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INSTALLATION MANUAL - Contrails

1. INSTALLATION MANUAL 26 00121 fi i AS 21 7 A A 12 77 X 14 37 RS NO A Sr 25 1 EI 1 00123 Cyl 4 2 h lt L 30 21 00124 Jm tj 2 i 39 s 00122 gt i p 62 Effectivity 914 Series page 22 Edition 1 Rev 0 Juli 01 2006 03188 03188 BRP Rotax INSTALLATION MANUAL 8 Technical data To maintain clarity only data relevant for engine installation and operation will be stated in the Manual NOTE Connecting dimensions filling capacities drive and reduction ratios elec tric output etc can be found in the respective chapter of engine installation or other relevant engine documentation see chap 4 4 8 1 Operating limits 1 Engine speed see Operators Manual 914 Series chap 10 1 2 Manifold pressure see Operators Manual 914 Series chap 10 1 3 Acceleration
2. 20 40 60 80 100 120 140 160 C 00327 CAUTION Thegraphresistance overtemperature has been determined and is effective at the following conditions only ambienttemperature 20 C 68 F tolerance 10 Effectivity 914 Series page 111 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 23 2 Sensor for oil temperature See fig 73 74 location oil pump housing marking 2 marked with TO on oil pump flange CAUTION Toavoidany mix up with indication wiring mark this particular cable also with TO position of the temperature sensor 1 on the oil pump flange support mm mm mm connection of sensor wiring spade terminal 6 3 x 0 8 to DIN 46247 grounding via engine block graph of sensor resistance over temperature CAUTION The graph resistance over temperature has been determined and is effective at the following conditions only ambienttemperature 20 C 68 F tolerance 10 BRP Rotax offers a non certified temperature indicating instrument Referto Illustrated Parts Catalog latest issue A WARNING Certification to the latest requirements such as FAR of EASA has to be conducted by the aircraft manufacturer Q 00227 00226 20 40 60 80 100 120 140 59 Effectivity 914 Series page 112 Edition 1 Rev 0 Ju
3. 56 13 5 1 Oilcircuit ENGINE ilies 56 13 5 2 Oil circuit turbo charger 57 19 5 8 58 13 6 Feasible position and location of the oil tank 59 13 7 Feasible position and location of the 60 13 8 General notes on oil 60 13 9 Filling 60 13 10 Venting purging or priming of lubrication system 61 13 10 1 Venting purging or priming of turbocharger lubrication system 62 13 11 Inspection for correct venting priming of hydraulic valve tappets 62 13 12 Replacement of components 63 14 Fuel ee ne ee Cee eee ere eee ee 65 14 1 Description of system iii 65 14 2 Operating limits sise 66 14 3 Requirements of the fuel 66 14 4 Connecting dimensions location of joints and directives for installation 67 14 41 Electric fuel PUMP sert co ero ces ibat ene cut eS Re pe a t 67 14 4 2 Fuel pressure control 69 14 5 Notes on checking of fuel 69 15 Carburetor oe rm enn 71 15 1
4. sas ns en max 20 mm 3 4 tightening torque of the banjo bolts M10x1x19 15 Nm 133 in lb CAUTION Utilize the full slip on length at hose joints Secure hose with suitable screw clamp or by crimp connection NOTE The control of the fuel pressure is achieved by a valve activated from a diaphragm Reverence pressure is the boost pressure in the airbox Any arrows shown on top of the fuel pressure control are of no significance for this application 05740 14 5 Notes on checking of fuel pressure See fig 34 There is no standard connection provided to measure the full pressure For general observation and at engine troubles fuel pressure readings would be helpful A feasible connection would be an additional hose nipple 4 6 1 joined to the fuel line Effectivity 914 Series Edition 1 Rev 0 remove banjo bolt M10x1x19 Fit additional hose nipple with integrated orifice 1 and 2 sealing rings 3 by use of a longer banjo bolt 4 M10x1x30 Tightening torque of the banjo bolt 15 Nm 133 in Ib CAUTION Attightening of the fuel lines 2 support the specific line to prevent any internal stresses NOTE The fig 34 shows the additional ring hose nipple connected to fuel line of carburetor 1 3 1 This ring hose nipple may be also fitted on the fuel line 2 4 7 but not on the outlet 5 and inlet 6 All the necessary items are available
5. 12mm 47 in n slip on length max 24mm 94 25 SEG tightening torque 25 Nm 220in Ib 4 CAUTION The oil tank cap is additionally marked with the term IN oil inlet 6 from crank case OUT oil outlet 7 to oil mi cooler oit tank See fig 28 05081 1x venting nipple 9 outside dia 2 23 8 mm 31 in slip on length max 15mm 59 Connection for circuit turbo charger hose nipple 10 4 6 DIN 7642 outside dia assetto 8 mm 31 in slip on length max 20mm 79 tightening torque of the banjo bolt 11 M10x1x19 15 Nm 133 in Ib NOTE In the standard supply volume the connection 12 is closed by the plug screw 13 This screw plug has to be removed and is replaced by the hose nipple 10 sealing ring 14 10x14 DIN 7603 and banjo bolt 11 Effectivity 914 Series page 58 Edition 1 Rev 0 Juli 01 2006 03191 03191 BRP Rotax INSTALLATION MANUAL 13 6 Feasible position and location of the oil tank See fig 29 The longitudinal axis z3 to be parallel to z axis of the system of coordinates Tolerated deviation of parallelism 10 NOTE Above notice is valid for both planes The oil tank 1 has to be positioned in its z axis such that the oil level 2 is always between 0 and 400 mm 15 75 in on the z axis A WARNING At higher location of the oil tank oil might trickle throu
6. 250 cm 2 m coolant hose 18 mm inside dia 500 cm total coolant quantity in engine approx 1 51 0 4 gal US Effectivity 914 Series page 43 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 12 9 Feasible location of radiator See fig 20 The expansion tank 1 must always be positioned at the highest point of the cooling system CAUTION If necessary the radiator outlet opening 8 may be max 1 5 5 ft above or below water inlet bend 5 on water pump see fig 20 NOTE On the standard engine version the expansion tank 1 is fitted on top of the engine see fig 20 N max 250mm max 9 84 in 2 HL 1 5 max 59 05 in 04872 For proper operation of the cooling system the expansion tank 1 with pressure cap 2 has to remain for all possible engine positions on the highest point of the cooling circuit A WARNING The oil cooler has to be planned and installed such that the specified operating temperatures are maintained and the max values are neither exceeded nor fall below This state has to be warranted for hot day conditions too If need be take appropriate measures like changing size of cooler partial covering of cooler etc Additionally the system needs an overflow bottle 7 where surplus coolant is collected and returned back into the circuit at the cooling down period NOTE For proper ope
7. js8 0 2 epo j LZE 187 6 D e e i i Ni CAUTION amp To 1135 9 9 WARN Wiring symbols to DIN 40712 40713 40716 and 40719 m 77 Verbraucher consumer Effectivity 914 Series page 90 Edition 1 Rev 0 Juli 01 2006 03195 03195 BRP Rotax INSTALLATION MANUAL 19 3 Description of the Turbo Control Unit TCU See latest Operators Manual 914 Series chapter 9 5 19 4 Technical data and connection of the electric components 19 4 1 Integrated generator See fig 55 ing 19 4 2 Rectifier regulator See fig 56 57 type electronic full wave rectifier regulator effective voltage 14 0 3 V from 1000 250 r p m current limit max 22 A max permissible Feeding wires 1 from the generator to rectifier regulator on left side of ignition housing see fig 55 2flexible cables 1 5 yellow in shielding metal braid length approx 660 mm 26 in starting from ignition hous with on each plug socket 6 3 x 0 8 to DIN 46247 NOTE approx 250W AC output at 5800 r p m For DC output in connection with rectifier regulator see chapter 19 4 2 componenttemperature 80 C 176 F measured in area 1 weight 0 3 kg 66 Ib Description of connections G R B L Es Effectivity 914 Series Edition 1 Rev 0
8. NOTE With suspension on the 4 top lugs R3 L4 and 4 only the tilting moment due to the pull of the propeller will be avoided while if attached on the bottom lugs only the moment of tilting has to be taken care of accordingly WARNING rubber mounts to neutralize vibrations and all the engine sus pension components not in the supply volume must be ground run tested to the specified loads and for vibration behaviour Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer CAUTION The engine suspension has to be designed to prevent any excessive engine movement and to minimize noise emission and vibration on air frame side See also SL 912 010 Identifying abnormal vibrations on aircrafts latest issue 003189 Effectivity 914 Series page 31 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES 003189 Effectivity 914 Series page 32 Edition 1 Rev 0 Juli 01 2006 003189 BRP Rotax INSTALLATION MANUAL 11 Exhaust system See fig 15 The complete exhaust system is in the volume of supply and is certified together with the engine WARNING Ifthe ROTAX exhaust system is not employed or if modified certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Modifications are permissible only if agreed with by BRP Rotax NOTE As an exception the exhaust tail pi
9. Calculated values maximum values found for coolant temperature and cylinder head temperature Refer to the current specification of the FAA and or EASA Coolant temperature 102 C 216 F Cylinder head temperature 110 C 230 F The cylinder head temperature is 8 C higher than the coolant temperature Thus Coolant temperature Ines 120 C 248 F Difference cylinder head and coolant temperature __8 C 46 F 128 C 262 F The highest cylinder head temperature permitted is 128 C 262 F so that the max coolant temperature is kept With this special application safe operation of the engine that prevents boiling of the coolant is possible up to a cylinder head temperature of 128 C 262 F CAUTION This cylinder head temperature with the limit found for this type must be displayed constantly in the cockpit The indicating instrument and the manuals must be changed to cylinder head temperature max 128 C 262 F CAUTION design of the radiator installation must be changed example cowl modifications such that the operating temperature will not exceed the specified limits Effectivity 914 Series page 40 Edition 1 Rev 0 Juli 01 2006 403190 03190 BRP Rotax INSTALLATION MANUAL 12 6 Requirements on the cooling system CAUTION All components of the cooling system have to secured siutably A WARNING Thesize and layou
10. see Operators Manual 914 Series chap 10 1 4 Critical flight level see Operators Manual 914 Series chap 10 1 5 Oil pressure see Operators Manual 914 Series chap 10 1 6 Oiltemperature see Operators Manual 914 Series chap 10 1 Cyl head temperature see Operators Manual 914 Series chap 10 1 8 Exhaust gas temperature see chapter 11 1 9 Airbox temperature see chapter 16 1 10 Range of starting temperature ji PRENNE 50 C 122 F FIGs A 25 C 13 F 11 Fuel pressure see Operators Manual 914 Series chap 10 1 12 Banking of plane deviation from the effective vertical See Operators Manual 914 Series chap 10 1 The engine design is for a conventional non aerobatic fixed wing tractor or pusher type configuration with the oil return port in the optimum position see chap 13 5 With this consideration the engine is properly lubricated in all flight profiles pitch or roll B current bank angle F1 gravity F2 acceleration Fr result of F1 and F2 04849 07191 The resulting bank angle depending acceleration deceleration may never exceed the max bank angle NOTE Pitch or role angle a is not equal with except stabilized condition without acceleration Effectivity 914 Series page 23 Edition 1 Rev 0 Juli 01 2006
11. BRP Rotax INSTALLATION MANUAL 8 2 Installation dimensions all dimensions in mm See fig 2 3 4 NOTE Dimensions to point of reference P See fig 2 3 4 Standard engine version pos neg total gt 656 6 665 1 576 0 531 0 8 3 Weights Weight of engine defined to the following conditions 04858 Engine dry from serial production with int alternator with overload clutch without fuel pumps see chapter Description of design Engine weight Version 2 4 71 7 kg 158 Ib Version 74 4 kg 164 Ib Weight of external generator assy 3 0 kg 6 6 Ib overload clutch 1 7 kg 3 7 Ib vacuum pump assy 0 8 kg 1 76 Ib hydraulic governor assy 2 7 kg 6 Ib ADS Nes additional 0 43 kg 1 Ib 8 4 Centre of gravity of engine and standard equipment See fig 2 3 4 engine from serial external hydraulic vacuum production alternator governor pump centre of gravity in x axis mm centre of gravity in y axis mm centre of gravity in z axis mm 102 6 s 56 NOTE Dimensions to point of reference P See fig 2 3 4 8 5 Moments ofinertia See fig 2 3 4 engine version 2 4 3 moment of inertia around 20 470 21210 axis x1 x1 kg cm moment of inertia aro
12. yellow from generator red to battery positive terminal battery positive terminal warning lamp circuit control or field circuit page 91 Juli 01 2006 BRP Rotax INSTALLATION MANUAL Requirements for flawless operation of the rectifier regulator the rectifier regulator has to be protected by a slow blowing 25A fuse wire size of the main circuit of at least 2 5 mm 14 AWG acapacitor fig 52 Pos 25 of at least 22 000 pF 25 V is necessary B CAUTION The voltage difference between battery and terminal C of regulator should be less than 0 2 V Use cables in this area as short as possible and with ad equate cross section CAUTION Never sever connection between terminal C and B of regulator e g by removal of a fuse During engine stop break circuit between battery and termi nal C to avoid discharge of battery NOTE A charge indicating lamp 3W 12V fig 52 pos 36 may be fitted on the instrument panel Current CAUTION The graph current over engine speed has been determined and is valid only at the following conditions ambient temperature 20 C 68 F VONAGE permanent 13 5 V tolerante max 5 HL 1 1000 2000 3000 4000 5000 6000 1 20 10 2 02500 Effectivity 914 Series page 92 Edition 1 Rev 0 Juli 01 2006 03195 03195 BRP Rotax INSTALLATION MANUAL 1
13. 107 21 1 Technical data i rie RUE eben 107 22 Hydraulic governor for constant speed propeller 109 22 1 Technical data 109 23 Connections for instrumentation 111 23 1 Sensor for cylinder head 111 23 2 Sensor for oil temperature si 112 23 3 Oil pressure Sensor b etatis 113 23 4 Mechanical rev counter tach drive 114 23 5 Monitoring of the intake manifold pressure ssssssen 115 23 6 Air temperature in the airbox optional 115 24 Preparations for trial run of engine en 117 25 BRP Rotax Authorized Distributors for Aircraft Engines 119 Effectivity 914 Series page 5 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 6 Juli 01 2006 d03186 d03186 2 Index A Acceleration 23 Air intake system 71 Air temperature in the airbox 109 Airbox 74 Airfilter 74 Attachment points 28 Auxiliary equipment 20 B Bankangle 23 Battery 97 Carburetor 65 Caution light 93 Coarse filter 60 Connection of electric rev counter 96 Connections cooling system 38 Connections oil circuit 52 Connections carburetor 66 Connections for instrumentation 105 Coolant capacity 40 Cooling system 35 Critical flight level 23 Cu
14. INSTALLATION MANUAL FOR ROTAX ENGINE TYPE 914 SERIES ROTAX 914 UL 3 WITH OPTIONS part 897816 BRP Rotax INSTALLATION MANUAL These technical data and the information contained therein are property of BRP Rotax GmbH amp CO KG and must not be reproduced neither entirely nor partially and passed to third parties without previous consent in writing by BRP Rotax GmbH amp CO KG This text must be written on every complete or partial reproduction The Manual must remain with the engine aircraft in case of sale WARNING Before starting with engine installation please read the Installation Manual completely as it contains important safety relevant information Approval of translation has been done to best knowledge and judgment in case the original text in the German language is authoritative Effectivity 914 Series page 2 Edition 1 Rev 0 Juli 01 2006 d03186 d03186 BRP Rotax INSTALLATION MANUAL 1 Table of contents 1 Table of Contents 3 NE aaa e ee E 7 MM cl CL Pee re 9 MARS 9 3 2 Engine serial number suisses 9 4 Safety ee een 9 4 1 Repeating 10 4 2 Safety information iii 10 4 3 INSTUCTIOME 5 12 4 4 Technical documentation si 13 5 List of the effective Pages cn msscmesrmarsnesreersseisenennntete 15
15. Route the lines without kinks and avoid tight bends Route the lines with a continuous decline The lines have to be protected against any kind of blockage e g by formation of ice CAUTION With closed or blocked leakage piping fuel could end up on exhaust system RISK OF FIRE Connecting nipple 2 for leakage line outside dia 6 mm 1 4 slip on length max 17 mm 11 16 Effectivity 914 Series page 71 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 15 2 Connections for Bowden cable actuation and limit load See fig 36 37 connection for throttle actuation 1 connection on throttle lever set screw M 5x12 tightening torque 4 Nm 35 suitable for 1 5 mm 06 in steel wire action travel 65 mm 2 1 actuating force min 1 5 3 Ib max 8 N 1 8 Ib limit load 20 4 5 Ib NOTE Throttle opens by spring connection for starting carb choke actuation 2 connection on choke lever clamping nipple 6 suitable for 1 5 mm 06 in steel wire action travel 23 mm 9 6 actuating force min 10 N 2 2 Ib max 45 N 10 Ib limit load 100 N 22 Ib Directive for choke actuation The choke shaft 3 is marked 4 This mark has to point towards cable engagement 5 d03193 Effectivity 914 Series page 72 Edition 1 Rev 0 Juli 01 2006 903193 BRP Rotax
16. current connections 1 M6 screw tightening torque 4 Nm 35 in Ib suitable for ring terminals to DIN 46247 MIL T 7928 control wiring 2 plug connector 6 3x0 8 suitable for spade connector to DIN 46247 MIL T 7928 grounding via housing CAUTION Activation of start relay limited to short duration Over a period of 4 min operation the duty cycle is 25 02503 Effectivity 914 Series page 95 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 19 4 7 Electric fuel pumps See fig 61 62 installation see fuel system chapter 14 voltage 12 V DC connections terminal M 4 screw connection terminal M 5 screw connection suitable for ring terminals to DIN 46225 For radio interference suppression a capacitor fig 52 Pos 41 of 1UF 100 V has to fitted as near as possible to the terminals A WARNING certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer current input 3 0A 2 5 ToO mT e 2 0 fig 62 connector 0 250 500 750 1000 1250 hPa Ap The current input per fuel pumps by one fuel pump 1 7A by two fuel pumps Series 1 5 The diagram shows the current input over pressure Take note of the following The diagram outlines minimum capacity at nominal voltage on pump Pressure and suction head are ZERO Graph is effective on a seasoned pump only r
17. 1 5 turn with ring spanner Effective thread length max 17 mm 9 16 net weight 0 8 kg 1 Ib power input max 300 W delivery rate max 0 165 dm 10 in per minute at 0 65 bar 10 p s i as from 1900 rpm pump speed CAUTION attention to manufacturer s specifications NOTE Speed reduction from crankshaft to vacuum pump is 1 842 i e the vacuum pump runs with 0 54 of engine speed A WARNING Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Effectivity 914 Series page 107 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 108 Juli 01 2006 03196 03196 BRP Rotax INSTALLATION MANUAL 22 Hydraulic governor for constant speed propeller 22 1 Technical data See fig 70 Design Woodward governor A210786 for engine design 3 only drive via prop gear Location of centre of connection Axes x axis y axis Z axis mm mm mm 04867 cable connection see fig 70 cable travel approx 54 mm 2 1 8 min Steigung 90 minimum pitch DS 5 oE 00556 actuating force approx 3 during operation at max speed 67 Ib limit load 6 1 35 Ib power input max 600 W operating pressure max 30 bar 435 p s i weight 1 44 kg 3 2 Ib 2 7 kg 6 Ib inclusive drive unit NOTE Reductio
18. Effectivity 914 Series Edition 1 Rev 0 date of change 2006 07 01 remark for approval date of approval from authorities date of inclusion 00568 signature page 17 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 18 Juli 01 2006 03187 03188 BRP Rotax INSTALLATION MANUAL 7 Description of design 7 1 Designation oftype Basic type e g ROTAX 914 version 2 version 2 with prop flange for fix pitch propeller version 3 with prop flange with drive of hydraulic governor for constant speed propeller version 4 with prop flange for fix pitch propeller but prepared for retro fit of hydraulic governor for constant speed prop Optional extras to the above stated basic type external vacuum drive for rev counter governor alternator pump hour meter for version 2 yes ye vws m for version 3 ye no ye for version 4 yes yes vws w NOTE Conversion of the version 2 4 to version 3 may be accomplished by BRP Rotax Authorized Distributors or their Service Center 7 2 Standard engine design 4 Stroke 4 cyl horizontally opposed spark ignition engine with turbo charger single central camshaft hydraulic tappets push rods OHV liquid cooled cylinder heads ram air cooled cylinders dry sump forced lubrication dual ignition of breakerless capacitor discharge design
19. INSTALLATION MANUAL 10 1 Definition of attachment points See fig 9 10 fig 10 2 03201 VA aen 49 n lt SNIT z 1113 NS Ap lt R3 f 4 is AE N ROTAX ROTAX HT L2 m7iR2 ME _ Wh E39 1 EA vz max usable TE EURO engl max usable 25 2 thread length up gearbox s n 28986 07137 04829 Pm oom tom tom point mm mm mm 14 282 870 00 R4 1283 870 00 2 starting from gearbox s n 28987 A WARNING The engine suspension to be designed by the aircraft or fuselage builder such that it will carry safely the maximum occurring opera tional loads without exceeding the max allowable forces and mo ments on the engine attachment points 04862 04861 attachment point max allowable forces limit load in N in x axis 5 000 max allowable bending moment limit load in Nm 100 in x y and 7 axis A WARNING Tighten all engine suspension screws as specified by the aircraft manufacturer d03189 Effectivity 914 Series page 28 Edition 1 Rev 0 Juli 01 2006 003189 BRP Rotax INSTALLATION MANUAL 10 2 Permissible fitting positions See fig 11 12 13 To simplify the
20. aminimum flow rate of 300 m h 390 has to be warranted for all conditions the pressure loss must not exceed 15 hPa CAUTION Noadditional forces ormoments are allowed on turbo charger or airbox therefore the intercooler has be supported inde pendent and free of vibrations CAUTION Check the CO emission when installing an intercooler and adjust the jeting if necessary A WARNING Thecertification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer n ath Effectivity 914 Series page 79 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 16 2 2 Airfilter CAUTION minimum flow rate of 6 23 m min 220 cfm has to be warranted for all conditions The pressure loss must not exceed 5 hPa A WARNING Use only filter elements which will not tend to restrict the flow when in contact with water 16 2 3 Airbox See fig 44 The airbox is furnished with 2 drain holes at the lowest position possible The holes are necessary to drain fuel from flooding float chambers caused by badly closing float valve NOTE This drain bores are very small 1 5 mm 1 16 dia Com pensation of process conditions is taken care of by the TCU Drainage lines WARNING Connect draining lines without fail otherwise emerging fuel could drip onto
21. bottle latest issue The shape size and location of one or more radiators depend mainly on the space available On good installation in the airplane the radiator has enough cooling capacity to keep the specified operating limits Also the flow of coolant liquid through the radiator is not restricted No provision is made for attachment of the radiator s on the engine CAUTION Install the radiator nondistorted and free of vibrations At installation of a non original ROTAX radiator take care of sufficient cooling capacity See chapter 12 7 Effectivity 914 Series page 35 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 12 2 Operating Limits Using conventional coolant Coolant temperature coolant exit temperature 120 C 248 F Cylinder head temperature te ere ere eerste 135 C 275 F Permanent monitoring of coolant temperature and cylinder head temperature is necessary Using waterless coolant Cylinder head temperature renee eee eee 135 275 F Permanent monitoring of cylinder head temperature is necessary WARNING The cooling system has to be designed so that operating temperatures will not be more than the maximum values Monitoring the cylinder head temperature is important to control the engine cooling and prevents detonation within the operating limits It is also necessary to design the cooling circuit s
22. 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 20060701 20060701 20060701 2006 07 01 2006 07 01 2006 07 01 20060701 20060701 20060701 20060701 20060701 chapter 17 18 19 20 21 22 23 24 25 page 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 date 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 20060701 20060701 2006 07 01 20060701 20060701 20060701 15 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 16 Juli 01 2006 03187 03187 6 Table of amendments BRP Rotax INSTALLATION MANUAL Approval The technical content is approved under the authority of DOA Nr EASA 21J 048
23. 6 Table of amendments acct oc cereal tee tte ce cece 17 7 nent 19 7 1 Designation of type usines 19 7 2 Standard engine design eene nnne 19 7 3 Engine components engine views definition of main 21 BID ui ro 2 4 23 8 1 Operating limits ertet rie tiere ee ae etie three redes 23 8 2 Installation dimensions si 24 8 9 24 8 4 Centre of gravity of engine and standard equipment 24 8 5 Moments of inertia iine ine nne cae 24 9 Preparations for engine installation 25 9 1 WANS POF Tr SR octets ries 25 9 2 State of delivery tette th nasi aaea a eo danda eda na 25 9 3 Engine preservation sisi 25 9 4 Protective Covering suisses 26 10 Engine suspension and position 27 10 1 Definition of attachment points ss 28 10 2 Permissible fitting positions ssssssssssesseeeneeeneeenenneeen nennen nnns 29 10 3 General directives for engine suspension 2 31 11 Exhaust SySten 33 11 1 Operating limits hier 34 12 COOLING 35 12 1 Description of the 35 12 2 Operating limits edant raten nna EENE EA ER 36 12 3 CoolanttyD8S erret eret eate
24. For this reason it is recommended to assist the pilot with an visual manual arrange ment at setting for max cruise performance A detent on your throttle lever at max continuous power would be most suitable Provide this detent at throttle position 104 corresponding to 8 9 mm 5 16 11 32 travel before full throttle stop The sketch fig 39 depicts a feasible arrangement The throttle lever is pressed onto throttle gate and comes to a stop at max continuous power Against the spring force the throttle lever will be released from the detent and can be moved further to take off performance max Dauerleistung max continous power 104 Startleistung Take off power 115 Leerlauf Idle z 0 fig 39 07601 e CAUTION A Adjustable positive stops for idle and full throttle position are of course required These stops have to be designed such to render adjustibility and to prevent overload of the idle stop on the carburetor d03193 Effectivity 914 Series page 74 Edition 1 Rev 0 Juli 01 2006 903193 BRP Rotax INSTALLATION MANUAL 15 5 Location and determination of the throttle position for max continuous power It is a necessity for trouble free engine operation that the pilot can locate the exact throttle position for max continuous performance CAUTION manual determination e g a graduated disk is not precise enough and therefore not permitted The exact determi
25. Manual show the typical construction They may not represent in full detail or the exact shape of the parts which have the same or similar function Specifications are given in the SI metric system with the USA equivalent in parenthesis Where precise accuracy is not required some conversions are rounded off for easier use Effectivity 914 Series page 9 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 4 1 Repeating symbols This Manual uses the following symbols to emphasize particular information These indications are important and must be respected WARNING Identifies an instruction which if not followed may cause serious injury including the possibility of death CAUTION Denotes an instruction which if not followed may severely damage the engine or other component NOTE Indicates supplementary information which may be needed to fully complete or understand an instruction 4 2 Safetyinformation A WARNING Only certified technicians authorized by the local airworthiness authorities and trained on this product are qualified to work on these engines A WARNING Never fly the aircraft equipped with this engine at locations air speeds altitudes of other circumstances from which a successful no power landing cannot be made after sudden engine stoppage Unless correctly equipped to provide enough electrical power for night VFR according latest requirement as ASTM the ROTAX 912 UL ULS ULSFR i
26. a warning instrument in the cockpit for an under shooting of the coolant level Effectivity 914 Series page 41 Edition 1 Rev O Juli 01 2006 07136 NOTE BRP Rotax INSTALLATION MANUAL 200 10 mm ww OL 457 The picture shows ROTAX 912 Series but the location of the expansion tank is identical as on ROTAX 914 Series Effectivity 914 Series Edition 1 Rev 0 page 42 Juli 01 2006 03190 03190 BRP Rotax INSTALLATION MANUAL water inlet bend 5 outside dia 27 mm 1 1 16 slip on length max 19 mm 3 4 00562 Choose between six possible fitting positions of water inlet bend 5 appropriate to specific installation see fig The inlet bend is attached to the water pump by two Allen screws M6x20 and lock washers Tighten screws to 10 Nm 90 in Ib CAUTION Utilize total slip on length for hose connection Secure hoses with suitable spring type clamp or screw clamp 12 8 Coolant capacity cylinder N S nu 560 dan 100 cm expansion tank uoo eia
27. as spare parts page 69 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES 903192 Effectivity 914 Series page 70 Edition 1 Rev 0 Juli 01 2006 d03193 BRP Rotax INSTALLATION MANUAL 15 Carburetor See fig 35 The carburetors on the standard engine are already attached by a flexable flange Only connections of the Bowden cable for throttle and starting carb have to be established It is recommended to make the adjustment of the Bowden cable after engine installation has been completed to ensure exact final adjustment CAUTION In case this has not been taken care of verification of the throttle position is required prior to the trial run Refer to chapter 15 5 15 1 Requirements onthe carburetor The carburetors are positioned above the exhaust sockets Below the carburetors one each drip tray 1 with a draining connection 2 is fitted which acts as heat shield as well WARNING Inthe area of the float chamber the temperature limit of the fuel must not be exceeded If need be provide additional insulation or heat shields Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Drainage piping WARNING Connect draining lines without fail otherwise emerging fuel from a possible leakage could drip onto the exhaust system RISK OF FIRE The lines have to be routed such that in case of a damage the surplus fuel is drained off suitably
28. as specified consult Operator s Manual Exclusively use tools and supplementary materials as listed in the Illustrated Parts Catalog This Manual for engine installation is only part of the Technical Documentation and will be supplemented by the respective Opera tor s Manual Maintenance Manual and Spare Parts List Pay attention to references to other documentation found in various parts of this Manual Effectivity 914 Series Edition 1 Rev 0 page 12 Juli 01 2006 03187 03187 BRP Rotax INSTALLATION MANUAL 4 4 Technical documentation The information given in the Installation Manual Manual Maintenance Manual Line Maintenance Heavy Maintenance Overhaul Manual Illustrated Parts Catalog IPC Alert Service Bulletin Service Bulletins Service Informations Service Letter User Manual are based on data and experience that are considered applicable for professionals under normal conditions The rapid technical progress and variations of installation might render present laws and regulations inapplicable or inadequate The illustrations in this Manual are mere sketches and show a typical arrangement They may not represent the actual part in all its details but depict parts of the same or similar function Therefore deduction of dimensions or other details from illustrations is not permitted NOTE The illustrations in this Manual are managed in a graphic data base and
29. by mistake or unintentionally The fixed and secured position is ON switching voltage 100 V switching current min 2A place of installation On the instrument panel in the pilot s field of view anytime and easy to reach Installation instruction The isolating switch has to be installed directly into the lines from 36 pole plug receptacle to servo motor CAUTION The servo motor is connected to DC supply The polarity wire 2 and 14 of the cables must not be changed other wise the sense of rotation would be reversed and control would be rendered ineffective To avoid any mix up of the polarity cut first one wire and connect on switch as per wiring diagram fig 52 After first wire is connected sever second wire and connect also to switch Effectivity 914 Series page 98 Edition 1 Rev 0 Juli 01 2006 03195 03195 BRP Rotax INSTALLATION MANUAL 19 4 10 Boost lamp See fig 52 colour of lamp red or colour as per effective regulations voltage 12 V DC depending on input voltage of TCU current max 0 5A connections terminal flexible wire 0 75 mm 18 AWG white No 10 terminal flexible wire 0 75 mm 18 AWG white No 28 from the 36 pole plug receptacle of the TCU plug 6 3 x 0 8 to DIN 46247 length approx 600 mm 24 in from TCU CAUTION Donotconnectthe neg terminal to ground or the pos terminal to bus 12 volt each wire must be connected directly to
30. is supplied with the wiring completed and ready to operate Only the following connections to the aircraft have to be established NOTE Throughout this documentation as name for the electrical load pressure control TCU stands for Turbo Control Unit integrated generator external rectifier regulator electronic modules electric starter start relay 2 electric fuel pumps TCU isolating switch for servo motor 2lamps boost and warning lamp items conditional for operation like circuit breakers ON OFF switches control lamps relays instrumentation and capacitors Optional extras external alternator as option if the output of the integrated generator is inadequate electric rev counter accessory Effectivity 914 Series page 87 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 19 1 Requirements on circuit wiring CAUTION A WARNING CAUTION A WARNING A WARNING 19 1 1 The connections have to be completed by the aircraft manufacturer in accordance to effective certification and wiring diagram fig 52 The electromagnetic compatibility EMC and electromagnetic inter ference is greatly affected by the wiring and has to be checked for each installation Refer to chapter 19 1 1 The supply to the various consumers e g battery has to be pro tected adequately by fuses consult wiring diagram Using fuses too large may result in damage to ele
31. matter reference is made only to the 2 engine attachment points R1 L1 and the 2 turbo charger attachment points R T 2 and L T 2 Location of the 2 turbo charger attachment points R T 2 und L T 2 NOTE Alldimensions to point of reference P and the system of coordinates remain unchanged Pe point mm mm mm The following details of engine position are with reference to aircraft on ground ready for take off 04863 engine suitable for propeller in tractor or pusher arrangement propeller shaft above cylinders See fig 2 WARNING For upside down installation of the engine the lubrication system fuel system and the cooling system are unsuitable Longitudinal axis The centre of the attachment points L1 and L T 2 must be on axis x2 parallel to the x axis Allowable pitch deviation of parallelism of axes max 6 counter clockwise on ground max 10 counter clockwise in operation max 30 clockwise see fig 11 A WARNING installations with fuel tank located above carburetor level com bined with badly closing carb float valve fuel could pass into cylinders at more than 6 decline of propeller shaft axis after longer periods of downtime See FAR 33 17 7 To prevent a possible hydraulic shock NN at engine start ensure proper closing rr of float valves If in doubt park the pu aircraft with inclining propeller shaft axis SPA 1 is PR
32. pumps 2 with 2 check valve 6 connected in series From the pumps fuel passes on via the fuel pressure control 3 to the two carburetors Via the return line 5 surplus fuel flows back to the fuel tank and suction side of fuel system NOTE The fuel pressure control ensures that the fuel pressure is always maintained approx 0 25 bar 3 6 p s i above the variable boost pressure in the airbox and thus ensures proper operation of the carburetors On the standard version of the engine the fuel lines from fuel pressure control to the carburetors are already installed The fuel system from tank to the fuel pressure control has to be installed by the aircraft manufacturer The fuel system includes the following items tank 2 electric fuel pumps legend coarse filter as well as the required 1 fine filter watertrap fine filter watertrap fuel lines and connec gascolator i m tions 2 2 x electric fuel pump 3 fuel pressure control 4 feeding line from tank 5 return line to tank 6 2 x check valve 5 gt 2 2 Tort 4 TPL MAIN Cig 30 04852 Q fey 4 P 6 6 Only the following connections per fig 30 have to be established Feeding lines to suction side of the electric fuel pumps 2 lines from pressure side of the electric fuel pump to inlet of fuel pressure control 3 Returnline from fuel pressur
33. the servo motor has to be performed operating temperature min 20 C 4 F max 60 C 140 F dimensions and attachment see sketch fig 51 location of installation vibration neutralized place WARNING Installation in the engine compartment is not per mitted since the servo motor is not of a fire re sistant construction Arecommendable location is in the cockpit below the instrument panel NOTE Place of installation is lim ited by the length of the servo cable location of installation approx 1000 mm 40 from waste gate Effectivity 914 Series page 85 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 18 2 Servocable bending radius min 50 mm 2 Following temperatures must be measured on the positions set out in figure 51a and must not be exceeded during take off and after engine stop heat accumulation Pos Description Temperature 1 cable conduit max 120 C 250 F 2 cable support max 120 C 250 F 3 wire rope max 140 C 280 F CAUTION All temperature limits must be verified at the first time of installation of the ROTAX 914 into an airframe or at any modification of the airframe as it may influence such temperatures 02617 Effectivity 914 Series page 86 Edition 1 Rev 0 Juli 01 2006 03194 03195 BRP Rotax INSTALLATION MANUAL 19 Electric system See fig 52 The engine
34. to EGT measurement See chapter Exhaust system CAUTION Anychangesonthe air intake system e g modification on the airbox usage of an intercooler etc can affect the flow rate in the air intake system and the fuel mixture ratio Inthe course of certification the fuel mixture process must be proofed by a CO measurement Effectivity 914 Series page 77 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 16 2 Requirements on the air intake system WARNING Carbicingisa common reason for engine trouble No implements included in the supply volume for preheating of the intake air Because of the generated heat by turbo charging preheating of the intake air is possibly not necessary But an alternate air door or flap that draws air from the engine compartment is recommended as the air filter could possibly close by formation of ice Door or flap must be in front of turbo charger suction side Preheating of the intake air will result in performance loss because of the lower air density A WARNING All items of the air intake have to be secured against loss A WARNING The certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer Air intake socket 1 on turbo charger outside dia 60 mm 2 3 8 slip on length max 25 mm 1 CAUTION Utilize the full slip on length on all connection Secure hoses by suitable spring type
35. 2 constant depression carburetors and airbox 2 electric fuel pumps 12V DC prop drive via integrated gear box with torsional shock absorber and overload clutch optional on configuration UL2 UL4 Stainless steel exhaust system engine suspension frame expansion tank coolant electric starter or starter with extended power output integrated AC generator with external rectifier regulator Effectivity 914 Series page 19 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL oil tank external start relay hydraulic governor for constant speed prop on version 3 only Auxiliary equipment optional CAUTION equipment not included as part of the standard engine version and thus not a fix component of the engine is not in the volume of supply Components especially developed and tested for this engine are readily available at BRP Rotax Following auxiliary equipment has been tested on ROTAX engine type 914 for safety and durability to the standards of aviation The furnishing of proof in accordance to the latest FAR or EASA has to be conducted by the aircraft manufacturer external alternator vacuum pump feasible on version 2 and version 4 only drive for rev counter hour meter Oil cooler with connections coolant radiator coolant overflow bottle Following equipment has not been tested for safety and durability to the standards of aviation WARNING The user ass
36. 3 11 mm e 43 length up to 2 6 6 min 12 mm 47 length up to 10 13 mm e 51 Length of a single oil line 118 11 in Cil circuit turbo charger suction pump Temperature durability mind 130 C 266 F Pressure durability mind 10 bar 145 p s i Bending radius mind 70 mm 2 75 in unless otherwise stated by the hose manufacturer Minimum inside dia of oil lines in reference to total length length up to 1m 3 3 min 6 mm e 23 length up to 2 m 6 6 min 7 mm 0 27 Vent line of oil tank See fig 22 Route the line without kinks and avoid sharp bends NOTE Water is a by product of combustion Most of this water will dissipate from the combustion chamber with the exhaust gases A small amount will reach the crankcase and has to be disposed through the vent line of oil tank via oil return line The venting line must be routed in a continuous decline or furnished with a drain bore at it s lowest point to drain possible condensate Theventline has to be protected from any kind of ice formation in the condensate Protection by insulation or routing in a hose with hot air flow or by furnishing vent line with a bypass opening 1 before passing through cowling 2 See fig 23 O4874 Effectivity 914 Series page 55 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 13 5 Connecting dimensions and locatio
37. 9 4 3 Electronic modules See fig 4 58 Ambient temp for the electronic modules 1 80 176 F 19 4 4 Ignition switches on off switch See fig 58 and 58 1 Wires to on off switches on the electronic module see fig 58 type two separate suitable on off switches fig 52 pos 33 switching voltage min 250 V switching current min 0 5 A one each flexible wire 0 75 mm 18 AMG brown length approx 35 mm 1 3 8 beginning at electronic module with one each plug socket and insulating sleeve 3 96 mm At the new version the cable grommet and faston connector are integrated in the 6 pole connector housing See also SI 914 016 latest issue NOTE One each cable grommet and flat pin terminal are supplied loosely packed Faston connector and insulation sheath of the old version are available as spare part See also SI 914 016 latest issue Wire of top electronic module marked A for ignition circuit A Wire of bottom electronic module marked B for ignition circuit B NOTE Ignition circuit A controls top spark plugs of cylinders Ignition circuit B controls lower spark plugs of cylinders B CAUTION Theelectromagnetic compatibility EMC and electromag Effectivity 914 Series Edition 1 Rev 0 netic interference EMI depends essentially on the wire used See fig 58 1 Min section area 2x0 75 mm 18 AMG shielded flexible cable shielding braid on
38. E BRP Rotax developed especially for this application a non certified electric rev counter Certification to the latest re quirements such as FAR or EASA has to be conducted by the aircraft manufacturer See also SI 13 1996 latestissue CAUTION The graphs depicting output signals have been determined and are effective only at the following conditions Ambient temperature 20 C 68 F Tolerance 5 The pick up for the rev counter generates one pulse per revolution Pulse shape and pulse voltage as per recordings oscillogram speed 500 rpm load 100 Q speed 500 rpm load 100 kQ V V RS D NO fig 67 V 1 e 1 rev bg pe 00219 e speed 6000 rpm load 100 Q speed 6000 rpm load 100 kQ V 100 50 0 50 100 1 Umar rev 150 360 2 1 rev Effectivity 914 Series page 102 Edition 1 Rev 0 Juli 01 2006 03195 03195 BRP Rotax INSTALLATION MANUAL 19 4 14 Battery See fig 52 CAUTION To warrant reliable engine start use a battery of at least 16 Ah capacity 19 5 Internal consumer of electric power WARNING The power consumption of extra users has to be limited to the extent that the internal need of power e g for fuel pumps is always covered Refer to graph current output over speed of the integrated generator and th
39. INSTALLATION MANUAL 15 3 Requirements on cable actuation See fig 38 The two throttles have to be controlled by two separate Bowden cables working synchronously Adjust the cables to a free travel of 1 mm 04 in WARNING With throttle lever not connected the carb will remain fully open The home position of the CD carburetor is full throttle Therefore never start engine without connecting throttle lever first A WARNING Route Bowden cable in such a way that carb actuation will not be influenced by any movement of engine or air frame thus possibly falsifying idle speed setting and carb synchronisation Adjust Bowden cable such that throttle and choke can be fully opened and closed Use Bowden cable with minimized friction so that the spring on the throttle can open the throttle completely Otherwise increase preten sion of spring by bending lever flap 1 or fit a stronger return spring 2 or a cable with pull push action would have to be used Effectivity 914 Series page 73 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 15 4 Requirements on the throttle lever See fig 39 From throttle position 108 to 110 the boost pressure rises rapidly and the throttle becomes very sensitive in this range Therefore try to prevent operation in this small range or if setting for take off performance pass this range quickly Consult also the chapter electric system for the description of the system
40. Requirements on the carburetor 2 71 15 2 Connections for Bowden cable actuation and limit load 72 15 3 Requirements on Cable actuation 4 73 15 4 Requirements the throttle lever 74 15 5 Location and determination of the throttle position for max continuous power 75 16 Air intake es 77 16 1 Operating limits t 77 16 2 Requirements on the air intake system 78 16 2 1 Requirements on the intake air ducting 78 16 2 2 Aimer Eee ete edt doesnt nid tua thine 80 16 23 Too ME Em 80 16 3 Notes to employment of the air filter 81 17 Pressure 83 17 1 Static pressure sensor 84 18 Servo molor Servo cable 85 181 SERVO cei a nai mn in ERR TRE EE REUS 85 18 2 Servo Cable c 86 Effectivity 914 Series page 4 Edition 1 Rev 0 Juli 01 2006 d03186 d03186 BRP Rotax INSTALLATION MANUAL 19 of SNS OR o OO 87 19 1 Requirements on circuit wiring ss 88 19 1 1 Electromagnetic compatibility EMC 04022 0 0 01 000000 88 19 2 Wiring diagram si
41. aft builder to the latest requirements such as FAR or EASA 1 36 pole plug receptacle 2 3 plug connection for pressure sensor 4 plug connection for lamps 5 plug connections for servo motor 5 1 for potentiometer 6 pressure sensor static pressure atmospheric pressure 7 pressure sensor airbox already wired in advance 8 servo motor 8 1 potentiometer 9 2 electronic modules and B 10 11 plug connection for ignition switch 12 integrated generator 13 14 external regulator rectifier with plug connections 15 electric starter 16 17 starter relay with plug connection 18 19 electric fuel pumps 20 3 way solenoid valve float valve pressure already wired in advance 21 23 external alternator with connections 24 electric rev counter 25 capacitor 30 31 lamps 32 isolating switch for servo motor 33 2 ignition switches 34 master switch 35 starter switch 36 control lamp 37 amperemeter 38 battery relay 39 battery 40 bus bar 41 capacitor 42 51 circuit breaker 52 plug connection for airbox temprature sensor 53 airbox temperature sensor already wired in advance 54 plug connection for trigger coil assy 55 trigger coil assy speed 56 plug connection for throttle positioning sensor 57 throttle positioning sensor already wired in advance Effectivity 914 Series page 89 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL e d qi i DII 3 08118 5L Hd 9 e pO NE
42. are identified by a consecutive non corresponding number This No e g 00277 does not have any meaning concerning the content All necessary documentation is available from the BRP Rotax Dis tribution and Service Center Effectivity 914 Series page 13 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 14 Juli 01 2006 03187 03187 5 List of the effective pages BRP Rotax INSTALLATION MANUAL 00567 chapter 3 4 10 11 Effectivity 914 Series Edition 1 Rev 0 page N 17 18 19 20 22 23 24 25 26 27 28 29 30 31 32 33 34 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 200607 01 chapter 12 13 14 15 16 page 35 37 38 39 40 41 SSESRSEGRSS 51 52 53 54 55 56 57 28628858 65 66 67 68 70 71 72 73 74 75 76 77 78 79 80 81 date 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07 01 2006 07
43. ations According to propeller configuration choose the appropriate connection for the oil return line Position 1 for tractor or 2 for pusher configuration See fig 25 hose nipple 2 us 10 DIN 7642 13 5 mm 53 in slip on length sisi coto otis max 24 mm max 94 in Tightening torque of banjo bolt 3 M16x1 5x28 35 Nm 310 in Ib alo lt 9 9 j ut d 2 LR 2 5 2 1 3 a Druckpropeller Zugpropeller pusher config tractor config 13 5 2 Oil circuit turbo charger See fig 26 Oil return hose nipple 4 4 6 DIN 7642 outside dia 8 mm 31 in Slip on length max 20 mm 79 in Tightening torque of banjo bolt 5 M10x1x19 15 Nm 133 in Ib F ea E m 1i Effectivity 914 Series page 57 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 13 5 3 Oiltank See fig 27 28 The oil tank is furnished with 2 screw connections 18 1 5 and with a tapped hole M10x1 Connections for oil circuit engine Oil inlet 6 and outlet 7 via standard swiveljoint 1 and connecting bend 8 2x connecting bend 90 8 9 3 54 in outside dia
44. authorized distributor www rotax aircraft engines com and TM are trademarks of BRP Rotax GmbH amp Co KG 2006 BRP Rotax GmbH amp Co KG All rights reserved
45. both ends grounded to prevent EMI Not or insufficient shielded cables can cause engine shut off due to electromagnetic and radio interference The metal base of each ignition switch must be grounded to aircraft frame to prevent EMI page 93 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 19 4 5 Electric starter See fig 59 Wire from starter relay to the electric starter Cross section of at least 16 mm 6 AWG output 0 7 kW 0 9 kW optional positive terminal 1 screw tightening torque 4 Nm 35 in Ib suitable for ring terminal to DIN 46225 MIL T 7928 grounding via engine block CAUTION Suitable for short starting periods only CAUTION 80 176 F temperature range by the electric starter housing Activate starter for max 10 sec without interrup tion followed by a cooling period of 2 min Bite R p Y SIAL Oa 1 ZO b 1 NI T LL cos Hil re Effectivity 914 Series page 94 Edition 1 Rev 0 Juli 01 2006 03195 03195 BRP Rotax INSTALLATION MANUAL 19 4 6 Starter relay See fig 60 nominal voltage 12 V control voltage min 6V max 18V switching current max 75 A permanent max 300 A for 1 sec ambient temperature range min 40 C 40 F max 100 C 214 F weight 0 145 kg 32 Ib
46. circuit 3 and warning lamp circuit 4 via supplied standard plug Sumitomo 6111 2568 see fig 66 Effectivity 914 Series page 100 Edition 1 Rev 0 Juli 01 2006 03195 03195 BRP Rotax INSTALLATION MANUAL Requirements for correct operation of the integrated rectifier regulator the rectifier regulator has to be protected by a slow blowing 50A fuse Cross section of the main circuit at least 4 mm 10 AWG acapacitor fig 52 Pos 25 of at least 22 000 uF 25 V is necessary current CAUTION The current over speed graph has been determined and is effective only at the following conditions ambienttemperature 20 C 68 F voltage permanent 13 5 V tolerance 5 NOTE The speed of the auxiliary generator is 1 24 times crankshaft speed or 3 times the prop speed 1 min rpm i 1000 1500 2000 2500 n propeller fig 66 2000 3000 4000 5000 6000 7000 8000 Generator 00547 rpm alternator Effectivity 914 Series page 101 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 19 4 13 Connection of the electric rev counter tachometer See fig 52 67 Feeding wiring to electric rev counter from the 36 pole receptacle of TCU connections flexible wire 0 75 mm 18 AWG white No 26 flexible wire 0 75 mm 18 AWG white No 13 from the 36 plug receptacle of TCU without plug connection length approx 1000 mm 40 in from TCU NOT
47. clamp or screw clamp 16 2 1 Requirements on the intake air ducting max length of ducting 500 mm 20 in min inside dia at least outside dia of the intake socket on turbo charger min mean bending radius 100 mm 4 NOTE Compression process in the turbo charger will heat up air considerably depending on pressure ratio Usual tempera ture rise of 40 C 72 F at take off performance High engine performance needs air temperature as low as possible at turbo air intake Therefore the air filter should be located in a recess of the engine cowling or separated from warm air by partitioning such that via on opening ambient air can be aspirated CAUTION Air temperature above the limit will automatically reduce boost pressure with consequent performance loss The au tomatic back off on boost pressure will protect the engine against damage from overstressing Effectivity 914 Series page 78 Edition 1 Rev 0 Juli 01 2006 03194 03194 BRP Rotax INSTALLATION MANUAL Notes regarding too high air temperatures in the air box If in case of high intake air temperature the max air temperature in the airbox is frequently or permanently above the limit the arrangement of air intake has to be improved or an intercooler has to be installed NOTE Intercooler is not in the supply volume Intercooler has to be installed between pressure side of turbo 2 and inlet 3 into airbox Requirements on the intercooler
48. ctric equipment Under no circumstances route consumers cables e g battery side by side with ignition cable Induction could cause problems An excess voltage protection has to be realized by the aircraft manufacturer in accordance to effective regulations The certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Do not bend kink pinch or otherwise improperly stress the wiring harness Use proper routing clamping and strain relief on wiring harnesses Electromagnetic compatibility EMC The engine complies with the requirements of EMI and lighting protection as per standard RT CA DO 160C sections 18 20 22 and IEC 801 2 The following EMC EMI tests were performed Radio frequency Susceptibility conducted Radio frequency Susceptibility radiated Audio Frequency Susceptibility Lightning Susceptibility Conducted RF Interference Radiated RF Interference Effectivity 914 Series Edition 1 Rev 0 page 88 Juli 01 2006 03195 03195 BRP Rotax INSTALLATION MANUAL 19 2 Wiring diagram See fig 52 Legend to wiring diagram fig 52 Items 1 20 52 54 are included in the standard volume of supply of the engine Items 21 25 are available as accessory Items 30 51 can t be supplied by BRP Rotax WARNING certification of items components which are not included in the standard volume of supply of engine has to be conducted by the aircr
49. dimensions see fig reduction ratio i 4 i e 1 4 of engine speed NOTE A flexible shaft for the mechanical rev counter is readily available from BRP Rotax page 114 Effectivity 914 Series Juli 01 2006 Edition 1 Rev 0 03196 03196 BRP Rotax INSTALLATION MANUAL 23 5 Monitoring of the intake manifold pressure See fig 79 Connection nipple 1 to measure manifold pressure outside dia 6 mm 1 4 slip on length max 17 mm 11 16 CAUTION Utilize the total slip on length on all joints Secure hose by suitable screw clamps or crimp connection Protective covering to be utilized fortrans x 7 A WARNING j 7 port and at engine installation only If con E i nection for pressure reading is not em ployed has to plugged suitably 03200 CAUTION Flawless operation of the indicating instrument needs the installa tions of a water trap between engine and instrument for the fuel condensate 23 6 Air temperature in the airbox optional See fig 80 To take air temperature readings in the airbox a connection is provided This connec tion is closed on the standard engine by a plug screw connection tapping 1 8 27 NPT thread length approx 9 mm 3 8 Effectivity 914 Series page 115 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectiv
50. e compartment and routed at distance from hot engine components without kinks and protected appropriately At very critical conditions e g problems with vapour formation the fuel lines could be routed in a hose with cold air flow Fuel filter See fig 30 Coarse filter on fuel tank as per valid certification Finefilter inthe feed line from tank to the 2 fuel pumps an additional fine filter with meshsize 0 1 mm 004 in has to be provided The filter has to be controllable for service A combination of filter watertrap gascolator is recommended Fuel temperature In case of temperatures over 45 C 113 F in the vicinity of fuel lines watch for vapour lock If you should encounter problems in this respect during the test period than the affected components such as the supply line to the fuel pumps have to be cooled Effectivity 914 Series page 66 Edition 1 Rev 0 Juli 01 2006 903192 903192 BRP Rotax INSTALLATION MANUAL 14 4 Connecting dimensions location of joints and directives for installation 14 4 1 Electric fuel pump See outline of fuel pump 2 fig 30 31 and 32 Design self priming vane pump Volume of supply electric fuel pump with attachment kit 2 hose clamps and various attachment elements Weight 0 35 kg 8 Ib inclusive attachment items Fitting position horizontal or vertical Engine start operating temperature 25 C 13 F 50 C 120 F Connections See fig 31 ies In
51. e control to fuel tank Effectivity 914 Series page 65 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 14 2 Operating limits WARNING Design and layout of the fuel system has to warrant engine operation within the specified limits Fuel pressure e airbox pressure 0 35 bar 5 p s i nl to airbox pressure 0 15 bar 2 2 p s i EE airbox pressure 0 25 bar 3 6 p s i The fuel pressure of the electric fuel pump must not exceed the manifold pressure by more than 0 35 bar 5 p s i A WARNING Fuel pressure in excess of stated limit can lead to an override of the float valve with subsequent engine stop NOTE On the standard engine no connection is provided for measuring the fuel pressure Refer to chapter 14 5 14 3 Requirements ofthe fuel system Fuellines See fig 30 A WARNING Fuel lines have to be established to the latest requirements such as FAR or EASA by the aircraft manufacturer CAUTION Thefuelreturn 5 mustbe aline of low flow resistance Max tolerated pressure loss is 0 1 bar 1 5 p s i between fuel pressure control and tank inlet with both electric fuel pumps in action Otherwise the carburetors could flood Secure fuel hoses with suitable screw clamps or by crimp connection CAUTION For prevention of vapour locks all the fuel lines on the suction side of the fuel pump have to be insulated against heat in the engin
52. e external alternator item current consumption fuel pump main ertet max 3A fuel pump stand by max 3A TOUS 0 3A SEVO MODE 1 warning lamp 925 irre approx 0 25 A caution lamp sms approx 0 25 A SUN 8A 0 internal power consumption without servo motor and lamps standard value actual value up to aircraft manufacturer e without electric starter and start relay Effectivity 914 Series page 103 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 104 Juli 01 2006 03195 03196 BRP Rotax INSTALLATION MANUAL 20 Propeller drive The propeller in tractor or pusher arrangement has to be fitted on the propeller flange in accordance to current certification As required utilize one of the three possible pitch circle diameters P C D on the flange Certification of the propeller sizing and arrangement to the latest requirement such as FAR or EASA has to be conducted by the aircraft manufacturer A WARNING Never run the engine without a propeller installed as engine would suffer severe damage by overspeeding Never fit propeller directly on crankshaft 20 1 Technical data See fig 68 direction of rotation of the prop flange counter clockwise looking towards face of flange location see system of coordinates attachment of propeller on prop shaft flange P C D 75 mm 2 95 6 bolt hol
53. e longitudinal axis z4 has to be parallel to z axis in system of coordinates tolerated deviation of parallelism 60 location of installation vibration neutralized installation in a stable zone e g in cockpit In the area of the pressure pick up approx the same atmospheric pressure static air pressure has to prevail as at inlet of turbo charger CAUTION Remove protective cap before operating the sensor CAUTION pressure connection has to be protected against entering of foreign matter e g oil fuel water etc NOTE Location of installation is limited by the length of the wiring harness length of cable assy approx 250 mm 10 in from TCU A z4 Effectivity 914 Series page 84 Edition 1 Rev 0 Juli 01 2006 03194 03194 BRP Rotax INSTALLATION MANUAL 18 Servo motor Servo cable See fig 50 51 The correct adjustment of the servo cable 1 and consequently the waste gate 2 was made already on the course of the testrun at BRP Rotax 04853 LE 77 e G M 3 2 18 1 Servo motor Prior to engine operation check the position of the waste gate as follows WARNING Engine stop ignition OFF Check ofthe waste gate accordance with the Maintenance Manual 914 F Additionally only the actual attaching of
54. enne 89 19 3 Description of the Turbo Control Unit 91 19 4 Technical data and connection of the electric 91 19 4 1 Integrated generator etie e ec e 91 19 4 2 Bectifierregulator us conocerte res etape 91 19 4 3 Electronicimodules fore co Rp red 93 19 4 4 Ignition switches On Off 93 19 4 5 Electric dental eas 94 19 46 Starter relay retentus pdt a eel dre ebd oed anes 95 19 4 7 Electric fuel PUMPS 2 2 dr erre ek Gece 96 19 4 8 Turbo Control Unit TOU 225 utes reve vta Dee 97 19 4 9 Isolating switch for servo motor 98 19 410 Boost lamp ariete nur etra Ed ca cues 99 19411 Get AMP is sae cscs TERES 99 19 4 12 External alternator optional 100 19 4 13 Connection of the electric rev counter tachometer 102 19 414 bodie Pee 103 19 5 Internal consumer of electric ss 103 20 Propeller driv s de 105 20 1 Technical datai 105 21 VACUUM T
55. es of 8 mm 32 in dia P C D 80 mm 3 15 6 bolt holes of 11 5 mm 45 in dia P C D 101 6 mm 4 6 bolt holes of 13 mm 51 in dia ratio of gear reduction 2 4286 51 T 21 T max torque 340 Nm 250 ft Ib at propeller max moment of inertia 6000 14 238 Ib ft permitted static out of balance on a prop max 0 5 gm 043 Ib in max extension of the propeller shaft 120 mm 4 72 in NOTE In the course of certification a vibration analysis of the whole system engine suspension propeller etc should be done lf there are limits found inthe technical literature a max of 0 1 IPS inches per second at 5000 1 min can be assumed Effectivity 914 Series page 105 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL e 1 6 e e i EB C BB Q p AS ES En LC S Xe 55 Se Se 96150 106 Juli 01 2006 Effectivity 914 Series Edition 1 Rev 0 03196 BRP Rotax INSTALLATION MANUAL 21 Vacuum pump 21 1 Technical data See fig 69 and 69 1 Type Airborne 211 CC drive via propeller gear location of the necessary connection 1 and 2 on the vacuum pump Axis x axis axis z axis Connections y mm mm mm fig 69 a 5226 o v 2 o 98 connections thread size 5 8 16 tightening torque hand tight and tighten up by max
56. f lubricating oil Never exceed maximum rated r p m and allow the engine to cool at idle for several minutes before turning off the engine The engine should only be installed and placed into operation by persons familiar with the use of the engine and informed with regard to possible hazards Never run the engine without a propeller as this will inevitably cause engine damage and present a hazard of explosion Propeller and its attachment with a moment of inertia in excess of the specified value must not be used and releases engine manufacturer from any liability Improper engine installation and use of unsuitable piping for fuel cooling and lubrication system releases engine manufacturer from any liability Unauthorized modifications of engine or aircraft will automatically exclude any liability of the manufacturer for sequential damage naddition to observing the instructions in our Manual general safety and accident preventative measures legal regulations and regulations of any aeronautical authority must be observed Where differences exist between this Manual and regulations provided by any authority the more stringent regulation should be applied This engine may be equipped with an other than the ORIGINAL ROTAX air pump The safety warning accompanying the air pump must be given to the owner operator of the aircraft into which the air pump is installed Effectivity 914 Series page 11 Edition 1 Re
57. gh clearances at bearings into crankcase during longer periods of engine stop If fitted too low it might badly effect the oil circuit Install the oil tank free of vibrations Oil tank cover 3 and oil drain screw 4 to be easily accessible m gt RU TUE 152 2 SUNT 400 5 05387 Effectivity 914 Series page 59 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 13 7 Feasible position and location of the oil cooler See fig 29 Onprinciple the oil cooler 5 has to be installed below the oil pump of the engine CAUTION oil cooler has to be installed with connections upwards i e in positive direction on z axis This will prevent an unintentional drain ing of the oil cooler at longer engine stop If this position is not practical install also the oil cooler with connections upwards i e in positive direction on z axis CAUTION This will prevent an unintentional draining of the oil cooler at longer engine stop A WARNING The oil cooler has to be planned and installed such that the specified operating temperatures are maintained and the max values are neither exceeded nor fall below This state has to be warranted for hot day conditions too If need be take appropriate measures like changing size of cooler partial covering of cooler etc 13 8 General notes on oil cooler BRP R
58. hat the oil suction line 1 and engine oil return lines 2 are connected to the proper fittings on the oil tank If the oil lines from the engine to the oil tank are incorrectly connected at the oil tank severe engine damage may result Add oil to engine oil tank to bring the oil level up to the full mark on the dipstick WARNING Carefully check all lubrication system connections lines and clamps for leaks and security Effectivity 914 Series page 61 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 13 10 1 Venting purging or priming of turbocharger lubrication system A WARNING Observe the appropriate safety precautions Make sure that there are no foreign items including tools in the engine compartment Secure aircraft to the ground appropriately and place chocks under the wheels Secure propeller zone to warrant safety for persons and property Be sure to approach only from engine side of propeller Permanently supervise engine operation from a secure position The cockpit must be occupied during the testing by a licensed pilot or an authorized person to conduct test runs of an aircraft To verify operation of the turbo charger oil circuit detach the turbo sump oil return line 7 on the oil tank banjo bolt M10x1x19 and route the line toa separate container Start the engine in accordance to the relevant Operators Manual and observe if oil is being returned back If oil is not flowing back within 10 sec s
59. he flow rate of coolant in the cooling system is approx 60 l min 16 US gal min at 5800 rpm As reference value for the necessary cooling airflow approx 0 75 m3 s at full load can be assumed Check flow rate and cooling capacity if other radiators are used Effectivity 914 Series page 47 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 12 11 Cooling air ducting Contrary to the cylinder heads the cylinders are ram air cooled Plan cooling air ducting according to installation requirement A WARNING The cooling air ducting has to be designed and built such that the operating temperatures are kept within the specified limits and maximum values are not exceeded This must also be warranted at hot day conditions Max permissible cylinder wall temperature on cylinder 2 200 C 392 F see fig 21 1 Schraube screw M5 02050 Effectivity 914 Series page 48 Edition 1 Rev 0 Juli 01 2006 03190 03190 BRP Rotax INSTALLATION MANUAL 12 11 1 General directives for ducting of the cooling air See fig 2 3 4 For front installation in a closed fuselage ducting of cooling air to the cylinders is recommended In this case a costly horizontal partitioning can be avoided BRP Rotax developed especially for this application a non certified cooling air ducting to be conducted by the aircraft manufacturer The following recommendations should assist the ai
60. heat transfer capability Its limitation is its lower boiling point Conventional coolant should be used with a mixture of 50 concentrate and 50 water NOTE Some conventional coolant is available pre mixed by the manufacturer In this case do not mix with water follow the manufacturers instructions on the container Conventional coolant with a rate of 50 water cannot boil at a temperature below 120 C 248 F at a pressure of 1 2 bar 17 5 psi Thus the coolant temperature limit is at max 120 C 248 F Permanent monitoring of coolant temperature and cylinder head temperature is necessary Type 2 Waterless coolant based on propylene glycol Waterless coolant is recommended if the design of the aircraft can not maintain the coolant temperature limit Waterless coolant has a very high boiling point that prevents coolant loss due to boiling over vapor loss but not to prevent detonation which can occur with cylinder head temperatures higher than 135 C 275 F It does not require pressure to maintain its boiling point Due to a lower thermal conductivity the engine temperature will typically run about 5 10 C 41 50 F higher with waterless coolant Permanent monitoring of cylinder head temperature is necessary Additional monitoring of the actual coolant temperature is possible Marking of the coolant to be used CAUTION The coolant to be used and its concentration percentage water rate must be commu
61. hment points are provided on the engine 4 on engine and 4 on engine frame The engine will be supplied with a well tried and certified suspension frame for attachment on the fire proof bulk head The exhaust system and the turbo charger are supported on this frame too The installation into the aircraft is as generally practised by captive rubber mounts which ensure also to balance out vibrations and sound from engine to aircraft frame A WARNING Ifthe engine suspension frame supplied by BRP Rotax is not used or if modified certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Furthermore a suitable suspension for turbo charger and exhaust system has to be devel oped Since these components weigh approx 6 kg 13 Ibs this suspension has to be carefully designed and tested Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer A WARNING The hex hd screws M10x60 1 on the attachment points R2 and L2 are only used for transport securing but must never be utilized for engine suspension See fig 9 Therefore it is recommended to use the ROTAX engine suspension frame and the 4 stated attachment points R2 L2 R3 and L3 A WARNING Atleast 4 of the eight anchorage points must be used in a side symmetrical pattern of the left L and right R side Effectivity 914 Series page 27 Edition 1 Rev O Juli 01 2006 BRP Rotax
62. ition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL For the completion of the lubrication system only the following connections need to be established Lubrication circuit engine main oil pump oil tank outlet gt cooler oil cooler oil pump inlet oil return c oil tank inlet oil tank venting line Oil circuit turbo charger suction pump oil return c oil tank inlet NOTE In the serial version of the engine an oil tank is included but no provision is made for attachment of an oil cooler WARNING Certification of oil cooler and connections to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufac turer 13 2 Limits of operation WARNING The lubrication system has to be designed such that operating temperatures will not exceed the specified limits Oil pressure For oil pressure sensor see fig 75 76 see OM 914 Serie chapter 10 1 Oil temperature Oil temperature sensor see fig 73 74 see OM 914 Serie chapter 10 1 WARNING At operation below nominal oil temperature formation of condensate in the lubrication system might influence oil quality NOTE For operation at low temperatures the installation of an oil thermostat parallel to the oil cooler is strongly recommended Advantages safe oil pressure after cold start prevention of fuel and water accumulation in the oil See therefore SL 914 009 Use of an oil thermostat latest is
63. ity 914 Series Edition 1 Rev 0 page 116 Juli 01 2006 03196 03196 BRP Rotax INSTALLATION MANUAL 24 Preparations for trial run of engine WARNING Prior to engine start and operation review all instructions stated in the Operator s Manual Verification of the throttle lever detent for max continuous power Performance check in accordance with Operator s Manual If nominal performance won t be reached or is in excess of examination of the installation and engine will be necessary Consult Maintenance Manual 914 CAUTION Don t conduct any test flights before fault has been traced and found Effectivity 914 Series page 117 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 118 Juli 01 2006 03196 03196 BRP Rotax INSTALLATION MANUAL 25 BRP Rotax Authorized Distributors for Aircraft Engines See latest Operators Manual chapter 14 or in the Internet at the official Homepage www rotax aircraft engines com Effectivity 914 Series page 119 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 120 Juli 01 2006 03196 ROTAX AIRCRAFT ENGINES HEINDL WERBEAGENTUR PRIBYL Motornummer Engine serial no Flugzeugtype Type of aircraft Flugzeugkennzeichen Aircraft registration no Vertriebspartner
64. let 1 suction side Outlet 2 pressure side vs B CAUTION Utilize the complete slip on length on all hose connections Secure fuel hoses with suitable spring type clamp or screw clamp Delivery rate pressure See diagram fig 32 USgalh 31 70 120 29 05 110 02473 23 77 90 238 21 13 80 013 3 18 49 70 15 85 60 13 20 50 10 56 40 7 92 30 5 28 20 2 64 10 0 250 500 750 1000 1250 1500 1750 2000 hPa 2 The diagram shows the delivery rate of the electric fuel pump over pressure 141 5 3 5 57 40 12 in Take note of the following diagram outlines min capacity at nominal voltage on pump pressure suction head are ZERO graph is effective the seasoned pump only running in period approx 30 min 20 0 5 0 79 0 02 NOTE A capacity increase of approx 20 is feasible 2 by running in process Effectivity 914 Series page 67 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL CAUTION Employ GENUINE ROTAX fuel pumps only Non compli ance will release BRP Rotax from any liability Place of installation Installation of the fuel pumps principally near the fuel tank to gain advan tage of a cool location especially important at tendency of vapour locks Install the pump in low position if possible below fuel tank free of
65. li 01 2006 03196 03196 BRP Rotax INSTALLATION MANUAL 23 3 Oilpressure sensor See fig 75 76 location oil pump housing position of connection on oil pressure pick up 1 Axes connectio mm mm mm connection of pick up wiring single pole screw connection for ring terminal 3 to DIN 46225 tightening torque max 1Nm 8 848 in Ib 04870 grounding via engine block graph of resistance over pressure CAUTION The graph resistance over pressure has been determined and is effective at the following conditions only ambienttemperature 20 C 68 F voltage 12 tolerance 5 BRP Rotax offers a non certified pressure gauge Refer to Illustrated Parts Catalog latest issue WARNING Certification to the latest requirements such as FAR of EASA has to be conducted by the aircraft manufacturer Effectivity 914 Series page 113 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 23 4 Mechanical rev counter tach drive See fig 77 78 location ignition housing 1 direction of rotation of the rev counter shaft 2 clockwise a 5 see fig LAO position of rev counter drive Axes point of x axis yaxis Zaxis engagement mm mm 16 063in 26 0 102 in HOOD 260402 00562 installation
66. n of connections CAUTION Utilize the full slip on length for hose connections Secure hoses with suitable screw clamp or by crimp connection NOTE The oil pipeline connections are optional as UNF thread See 1 914 005 13 5 1 Oil circuit engine See fig 24 24 1 and 25 Depending on engine certification the oil pump inlet connectors can vary 914 thread M18 optional UNF thread 914UL inlet nipple optional M18 or UNF thread Oil pump inlet 1 thread M18 x 1 5x 11 NOTE Suitable for use of a swivel joint See fig 28 Tightening torque 35 Nm 310 and Loctite 243 x 1 E 02468 Oil pump inlet nipple 1 1 outside dia 13 2 mm 0 52 in slip on length max 21 mm 0 83 in 00226 Effectivity 914 Series page 56 Edition 1 Rev 0 Juli 01 2006 03191 03191 BRP Rotax INSTALLATION MANUAL Oilreturn CAUTION The engine design is for a conventional non aerobatic fixed wing tractor or pusher type configuration with the oil return port in the optimum position With this consideration the engine is properly lubricated in all flight profiles Aircraft that are not conventional e g airship gyrocopters dive brake equipped aircraft etc that require engine load in steeply incline and decline angles see also chap 8 1 point 12 may require special lubrication consider
67. n ratio of crankshaft to governoris 1 842 e g the governor speed is 0 54 of the engine speed Effectivity 914 Series page 109 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 110 Juli 01 2006 03196 03196 BRP Rotax INSTALLATION MANUAL 23 Connections for instrumentation These connections to be established in accordance to certification and or national specifica tions The certification for connections and connection lines have to be conducted by the aircraft builder to the latest requirements like FAR and EASA For notes regarding the electric rev counter consult the chapter 19 4 13 23 1 Sensor for cylinder head temperature See fig 71 72 NOTE A direct reading of the coolant temperature is not provided for The temperature sensor 1 is directly fitted into cylinder head i e a direct temperature reading of the cylinder head material is taken This allows the exact measuring of the cylinder head temperature even in the case of coolant loss NOTE Readings are taken on the hottest cylinder depending on engine installation location in the cylinder head of the cylinders 2 and see fig 4 connection spade terminal 6 3x0 8 to DIN 46247 grounding via engine block graph of sensor resistance over temperature 04868 Axes x axis axis 2 axis 600 400 00227
68. nation is achieved electronically by a PC program especially developed for this engine For further details refer to Maintenance Manual 914 chapter Control system of the turbo charger Effectivity 914 Series page 75 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES 903193 Effectivity 914 Series page 76 Edition 1 Rev 0 Juli 01 2006 03194 BRP Rotax INSTALLATION MANUAL 16 Air intake system See fig 43 The pressure side intake system from turbo charger to the carburetors is included in the volume of supply Only the airduct to turbo charger and drainage line of airbox have to established 16 1 Operating limits Temperature in airbox max intervention temperature 72 C 162 F max intervention temperature 88 C 162 F 914 UL from S N 4 420 200 TCU p no 966741 version 4 6 914 F from S N 4 417 598 TCU p no 966741 version 4 5 Low air temperature in the airbox is favourable for engine performance and against knocking tendency at combustion If need be install intercooler The certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft builder CO Measurement CO Emission min 1 5 96 CO at max continuous output GO EMISSION min 3 0 CO at full throttle and maximum speed Measured on each single cylinder Measuring point is analog
69. ngine 25 Pressure sensors 77 Propeller drive 99 Protective covering 26 R Range of starting temperature 23 Rectifier regulator 85 Remarks 9 Rev counter drive 108 page 7 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 5 Safety 9 Safety information 10 Sensor for oil temperature 106 Servo motor 79 Standard engine design 19 Starter relay 89 State of delivery 25 Symbols 10 Take off speed 23 Technical data 23 Technical documentation 13 Temperature in airbox 71 Throttlelever 68 Throttle position 69 Transport 25 Trialrun 111 Turbocharger 72 Turbo Control Unit TCU 85 91 V Vacuum pump 101 Venting line of oiltank 51 W Warning light 93 Waterinletbend 40 Wiring diagram electric 83 Effectivity 914 Series Edition 1 Rev 0 page 8 Juli 01 2006 d03186 03187 BRP Rotax INSTALLATION MANUAL 3 Preface In this Manual the installation of all ROTAX 914 Series engines is described NOTE ROTAX 914 Series includes 914 F and 914 UL Before starting with the engine installation read this Installation Manual carefully The Manual will provide you with basic information on correct engine installation a requirement for safe engine operation If any passages of the Manual are not completely understood or in case of questions please contact an authorized Distribution or Service Center for ROTAX engines BRP Rotax GmbH amp Co KG hereinafter BRP Rotax wish you much pleasure and satisfacti
70. nicated to the owner in the correct form Waterless coolant must not mix with water as otherwise to lose the advantages of the high boilling point Example EVANS NPG See fig 16 1 1 Warning sticker 2 Radiator cap 3 Opening pressure information of radiator cap 07012 Effectivity 914 Series page 37 Edition 1 Rev O Juli 01 2006 BRP Rotax INSTALLATION MANUAL 12 4 Check cooling system Efficiency of the cooling system For a measurement of the cooling system the maximum values for coolant exit temperature and cylinder head temperature must be found According to the current specifications 12 4 1 Measurement of cylinder head temperature and coolant exit temperature There are two temperature sensors 1 onthe cylinder 2 and 3 for measuring the cylinder head temperature During flight test the place with the highest cylinder head temperature must be found this can vary with different engine installation cowling or free installation tractor or pusher fight speed etc The measuring of the coolant exit temperature is performed using a seperate sensor which has to be installed in the line between expansion tank 1 and radiator inlet 2 00125 The sensor be installed in a TEE inline with the fluid hose or the expansion tank may be modified to attach the sensor not supplied by BRP Rotax A WARNING Do not restrict the coolant flow wi
71. o that under no conditions the coolant does get near its boiling point because a subsequent loss of coolant can quickly cause the engine to overheat The boiling point of the coolant is influenced mainly by the type of coolant the proportion of the mixture percentage water rate the system pressure opening pressure of radiator cap Correlation between coolant temperature and cylinder head temperature There is in principle a regular relationship between coolant temperature and cylinder head temperature The coolant transfers some of the combustion heat to the radiator Thus the coolant temperature is usually lower than the cylinder head temperature But the temperature difference between coolant and cylinder head is not constant and can vary with different engine installation cowling or free installation tractor or pusher flight speed etc NOTE The basic requirement for safe operation is that boiling of conventional coolant must be prevented The boiling point of conventional coolant is 120 C 248 F with a 50 50 mixture proportion and a system pressure of 1 2 bar 17 5 psi Effectivity 914 Series page 36 Edition 1 Rev 0 Juli 01 2006 d03190 d03190 BRP Rotax INSTALLATION MANUAL 12 3 Coolant types In principle 2 different types of coolant are permitted Type 1 Conventional coolant based on ethylene glycol Conventional coolant is recommended as it is commonly available and has a greater thermal
72. oil pump connections Older engines may be equipped with oil tanks that have oil ports differently located CAUTION Incorrectly connected oil lines to the oil tank or to the engine will result in severe engine damage Disconnect oil line 2 at the oil tank connection Place the free end 3 of the return oil line into a suitable container 4 below the engine Plug open connection 5 at the oil tank with suitable air tight cap See fig 29a Remove the spark plug connectors For easier rotation of engine remove the four top spark plugs CAUTION Prevent entering of foreign substance through spark plug hole Using acompressed air line pressurise the oil tank through its breather connec tion 6 on the neck of the tank The air line pressure should be between 0 4 6 psi and 1 bar 15 psi and not more than 1 bar 15 psi WARNING Donotremove oil tank or cover before ensuring that air pressure has been completely released from the tank The pressure in the oil tank has to be maintained during the following step Turn the engine in direction of normal rotation until the pressure rises on the oil pressure gauge Normally this will take approx 20 turns Depending on installa tion it may take up to 60 turns Release the pressure from the oil tank Un block the oil return port on 5 the oil tank and reconnect the engine return oil line 2 to the oil return port on the oil tank CAUTION Ensure t
73. on b Maximum cylinder head temperature and coolant exit temperature is below operating limit For operating with conventional coolant it is necessary to monitoring constantly cylinder head temperature and coolant exit temperature NOTE For detection of possible indication error an additional monitoring of the cylinder head temperature is necessary which shows an exceedance in case of coolant loss The aircraft manufacturer has the option of converting the coolant temperature and the cylinder head temperature to an aircraft specific cylinder head temperature This is possible by calculating the difference between the head material and the coolant temperature This is done by following the flight test procedure on page 40 Once the calculation is made and the indicating instrument re labeled it is acceptable to use the cylinder head temperature as the primary cockpit display instead of installing a sensor in the coolant flow The measurement is based on the maximum coolant temperature and cylinder head temperature according to the current requirement CAUTION no case a cylinder head temperature higher than the limit of 135 C 275 F can be defined because detonation could not be sufficiently prevented Refer to the flight test example that follows Cooling capacity of the installation too low Effectivity 914 Series page 39 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL Flight test example
74. on flying your aircraft powered by this ROTAX engine 3 1 Remarks This Installation Manual is to acquaint the owner user of this aircraft engine with basic installation instructions and safety information For more detailed information on operation maintenance safety or flight consult the documentation provided by the aircraft manufacturer and dealer For further information on maintenance and spare part service contact the nearest BRP Rotax distributor see chapter Distributors 3 2 Engine serial number On all enquiries or spare parts orders always indicate the engine serial number as the manufacturer makes modifications to the engine for further development The engine serial number is on the top of the crankcase magneto side 4 Safety Although the mere reading of these instructions will not eliminate a hazard the understanding and application of the information herein will promote the proper installation and use of the engine The information and components system descriptions contained in this Installation Manual are correct at the time of publication BRP Rotax however maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on its products previously manufactured BRP Rotax reserves the right at any time to discontinue or change specifications designs features models or equipment without incurring obligation The illustrations in this Installation
75. on of a new engine Effectivity 914 Series page 25 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 9 4 Protective covering All openings are protected against ingress of contamination and dampness It is recommended not to remove these plugs until installation of the specific feed line NOTE If the engine will be sent to the manufacturer or distributor reuse transport equipment and replug openings List of protective covering exhaust socket 1x cone plug air intake socket on turbo 1x cover connection for manifold pressure 1x cap fuel pressure control in and outlet 1x each cap oil supply and oil discharge 1x each cap oil return turbo ne 1x cap supply and discharge 1x each cone plug propshaft on version 3 1x disk plug da eee 2x WARNING Protective covering to be utilized for transport and at engine installa tion only Before engine operation remove these protections Effectivity 914 Series page 26 Edition 1 Rev 0 Juli 01 2006 03188 003189 BRP Rotax INSTALLATION MANUAL 10 Engine suspension and position CAUTION At installation of engine be aware of engine weight and assure careful handling The engine suspension is determined essentially by the aircraft design Eight attac
76. otax offers for this engine an oil cooler see Illustrated Parts Catalog latest issue A WARNING Certification of this cooler to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer CAUTION cooler has to be designed to dissipate approx 10 kW 8 5 BTU s heat energy at take off power NOTE From years of experience we recommend an oil cooler size of at least 160 cm 25 in provided that air flow is adequate 13 9 Filling capacity Oil quantity without oil cooler and connecting lines min 3 I 0 8 US gal depending on the respective installation Volume of oil tank up to the MIN mark 2 5 0 66 US gal up to the MAX mark 3 01 0 8 US gal Perform oil level check and add oil if necessary Effectivity 914 Series page 60 Edition 1 Rev 0 Juli 01 2006 03191 03191 BRP Rotax INSTALLATION MANUAL 13 10 Venting purging or priming of lubrication system see fig 29 1 Verify that oil tank connections are connected correctly and secured and that the oil cooler is in the suction line 1 between the oil tank and the oil pump inlet Verify that the oil tank is filled up to the maximum level to the top of the flat portion of the dipstick Additional oil must be added up to the MAX mark after this procedure NOTE Consult appropriate engine installation manual for diagrams to identify oil tank and
77. ounts which ensures an attachment free of vibrations A WARNING _ Ifthe standard attachment should not be utilized or changed certifi cation to the latest requirements such as FAR or EASA has to be conducted by the aircraft manu facturer dE A WARNING Choose place of installation Ma such that operation is within the specified temperature limits Le 9 fig 63 Effectivity 914 Series page 97 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL WARNING TCU comprises electronic components and is there fore completely sealed The TCU is allowed to be opened only by persons authorized by BRP Rotax connections terminal flexible cable 0 75 mm 18 AWG white No 1 terminal flexible cable 0 75 18 AWG white No 25 from the 36 pole plug receptacle of the TCU with ring terminal 4 2 mm dia to DIN 46225 fuse The TCU has to be protected by a slow blowing 2A fuse in accordance with the wiring diagram fig 52 19 4 9 Isolating switch for servo motor See fig 52 The isolating switch serves to break the circuit of the servo motor for a short time in case of surging of the TCU After a short hunting stable operation should follow design 2 pole on off switch fig 52 Pos 32 CAUTION The isolating switch has to be designed such that it is guarded against being turned off
78. pe can be modified to the following requirements Mean bending radius of an tail pipe min 40 mm 1 57 in Exhaust bend inside diameter min 38 mm 1 50 in Medium tube length max 250 mm 10 in The insertion depth of the tail pipe into the muffler must be ensured see fig 15 1 CAUTION Atamediumtube length of 250 mm 10 in and more the tail pipe musthave additional support Material of the exhaust system X 15CrNiSi 20 DIN 1 4828 AISI 309 07618 Tube end P1 Location of the exhaust tail pipe P1 See fig 15 x axis y axis z axis mm mm mm Detail S B B e lt lt p P1 05385 271 mm 10 67 in fig 15 CAUTION A Always fit heat shields near carburetors as required Because of the high temperatures occurring provide suitable protection against unintentional contact Effectivity 914 Series page 33 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL radius mind 40 mm M 1 575 in 05720 11 1 Operating limits Exhaust gas temperature both ignition circuits on e nr a er 950 C 1740 F qur Mer 900 C 1650 F Reading taken approx 100 mm 3 93 in after exhaust flange Reading of the exhaust gas temperature has to be taken for certification
79. porated viscous damper may be fitted instead of the magnetic plug 5 or the crankshaft locking screw 6 see fig 22 2 NOTE The connecting thread is M12x1 5 metric for the magnetic plug and M8 for the crankshaft locking screw use always new gasket The pressure in the crankcase at full load must not exceed the prevailing ambient pressure by more than 0 45 bar 6 53 psi at 90 C 194 F oil temperature If both pressure readings are within the specified limits under all operating conditions the lubrication circuit should be working sufficiently WARNING the readings exceed the pressure limits then the flow resistance of the oil backflow from oil sump to oil tank contamination restrictions of cross section etc is too high This condition is unsafe and must be rectified without delay 4 x Ad a max 0 45 bar berdruck YA max 0 45 bar above atmospheric pressure fig 22 2 04073 Effectivity 914 Series page 54 Edition 1 Rev 0 Juli 01 2006 03191 03191 BRP Rotax INSTALLATION MANUAL 13 4 Requirements on the oil and venting lines Oillines Oil circuit engine main oil pump Temperature durability mind 130 C 266 F Pressure durability mind 10 bar 145 p s i Bending radius mind 70 mm 2 75 in unless otherwise stated by the hose manufacturer Minimum inside dia of oil lines in reference to total length length up to 1m 3
80. pum gt a L1 R1 R T 2 Effectivity 914 Series page 29 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL Propeller axis Thecentres of attachment points L1 und R1 must be on axis y2 parallel to y axis SUN Va If K S AN f is 02454 R1 L1 Tolerated roll deviation of parallelism 5 see fig 12 Vertical axis y axis must be square to the longitudinal axis of the aircraft 02455 X Tolerated roll deviation of Yaw tolerance 10 see fig 13 8 Effectivity 914 Series page 30 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 10 3 General directives for engine suspension Rubber mounts to be used between engine and aircraft frame to neutralize vibrations Damping elements as generally used in the aircraft industry e g LORD are suitable See fig 14 NOTE Zelle a The fig shows rubber mount eee ee St tscheibe Lord J 3608 1 resp J 3608 2 A WARNING Allelements to balance out vibrations have to be of captive design Distanzrohr distance tube MC A support washer metere nnn irframe mount 07 7 7 re airframe mount MSS ae 4 VM D n n 07600
81. ration keep hose to overflow bottle as short and small as possible CAUTION warrant the proper operation of the cooling system the delivery head between overflow bottle and expansion tank must not exceed 250 mm 10 Effectivity 914 Series page 44 Edition 1 Rev 0 Juli 01 2006 03190 03190 BRP Rotax INSTALLATION MANUAL Requirements on the overflow bottle 7 transparent material unaffected by temperatures from 40 C 40 F to 125 C 257 F resistant against 100 Glycol and any other anti freeze agent volume approx 0 5 13 05 gal possible to vent 6 NOTE NOTE A WARNING NOTE See therefore SB 914 025 Modifications of the overflow bottle latest issue The overflow bottle ought to be furnished with a label indicating function and content Ensure that the overflow bottle will never be empty otherwise air will be sucked into cooling circuit with big effect to safe operation of the engine To enable an aimed drain of the leaking coolant steam from the expansion bottle in case of overheating the plastic plug can be retrofitted with hose nipple and hose Unscrew cap 2 from the overflow bottle Bore the existing vent hole from dia 1mm 0 04 in to dia 6mm 0 236 in Apply LOCTITE 603 to the threads of the hose nipple 3 Insert nipple 3 into the vent hole Install nut 1 onto the hose nipple 3 Tightening torque 5 Nm 44 in Ib Sc
82. rbox k 7 10 engine suspension frame 00120 18 11 stainless steel exhaust 20 0580 23 oil filter a OS 10 24 electric starter em ney 25 electronic modules for 14 fuel pressure control ignition 15 servo motor i 16 bl e 2e 33 connection for additional 17 cable assembly pressure 34 drip tray 18 coolant pump 28 sensor for H pressure 35 water trap ee xpabsiotnalk 2 36 three way solenoid valve 20 2 separate oil pumps 89 2 Los 37 2x electric fuel pump 21 connection for oil return E 38 oil tank line engine 31 2x pressure sensor 39 external alternator 22 connection for oil return 3932 connection for mechanical i rev counter 40 enrichment jet Effectivity 914 Series page 21 Edition 1 Rev 0 Juli 01 2006 BRP Rotax
83. rcraft manufac turer at the planning of a suitable cooling air ducting The cooling air ducting to be adequate to transfer thermal energy of approx 6 kW 5 7 BTU s at take off power required cross section of air duct at least 100 cm 16 in material glass fibre reinforced plastic or heat resistant non inflammable mate rial attachment formlocking on engine case and cylinders NOTE In case formlocking attachment won t be adequate addi tional attachment is possible on two tapped lugs M8 on top side of engine CAUTION The stated limit loads are valid only at utilization of min attachment points Effectivity 914 Series Edition 1 Rev 0 specified thread length and must never be exceeded Depth of thread 18 mm 71 in attachment points 2 000 0 59 in 04876 Axes mm axis 2 1 mm 14 4 max allowable forces limit load in N in x y and z axis max allowable bending moment limit load in Nm in x y and z axis 300 11 81 in 1 i 0 55 in 300 4 11 81 in 1 M un 0 55 in min length of thread engagement mm page 49 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 50 Juli 01 2006 03190 03191 BRP Rotax INSTALLATION MANUAL 13 Lubrication system 13 1 Description of the system See fig 22 The ROTAX 914 engine is provided with a dry sump forced l
84. rew the cap onto the overflow bottle Steps to attach the hose Attach the hose with a gear type hose clamp 4 Make sure the hose 5 has no kinks Route it overboard and secure Effectivity 914 Series Edition 1 Rev 0 45 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 05294 05295 8 ep EG ED ER ET S 5 yy E 1 2 3 05033 05039 fig 20 3 fig 20 4 Effectivity 914 Series page 46 Edition 1 Rev 0 Juli 01 2006 03190 03190 BRP Rotax INSTALLATION MANUAL 12 10 General directives for the cooling system See fig 21 BRP Rotax offers essential parts of the cooling system for this engine such as radiator etc WARNING Certification to the latest requirements to FAR or EASA has to be conducted by the aircraft manufacturer 04873 In an installation as depicted with the radiator 9 in a higher position than the standard supplied expansion tank a water accumulator 10 has to fitted instead of the expansion tank Additionally a suitable expansion tank 1 has to be installed at the highest point of the cooling circuit CAUTION size and type of radiator should be adequate to transfer thermal energy of approx 30 kW 28 BTU s at take off power NOTE Assessment data by experience For troublefree operation at good airflow a radiator of at least 500 cm 78 in area has to be used T
85. rrentpages 15 Cylinder head temperature sensor 105 D Definition of mainaxes 21 Denomination of cylinders 21 Description of design 19 Designation of type 19 Documentation 13 Drainage lines airbox 74 Drainage piping drip tray 65 Drip tray 65 E Electric fuel pump 61 90 Electric starter 88 Electromagnetic compatibility 82 Electronic modules 87 Elektric system 81 Engine components 21 Engine serialnumber 9 Engine speed 23 Engine suspension 27 31 Engine views 21 Exhaust gas temperature 34 Exhaust system 33 Expansion tank 38 External alternator 94 Effectivity 914 Series Edition 1 Rev 0 BRP Rotax INSTALLATION MANUAL F Fine filter 60 Fitting positions 29 Fuel filter 60 Fuel pressure 60 Fuel pressure control 63 Fuel pressure check 63 Fuel system 59 H Hour meter 108 Hydraulic governor for constant speed propeller 103 Ignition switches 87 Instruction 12 Instrumentation connection 105 Intake airducting 72 Integrated generator 85 Intercooler 73 Internal consumer of electric power 97 Isolating switch for servo motor 92 L Location of radiator 41 Lubricationsystem 47 M Main axes 21 Manifold pressure 23 Manifold pressure connector 109 Mechanical rev counter 108 Oilcooler 55 Oillines 51 Oilpressure 48 Oil pressure sensor 107 Oiltank 53 54 Oiltemperature 48 On off switch 87 Operating limits 23 Overflow bottle 42 Position of engine 27 Preface 9 Preservation e
86. s restricted to DAY VFR only This engine is not suitable for acrobatics inverted flight etc This engine shall not be used on rotor wing aircraft helicopters gyrocopters etc or any similar aircraft ltshould be clearly understood that the choice selection and use of this particular engine on any aircraft is at the sole discretion and responsibility of the aircraft manufacturer assembler and owner user Duetothe varying designs equipment and types of aircraft BRP Rotax makes no warranty or representation on the suitability of its engine s use on any particular aircraft Further BRP Rotax makes no warranty or representation of this engine s suitability with any other part component or system which may be selected by the aircraft manufacturer assembler or user for aircraft application Unlessina run up area never run the engine with the propeller turning while on the ground Do not operate engine if bystanders are close To prevent unauthorized use never leave the aircraft unattended with the engine running To eliminate possible injury or damage ensure that any loose equipment or tools are properly secured before starting the engine Effectivity 914 Series page 10 Edition 1 Rev 0 Juli 01 2006 03187 03187 BRP Rotax INSTALLATION MANUAL When in storage protect the engine and fuel system from contamination and exposure Never operate the engine and gearbox without sufficient quantities o
87. sue Effectivity 914 Series page 52 Edition 1 Rev 0 Juli 01 2006 03191 03191 BRP Rotax INSTALLATION MANUAL 13 3 Checking of the lubrication system To control the proper function of the lubrication system the following readings have to be taken on the running engine NOTE The required pressure gauges and connection parts are not in cluded in the ROTAX engine delivery 13 3 1 Measuring of the vacuum Measuring of vacuum in the oil suction line 1 line from oil tank to oil pump via oil cooler at a max distance of 100 mm 4 in from pump inlet 2 At take off performance the indicated vacuum 3 must not be more than 0 3 bar 4 35 psi otherwise the oil hose 1 could colapse and thus blocking the oil supply to the engine fig 22 1 WARNING The vacuum 3 must be verified over the total range of engine operation Specially on cold oil temperature the flow resistance increases so that not enough oil can flow on suction side max 100 mm i or 4 inch max 0 3 bar Unterdruck 04050 max 0 3 bar below atmospheric pressure Effectivity 914 Series page 53 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 13 3 2 Measuring of the pressure in the crankcase Measure of the mean crankcase pressure at full load blow by gas pressure responsible for proper oil return from crankcase to oil tank A pressure indicator 4 pressure gauge with incor
88. t of the cooling system must be designed to keep the operating temperatures within the specified limits To minimize flow resistance employ radiator with low flow resistance and parallel flow as realized on the original BRP Rotax radiator and use short hoses and pipelines Coolant hoses temperature durability min 125 C 257 F pressure durability min 5 bar 73 p s i nom inside dia 25 mm 1 bending radius min 175 mm 7 material Suitable for 100 Glycol and antifreeze agents CAUTION CAUTION to ozone stability NOTE If installation require longer distances use aluminium pipes 25 mm 1 inside dia instead of hoses Expansion tank hoses Hose for expansion tank must be rated for vacuum suction for min 125 C 257 F 12 7 Size and position of connections See fig 17 18 19 expansion tank 1 with radiator cap 2 to radiator 3 outside dia 25 mm 1 slip on length max 22 mm 7 8 to overflow bottle 4 outside dia 8 mm 3 8 slip on length max 15 mm 9 16 NOTE See therefore also SI 25 1997 Running modifications latest issue The aircraft manufacturer has to carry outthe check of coolant level in the expansion tank and note it in the daily inspection section of his flight manual according latest issue of Operator s Manual ROTAX 914 It is recommended to make adequate precautions for accomplishment of these inspections e g a flap or panel on the cowling or
89. tax INSTALLATION MANUAL 13 12 Replacement of components malfunction of hydraulic valve tappet should be found during this check of priming process the relevant hydraulic valve tappet has to be replaced and the valve spring support has to be inspected for wear All work has to be performed in accordance with the relevant Maintenance Manual 05455 direction of rotation of engine appropriate plug 6 pressure max 1 ba 15 psi i lee 10 9 9 zal oe E to pump 1 back from engine 2 3 F 0 5 mm 0 02 in fig 29 2 Effectivity 914 Series page 63 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 914 Series Edition 1 Rev 0 page 64 Juli 01 2006 03191 903192 BRP Rotax INSTALLATION MANUAL 14 Fuel system 14 1 Description of system See fig 30 The fuel flows from the tank via a coarse filter water trap 1 to the two electric fuel
90. tea ska aenea s ausge sees eruere eei 37 12 4 Check cooling system Efficiency of the cooling 38 12 4 1 Measurement of cylinder head temperature and coolant exit temperature 38 12 5 Determination of operating limits 39 12 6 Requirement on the cooling system 41 12 7 Size and position of connections ssssssssssssssssseeeeeeeneeeeenee nns 41 12 8 Coolant capacity eite Si in lt Fe XE SERES RR 43 12 9 Feasible location of radiator danni NEEESE raian 44 Effectivity 914 Series page 3 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 12 10 General directives for the cooling system 47 12 11 Cooling 48 12 11 1 General directives for ducting of the cooling air 49 12 L brication 51 13 1 Description of the system is 51 13 2 Limits of operation sie 52 13 3 Checking of the lubrication system 53 13 31 M asuring of tlie VACUUM suction tite aient feat 53 13 3 2 Measuring of the pressure in the 54 13 4 Requirements on the oil and venting lines 55 13 5 Connecting dimensions and location of connections
91. th the sensor devise CAUTION Itispossibletoreceive a misleading reading when measuring fluid temperatures If fluid volume is lost and the probe is not fully submerged in the fluid the display could show a lower temperature than actual measuring airtemperature instead of fluid temperature Effectivity 914 Series page 38 Edition 1 Rev 0 Juli 01 2006 d03190 d03190 BRP Rotax INSTALLATION MANUAL 12 5 Determination of operating limits Coolant and necessary modification on radiator installation Depending on the achieved maximum values of the cylinder head temperature and the coolant temperature following action are necessary 07818 maximum values for coolant used for tests Coot Ciney Conventional coolant Waterless coolant temperature temperature Additional instruments for less than less than displaying coolant 120 248 F 135 C 275 F temperature is necessary Modifications to the instruments or limit not necessary more than less than a 120 C 248 F 135 275 F Cooling capacity too low less than more than Check of the installation 120 C 248 F 135 C 275 F necessary Cooling capacity too low Check c of the installation necessary more than more than c 120 C 248 F 135 275 F a Maximum cylinder head temperature is below operating limit Operating with waterless coolant is permissible without modification to the installati
92. the exhaust system RISK OF FIRE The lines have to be routed such that in case of damage the surplus fuel is drained away suitably Route the lines without kinks and avoid narrow bends Route the lines with a continuous decline The lines have to be protected against any kind of blockage e g by formation of ice CAUTION With closed or blocked drainage bores fuel could flow into combustion chamber possibly ruining the engine by hy draulic lock Effectivity 914 Series Edition 1 Rev 0 page 80 Juli 01 2006 03194 03194 BRP Rotax INSTALLATION MANUAL Connecting nipple 1 of drainage line outside dia 6 mm 1 4 slip on length sisi max 17 mm 11 16 CAUTION Utilize the complete slip on length Secure hoses by suit able screw clamps or by crimp connection Location of connecting nipple P2 nipple mm mm mm 02486 16 3 Notes to employment of the air filter BRP Rotax offers an air filter as described below WARNING certification to the latest requirement such as FAR and EASA has to be conducted by the aircraft manufacturer The following points should assist the aircraft manufacturer at the choice of a suitable filter Air filter four fold cotton fabric face covered with metal screen amin flow rate of 6 23 m3 min 220 cfm Effectivity 914 Series page 81 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL NOTES Effecti
93. the lamp Use a two wire lamp do not use a lamp that grounds through the base as this will defeat the warning system 19 4 11 Caution lamp See fig 52 Colour of lamp orange or colour as per effective regulations Voltage 12 V DC depending on input voltage of the TCU current max 0 5A connections terminal flexible wire 0 75 18 AWG white No 35 terminal flexible wire 0 75 mm 18 AWG white No 11 from the 36 pole plug receptacle of the TCU plug 6 3 x 0 8 to DIN 46247 length approx 600 mm 24 in from TCU CAUTION Donotconnectthe neg terminal to ground or the pos Effectivity 914 Series Edition 1 Rev 0 terminal to bus 12 volt each wire must be connected directly to the lamp Use a two wire lamp do not use a lamp that grounds through the base as this will defeat the warning system page 99 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 19 4 12 External alternator optional extra See fig 64 65 66 output max 600 W DC at 6000 r p m voltage 14 2 V 14 8 V ambient temperature range min 30 C 22 F max 90 C 194 F NOTE Voltage regulator is integrated in the alternator Feeding wiring to external alternator 1 located on the outside of propeller gear see fig 64 plus terminal 2 M6 screw suitable for ring terminal to DIN 46225 tightening torque 4 Nm 35 in Ib grounding via engine block mount bracket control wiring field
94. to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer d03189 Effectivity 914 Series page 34 Edition 1 Rev 0 Juli 01 2006 d03190 BRP Rotax INSTALLATION MANUAL 12 Cooling system 12 1 Description of the system See fig 16 The cooling system of the ROTAX 914 is designed for liquid cooling of the cylinder heads and ram air cooling of the cylinders The cooling system of the cylinder heads is a closed circuit with an expansion tank and overflow bottle The coolant flow is forced by a water pump driven from the camshaft from the radiator to the cylinder heads From the top of the cylinder heads the coolant passes on to the expansion tank 1 Since the standard location of the radiator 2 is below engine level the expansion tank located on top of the engine allows for coolant expansion The expansion tank is closed by a pressure cap 3 with pressure relief valve and return valve At temperature rise and expansion of the coolant the pressure relief valve opens and the coolant will flow via a hose at atmospheric pressure to the transparent overflow bottle 4 When cooling down the coolant will be sucked back 1 3 aas 4 4 00125 into the cooling circuit See therefore SB 914 025 Modifications of the overflow
95. top the engine immediately and find the trouble Repeat previous steps until proper oil flow is observed The engine must not be started before rectification Fit the turbo sump oil return line 7 on oil tank and tighten to 15 Nm 133 in Ib Restore aircraft to original operating configuration 13 11 Inspection for correct venting priming of hydraulic valve tappets See fig 29 2 The subsequent check procedure describes the correct method to verify adequate priming of hydraulic valve tappets CAUTION Engine has reached operating temperatures here Use appropriate safety equippment and clothing Remove valve cover on cylinder 1 Turncrankshaft direction in of normal rotation so that the piston on cylinder 1 is on ignition top dead center both valves are closed Press both rocker arms on hydraulic valve tappet side with a force F about 70 N 15 7 LB offorce forabout 3 sec Approximate force can be verified with a fan belt tester Check distance between rocker arm and valve contact surface Max allowable distance 0 5 mm 0 02 in Repeat on all other cylinders CAUTION ffitis possible to push the valve tappets further than this limit refit the valve covers and perform an additional engine run for about 5 min at 3500 rpm To get the hydraulic valve tappets adequately primed this process can be repeated up to 2 times Effectivity 914 Series page 62 Edition 1 Rev 0 Juli 01 2006 03191 BRP Ro
96. ubrication system with a main oil pump with integrated pressure regulator and an additional suction pump NOTE The oil pumps are driven by the camshaft The main oil pump sucks the motor oil from the oil tank 1 via the oil cooler 2 and forces it through the oil filter to the points of lubrication lubricates also the plain bearings of the turbo charger and the propeller governor The surplus oil emerging from the points of lubrication accumulates on the bottom of crankcase and is forced back to the oil tank by the blow by gases The turbo charger is lubricated via a separate oil line 3 from the main oil pump The oil emerging from the lower placed turbo charger collects in the oil sump and is pumped back by a separate pump to the oil tank via the oil line 4 NOTE The oil circuit is vented via nipple 5 in the oil tank 05386 NU Effectivity 914 Series page 51 Ed
97. umes all risks possibly arising by utilizing auxiliary equipment The furnishing of proof in accordance to the latest FAR or EASA has to be conducted by the aircraft manufacturer intake filter mechanical rev counter electric rev counter hour meter shock mount Effectivity 914 Series page 20 Edition 1 Rev 0 Juli 01 2006 03188 03188 BRP Rotax INSTALLATION MANUAL 7 3 Engine components engine views definition of main axes See fig 2 3 4 5 6 PTO power take off side MS magneto side A points of attachment for engine transport centre of gravity P zero reference point for all dimensions NOTE Allow 1 mm on all stated dimensions as manufacturing tolerance x y z axes for system of coordinates Cyl 1 1 Cyl 3 Cylinder 3 Cyl 2 Cylinder 2 Cyl 4 Cylinder 4 1 engine number S 2 propeller flange Z 8 MS 3 propeller gear 3 4 A Bi 4 vacuum pump or s Le eer hydraulic governor Tus pt Se forconstantspeed DAT IE EN L JAH X Il rw propeller d 22 S sis 5 intake manifold S AT TT LIKE 34 Te lt X15 X1 6 ignition housing Ai L 24 ae 32 7 ignition cover BOTAX oray Dis 8 constant depression carb a 2 7 So 35 9 ai
98. und 24 560 25 450 axis y1 y1 kg cm moment of inertia around 26 520 27 480 axis z1 z1 kg cm Effectivity 914 Series page 24 Edition 1 Rev 0 Juli 01 2006 04860 03188 03188 BRP Rotax INSTALLATION MANUAL 9 Preparations for engine installation B CAUTION The stated directives are measures to pay CAUTION to at engine installation to prevent any accidents and engine damage 9 1 Transport The engine to be lifted by two hooks or straps around the middle of the intake manifolds See chapter engine views numbering of cylinders and definition of main axes 9 2 State of delivery The engine is attached with to steel angles anchored on a timber plate CAUTION attachment screws are only for transport and must not be used in the aircraft 9 3 Enginepreservation The engine is preserved at BRP Rotax thus warranting proper protection against corrosion for at least 12 month after date of delivery from BRP Rotax This warranty is subject to the following conditions the engine has to be stored in the packing as supplied by BRP Rotax the covers on various openings must not be removed see chapter of protective covering engine has to be stored in a suitable place at min 40 C 40 F and max 80 C 176 F If the engine is stored for a period longer than 12 month perform every 3 months the tasks given in the current valid Maintenance Manual chapter 11 11 1 Preservati
99. unning in period approx 30 min Fuse Each of the two fuel pumps has to be protected by y slow blowing 5A fuse in accordance with wiring diagram fig 52 WARNING Allconnections have to be established by the aircraft manu facturer in compliance with regulations such as FAR or EASA and the effective wiring diagram fig 52 WARNING essential point is according to regulations that the fuel pumps are connected on two completely independent power supplies Effectivity 914 Series page 96 Edition 1 Rev 0 Juli 01 2006 03195 03195 BRP Rotax INSTALLATION MANUAL 19 4 8 Turbo Control Unit TCU See fig 63 voltage 12 V DC min 6 V max 18 V current input see chapter 19 5 NOTE At wrong polarity of the supply voltage both lamps will light up Operating temperature range min 25 C 13 F max 70 160 F storage temperature range min 40 C 40 F max 70 160 F weight approx 425 9 1 Ib dimensions and attachment see sketch fig 63 place of installation WARNING Installation in the engine compartment is not permitted since the TCU is not of a fire resistant construction A recommendable location is in the cockpit below the instrument panel The TCU has to be in an area were it is protected against moisture NOTE Place of installation is limited by the length of the wiring harness Support of the TCU on the 4 rubber shock m
100. v 0 Juli 01 2006 4 3 Instruction BRP Rotax INSTALLATION MANUAL Engines require instructions regarding their application use operation maintenance and repair Technical documentation and directions are useful and necessary complementary elements for personal instruction but can by no means substitute theoretical and practical instructions These instructions should cover explanation of the technical context advice for operation maintenance use and operational safety of the engine All technical directives relevant for safety are especially emphasized Pass on safety instructions to other users without fail This engine must only be operated with accessories supplied recommended and released by BRP Rotax Modifications are only allowed after consent by the engine manufacturer CAUTION A WARNING A WARNING A WARNING Spare parts must meet with the requirements defined by the engine manufacturer This is only warranted by use of GENUINE ROTAX spare parts and or accessories see illustrated parts catalog They are available only at the authorized BRP Rotax Distribution and Service Centers The use of anything other than genuine ROTAX spare parts and or accessories will render any warranty relating to this engine null and void see Warranty Conditions Engine and gear box are delivered in dry conditions without oil Before putting engine in operation it must be filled with oil Use only oil
101. vibrations Therefore fuel pump attached directly on the engine is not permitted Max suction head 250 mm 10 in A WARNING Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Because of the risk of steam vapour formation on the suction side of the pumps and other safety reasons is the pump installation not permitted in the engine compartment A WARNING Installation of the fuel pumps inthe engine compartment and in the cockpit is not permitted since the fuel pumps are not of a fire resistant construction WARNING Should the situation arise certification to the latest require ments such as FAR or EASA would have to be conducted by the aircraft manufacturer Check valve Specification opening pressure 0 1 0 15 bar 1 5 p s i 2 2 p s i permitted pressure in reverse biasing 2 bar 29 p s i burst pressure 5 bar 72 5 p s i Effectivity 914 Series page 68 Edition 1 Rev 0 Juli 01 2006 d03192 903192 BRP Rotax INSTALLATION MANUAL 14 4 2 Fuel pressure control See outline of fuel pressure control 3 fig 30 and fig 33 Connections inlet 1 feed line from fuel pumps and S N V er WEN outlet 2 fuel return to tank hose nipple 4 6 DIN 7642 did eH 8 mm 5 16 Slip on
102. vity 914 Series Edition 1 Rev 0 page 82 Juli 01 2006 03194 03194 BRP Rotax INSTALLATION MANUAL 17 Pressure sensors See fig 45 46 2 pressure sensors are included in the supply volume of the engine and connected by plugs with the wiring harness WARNING Since a failure of pressure interconnections 1 of airbox float chambers fuel control and pressure sensor would possibly result in an engine stop all these interconnections have to made very carefully RK FS y E Miam eS ee woe 5 05740 To avoid any mix up of pressure sensor wiring plug yyy connections are colour coded grey plug connection gt static pressure sensor black plug connection gt airbox pressure sensor Umgebungsdruck Sensor static pressure sensor 4 1 Airboxdruck Sensor X p pressure sensor Effectivity 914 Series page 83 Edition 1 Rev 0 Juli 01 2006 BRP Rotax INSTALLATION MANUAL 17 1 Static pressure sensor See fig 47 effective range 100 1200 hPa deviation max 40 hPa operating temperature 40 C 40 F max 125 C 257 F dimensions and attachment see sketch fig 47 fitting position The pressure connection Pos 3 fig 47 points downwards to prevent possible condensate from entering the sensor i e th

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