Page 2: Table Of Contents
Electric system (Ignition, generators) ..............48 9.4.1) Ignition ......................50 9.4.2) Allocation of trigger coils and ignition circuits..........51 9.4.3) Firing order ....................51 9.4.4) Ignition cables .................... 51 Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 3 11.7.13) MICRONORM shot blasting abrasive ............78 11.7.14) Lapping fleece SR 4600 A - very fine grading ..........78 11.7.15) Cleaning agents ..................79 11.7.16) Valve lapping paste ..................79 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 4 12.3.21) Inspection of the fuel filter in fuselage ............109 12.3.22) Test run of engine ..................110 12.3.23) Renewal of rubber parts ................111 12.3.24) Overhaul ....................111 Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 5 13.1.9) Fuel pressure regulator ................135 13.1.10) Fuel pump ....................136 13.1.11) Pressure connection tubes ..............138 13.1.12) Reassembly of carburetors, carburetor flanges, fuel tubes and drip trays ................... 140 Modification no. Reference Main Date Page - 5 - 914 F 2003 03 01...
Page 6 13.4.14) Re-fitting of ignition electric set ..............179 13.4.16) Exchange of external trigger coils ............180 13.4.16) Stator removal and re-fitting ..............181 13.4.17)Flywheel ass'y ..................182 Date Main Reference Page Modification no. 914 F 1997 02 01 - 0 -...
Page 7 14.2.3) Sprag clutch — installation ............... 232 14.2.4) Reduction gear for electric starter ............232 14.2.5) Fitting of ignition housing ................232 14.3) Rev. counter drive ....................233 Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 8 14.9.4) Fitting of cylinder head ................258 14.10) Fitting of coolant hoses ..................259 14.11) Fitting of intake manifolds ..................260 15) Wear limits for ROTAX 914 F ................261 16) Form Sheets ....................... 266 16.1) Form Sheet for Cylinders and Pistons ..............266 16.2) Form Sheet for igniton unit ..................
Page 9: Index
Cleaning agents 79 Gearbox reassembly 244 Engine versions 23 Climatic conditions 115 Gearbox version 61 Engine views 24 Communication program 196 Generator coil 166 Components maintenance 228 Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 10 Pressure connection tubes 138 Lubricating system 142 Pressure difference method 108 Lubrication circuit 44, 46 Pressure observation 224 Lubrication system 42 Pressure sensors check 217 Proceeding instructions general 68 Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 11 Turbo charger assembly 190 Rope sheave 194 Turbo charger check 188 Rotary seal removal 158 Turbo charger control check 206 ROTAX 914 F2 23 Turbo charger control system 52, 196 ROTAX 914 F3 23 Turbo charger dismantling 184 ROTAX 914 F4 23...
Page 12: Introduction
3) Introduction We are pleased you decided for a ROTAX aircraft engine. ® Before carrying out maintenance work on the engine, carefully read the Maintenance Manual. It provides you basic information on safe operation of the engine. If any passages of the Manual are not understood or in case of any questions, please, contact an authorized Distribution- or Service Partner for ROTAX aircraft engines.
Page 13: Repeating Symbols
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 on any particular aircraft. Further, BOMBARDIER-ROTAX makes no warranty or representation 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.
Page 14: General Operating And Safety Instructions
We point to the fact that spare parts and accessories not supplied as genuine ROTAX parts are not tested and therefore not released by ROTAX. Installation and/ or use of such products may change and negatively affect the constructive properties of the engine.
Page 15 Do not smoke when refuelling. Only use oil and fuel of the specified quality and store them in approved containers only. Modification no. Reference Main Date Page 1997 02 01 - 0 - 914 F...
Page 16: Technical Documentation
The illustrations in this Maintenance Manual are stored in a graphic data file and are provided with a consecutive irrelevant number. This number (e.g. 00277 ) is of no significance for the content. Page Date Main Reference Modification no. 2003 03 01 914 F - 5 -...
Page 17: Use For Intended Purpose
4.4.1) Use for intended purpose The engine ROTAX 914 F is intended for use in certified aircraft. In case ® of doubt the regulations of the national authorities or the respective sportive federations have to be observed. This is a certified aircraft engine tested as per aeronautical standards for safety and lifetime.
Page 18: List Of The Current
97 02 01 ACG-approved 106 97 02 01 97 02 01 ACG-approved 107 97 02 01 97 02 01 97 02 01 ACG-approved 108 97 02 01 Page Date Main Reference Modification no. 2003 03 01 914 F - 5 -...
Page 19 97 02 01 97 02 01 97 02 01 97 02 01 97 02 01 97 02 01 97 02 01 97 02 01 97 02 01 Modification no. Reference Main Date Page - 5 - 914 F 2003 03 01...
Page 20: Table Of Amendments
216, 252 1,2,4,5 5,8,11,16,18,19,128 2003 03 01 not required 13,14,16 140,162,248, 267-272 6,20 20,89,94,101,111 2003 03 01 english version german version not required 01. 07. 2003 Page Date Main Reference Modification no. 2003 03 01 914 F - 5 -...
Page 21 Pic. 3 00568 chapter page date of remark for date of approval date of signature change approval from authorities inclusion Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 22: Description Of Design
Vacuum pump: (only for F2 and F4 possible), optional Hydraulic constant speed propeller governor: (for F3 only), optional 7.1) Type description e.g. ROTAX 914 F 2 F 2: Prop shaft with flange for fixed pitch prop F 3: Prop shaft with flange for constant speed propeller and drive...
Page 23: Engine Versions
7.2) Engine versions See Pic.004. Configuration no. Description ROTAX 914 F2 37.914.0120.06 .... without mechanical rev counter 37.914.0121.06 .... without mechanical rev counter, with vacuum pump 37.914.0122.06 .... with mechanical rev counter 37.914.0123.06 .... with mechanical rev counter, with vacuum pump 37.914.1120.06 ....
Page 24: Engine Views
2 separate oil pumps g external alternator J 2x pressure sensor o connection for oil return h external alternator line (engine) Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 25 Pic. 6 00121 00123 Pic. 8 Cyl. 4 Cyl. 3 Cyl. 2 Cyl. 1 00122 Pic. 7 00124 Pic. 9 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 26: Technical Data
Fuel consumption Refer to the current Operator's Manual 914, section 8) technical data. 8.4) Weights Refer to the current Operator's Manual 914, section 8) technical data. Page Date Main Reference Modification no. 1999 01 01 914 F - 3 -...
Page 27: Engine / Components
1) Main lubrication circuit: OIL DELIVERY RATE: approx. 16 l/min. at 5500 rpm 2) Suction pump circuit: approx. 4 l/min. at 5500 rpm ROTAX dual ignition, breakerless, capacitor discharge, IGNITION UNIT: interference suppression at start: circuit A and B: ..4° B.T.D.C.
Page 28 Electronic, proportional plus integral plus derivative TURBO CONTROL UNIT (TCU): controller with 2 external indicating lamps. to FAR 33 and JAR-E, CERTIFICATION: TW 10-ACG CERTIFICATION DATA SHEET: Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 29 Blank page Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 30: Description Of The Systems
Cooling system See Pic.10. The cooling system of the ROTAX 914 F is designed for liquid cooling of the cylinder heads and ram-air cooling of the cylinders. The cooling system of the cylinder heads is a closed circuit with an expansion tank.
Page 31 Blank page Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 32: Fuel System
Q coarse filter / water trap T fuel pressure regulator 00103 W main fuel pump Y feeding line from tank E auxiliary fuel pump U return line to tank Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 33: 1) Fuel Filter
For engine operation the rate of delivery of one pump only is completely sufficient. ATTENTION:Employ genuine ROTAX fuel pumps only, as the pump must meet certain requirements. Modification no. Reference...
Page 34: 3) Fuel Pressure Control
Fuel pressure = 1350 + 250 = 1600 hPa Therefore the required delivery pressure of the fuel pump will be 1600 - 900 = 700 hPa Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 35 (wrong calibration, malfunction of regulator, in- creased flow resistance, blockage of retour line,...) leads to a richer mixture till flooding of carburetors causing engine troubles or engine stop. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 36: 4) Air Pressure Hoses Q
Air pressure hoses Q 9.2.4) See Pic. 14. The ROTAX 914 F is equipped with constant depression carburetors. For the operation of the carburetors it is necessary that a) the pressure in the float chamber corresponds with pressure at carburetor air intake (airbox) With varying airbox pressure (carb air intake) this changing pressure must also act upon float chamber.
Page 37 Blank page Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 38: 5) Bing Constant Depression Carburetor Type 64-3
When the fuel has reached a specified level in the float chamber, then the floats close the needle valve R via the float bracket thus preventing any further supply of fuel. Pic. 15 02931 Page Date Main Reference Modification no. 1999 01 01 914 F - 3 -...
Page 39 WARNING: With throttle lever not connected the carb will remain in full throttle position. See Pic. 12. Therefore never start engine without connecting throt- full tle lever first. throttle Pic. 16 Pic. 17 00035 00128 Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 40: 6) Handling Of Fuel
Do not smoke, do not allow open flames or sparks in the vicinity. Do not fill the tank brimful. allow for expansion of the fuel. Never refuel while engine is running. Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 41 Blank page Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 42: Lubrication System
9.3) Lubrication system See Pic. 18. The 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.
Page 43 Blank page Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 44: 1) Main Oil Pump (Engine Lubrication Circuit)
J S1 in gear box cover. Electric terminal for oil pressure gauge on pressure sensor K. At engine version with hydraulic governor, ROTAX 914 F3, the hydraulic governor a is supplied with oil at adequate pressure via the oil line L. From the governor flange : oil flows to gear pump of governor which raises the pressure to approx.
Page 45 Venting of the oil tank via the connection ; to intake filter, to suitable container or into atmosphere. For oil change, the oil is drained at drain screw Z. 00130 Rotor X of suction oil pump. NOTE: Pic. 19 Reference Date Page Modification no. Main - 0 - 914 F 1997 02 01...
Page 46: 2) Suction Pump (Turbo Charger Lubrication Circuit)
The suction pump is also a trochoid pump and will be driven as well as the main oil pump } by the common pump shaft engaging in the cam shaft. Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 47: Oil Pressure Switch
(suction oil pump) e oil pump shaft r oil inlet 00131 t oil pressure switch y oil filter u excess pressure valve Pic. 20 Reference Date Page Modification no. Main - 0 - 914 F 1997 02 01...
Page 48: Electric System (Ignition, Generators)
9.4) Electric system (Ignition, generators) See Pic. 21. The ROTAX 914 F is equipped with a breakerless Dual Capacitor Discharge Ignition (DCDI). The ignition unit is completely free of maintenance and needs no external power supply. Two independent charging coils Q located on the generator stator supply one ignition circuit each.
Page 49 For safety reasons, the ignition electrics must not be exposed to ambient temperatures higher than 80°C (176°F). 00134 Pic. 23 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 50: Ignition
Q. Trigger cam for ignition circuit A (raised position) is approx. 4 mm (.16") longer. B3/4 A1/2 Pic. 24 00135 Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 51: Allocation Of Trigger Coils And Ignition Circuits
These ignition cables can only be routed into position without spark plug connector. The connection of ignition cable on ignition coil and spark plug connector is by threaded prong, thus enabling easy exchange. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 52: Turbo Charger And Control System
9.5) Turbo charger and control system The ROTAX engine 914 F is equipped with an exhaust gas turbo charger, making use of the energy in the exhaust gas for pre-compression of the intake air. The boost pressure in the airbox is controlled by means of an electronically controlled flap (waste gate) on the exhaust gas turbine.
Page 53 Blank page Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 54: Turbo Charge Control
NOTE: In the course of model refinement some parameters have been slight changed. Diagram and table show the presently valid state of software. Page Date Main Reference Modification no. 1999 01 01 914 F - 3 -...
Page 55 2 wires for an additional eletronic rev-counter w PC interface e for reading the TCU data by a computer. Q turbo charger W waste gate E servo motor Pic. 29 00139 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 56: Reduction Of The Target Pressure
265 hPa (according to diagram). actual boost pressure now 1085 hPa corresponds to a performance of 70 kW instead of 84,5 kW. Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 57: 2) Target Pressure Reduction At Excessive Airbox Temperature
On TCU part no. 966.741 the target pressure reduction starts at 88° C. See Pic. 31/1. Pic. 31/1 Airbox Tem peratur [°C] 00902 (airbox tem perature) Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 58: 3) Target Pressure Reduction By Limiting The Compressor Pressure Ratio
1140 hPa, even with the waste gate completely closed. Deactivation would not start until airbox pressure of 1300 hPa is reached. NOTE: Deactivation happens very rarely and only under certain climatic conditions and altitudes. Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 59: Output Connections On The Tcu For Lamps
The warning stops again as soon the boost pressure falls below 1250 hPa. If the pressure is exceeding again, warn- ing by red warning lamp starts anew. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 60: 5) 3 Way Solenoid Valve (Economy Valve)
NOTE: This communication program is not in the supply volume of the engine but is readily available as spare part from the respective dealer. Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 61: Propeller Gearbox
9.6.1) Gearbox version See Pic. 32. 3 gearbox versions are provided for Engine Type 914 F. Version F2: Hollow prop shaft with flange for fix pitch propeller of for propeller electri- cally in-flight adjustable.
Page 62 Blank page Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 63: Connections For Instrumentation
9.7.8) Boost pressure observation A Connection is proveded for an absolute pressure gauge in the compensat- ing tube of the two carburetors. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 64: 9) De-Icing System And Winter Operation
De-icing system and winter operation The risks of carburetor icing are commonly known. By air preheating the icing of air humidity in the carburetor may be avoided. ROTAX does not supply any carburetor preheating device. WARNING: Carburetor icing is a common cause for engine trouble.
Page 65 Blank page Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 66: Auxiliary Units
The internal generator can supply approx. 20A DC. To meet an increased energy demand, installation of an external 40A alternator is possible, either at serial produc- tion or as retrofit kit later on. Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 67 Blank page Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 68: Maintenance
11) Maintenance In this chapter the maintenance of engine 914 F is described. The description is subdivided into sections and description of function of the various systems. Some overlapping mainte- nance instructions are treated as generally valid information at the beginning of this chapter.
Page 69: Basic Information
Always replace self-locking nuts once unscrewed. Respect without fail the tightening torques indicated in the respective table. Replace all sealing rings, gaskets, lock washer, O-rings and oil seals at engine re-assembly. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 70: Auxiliary Tools
(copper bar). Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 71: Measuring Tools
Accoustic continuity tester. Oscilloscope: TEKTRONIX 2225 or equivalent 2 channels Analogous Sensitivity 5 mV to 5V/div Frequency limit 50 MHz WARNING: Using these instruments, observe the manufacturer's specifications. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 72 S W 4 6 8 7 7 4 5 0 8 7 7 60 5 7 6 0 0 8 7 7 5 9 0 00142 Pic. 34 Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 73: Special Tools And Devices
877 710 dial gauge adapter assy., ............ 1 876 950 precision dial gauge ............1 877 700 spring scale ................. 1 for check of valve spring force Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 74 ..............1 to compress dog gear 45 ÷ 48 877 615 puller assy., ................. 1 for prop shaft, roller bearing 25x52x15 and oil seal 30x52x7 Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 75 ............1 63-65 877 760 crankcase splitting tool assy.,..........1 877 570 hand tap drill M18x1 ............1 to clean the tapping at exchange of coolant bends Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 76: Consumables
Vo lventi Pic. 35 ENGINE gasket set F A G F A G K ugelfis c h e o r g S chäfer K G 00143 Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 77: 1) Motor Oil
11.7.1) Motor oil Consulg chapter 10.2.) "Operating Media" in the Operator's Manual 914 F. In principle motor oil is used for lubrication of components during re-assem- bly, except where specified otherwise. Use only oils specified in the "Chart of Lubricants" in order to avoid chemical reaction.
Page 78: 9) Loctite "574 Orange
Before re-applying LOCTITE, clean surfaces with nitro-thinner or degreasing agent (CASTROL ZA 30 or OMV - SOFT SOL). When using solvents, mind the safety regulations for persons and environments. Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 79: 15) Cleaning Agents
This paste produced by various manufacturers is a fine granulate lapping paste for valve seats and valves. The paste is usually available in 3 different granulate sizes. Use as per manufacturer's directives. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 80: Securing Elements
Cut off excess Bend wire end the screw and twist end around screw length or wire and press it approx. 4 times towards screw Pic. 37 Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 81: 2) Nut Securing
When using a self-locking nut, take care that the polyamide insert ring on nuts according to DIN 985 as well as the securing element on nuts according to DIN 980 is positioned towards outside. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 82: Tightening Torques
Oil pressure sensor ..oil pump ........1/8-27 NPTF ... 15 Nm (265 in.lb) Valve housing ....oil line, turbo charger ....M 12x1,5 ..25 Nm (220 in.lb) Page Date Main Reference Modification no. 2002 01 01 914 F - 4 -...
Page 83 ........10 Nm(90 in.lb) plus 3/4 turn Cap nut ......carburetor............5,5Nm (49 in.lb) Plug screw ....... fuel pressure regulator ......... 8 Nm (70 in.lb) Modification no. Reference Main Date Page - 4 - 914 F 2002 01 01...
Page 84: Treatment Of Corrosion And Surface Damages
11.11) Engine preservation Due to the special material of the cylinder wall, the ROTAX aircraft engine needs no extra protection against corrosion. At extreme climatic conditions and for long out of service periods we recommend the following to protect the valve guides against corrosion : —...
Page 85: 1) Preservation Of A New Engine
914 F: BOMBARDIER-ROTAX as the manufacturer of the engine warrants for perfect corrosion protection of aircraft engine 914 F for min. 12 months from date of delivery by BOMBARDIER-ROTAX. This warranty consent is subject to the following conditions: The engine must be stored in the original packing as supplied by ROTAX.
Page 86 Blank page Date Main Page Reference Modification no. 1997 02 01 914 F - 0 -...
Page 87 Blank page Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 88: Maintenance Checks
“MAINTENANCE SCHEDULE“. 12.1.2) Seasonal checks Besides the checks already indicated periodical checks have to be made. These tasks are also shown in the “MAINTENANCE SCHEDULE“. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 89: Maintenance Schedule
12.2) Maintenance Schedule The following maintenance is planned and necessary for ROTAX 914 F: ® Description see Chapter 12.3.1) Engine cleaning 12.3.2) Visual engine check Leakage check 12.3.3) Inspection of engine suspenion 12.3.4) Check of external engine parts 12.3.5) Check of waste-gate position 12.3.6)
Page 90: Maintenance Instructions
➪ Servo motor - refer to chapter 13.6) ➪ Pressure sensors ➪ Fuel pumps ➪ Air pressure hoses airbox - fuel pressure control airbox airbox pressure sensor Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 91 Cooling air guide and cooling fins on cylinder Condensate water trap Between airbox and pressure sensor a condensate water trap is located. Renew water trap in case of water accumulation. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 92: 3) Leakage Check
12.3.5) Inspection of external engine components Check nuts and screws attaching external components for tight fit. For tightening torques refer to the relevant chapter. Verify wire securing, renew as required. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 93: 6) Check Of The Waste Gate
(N x m = Nm). If the above mentioned friction torque is not achieved, remove gearbox and inspect it. See Chapter 14.4). Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 94: 8) Oil Level Check
Only use oil of a registered brand according to the current Operator's Manual. L WARNING: Pay attention to specifications in the Operator's Manual. I CAUTION: Venting the lubrication system, see section 13.2.10). Page Date Main Reference Modification no. 2003 03 01 914 F - 5 -...
Page 95: 10) Oil Filter - Replacement And Inspection
Slightly lubricate the rubber seal of the new oil filter. Screw oil filter on by hand. Then tighten an extra 3/4 turn. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 96: 11) Inspection Of The Magnetic Plug
Proper judgement needs a man with years of experience in repair of internal combustion engines. Clean magnetic plug and refit. Tightening torque 25 Nm (220 in.lb). Wire secure plug. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 97: 12) Examination Of The Drive Gear Set
Depending on size, grade and number of pitting distinguish between the following: tiny pitting (seasoning pitting) progressing pitting spallation over a wide zone Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 98 Because of the tiny pitting depicted and the copying process these iIlustrations might not proof very revealing. In case of doubt seek assistance by studying technical publications. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 99 Pic. 46 magnification: approx. 1,5 times 00152 WARNING: Always exchange gears set wise. Renewal of a single gear is not permitted Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 100 2 times 00153 Pic. 48 magnification: approx. 2 times 00154 WARNING: Always exchange gears set wise. Renewal of a single gear is not permitted. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 101: 13) Check Of The Cooling System
Refill newly mixed coolant into expansion tank (highest position in cooling system). N NOTE: Let engine run for a short time and then, if necessary, replenish with pure coolant. Pic. 49 00155 Modification no. Reference Main Date Page - 5 - 914 F 2003 03 01...
Page 102: 14) Check Of The Air Filter
Only use dry type air filters which are specified by the aircraft manufacturer! Attach new filter, free of grease at connection faces, and wire-secure against loss. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 103: 15) Checking Of The Carburetor
WARNING: Correction of the main jetting only at Aeronautical Service Centres or by authorized test staff to specifications from ROTAX. See Chapter 11.3). 12.3.15.5) Carburetor synchronization The throttle valves have to open synchronously to achieve a steady run on all four cylinders.
Page 104: 7) Throttle Cable And Linkage
12.3.15.8) Checking of starting carburetor (choke) Check Bowden cable and lever for easy movement. Bowden cable must allow complete travel of lever from stop to stop. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 105: 16) Check Of Wiring
— Verify tight plug connections of cable assy, on Turbo Control Unit (TCU) on 2 pressure sensors, rev-counter pick-up, throttle potentiometer, air box temperature sensor, servo motor, isolating switch, control valve and on the two lamps. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 106: 17) Check Of V-Belt Tension
Thighten screws M8 to 22 Nm (195 in.lb), and screw M10 to 35 Nm (310 in.lb). Check V-belt tension as per drawing beside. Pic. 54 00186 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 107: 18) Renewal Of Spark Plugs
Check spark plug connector for tight fit on spark plug every 200 hours of operation. Min. pull-off force to be 30 N (7 lbf.). Renew loosely fitting spark plug connectors. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 108: 20) Check Of Compression
- approx. 5,2 ÷ 5,8 bar (75 ÷ 84 psi). If the pressure drop is not within the allowance, check pistons, cylinders, valves and cyl. heads. 00156 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 109: 21) Inspection Of The Fuel Filter In Fuselage
R integrated in the fuel pumps. ATTENTION: The fine filters R in the fuel pumps can't be exchanged. Renew complete pump as required. MAIN Pic. 56 00103 00157 Pic. 57 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 110: 22) Test Run Of Engine
When stopping the engine, switch off ignition and remove ignition key! — replenish engine oil and coolant as required — carry out leakage test — register operations in log book Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 111: 23) Renewal Of Rubber Parts
Type description engine s/n Time Between Overhaul extension of the TBO SB-914-027 1000 h or 10 years, 914 F up to and incl. 4,420.313 (1000 h to 1200 h whichever comes first or 12 years) 1200 h or 12 years, 914 F from 4,420.314...
Page 112 Blank page Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 113: Special Checks
— Observe directives of aircraft manufacturer. — After taking the engine again into operation, visually check for leak- age. 00024 Dimensions wear limit Consult chapter 15. Modification no. Reference Main Date Page - 4 - 914 F 2002 01 01...
Page 114: 2) Checking Of The Overload Clutch
If the torque is below or above this value, inspect, repair or overhaul the propeller gearbox in accordance with the instructions for continued airworthi- ness. Detailed inspection of all gearbox components. Page Date Main Reference Modification no. 2002 01 01 914 F - 4 -...
Page 115: 3) Check After Engine Failure
Flying in areas of extreme climatic conditions or in extreme altitudes requires correction of carburetor jetting and of the cooling system. This requires consultation with the engine manufacturer. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 116: 6) Exceeding Of Maximum Admissible Engine Speed
— insufficient coolant, badly vented system — radiator contaminated — malfunction of water pump. See details in chapter 12.3.13) and 13.3) cooling system. Pic. 60 00187 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 117: 8) Exceeding Of Oil Temperature
Chapter 8.2) and 13.2). — If after the previous checks the oil pressure remains too low, the engine must be completely checked and overhauled. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 118: 10) Oil Specification Not Respected
ATTENTION: If the limits of operation are exceeded or fall short of conduct the additional relevant checks. WARNING: Don't start engine before trouble is found and rectified. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 119: 13) Periodical Rising And Dropping Of Boost Pressure And Engine Speed (Surging Of The Tcu)
ATTENTION: If the limits of operation are exceeded or fall short of conduct the relevant checks additionally. WARNING: Do not start engine before trouble is found and rectified. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 120: 14) Constant Lighting Of The Red Boost Lamp Of The Tcu
Examination of pistons, cylinders, valves and cylinder heads is necessary. ATTENTION: If further limits of operation were exceeded or fell short of conduct the additional relevant checks. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 121: 15)Flashing Of The Red Boost Lamp Of Turbo Control Unit (Tcu)
Examination of the pistons, cylinders, valves and cylinder heads is neces- sary. ATTENTION: If further operating limits were exceeded or fell short of conduct the additional relevant checks. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 122: 16) Flashing Of The Orange Caution Lamp
ATTENTION: If the limits of operation are exceeded or fall short of, conduct additional relevant checks. WARNING: Do not start the engine before trouble is found and rectified. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 123: 18) Tight Movement Of Engine
Carry out detailed inspection of crank drive. Länge L (m) / length L in m 05694 Pic. 60/1 Kraft F in N / force F in N Modification no. Reference Main Date Page - 5 - 914 F 2003 03 01...
Page 124: Maintenance Of The Various Systems
I ATTENTION: To avoid contamination in the fuel system proceed with great care and cleanliness. Put carburetor and parts re- moved on a clean surface. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 125: 2) Leakage Test Of Float Needle Valve
Renewal of the float needle seat is not allowed. 13.1.2.3) Carburetor components x 0,1 Pic. 62 00025 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 126 13.1.2.4) Diaphragm l . ( l . ) l . ( l . ) Pic. 63 00027 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 127: 4) Diaphragm
I ATTENTION: The jet needle fitted must move freely. Visually check outside of plunger { and the two inside compensation bores u. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 128: 6) Float Chamber, Floats
Check inner diameter of needle jet if oval, replace if neces- sary. Check the size. ■ CAUTION: At all work on the carburetor proceed with optimum cleanliness. Pic. 69 00027 Page Date Main Reference Modification no. 2003 03 01 914 F - 5 -...
Page 129: 9) Check Of Float Needle Valve
Clean all parts and blow all bores and ducts with compressed air. Check all parts and replace imperfect ones. 13.1.2.11) Carburetor reassembly Reassembly of the carburetor with new O-rings and gaskets in reversed sequence. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 130: 3) Carburetor Synchronization
ATTENTION: Respect the indication of the instrument manufacturer. Refit plug screws M3,5x5. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 131: 4) Idle Speed Adjustment
(see Pic. 74) and, if necessary, by adjusting again mixture control screw. ATTENTION: If satisfactory idle ajdustment is not possible, an additional pneumatic synchronization is necessary. 00040 Pic. 76 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 132: 5) Check Of The Fuel System
The float needle valve cannot retain the fuel pressure over a longer period or during transport of the aircraft. If problems with fuel supply are encountered and cannot be resolved, contact a ROTAX Distribution Partner or Service Centre. Page Date...
Page 133: 6) Fuel Pressure
If during the test run the nominal fuel pressure values are not met, stop engine and start with the trouble shooting procedure. WARNING: No aircraft take-off before an obvious fault has been found and eliminated! Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 134: 7) Carburetor Flange, Drip Tray
No additional weight must be charged on the carburetor flange. WARNING: Certification to the latest requirements such as FAR or JAR has to be conducted by the aircraft builder. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 135: 8) Fuel Tubes
If necessary, renew the complete regulator. Fitting of fuel pressure regulator by hex. screws M6x16 and lock washers on the airbox. Tightening torque 8 Nm (70 in.lb). Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 136: 10) Fuel Pump
The graph applies only to a seasoned pump: Run-in period approx. 30 minutes. NOTE: The pump may increase its performance by approx. 20 % after running-in. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 137 Blank page Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 138: 11) Pressure Connection Tubes
See Pic. 86 and 87. Pic. 86 00048 110 mm 130 mm 00049 75 mm 130 mm Pic. 87 Length of tubes depending on installation conditions Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 139 I ATTENTION: For all pressure connection tube, utilize the total slip-on length for tube connection, and secure tubes with suitable clamps. Route the tubes so that scouring or kinks are avoided. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 140: 12) Reassembly Of Carburetors, Carburetor Flanges, Fuel Tubes And Drip Trays
Now the airbox e can be fitted on the connections of the carburetors. Do not damage the previously fitted fuel tubes and pressure connection tubes. Pay attention that all faces of attachment are free of grease. Page Date Main Reference Modification no. 2003 03 01 914 F - 5 -...
Page 141 ATTENTION: At fitting of fuel tubes support them adequately to avoid strain or additional load. Reconnect plug connectors to temperature sensors and throttle valve potentiometer. Check plug connections for security. Pic. 90 00031 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 142: Lubricating System
Remove 4 Allen screws } M6x65 with lock washers and the oil pump ass’y with 2 O-rings 11x2,7 q and 1 O-ring 30x2,5 Pic. 92 00072 Page Date Main Reference Modification no. 2002 01 01 914 F - 4 -...
Page 143: 2) Oil Pump Disassembly
Remove oil pump housing D of suction pump, revolving piston with rotor F and O-ring 57x3 G of main oil pump. Remove last peg S (drive pin) and oil pump shaft H with driving pin J pressed-in. Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 144: 3) Oil Pump Checking
The shim q is only fitted if required to reach specified oil pressure. Clean all parts and clear oil bores with compressed air. Dimensions Wear limit See Chapter 15. 00071 Pic. 97 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 145: 4) Oil Pump Re-Assembly
LOCTITE 221. Tightening torque 8 Nm (70 in.lb). Fit oil pressure sensor t secured with LOCTITE 221. Tightening torque 15 Nm (130 in.lb). Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 146: 2) Check Valve (Turbo)
2 Allen screws U M6x55. Tightening torque 10 Nm (90 in.lb). Tighten union nut W of turbo suction oil tube to 20 Nm (180 00075 in.lb). Pic. 99 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 147: 4) Magnetic Screw
Remove both screws, drain remaining oil and check. Refit the cleaned screws, tighten to 35 Nm (310 in.lb) and secure with safety wiring. 00081 Pic. 100 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 148: 6) Oil Tank
WARNING: After re-installation of the engine en- sure no air is trapped in the lubrica- tion system. For correct procedure, see Chapter 13.2.10). Pic. 101 00077 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 149: 7) Oil Tubes (Steel Tubes)
Hex. screw M8x20 w:15 Nm (135 in.lb) (secure with LOCTITE 221). NOTE: On versions F2/F4 instead of the gover- nor oil tube Q a spacer e 10,5/15/10 is used. Pic. 103 Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 150: 8) Oil Tubes
At oil level check the max. mark must not be exceeded. WARNING: Always observe the engine while running from a secure place. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 151 Blank page Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 152: Cooling System
Turn crankshaft with a ring wrench slightly to Pic. 105 and fro until the locking screw engages in the recess I of the crankshaft, and tighten to 10 Nm (90 in. lb). Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 153: 2) Water Pump Housing - Disassembly And Check
80° C (180° F) and remove the socket. Clean threads carefully from LOCTITE remains, apply LOCTITE 648 to the new bent water socket and fit it into position after 5 turns. Pic. 108 00378 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 154: 3) Magneto Hub
Otherwise the car- bon brushes will jump off the rotor. Remove O-ring W. Pic. 111 00381 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 155 { (dimension E) of bearing bush for crank- Pic. 112 shaft support },(dimension R) , see Chapter 15). 00382 dimensions wear limit See Wear Limits, Chapter 15). Pic. 113 00084 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 156 At emergency of liquid, renew rotary seal and oil seal r. Visually check support t for electric starter. y = Drive shaft for mechanical rev. counter. Pic. 114 00383 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 157: 5) Water Pump Shaft - Removal
00384 Pic. 116 00385 If corroded, replace the water pump shaft. The shaft has a conical end T. NOTE: Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 158: 6) Rotary Seal - Removal
00388 pump shaft outwards towards Pic. 118 the sealing face Y, depending on axial clearance O. See Pic. 121. 00387 Pic. 120 00389 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 159: 8) Section Through Water Pump
Check impeller R for out-of-round. At notice- able out-of-round replace impeller or if nec- essary also the pump shaft. Pic. 121 00085 dimensions wear limit See Wear Limits, Chapter 15). Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 160: 9) Fitting Of Ignition Housing
The Allen screw O M6x30 reaches into the oil compartment NOTE: and must be sealed with LOCTITE 221. P = drive shaft for mechanical rev. counter. 00391 Pic. 123 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 161: 10) Water Pump Housing - Reassembly
180° if required. Fit coolant hoses and fix them with genuine hose clamps. I ATTENTION: Do not tighten hose clamps excessively in order not to damage the hose! Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 162: 11) Expansion Tank
Visually check for damages, cracks, chafing marks, burnt spots etc. At noticeable damages replace the air baffle. Page Date Main Reference Modification no. 2003 03 01 914 F - 5 -...
Page 163 Blank page Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 164: Ignition System
— Check all plug- and screwed connections for oxidation and tight fit. — Check short-circuit cables and ignition switch. If an ignition switch failure is suspected, the short-circuit cable can be withdrawn from the ignition switch. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 165: 3) Electronic Module, Trigger Set
ATTENTION: If one ignition circuit fails, do not interchange the 2 4-pole plug connectors Q of trigger cables for failure tracing. Contrary to ROTAX engine 912 the ignition timing for circuit A and B are different! It, however, is possible to interchange the modules W as they are identical.
Page 166: 4) Charging Coil
ATTENTION: On all these works pay special attention that no foreign matter will enter the ignition. dimensions wear limit See Wear Limits, Chapter 15). Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 167: 6) Double Ignition Coil
A1/2. Start engine, aim stroboscope towards trig- ger coil A1/2 and observe flashing light. This procedure should be conducted with all ignition cables. 00402 Pic. 135 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 168: 8) Ignition Timing Control
Pic. 138. B3/4 B3/4 A1/2 A1/2 A3/4 A3/4 00088 Pic. 137 Pic. 136 00087 B1/2 B1/2 Operating ignition timing Start ignition timing Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 169: 9) Check Of Ignition Circuits (Magneto Check)
Also here the speed drop must not exceed 300 r.p.m. Difference of speed by use of either circuit, A or B, must not exceed 115 r.p.m. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 170: 10) Wiring Diagrams
”A” electronic module for circuit ”B” double ignition coil engine cylinder 1 - 4 spark plugs charging coils consumer connection colour code Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 171 0,75 br 0,75 sw 0,75 br 0,75 sw 0,5 ws/ge 0,5 bl/ge blue brown ge yellow gn green pink sw black ws white Pic. 138 00218 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 172: 2) Engine, External
Position 21-25 available as accessories. Position 30-51 not supplied by ROTAX s WARNING: Check of parts/components which are not in the serial supply scope of ROTAX have to be checked as per aircraft or fuselage manufac- turer's specifications. 36-pole plug receptacle for TCU...
Page 173 Verbraucher (consumer) Pic. 139 00216 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 174 Blank page Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 175 Blank page Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 176: 11) Removal Of Ignition Electric Set
2 intake manifolds with O-rings, compensating tube O, and ignition electric set can be removed, proceeding with great care. Plug all 4 intake apertures to avoid entry of foreign matter. Pic. 140 00334 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 177: 12) Dismantling Of Ignition Electric Set
P from the 4 ignition coils as well as the ground cable of the trigger coil cable assembly S. Pay atten- tion to the correct connection between electronic modules and ignition coils. Pic. 141 00406 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 178: 13) Re-Assembly Of Ignition Electric Set
= unten / bottom = oben / top ws = weiß / white sw = schwarz / black 00407 Magnetseite / magneto side Propellerseite / propeller side Pic. 142 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 179: 14) Re-Fitting Of Ignition Electric Set
Allen screw Y M5x25 on the ignition coil bracket t. ATTENTION: The cable shielding must be fully inserted into the cable clamp to assure optimum mass connection. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 180: 16) Exchange Of External Trigger Coils
I. Pic. 144 00089 ATTENTION: Fit the clamps as to ensure perfect ground connection between shielding and ignition housing. dimensions wear limit See Chapter 15. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 181: 16) Stator Removal And Re-Fitting
One each charging coil grounding cable is screwed with the stator fixation. At assembly apply Lithium grease to the contact faces i of the stator and the screw heads. Pic. 145 00410 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 182: 17)Flywheel Ass'y
Adjust the air gap of the external triggers with feeler gauge to dimension U. Check external trigger coils for correct axial position with reference to the trigger cam of the magneto hub. Max. off-set by dim. I is allowed. Page Date Main Reference Modification no. 2002 01 01 914 F - 4 -...
Page 183 Blank page Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 184: Turbo Charger And Exhaust System
M8x35 along with washer and support plate e. After removal of the 4 nuts r and washers, the muffler can be taken off. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 185 Zyl. Cyl. Zyl. Cyl. Zyl. Cyl. Zyl. Cyl. Pic. 147 00095 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 186 Further detach connection S of exhaust bracket with engine frame (not in supply volume of engine). Take out spacer D 10,5/17/15 from arm of engine frame. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 187 After removal of the two Allen screws M10x110 E and M10x35 R along with lock washers the engine suspension frame can be taken off. 00161 00161 Pic. 148 Pic. 149 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 188: 2) Checking Of The Engine Suspension Frame, Exhaust System And Turbo Charger Components
NOTE: The turbo charger is handled as a complete unit e.g. no spare parts are available at BOMBARDIER-ROTAX. In case of damage the complete unit has to be renewed. Check waste gate lever for easy movement and verify the bearing clearance.
Page 189 Blank page Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 190: 3) Assembly Of The Complete Exhaust System Inclusive Turbo Charger
Tightening torque as specified by the aircraft builder. Tightening torque of the M10 screws = 35 Nm (310 in.lb). Pic. 151 00095 Page Date Main Reference Modification no. 2002 01 01 914 F - 4 -...
Page 191 Zyl. Cyl. Zyl. Cyl. Zyl. Cyl. Zyl. Cyl. Pic. 151/1 00095 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 192 See Pic. 153. ATTENTION: In the high temperature zone of turbo charger and exhaust system use exclusively high grade, stain- less steel screws. 00165 Pic. 153 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 193 Blank page Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 194: 4) Servo Cable, Rope Sheave And Spring For Waste Gate Control
Visual inspection of all components. Check servo cable for easy movement. ATTENTION: Renew servo cable if damaged. Refer to section 12.3.6). Check spring engagement holes { for wear. fig. 154 02618 Page Date Main Reference Modification no. 1998 07 01 914 F TM 914-08 - 1 -...
Page 195: 3) Assembly And Adjustment
Wire secure W between servo motor and traction relief such, that the servo cable cannot escape from cable retainer and consequently changing the setting. fig. 154/1 02618 Modification no. Reference Main Date Page - 2 - 914 F 1998 11 01...
Page 196: Control System Of The Turbo Charger
All the required items, except the computer are available in form of a monitoring kit Q or as diskette W. Communication- Communication- program program tlr V4.3a tlr V4.6a 00427 00210 00210 Pic. 155 Page Date Main Reference Modification no. 1999 01 01 914 F - 3 -...
Page 197: 3) Introduction To Employment Of The Communication Program
13.6.1.3) Introduction to employment of the communication program a) Software The software is the property of BOMBARDIER-ROTAX. Duplication is only permitted for transmission on a fixed disk or for back up and filing. b) Necessary connections See Pic. 156 and 157.
Page 198: 4) Application Of The Communication Program
C:\914\prog46\>tlr46a [Enter] NOTE: If only the message C:\> appears start the program with the same command line but in bold face print C:\>914\prog43\tlr43a [Enter] C:\>914\prog46\tlr46a [Enter] Page Date Main Reference Modification no. 1999 01 01 914 F - 3 -...
Page 199 TCU and computer is necessary. In addition verify voltage supply to TCU. Rectify any detected interruption between TCU and compu- ter and switch "OFF" and "ON" TCU power supply. 00191 Pic. 161 Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 200 O and P w target pressure reduction by I effective target pressure excessive engine speed input (possibly reduced for e airbox temperature instance by excessive Page Date Main Reference Modification no. 1999 01 01 914 F - 3 -...
Page 201 MS-DOS Monitor. After finding the requested LOG file, data can be transferred to diskette by command line C:\914\progxx\>COPY C:\FILE-Name A:\ e.g.11061014.log Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 202 2 7 ,6 00475 For above numbering see also monitor display. Pic. 163 NOTE: The Pic. 163 shows an EXCEL-table of the program version TLR V4.3A. Page Date Main Reference Modification no. 1999 01 01 914 F - 3 -...
Page 203 1000 to 1400 hPa (mPa). The program is for graphic evaluation of the parameters I and O in the monitor program. 00195 Pic. 165 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 204 If this command should be carried out during establishing of a LOG file the error message "SERIAL ACCESS DENIED" will appear. In this case repeat the reading procedure. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 205 Q. Pic. 170 d) End of program With "Q" for QUIT stop communication program Turn off the TCU Disconnect wiring. Store Dongle properly Switch off PC Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 206: 5) Checking The Items Of Turbo Charger Control
By use of the communication program shortcomings of the components can be quickly detected on the sub program "MONITOR". NOTE: The respective error detection chart is available at request from the authorized distributor. See chapter 17. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 207 Blank page Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 208: 6) Checking Of The Throttle Position
If the throttle position for idle and full throttle are not within the allowance or if not proceeding linear, then a new calibration of the throttle position is absolutely necessary. Recalibration exclusively by an authorized ROTAX- Dealer or his Service Center if the TCU is of part no. 966.470.
Page 209: 7) Calibration Of The Throttle Position
Pic. 173/2 03072 Calibration data will be transferred automatically and the calibration takes place. Pic. 173/3 03073 Verification of the throttle position as per section 13.6.1.6). Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 210: 2) Static Check Of The Turbo Charger Control
If this aid is not at disposal, a trial run of the engine is required. See chapter 12.3.22. Engine operation is only allowed for transfer to the nearest service place, where this check has to be conducted afterwards. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 211: 2) Warning Lights
The two warning lamps are not in the supply volume of engine. øV +12V Pic. 175 øV +12V CAUTION LAMP 00211 ATTENTION: Exchange any part with physical damage or if not operating correctly, without delay. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 212: 3) Wiring Harness
Pic. 176 contains a lot of information. Besides the wiring designations, plugs allocation, cable length, the polarity of the voltage supply to the single components is stated, too. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 213 Pic. 176 00211 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 214: 3.1) Throttle Position Potentiometer
Small installation tolerances can be compensat- ed by turning of the throttle position potentiome- ter. Refer to chapter 13.6.16). Otherwise new calibration will be necessary. Pic. 178/1 00517 Page Date Main Reference Modification no. 1999 01 01 914 F - 3 -...
Page 215 Pic. 180 Drosselklappenstellung throttle position open closed ATTENTION: Parts physically damaged or of not correct function have to 00222 be exchanged without delay. Modification no. Reference Main Date Page - 3 - 914 F 1999 01 01...
Page 216: 4) Resistance Thermometer (Intake Air Temperature Sensor)
ATTENTION: At physical damage or readings outside allowance ex- change sensor without delay. At fitting of the resistance thermometer secure with LOCTITE 221 and tighten to 15 Nm (135 in.lb). Page Date Main Reference Modification no. 2002 01 01 914 F - 4 -...
Page 217: 5) Pressure Sensors
Q static pressure sensor black plug connection W airbox pressure sensor Umgebungs-Drucksensor static pressure sensors Airbox-Drucksensor airbox pressure sensors Pic. 184 00057 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 218 Max. allowance ± 40 hPa 00442 Druck [hPa] absolut pressure absolute ATTENTION: At physical damage or readings outside allowance exchange sensor without delay. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 219 Max. allowance ± 60 hPa 00441 Druck [hPa] absolut pressure absolute ATTENTION: At physical damage or readings outside allowance exchange sensor without dealy. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 220: 6) Servo Motor
See chapter 00059 12.3.22. WARNING: If at checking shortcomings arise, then the engine must not be taken in operation until trouble is found and rectified. Pic. 187 Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 221: 7) Circuit Breaker For Servo Motor
Until finding of trouble and rectifying, engine operation is only permitted for ground testing. ATTENTION: At physical damage or incorrect operation exchange circuit breaker without delay. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 222: 8) Three-Way Solenoid Valve
28,3 ÷ 31,1 Ω - resistance at 20°C: ATTENTION: At physical damage, mechanical defects or readings out- side tolerance exchange the threeway solenoid valve with- out delay. Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 223: 9) Trigger Coils For Electric Rev-Counter And Ignition
6000 rpm (load 100 Ω Ω Ω Ω Ω ) (+V) (+V) 1 Umdr. (rev.) (-V) 360° 1 Umdr. (rev.) (-V) 360° Pic. 191 00219 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 224: Temperature- And Pressure Observation
Besides the special checks, see chapter 12.4 and description of the systems find further maintenance precedures as follows. NOTE: Several temperature control points are located on the Rotax engine 914 F. Refer to wiring diagram in Maintenance Manual. 13.7.1) Cylinder head temperature sensor See Pic.
Page 225: 2) Oil Temperature Sensor
At installation secure temperature sensor with LOCTITE 221 and tighten to 10 Nm (90 in.lb). ATTENTION: Before exchanging a temperature sensor let the engine cool down first. Hazard of burning or scalds. Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 226: 3) Oil Pressure Sensor
± 5% After removal of oil pressure sensor clean the thread. Secure new sensor with LOCTITE 221 and tighten to 15 Nm (133 in.lb). Page Date Main Reference Modification no. 1997 02 01 914 F - 0 -...
Page 227 Blank page Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 228: Maintenance Of Components
E from starter housing and remove carbon brush holder R together with springs from armature T. Withdraw armature and thrust washer Y from starter housing. Clean parts carefully (see Chapter 11.7). 00231 Pic. 198 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 229: 2) Electric Starter Single Parts - Check
Renew all O-rings u and oil seal i at repair of electric starter. Starter housing Visually check inner magnets o for cracks. Studs Visually check both studs p . To be removed only if required. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 230: 3) Electric Starter - Re-Assembly
Remove hex. nut R M34x 1,5 with socket wrench 46 a/f, part no. 877 450, from crank- shaft. Hex. nut R with left hand NOTE: Pic. 202 thread! 00235 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 231: 1) Sprag Clutch - Removal
Inspect taper bore U in housing. Check teeth I and sprag engagement face O on free wheel gear and inspect bearing bush P. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 232: 3) Sprag Clutch - Installation
E and push into position. Fit thrust washer R 12,5/21,5/1 on top of it. 14.2.5) Fitting of ignition housing See Chapter 13.3.9). 00240 Pic. 207 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 233: Rev. Counter Drive
M8 taps T of gear cover E. Now the complete gearbox can be pulled off with the impact puller Y without damaging the ball bearing and the propeller shaft. Pic. 210 00244 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 234 T and on dog gear. 00247 The gears are paired as a set and must not be exchanged individually. Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 235: 1) Removal Of Roller Bearing For F2 Only
Remove extractor ass'y from crankcase. ATTENTION: During this procedure the oil seal P is destroyed and must be renewed. 00248 Pic. 215 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 236: 2) Removal Of Roller Bearing For F3 Only
U and nut O together with shim I. By turning hex. screw clockwise, the roller bearing is pulled out together with the oil inlet cover. Remove O-ring Pic. 217 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 237: 4) Vacuum Pump - Removal
Clean and inspect bearing seat. At this procedure the needle sleeve Q, oil seal O and ball NOTE: bearing E are damaged and must be renewed. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 238: 6) Drive For Vacuum Pump And Propeller Governor - Re-Fitting
Only tighten connections with ring- or socket wrench and bring them to correct position. Retighten by max. 1,5 turn. Pic. 222 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 239: 8) Drive For Propeller Governor - Removal
00257 If service work is necessary on the pro- peller governor, it must be sent to the engine manufacturer. dimension wear limit See Chapter 15). Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 240: 9) Drive Of Propeller Governor - Installation
The maximum control pressure is between 22 and 25 bar (320 ÷ 360 p.s.i.). The governor starts regulating at 3600 ÷ 3700 r.p.m. Date Main Reference Page Modification no. 1999 01 01 914 F - 3 -...
Page 241: 10) Gearbox - Disassembly
Remove overload clutch ass’y Q, 3 disk springs W 80x35x3, step collar E, shims R, eccentric collar T for fuel pump and 8 mm (.315 in.) distance sleeve 00262 Pic. 229 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 242: 11) Propeller Shaft - Removal
ATTENTION: At this procedure the oil seal w will bedamaged and must be renewed. 00264 Pic. 231 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 243: 12) Gearbox Components - Checking
Check clearance, dimension r in Chapter 15). Slight wear and pitting on the dogs is permissi- ble. Maß/dim. 00268 Pic. 235 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 244: 13) Gearbox - Re-Assembly
Make absolutely sure to support the inner ring { of the bearing with suitable tube }. It is an advan- tage if gear cover is still warm at this stage. 00272 Pic. 238 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 245: 14) Adjustment Of Disk Spring Pre-Tension
The ring halves must be completely in- serted in the groove on propeller shaft! Pic. 240 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 246: 15) Propeller Gearbox - Re-Fitting
Cu sealing ring and tighten to 22 Nm (195 in.lb). For verification turn crankshaft with wrench 24 a/f on hex. screw on magneto side. Pic. 242 00473 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 247: Cylinder Head - Removal
Coordinate push rods with cylinder heads to pre- vent any mix-up. 00278 Pic. 244 Modification no. Reference Main Date Page - 0 - 914 F 1997 02 01...
Page 248: 1) Cylinder Head - Disassembly
(max. 0,1 mm / 0.004 in. per side) is allowed. Renew valve stem seals. If the engine has been "run hot", check in any case hardness of cylinder head and cylinder material, see Chapter 12.4.7). Date Main Reference Page Modification no. 914 F 2003 03 01 - 5 -...
Page 249: 2) Valve Guides
The exhaust valves (dia. 32 mm = 1,3 in.) are thermally higher stressed and therefore should be particularly checked. Seal-lap both valves and check for leakage. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 250: 5) Valve Springs
S, see Chapter 15). Deburr bores and clean oil ducts with compressed air. Dimension wear limit Maß dim. See Wear Limits, Chapter 15). Pic. 253 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 251: 7) Re-Assembly Of Cylinder Head
The rocker arm bearing support is a slide fit. Do not act with force! Lubricate all moving internal parts with engine oil (see Chapter 11.7.1, 13.2.10 and 13.2.11). Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 252: Cylinder And Piston - Removal
14.6.1) Piston checking See Pic. 257 and 258. On engine type 914 F cast light alloy, full skirt pistons are used. The piston axis is offset by 1 mm (.039 in.). Remove piston rings using a pair of piston ring pliers. Make absolutely sure to re-fit rings in their initial position.
Page 253: 2) Piston Ring Checking
Fit piston rings using piston ring pliers, with marking Y "TOP" or the dot mark towards piston crown. Kompressionsring/compression ring Minutenring/bevel-edged ring Pic. 260 Ölabstreifring / Pic. 261 oil scraper ring 00295 00296 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 254: 3) Dimensions Of Pistons And Piston Rings
See Wear Limits, Chapter 15). NOTE: Slight oil carbon residues on the cylinder sealing face indicate leakage. True up cylinder along with cylinder head. Pic. 263 Pic. 262 00298 00297 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 255: Hydraulic Valve Tappets
Check push rods for straightness. Through the bores E oil passes from the valve tappet to the rocker arm. Pic. 267 00302 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 256: Fitting Of Piston And Cylinder Assembly
Zylinder 1 und 3 / Zylinder 2 und 4 / auf den Propellerflansch gesehen / Cylinder 1 and 3 Cylinder 2 and 4 looking at propeller flange Pic. 270 00305 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 257 ATTENTION: The opening of circlip must show downward, to 6 position, to maintain tangential force of the circlip. WARNING: Always use new piston pin circlips! Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 258: 3) Fitting Of Cylinder
En- sure to squeeze O-rings W evenly into crank- case. Repeat this procedure on the other cylinder heads. 00278 Pic. 275 Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 259: Fitting Of Coolant Hoses
23 mm (.905 in.). NOTE: Position the hose clamps so that no neighbouring coolant hoses can be damaged. Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...
Page 260: Fitting Of Intake Manifolds
Tighten compensating tube and the hoses on both ends with hose clamps 15/9. Attach fuel manifold with fuel lines on compensating tube, see also Chapter 13.1.5 and 13.1.8). Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 261: Wear Limits For Rotax 914 F
15) Wear limits for ROTAX 914 F Designation wear limit actual dim. (in.) (in.) int. / exh. Cylinder/Piston cylinder bore Cyl. 1 ....... 79,50 ÷ 79,524 (3,13 ÷ 3,131) ..79,58 (3,13) ......ovality ............. 0,000 ÷ 0,007 (0,000÷ 0,0003) ... 0,05 (0,002) ......
Page 262 / groove clearance ......0,03 ÷ 0,062 (0,001÷0,002) ....0,1 (0,004) ......ring end gap F ........0,15 ÷ 0,35 (0,006÷0,014) ....1,0 (0,04) ......Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 263 [ ..1,50 ÷ 1,90 (0,059 ÷ 0,075) .... 2,50 (0,098) ......out-of-true on valve head ] ....0,00 ÷ 0,01 (0,0 ÷ 0,0004) ... 0,03 (0,0012) ...... Modification no. Reference Main Date Page - 3 - 1999 01 01 914 F...
Page 264 { ........28,02 ÷ 28,03 (1,103 ÷1,104) ..28,10 (1,106) ......radial clearance, p.t.o. side ..... 0,02 ÷ 0,04 (0,0008÷0,0016) ..0,12 (0,005) ......Date Main Reference Page Modification no. 1997 02 01 914 F - 0 -...
Page 265 9 ....0,1 ÷ 0,2 (0,004 ÷0,008) .... 0,3 (0,012) ......Push rod out of round G ........0,0 ÷ 0,1 (0,0 ÷ 0,004) .... 0,2 (0,008) ......Modification no. Reference Main Date Page - 3 - 1999 01 01 914 F...
Page 266: Form Sheets
Formblatt Nr. KD-17-015/E—96 01 18 16) Form Sheets Rotax 914 ___ for engine no.: _________________ 16.1) Form Sheet for Cylinders and Pistons Cylinder and piston position (mark appropriate position on illustration ) 1) Cylinder Checking of the dia. D and D 00318 Pic.
Page 267: Form Sheet For Igniton Unit
Pic. 284 16.2) Form Sheet for igniton unit 05618 Modification no. Reference Main Date Page - 5 - 914 F 2003 03 01...
Page 268: Form Sheet For Electric Starter
Pic. 285 16.3) Form Sheet for electric starter 05619 Date Main Reference Page Modification no. 914 F 2003 03 01 - 5 -...
Page 269: Form Sheet For Crack Detection
HB 85 ÷ 120 cyl. head act............Kundenauftragskarte / Datum / Labor client assignment no.: date: Magnaflux Formblatt Nr. 17-086/A—2003 03 01 Printdatum Vert./co.: Layout: Materialprüfung Modification no. Reference Main Date Page - 5 - 914 F 2003 03 01...
Page 270: Authorized Distributors And Service Centers
17) ROTAX Authorized Distributors for Aircraft Engines ® See latest Operators Manual chapter 14 or in the Internet at the official website www.rotax-aircraft-engines.com. Date Main Reference Page Modification no. 914 F 2003 03 01 - 5 -...
Page 271: Reporting
ROTAX distributor. ® N NOTE: The form is also available from the official ROTAX AIRCRAFT ENGINES ® website www.rotax-aircraft-engines.com in electronic version.
Page 272 Date Main Reference Page Modification no. 914 F 2003 03 01 - 5 -...
Page 273 Modification no. Reference Main Date Page - 0 - 1997 02 01 914 F...

Rotax 914 F Maintenance Manual

1 Table of Contents

2 Index

3 Introduction

4 Safety

5 List of the Current

6 Table of Amendments

7 Description of Design

8 Technical Data

9 Description of the Systems

10 Auxiliary Units

11 Maintenance

12 Maintenance Checks

13 Maintenance of the Various Systems

14 Maintenance of Components

Quick Links

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Rotax 914 F