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Europa Aircraft Rotax 914 Installation Manual

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Europa XS
Rotax 914 Installation Manual
Europa XS Rotax 914 Engine Manual
Issue 7
October 2004

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Summary of Contents for Europa Aircraft Rotax 914

  • Page 1 Europa XS Rotax 914 Installation Manual Europa XS Rotax 914 Engine Manual Issue 7 October 2004...
  • Page 2 Index of Chapters Chapter Description Engine installation Engine controls Oil tank Cooling duct and coolers Fuel system Engine cowlings Access doors Propeller and spinner Commissioning the engine Annex A Final inspection checklist September 2002 Issue 5 Europa XS Rotax 914 Engine Manual...

  • Page 3: Engine Installation

    1. Engine installation Preparation Before starting work on the engine installation read this manual and the Rotax 914 installation manual. There are some delicate parts attached to the engine, notably the ignition triggers, which require care in handling. Instead of installing the engine mounting to the aircraft, then trying to position a heavy engine onto it, the engine mounting should be attached to the engine first.
  • Page 4 Be careful to take into account the length of the already made up cables which connect the various engine related components together before making your final decision on their positions. Page 1 - 2 June 2004 Issue 7 Europa XS Rotax 914 Engine Manual...
  • Page 5 Fig 2. 914 engine installation exploded view. Page 1 - 3 Europa XS Rotax 914 Engine Manual Issue 7 March 2006...
  • Page 6 NAS1169C10 Tinnerman washers into the recess with flox, ensuring that the recessed face of the washers is kept clear of the flox. Mount the unit with spring washers and M4 nuts. Page 1 - 4 September 2003 Issue 6 Europa XS Rotax 914 Engine Manual...
  • Page 7 The static pressure tube should terminate close to the engine air inlet filter. Page 1 - 5 Europa XS Rotax 914 Engine Manual Issue 6 September 2003...
  • Page 8 Ensure that the drive lugs are fitted with no gap between the back of the propeller flange and the drive lug collar. Page 1 - 6 February 2005 Issue 7 Europa XS Rotax 914 Engine Manual...

  • Page 9: Engine Controls

    Throttle Lever Housing Drill the holes in the throttle lever housing, as shown in figure 1. Fig 1. Throttle lever housing drilling dimensions. Page 2 - 1 Europa XS Rotax 914 Engine Manual Issue 9 April 2006...
  • Page 10 - a suitably sized rubber grommet would be ideal. Fig 2. Exploded diagram of throttle lever assembly. Page 2 - 2 November 2004 Issue 8 Europa XS Rotax 914 Engine Manual...
  • Page 11 Note: You should set the throttle closed stop such that a fully warmed engine idles at 1200 - 1400 rpm. Although the engine idles more smoothly at 1600 rpm or more, when landing the aircraft you will benefit from minimal residual thrust. Page 2 - 3 Europa XS Rotax 914 Engine Manual Issue 9 April 2006...
  • Page 12 To ensure that the cables don’t come out of their guides, use locking wire wrapped around the cable outer and also the cable guides. Page 2 - 4 April 2006 Issue 9 Europa XS Rotax 914 Engine Manual...
  • Page 13 Ignition shorting cables connection Recent Rotax engines have modified ignition shorting cable connections. The photographs in figure 4 are self-explanatory. Fig 4. Ignition shoring cables connection. Page 2 - 5 Europa XS Rotax 914 Engine Manual Issue 10 November 2007...
  • Page 14 INTENTIONALLY BLANK Page 2 - 6 November 2007 Issue 10 Europa XS Rotax 914 Engine Manual...

  • Page 15: Oil Tank

    With the engine and lower cowling in place position the oil tank and bracket onto the front face of the starboard side footwell. Position the tank so that there is reasonable clearance from both the engine and cowling. Page 3 - 1 Europa XS Rotax 914 Engine Manual Issue 4 September 2001...
  • Page 16 Another consideration is that the oil mist will tend to coat the fuselage if left to vent freely. To avoid this you can run the vent line into a collector bottle before it goes to atmosphere; however, no bottle is provided. Page 3 - 2 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual...
  • Page 17 Duct Figures 1 shows the assembly of the aluminium duct from the individual components. Fig 1. Assembly of cooling duct. Page 4 - 1 Europa XS Rotax 914 Engine Manual Issue 4 September 2001...
  • Page 18 CD4 and CD5 are then bolted to the duct and to the front faces of the footwell, again using AN3-5A bolts - these should have AN970-3 washers to spread the load into the fibreglass structure, and MS21042-3 stiffnuts. Page 4 - 2 June 2004 Issue 7 Europa XS Rotax 914 Engine Manual...
  • Page 19 Figure 3 illustrates the mounting of the duct and the coolers. Fig 3. Installation of duct and coolers. Page 4 - 3 Europa XS Rotax 914 Engine Manual Issue 4 September 2001...
  • Page 20 For details of the oil system connections see the schematic view at figure 9 at the end of this chapter. Page 4 - 4 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual...
  • Page 21 Holes for the oil breather hose (from the neck of the oil tank), static pressure sensor tube and for the wastegate cable to enter and exit the compartment are required. Page 4 - 5 Europa XS Rotax 914 Engine Manual Issue 4 September 2001...
  • Page 22 Fig 6. Air filter chamber detail. Fig 7. Top view of air filter chamber. Page 4 - 6 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual...
  • Page 23 The wastegate cable needs to loop through the compartment to avoid sharp bends which would inhibit its operation. Page 4 - 7 Europa XS Rotax 914 Engine Manual Issue 4 September 2001...
  • Page 24 Fig 9. Schematic view of oil cooling system. Page 4 - 8 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual...

  • Page 25: Fuel System

    The electric pumps are pilot activated, and are duplicated as the Rotax 914 engine is not fitted with a mechanical pump. From the electric pumps the fuel lines join again . This line is connected to the inlet of the fuel pressure regulator on the top rear of the engine. A further line from the regulator takes a small flow of fuel back to the starboard side of the fuel tank.
  • Page 26 The fuel tank is designed to hold approximately 9 litres of reserve fuel. However, this amount may be reduced in turbulent conditions. There will be a small quantity of unusable fuel. Page 5 - 2 November 2004 Issue 8 Europa XS Rotax 914 Engine Manual...
  • Page 27 Fig 1. Schematic diagram of fuel system fittings. Page 5 - 3 Europa XS Rotax 914 Engine Manual Issue 8 November 2004...
  • Page 28 Fig 2. Fuel system Page 5 - 4 November 2004 Issue 8 Europa XS Rotax 914 Engine Manual...

  • Page 29: Engine Cowlings

    For the tri-gear version an extra slot must be cut in the rear of the lower cowling to allow for the nose gear leg - the size is shown in figure 1. Fig 1. Slot for nose gear leg. Page 6 - 1 Europa XS Rotax 914 Engine Manual Issue 8 November 2004...
  • Page 30 Finally, after fitting the cowlings, cut out the front circular face of the cowlings to leave a flange 25 mm (1") wide. Page 6 - 2 November 2004 Issue 8 Europa XS Rotax 914 Engine Manual...
  • Page 31 Page 6 - 3 Europa XS Rotax 914 Engine Manual Issue 8 November 2004...
  • Page 32 INTENTIONALLY BLANK Page 6 - 4 November 2004 Issue 8 Europa XS Rotax 914 Engine Manual...

  • Page 33: Access Doors

    Lay up four plies of ‘bid’ at +/- 45 around the door panels lapping onto the cowling approximately 2-3cm (1"). Page 7 - 1 Europa XS Rotax 914 Engine Manual Issue 4 September 2001...
  • Page 34 Bond and rivet the hinge in place using countersunk TLPK 424 BS rivets. Countersink the cowling and door panel with a drill before riveting. Page 7 - 2 June 2004 Issue 7 Europa XS Rotax 914 Engine Manual...
  • Page 35 Although it’s a good starting point, don’t rely on the alignment of the flanges of the spinner and rear bulkhead to ensure the spinner is true. Page 8 - 1 Europa XS Rotax 914 Engine Manual Issue 4 September 2001...
  • Page 36 Blade pitch adjustment You may find your own method for adjusting the propeller blade pitch but the following method has been found to work well. Page 8 - 2 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual...
  • Page 37 This operation is normally carried out by specialists who have the requisite equipment and expertise. Page 8 - 3 Europa XS Rotax 914 Engine Manual Issue 4 September 2001...
  • Page 38 Looking at how the two zeros have misaligned will confirm that the inner scale has moved something like 1/4 but, without the vernier it would be difficult to be absolutely sure. Fig 1. Vernier scales Page 8 - 4 September 2001 Issue 4 Europa XS Rotax 914 Engine Manual...
  • Page 39 Fig 2. Propeller and spinner assembly Page 8 - 5 Europa XS Rotax 914 Engine Manual Issue 6 September 2003...
  • Page 40 INTENTIONALLY BLANK Page 8 - 6 September 2002 Issue 5 Europa XS Rotax 914 Engine Manual...
  • Page 41 To check this a ‘T’ piece must be inserted into the oil pump suction line. Because this test has to be done with the engine running at full throttle it will be carried out later. Page 9 - 1 Europa XS Rotax 914 Engine Manual Issue 5 September 2002...
  • Page 42 0.3 bar (4.4 psi). If the depression is greater than this, check the hoses for kinks or for any other restriction in the system before continuing to operate the engine. Page 9 - 2 September 2002 Issue 5 Europa XS Rotax 914 Engine Manual...
  • Page 43 0.35 bar (5.1 psi). If the fuel pressure does exceed this limit there may be several reasons. For example, the pressure regulator may be incorrectly adjusted, it may be faulty or there could be a restriction in the return line. Page 9 - 3 Europa XS Rotax 914 Engine Manual Issue 7 June 2004...
  • Page 44 INTENTIONALLY BLANK Page 9 - 4 September 2002 Issue 5 Europa XS Rotax 914 Engine Manual...

  • Page 45: Appendix A - Final Inspection Checklist

    Owner........Kit Serial no........Date......Engine serial no........Note: This check list only covers specific items for inspection of the Europa aircraft. General inspection must be carried out in addition to these items. Items covered in the inspection stages during construction are not included in this list.
  • Page 46 A warning label close to the switch should also be present marked: Warning: Engine over boost may be possible with TCU switched off. Run the engine at full power for 2 minutes prior to the first flight. Page 10 - 2 March 2008 Europa XS Rotax 914 Engine Manual...
  • Page 47 Rotax engines are designed to run on Mogas. Please note that if you intend to use Mogas in your aircraft it is necessary to apply for permission from the L.A.A. Europa XS Rotax 914 Engine Manual March 2008 Page 10 - 3...