Rotax 914 F, Installation Manual

Page 1: ... GmbH and must not be reproduced neither in entirety nor partially and passed on to third parties without previous consent in writing by BOMBARDIER ROTAX GmbH This text must be written on every complete or partial reproduction Copyright BOMBARDIER ROTAX GmbH Approval of translation to best knowledge and judgement in any case the original text in German language is authoritative AIRCRAFT ENGINES Re...

Page 2: ...ts 21 8 4 Centre of gravity of engine and standard equipment 21 8 5 Moments of inertia in kg cm2 21 9 Preparations for engine installation 22 9 1 Transport 22 9 2 State of delivery 22 9 3 Engine preservation 22 9 4 Protective covering 23 10 Engine suspension and position 24 10 1 Definition of attachment points 25 10 2 Permissible fitting positions 26 10 3 General directives for engine suspension 2...

Page 3: ... for installation 50 14 4 1 Electric fuel pump 50 14 4 2 Fuel pressure control 52 14 5 Notes on checking of fuel pressure 52 15 Carburetor 54 15 1 Requirements on the carburetor 54 15 2 Connections for Bowden cable actuation and limit load 55 15 3 Requirements on cable actuation 56 15 4 Requirements on the throttle lever 57 15 5 Location and determination of the throttle position for max continuou...

Page 4: ... motor 85 19 4 10 Warning light 86 19 4 11 Caution light 86 19 4 12 Externernal alternator optional extra 87 19 4 13 Connection of the electric rev counter 88 19 4 14 Battery 89 19 5 Internal consumer of electric power 89 20 Propeller drive 90 20 1 Technical data 90 21 Vacuum pump 91 21 1 Technical data 91 22 Hydraulic governor for constant speed propeller 92 22 1 Technical data 92 23 Connections ...

Page 5: ...Reference Modification No 0 Page 5 Date 1996 05 10 Install 914 F Blank page ...

Page 6: ...odules 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 temperatur...

Page 7: ...o 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 oil tank 42 W Warning light 86 Water inlet bend 34 Water trap 69 Weights 21 Wirin...

Page 8: ... 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 pro...

Page 9: ...s 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 to the varying designs equipment and types of aircraft BOMBARDIER ROTAX makes no warranty or representation on the suitability of its engine s use ...

Page 10: ... 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 Period...

Page 11: ...r users without fail Thisenginemustonlybeoperatedwithaccessoriessupplied recommendedand released by ROTAX Modifications are only allowed after consent by the engine manufacturer 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 aut...

Page 12: ...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 13: ...Reference Modification No 0 Page 13 Date 1996 05 10 Install 914 F Blank page ...

Page 14: ... 96 05 10 4 2 96 05 10 4 3 96 05 10 4 4 96 05 10 45 blank 96 05 10 4 6 96 05 10 4 7 96 05 10 1 4 4 8 96 05 10 4 9 96 05 10 5 0 96 05 10 4 8 96 05 10 4 9 96 05 10 5 0 96 05 10 5 1 96 05 10 5 2 96 05 10 53 blank 96 05 10 1 5 5 4 96 05 10 5 5 96 05 10 5 6 96 05 10 5 7 96 05 10 5 8 96 05 10 5 9 96 05 10 6 0 96 05 10 61 blank 96 05 10 1 6 6 2 96 05 10 6 3 96 05 10 6 4 96 05 10 6 5 96 05 10 66 blank 96 ...

Page 15: ...ge 15 Date 1996 05 10 Install 914 F 6 Table of amendments number chapter page date of change remark for approval date of approval from authorities date of inclusion signature 0 0 2 5 1996 05 10 not required 1996 05 10 KD Me 1 1 0 1 ...

Page 16: ...ft 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 tan...

Page 17: ...eloped and tested for this en gine are readily available at BOMBARDIER ROTAX 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...

Page 18: ...tolerance x y z axes for system of coordinates Cyl 1 cylinder 1 Cyl 2 cylinder 2 Cyl 3 cylinder 3 Cyl 4 cylinder 4 Q engine number W propeller flange E propeller gear R vacuum pump or hydraulic governor for constant speed propeller T intake manifold Y ignition housing Ill 2 J 2x pressure sensor K connection for mechanical rev counter L connection for additional temperature sensor airbox drip tray ...

Page 19: ...ion No 0 Page 19 Date 1996 05 10 Install 914 F 30 30 A A x x y y P x1 y1 y1 x1 9 z1 y1 y1 z1 z z y y P 1 18 Cyl 1 Cyl 3 Cyl 4 Cyl 2 22 29 12 11 17 13 15 16 26 7 23 38 28 5 25 5 37 14 Ill 3 Ill 4 31 33 39 Ill 5 Ill 6 27 36 ...

Page 20: ...imit for engine operation at weightless condition and with negative gravity acceleration max 5 sec at max 5 g 4 Critical flight level Take off performance to max 2450 m 8000 ft ASL maximum continuous performance to max 4500 m 16000 ft ASL ATTENTION Up to the critical flight level the stated respective performance is available 5 Oil pressure see chapter 13 2 6 Oil temperature see chapter 13 2 7 Cyl...

Page 21: ... lb 8 4 Centre of gravity of engine and standard equipment See illustration 2 3 4 NOTE Dimensions to point of reference P See ill 2 3 4 8 5 Moments of inertia in kg cm2 See illustration 2 3 4 Standard engine version pos neg total max dimension in x axis 8 5 6 5 6 6 665 1 max dimension in y axis 2 8 8 2 8 8 576 0 max dimension in z axis 2 2 0 3 1 1 531 0 engine from serial production F3 external al...

Page 22: ...is 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 Q along...

Page 23: ... is recommended not to remove these plugs until installation of the specific feed line NOTE If the engine will be sent to the manufacturer or distributor reuse transport equipment and replug openings List of protective covering exhaust socket 1x cone plug Air intake socket on turbo 1x cover connection for manifold pressure 1x cap fuel pressure control in and outlet 1x each cap oil supply and oil d...

Page 24: ...ircraft frame WARNING IftheenginesuspensionframesuppliedbyROTAXisnotusedorifmodified 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 lbs this suspension has to be carefully designed and tested Certification to...

Page 25: ... 0 8 7 1 0 2 1 1 0 R1 2 0 0 8 7 1 0 2 1 1 0 L2 5 6 2 0 105 0 2 7 7 0 R2 5 6 2 0 1 0 5 0 2 7 7 0 L3 5 6 2 0 105 0 7 0 R3 5 6 2 0 1 0 5 0 7 0 L4 1 3 0 3 7 1 0 0 0 R4 1 3 0 3 7 1 0 0 0 attachment point 1L 1R 4L 4R thread size M10 min length of thread engagement 25 mm 1 attachment point 2L 2R 3L 3R max allowable forces limit load in N in x axis 5 000 in y axis 2 000 in z axis 3 000 max allowable bendi...

Page 26: ...e 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 WARNING On installations with fuel tank located above carbur...

Page 27: ...ntres of attachment points L1 und R1 must be on an axis y2 parallel to y axis Tolerated roll deviation of parallelism 5 see ill 12 Vertical axis y axis must be square to the longitudinal axis of the aircraft Yaw tolerance 10 see ill 13 z y y P z L1 R1 y2 5 5 x x y y P 10 10 Ill 12 Ill 13 ...

Page 28: ...nt Distanzrohr 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 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 specifi...

Page 29: ...Reference Modification No 0 Page 29 Date 1996 05 10 Install 914 F Blank page ...

Page 30: ...aust end pipe can be modified to the following requirements Mean bending radius of an exhaust bend min 40 mm 1 57 in Exhaust bend inside diameter min 38 mm 1 50 in Medium tube length max 500 mm 20 in ATTENTION At a 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...

Page 31: ...eference Modification No 0 Page 31 Date 1996 05 10 Install 914 F 11 1 Operating limits Exhaust gas temperature max 950 C 1740 F normal 900 C 1650 F Reading taken approx 70 mm 2 75 in after exhaust flange ...

Page 32: ...e allows for coolant expansion The expansion tank is closed by a pressure cap E 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 R When cooling down the coolant will be sucked back into the cooling circuit The shape size and location of one o...

Page 33: ...radiator and use short hoses and pipelines Coolant hoses temperature durability min 125 C 257 F pressure durability min 5 bar 73 p s i nom inside dia 25 mm 1 bending radius min 175 mm 7 material Suitable for 100 Glycol and antifreeze agents 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 ...

Page 34: ...tion 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 lb 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 heads 560 cm3 water pump 100 cm3 expansion tank 250 cm3 2 m coolant hose 18 mm inside dia 500 cm3 total...

Page 35: ...le U 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 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 U transparent material un...

Page 36: ...on as depicted with the radiator O in a higher position than the standard supplied expansion tank a water accumulator P has to fitted instead of the expansion tank Additionally a suitable expansion tank Q has to be installed at the highest point of the cooling circuit 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 As...

Page 37: ...Reference Modification No 0 Page 37 Date 1996 05 10 Install 914 F Blank page ...

Page 38: ...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 cm2 16 in2 material glass fibre reinforced plastic or heat resistant non inflammable material atta...

Page 39: ...Reference Modification No 0 Page 39 Date 1996 05 10 Install 914 F Blank page ...

Page 40: ...il cooler W 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 E from the main oil pump The oil...

Page 41: ...ducted by the aircraft builder 13 2 Limits of operation WARNING The lubrication system has to be designed such that operating temperatures will not exceed the specified limits Oil pressure For oil pressure sensor see ill 75 76 max 7 bar 100 p s i ATTENTION Permitted at engine start for a short period min 1 5 bar 22 p s i normal 1 5 5 bar 22 73 p s i ATTENTION Atfullthrottleoperationthedepressionat...

Page 42: ...of oil lines in reference to total length length up to 1m 3 min 11 mm ø 43 length up to 2 m 6 6 min 12 mm ø 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 v...

Page 43: ... return According to propeller configuration choose the appropriate connection for the oil return line Position 1 for tractor or 2 for pusher configuration See ill 28 hose nipple W 10 DIN 7642 outside dia 12 mm 0 5 in slip on length max 24 mm max 0 94 in Tightening torque of banjo bolt E M16x1 5x28 35 Nm 310 in lb 13 4 2 Oil circuit turbo charger See ill 26 Oil return hose nipple R 4 6 DIN 7642 ou...

Page 44: ...gth max 24 mm 0 94 in tightening torque 25 Nm 220 in lb 1x venting nipple O outside dia 8 mm 0 31 in slip on length max 15 mm 59 in Connection for oil circuit turbo charger ø165 90 248 ø139 2 Ill 27 hose nipple P 4 6 DIN 7642 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...

Page 45: ...Reference Modification No 0 Page 45 Date 1996 05 10 Install 914 F Blank page ...

Page 46: ... for both planes The oil tank Q has to be positioned in its z axis such that the oil level W is always between 0 and 400 mm on the z axis 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 E and o...

Page 47: ...re neither exceeded nor fall below This state has to be warranted for hot day conditions too If need be take appropriate measures like changing size of cooler partial covering of cooler etc 13 7 General notes on oil cooler BOMBARDIER ROTAX offers for this engine a non certified oil cooler see spare parts list WARNING Certification of this cooler to the latest requirements such as FAR or JAR has to...

Page 48: ...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 Ill 30 Only the following connections per Ill 30 have to be established Feeding lines to suction side of the electric ...

Page 49: ...esistance Max tolerated pressure loss is 0 1 bar 1 5 p s i between fuel pressure control and tank inlet with both electric fuel pumps in action Otherwise the carburetors could flood Secure fuel hoses with suitable screw clamps or by crimp connection 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 compa...

Page 50: ...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 The diagram shows the delivery rate of the electric fuel pump over pressure 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...

Page 51: ...specially 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 permitted Max suction head 250 mm 10 in WARNING Certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder WARNING Installation of the fuel pumps in the engine compart ...

Page 52: ... 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 Q joined to the fuel line...

Page 53: ...Reference Modification No 0 Page 53 Date 1996 05 10 Install 914 F Blank page ...

Page 54: ...on is fitted which acts as heat shield as well WARNING In the area of the float chamber the temperature limit of the fuel must not be exceeded If need be provide additional insulation or heat shields Certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder Drainage piping WARNING Connect draining lines without fail otherwise emerging fuel from a possi...

Page 55: ...ion travel 65 mm 2 1 2 actuating force min 1 5 N 3 lb max 8 N 1 8 lb limit load 20 N 4 5 lb NOTE Throttle opens by spring Ill 36 2 1 E R W T 5 2 2 2 ø6 7 Ill 37 connection for starting carb choke actuation W connection on choke lever clamping nipple 6 suitable for 1 5 mm steel wire action travel 23 mm 15 16 actuating force min 10 N 2 2 lb max 24 N 5 4 lb limit load 100 N 22 lb Directive for choke ...

Page 56: ...fore never start engine without connecting throttle lever first WARNING Route Bowden cable in such a way that carb actuation will not be influenced by any movement of engine or air frame thus possibly falsifying idle speed setting and carb synchronisation Adjust Bowden cable such that throttle and choke can be fully opened and closed Use Bowden cable with minimized friction so that the spring on t...

Page 57: ...ur 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 released from the detent a...

Page 58: ...since these units can be utilized also directly on engine or aircraft The computer will be required on maintenance tasks too communication program TLR 43a exe between TCU and computer decoding unit Dongle with data cable to connect to computer NOTE All the required items except the computer are available in form of a monitoring kit 15 5 2 General information about the communication program The sof...

Page 59: ...xe You are on the main menu now 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 back to the main menu NOTE If the bottom line Q displays Error instead of the sub program some connection between TCU and computer has been interrupted Chec...

Page 60: ...th throttle fully open nominal 115 tolerance 2 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 Check of the display at max continuous power ATTENTION Throttle lever must be in positive stop position nominal 100 tolerance 3 WARNING This check of position is only meaningful and allowed if idle and ...

Page 61: ...Reference Modification No 0 Page 61 Date 1996 05 10 Install 914 F Blank page ...

Page 62: ...ded 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 WARNIN...

Page 63: ...ressing Notes regarding too high air temperatures in the air box If in case of high intake air temperature the max air temperature in the airbox is frequently or permanently above the limit the arrangement of air intake has to be improved or an intercooler has to be installed NOTE Intercooler is not in the supply volume Intercooler has to be installed between pressure side of turbo W and inlet E i...

Page 64: ...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 ATTENTION With closed or blocked drainage bores fuel could flow into combustionchamber possiblyruiningtheenginebyhydrau lic lock Connecting nipp...

Page 65: ... type air filter 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 cm2 220 in2 ...

Page 66: ...Reference Modification No 0 Page 66 Date 1996 05 10 Install 914 F Blank page ...

Page 67: ...connected by plugs with the wiring harness WARNING Since a failure of pressure interconnections Q of airbox float chambers fuel control and pressure sensor would possibly result in an engine stop all these interconnections have to made very carefully Ill 46 2 3 x x1 NOTE To avoid any mix up of pressure sensor wiring plug connections are colour coded grey plug connection W static pressure sensor bl...

Page 68: ...o be parallel to z axis in system of coordinates tolerated deviation of parallelism 60 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 ATTENTION The pressure connection has to be protected against entering of foreign matt...

Page 69: ...nates tolerated deviation of parallelism 60 location of installation vibration neutralized installation 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 48 49 Water ...

Page 70: ...ment 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 dimensions and attachment see sketch Ill 51 location of installation vibration neutralized place WARNING Instal...

Page 71: ...Reference Modification No 0 Page 71 Date 1996 05 10 Install 914 F Blank page ...

Page 72: ...ctric rev counter accessory 19 1 Requirements on circuit wiring 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 is greatly affected by the wiring and has to be checked for each installation Refer to chapter 19 1 1 WARNING The supply t...

Page 73: ... requirements of EMI and lighting protection as per standard RT CA DO 160C sections 18 20 22 and IEC 801 2 The following EMC EMI tests were performed Radio frequency Susceptibility conducted Radio frequency Susceptibility radiated Audio Frequency Susceptibility Lightning Susceptibility Conducted RF Interference Radiated RF Interference ...

Page 74: ...sensor 4 plug connection for lamps 5 plug connection for servo motor 6 pressure sensor static pressure atmospheric pressure 7 pressure sensor airbox 8 servo motor 9 2 electronic modules 10 11 plug connection for ignition switch 12 integrated generator 13 14 external regulator rectifier with plug connections 15 electric starter 16 17 starter relay with plug connection 18 19 electric fuel pumps 20 3...

Page 75: ...35 11 10 28 2 14 13 26 1 25 B A B IG L P I G G R B L C A P P Verbraucher consumer 30A 5A 2A 2A 80A 5A 5A 2A 50A Q O o e W E U Y R R R R J H K I T P P L L u y s A s r a d f g M X l Z k V B N C w q t p h j j O 22 i 5 A 2A WARN CAUTION Ill 52 Wiring symbols to DIN 40712 40713 40716 and 40719 ...

Page 76: ...e in the airbox refer to the diagram ill 54 28 1400 1300 1200 1100 1000 900 hPa 0 10 20 30 40 50 60 7 0 80 90 100 110 115 30 32 34 36 38 40 in HG 100 115 0 Ill 54 Ill 53 The most important points for engine operation ATTENTION As shown in the diagram the throttle position at 108 110 results inarapidriseofnominalboostpressure Toavoidunstableboost the throttle should be moved speedily through this a...

Page 77: ... 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 WARNING Theenginemustnotbetakenintooperationbefore havingcorrected the cause of deficiency Orange caution lamp The non illuminated orange caution lamp signals that TCU is ready for operation If the lamp i...

Page 78: ...ectifier regulator effective voltage 14 0 3 V from 1000 250 r p m current limit max 28 A ambient temperature range min 25 C 13 F max 90 C 194 F weight 0 3 kg 66 lb 2 flexible cables 1 5 mm2 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 wit...

Page 79: ...ent over engine speed has been determined and is valid only at the following conditions ambient temperature 20 C 68 F voltage permanent 13 5 V tolerance max 5 0 10 20 1000 2000 3000 4000 5000 6000 A 1 min Ill 57 NOTE A charge indicating lamp 3W 12V Ill 52 pos s may be fitted on the instrument panel ...

Page 80: ...ule with one each plug socket and insulating sleeve 3 96 mm 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 ATT...

Page 81: ...ector 6 3x0 8 suitable for plug socket to DIN 46247 grounding via housing ATTENTION Activation of start relay limited to short duration Over a period of 4 min operation the duty cycle is 25 2 1 1 Ill 60 19 4 5 Electric starter See Ill 59 Feeding lines from starter relay to the elec tric starter cross section of at least 16 mm2 output 6 kW plus terminal Q M6 screw tightening torque 8 Nm 70 in lb su...

Page 82: ...ows the current input over pressure 11 75 8 11 M5 M4 Anschluß connector Ill 61 1 5 2 0 2 5 3 0 A 250 500 750 1250 hPa 0 1000 Ill 62 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 Fuse Each of the two fuel pumps has to be protected by y slow blow...

Page 83: ...Reference Modification No 0 Page 83 Date 1996 05 10 Install 914 F Blank page ...

Page 84: ...llation 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 WARNING If the standard attachment should...

Page 85: ...unting stable operation should follow design 2 pole on off switch Ill 52 Pos 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 instruction...

Page 86: ...e 0 75 mm2 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 mm2 white No 11 terminal flexible cable 0 75 mm2 white No 35 f...

Page 87: ...n the generator Feeding wiring to external alternator Q located on the outside of propeller gear see ill 64 plus terminal W M6 screw suitable for cable eyes to DIN 46225 tightening torque 8 Nm 70 in lb grounding via engine block control wiring E via supplied standard plug Sumitomo 6111 2568 Requirements for flawless operation of the integrated rectifier regula tor the rectifier regulator has to be...

Page 88: ...ric rev counter Certification to the latest require ments such as FAR or JAR has to be conducted by the aircraft builder 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 osci...

Page 89: ...hat the internal need of power e g for fuel pumps is always covered Refer to graph current output over speed of the integrated generator and the external alternator item current consumption fuel pump main max 3 A fuel pump stand by max 3 A TCU 1 max 0 3 A servo motor max 1 A warning lamp 2 approx 0 25 A caution lamp 2 approx 0 25 A sum 3 8 A 1 internal power consumption without servo motor and lam...

Page 90: ...nstalled 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 mm di...

Page 91: ...ctive thread length max 17 mm 9 16 net weight 0 8 kg 1 3 4 lb power input max 300 W delivery rate max 0 165 dm3 10 m3 per minute at 0 65 bar 10 p s i as from 1900 r p m pump speed 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 WARNING Certification to the latest requirements su...

Page 92: ...ion P3 cable connection see ill 70 cable travel approx 54 mm 2 1 8 actuating force approx 3 N during operation at max speed 67 lb limit load 6 N 1 35 lb power input max 600 W operating pressure max 30 bar 435 p s i weight 1 44 kg 3 2 lb 2 7 kg 6 lb 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 90 15 5 3 8 7 P3 P3 Ill...

Page 93: ... material is taken This allows the exact measuring of the cylinder head temperature even in the case of coolant loss NOTE Readings are taken on the hottest cylinder depending on engine installation location in the cylinder head of the cylinders 2 and 3 see Ill 4 connection plug for socket 6 3x0 8 to DIN 46247 grounding via engine block graph of sensor resistance over temperature ATTENTION The grap...

Page 94: ...247 grounding via engine block graph of sensor resistance over temperature Ill 73 TO Axes x axis y axis z axis 1 1 5 4 6 1 5 0 point of support Ill 74 120 100 80 60 40 20 140 160 1200 1000 Ω ohm C 800 600 400 200 0 2 1 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 off...

Page 95: ...stance over pressure Axes x axis y axis z axis ca 100 7 5 ca 150 point of connection 200 bar 150 100 50 0 10 8 6 4 2 Ω ohm Ill 76 Ill 75 1 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 WA...

Page 96: ...exible shaft for the mechanical rev counter is readily available from BOMBARDIER ROTAX 23 4 Mechanical rev counter or hour meter See Ill 77 78 location ignition housing Q direction of rotation of the rev counter shaft W clockwise see illustration position of rev counter drive Axes x axis y axis z axis 4 6 5 8 7 1 6 0 point of engagement P4 P4 Ill 77 Ill 78 1 2 ...

Page 97: ...vecoveringtobeutilizedfortrans port and at engine installation only If connection for pressure reading is not employed it has to plugged suitably 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 connec...

Page 98: ...d in the Operator s Manual Verification of the throttle lever detent for max continuous power Performance check in accordance with Operator s Manual If nominal performance won t be reached or is in excess of examination of the installation and engine will be necessary Consult Maintenance Manual 914 F ATTENTION Don t conduct any test flights before fault has been traced and found ...

Page 99: ...lugplatz D 27777 GANDERKESEE Tel 04222 3789 Fax 04222 6042 Contact person Volker Roßbach GREAT BRITAIN IRELAND ICELAND CYCLONE HOVERCRAFT LTD Burnside Deppers Bridge LEAMINGTON Spa CV 33 OSU Tel 1926 612 188 Fax 1926 613 781 Contact person Nigel Beale GREECE CYPRUS KINISI Ellis 1 str GR 14563 KIFISSIA Tel 01 620 8611 Fax 01 625 0026 Contact person Michael Poulikakos Nick Siganos HUNGARY HALLEY Bak...

Page 100: ... P O Box 192 Tuakau SOUTH AUCKLAND Tel 09 233 4898 Fax 09 233 4798 Contact person Murray Tippins 4 A F R I C A 4 A F R I C A 4 A F R I C A EGYPT SALEM BALLOONS 40 Talaat Harb St CAIRO Tel 2 2991 946 2 3453 244 Fax 2 2430 541 Contact person Weaam Salem General Manager ANGOLA BOTSWANA LESOTHO MADAGASCAR MALAWI MOZAMBIQUE NAMIBIA SOUTH AFRICA SWAZILAND ZAMBIA ZIMBABWE MICROLIGHT ENGINES AND ACCESSORI...

Page 101: ...135 AUSTRALIA Tel 03 87 93 511 Fax 03 87 96 575 Tlx 36444 brtfld Contact person Bert Flood PHILIPPINES PHILIPPINE AIRCRAFT CO INC P O Box 7633 Domestic Airport Post Office Lock Box 1300 Pasay City METRO MANILA Tel 2 832 2777 Fax 2 833 0605 Tlx 66621 wpac pn Contact person Rolando P Moscardon TAIWAN TAIWAN MAXIEM INDUSTRIES 7 1 Tung Feng Street TAIPEI 10 651 Tel 2 704 6163 Fax 2 702 84 85 Contact p...

Page 102: ...Reference Modification No 0 Page 102 Date 1996 05 10 Install 914 F Leerseite ...