Rotax 912-UL, Repair Manual

Page 1: ...GUL Edition 07 L992 recommended BOMBARDIER ROTAX GMBH MOTORENFABRIK A 4623 GUNSKIRCHEN _ AUSTRIA Telef on 43 O 7 246 271 0 Telef ax 431017 246 37 O Telex 25546brgka Telegi Bombrotax Grinskirchen ATS 4...

Page 2: ...ng 2 3 4 s 6 2 Crankcase andjournal bearings L7 l8 19 20 2T 22 22 23 23 23 24 24 25 25 6 Inspection andjudgementof components andunits 20 Evaluationof wearlimits clearances andtolerances 6 1 Crankshaf...

Page 3: ...box 34 6 15 1 Checking of theslipping torque 35 6 15 2 Dis assembly of gearbox 35 6 15 3 Dis assembly of overload clutch 37 6 15 4 Re assembly of overload clutch 38 6 15 5 Re assembly of gearbox 38 6...

Page 4: ...61 7 15 4 Mainregulating system withpressure control 63 7 15 5 Idlingsystem 66 7 15 6 Staning carburator choke 67 7 16 Carburetoractuation 68 7 16 1 Pneumatic synchronization 68 7 16 2 Mechanical syn...

Page 5: ...ENTION Denotesan instructionwhich if not followed could severelydamage englne components I NOTE Indicatessupplementary informationneededto fully completeaninstruc tion Althoughthemerereading of such i...

Page 6: ...ine onecentralcamshaft pushrods OHV 79 5mm 3 13in 61mm 2 4in 1211 cm3 73 9 cu in c 59kW 80hp at5500r p ffi performance sheet Lb 365 c 103Nm 60ft lb at4800r p rr perform sheet Lb 365 5800r p m lightall...

Page 7: ...ischarge design inter fercnce suppression andintegrated generator AC 12V250W 13 5 to 14 2 V DC atstart6oB T D C atoperation 260B T D C srze 12mm 47in EYQLJEM AD 800L 0 5 0 6mm 02 023in 2xBINGconstant...

Page 8: ...Description application qty Trestle ass y for workbench 1 Mounting plate ass y 1 Insertion punch foroil seal 850977 12x30x7 1 Insertion punch forrotary seal 1 Insertion punch fortiminggear 1 Insertion...

Page 9: ...pinstalllationpusher piston pincirclip 1 Circlipinstallation sleeve piston pincirclip 1 Dialgauge 1 Sraight edgeto checkprotnrsion of journalbearing half 1 Cylinder aligning tool 1 Alignment plate for...

Page 10: ...om theaircraft carryoutthefollowing Cooldownengine first Disconnect battery Draincoolingsystem Since coolant isnotjustplainwaterbutantifreeze concentrate store for re use Removecarburetor from intakem...

Page 11: ...f possible damage 4 2 Re installationof engineinto aircraft Generallyinverse rcmovalprocedures However payattentionto thefollowing After fining carbs checkfunctionandeasymovement Checkfunctionof throt...

Page 12: ...rbox If fitted remove vacuum pump 5 1 Intake manifold Remove the4Allenhd screws M6 O andtakeoff intakemanifolds alongwithO ringsand pressure equalizing tube0 Slacken clamps 25 12 oncoolant hose betwee...

Page 13: ...tnumber O onflywheelg withtheedge 0 of ignitioncoveris given To ensureproper engagementof locking screw in crankshaft turn crankshaftback andforth till engagedandttrentightenlock scrcwto apprcx l0 Nm...

Page 14: ...Woodruff key prior to removal of lgnruoncoveras preventive measure against damage of oil sealandjournalbearing 5 5 Ignitioncoverassfy Remove seven M6 Allen screws andthetwo nutsM5 on electricstarters...

Page 15: ...iece8TT4I0oncrankshaftandpulloffoverunningclutch housing usingpuller 877375 Thefollowingitems i e freewheeling gearOandtiminggear26T placed behind the worrngear O andpumpgear pressed tocamshaft aswell...

Page 16: ...34I 60fromP T O end of crankshaft If needbe usetwo screwdrivers I NOTE Hex nutwithleft hand thread 5 9 Cylinderhead Turnengine fittedtotres tle with cylinders1and3 pointing upwards and numberthefourcy...

Page 17: ...ersin a mannerto ensure refit tingin theirinitial place Now turn engineon trestle and proceed with disassembly of cylinder2and4 Priorto removal markcylindersandpistonsto ensure correctco ordinationatr...

Page 18: ...tillfitted i e if notbeen used forengine suspension remove studM10alongwithdistance sleeves washers andnuts Separate thetwocrankcase halves if necessary byapplyingpressure atthelugsO Lift off left cra...

Page 19: ...andretaining ring Onengine version withvacuum pump remove drivegearO shaftass y with ballbearing andoil seal Takeoff 7 O rings 9 2 I ATTENTION Forlongerstorage protectall partsagainst dustanddirt 5 13...

Page 20: ...larmagnero side MS 0 mainbcaring radialclcarance crankpin radialclearance crankshaft radialclcarance magneto sidc crankshaft radialclearance pTOside crankshaft axialclearance crankshaft outof round pT...

Page 21: ...er imprintedoncrankshaft centre I ATTENTIbNTXrep crankshaft absolutely clean 6 2 Crankcase andjournal bearings Cleancrankcase in gasoline Visualcheckof all bearingseatsandsealingfaces Check crankcase...

Page 22: ...screws atthe centrebearing otherwise readings will beincorrect Readings of the3 mainbearings Dimension withoutbcaring halves withbcaring halves Dimensions camshaft bcaring 6 2 2 Thrust ring halves Di...

Page 23: ...2 6 20 0244 g l3 0 359 Renew camshaft if thedimensions arenotwithinthewearlimits 6 3 1 Hydraulic valve tappets Visual inspectionof the hydraulic tappets The hydraulic valve tappetis slowly rotating th...

Page 24: ...7 respectively measured at right angletopistonpin axisat hcightI5 mmfrombonom pistonto wallclcarancc pistonpinborc lrring heightofgroove heightof ring flankclcarance endgap 2dring heightofgroove heigh...

Page 25: ...in piston conrodbors clearancc pin in conrod Dimensions cylinderbore A cylinderborc B pistonskirt red at hcight15mm pistonskirt geen atheigtu 15mm pistonto wall clearance ovality tapcr I NOTE newmm i...

Page 26: ...ionby activatingstarter untilmaximumpressure isreached Successively takereadings on all fourcylindersandcompare results Individualreadings of thecylindersmostnot differ by morethan2bar 29psi Pressure...

Page 27: ...cylinder afterwards Visual checkof oil tubesfor tightness If leaking exchan gerespectively Forthisrenewal heatupcylinder to approximately 180oC 360 F Extract tubesand removeany glueresiduefrom bore Ap...

Page 28: ...de Dimension valveguideintemaldia valvcguidecxtcmaldia inrcrferencc fit in cylindcrhcad valvcstemdia cleannccof valvestcm newmm in wearlimit mm in 7 006 7 018 0 276 7 15 0281 12 O64 12 U5 0 474 12 M4...

Page 29: ...aranceangle intakevalve seat 35o exhaustvalve seat 30o 6 6 5 Valves Checkvalveheadfor wearandwarpage max allow ableoutof trueis 0 03mm 001in atoutside of valvehead Sealingfaceof valveheadis armoured T...

Page 30: ...letsideonly Insert pre oiled valves placeinnerandoutervalvespringandspring retainer in position compress valvesprings by utilizingfittingjig andclamp seechapter 6 6 2 Insert valvecotters and release s...

Page 31: ...n At renewalof bush because of wear exchange coverass y coverwithbush or sendtheunitfor repairtoROTAX Checkoil seal 32x52x7 exchange as required SimmerA32 57 7 LDR using punch877270 Visualcheckfor eme...

Page 32: ...woil and rotaryseal Inspectwaterpumpshaft for wear renewasrequired 6 11 Fitting of the rotary sealand water pump Pressnewoil seal0 12x30x7 pre oiled sealinglip pointing inwards into ignition coverusin...

Page 33: ...kl l 1400lb capacity onaplane faceandpress pumpshaft intoposition untilstop usingpunch 877250 O NOTE To warrantthecor rectgapO between impeller O and pumpcover en sure alignmentof shaft shoulder0 with...

Page 34: ...x3 andO ring6 Pressin newoil sealright down to stopin cover usingpunch877 400 ru 6 14 Magnetohousingassfy Normallythere isnoneed todis assemble magneto housing justchecktightening tonque 25Nn 220in lb...

Page 35: ...y assigned screw andtorquemeasured as abovewith leverandspringscale Adjusttheslipping torque to450Nmt30 Nm 4000in lb 60 in lb byturningthe collarnut thussetting thepre load of thespringin theoverload...

Page 36: ...ace ball bear ing once prop shaft has beenpressed out For theremovalof theball bearing remove fint4 screws M6x16alongwithwashersfrom gearcover heatup coverto 80o 100oC 180 210oD andpushbearingtowards...

Page 37: ...ialclcarance of propshaft rcar 0 01 0 03 axialclearance of propshaft O A2 0 07 bronzc thrustwasher 1 00 depthof wcarondogs 0 00 t 6 15 3 Dis assembly of overload clutch inJ I 103 0 m1 O ml 0 001 0 63...

Page 38: ...ftersetring of thgrfif p gtorque secure collarnutbydenting intothefixingholes o 6 15 5 Assembly of gearbox Afterheating upgearcoverin ovento 100o C 215 F insertoil seal40 52 I from theinside usingpunc...

Page 39: ...earbox ass y undersuitable fixture see i 44 mdputpressure viayokeondoggear O until springpackage is compressed to flat With springs compressed flat measure distance A from top edgeof retainingring to...

Page 40: ...TE ANTI SEZEand retaining ring o With springs in this released state the face for the ring halvesmustbein line with the upperedgeO of the groovein propshaft Compensate thedif ference byshims Dplaced w...

Page 41: ...100mm 4in above crankshaft cenre If tankis fitted anyhigher oil might rickle by gravityinto the crankcase atlongerengine stops Nominaloil pressure is3 5bar 51p s i at5500rpmandoil temp of I l0oC 230 F...

Page 42: ...ch The energyis storedin capacitors At themomentof ignition thetwo eachexternaltrigger coils actuatethedischargeof thecapacitortotheprimary circuit of thedualignition coils The operationof the ignitio...

Page 43: ...pression box The2 electronic boxes 4 doubleignitioncoilsand2 feed through capacirors are placed in theinterference suppression box Oneverysuppression boxyouwill find a successive serialnumber onitscov...

Page 44: ...itA cyl I whitc red forignitioncircuitA cyl 2 primarycablefor ignitioncoil ignitioncircuit A cyl 3l4 black ground ignitioncircuitA cyl 3 4 white primarycablcfor ignitioncoil ignitioncircuitA cyl l2 bl...

Page 45: ...M4xl2to boxwall Secure allscrews using LOCTITE 221 AttachH V leadslT and38 to ignition coil supportby cable retainingstraps O NOTE As everysuppression box is numbered and essential datais registered u...

Page 46: ...ng the ignitionunit 3 l ct o E o E E I oo t F o IJ E o E C JJ f O L O lgnition S G B piclup circuit I ignition S G R u L o ignition cicuitB marled red onbothends r l lightingcoil onsator ycUow yellow...

Page 47: ...ow Theregulating andrecti fying is carriedoutbyan electronicseriesregula tor and full waverecti fier 6 20 1 DCoutput 13 8 V 14 0 0 A 1 8 A 30 25 20 1 5 10 5 0 7r7 13 7 7r8 11 6 15 2 17 8 13 9 4rO 13 3...

Page 48: ...000uF zsv interference suppression box bottorn2 L _ _ _ _ _ _ J nrorzvZw l _ohrequest I i g eoE Eeo e E EE EE EE t k E A r F c o o E f f t affttattffaftt arftttftrfrf t consumeriil f 1 1 f l l I f t r...

Page 49: ...nd terminal C onregulaton could cause overcharging thebattenie I t J te 9 e v r 5 goa da zts q E D D a t startswitch max 14 1 V permissible B 22000 pF 25V extra 2 bcnorn etE_i i t l 3 i i il i i ii ii...

Page 50: ...on R or B connector heating uptheconnection and ruiningtheSCR The damageof theSCRmight leadto shortingthebatteryvia statorcoil or the regulator resultingin burned out coilsandemptybattery b Control ci...

Page 51: ...nerate onepositiveandonenegative impulseper revolutionof crankshaft A suitable tachometer 0 7000rpm AviasportT7K5A is providedfrom ROTAX panno 966 073 Connection atpick uponignition cover Themechanica...

Page 52: ...this machining process asbestparticles are set free and could possiblybeinhaled Therefore theundercutting isprohibited according toenviron mentallaw Check armature using 12or 24 V testlamp for shorti...

Page 53: ...0 0 Oil ovemrnning gear50T andbearing bushandfit on magneto endof crankshaft Apply MOLYKOTEGN paste to camsandlubricate bearings of camshaft Place camshaftfitted with timinggear pumpgearandhelicalgear...

Page 54: ...nkshaft aftertightening of screws Ifnot turningfreely dis assemble find cause andrectify 7 2 Pistonandcylinder ForenginescertifiedtoJAR 22 setupdimension sheetfor cylindersandpistons seechapter1I Remo...

Page 55: ...s andinstallthemin respectiveorder but on one side only topreventdroppingoutwhen turningengineover 7 3 Cylinder head Apply athinfilm of LOCfifEzzl tosealing faceofcylinder Installrespective pushrod Oi...

Page 56: ...ghtly usingcir clippliersandensure thatclipremains in position andengages fully onthecatches of theclutchring Fit circlip68 Lockcrankshaft usingfixing sqew241 965 Degyease taperandthreadof crankshaft...

Page 57: ...htening M5 hex nutsO fix starterwith pre shapedclamp toignitioncover 7 8 Waterpump Always useoil seal guide s1eeve879360 whenfining ignitioncoverto en gine thuskeywayin crankshaft cannot damage oil se...

Page 58: ...a renewalof the lockwas her rework joint to prevent damageto drive gear Startingwith engineno 3 792 88t aserrated washer g VS30 isused instead ofthe lockwasher Fit dowelpin 6x20intocrankcase Grease o...

Page 59: ...aft pushdriving pin0 4x15 8intopositiononshaftandinstallrevolvingpistonO androtorO InscrtGrings IG 2 7and2n 87 1 78andfit oil pump housingto crankcase IATTENTION DoweltubeOonpumpshafthastoengage in ca...

Page 60: ...stem useonlycoolant compatible withaluminium andfreeof silicate andphosphate Positive experiences weremade by enginemanufacturer using BASFGlysantine Anticorrosion As longasno problemswith boiling are...

Page 61: ...oketubesothat thecarburetor canbetiltedveryfarin alldirections withoutimpairingoperation The objectof thefloatis to maintain thefuellevelin thefloat chamber 15 constant Whenthefuelhasreached aspecifie...

Page 62: ...26 23 28 25 24 17 3 10 15 14 12 7 18 ROTAX...

Page 63: ...velin thefloatchamber isexceeded substantially duetoaleaking needle valve 7 15 4 Main regulating systemwith pressureregulator Theamount ofmixture drawn inbytheengine andthusitsperformance isdetermined...

Page 64: ...cl frN...

Page 65: ...openedthecarburetor cross section Fromthispointonwards thecarburetor actsasathrottlevalvecarburetorwith frxed choke tube Thevacuum increases withincreasing speed Thespace inthecover 27 above theplung...

Page 66: ...uredby spring 50 to preventit from bcoming slack The fuel passes throughtheidlingjet 8 whose borewill determine theamount of fuel Behindthejet borethefuelmixeswithairwhichissupplied viacross ducts in...

Page 67: ...ns thefuelsysrem of thestaq_fing carburetor viabores matched tothediskposition Thefuelflowsfrom the float charnber throughthe startingjet into the ventedstartingchamberalso contained in thefloat chamb...

Page 68: ...lflow ratcatidling Withalternating accelerationoneach carburetorrespectively themixturescrewscan befine adjusted toachieve equalresponse tothronlemovement onbothcarbureton 7 L6 2 Mechanical synchroniz...

Page 69: ...I t t l tttrr l i l l t i r l 0 t r i r i...

Page 70: ...s 8 Tighteningtorquesof screws andnuts...

Page 71: ...m in 48 13 48 14 44 474 4 5U2 1J51 4 45 44A6 0 C2 5 0 06 0 001 28 42 28 03 27 9 28 N O U2 0 04 32 V2 32 O3 31 9 32 ffi 0 4 0 04 34 065 Y O 1 341 l M 1 05 1 340 0 015 0 050 0 001 0 04 0 m1 0 ol 0 m1 0...

Page 72: ...0 15 0 35 1 27 1 29 l l2 1 24 0 03 O Mz 0 03 p 0 5 3 01 3 03 2 84 2 99 0 02 0 045 0 15 0 4 0 7 006 7 018 6 965 6 980 0 U26 0 053 12 06 12 08 12 023 12 0Y 0 026 0 057 0 0 1 0 l u 1 85 24 15 0 01 0 01 r...

Page 73: ..._ i 10 Log of reVision date kind of modification remark 31ii1992...

Page 74: ...1 3 02 34 05 1 3406 34 065 1 341 34 090 1342 33 91 1 3350 33 92 1 3354 0 14 6955 0 12 0047 3 Journal dia of main andbackingbearings HIlUZ H3 1n fit n 1 fi n 4 Dellectionbetweencentres H1IH2 H3 Nom ma...

Page 75: ...ts andsealing faces Aftenarards place main bearing halves inposition and joincrankcase thighten screws and takereadings ofcrankshaft andcamshaft bearings U o o Fitting of crankshaft no amounts to nomi...

Page 76: ...ithrings butwithout pistonpin g Checking ofthenominaldia DNat height 37 3 nomlnal actual DN1 itin rem DN DN clearance 3 Grading andClearance cylinder A withpiston red nomlnal actual rem 79 50 3 13079...

Page 77: ...must beinignition T D C range no ofcylinder 1 2 3 4 nominal Tappet clearance inlet 2 5mm 079 197in ex ilausl remarK 2 Valvetiming at 1 mm valvelift Setvalvetrainfreeofplaybydistance pieceandtakereadin...

Page 78: ...einto aircraft and operatinginstructions in your manual Neverexceedspeed limit of 5800 rpm Payspecialattentiontoindicationoninstruments duringwarming upperid observeenginefor odd noises andvibrations...

Page 79: ...353 Fax 37462686 Contactpsrson Parick Coyette SERVICE CENTERSOF AVIREX IN FRANCE for postcodes 62 59 8U02 7640 9 5 78 77 9L 2841 45 37 36 l 8 s0 l4 6l 29 22 56 35 53 72 449 85 AVIREX SHOP AerodromedeD...

Page 80: ...veien 33 N I34I BEKKESTUA Tcl 02 538562 Fax 021532074 Contactpcrson ArneLaudal PO LAN D FASTONLTD ul Szeroka 2 PL 05 860PLOCHOCTN Tel Fax QD400196 Contactpersiln Wojtek Madry lvlanager R OMAN IA J S C...

Page 81: ...4 549 7lll Contactperson DonButterworth PartsManager ALBERTA A C ALTRA AVIATION LTD Box541 SmokyLake AB TOA 3 CO Tel 403 6564207 Fax 403 16564 M Contactperson MarkPaskcvich President B C REG S AIR C O...

Page 82: ...EASIS IDE aLTRALIGHTS INC 47ffi t88rhSr N E ARLINGTON WA 98223 Tel 206 435 37 37 Faxz Ml 435 617 9 Contact person JimScott Prcsident VENEZUELA utxtuo or rvrERr sRL 3ra Avenidade LosPalosGrandes Esquin...

Page 83: ...lx 882237S ISRAEL coNoon AvIATIoNINDI STRIE9 LTa 34 ArlozorovSt IL 5248I RAMAT GAN Tel 03172488 Fax 031723 151 eoii tai tftson Di JioVilrn 1 s JAPAN t alal rrn r i r 1793 Fukazawa Gotemba City rr SHIZ...