Rotax 914 series Manuals

Manuals and User Guides for Rotax 914 series. We have 9 Rotax 914 series manuals available for free PDF download: Maintenance Manual, Installation Manual, Operator's Manual, Service Bulletin, Service Instruction, Service Instructions Manual, Service Information

Rotax 914 series Maintenance Manual

Rotax 914 series Maintenance Manual (456 pages)

912/914 Series

Brand: Rotax | Category: Engine | Size: 15 MB

Table of Contents

Table of Contents

3
- 2 List of Chapters
  
  5
- 3 Index
  
  7
- 4 List of the Valid Pages
  
  11
- 5 Table of Amendments
  
  19
- 6 General Note
  
  21
- 7 Safety Notice
  
  23
  - Repeating Symbols
    23
- 8 Technical Documentation
  
  25
  - Filling in the Dimension Sheets
    25
  - List of Abbreviations
    26
- 9 Classification of Parts for Maintenance/Repair
  
  27
  - Determination of Actual Wear [%]
    30
- 10 Maintenance
  
  33
  - Trouble Shooting
    33
  - Tightening Torques
    33
  - Consumable Materials
    34
  - Auxiliary Tools
    37
  - Measuring Tools
    39
Table of Contents

47
- 2 System Description
  
  49
  - Description of Design
    49
  - Type Description
    50
- 3 Technical Data
  
  57
  - Operating Limits
    57
  - Operating Fluids / Capacity
    57
  - Weights
    57
  - Engine / Components
    58
- 4 Treatment of Corrosion and Surface Damage
  
  61
  - Propeller Shaft
    61
- 5 Preservation and Returning to Service
  
  63
- 6 Maintenance
  
  65
  - Engine Suspension Frame
    65
    
    1) Engine Suspension Frame Disassembly
    65
    
    2) Engine Suspension Frame Inspection
    66
    
    3) Engine Suspension Frame Assembly
    66
  - Temperature- and Pressure Observation
    68
Systems Description/Maintenance

69
- 2 Systems Description
  
  73
  - Propeller Gearbox
    73
  - Hydraulic Governor
    75
  - Vacuum Pump
    76
  - Connections for Instrumentation
    76
    
    1) Mechanical Rev Counter and Hourmeter (Optional)
    76
- 3 Maintenance
  
  77
  - Removal of the Fly Wheel Hub
    77
  - Vacuum Pump Removal and Inspection
    78
  - Governor Removal and Inspection
    78
  - Ignition Housing Removal and Inspection
    79
  - Ignition Housing Fitting
    82
  - Sprag Clutch
    83
    
    1) Sprag Clutch Removal
    84
    
    2) Sprag Clutch Dismantling
    85
    
    3) Sprag Clutch Installation
    86
  - Reduction Gear for Electric Starter
    88
  - Rev Counter Drive
    89
  - Propeller Gearbox
    90
    
    3) Removal of Roller Bearing for - Series 4
    92
    
    4) Propeller Gearbox Disassembly
    96
    
    5) Propeller Shaft Removal
    98
    
    6) Vacuum Pump Drive Removal
    100
    
    7) Propeller Governor Drive Removal
    101
    
    9) Vacuum Pump Drive Installation
    106
    
    10) Gearbox Components Inspection
    107
    
    11) Toothed Shaft Profiles Inspection
    111
    
    12) Gear Set (Gear Wheels) Inspection
    112
    
    13) Propeller Gearbox Reassembly
    117
    
    14) Disc Spring Pre-Tension Adjustment
    119
    
    15) Propeller Gearbox - Installation
    121
  - Cylinder Head - Removal
    123
  - Cylinder Head - Disassembly
    125
    
    1) Cylinder Head and Studs
    127
    
    2) Reworking of the Sealing Surface to the Exhaust Manifold
    129
    
    3) Valve Guides
    130
    
    4) Valve Seats
    131
    
    5) Valves
    132
    
    6) Valve Springs
    135
    
    7) Washers
    137
    
    8) Rocker Arm and Rocker Arm Shaft
    138
    
    1) Rocker Arm with Plastic Bushing
    139
    
    2) Rocker Arm with Pressed Sinter Bushing
    140
    
    3) Rocker Arm Shaft
    140
  - Cylinder Head Reassembly
    141
  - Cylinder and Piston - Removal
    143
    
    1) Checking Pistons
    145
    
    2) Checking the Piston Ring
    147
    
    3) Piston Pin
    148
    
    4) Cylinders Inspection
    149
  - Hydraulic Valve Tappets
    151
  - Pushrods
    153
    
    1) Hydraulic Valve Tappets Fitting
    154
    
    2) Pistons Fitting
    154
    
    Piston and Cylinder Assembly Fitting
    154
    
    3) Cylinders Fitting
    158
    
    4) Cylinder Head Fitting
    160
    
    Intake Manifold and Compensation Tube Assembly
    163
- 4 Wear Limits
  
  165
  - Cylinder Head
    176
- 5 Form Sheets
  
  185
  - Form Sheet for Material Testing ROTAX 912/914 Series
    185
    
    1) Inspection on Cracks
    185
Systems Description/Maintenance

187
- 2 Systems Description
  
  189
  - Fuel System (on 912 Series)
    189
  - Fuel System (on 914 Series)
    191
  - Fuel Filter
    193
  - Fuel Pump (on 912 Series)
    193
  - Fuel Pump (on 914 Series)
    193
  - Fuel Pressure Regulator (Only on 914 Series)
    194
  - Pressure Connecting Lines (Only on 914 Series)
    196
  - BING Constant Depression Carburetor Type 64-3
    198
  - Handling of Fuel
    201
  - Connections for Instrumentation
    202
    
    1) Airbox Air Temperature Display (Only on 914 Series)
    202
    
    2) Boost Pressure Display
    202
  - Carb Heat System and Winter Operation
    202
- 3 Maintenance
  
  203
  - BING-Constant Depression Carburetor Inspection
    207
    
    2) Float Needle Valve Leakage Test
    208
    
    3) Individual Components of the Carburetor (on the 912 Series)73-00-00
    209
    
    4) Individual Components of the Carburetor (on the 914 Series)73-00-00
    210
    
    5) Diaphragm
    211
    
    6) Jet Needle
    211
    
    7) Float Chamber, Floats
    213
    
    8) Float Brackets
    214
    
    9) Carburetor Jets
    215
    
    10) Float Needle Valve Inspection
    216
  - 11) Starting Carburetor (Choke)
    217
  - 12) Carburetor Assembly
    217
  - 13) Carburetor Synchronization
    219
  - 14) Idle Speed Adjustment
    219
  - 15) Throttle Cable and Linkage
    219
  - General Information on the Fuel System
    220
    
    1) Fuel Pressure (on 912 Series)
    221
    
    2) Fuel Pressure (on 914 Series)
    223
    
    3) Carburetor Sockets
    224
    
    4) Fuel Lines (on 912 Series)
    226
    
    5) Fuel Lines (on 914 Series)
    229
    
    6) Fuel Pressure Regulator (Only on 914 Series)
    230
    
    7) Fuel Pump (on 912 Series)
    231
    
    8) Fuel Pump (on 914 Series)
    233
    
    9) Pressure Connecting Lines (Only on 914 Series)
    235
  - Assembly of Carburetor Sockets, Carburetor and Fuel Lines
    239
    
    1) Carburetors and Carburetor Sockets
    239
    
    2) Fuel Lines (on 912 Series)
    241
    
    3) Fuel Lines (on 914 Series)
    244
  - Intake Manifolds Fitting
    246
  - Engaging the Carburetor Support
    246
  - Connecting Fuel Lines (Tank)
    247
Systems Description/Maintenance / Troubleshooting

249
- 2 Systems Description
  
  251
  - Electric System (Alternators, Ignition)
    251
    
    1) Ignition
    254
    
    2) Allocation of Trigger Coils and Ignition Circuits
    256
    
    3) Firing Order
    257
  - Connections for Instrumentation
    257
    
    1) Electronic Rev Counter
    257
- 3 Maintenance / Troubleshooting
  
  259
  - Treatment of Corrosion and Surface Damage
    259
    
    Electric System
    259
  - Checking the Ignition Unit, Trouble Shooting
    259
  - Spark Plugs
    260
  - Spark Plug Connectors and Ignition Cables
    260
  - Electronic Module, Trigger Coil Kit
    262
  - Charging Coil
    263
  - Generator Coils
    264
  - Dual Ignition Coil
    265
  - Cut-In Speed of Ignition
    266
  - Ignition Timing Control
    267
  - Ignition Circuits Inspection (Ignition Check)
    269
  - Measurement Values for the Ignition Unit
    270
  - Wiring Diagrams
    272
    
    1) Engine Internal (on the 912 Series)
    272
    
    Engine Internal (on the 914 Series)
    278
    
    Engine External (on the 914 Series)
    282
  - Ignition Electric Set Removal
    283
  - Ignition Electric Set Dismantling
    285
    
    Dual Ignition Coils Replacement
    285
  - Ignition Electric Set Reassembly
    289
  - Ignition Electric Set Refitting
    291
  - Trigger Coil Kit Replacement
    294
  - Stator Removal and Refitting
    296
  - Fly Wheel Hub
    297
  - Interference Suppression Box (Only on the 912 Series)
    300
    
    1) Interference Suppression Box Dismantling
    300
    
    2) Interference Suppression Box Wiring Diagram
    301
    
    3) Interference Suppression Box Assembly
    302
    
    4) Interference Suppression Box Fitting
    302
  - Rev Counter and Ignition Trigger Coils
    303
  - External Alternator (Optional on 912/914 Series)
    305
    
    1) Vbelt Pulley Assembly
    305
    
    2) Alternator Assembly
    305
    
    3) V-Belt Tension
    307
- 4 Wear Limits
  
  309
- 5 Form Sheets
  
  311
Table of Contents

313
- 2 Systems Description
  
  315
  - Cooling System
    315
  - Connections for Instrumentation
    316
- 3 Maintenance
  
  317
  - Water Pump Removal and Inspection
    318
  - Water Pump Housing - Dismantling and Inspection
    319
  - Fly Wheel Hub Removal
    321
  - Ignition Housing Removal
    321
  - Water Pump Shaft - Removal
    321
  - Rotary Seal - Removal
    322
  - Rotary Seal - Installation
    322
  - Axial Position of the Water Pump Shaft
    324
  - Ignition Housing Assembly
    325
  - Water Pump Housing - Reassembly
    325
  - Coolant Hoses Fitting
    326
  - Spring Band Hose Clamps
    326
  - Radiator (Optional 912/ 914 Series)
    326
  - Cooling Air Duct (Optional 912/ 914 Series)
    326
  - Expansion Tank
    327
  - Overflow Bottle
    327
  - Temperature Measurement System
    327
  - 1) Cylinder Head Temperature Sensor
    327
- 4 Wear Limits
  
  331
  - Water Pump
    331
Systems Description/Maintenance

333
- 2 Systems Description
  
  335
  - Turbocharger Control (Only on 914 Series)
    335
    
    1) Target Pressure Reduction at Overspeeding
    340
    
    2) Target Pressure Reduction
    340
    
    2) Target Pressure Reduction at Excessive Airbox
    341
    
    3) Target Pressure Reduction by Limiting the Compressor
    342
    
    Pressure Ratio
    342
    
    3) Lamp Output Connections on the TCU
    343
    
    4) Three-Way Solenoid Valve
    344
    
    5) PC Interface
    344
- 3 Maintenance
  
  345
  - Control System of the Turbocharger (Only on 914 Series)
    345
    
    1) Checking the Turbocharger Control Unit (TCU) by Means
    345
    
    1) Functions of the Communication Program
    345
    
    2) Required Items
    345
    
    3) Scope of the Communication Program
    347
    
    4) Application of the Communication Program
    349
    
    6) Checking the Throttle Valve Position
    361
    
    7) Recalibration of the Throttle Position
    363
  - 2) Static Check of the Turbocharger Control
    364
    
    1) Turbo Control Unit (TCU)
    364
    
    2) Caution Lamps
    366
    
    3) Wiring Harness
    367
    
    4) Throttle Potentiometer
    369
    
    5) Resistance Thermometer
    374
    
    6) Pressure Sensors
    376
    
    7) Servo Motor
    382
    
    8) Circuit Breaker for Servo Motor
    384
    
    9) Three-Way Solenoid Valve
    385
  - Wiring Diagrams
    386
  - Engine External (on the 914 Series)
    386
- 4 Form Sheets
  
  387
Systems Description/Maintenance

389
- 2 Systems Description
  
  391
- 3 Maintenance
  
  395
Table of Contents

411
- 2 Systems Description
  
  413
  - Lubrication System
    413
  - Main Oil Pump (Engine Lubrication Circuit)
    415
  - Suction Pump (Turbocharger Oil Circuit, Only on 914 Series)
    418
  - Magnetic Plug
    420
  - Drain Plug
    420
  - Connections for Instrumentation
    420
    
    1) Oil Pressure Indication
    420
    
    2) Oil Temperature Indication
    420
- 3 Maintenance
  
  421
  - Oil Pump
    421
    
    1) Oil Pump Removal (Main and Suction Pump)
    421
    
    2) Oil Pump Disassembly
    424
    
    4) Oil Pump Assembly (on 912 Series)
    428
  - Pressure Check Valve (Only on 914 Series)
    430
  - Oil Sump (Only on 914 Series)
    431
  - Oil Tank
    432
  - Oil Lines (Steel Lines)
    433
  - Oil Lines
    435
  - Oil Cooler
    435
  - Purging of Lubrication System
    436
  - Temperature- and Pressure Observation
    436
    
    1) Oil Temperature Sensor
    436
    
    2) Oil Pressure Sensor
    437
- 4 Wear Limits
  
  439
  - Systems Description
    443
    
    Electric Starter
    443
  - Maintenance
    445
    
    Electric Starter Dismantling
    445
    
    1) Standard Starter
    447
    
    Electric Starter - Inspection of Individual Parts
    449
    
    Electric Starter - Reassembly
    451
    
    1) Standard Starter
    452
    
    2) HD Starter
    452
    
    Electric Starter - Installation
    452

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Rotax 914 series Maintenance Manual

Rotax 914 series Maintenance Manual (184 pages)

914 series;

Brand: Rotax | Category: Engine | Size: 3 MB

Table of Contents

Chapter: 00-00-00 General Note

11
- Table of Amendments
  9
- Table of Contents
  11
- General Note
  13
- Abbreviations and Terms Used in this Manual
  15
  - Conversion Table
    17
- Safety
  19
  - Safety Notice
    20
  - Instruction
    22
  - Maintenance Concept
    23
  - Technical Documentation
    24
  - Use for Intended Purpose
    26
Chapter: 05-00-00 Maintenance

29
- Maintenance
  31
  - General Note
    31
  - Authorized Personnel
    32
  - Procedure Notes
    33
  - Trouble Shooting
    34
  - Consumable Materials
    35
Chapter: 05-10-00 Time Limits

39
- Definition of Terms
  41
  - Operating Hours
    41
  - Time Limit
    41
  - Life Cycle
    41
  - General Overhaul (TBO)
    42
- Time Limit
  43
  - Time Limit for Rubber Parts
    46
  - Time Limit for the Coolant
    46
  - Annual Inspection
    46
Chapter: 05-50-00 Unscheduled Maintenance Checks

65
Chapter: 12-10-00 Replenishing Operating Fluids

97
- Fluid Capacities
  101
- General Note
  101
- Cooling System
  103
  - Coolant Check/Replenish
    103
- Lubrication System
  105
  - Oil Level Check/Replenish
    105
Chapter: 12-20-00 Scheduled Maintenance

107
- Engine Cleaning
  109
- Checking the Air Filter
  111
  - Cleaning the Dry Air Filter
    111
  - Replacing the Dry Air Filter
    113
- Visual Inspection
  115
  - Checking the Engine Suspension
    117
  - Corrosion
    117
- Leakage Check
  119
- Checking the Compression
  121
- Checking the V-Belt Tension
  125
- Locking the Crankshaft
  127
- Checking the Wastegate Flap
  129
- Inspection of the Fuel Filter in the Airframe
  131
- Test Run of Engine
  133
- Cooling System
  135
  - Checking the Cooling System
    135
  - Replacing the Coolant
    136
  - Flushing the Cooling System
    138
  - Expansion Tank, Radiator Cap
    139
  - Overflow Bottle
    141
  - Accessories
    141
- Fuel System
  143
  - Carburetor Synchronization
    143
  - Mechanical Synchronization
    144
  - Pneumatic Synchronization
    146
  - Idle Speed Check
    150
  - Operating Range Check
    151
  - Checking of the Float Chamber
    153
  - Idle Speed Adjustment
    155
  - Checking the Carburetor Actuation
    156
  - Oil Change
    161
  - Oil Filter Replacement
    162
  - Install Oil Filter
    163
  - Inspection of the Oil Filter Insert
    164
  - Cleaning the Oil Tank
    166
  - Purging the Oil System
    168
- Inspecting the Magnetic Plug
  169
  - Installation of the Magnetic Plug
    170
- Flushing the Oil Circuit
  171
- Electric System
  173
  - Check of Wiring
    174
  - Inspection and Replacement of Spark Plugs
    175
  - Remove the Spark Plugs
    175
  - Installation of Spark Plug
    177
- Propeller Gearbox
  179
  - Checking the Friction Torque in Free Rotation
    179
  - Checking the Propeller Gearbox
    181

Rotax 914 series Installation Manual

Rotax 914 series Installation Manual (142 pages)

914 series

Brand: Rotax | Category: Engine | Size: 4 MB

Table of Contents

1 Table of Contents

3
2 Index

7
3 Preface

9
4 Safety

11
- Repeating Symbols
  11
- Safety Information
  11
- Instruction
  13
- Technical Documentation
  14
5 List of the Effective

17
6 Table of Amendments

19
7 Description of Design

21
8 Technical Data

27
9 Preparations for Engine Installation

31
- Transport
  31
- State of Delivery
  31
- Engine Preservation
  31
- Protective Covering
  32
10 Engine Suspension and Position

33
11 Exhaust System

39
- Operating Limits
  40
- General Notes Concerning the Exhaust System
  41
12 Cooling System

43
13 Lubrication System

63
14 Fuel System

83
15 Carburetor

91
16 Air Intake System

97
- Operating Limits
  97
- Requirements on the Air Intake System
  98
  - 1) Requirements on the Intake Air Ducting
    98
  - 2) Requirements on the Intercooler
    99
  - 3) Airfilter
    100
  - 4) Airbox
    100
- Additional Notes Concerning Air Intake System
  102
17 Pressure Sensors

103
- Static Pressure Sensor
  104
18 Servo Motor/Servo Cable

105
- Servo Motor
  105
- Servo Cable
  106
19 Electric System

107
- Requirements on Circuit Wiring
  108
  - 1) Electromagnetic Compatibility (EMC)
    108
- Wiring Diagram
  109
- Description of the Turbo Control Unit (TCU)
  111
- Technical Data and Connection of the Electric Components
  111
  - 1) Integrated Generator
    111
  - 2) Rectifier-Regulator
    112
  - 3) Electronic Modules
    114
  - 4) Ignition Switches (On-Off Switch)
    114
  - 5) Electric Starter
    116
  - 6) Starter Relay
    117
  - 7) Electric Fuel Pumps
    118
  - 8) Turbo Control Unit (TCU)
    119
  - 9) Isolating Switch for Servo Motor
    121
  - 10)Boost Lamp
    122
  - 11)Caution Lamp
    122
  - 12)External Alternator (Optional Extra)
    123
  - 13)Connection of the Electric Rev-Counter (Tachometer)
    125
  - 14) Battery
    126
  - 15) Relay
    126
- Internal Consumer of Electric Power
  126
20 Propeller Drive

127
- Technical Data
  127
21 Vacuum Pump

129
- Technical Data
  129
22 Hydraulic Governor for Constant Speed Propeller

131
- Technical Data
  131
23 Connections for Instrumentation

133
24 Preparations for Trial Run of Engine

139

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Rotax 914 series Maintenance Manual

Rotax 914 series Maintenance Manual (124 pages)

Brand: Rotax | Category: Engine | Size: 2 MB

Table of Contents

Rotax 914 series Operator's Manual

Rotax 914 series Operator's Manual (92 pages)

Engine types 914 Series

Brand: Rotax | Category: Engine | Size: 1 MB

Table of Contents

1) General Note

11
- Table of Contents
  11
- Technical Documentation
  18
- Standard Version
  20
- Type Description
  21
- Denomination of Cylinders, Engine Views
  22
- Technical Data
  24
- Fuel Consumption
  24
- Direction of Rotation
  24
2) Operating Instructions

25
- Operating Limits
  26
  - Performance
    26
  - Speed
    26
  - Manifold Pressure
    26
  - Acceleration
    26
  - Critical Flying Altitude
    27
  - Airbox Temperature
    27
  - Oil Pressure
    27
  - Oil Temperature
    27
  - Egt
    27
  - Conventional Coolant
    28
  - Waterless Coolant
    28
  - Engine Start, Operating Temperature
    28
  - Fuel Pressure
    28
  - Power Consumption of the Hydraulic Propeller
    29
  - Power Consumption of the Vaccum Pump
    29
  - Power Consumption of the External Alternator
    29
  - Deviation from Bank Angle
    29
- Operating Media-Coolant
  30
  - Conventional Coolant
    30
  - Application
    30
  - Mixture
    30
- Operating Media-Fuel
  31
  - Mogas
    31
  - Avgas
    31
- Operating Media-Lubricants
  32
  - Oil Type
    32
  - Oil Consumption
    32
  - Oil Specification
    32
  - Oil Viscosity
    32
  - Table of Lubricants
    33
3) Standard Operation

35
- Daily Checks
  36
  - Coolant Level
    37
  - Check of Mechanical Components
    38
  - Gear Box
    38
  - Carburetor
    38
  - Exhaust System and Turbocharger
    38
- Before Engine Start
  39
- Pre-Flight Checks
  39
  - Operating Media
    39
  - Coolant
    39
  - Oil
    40
  - Oil Level (Oil Dipstick)
    40
- Engine Start
  41
  - Tcu
    41
  - Lamps
    41
- Prior to Take-Off
  43
  - Warming up Period
    43
  - Throttle Response
    43
  - Ignition Check
    43
  - Propeller Governor
    43
- Take-Off
  44
  - Take-Off (Standard-With Active TCU)
    44
  - Take-Off
    45
- Cruising
  45
  - Performance
    45
  - Oil Temperature
    45
- Engine Shut-Off
  45
- Cold Weather Operation
  46
  - Coolant
    46
  - Lubricant
    46
  - Cold Start
    46
  - Icing in the Air Intake System
    46
  - Icing Due to Water in Fuel
    47
7) Description of Systems

67
- Cooling System of Engine
  68
  - Coolant
    68
  - Expansions Tank
    68
  - Coolant Temperature Measuring
    68
- Fuel System
  70
  - Fuel
    70
  - Return Line
    70
- Lubrication System
  72
  - Lubrication
    72
  - Crankcase
    72
  - Oil Pump
    72
  - Oil Circuit Vented
    72
  - Oil Temperature Sensor
    72
  - Turbocharger
    72
- Electric System
  74
  - Charging Coils
    74
- Turbocharger and Control System
  75
  - Regulation Boost Pressure
    75
  - Throttle Position
    75
  - Nominal Boost Pressure
    76
  - Throttle Position Versus Nominal
    76
  - Airbox Pressure
    76
  - Nominal Pressure
    77
- TCU Caution Lamps
  77
  - Caution Lamp
    77
  - Function Test
    77
  - Orange Caution Lamp
    77
  - Red Boost Lamp
    77
- Propeller Gearbox
  78
  - Reduction Ratio
    78
  - Overload Clutch
    78
  - Torsional Shock Absorber
    78
  - Backlash
    79
  - Vacuum Pump
    79

Rotax 914 series Service Bulletin

Rotax 914 series Service Bulletin (35 pages)

Aircraft Engines

Brand: Rotax | Category: Engine | Size: 1 MB

Table of Contents

Rotax 914 series Service Information

Rotax 914 series Service Information (3 pages)

Brand: Rotax | Category: Engine | Size: 0 MB

Table of Contents

Repeating Symbols
1
Introduction
1
Technical Data and General Information
1
Subject
1
Engines Affected
2
Reason
2
Responsibility
2
Compliance
2
Remedy
2
Accomplishment
2
Instructions
2
Oil Level Check
3
Replenishing of Oil Quantity
3

Rotax 914 series Service Instruction

Rotax 914 series Service Instruction (13 pages)

Brand: Rotax | Category: Engine | Size: 0 MB

Rotax 914 series Service Instructions Manual

Rotax 914 series Service Instructions Manual (11 pages)

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Brand: Rotax | Category: Engine | Size: 0 MB

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