivet that you can for attaching each anchor nut into the fuselage Countersink the outside face of all the holes of the upper cowling and the rearmost holes only of the lower cowling except the upper rear holes to allow the Tinnerman washers to lie flat against the cowling surface The cowlings may now be fitted using the AN507C 1032R12 screws Shorter MS24693 C272 screws may be used for joining the two cowlings together and these may be long enough to be used in some places securing the cowlings to the fuselage however note that the lower inboard screws need to be longer than the rest Page 6 3 Europa XS Rotax 914 Engine Manual Issue 8 November 2004 INTENTIONALLY BLANK Page 6 4 November 2004 Issue 8 Europa XS Rotax 914 Engine Manual 7 Access doors To enable access to check oil and coolant before flight two hinged doors are required in the top cowling See figure 1 1 0 25 OlL Fig 1 Position of access doors The doors themselves are cut from the cowling so mark out 12cm 434 squares centred over both the water expansion tank not to be confused with the optional overflow bottle and the oil tank Carefully cut the door panel from the cowling with a knife or thin hacksaw blade to minimise the gap around it The scribed outline of a NACA inlet on the top cowling is for the Rotax 912 S engine You can ignore this Flange Reposition
33. pitch adjustments of no more than 1 at a time assessing the difference in flight performance each time Page 8 2 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual Blade pitch adjustment You may find your own method for adjusting the propeller blade pitch but the following method has been found to work well Measure the angle that the aircraft is sitting by using the inclinometer which is provided with the Warp Drive propeller on the port side door rebate and make a note of it This angle will have to be added to the angle measured at the blade tip to give the actual blade pitch angle required For example if a blade angle of 21 is required and the aircraft deck angle is 7 you should set the blade to an angle of 14 from the vertical The vernier scale enables accurate measurement of angles to within 5 minutes of arc A description of how to use it is included later Adjusting method Set the propeller blade that is to be adjusted horizontal with the leading edge uppermost checking this with a spirit level Clamp the inclinometer to the back of the blade tip Slacken off the four blade clamping bolts and the four closest propeller hub securing bolts It should now be possible to rotate the blade to the desired angle Ensure that the blade is fully pulled out against the stops in the hub as there is some radial movement available if this is not done the propeller balance will be degraded Once the blade angle i
34. r frame and the appropriate cup washer using AN960 516L washers In order to ensure that the split pin is correctly positioned relative to the castellated nut it will be necessary to use a total of at least 4 washers on each bolt Any washers that are not needed to act as positioning shims should be placed immediately under the nut Make a note of where and how many shim washers are used for later reference Note The 4 AN5 41 mounting bolts must be tightened fully to compress the rubber anti vibration mounts MT04 onto the steel spacers MT03 Caution It should be noted that before the two ignition leads which come from the ignition box are earthed the ignition is live Even though the engine speed must be at least 1200 rpm for the ignition to fire it would be a sensible precaution to fit the magneto switches before further work is carried out on the engine or at least temporary earth leads connecting the ignition wires to the engine casing Wastegate control The turbocharger wastegate is controlled by the TCU and operated by the servo motor unit These two items have to be positioned away from sources of high temperatures Consequently they are to be fitted in the cabin on the top of the tunnel right at the front behind the firewall Servo motor The servo motor is mounted horizontally on the right of the tunnel with the operating cable facing forwards The positions shown in figure 3 are suggested but depending on the equipment in the
35. ril 2006 Issue 9 Europa XS Rotax 914 Engine Manual Ignition shorting cables connection Recent Rotax engines have modified ignition shorting cable connections The photographs in figure 4 are self explanatory ROTAX 912UL 912ULS IGNITION SHORTING CABLE CONNECTIONS zn t oe CRIMP CONNECTOR AND GROMMET AS SHOWN 5 Fig 4 Ignition shoring cables connection Page 2 5 Europa XS Rotax 914 Engine Manual Issue 10 November 2007 INTENTIONALLY BLANK Page 2 6 November 2007 Issue 10 Europa XS Rotax 914 Engine Manual 3 Oil tank Oil Tank Mounting Bracket The oil tank is to be mounted to the front of the starboard footwell using a steel bracket To make the mounting bracket first mark out and cut out the steel sheet LBO1 according to the drawing at the end of this chapter Next bend the central wide portion into a curve to match the outside of the oil tank This can be accomplished by running the metal backwards and forwards across the corner of a wooden bench whilst applying a bending force on it Finally bend the lugs each side of the curved portion so that the two narrow flanges can sit flat against the footwell front face See figure 1 Bending can be done by clamping the steel between lengths of wood in a vice Try to avoid a sharp bend radius a 10mm 3 8 radius is ideal Make a 90 angle bracket from the narrow strip shown on the template and rivet it to the top right port side using TLPD424BS rivets it should
36. rled nut refit the end fitting Use firm hand pressure to screw on the end fitting as over tightening with spanners could damage or displace the O ring seals and even break the transparent tube Page 5 1 Europa XS Rotax 914 Engine Manual Issue 8 November 2004 The outlet of the selector valve points aft connect a length of the 8mm fuel hose to the outlet fitting HFSB 8 4N which should already be fitted to the selector valve and route it aft through the tunnel under the fuel tank and into the port underfloor chamber Connect the filters fuel pumps and non return valves according to the fuel schematic on page 3 figure 1 Arrange for the fuel filters to be positioned above the pumps this will assist when filter cleaning is carried out Electric pumps to engine From the T piece after the electric fuel pumps to the engine use 8mm fuel hose Route it forward under the fuel tank and run it forward to emerge through the landing gear mount approximately 10 cm 4 below the top of the tunnel Run the hose up the rear of the engine and connect it to the fuel inlet fitting of the fuel pressure regulator To protect against vapour locking sleeve the hose forward of the firewall with insulating fire sleeve and ensure that you don t route the hose too close to components which will be very hot e g cooling system exhaust etc Use hose clips to secure the connections Fuel return line From the return line fitting on the engine run a lengt
37. rottle it will be carried out later Page 9 1 Europa XS Rotax 914 Engine Manual Issue 5 September 2002 Disconnect the hose from the oil pump inlet and connect the short hose and T piece from the test kit with the pressure vacuum gauge connected to the leg of the T Before first start it is necessary to prime the oil system There are several methods to achieve this the easiest is as follows Disconnect one of the oil cooler hoses at the cooler and fill the cooler utilizing a suitable funnel reconnect the hose Fill the oil tank with approximately 2 litres of oil Disconnect the suction line from the oil tank and fill the oil hose with oil utilizing a suitable funnel Ensuring that the ignition is switched off crank the engine by hand a few turns the oil pump will suck the oil in Reconnect the oil suction line to the tank Crank the engine with the starter with the ignition off until a steady minimum oil pressure is indicated on the oil pressure gauge Start the engine and observe oil pressure it must rise within 10 seconds to at least 2 bar 30 psi If the pressure does not rise stop the engine straight away and prime the oil system again CAUTION When conducting any checks do not run the engine at high power settings without having suitably secured the aircraft against unwanted movement For monowheel aircraft it is strongly advised to tie the tailwheel down to prevent the possibility of nosing over Aft
38. s set tighten the bolts 20 inch pounds at a time starting with the bolts nearest the centre and working outwards After tightening the bolts check that the blade angle setting has not altered Turn the propeller to the next blade and repeat the sequence After the last blade has been set check that the others have not been disturbed Don t accept a mismatch between blades of an angle any more than 15 minutes Having satisfied yourself that the blades are within acceptable limits wirelock the six propeller securing bolts in pairs See the inset diagram in the main figure Run the engine to check that the desired static R P M is achieved then install the spinner checking it for concentricity Warning If is imperative that special care is taken in the attachment of the spinner If it is not securely fastened and departs the aircraft in flight it will destroy the propeller which could result in failure of the engine mounting Page 8 3 Europa XS Rotax 914 Engine Manual Issue 4 September 2001 Because the propeller is delivered disassembled and because there will be small variations between individual spinners it is important that the propeller spinner combination is dynamically balanced This operation is normally carried out by specialists who have the requisite equipment and expertise Balance To avoid damage to engine parts instruments etc it may be necessary to balance the propeller spinner assembly Dynamic balancing is r
39. stance from the rear bulkhead s rear flange to the radial centre line for the front bulkhead screws Mark a line around the spinner for the front screw radial centre line then mark off six equally spaced centres around the circumference Drill through both the spinner and the front bulkhead flange with a 4 8mm drill at the six centres then install MS21047 3 anchor nuts to the bulkhead using TAPK 33 BS rivets The spinner is now ready for installation with screws however the propeller pitch must be set beforehand Propeller pitch The relationship between propeller pitch and aircraft performance is something which will vary slightly between aircraft so a certain amount of experimentation will be required to establish individual aircraft performance figures Also individual requirements such as runway length available will influence the final propeller setting used It is suggested that you set the Warp Drive 64 diameter propeller with non tapered blades to 21 pitch angle initially Whichever fixed pitch or ground adjustable propeller is fitted when the aircraft is stationary and the engine is at full throttle you should see a minimum of 5200 rpm Check also that no more than 5600 rpm is reached at 115 throttle The blade angle referred to is the angle between the propeller s rotational plane and the flat rear surface of the blade at the propeller tip Ensure that all blades are within 1 4 of ech other Make any subsequent
40. to the footwell and check that the lower cowling will fit The gap between the lower cowling and edges of the assembly is bridged with strips of fabric reinforced rubber sealing riveted to it using TAPD46BS rivets It is probably best to leave attaching the seal until the cowlings are properly attached With the air filter compartment in place check that the filter itself fits On early kits it will be necessary to enlarge the hole to allow the filter to pass through and engage fully onto the compressor inlet Holes for the oil breather hose from the neck of the oil tank static pressure sensor tube and for the wastegate cable to enter and exit the compartment are required Page 4 5 Europa XS Rotax 914 Engine Manual Issue 4 September 2001 Sx ANS2StoR8 BATS THROUGH lt STAREOAKD footie INTO MS24042 5 NUTS WITH ANS70 3 WASHERS Fig 6 Air filter chamber detail Fig 7 Top view of air filter chamber Page 4 6 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual Fig 8 Lower view of air filter chamber Indication of where these holes should be are shown in the diagram however actual positions are best determined on the actual aircraft Remember to use grommets in the holes to avoid chafing After final fitting of the air filter compartment secure the static pressure sensor tube so that its end is about 4 5 cm within it The oil breather hose should be routed so it can continuously drain Arranging it so that it ve
41. uct using TAPD46BS rivets with EUR011 load spreading washers to prevent the rivets pulling through the sealing material The assembled duct is fitted to the footwell using three bolts each side The height and angle of the duct should be arranged to provide a clearance underneath the exhaust silencer of approximately 5 mm and be arranged to fit the air intake opening in the lower cowling See figure 2 Fig 2 Approximate position of duct A single AN3 5A bolt screws the side of the duct onto the inside face of the footwell using an MS21047 3 anchor nut installed in reverse into the footwell using TAPK 36 BS rivets to make it nearly flush the brackets CD4 and CDS are then bolted to the duct and to the front faces of the footwell again using AN3 5A bolts these should have AN970 3 washers to spread the load into the fibreglass structure and MS21042 3 stiffnuts Page 4 2 June 2004 Issue 7 Europa XS Rotax 914 Engine Manual Figure 3 illustrates the mounting of the duct and the coolers BULKHEAD Eb DETA L CDS COOLANT RADIATOR Fig 3 Installation of duct and coolers Page 4 3 Europa XS Rotax 914 Engine Manual Issue 4 September 2001 The photographs figures 4 and 5 illustrate the duct installation To ensure adequate cooling it will be necessary to blank off the gap between the bottom of the radiator and the lower cowling Fig 4 Side view of duct Fig 5 Front view of duct showing radiator non typical e
42. uropa XS Rotax 914 Engine Manual Engine serial no Note This check list only covers specific items for inspection of the Europa aircraft General inspection must be carried out in addition to these items Items covered in the inspection stages during construction are not included in this list The inspector should check and initial each separate item of these inspection sheets Duplicate check items require a second signature For aircraft registered with the L A A a copy must be sent to the Engineering Department of the L A A The following checklist covers specific items which should be checked along with the overall inspection Check that the engine complies with all Rotax mandatory bulletins issued to date The engine may be new but a bulletin or two may have been issued since the engine was built or since purchase General Check incorporation of Mod 72 Undercarriage Mounting Frame Reinforcement Check clearance between the engine mounting frame and the moving parts CS21 of the rudder and cable installation Check that the cooling opening for the turbocharger is present in the cooling duct Verify that the coolant mixture is 50 50 glycol water in accordance with the Rotax Operators Handbook and Service Bulletin SB3UL97R1 Mounting bolts Check that a total of four washers are present on each bolt whether used between engine mount and landing gear frame to adjust engine orientation or
43. xhaust shown Oil cooler The oil cooler is mounted behind the radiator and is bolted to the duct top plate CD1 with four AN4 5A bolts and MS21042 4 stiffnuts Two unions are supplied one straight and one right angled Fit these so that the straight fitting is on the starboard side To improve oil cooling in hot climates the oil cooler can be lowered approximately 2 SOmm so that it fits against the lower cowling use longer bolts with appropriate spacers In this case the blanking plate fitted below the radiator will not be needed For details of the oil system connections see the schematic view at figure 9 at the end of this chapter Page 4 4 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual Connect one side of the oil cooler to the 90 union fitted to the oil tank and the other side of the oil cooler to the oil pump inlet using the pre formed hose C06 Trim the short straight section to attach the hose to the pump inlet so that the hose is the maximum distance from the right hand exhaust pipe The hose runs aft and up to go over the rear cylinder water hose under the starter motor and inside the ring mount thence it goes down to the radiator on the opposite port side Connect the oil sump drain at the bottom of the engine to the tangential fitting on the oil tank For this connection use the hose marked Conti supplied with the Rotax engine Set the banjo union at the bottom of the engine to point to the right
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