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Installation Manual 914 F Rev.1 09/2004

1. engine engine version version F2 F4 F3 moment of inertia around 20 470 axis x1 x1 moment of inertia around 24 560 axis y1 y2 moment of inertia around 26 520 axis z1 z3 Modification No Reference Install Date Page 0 914 F 1996 05 10 21 9 Preparations for engine installation E ATTENTION The stated directives are measures to pay attention 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 4 Allen screws M10x20 to steel angles anchored ona timber plate 9 3 Engine preservation The engine is preserved at ROTAX thus warranting proper protection against corrosion for at least 12 month after date of delivery from BOMBARDIER ROTAX This warranty is subject to the following conditions the engine has to be stored in the packing as supplied by ROTAX the covers on various openings must not be removed see chapter of protective covering engine has to be stored in a suitable place If the engine is stored for a period longer than 12 month the following tasks have to be performed every six months remove the 3 Allen screws M6x16 along with washer and lock washer and take off ignition cover Crank the engine by hand on
2. Fuse Each of the two fuel pumps has to be protected by y slow blowing 5A fuse in accordance with wiring diagram Ill 52 A WARNING Allconnections have to be established by the aircraft builder in compliance with regulations such as FAR or JAR and the effective wiring diagram lll 52 A WARNING An essential point is according to regulations that the fuel pumps are connected on two completely independent power Supplies Page Date Install Reference Modification No 82 19960510 914F eee Blank page Modification No Reference Install Date Page sO 914 F 1996 05 10 83 19 4 8 Turbo Control Unit TCU See Ill 63 voltage 12 V DC min 6V 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 0 C 160 F storage temperature range min 40 C 40 F max 0 C 160 F weight approx 425 g 1 Ib gt dimensions and attachment see sketch Ill 63 place of installation A 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 NOTE Place of installation is limited by the length of the wiring harness Support of the TCU on the 4 silent blocks which ensures an attachment free of vibrations A WARNING Ifthe standard a
3. Modification No Reference Install Date Page Q 914 F 1996 05 10 11 4 4 Technical documentation The information given in the Installation Manual Operator s Manual Maintenance Manual Overhaul Manual Spare parts list Technical bulletins Service Informations are based on data and experience that are considered applicable for professionals under normal conditions The fast technical progress and variations of installation might render present laws and regulations inapplicable or inadequate Page Date Install Reference Modification No 12 19960510 914F Q Blank page Modification No Reference Install Date Page 0 914 F 1996 05 10 13 5 List of the current pages He 07056 50 96 05 10 9 10 11 12 13 blank 17 18 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 6 s 200407 07 16 96 05 10 96 05 10 96 05 10 96 05 10 66 blank 1 2 2004 07 01 96 05 10 3 96 05 10 96 05 10 4 96 05 10 96 05 10 5 blank 96 05 10 96 05 10 2 6 96 05 10 gt oo 3 8 4 8 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 71 blank 96 05 10 96 05 10 96 05 10 67 69 70 12 73 96 05 10 23 blank 9605 10 2 2 26 2 28 29 blank 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 19 20 96 05 10 22 4 5 19 76 11
4. IN LS Lai ARARA y o eo AN EN i Chet 7 say mre engine connection for oil return line stainless steel exhaust turbo le 2x pressure sensor o Sya om oil filter connection for mechanical uroocharger rev counter electric starter a turbo control unit TCU connection for additional fuel pressure control eli modules for temperature sensor airbox ignition drip tray amp water trap three way solenoid valve amp 2x electric fuel pump oil tank external alternator servo motor servo cable cable assembly coolant pump expansion tank compensation tube connection for manifold pressure sensor for oil pressure sensor for oil temperature 2 separate oil pumps sensor for cylinder head temperature Page Date Install Reference Modification No 18 19960510 914F Q pe Nes A XN N A f LS 26 I ALI h X VA 4 Ma a amare CH E H We f ui Se g OHHH 28 No Reference Install Date Page 914F 1996 05 10 19 0Q Modification 8 Technical data To maintain clarity only data relevant f
5. NOTE One each plug and insulating sleeve are supplied loosely packed shorting cable of top electronic module marked A for ignition circuit A Shorting cable 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 E ATTENTION The electromagnetic compatibility EMC and electromag netic interference EMI depends essentially on the shorting cables used Min section area 2x 0 75 mm shielded flexible cable shielding braid on both ends grounded E ATTENTION The metal base of each ignition switch must be grounded to air craft frame Page Date Install Reference Modification No 80 19960510 914F eee 19 4 5 Electric starter AG niga T_T See Ill 59 N Feeding lines from starter relay to the elec tric starter TETN Xt I A cross section of at least 16 mm 7 RNS CED output 6 kW SIA a ko RUN r plus terminal M6 screw tightening a AN torque 8 Nm 70 in lb suitable for cable f eyes to DIN 46225 P grounding via engine block M ATTENTION Suitable for short starting periods only Activate starter for max 10 sec without interruption followed by a cooling period of 2 min 19 4 6 Starter relay See Ill 60 nominal voltage 12 V control voltage min 6 V max 18 V switching current max 75 A
6. Ps oa e A 25 C 13 F 11 Fuel pressure see chapter 14 2 12 Banking of plane deviation from the ef fective vertical See ill 7 aT D A 40 NOTE Up to this inclination the dry sump lubrication system warrants adequate lubrication in every flight situation Page Date Install Reference Modification No 20 1996 05 10 914 F ee 8 2 Installation dimensions all dimensions in mm See illustration 2 3 4 Standard engine version pos neg total 656 6 665 1 576 0 531 0 NOTE Dimensions to point of reference P See ill 2 3 4 8 3 Weights Weight of engine defined to the following conditions Engine dry from serial production with external alternator but without fuel pumps see chapter description of design Engine weight Version F2 and F4 naassen 74 7 kg 164 Ib VErSION FS acosa 77 4 kg 170 Ib Weight of external generator assy 3 0 kg 6 6 Ib VACUUM pump ASS eeeee ee 0 8 kg 1 76 Ib hydraulic governor assy 2 kg 6 lb 8 4 Centre of gravity of engine and standard equipment See illustration 2 3 4 engine from serial external hydraulic production alternator governor F3 centre of gravity in y axis 9 139 o centre of gravity in z axis 102 6 56 56 NOTE Dimensions to point of reference P See ill 2 3 4 8 5 Moments of inertia in kg cm see illustration 2 3 4
7. ROTAX AIRCRAFT ENGINES Installation Manual for ROTAX Engine Type 914 F A WARNING Before starting with the engine installation please read the Installation Manual completely as it contains important safety relevant information Failure to do so may result in personal injuries including death Edition 0 of 1996 05 10 These technical data and the information contained therein are property of ROTAX GmbH and must not be reproduced neither in entirety nor partially and passed on to third parties without previous consent in writing by ROTAX GmbH This text must be written on every complete or partial reproduction Copyright ROTAX GmbH Approval of translation to best knowledge and judgement in any case the original text in German language is authoritative Recommended price ATS 200 Part no 897 816 DM 28 D Table Ol COMLCINS ai aa eaaa 2 2 INAO assan eersieana geet teaceuatedauarabene care vuausedseatwaba uti 6 9 ERO VAC cirimonia ea ae aE anaia 8 SA ENING annie oa a a a daebaeonctnds Gade temtneeanteneatanee 8 32 Engne seral number sese ease ence eerie ee ieee ae ened 8 A SOU specie ete tacts sito ona osac nb ataduteieeiiencaened sadness devon vonesaaumeavaraussaaandseteds 8 AN TAGDealInG SYINOOIS ste tonssoi ae auneete E E ON 9 4 2 Sally IMONMALOM N essaie Eaa e E EA EUERE 9 Ao ASG OM on E ET e 11 AA Technical documentalo Meesi a T ek ian a EG 12 5 LEIist f the curent DAG
8. The cooling system of the cylinder heads is a closed circuit with an expansion tank 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 Since the standard location of the radiator 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 amp with excess pressure valve and return valve At temperature rise of the coolant the excess pressure valve opens and the coolant will flow via a hose at atmospheric pressure to the transparent overflow bottle When cooling down the coolant will be sucked back into the cooling circuit yy ry eee O D eee a ET Reh ce ns PA ee rs ar a ina g GDA e aia aai i i ea ie ae i i oe Ley a T T T T TT TTT T a T a T a a a E a E a E a E a E a E a E The shape size and location of one or more radiators depend mainly on the space available No provision is made for attachment of the radiator s on the engine d03273 Page Date Install Reference Modification No 32 20040701 914 F aie d03273 12 2 Operating Limits The operating limits max permissible cylinder head temperature are dependent on the engine design but also essentially on the coolant used The hottest measuring point cylinder 2 o
9. 18 19 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 30 96 05 10 80 96 05 10 31 blank 81 96 05 10 2004 07 01 82 96 05 10 2004 07 01 83 blank 960510 2004 07 01 84 96 05 10 33 34 35 36 37 blank 38 39 blank 40 41 42 43 44 45 blank 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 85 86 87 88 89 96 05 10 96 05 10 96 05 10 96 05 10 96 05 10 90 960510 96 05 10 96 05 10 46 96 05 10 a 960510 96 05 10 2 99 2004 07 01 47 14 48 96 05 10 100 blank 2004 07 01 49 96 05 10 101 blank 2004 07 01 Page Date Install Reference Modification No 14 20040701 914 F 1 23 93 96 05 10 94 96 05 10 95 96 05 10 96 96 05 10 97 96 05 10 5 d03273 d03273 6 Table of amendments date of remark for date of approval date of no chapter page signature change approval from authority inclusion o oa rior i010 notrequres __ 19060510 Kome 1 1 5 6 2 14 15 2004 0701 12 32 32A 32B 25 99 100 101 Modification No Reference Install Date Page 1 914 F 2004 07 01 15 7 Description of design 7 1 Designation of type Basic type e g ROTAX 914 F2 F2 with prop flange for fix pitch propeller F3 with prop flange with drive of hydraulic governor for constant speed propeller F4 with prop flange for fix pitch propeller but prepared for retro fit of hydraulic gove
10. 3 min 11 mm 43 length up to 2 m 6 6 min 12 mm 47 Venting line of oil tank See ill 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 venting 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 The venting line 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 venting line with a Gp bypass opening before passing through cowling See ill 23 2 Page Date Install Reference Modification No 42 1996 05 10 914 F eee 13 4 Connecting dimensions and location of connections E ATTENTION Utilize the full slip on length for hose connections Secure hoses with Suitable screw clamp or by crimp connection 13 4 1 Oil circuit engine See ill 24 25 Oil pump inlet thread M18 x 1 5 x 11 HHT NOTE Ped Suitable for use of a swivel joint See ill 28 Tightening torque 25 Nm 220 in lb Oil return According to propeller configuration choose the appropriate connection for the oil return line Position 1
11. Only the following connections per Ill 30 have to be established gt Feeding lines to suction side of the electric fuel pumps gt lines from pressure side of the electric fuel pump to inlet of fuel pressure control Returnline from fuel pressure control to oil tank Page Date Install Reference Modification No 48 19960510 914F Ei 14 2 Operating limits A WARNING Design and layout of the fuel system has to warrant engine operation within the specified limits Fuel pressure Ake Gens eee ae eee Peer tener a Renee Stet E EEE eae a airbox pressure 0 35 bar UN states A E EE E E aia E EA TE airbox pressure 0 15 bar DOIN eae E cannes aaee nate ene airbox pressure 0 25 bar 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 of the fuel system fuel lines See Ill 30 A WARNING Fuel lines have to be established to the latest requirements such as FAR or JAR by the aircraft builder E ATTENTION The fuel return must be a line 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 Otherwis
12. permanent max 300 A for 1 sec ambient temperature range from 40 C 40 F to 100 C 214 F weight 0 145 kg 32 Ib current connections M6 screw tightening torque 8 Nm 70 in lb Suitable for cable eyes to DIN 46247 control wiring plug connector 6 3x0 8 suitable for plug socket to DIN 46247 grounding via housing E ATTENTION Activation of start relay limited to short duration Over a period of 4 min operation the duty cycle is 25 Modification No Reference Install Date Page Q 914 F 1996 05 10 81 19 4 7 Electric fuel pumps See Ill 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 cable eyes to DIN 46225 For radio interference suppression a capacitor Ill 52 Pos of juF 100 V has to fitted as near as possible to the terminals A WARNING The certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder current input pu The diagram shows the current input over pressure 3 0A 2 0 2 0 Anschlu connector lil 67 0 290 900 750 1000 1250 hPa 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 running in period approx 30 min
13. 48 49 Water trap is included in the supply volume of the engine dimensions and attachment see sketch Ill 49 location of installation The water trap has to be installed by clamps free of stress between hose 4x7 of airbox and the airbox pressure sensor E ATTENTION Utilize full slip on length on all connections Modification No Reference Install Date Page O 914 F 1996 05 10 69 18 Servo motor See Ill 50 51 The correct adjustment of the servo lt SS SS y 1 amp i tt OH WYN cable and consequently the waste ON E lt gate was made already on the no aa course of the testrun at ROTAX A l o Prior to engine operation check the position of the waste gate as follows A WARNING Engine stop ignition OFF switch on TCU servo motor runs with waste gate closed slacken adjustment screw on servo cable support and turn adjustment screw until waste gate is completely closed proper pretensioning of the servo cable is achieved by turning in the adjustment screw by one complete rotation Additionally only the actual attaching of the servo motor has to be performed operating temperature min 20 C 4 F max 60 C 140 F gt dimensions and attachment see sketch Ill 51 location of installation vibration neutralized place A WARNING Installation in the engine com partment is not permitted since the ser
14. 51 can t be supplied A WARNING The certification of items components which are not included in the 13 14 16 17 18 19 20 21 23 24 25 30 31 32 33 34 35 36 37 38 39 40 41 42 51 standard volume of supply of engine has to be conducted by the aircraft builder to the latest requirements such as FAR or JAR 36 pole plug receptacle plug connection for pressure sensor plug connection for lamps plug connection for servo motor pressure sensor static pressure atmospheric pressure pressure sensor airbox servo motor 2 electronic modules plug connection for ignition switch integrated generator external regulator rectifier with plug connections electric starter starter relay with plug connection electric fuel pumps 3 way solenoid valve float valve pressure external alternator with connections electric rev counter capacitor lamps isolating switch for servo motor 2 ignition switches master switch starter switch control lamp amperemeter battery relay battery bus bar capacitor circuit breaker Page Date Install Reference Modification No 74 19960510 914F 0 6LLOv PUB OLZOP ELLOP ZLO NIG 0 SjoqwAs BULA poese o gA a aa 31 oe 9 zese 6 Selr ee sl 0 9 kk ____ Ob Q JO Q TEE EEE i l I lo 7 E Verbraucher consumer Modification No Reference Install Date Page Q 914 F 1996 05 10 75 19 3 Description of the Turbo Cont
15. Aee aa anak Centon adasiteuntias 63 tooa ABa S 64 16 3 Notes to employment of the air filter nn0nnnannaannnannannnennnannnnnnnnnnsnensnnrnnrrnrrsnrrsrenne 65 17 Pressut Sensors oeiia eia esa aeaaeae ar EEE 67 172i otaliG pressure Sen O eener a raed esses 68 17 2 AiDOX Pressure SCNSOM erosin ne e EEEE E N TE 69 TALE ANAO AO a a a a a ketioosmtuicis 69 18 SERVO MOTOT wsccaiicuiawedacteccaaceiatnavacnaa ces cbcasiacsareseactoceneesiacvivevenseveanecdeiwnieinaerecnceeuaeens 70 Modification No Reference Install Date Page Q 914 F 1996 05 10 3 19 EIGKINIC SVStE Maassa iaia eaaa ao aa E 72 19 1 Requirements on circuit wiring ceccceeecceeeeeeeeeceeeeeeeeeseeeeeeeeeeseeeeseeeesseeeseeeesseeenees 12 19 1 1 Electromagnetic compatibility EMC cc ceeececeesseeeeeeeneeeeeeeeaeeeeeeeeseaeeeeeeaaaees 73 19 2 Wiripo didgram siiededitetiutetaivetelamabintanetlaiatiiadabeig a a 14 19 3 Description of the Turbo Control Unit TCU sannesannnannnnnnnnsnnnsennosnnnnnrnnsnnresnrnennne 76 19 4 Technical data and connection of the electric component ccceeeeeeeeeeeeeeees 78 19 4 2 Rectifier reQulator ccccccecccceececeeececeeceecesecceeeeceuseeseuseesueeesausessuseesseeeesueeeneas 78 TOAST SEISCIFONIGINOGUICS ncaro ga ee eer 80 19 4 4 Ignition switches on off SWITCH cccceeccccseeeeeeaeeeeeseeeeeeseeeeeeeeeeeseaeeessaeeeeesaneees 80 t945 EIECIIC SS ONMeC ies tentat
16. Modification No 54 19960510 914F eee 15 2 Connections for Bowden cable actuation and limit load See Ill 36 37 lt gt connection for throttle actuation connection on throttle lever set screw M 5x12 tightening torque 4 Nm 35 in lb suitable for 1 5 mm steel wire action travel 65 mm 2 1 actuating force min 1 5 N 3 Ib max 8 N 1 8 Ib limit load 20 N 4 5 Ib NOTE Throttle opens by spring Wiese RF OO an EK Hh o goes Ls z eo Ror ch We a eT A I IRS CE EN HN A TAE oe N JO CSa LIN connection for starting carb choke actuation connection on choke lever clamping nipple 6 suitable for 1 5 mm steel wire action travel 23 mm 4 actuating force min 10 N 2 2 Ib max 24 N 5 4 Ib limit load 100 N 22 Ib Directive for choke actuation The choke shaft is marked This mark has to point towards cable engagement Modification No Reference Install Date Page Q 914 F 1996 05 10 59 15 3 Requirements on cable actuation See Ill 38 The two throttles have to be controlled by two separate Bowden cables working synchronous Adjust the cables to a free travel of 1 mm 04 in A 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
17. Refer to graph current output over speed of the integrated generator and the external alternator item current consumption fuel pump MAIN cceeeeeeee scenes max 3A fuel pump stand by cce max 3A DES UE AEE E E E max 0 3A SEVO MOLO oeaio oneni ia max 1A warming lamp Scns approx 0 25 A ca tiomlamp aan approx 0 25 A SUM Vissa 8A internal power consumption without servo motor and lamps standard value actual value up to aircraft builder 8 without electric starter and start relay Modification No Reference Install Date Page sO 914 F 1996 05 10 89 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 JAR has to be conducted by the aircraft builder 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 illustration 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 holes of 8 mm dia P C D 80 mm 3 15 6 bolt holes of 11 5
18. against 100 Glycol and any other anti freeze agent possible to vent volume c 0 51 13 us gal NOTE The overflow bottle ought to be furnished with a label indicating function and content A WARNING Ensure that the overflow bottle will never be empty otherwise air will be sucked into cooling circuit with ill effect to safe operation of the engine Modification No Reference Install Date Page 0 914 F 1996 05 10 35 12 7 General directives for the cooling system See illustration 21 BOMBARDIER ROTAX offers essential parts of the cooling system for this engine such as radiator overflow bottle etc see spare parts list in the non certified state Certification to the latest requirements to FAR or JAR has to be conducted by the aircraft builder In an installation as depicted with the radiator in a higher position than the standard supplied expansion tank a water accumulator has to fitted instead of the expansion tank Additionally a suitable expansion tank has to be installed at the highest point of the cooling circuit E ATTENTION The size and type of radiator should be adequate to transfer thermal energy of c 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 The flowrate of coolant in the cooling system can be assumed with c 55 I min 16 US gal min at 5500 r p m P
19. ci keccsicaie aii are tecptnbet ete taw O 1 5 5 bar 22 73 p s i E ATTENTION Atfull throttle operation the depression at pump inlet must be 0 3 bar 4 4 p s i below the ambient pressure Reading must be taken ata distance of max 100 mm 4 before pump inlet See ill 24 Oil temperature Oil temperature sensor see ill 73 74 NA EETA E nn ueae AA E AA 130 C 266 F PIIA AA E E E EE NAPE AEN EI AA ATA 50 C 120 F most favourable oil temperature cccceeeeeees ca 90 110 C 190 250 F A WARNING At operation below nominal oil temperature formation of condensate in the lubrication system might influence oil quality Modification No Reference Install Date Page Q 914 F 1996 05 10 41 13 3 Requirements on the oil and venting lines Oil lines 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 Minimum inside dia of oil lines in reference to total length length up to 1m 3 min 11 mm 43 length up to 2 m 6 6 min 12 mm 47 length up to 3 m 10 min 13 mm 51 Oil 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 Minimum inside dia of oil lines in reference to total length length up to 1m
20. coolant concentrate depends on the mixture ratio and on the system pressure i e radiator cap Corresponding to the following table the max permissible cylinder head temperature Is limited depending on the coolant concentrate used and may not be exceeded radiator ca max permissible P cylinder head temperature 0 9 bar 13psi 115 C 239 F 1 2 bar 17 5psi 120 C 248 F wei During exclusive operation within the max permissible cylinder head tem perature the following coolant can be used in the corresponding mixture ratio 07001 i or equivalent 50 antifreeze concentrate and 50 pure water or an equivalent pre mixed liquid M CAUTION The antifreeze frost protection of this mixture is to be observed according to the manufacturer s specifications M CAUTION The correct mixture ratio is to be observed since otherwise the coolant can thicken and as a result can lead to damages to the cooling system d03273 Page Date Install Reference Modification No 32B 20040701 914F 1 12 3 Requirements on the cooling system E ATTENTION All components of the cooling system have to be secured suitably A WARNING The size and layout 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 BOMBARDIER ROTAX radiator and use short hoses and pipelines
21. for tractor or 2 for pusher configuration See ill 28 hose nipple ee 10 DIN 7642 outside dia cccceeeecseeeeceeeees 12 mm 0 5 in ne length aacedainansesnsieansaesatie max 24 mm max 0 94 in Tightening torque of banjo bolt M16x1 5x28 35 Nm 310 in lb Druckpropeller Zugpropeller pusher config tractor config 13 4 2 Oil circuit turbo charger See ill 26 Oil return hose nipple uu ee 4 6 DIN 7642 outside dia cccseeeeeeeeeseeeees 8 mm 0 31 in slip on length ccceceeeeeeeeeeees max 20 mm 0 79 in HHH ne ee HHH Te Yy Tightening torque of banjo bolt nity Bic 1O i 4 M10x1x19 17 Nm 150 in lb h Do T J7 7 aii ER Modification No oo Install Date Page 914 F 1996 05 10 43 B IF 13 4 3 Oil tank See ill 27 28 The oil tank is furnished with 2 screw connections M18x1 5 and with a tapped hole M10x1 165 Connections for oil circuit engine Oil inlet and outlet via standard swivel joint and connecting bend 2x connecting bend 90 outside dia 12mm 0 47 in slip on length max 24mm 0 94 in tightening torque 25 Nm 220 in lb 1x venting nipple outside dia cceee 8mm 0 31 in slip on ENGUM zeessen max 15mm 59 in Connection for oil circuit turbo charger hose nipple 4 6 DIN 764
22. mm dia P C D 101 6 mm 4 6 bolt holes of 13 mm dia ratio of gear reduction 2 4286 51 T 21 T max torque 340 Nm 108 ft lb at propeller max moment of inertia 6000 kgcm max permitted out of balance on a prop max 0 5 gm 47 0 05 Page Date Install Reference Modification No 90 19960510 914F ee 21 Vacuum pump 21 1 Technical data See Ill 69 Type Airborne 211 CC drive via propeller gear location of the necessary connection and on the vacuum pump AxisAchsen Pott 226 O 98 2 d 293 0 98 gt connections thread size 5 8 16 T P I tightening torque hand tight and tighten up by max 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 m per minute at 0 65 bar 10 p s i as from 1900 r p m pump speed E ATTENTION Pay 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 JAR has to be conducted by the aircraft builder 3 Modification No Reference Install Date Page Q 914 F 1996 05 10 91 22 Hydraulic governor for constant speed propeller 22 1 Technical data See Ill 70 Type Woodward governor A210786 for engine type F3 only drive via pr
23. must not be used and releases engine manufacturer from any liability gt 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 3 Page Date Install Reference Modification No 10 1996 05 10 914 F 0 In addition 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 Airborne air pump The safety warning accompanying the air bump must be given to the owner operator of the aircraft into which the air pump is installed 4 3 Instruction Engines require instructions regarding their application use operation maintenance and repair Technical documentation and directions are useful and necessary complemen tary 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
24. the adjustment of the Bowden cable after engine installation has been completed to ensure exact final adjustment E ATTENTION Incase 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 on the carburetor The carburetors are positioned above the exhaust sockets Below the carburetors one each drip tray with a draining connection is fitted which acts as heat shield as well A WARNING Inthe area of the float chamber the temperature limit of the fuel must not be exceeded lf need be provide additional insulation or heat shields Certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder Drainage piping A WARNING Connect draining lines without fail otherwise emerging fuel from a possible leakage could drip onto the exhaust system RISK OF FIRE Thelines have to be routed such that in case of adamage the surplus fuel is drained off suitably Route the lines without kinks and avoid narrow bends Route the lines with a continuous decline Thelines have to be protected against any kind of blockage e g by formation of ice E ATTENTION With closed or blocked leakage piping fuel could end up on exhaust system RISK OF FIRE Connecting nipple for leakage line outside dia 6 mm 1 4 slip on lengthmax 17 mm 11 16 Page Date Install Reference
25. the oil sump and is pumped back by a separate pump to the oil tank via the oil line NOTE The oil circuit is vented via bore in the oil tank o Page Date Install Reference Modification No 40 1996 05 10 914 F eee For the completion of the lubrication system only the following connections need to be established Lubrication circuit engine main oil pump oil tank outlet oil cooler oil cooler gt oil pump inlet oil return oil tank inlet oiltank venting line Oil circuit turbo charger suction pump oil return 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 A WARNING Certification of oil cooler and connections to the latest requirements such as FAR and JAR has to be conducted by the aircraft builder 13 2 Limits of operation A 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 ill 75 76 VAX le EPEE TO EE E EE EEA E 7 bar 100 p s i E ATTENTION Permitted at engine start for a short period A eena weucirasateeunaseutcp ius ensas oeatacu ti sasedaeaaeat 1 5 bar 22 p s i IOI GN
26. the throttle lever detent for max continuous power Performance check in accordance with Operator s Manual lf nominal performance won t be reached or is in excess of examination of the installation and engine will be necessary Consult Maintenance Manual 914 F E ATTENTION Don t conduct any test flights before fault has been traced and found Page Date Install Reference Modification No 98 19960510 914F 0 d03273 25 ROTAX Authorized Distributors for Aircraft Engines See current issue of Operator s Manual section 14 or in the Internet on the official website www rotax aircraft engines com Modification No Reference Install Date Page 1 914 F 2004 07 01 99 blank page Page Date Install Reference Modification No 100 20040701 914F 1 d03273 d03273 blank page Modification No Reference Install Date Page 1 914 F 2004 07 01 101
27. this engine must only fly in DAYLIGHT VFR conditions gt This engine is designed for possible application on aircraft used in VFR condi tions which have the capability of controlled gliding without engine power 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 It should 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 Due tothe varying designs equipment and types of aircraft BOMBARDIER ROTAX makes no warranty or representation on the suitability of its engine s use on any particular aircraft Further BOMBARDIER ROTAX makes no warranty or represen tation 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 gt Whether you are a qualified pilot or a novice complete knowledge of the aircraft its controls and operation is mandatory before venturing solo Flying any type of aircraft involves a certain amount of risk Be informed and prepared for any situation or hazard associated with flying A recognized training program and continued education for piloting an aircraft is absolutely necessary for all aircraft pilots Make sure you al
28. 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 or fit a stronger return spring or a cable with pull push action would have to be used Page Date Install Reference Modification No 56 1996 05 10 914 F eee 15 4 Requirements on the throttle lever See Ill 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 this small range or if setting for take off performance pass this range speedily Consult also the chapter electric system for the description of the system 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 4 corresponding to 8 9 mm 5 16 11 32 travel before full throttle stop The sketch Ill 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 re
29. 0 location of installation vibration neutralized installation in a calm 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 E ATTENTION The 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 Page Date Install Reference Modification No 68 19960510 914F eee 17 2 Airbox pressure sensor See Ill 47 effective range 500 2500 hPa deviation max 60 hPa operating temperature min 40 C 40 F max 125 C 257 F dimensions and attachment see sketch Ill 47 fitting position The pressure connection Pos Ill 47 points downwards to prevent possible condensate from entering the sensor i e the 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 E ATTENTION The pressure connection has to be protected against entering of foreign matter e g oil fuel water etc see chapter 17 2 1 NOTE Location of installation is limited by the length of the wiring harness length of cable assy approx 250 mm 10 in from TCU 17 2 1 Water trap See Ill
30. 2 outside dia 8 mm slip on length max 20 mm tightening torque of the banjo bolt M10x1x19 17 Nm 150 in lb NOTE In the standard supply volume the connection is closed by the plug screw This screw plug has to be removed and is replaced by the hose nipple sealing ring 10x14 DIN 7603 and banjo bolt Page Date Install Reference Modification No 44 19960510 914F se Blank page Modification No Reference Install Date Page sO 914 F 1996 05 10 45 13 5 Feasible position and location of the oil tank See illustration 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 has to be positioned in its z axis such that the oil level is always between 0 and 400 mm on the z axis A WARNING At higher location of the oil tank oil might trickle through 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 and oil drain plug to be easily accessible A a ni obo L Aa ase eee e a A lt max 400 mm Page Date Install Reference Modification No 46 1996 05 10 914 F eee 13 6 Feasible position and location of the oil cooler s
31. 7 Feeding wiring to electric rev counter from the 36 pole receptacle of TCU connections flexible cable 0 75 mm white No 26 flexible cable 0 75 mm white No 13 from the 36 plug receptacle of TCU without plug connection length approx 1000 mm 40 in from TCU NOTE BOMBARDIER ROTAX developed especially for this application a non certified electric rev counter Certification to the latest require ments such as FAR or JAR has to be conducted by the aircraft builder E ATTENTION 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 speed 500 rpm load 100 kO V 15 10 1 revolution V 360 speed 6000 rpm load 100 Q speed 6000 rpm load 100 kO V V 100 50 0 50 100 1 revolution 150 360 V Page Date Install Reference 88 19960510 914F 1 revolution O 360 Modification No 0 19 4 14 Battery See Ill 52 E ATTENTION To warrant reliable engine start use a battery of at least 16 Ah capacity 19 5 Internal consumer of electric power A 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
32. CS neii a a a AEREA 14 6 Table of mendMentS srenriinai aa 15 7 DESCHIDUON Of GESIGMIN sssi anaiena aoaaa eaaa aa 16 TN DSIGMATON OF DC src snueusnacaunsandzaty avs barcacmpuedleanphincedenenstiuleiong sands aa EAE DEEE AEE 16 2y Standard Engine desig societeit tinn stave cast esschaactauentcacc r E a aa aaa Ta 16 7 3 Engine components engine views numbering of cylinders definition of main axes18 8 Techical datarie iaaii 20 S IPS haus IMIS ern a a a E a a aaa toed teem 20 8 2 Installation dimensions all dimensions IN MM cccccceceeceeceeeceeeeeeeeeeseeeeeseeeeees 21 o WEIN ean caciaata nn aehdtiaedi a smuamacuiaeMakenamnineliietes 21 8 4 Centre of gravity of engine and standard EQuIDPMEN cccccsseeeeeeseeeeseeeeeesanes 21 6 5 Moments of inerta INKO CM2 a rctuctacaiei ind Men cic tiacta hin eetiucntaser a a 21 9 Preparations for engine installation ccccesseessseesesseseeseeeeseeeeseesennesseneeeeass 22 OV anspor sects cits sepccascnelt zona ces E Conk cuindaied witete euncceaananstidte Cmusharendeiatuiteteemuncveadn 22 9 2 State Ol delV y meanen a E eee iuee 22 9 3 ENGINE Preservation E seat anmiadreeiunedint 22 OA Protective COV ENING eriin a uaa a inde sound aun eked nade genes 23 10 Engine suspension ANC POSITION cccceesceeeseeeeeeeeeeeeseeseeeeseeseasenenneeeeneeeeseenes 24 10 1 Definition of attachment POINTS cece cceeecceeeeeeeeeeseeeeeeeeesseeeesseeees
33. Coolant hoses gt 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 E ATTENTION Pay attention to ozone stability NOTE If installation require longer distances use aluminium pipes 25 mm 1 inside dia instead of hoses 12 4 Size and position of connections See illustration 17 18 19 expansion tank with radiator cap to radiator outside dia 25 mm 1 slip on length max 22 mm 7 8 to overflow bottle outside dia 8 mm 3 8 slip on length max 15 mm 9 16 7 i wat an Q WY Modification No Reference Install Date Page Q 914 F 1996 05 10 33 water inlet bend outside dia 27 mm 1 1 16 slip on length max 19 mm 3 4 n me wat Gai NOTE Choose between four possible fitting positions of water inlet bend appropriate to specific installation see illustration 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 E ATTENTION Utilize total slip on length for hose connection Secure hoses with suitable screw clamp or by crimp connection 12 5 Coolant capacity 4 cylinder N adS ccccseeeeeseeeeeeeeeeeeeeeees 560 cm Waler DUMIDA 100 cm expansion tank onincctxcstbinersenecimnsxes
34. No 66 19960510 914F 0 17 Pressure sensors See Ill 45 46 2 pressure sensors are included in the supply volume of the engine and connected by plugs with the wiring harness A WARNING Since a failure of pressure interconnections of airbox float chambers fuel control and pressure sensor would possibly result in an engine stop all these interconnections have to made ven carefully E N z UD eee E HAN ia a an m AE EA Ma AA N Cay K WA ilk a m D LY Sa he e R A WY M P NOTE To avoid any mix up of pressure sensor wiring plug connections are colour coded grey plug connection gt static pressure sensor black plug connection airbox pressure sensor Umgebungs Drucksensor static pressure sensors Airbox Drucksensor airbox pressure sensors Modification No Reference Install Date Page Q 914 F 1996 05 10 67 17 1 Static pressure sensor See Ill 47 effective range 100 1200 hPa deviation max 40 hPa Operating temperature min 40 C 40 F max 125 C 257 F dimensions and attachment see sketch Ill 47 fitting position The pressure connection Pos Ill 47 points downwards to prevent possible condensate from entering the sensor i e the longitudinal axis z4 has to be parallel to Z axis in system of coordinates tolerated deviation of parallelism 6
35. OTE All the required items except the computer are available in form of a monitoring kit 15 5 2 General information about the communication program gt The software is property of BOMBARDIER ROTAX Duplication is only permitted for transmission on a fixed disk or for back up and recording lt gt The TCU must be switched on A WARNING Ensure engine ignition off and secured against uninten tional ON necessary connections Connect decoding unit Dongle with the RS 232 9 pole plug of the cable harness and then connect data cable of the decoding unit Dongle with the interface COM 1 of the computer NOTE l e the decoding unit Dongle has to be connected into the circuit between cable harness and computer Page Date Install Reference Modification No 58 1996 05 10 914 F 0 gt start of the program see Ill 40 The program can be started by two different methods 1 Call of the program direct from MS DOS Name of the program tlr 43a exe 2 Direct via windows file manager by double strike Name of the program tlr 43a exe You are on the main menu now ILE Y JA AONTTORING PROGAAA c COWTEC 19 u aid AA PEA ORDO 1 See x pL p LE menu name sub programs gt starting of the sub programs see Ill 41 The sub programs are always listed on the bottom line and activated by input of the first letter of the program e g M for MONITOR NOTE The key ESC will transfer you always b
36. Reference Modification No 86 1996 05 10 914 F 0 19 4 12 External alternator optional extra See Ill 64 65 66 Output max 600 W DC at 6000 r p m voltage 14 2 14 8 V ambient temperature range min 30 C 22 F max 90 C 194 F NOTE Voltage regulator is inte grated in the generator Feeding wiring to external alternator located on the outside of propeller gear see ill 64 plus terminal M6 screw suitable for cable eyes to DIN 46225 tightening torque 8 Nm 70 in Ib grounding via engine block control wiring amp via supplied standard plug Sumitomo 6111 2568 Requirements for flawless operation of the integrated rectifier regula tor the rectifier regulator has to be protected by a slow blowing 50A fuse cross section of the main circuit at least 4 mm a capacitor Ill 52 Pos of at least 22 000 uF 25 V is necessary current E ATTENTION The current over speed graph has been determined and is effective only at the following conditions ambient temperature 20 C 68 F voltage permanent 13 5 V tolerance 5 n rpm n Propeller 2000 3000 4000 5000 6000 7000 8000 n Alternator li 65 NOTE The speed of the auxiliary generator is 1 24 times crankshaft speed or 3 times the prop speed Modification No Reference Install Date Page Q 914 F 1996 05 10 87 19 4 13 Connection of the electric rev counter See Ill 52 6
37. acitor Ill 52 Pos of at least 22 000 uF 25 V is necessary amp amp OG 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 adequate cross section never sever connection between terminal C and B of regulator e g by removal of a fuse Page Date Install Reference Modification No 78 19960510 914F eee Current E ATTENTION The graph current over engine speed has been determined and is valid only at the following conditions ambient temperature 20 C 68 F voltage oannnenoennnennnnnnenns permanent 13 5 V TOICFANCE sei max 5 1000 2000 3000 4000 5000 6000 1 min NOTE A charge indicating lamp 3W 12V Ill 52 pos may be fitted on the instrument panel Modification No Reference Install Date Page Q 914 F 1996 05 10 79 19 4 3 Electronic modules See Ill 4 58 Ambient temp for the electronic modules max 80 C 176 F 19 4 4 Ignition switches on off switch See Ill 58 type two separate suitable on off switches Ill 52 pos switching voltage min 250 V switching current min 0 5 A Feeding lines to on off switches on the electronic module see Ill 58 1 each flexible cable 0 75 mm brown length approx 35 mm 1 3 8 beginning at electronic module with one each plug socket and insulating sleeve 3 96 mm
38. ack to the main menu NOTE If the bottom line displays Error instead of the sub program some connection between TCU and computer has been interrupted Checking of all plug connections between TCU and computer is necessary Modification No Reference Install Date Page Q 914 F 1996 05 10 59 15 5 3 Checking of the throttle position See Ill 42 gt Start of the sub program MONITOR throttle position Throttle position is displayed in the middle of the top line carb 2 4 0 o gt throttle completely closed 115 gt throttle fully open gt visually check whether the throttle on both carburetors can be fully opened and closed If necessary correct the installation setting gt check of the display with throttle completely closed nominal 0 tolerance 3 gt check of the display with throttle fully open nominal 115 tolerance 2 E ATTENTION Check whether indication is linear over the complete range from 0 to 115 i e the 115 position is not indicated before throttle is fully open gt Check of the display at max continuous power E ATTENTION Throttle lever must be in positive stop position nominal 100 tolerance 3 A WARNING This check of position is only meaningful and allowed if idle and full throttle position are within the allowance variation If the throttle position for idle and full throttle are not within the allowance variation or if not proceeding linear then a ne
39. aeeeseneessaeeesees 25 10 2 Permissible fitting positions sicsviscetinsiicessacbveicenidetioe scant tovceeondiduwtasavaiceeiatt deseadavaicebuaiies 26 10 3 General directives for ENGINE SUSPENSION c cccccccceeeceeceeeeeecaeeeeeseaeeeesaaeeeesaaeees 28 TH EXMAUSE SYSTEM siioni a eia aa 30 HT Operaung IMIS sessiossa en ENE can bedi UNan eE aE RERA i 31 ZAC OOMMO SY SUC Maren wen cueeivniesebacsiwdcatndass veeuamieaneotesreeiude 32 12 1 Description of the system ix tesraiunrisstanesderieamndintiin sladvubeatcaststeninatedentanenndaaitceacdeuaxate le 32 12 2 Operating MAIS estes cite a a N Bi Geand at 32A t221 Water Nee coolant a E O Nal ited 32B 12 2 1 Conventional Glycol Water coolant mixture seannnannnnsnnnnnennnsnnnnnnnnnosnrrnsnnnnne 32B 12 3 Requirements on the cooling system cccccccceseeceeeeeeeseeceeeeeceuseeseseesseessneseesees 33 10 2 Size and position of CONNECTIONS sessseee2yecosseciesagcienciucvedesoneee nanninta aran 33 129 SOOlAME CODACILY gaa da atueacacion ven teen eae da deacetosaeaaheculeeen taeda aete 34 12 6 JFEasSibie locaton Of radiato da tiectot ti taaa a a ehtdee ome aan 35 12 7 General directives for the cooling system cccceeeeeeeeeeeeeeeeeeeeeeeeaeeeeeeeeeeaaaeeeeeees 36 1225 GOOMMG AI CUCU nasisa sane e tenes dne SRRA T EEIE i 38 12 8 1 General directives for ducting of the cooling air nnnnannnnennnnennnnnnnnnennnsennnnennee 38 Page Date Install Ref
40. age Date Install Reference Modification No 36 19960510 914F eee Blank page Modification No Reference Install Date Page Q 914 F 1996 05 10 37 12 8 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 warranted even at hot day conditions 12 8 1 General directives for ducting of the cooling air See illustration 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 BOMBARDIER ROTAX developed especially for this application a non certified cooling air ducting A WARNING Certification to the latest requirement like FAR or JAR has to be conducted by the aircraft builder The following recommendations should assist the aircraft builder at the plan ning of a suitable cooling air ducting The cooling air ducting to be adequate to transfer thermal energy of c 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 material attachment formlocking on engine case and cylinders NOTE In case formlocking attachment won t be adequate addition
41. al at tachment is possible on two tapped lugs M8 on top side of engine attachment points max allowable forces limit load in N in x y and z axis Axes attachment points 300 0 max allowable bending moment limit load in Nm in x y and Z axis min length of thread engagement mm E ATTENTION The stated limit loads are valid only at utilization of min specified thread length and must never be exceeded Depth of thread 18 mm 11 16 Page Date Install Reference Modification No 38 19960510 914F 0 Blank page Modification No Reference Install Date Page sO 914 F 1996 05 10 39 13 Lubrication system 13 1 Description of the system See Ill 22 The BOMBARDIER ROTAX 914 F engine is provided with a dry sump forced lubrication 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 via the oil cooler 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 from the main oil pump The oil emerging from the lower placed turbo charger collects in
42. arburetor 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 To prevent a possible hydraulic shock at engine start ensure proper closing of float valves If in doubt park the aircraft with rising propeller shaft axis Z eee R Vi a X qin hh A fi Wl Lit 1 1 1 x2 Page Date Install Reference Modification No 26 1996 05 10 914 F eee Propeller axis The centres of attachment points L1 und R1 must be on an axis y2 parallel to y axis 2 lll 12 R1 L1 Tolerated roll deviation of parallelism 5 see ill 12 Vertical axis y axis must be square to the longitudinal axis of the aircraft X Tor T D lon 4p BS il AA BID DPN y AG LL i yA O N Yt EY QNE a g H i amp nS A A W 2 imsi N H 2 AV AN A wf a H l ell LE AF 1 y i l Il 2i i ita E i I Yaw tolerance 10 see ill 13 Modification No Reference Install Date Page Q 914 F 1996 05 10 27 10 3 General directives for engine suspension Rubber mounts t
43. attachment screw of flywheel 3 complete turns anticlockwise viewed from Magneto side Refit ignition cover in reversed sequence Tighten the 3 Allen screws to 10 Nm 90 in Ib inspect for corrosion e g prop shaft At detection of corrosion send the engine to an authorized overhauler without delay A WARNING The engine must not be put into service repack engine into original packaging and seal properly Page Date Install Reference Modification No 22 19960510 914F eee A WARNING The maximum storage period is limited to 24 month Preservation for periods of longer than 24 months is only possible after a written permission of BOMBARDIER ROTAX Should the situation arise send engine for inspection to ROTAX NOTE No trouble to put engine back into operation after preservation 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 OXNAUSl SOCKEL ssccssvicodsaernsunessereviasvinetezensneesss 1x cone plug Air intake socket On turbo ccseeeeeeeeeees 1x cover connection for manifold pressure 1x cap fuel pressure control in and outlet 1x each cap oil supply and
44. cceeeeeeeneeenneeenseeeneecenseeseeenseseasesensesenees 93 23 1 Sensor for cylinder head temperature ccccsscccsececcseececeececceeeeeceueeesseeeesseeeesenes 93 23 2 Sensor fOr Oll temperature cot cihaiesial cadet ectind a a EEA 94 23 3 OM DFESSUFE SCNSOM eesti sche nee eoladseees sien a a ei 95 23 4 Mechanical rev counter or hour meter ccceccceeceeeeeceeeceeeceeeeceeeseueeeeeeseeeseesaees 96 23 5 Monitoring of the intake manifold pressure cccceeeccseeeeeeeeeaeeeeeeeeeeeeeseeeseeeenanes 97 23 6 Al temperature IMIN AINDOX secre E aero leas ein tnd stad dtrddstedonaga iis 97 24 Preparations for trial run of engine sssssnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnn nn 98 25 gt AUTHORIZED DISTRIBUTORS for Aircraft Engines sseeeeeeeeeees 99 Page Date Install Reference Modification No 4 1996 05 10 914 F 0 Blank page Modification No Reference Install Date Page Q 914 F 1996 05 10 5 2 Index A Acceleration 20 Air intake system 62 Air temperature in the airbox 97 Airbox 64 Airfilter 63 Attachment points 25 Auxiliary equipment 17 B Bank angle 20 Battery 89 Boost lamp 77 C Carburetor 54 Caution lamp 77 Caution light 86 Centre of gravity 21 Coarse filter 49 Communication program 58 Connection of electric rev counter 88 Connections cooling system 33 Connections oil circuit 43 Connections carburetor 55 Connections for instru
45. connection plug for socket 6 3x0 8 to DIN 46247 Axes grounding via engine block graph of sensor resistance over temperature Q ohm 1200 1000 20 40 60 80 100 120 140 160 C E ATTENTION The graph resistance over temperature has been determined and is effective at the following conditions only ambient temperature 20 C 68 F tolerance 10 NOTE BOMBARDIER ROTAX recommends the temperature indication VDO instrument VDO 310 274 082 01 7 with an indicating range of 50 to 150 C 120 F 300 F F Modification No Reference Install Date Page _Q 914 F 1996 05 10 93 23 2 Sensor for oil temperature See Ill 73 74 location oil pump housing c gt ae marked with TO on oil pump flange Oy E ATTENTION To avoid any mix up with indication wiring mark this D Oe D particular cable also with TO position of the temperature sensor on the oil pump flange ai connection of sensor wiring plug for socket 6 3 x 0 8 to DIN 46247 grounding via engine block graph of sensor resistance over temperature Q ohm 1200 20 40 60 80 100 120 140 160 C E ATTENTION The graph resistance over temperature has been determined and is effective at the following conditions only ambient temperature 20 C 68 F tolerance 10 BOMBARDIER ROTAX offers a non certified temperature indicating instrumen
46. d Max suction head 250 mm 10 in A WARNING Certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder A WARNING Installation of the fuel pumps in the engine compart ment is not permitted since the fuel pumps are not of a fire resistant construction and because of the risk of vapour lock formation A WARNING Should the situation arise certification to the latest require ments such as FAR or JAR would have to be conducted by the aircraft builder Modification No Reference Install Date Page sO 914 F 1996 05 10 51 14 4 2 Fuel pressure control See outline of fuel pressure control Ill 30 and Ill 33 Connections inlet feed line from fuel pumps and outlet fuel return to tank hose nipple cece eeeeeeeeeee ees 4 6 DIN 7642 outside dia cccseecccseeeeeees 8 mm 5 16 slip on length 00 max 20 mm 3 4 tightening torque of the banjo bolts M10x1x19 17 Nm 150 in lb A PA E ATTENTION Ill 33 Y yO The fuel return from connection must be a line of low flow o Bmiatiiae resistance Prevent any restrictions of section or blockage otherwise the carburetor could flood E ATTENTION Utilize the full slip on length at hose joints Secure hose with suitable screw clamp or by crimp connection MO AT SKER EE NOTE The control of the fuel pressure is achieved by a valve activated from a diaphragm Re
47. der Air intake socket on turbo charger outside dia 60 mm 2 3 8 slip on length max 25 mm 1 E ATTENTION Utilize the full slip on length on all connection Secure hoses by Suitable screw clamps N A a K 3 Flo OS 5 OS 4 14 J C E L a Page Date Install Reference Modification No 62 19960510 914F ee 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 E ATTENTION 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 Air temperature above the limit will automatically reduce boost pressure with consequent performance loss NOTE The automatic back off on boost pressure will protect the engine against damage by overstressing 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 arran
48. e tank via a coarse filter water trap to the two electric fuel pumps connected in parallel From the pumps fuel passes on via the fuel pressure control to the two carburetors Via the return line 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 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 have already been laid The fuel system from tank to the fuel pressure control has to be installed by the aircraft builder The fuel system includes the following items 4 gend gt tank jee gt coarse filter coarse filter watertrap gt watertrap 2 x electric fuel pump PEU ai fuel pressure control gt 2 electric fuel pumps gt as well as the required fuel lines and feeding line from tank A connections return line to tank Z gt UT NON i N m hl amp ASS 7 Le iwa gie rT an lt t Q m in nee f A cP ay ge oo J ULL UL J EN IIl 30 K han Lee Z a CAA o DERN y r aD GZL Lp E mI EAW 77 m lt mK 7 IS o a lt _ I AN N NY 7 DH LAN 0 a Gio s TE T E
49. e the carburetors could flood Secure fuel hoses with suitable screw clamps or by crimp connection E ATTENTION 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 engine 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 Ill 30 Coarse filter on fuel tank as per valid certification Fine filter inthe feed line from tank to the 2 fuel pumps an additional fine filter with meshsize 0 1 mm has to be provided The filter has to be controllable for service A combination of filter watertrap is recommended Fuel temperature To prevent vapour locks temperatures in excess of 36 C 100 F are not permis sible in the vicinity of fuel lines float chamber and such Modification No Reference Install Date Page sO 914 F 1996 05 10 49 14 4 Connecting dimensions location of joints and directives for installation 14 4 1 Electric fuel pump See outline of fuel pump Ill 30 Ill 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 Connections See lll 31 Inlet suc
50. ee illustration 29 On principle the oil cooler has to installed below the engine See Illustration 29 E ATTENTION If this position is not be practicable install with connections upwards i e in positive direction on z axis See Illustration 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 lf need be take appropriate measures like changing size of cooler partial covering of cooler etc 13 7 General notes on oil cooler BOMBARDIER ROTAX offers for this engine a non certified oil cooler see spare parts list A WARNING Certification of this cooler to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder E ATTENTION The oil cooler has to be designed to dissipate approx 9 kW 8 5 BT U 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 8 Filling capacity Oil quantity without oil cooler and connecting lines 31 0 8 US gal min 21 0 5 US gal Modification No Reference Install Date Page Q 914 F 1996 05 10 47 14 Fuel system 14 1 Description of system See Ill 30 The fuel flows from th
51. erence Modification No 2 2004 07 01 914 F 1 d03273 13 PUDHIGATION System sirian aas aeaea NE e aaa a s ee a a aaia 40 1321 D sciption OF TNC Syste mM ssori a E A 40 13 2 LIMS Or Opera lo N sa a r E O 41 13 3 Requirements on the oil and venting lines ccccceececeeeeeeeeeeeeeeeseeeseeeeseeeeneeeens 42 13 4 Connecting dimensions and location of connections cccceeceseeeeseeeeeeeeeeeeeeaes 43 AD os os Uh endine ze EN 43 13 AZ ONCIRCUNATORDOCMALQGN iaa E a 43 Dosis OMT UIA teh eae ara rcanee ctadeinas arated ate i dcjancles naa deans tere doe E ace asenan a daabeneeen 44 13 5 Feasible position and location of the oil tank ccccccceeccseeeseeeseeeeseeeseeeeeeeeseeees 46 13 6 Feasible position and location of the oil cooler 0 2 ceccceecceeeceeeeseeeceeeseeeeseeeees 47 43 7 Genel al NOlesS Of Olli Oole ais ceaat ape aiishcuasniwiatia tie entntaedatee aay Seatocungnenereedien 47 13 8 Filing Capaci enirere a a haan a e a N 47 WA HUGIES Y SIOIN sisisi esrar eE aE iaaa EN Ena 48 14 1 Description of system xpccStitasescn sin dauieadshtacanavetsaveh Reats enn hderbledautdeceloniindiseidustilmmendutedenaes 48 142V OSL AUG NIMES css iaie cee cael ctdlan elnc ool da ons en alvelae et acta ati es 49 14 3 Requirements of the fuel system cccceeccceeccceeeeceeeeceeeeee secs sessueessusesseeesseeenees 49 14 4 Connecting dimensions location of joints and directives for instal
52. 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 ROTAX Modifications are only allowed after consent by the engine manufacturer E ATTENTION 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 spare parts list They are available only at the authorized ROTAX Distribution and service partners 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 A WARNING 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 as specified consult Operator s Manual NOTE For longer periods longer than 2 months of engine stop preserva tion of engine is recommended see chapter engine preservation in Operator s Manual A WARNING Exclusively use tools and supplementary materials as listed in the spare parts list A WARNING 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
53. gement 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 and inlet into airbox Requirements on the intercooler aminimum flow rate of 300 m h 890 yd h has to be warranted for all conditions the pressure loss must not exceed 15 hPa E ATTENTION No additional forces or moments are allowed on turbo charger or airbox therefore the intercooler has be supported independent and free of vibrations A WARNING The certification to the latest requirements such as FAR and JAR has to be conducted by the aircraft builder 16 2 2 Airfilter E ATTENTION A minimum flow rate of 300 m h 390 yd h 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 Modification No Reference Install Date Page sO 914 F 1996 05 10 63 16 2 1 Airbox See Ill 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 Compensation of process conditions is taken care of by the TCU Drainage lines A WARNING Connect draining lines without fail otherwise emerging fuel could drip on
54. his area either to full power 115 or on a power reduction to max continuous power In this range 108 110 throttle position small changes in throttle position have a big effect on engine performance and speed but are virtually not apparent for the pilot from the throttle lever position E ATTENTION The exact setting for a specific performance is virtually impossible in this range and has to be prevented as it might cause control fluctuations Surging Page Date Install Reference Modification No 76 19960510 914F eee Besides the throttle position overspeeding of the engine and too high intake air temperature have an effect on the nominal boost pressure lf one of the stated factors exceeds the specified limits the boost pressure is automatically reduced thus protecting the engine against overload The TCU Turbo Control Unit is furnished additionally with output connections for an external red boost lamp and an orange caution lamp for indication of function of the TCU When switching on the voltage supply the two lamps are automatically subject to a function test Both lamps illuminate for 1 2 seconds then they extinguish If they do not a check as per Maintenance Manual is necessary A WARNING The engine must not be taken into operation before having corrected the cause of deficiency Orange caution lamp The non illuminated orange caution lamp signals that TCU is ready for operation lf the lamp is blin
55. idaementeaens 250 cm 2 m coolant hose 18 MM inside dia i s soonsessonnennonnenrrenneen 500 cm total coolant quantity in engine approx 1410 cm 3 8 gal us Page Date Install Reference Modification No 34 19960510 914F eee 12 6 Feasible location of radiator See illustration 20 The expansion tank must always be positioned at the highest point of the cooling system E ATTENTION If necessary the radiator outlet opening may be max 1 5 m 5 ft above or below water inlet bend on water pump see ill 20 NOTE On the standard engine version the expansion tank is fitted on top of the engine see ill 20 2 O Us z t For proper operation of the cooling system the expansion tank with pressure cap has to remain for all possible engine positions on the highest point of the cooling circuit max 1 5 m Additionally the system needs an overflow bottle where surplus coolant is collected and returned back into the circuit at the cooling down period NOTE For proper operation keep hose to overflow bottle as short and small as possible E ATTENTION To warrant the proper operation of the cooling system the delivery head between overflow bottle and expansion tank must not exceed 250 mm 10 Requirements on the overflow bottle transparent material unaffected by temperatures from 40 C 40 F to 125 C 257 F resistant
56. inders 18 O Oil cooler 47 Oil lines 42 Oil pressure 41 Oil pressure sensor 95 Oil tank 44 46 Oil temperature 41 On off switch 80 Operating limits 20 Overflow bottle 35 P Position of engine 24 Preface 8 Preservation engine 22 Pressure sensors 67 Propeller drive 90 Protective covering 23 Page Date Install Reference Modification No 6 1996 05 10 914 F 0 R Range of starting temperature 20 Rectifier regulator 78 Remarks 8 Rev counter drive 96 S Safety 8 Safety information 9 Sensor for oil temperature 94 Servo motor 70 Standard engine design 16 Starter relay 81 State of delivery 22 Symbols 9 T Take off speed 20 Technical data 20 Technical documentation 12 Temperature in airbox 62 Throttle lever 57 Throttle position 58 Transport 22 Trial run 98 Turbo charger 62 Turbo Control Unit TCU 76 84 V Vacuum pump 91 Venting line of oiltank 42 W Warning light 86 Water inlet bend 34 Water trap 69 Weights 21 Wiring diagram electric 74 Modification No Reference Install Date Page Q 914 F 1996 05 10 7 3 Preface Congratulation on your decision to use a ROTAX aircraft engine 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 lf any passages of the Manual are not completely understood or in case of questions plea
57. instruction The isolating switch has to be installed directly into the lines from 36 pole plug receptacle to servo motor E ATTENTION The servo motor is connected to DC supply The polarity wire 2 and 14 of the cables must not be changed otherwise the sense of rotation would be reversed and control would be rendered ineffective To avoid any mix up of the polarity sever first one cable and connect on switch as per wiring diagram Ill 52 After first cable is connected sever second wire and connect also to switch Modification No Reference Install Date Page sO 914 F 1996 05 10 85 19 4 10 Warning light See Ill 52 colour of lamp red or colour as per effective regulations voltage 12 V DC depending on input voltage of TCU current max 0 5 A connections terminal flexible cable 0 75 mm white No 10 terminal flexible cable 0 75 mm 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 19 4 11 Caution light See Ill 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 5 A connections terminal flexible cable 0 75 mm white No 11 terminal flexible cable 0 75 mm white No 35 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 Page Date Install
58. is greatly affected by the wiring and has to be checked for each installation Refer to chapter 19 1 1 A WARNING The supply to the various consumers e g battery has to be protected adequately by fuses consult wiring diagram Using fuses too large may result in damage to electric equipment Under no circumstances route consumers cables e g battery side by side with ignition cable Induction could cause problems E ATTENTION An excess voltage protection has to be realized by the aircraft builder in accordance to effective regulations A WARNING The certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder Page Date Install Reference Modification No 72 19960510 914F 0 19 1 1 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 gt Radiated RF Interference Modification No Reference Install Date Page Q 914 F 1996 05 10 13 19 2 Wiring diagram See Ill 52 Legend to wiring diagram Ill 52 Items 1 20 are included in the standard volume of supply of the engine Items 21 25 are available as accessory Items 30
59. iscontinue or change specifica tions designs features models or equipment without incurring obligation The illustrations in this Installation 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 Page Date Install Reference Modification No 8 19960510 914F Q 4 1 Repeating symbols This Manual uses the following symbols to emphasize particular information These indications are important and must be respected A WARNING Identifies an instruction which if not followed may cause serious injury including the possibility of death E ATTENTION 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 Safety information A WARNING Only certified technicians authorized by the local airworthiness au thorities and trained on this product are qualified to work on these engines A WARNING Never fly the aircraft equipped with this engine at locations airspeeds altitudes of other circumstances from which a successful no power landing cannot be made after sudden engine stoppage Aircraft equipped with
60. ively ivavac drei O meena daae eaves 81 1946 Starter relay censuris nie a aaa aia a a a a aaa Ea a Aaa 81 19427 BICC TUG PUMPS rraren na a ES 82 19 4 8 Turbo Control Unit TCU ec ccccccceeeceeeeseeeeeeeeeseeeeeeeesseeeeseeeesseaeeeesseeeeeeeesaas 84 19 4 9 Isolating switch for servo motor esnnsennsnensernssnrnsresrnrenrerrnrenenrenrenerrerrerereerenent 85 19 4 10 Waming IOA eroari aaa aa aaa AE aN a AAAren 86 OAT AUTON N eaaa ae a a eet 86 19 4 12 Externernal alternator optional extra ccccecccceeeeeseeeeeeeeeeeeeeeseeeeeeeeeeseeeeeseesenees 87 19 4 13 Connection of the electric rev counter cccccceeecceecaseeeeeeeeeeeeeeeeaeeeeeeeaeeeeeeesaaaees 88 TAA BATON Y iriiria aaa aipa aa aian a aa idie aa 89 19 5 Internal consumer of electric DOWEL ccccceecccesceceeeeceeeeceeseceusecsueecsusesseeeseeeesses 89 20 Propeler CHIV Cacia isc uv entensccwenudseisebeusstuorcimeccetanedvectvastanriawonnceuvennseoweauiuanneeustenuivenss 90 20 1 Technical Cala eese T iced da neuceanevaneBex thsotetedastenieuitee 90 21 Vacuum DUMP csa ideaa Eea 91 ag ea ib ae Tei ale ers lle rs Ls eaaa e s a ee ee ern eee ee 91 22 Hydraulic governor for constant speed propeller ccccceeseeseeseeeeeeeeeeeeeeaes 92 22 1 Technical Ola cen ticesusveeuegutcaseuceen th ePe atin tieeden aban tater aencoaadeleceedassuebbeepeatacusticnen 92 23 CONNECTIONS for instrumentation cc
61. king this indicates a malfunction of the TCU or its periphery Red boost lamp Exceeding of the admissible boost pressure will activate the red boost lamp being continuously illuminated The TCU registers the time of full throttle operation boost pressure Full throttle operation for longer than 5 minutes will make the red boost lamp blinking Modification No Reference Install Date Page Q 914 F 1996 05 10 77 19 4 Technical data and connection of the electric components 19 4 1 Integrated generator See Ill 55 Feeding wires from the generator to rectifier regulator on left side of ignition housing see ill 55 2 flexible cables 1 5 mm yellow in shielding metal braid length approx 660 mm 26 in starting from ignition housing 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 19 4 2 Rectifier regulator See Ill 56 57 type electronic full wave rectifier regulator effective voltage 14 0 3 V from 1000 250 r p m current limit max 28 A amp amp G OG amp G ambient temperature range min 25 C 13 F max 90 C 194 F weight 0 3 kg 66 Ib Requirements for flawless operation of the rectifier regulator the rectifier regulator has to be protected by a slow blowing 30A fuse cross section of the main circuit of at least 2 5 mm a cap
62. lation 50 AAA lt EISCIIC TUG DUMP a a eeuinpaavian 50 144 2 Fuel press re COMMON srren diteindaanttetedi ada a 52 14 5 Notes on checking of fuel PreSSUIe cccccceeecceeeeceececeeeeceacesseeeseaeessueeecseeeneeeens 52 15 Gall DUTE TOT asidinin aai iaa aiia 54 15 1 Requirements on the carburetor n nnnnannnennnnennnnnnnnennnsrrnnsnrrsrrrrnrrrnerresnrrrnnersrrerne 54 15 2 Connections for Bowden cable actuation and limit load ccccsecceeeeeeeeeeeeeeeees 55 15 3 Requirements on cable actuation ccccccccseeececeeeeeseeeeeeeeeeeeseseeeeeeeessaeessaneeesaaes 56 15 4 Requirements on the throttle lever ccccccccsseecceeeeceeeeeeeeeseeeeseeeessaeesseeesseeeeneeeeas 57 15 5 Location and determination of the throttle position for max continuous power 58 126 0 7 WREGUINE GILG HIS sso aesccti sol eae ear a ose ue lee ceca aie ces 58 15 5 2 General information about the COMMUNICATION program ceccceseeeeeseeeeeeeeeeeees 58 15 5 3 Checking of the throttle position ccccccceececeeseeeceeeeeceeececseeeeeseeeeessaneessaeseesaaess 60 16 Alr MAKE SV SUC IN iridioa a iep AEEA EE Eaire EESE 62 1621 OPEraUnNolIMIS esnan aa 62 16 2 Requirements on the air intake SYStOM cccccssceceseeceeceseeeeseeeeeceeeecaeeeseeseneeens 62 16 2 1 Requirements on the intake air ducting cccceeecccesecceeeeceeeeeceeeceeseeceusesseeeesees 63 Oea
63. leased from the detent and can be moved further to take off performance max Dauerleistung max continous power 104 4 Startleistung _ Take off power 115 Leerlauf e 2 aa E ATTENTION 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 bending of the idle stop on the carburetor Modification No Reference Install Date Page Q 914 F 1996 05 10 57 15 5 Location and determination of the throttle position for max continuous power lt is a necessity for trouble free engine operation that the pilot can locate the exact throttle position for max continuous performance E ATTENTION A manual determination e g by a graduated disk is not precise enough and therefore not permitted The exact determination is achieved electronically by a PC program especially developed for this engine 15 5 1 Required items gt PC with processor 80 286 or higher level with a working storage of min 640 KB RAM graphic card EGA or VGA interface COM 1 operating system MS DOS 5 0 or higher level NOTE We recommend a laptop or notebook computer since these units can be utilized also directly on engine or aircraft The computer will be required on maintenance tasks too gt communication program TLR 43a exe between TCU and computer decoding unit Dongle with data cable to connect to computer N
64. ly available at BOMBARDIER ROTAX A WARNING This equipment has not been tested for safety and durability to the standards of aviation The user assumes all risks possibly arising by utilizing auxiliary equipment The furnishing of proof in accordance to the latest FAR or JAR has to be conducted by the aircraft builder Intake filter Oil cooler Coolant radiator Flydat Mechanical rev counter Electric rev counter Re Hs oe Ro oR a Hour meter Modification No Reference Install Date Page Q 914 F 1996 05 10 17 7 3 Engine components engine views numbering of cylinders definition of main axes See illustration 2 3 4 5 6 PTO power take off side MS magneto side A points of attachment for engine transport a 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 cylinder 1 Cyl 3 cylinder 3 Cyl 2 cylindex 2 Cyl 4 cylinder 4 8 Z 3 A WEE gio MS AS P on ne aaa ett eee a Y EZT Z n 1771 bo OS MA i E engine number propeller flange propeller gear vacuum pump or hydraulic governor for constant speed propeller intake manifold O ignition housing ignition cover constant depression carb airbox engine suspension frame SEE l
65. ly designed and tested Certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder A WARNING The hex hd screws M10x60 on the attachment points R2 and L2 are only used for transport securing but must never be utilized for engine Suspension See ill 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 Page Date Install Reference Modification No 24 1996 05 10 914 F 0 10 1 Definition of attachment points See Ill 9 10 Z R3 Olp NO SA JJ NO attachment point min length of fi thread engagement ee tial A1 Axes X axis y axis ooint 200 8 200 8 562 0 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 attachment point attachment point i max allowable forces limit load in N in x y and z axis aaay Le max allowable bending
66. mentation 93 Coolant capacity 34 Cooling air ducting 38 Cooling system 32 Critical flight level 20 Current pages 14 Cylinder head temperature sensor 93 Cylinder head temperatures 32 D Definition of main axes 18 Denomination of cylinders 18 Description of design 16 Designation of type 16 Distributors 99 Documentation 12 Drainage lines airbox 64 Drainage piping drip tray 54 Drip tray 54 E Electric fuel pump 50 82 Electric starter 81 Electromagnetic compatibility 73 Electronic modules 80 Elektric system 72 Engine components 18 Engine installation 22 Engine serial number 8 Engine speed 20 Engine suspension 24 28 Engine views 18 Exhaust gas temperature 31 Exhaust system 30 Expansion tank 33 External alternator 87 F Fine filter 49 Fitting positions 26 Fuel filter 49 Fuel lines 49 Fuel pressure 49 Fuel pressure control 52 Fuel pressure check 52 Fuel system 48 Fuel temperature 49 H Hour meter 96 Hydraulic governor for constant speed propeller 92 Ignition switches 80 Installation dimensions 21 Instruction 11 Instrumentation connection 93 Intake air ducting 63 Integrated generator 78 Intercooler 63 Internal consumer of electric power 89 Isolating switch for servo motor 85 L Location of radiator 35 Lubrication system 40 Main axes 18 Manifold pressure 20 Manifold pressure connector 97 Mechanical rev counter 96 Moments of inertia 21 N Negative gravity 20 Numbering of cyl
67. moment limit load in Nm in x y 77 39 and Z axis A WARNING Tighten all engine suspension screws as specified by the aircraft builder Modification No Reference Install Date Page Q 914 F 1996 05 10 20 max allowable forces limit load in N in X axis max allowable bending moment limit load in Nm in X y and z axis 10 2 Permissible fitting positions See Ill 11 12 13 To simplify the 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 All dimensions to point of reference P and the system of coordi nates remain unchanged Axes x axis y axis Z axis point The following details of engine position are with reference to aircraft on ground ready for take off engine suitable for propeller in tractor or pusher arrangement propeller shaft above cylinders See ill 2 A 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 ill 11 A WARNING On installations with fuel tank located above c
68. nic approved by the local airworthiness authority Toeliminate possible injury or damage ensure that any loose equipment or tools are properly secured before starting the engine When in storage protect the engine and fuel system from contamination and exposure Certain areas altitudes and conditions present greater risk than others The engine may require carburetor recalibration or humidity or dust sand preventative equip ment or additional maintenance may be required Consult your aircraft dealer or manufacturer and obtain the necessary information especially before flying in new areas Never operate the engine and gearbox without sufficient quantities of lubricating oil Periodically verify level of coolant Never exceed maximum rated r p m and allow the engine to cool at idle for several minutes before turning off the engine Operating the engine at high speed at low throttle position for example during descent may increase engine and exhaust temperatures and cause critical over heating Always compensate and match r p m with throttle position 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
69. nstallation dimensions see illustration reduction ratio i 4 i e 1 4 of engine speed NOTE A flexible shaft for the mechanical rev counter is readily available from BOMBARDIER ROTAX Page Date Install Reference Modification No 96 19960510 914F eee 23 5 Monitoring of the intake manifold pressure See Ill 79 Connection nipple to measure manifold pressure outside dia 6 mm 1 4 Slip on length max 17 mm 11 16 E ATTENTION Utilize the total slip on length on all joints Secure hose by suitable screw clamps or crimp connection A WARNING Protective covering to be utilized for trans port and at engine installation only If connection for pressure reading is not employed it has to plugged suitably TON Va gt a E ATTENTION 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 See Ill 80 To take air temperature readings in the airbox a connection is provided This connection is closed on the standard engine by a plug screw connection tapping 1 8 27 NPT thread length approx 9 mm 3 8 Modification No Reference Install Date Page Q 914 F 1996 05 10 97 24 Preparations for trial run of engine A WARNING Prior to engine start and operation review all instructions stated in the Operator s Manual Verification of
70. o 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 ill 14 NOTE The illustration shows rubber mount Lord Stitzschelbe 33608 1 resp 33608 2 A WARNING eae All elements to balance out vibrations ee ee have to be of captive design distance tube ae support washer NOTE With suspension on the 4 top lugs 3L 3R 4L and 4R 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 A WARNING The rubber mounts to neutralize vibrations and all the engine suspension components not in the supply volume must be ground run tested to the specified loads and for vibration behaviour Certifi cation to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder NOTE The engine suspension has to be designed to prevent any excessive engine movement and to minimize noise emission and vibration on air frame side Page Date Install Reference Modification No 28 19960510 914F _0Q Blank page Modification No Reference Install Date Page Q 914 F 1996 05 10 29 11 Exhaust system See ill 15 The complete exhaust system is in the volume of supply and is certified together with the engine A WARNING Ifthe ROTAX exhaust system is not employed
71. oil discharge s 1x each cap A OM KETUNN CUDO uea ates faba leads 1x cap supply and discharge of coolant 1x each cone plug propshaft ON version F3 cceeeeeeeeeeeeeeees 1x disk plug A WARNING Protective covering to be utilized for transport and at engine instal lation only Before engine operation remove these protections Modification No Reference Install Date Page Q 914 F 1996 05 10 23 10 Engine suspension and position E ATTENTION At installation of engine be aware of engine weight and assure careful handling The engine suspension is determined essentially by the aircraft design Eight attachment 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 ROTAX is not used or if modified certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder Furthermore a suitable suspension for turbo charger and exhaust system has to be developed Since these components weigh approx 6 kg 13 Ibs this suspension has to be careful
72. op gear Location of centre of connection P3 Axes Cable connection see ill 70 cable travel approx 54 mm 2 1 8 actuating force approx 3 N during operation at max speed 67 Ib limit load 6 N 1 35 Ib power input max 600 W Operating pressure max 30 bar 435 p s 1 weight 1 44 kg 3 2 Ib 2 kg 6 Ib inclusive drive unit NOTE Reduction ratio of crankshaft to governor is 1 842 e g the governor speed is 0 54 of the engine speed Page Date Install Reference Modification No 92 19960510 914F eee 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 JAR For notes regarding the electric rev counter consult the chapter 19 4 13 23 1 Sensor for cylinder head temperature See Ill 71 72 NOTE A direct reading of the coolant temperature is not provided for The temperature sensor 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 inthe cylinder head of the cylinders 2 and 3 see Ill 4
73. or engine installation and operation will be stated in the Manual NOTE Connecting dimensions filling capacities drive and reduction ratios electric output etc can be found in the respective chapter of engine installation 8 1 Operating limits 1 Engine speed Take off speed ccceccceeeceeeeeeeees 5800 r p m 5 min max continuous Speed 5500 r p m idle speed around 1400 r p m 2 Manifold pressure Take off performance cccccseeeeeeeeeeeees 1300 hPa 38 4 in HG maximum continuous performance 1150 hPa 34 0 in HG 3 Acceleration Time limit for engine operation at weightless condition and with negative gravity acceleration cccceeccceeecceeeeeeeeseeeeseeeenees max 5 sec at max 5 g 4 Critical flight level Take off performance cccccceeeeeeeeee ees to max 2450 m 8000 ft ASL maximum continuous performance to max 4500 m 16000 ft ASL E ATTENTION Up to the critical flight level the stated respective performance is available 5 Oil pressure ccccceeeeeceeeeeeseeeeeeeeees see chapter 13 2 6 Oil temperature ce ceceeeeeeeeee ees see chapter 13 2 7 Cyl head temperature 008 see chapter 12 2 8 Exhaust gas temperature see chapter 11 1 9 Airbox temperature cceeeees see chapter 16 1 10 Range of starting temperature TV EEE E E caacnceee 50 C 122 F
74. or if modified certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder Modifications are permissible only if agreed with by BOMBARDIER ROTAX NOTE As an exception the exhaust end pipe can be modified to the following requirements Mean bending radius of an exhaust bend min 40mm 1 57 in Exhaust bend inside diameter min 388mm 1 50 in Medium tube length max 500mm 20 in E ATTENTION Ata medium tube length of 250 mm 10 in and more the end pipe has to be supported additionally Material of the exhaust system X 15CrNiSi 20 DIN 1 4828 Location of the exhaust end pipe P1 See ill 15 om 420 0 EZS 0 371 0 E ATTENTION Always fit heat shields near carburetors or as required Because of the high temperatures occurring provide suitable protection against unintentional contact Page Date Install Reference Modification No 30 1996 05 10 914 F eee 11 1 Operating limits Exhaust gas temperature VIX E EE E EAA A ANE AE EAEE 950 C 1740 F POMA meer tree Rint tn eno Mert en Toner ee 900 C 1650 F Reading taken approx 70 mm 2 75 in after exhaust flange Modification No Reference Install Date Page sO 914 F 1996 05 10 31 12 Cooling system 12 1 Description of the system See ill 16 The cooling system of the ROTAX 914 F is designed for liquid cooling of the cylinder heads and ram air cooling of the cylinders
75. r 3 is to be specified by testing For this purpose see section 7 3 Engine Views This is dependent on the installation pulling or pushing propeller design The coolant to be used is defined clearly in the Operators Manual Depending on the installation conditions conventional coolants can also be used The provision of proof about the max reachable cylinder head temperature and thus the coolant to be used is the responsibility of the airplane manufacturer in regard to 12 2 1 and 12 2 2 E CAUTION The coolant to be used and its concentration is to be communicated in written form to the owner NOTE From ROTAX awarning sticker is to be delivered for the water free coolant which is mounted separately on the expansion tank When using this coolant the warning sticker is to be mounted on the radiator cap in such a manner prior to delivery that the opening pressure 3 applied on the radiator cap remains visible For this purpose see fig 16 1 OOLANT ONLY A Woe SLOX y 07012 1 Warning sticker 2 Radiator cap 3 Excess pressure information of radiator cap Modification No Reference Install Date Page 1 914 F 2004 07 01 32A 12 2 1 Water free Coolant max permissible cylinder head temperature see Operator s Manual section 10 1 Operating Limits Coolant see Operator s Manual section 10 2 1 Coolant 12 2 2 Conventional Glycol Water Coolant Mixture The boiling point of conventional glycol water
76. rnor for constant speed prop Optional extras to the above stated basic type NOTE Conversion of the types F2 F4 to type F3 may be accomplished by the manufacturer BOMBARDIER ROTAX 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 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 stainless steel exhaust system engine suspension frame expansion tank coolant electric starter integrated AC generator with external rectifier regulator 12V 250 W oil tank external start relay hydraulic governor for constant speed prop optional extra on F3 only external alternator optional extra 12V 40A DC vacuum pump optional extra feasible on F2 and F4 only drive for rev counter hour meter optional extra Page Date Install Reference Modification No 16 19960510 914F Q oooeo 0 8 O oo oo 000060060 0 Auxiliary equipment E ATTENTION Any 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 en gine are readi
77. rol Unit TCU See Ill 53 54 The ROTAX 914F engine is equipped with an exhaust gas turbo charger making use of the energy in the exhaust gas for precompression of the intake air boost pressure The boost pressure in the airbox is controlled by means of an electronically controlled flap waste gate in the exhaust gas turbine NOTE The waste gate regulates the speed of the turbo charger and consequently the boost pressure in the airbox The required nominal boost pressure in the airbox is determined by the throttle position sensor mounted on the carburetor 2 4 The sensor s 415 transmitted position is linear from O to 115 oe corresponding to a throttle position from idle to full power See ill 53 100 X vw 7 ve HLL judi z A A nm Gapes OKA eane k On JAG VA For correlation between throttle position and nomi nal boost pressure in the airbox refer to the i 53 Te E A diagram ill 54 2 oe hPa 1300 SESE EES i or 110 115 The most important points for engine operation engine performance throttle position nominal airbox pressure idling of engine 1100 hPa 32 5 in HG 100 108 1190 hPa 35 1 in HG take off performance 110 115 1350 hPa 39 9 in HG E ATTENTION As shown in the diagram the throttle position at 108 110 results in a rapid rise of nominal boost pressure To avoid unstable boost the throttle should be moved speedily through t
78. se contact an authorized Distribution or Service Partner for ROTAX engines We wish you much pleasure and satisfaction 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 builder and dealer For further information on maintenance and spare part service contact the nearest BOMBARDIER ROTAX distributor see chapter of Service Partners 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 BOMBARDIER 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 BOMBARDIER ROTAX reserves the right at any time to d
79. so obtain as much information as possible about your aircraft its maintenance and operation from your dealer You should be aware that any engine may seize or stall at any time This could lead to a crash landing and possible severe injury or death For this reason we recommend strict compliance with the maintenance and operation and any addi tional information which may be given to you by your dealer Modification No Reference Install Date Page Q 914 F 1996 05 10 9 Select and use proper aircraft instrumentation This instrumentation is not included with the BOMBARDIER ROTAX engine package Only approved instrumentation can be installed gt Before flight ensure all engine controls are operative Make sure all controls can be easily reached in case of an emergency Unless in a run up area never run the engine with the propeller turning while on the ground Do not operate engine if bystanders are close gt To prevent unauthorized use never leave the aircraft unattended with the engine running Keep an engine log and respect engine and aircraft maintenance schedules Keep the engine in top operating condition at all times Do not operate any aircraft which is not properly maintained or has engine operating irregularities which have not been corrected Since special tools and equipment may be required engine servicing should only be performed by an authorized BOMBARDIER ROTAX engine dealer or a qualified trained mecha
80. t Refer to current spare parts list A WARNING Certification to the latest requirements such as FAR of JAR has to be conducted by the aircraft builder Page Date Install Reference Modification No 94 19960510 914F ee 23 3 Oil pressure sensor See Ill 75 76 location oil pump housing ea EZ Ht Bi sD 7 N position of connection on oil pressure pick up a connection of pick up wiring single pole screw connection for cable eye 3 to DIN 46225 grounding via engine block graph of resistance over pressure E ATTENTION The graph resistance over pressure has been determined and is effective at the following conditions only ambient temperature 20 C 68 F voltage 12 V tolerance 5 BOMBARDIER ROTAX offers a non certified pressure gauge Refer to current spare parts list A WARNING Certification to the latest requirements such as FAR of JAR has to be conducted by the aircraft builder Modification No Reference Install Date Page Bg 914 F 1996 05 10 95 23 4 Mechanical rev counter or hour meter See Ill 77 78 on location ignition housing iA direction of rotation of the o rev counter shaft clockwise see illustration position of rev counter drive Axes engagement P4 AD zS 7 5 DE ji SS D es E DOK AHO D Td i
81. tion side Outlet pressure side E ATTENTION Utilize the complete slip on length on all hose connections secure fuel hoses with suitable screw clamps or by crimp connection Delivery rate pressure See diagram Ill 32 0 250 500 750 1000 1250 1500 1750 2000 hPa aP P2 P1 The diagram shows the delivery rate of the electric fuel pump over pressure 141 5 3 Take note of the following diagram outlines min capacity at nominal voltage on pump pressure and suction head are ZERO graph is effective on the seasoned pump only running in period approx 30 min 20 0 5 NOTE A capacity increase of approx 20 is feasible by running in process Page Date Install Reference Modification No 50 19960510 914F ee NOTE There is no need for a checkvalve for the operation of the two electric fuel pumps since the pump itself won t allow any passage against correct direction of flow E ATTENTION Employ GENUINE BOMBARDIER ROTAX fuel pumps only Non compliance will release BOMBARDIER ROTAX from any liability Place of installation Installation of the fuel pumps principally near the fuel tank to gain advantage of a cool location especially important at tendency of vapour locks Install the pump in low position if possible below fuel tank free of vibrations Therefore fuel pump attached directly on the engine is not permitte
82. to 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 E ATTENTION With closed or blocked drainage bores fuel could flow into combustion chamber possibly ruining the engine by hydrau lic lock Connecting nipple of drainage line outside dia 6 mm 1 4 slip on length irisrnsicneastivoeswenccneceads max 17 mm 11 16 E ATTENTION Utilize the complete slip on length Secure hoses by suitable screw clamps or by crimp connection Location of connecting nipple P2 axis cylinder _side_1 3 cylinder_side_2 4 Page Date Install Reference Modification No 64 19960510 914F eee 16 3 Notes to employment of the air filter BOMBARDIER ROTAX offers a dry type air filter A WARNING The certification to the latest requirement such as FAR and JAR has to be conducted by the aircraft builder The following points should assist the aircraft builder at the choice of a suitable filter Air filter four fold cotton fabric face covered with aluminium screen total filter area of at least 1400 cm 220 in Modification No Reference Install Date Page sO 914 F 1996 05 10 65 Blank page Page Date Install Reference Modification
83. ttachment should not be utilized or changed certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder EN A WARNING Choose place of installation such that operation is within the specified temperature limits Page Date Install Reference Modification No 84 19960510 914F Ei A WARNING The TCU comprises electronic components and is therefore completely sealed The TCU is allowed to be opened only by persons authorized by BOMBARDIER ROTAX connections terminal flexible cable 0 75 mm white No 1 terminal flexible cable 0 75 mm white No 25 from the 36 pole plug receptacle of the TCU with cable eye 4 2 mm dia to DIN 46225 gt fuse The TCU has to be protected by a slow blowing 5A fuse in accordance with the wiring diagram Ill 52 19 4 9 Isolating switch for servo motor See Ill 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 Ill 52 Pos E ATTENTION The isolating switch has to be designed such that it is safe for off by mistake or unintentionally The fix and secured position is ON switching voltage min 100 V switching current min 2 A place of installation On the instrument panel in the pilot s field of view anytime and easy to reach Installation
84. verence pressure is the boost pressure in the airbox The arrows on top of the fuel pressure control are of no significance for this application 14 5 Notes on checking of fuel pressure See Ill 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 joined to the fuel line LZ remove banjo bolt M10x1x19 Fit additional hose nipple with inte grated orifice and 2 sealing rings by use of a longer banjo bolt M10x1x30 tightening torque of the banjo bolt 17 Nm 150 in Ib E ATTENTION At tightening of the fuel lines support the specific line to prevent any internal stresses NOTE The illustration 34 shows the additional hose nipple connected to fuel line of carburetor 1 3 The additional nipple can be fitted of course to any other connections with the exception of outlet All the necessary items are available as spare parts Page Date Install Reference Modification No 52 19960510 914F ee Blank page Modification No Reference Install Date Page sO 914 F 1996 05 10 53 15 Carburetor See illustration 35 The carburetors on the standard engine are already attached by a flexibly flange Only connections of the Bowden cable for throttle and starting carb have to be established It is recommended to make
85. vo motor is not of a fire resistant construction A recommendable location is in the cockpit below the instrument panel NOTE Place of installation is limited by the length of the servo cable cable length approx 1000 mm 40 from waste gate bending radius min 50 mm 2 Page Date Install Reference Modification No 70 19960510 914F Ei Blank page Modification No Reference Install Date Page Q 914 F 1996 05 10 71 19 Electric system See Ill 52 The engine 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 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 2 lamps 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 19 1 Requirements on circuit wiring E ATTENTION The connections have to be completed by the aircraft builder in accordance to effective certification and wiring diagram ill 52 The electromagnetic compatibility EMC and electromagnetic inter ference EMI
86. w calibration of the throttle position is absolutely necessary Refer to Maintenance Manual 914 F Page Date Install Reference Modification No 60 19960510 914F eee Blank page Modification No Reference Install Date Page sO 914 F 1996 05 10 61 16 Air intake system See Ill 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 TVG ciosnacinranene nesiebeineeciatniciaria anata E 72 C 162 F Low air temperature in the airbox is favourable for engine performance and against knocking tendency at combustion If need be install intercooler 16 2 Requirements on the air intake system A WARNING Carbicing isacommon reason for engine trouble No implements are 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 a switch over flap to intake air from the engine compartment is recommended as the air filter could possibly close by formation of ice 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 Thecertification to the latest requirements such as FAR and JAR has to be conducted by the aircraft buil

Installation Manual 914 F Rev.1 09/2004

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