BRP ROTAX 912 Series Maintenance Manual
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BRP ROTAX 912 Series Maintenance Manual

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MAINTENANCE
MANUAL LINE
FOR ROTAX ENGINE TYPE 912 SERIES
REF NO.: MML-912 | PART NO.:
899196

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Summary of Contents for BRP ROTAX 912 Series

  • Page 1 MAINTENANCE MANUAL LINE FOR ROTAX ENGINE TYPE 912 SERIES REF NO.: MML-912 | PART NO.: 899196...
  • Page 2 GmbH & CO KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior written permission of BRP-Rotax GmbH & Co KG, be disclosed in whole or in part to third parties. This legend shall be included on any reproduction of these data, in whole or in part. The Manual must remain with the engine/aircraft in case of sale.
  • Page 3 BRP-Rotax MAINTENANCE MANUAL LINE Table of Content Chapter INTRO – GENERAL NOTE Chapter LEP – LIST OF EFFECTIVE PAGES Chapter TOA – TABLE OF AMENDMENTS Chapter 00–00–00 – GENERAL NOTE Chapter 04–00–00 – AIRWORTHINESS LIMITATIONS Chapter 05–00–00 – MAINTENANCE Chapter 05–10–00 –...
  • Page 4 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 912 Series January 01 2020...
  • Page 5 ROTAX® Authorized Aircraft Engines Distributors or their independent Service Centers. BRP-Rotax wishes you much pleasure and satisfaction flying your aircraft powered by this ROTAX®-aircraft engine. The structure of the Manual follows whenever it is possible the structure of the ATA (Air Transport Association) standards.
  • Page 6 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 912 Series January 01 2020...
  • Page 7 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: LEP LIST OF EFFECTIVE PAGES Each new revision to the Maintenance Manual Line will have a new List of Effective Pages. Chapter Page Date Chapter Page Date Cover page January 01 2020 INTRO January 01 2020...
  • Page 8 BRP-Rotax MAINTENANCE MANUAL LINE Chapter Page Date Chapter Page Date January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020...
  • Page 9 BRP-Rotax MAINTENANCE MANUAL LINE Chapter Page Date Chapter Page Date January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020 January 01 2020...
  • Page 10 BRP-Rotax MAINTENANCE MANUAL LINE Chapter Page Date Chapter Page Date Rear page Effectivity: 912 Series Rev. 0 Page 4 January 01 2020...
  • Page 11 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: TOA TABLE OF AMENDMENTS Approval* The technical content of this document is approved under the authority of DOA ref. EASA.21J.048. This document is part of the ICA for product as specified in this manual. NOTE THE APPROVAL IS GIVEN TO ALL CHAPTERS EXCEPT THE AIRWORTHINESS LIMITATIONS SECTION 04-00-00 WHICH IS SUBJECT TO SPECIFIC APPROVAL OF THE EASA.
  • Page 12 BRP-Rotax MAINTENANCE MANUAL LINE Summary of amendments Summary of the relevant amendments in this context, but without requirement on completeness. page chapter date of comment change Jan. 01 2020 New layout and change of company name 05–20–00 9–16 Jan. 01 2020 Change of maintenance schedule 05–50–00...

  • Page 13: Table Of Contents

    BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 00–00–00 GENERAL NOTE TOPICS IN THIS CHAPTER General..............................2 Abbreviations and terms (depending on respective engine type)............3 Wiring color codes ..........................7 Conversion table ...........................8 Safety notice ............................9 Safety information ..........................10 Instruction............................12 Maintenance Concept..........................13 Technical documentation........................14 Use for intended purpose ........................16 Effectivity: 912 Series 00–00–00...

  • Page 14: General

    BRP-Rotax MAINTENANCE MANUAL LINE GENERAL In this Manual all ROTAX® 912 Series engines are described. NOTE ROTAX® 912 Series includes 912 A, 912 F, 912 S, 912 UL, 912 ULS and 912 ULSFR. Purpose The purpose of this Manual is to provide aircraft manufacturers with technical require- ments (e.g.

  • Page 15: Abbreviations And Terms (Depending On Respective Engine Type)

    BRP-Rotax MAINTENANCE MANUAL LINE ABBREVIATIONS AND TERMS (DEPENDING ON RESPECTIVE ENGINE TYPE) Abbreviations Description Reference to another section center of gravity The drop symbol indicates use of sealing agents, adhesives or lubri- cants (only in the Illustrated Parts Catalog). °C Degrees Celsius (Centigrade) °F...
  • Page 16 BRP-Rotax MAINTENANCE MANUAL LINE Abbreviations Description CGSB Canadian General Standards Board DCDI Dual Capacitor Discharge Ignition direct current Design Organisation Approval Department of Transport EASA European Aviation Safety Agency Installation Manual Engine Control Unit Exhaust Gas Temperature INTRO Introduction Engine Management System...
  • Page 17 Pressure Control Valve Permanent magnet alternator Production Organisation Approval Power supply PTFE Polytetrafluoroethylene (Teflon) Power Take Off Rev. Revision ROTAX® is a trademark of BRP-Rotax GmbH & Co KG Effectivity: 912 Series 00–00–00 Rev. 0 Page 5 January 01 2020...
  • Page 18 BRP-Rotax MAINTENANCE MANUAL LINE Abbreviations Description Research Octane Number RON 424 ROTAX® Standard 424 s.v. still valid (only Illustrated Parts Catalog) Serial Number Society of Automotive Engineers Single Engine Piston Service Bulletin Service Instruction SI-PAC Service Instruction Parts and Accessories...

  • Page 19: Wiring Color Codes

    BRP-Rotax MAINTENANCE MANUAL LINE WIRING COLOR CODES Figure 1.2 Effectivity: 912 Series 00–00–00 Rev. 0 Page 7 January 01 2020...

  • Page 20: Conversion Table

    BRP-Rotax MAINTENANCE MANUAL LINE CONVERSION TABLE Units of length: Units of power: 1 mm = 0.03937 in 1 kW = 1.341 hp 1 in = 25.4 mm 1 hp = 0.7457 kW 1 ft = 12 in 1 kW = 1.3596 PS = 0.3048 m...

  • Page 21: Safety Notice

    The information and descriptions of components and systems contained in this Manual are correct at the time of publication. BRP-Rotax maintains a policy of continuous im- provement of its products without imposing upon itself any obligation to retrofit products previously manufactured.

  • Page 22: Safety Information

    • Due to the varying designs, equipment and types of aircraft, BRP-Rotax grants no war- ranty on the suitability of its engines use on any particular aircraft. Further, BRP-Rotax...
  • Page 23 BRP-Rotax MAINTENANCE MANUAL LINE • This engine may be equipped with a vacuum pump. The safety warning accompanying the air pump must be given to the owner/operator of the aircraft into which the air pump has been installed Engine operation •...

  • Page 24: Instruction

    GENUINE ROTAX® spare parts and/or accessories. Spare parts are available at ROTAX® Authorized Distributors and their independent Service Centers. Any warranty by BRP-Rotax will become void if spare parts and/ or accessories other than GENUINE ROTAX® spare parts and/or accessories are used (see latest War- ranty Conditions).

  • Page 25: Maintenance Concept

    BRP-Rotax MAINTENANCE MANUAL LINE See latest Operators Manual and Service Instruction SI-912-016 “Selec- tion of suitable operating fluids“, current issue. MAINTENANCE CONCEPT General note The maintenance functions detailed in this Manual are divided into two categories: • Maintenance I (Line Maintenance) •...

  • Page 26: Technical Documentation

    BRP-Rotax MAINTENANCE MANUAL LINE TECHNICAL DOCUMENTATION These documents form the instructions ensuring continued airworthiness of ROTAX® air- craft engines. The information contained herein is based on data and experience that are considered ap- plicable for authorized mechanics (iRMT, see Maintenance Manual Line) under normal conditions for engine removal and installation.
  • Page 27 BRP-Rotax MAINTENANCE MANUAL LINE Illustrations The illustrations in this Manual are merely sketches and show typical arrangements. They may not represent full detail or the exact shape of the parts but should outline the same or similar function. Therefore deriving dimensions or other details from illustrations is not permitted.

  • Page 28: Use For Intended Purpose

    NOTE These engines are technically equivalent to certified engines and have been man- ufactured by BRP-Rotax using the same quality assurance system. Engine stoppage In using the engine the operator assumes all risk of use and acknowledges that he/she knows this engine is subject to sudden stoppage.
  • Page 29 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 04–00–00 AIRWORTHINESS LIMITATIONS TOPICS IN THIS CHAPTER Approval THE AIRWORTHINESS LIMITATIONS SECTION IS APPROVED BY THE EUROPEAN AVIATION SAFETY AGENCY (EASA) IN ACCORDANCE WITH PART 21A.31(a)(3) AND FAR 33.4. ANY CHANGE TO MANDATORY REPLACEMENT TIME, INSPECTION INTERVAL, AND RELATED PROCEDURES CONTAINED IN THIS AIRWORTHINESS LIMITATIONS SECTION MUST ALSO BE APPROVED.
  • Page 30 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 912 Series January 01 2020...
  • Page 31 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 05–00–00 MAINTENANCE TOPICS IN THIS CHAPTER General note ............................2 Authorized personnel ..........................3 Procedure notes ............................4 Troubleshooting ............................6 Consumable Materials ..........................7 Acceptable methods, techniques and practice ..................10 Introduction The information given in the Maintenance Manual is based on data and experience which are considered to be applicable for a skilled aviation mechanic (iRMT) under normal working conditions.

  • Page 32: General Note

    We particularly emphasize that parts and accessories not supplied as genuine BRP-Rotax accessories parts are not verified for suitability by BRP-Rotax and thus are not authorized for use. In- stallation and/or use of such products may possibly change or negatively influence the constructive characteristics of the engine.

  • Page 33: Authorized Personnel

    • ensure the requirements of the applicable regulatory authority regarding maintenance procedures are met. For more detailed information, maintenance organizations and individuals are encouraged to contact BRP-Rotax through its worldwide distribution network for information and guid- ance on any of the tasks outlined herein. Chapter 00-00-00 section Technical Documentation.

  • Page 34: Procedure Notes

    BRP-Rotax MAINTENANCE MANUAL LINE PROCEDURE NOTES General note m WARNING Non-compliance can result in serious injuries or death! When carrying out maintenance and service work, respect without fail all safety regulations. Ignition “OFF“ m WARNING Non-compliance can result in serious injuries or death! This precautionary measure serves to avoid any injuries in case of an unintentional start of the engine.
  • Page 35 BRP-Rotax MAINTENANCE MANUAL LINE Disassembly At disassembly of the engine, mark the components as necessary to avoid any mix-up. Take care of these marks, don’t ruin them. Tool ATTENTION In order to avoid mechanical damage, always loosen or tighten screws and nuts with specified tools.

  • Page 36: Troubleshooting

    BRP-Rotax MAINTENANCE MANUAL LINE TROUBLESHOOTING General notes Possible problems are listed in the Operators Manual. At the same time, a brief description of the necessary remedial action is given. See Chapter 4 in the Operators Manual for engine type 912 Series.

  • Page 37: Consumable Materials

    BRP-Rotax MAINTENANCE MANUAL LINE CONSUMABLE MATERIALS General note ATTENTION Use only the specified or technically equivalent materials for all maintenance work. NOTE To some extent product descriptions deviate in spite of equivalent technical prop- erties, i.e.: LOCTITE 243 and LOCTITE 648. If necessary contact the manufac- turer concerning the comparability.
  • Page 38 BRP-Rotax MAINTENANCE MANUAL LINE part no. Description, Application Qty. 297386 Locking paint 897186 SILICONE HEAT CONDUCTION 150 g COMPOUND, (0.33 lb) Application of the heat conduction compound will increase heat transfer resistance. The greaselike, temperature-resistant silicon com- pound fills cavities between components and the cooling element (e.g.: spark plug-cylinder...
  • Page 39 BRP-Rotax MAINTENANCE MANUAL LINE Additional materials ATTENTION Use only the specified or technically equivalent materials for all maintenance work. ATTENTION Exhaust valves and intake valves may NOT undergo a compressed air blasting treatment with solid blasting, strong abrasive material. Due to this surface treat- ment one does gain a microscopic surface roughness/pitting which does allow as a consequence the adhesion of fuel residues.

  • Page 40: Acceptable Methods, Techniques And Practice

    BRP-Rotax MAINTENANCE MANUAL LINE ACCEPTABLE METHODS, TECHNIQUES AND PRACTICE General note All general inspection, maintenance and repair has to be carried out in accordance with Advisory Circular AC 43.13 from FAA. Advisory Circular This Manual "Advisory Circular" AC describes maintenance methods, techniques and practice.
  • Page 41 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 05–10–00 TIME LIMITS TOPICS IN THIS CHAPTER Definition of terms ...........................2 Operating hours ............................2 Terminology ............................2 Time limit ..............................2 Life cycle ..............................3 General overhaul (TBO).........................3 Purging the oil system..........................3 Time Limit..............................4 Time limit for parts ..........................7 Time limit for fuel pump ..........................7...

  • Page 42: Definition Of Terms

    BRP-Rotax MAINTENANCE MANUAL LINE DEFINITION OF TERMS OPERATING HOURS Definition All of the maintenance intervals, such as the 100 hr. inspection and the engine TBO, relate to the number of operating hours of the engine. The operating hours are defined as follows in order to prevent misunderstanding and to ensure safety: •...

  • Page 43: Life Cycle

    BRP-Rotax MAINTENANCE MANUAL LINE LIFE CYCLE Definition The life cycle is always specified as an exact time span and is also quoted in flight hours. NOTE Parts with a limited life cycle must be taken out of operation and overhauled if the specified time span or number of flight hours is reached (whichever comes first).

  • Page 44: Time Limit

    BRP-Rotax MAINTENANCE MANUAL LINE TIME LIMIT General ATTENTION A general overhaul is due after a defined period of operation or after a specified calendar life since initial start of operation (whichever comes first). The time limit for engine operation will be specified by the TBO.
  • Page 45 BRP-Rotax MAINTENANCE MANUAL LINE Engine Engine affected engine S/N Type description Time Between Overhaul 912 F from S/N 4412817 up to S/N 1500 h or 12 years, whichever 4412974 incl. comes first 912 F from S/N 4412975 2000 h or 15 years, whichever...
  • Page 46 BRP-Rotax MAINTENANCE MANUAL LINE Authorized Extension or exceeding of the TBO by 5% or 6 months is allowed, whichever comes first. exceeding Shipment The shipment to an authorized ROTAX® overhaul facility must include the following: Engine log book. Maintenance records of the engine (i.e. all maintenance check lists, and re- ports of operation, of maintenance, of findings and of oil analysis).

  • Page 47: Time Limit For Parts

    BRP-Rotax MAINTENANCE MANUAL LINE TIME LIMIT FOR PARTS General note ATTENTION This time limit must be followed independently and in addition to the visual in- spections (see Chapter 05-20-00 section: Visual Inspection) of the respective components. Time limit The following components and systems must be replaced every 5 years: •...
  • Page 48 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 8 Effectivity: 912 Series January 01 2020...

  • Page 49: Introduction

    BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 05–20–00 SCHEDULED MAINTENANCE CHECKS TOPICS IN THIS CHAPTER Scheduled maintenance checks ......................2 Unscheduled maintenance checks ......................3 Visual inspection .............................5 Maintenance schedule procedures (maintenance check list) ..............6 Check List/Maintenance Schedule......................7 Maintenance Schedule ..........................9 Introduction The owner and/or user is primarily responsible for the maintenance and airworthiness of the engine.

  • Page 50: Scheduled Maintenance Checks

    BRP-Rotax MAINTENANCE MANUAL LINE SCHEDULED MAINTENANCE CHECKS Definition This section lists the periodic inspections which must be carried out after specified periods of operation. Intervals Periodic inspections are those which must be performed at 25, 100, 200, 600 hr. intervals...

  • Page 51: Unscheduled Maintenance Checks

    BRP-Rotax MAINTENANCE MANUAL LINE UNSCHEDULED MAINTENANCE CHECKS Operating limits An inspection of the engine must be performed if the operating limits of the engine have exceeded been exceeded (e.g. overspeed, excessive temperature etc.), or if unusual operating con- ditions have occurred during operation (e.g. lightning strike). In such cases the engine must be inspected in accordance with the applicable unscheduled maintenance checks.
  • Page 52 BRP-Rotax MAINTENANCE MANUAL LINE part inspection possible danger Engine damage, unusu- • Undamaged and runs true al vibrations Propeller • Carry out dynamically balancing including verification of propeller track Aircraft air intake See specifics of • As specified by the aircraft system (NACA manufacturer.

  • Page 53: Visual Inspection

    BRP-Rotax MAINTENANCE MANUAL LINE VISUAL INSPECTION General note The scope of a visual inspection generally includes, but is not necessarily limited to, the following: Moving parts Normal operating condition, accurate alignment, leak-tightness, cleanliness, ease of movement, adjustment, mechanical stress, travel, catching, extreme wear, cracks, corro- sion, deformation and other visually evident damage.

  • Page 54: Maintenance Schedule Procedures (Maintenance Check List)

    BRP-Rotax MAINTENANCE MANUAL LINE MAINTENANCE SCHEDULE PROCEDURES (MAINTENANCE CHECK LIST) Inspections All stated checks are visual inspections for damage and wear, unless otherwise stated. Specified period All listed work must be carried out within the specified period. Maintenance Checks are carried out as per the maintenance check lists, where type and volume of check lists maintenance work is outlined in key words.

  • Page 55: Check List/Maintenance Schedule

    BRP-Rotax MAINTENANCE MANUAL LINE CHECK LIST/MAINTENANCE SCHEDULE Identification AIRCRAFT Registration number Aircraft make Aircraft model and S/N Time since new Propeller Propeller brand Propeller model and S/N Governor brand Governor model and S/N ENGINE Engine type Engine S/N TSN (time since new)
  • Page 56 BRP-Rotax MAINTENANCE MANUAL LINE Identification AIRCRAFT OPERATOR Name Contact Address Telephone/Fax E-mail MAINTENANCE FACILITY Maintenance workshop Address Telephone/Fax E-mail Certificate This check is applica- 200 hr. 400 hr. 600 hr. 1000 hr. ble (circle one) leaded fuel more than 30% of operation.

  • Page 57: Maintenance Schedule

    If the tasks 1-3 are correct continue with the maintenance schedule. If one of the tasks 1-3 is not fulfilled, the engine must be checked and repaired in accordance with the BRP Rotax instructions for continued airworthiness. Interval Operating hours...
  • Page 58 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 400 600 1000 quirement after the first 25 hours of operation) 3) Spark plug 12–20–00 Check that resistance spark plug connectors fit tightly on the spark Inspection plugs.
  • Page 59 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 400 600 1000 quirement after the first 25 hours of operation) Take note of changes caused by temperature influence. Inspect temperature sensors and oil pressure sensor for secure fit and signs of wear.
  • Page 60 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 400 600 1000 quirement after the first 25 hours of operation) Inspect the wiring and its connec- 12–20–00 tions for secure fit, damage and Check of signs of wear.
  • Page 61 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 400 600 1000 quirement after the first 25 hours of operation) Install new oil filter 12–20–00 Oil filter change In the case more than 30% of operation with leaded fuel e.g.: AVGAS 100 LL...
  • Page 62 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 400 600 1000 quirement after the first 25 hours of operation) Take note of changes caused by temperature influence. See SB-912–030 — latest edition.
  • Page 63 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 400 600 1000 quirement after the first 25 hours of operation) 14) Checking the air intake system Checking the air filter 12–20–20...
  • Page 64 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance (re- 400 600 1000 quirement after the first 25 hours of operation) Returning engine to service On the engine identified as per Checklist, a 25 hr; 50 hr; 100 hr; 200 hr; 400 hr; 600 hr; 1000 hr (please strike out not applicable intervals) maintenance interval was performed.
  • Page 65 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 05–50–00 UNSCHEDULED MAINTENANCE CHECKS TOPICS IN THIS CHAPTER Engine check after propeller strike incidents ..................2 Removal of the propeller gearbox ......................2 Drive gear — removal ..........................5 Installation of propeller gearbox ......................6 Propeller strike inspection ........................11 Checking of the overload clutch ......................12...

  • Page 66: Engine Check After Propeller Strike Incidents

    BRP-Rotax MAINTENANCE MANUAL LINE ENGINE CHECK AFTER PROPELLER STRIKE INCIDENTS Definition A propeller strike is: • Any incident while the engine is stationary or running which makes it necessary to per- form repairs on the propeller. See Service Letter SL-912-015, current edition.
  • Page 67 BRP-Rotax MAINTENANCE MANUAL LINE ATTENTION When removing the propeller gearbox, take care not to damage the bearing point and the oil seal running surface (on the roller bearing side) of the propeller shaft. Figure 5.1: typical Allen screw M8 Allen screw M6 Figure 5.2...
  • Page 68 BRP-Rotax MAINTENANCE MANUAL LINE NOTE Alternative If desired, the compact special tool part no. 877540 can be used to remove the propeller gearbox. Step Procedure Insert the dowel pin 8x20 into the bore on the right and left of the gearbox housing.

  • Page 69: Drive Gear - Removal

    BRP-Rotax MAINTENANCE MANUAL LINE DRIVE GEAR — REMOVAL ATTENTION The large and small gears are considered the same part (with the same part num- ber and same serial number). They must not be mixed up with other gear sets. Step Procedure Lock the crankshaft into place.

  • Page 70: Installation Of Propeller Gearbox

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.5 Drive gear Crankshaft Friction washer Hex. nut M30x1.5 Make sure that both dowel sleeves remain in the crankcase and not in the gearbox housing. INSTALLATION OF PROPELLER GEARBOX Preparation ATTENTION No hammering or pressing! The drive gear must only be pushed on manually.
  • Page 71 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.6 Crankshaft (power take off side) Drive gear Friction washer VS-30 Hex. nut Step Procedure Push the drive gear onto the crankshaft. NOTE Due to limited tolerances, it may be difficult to push the drive gear onto the end of the crankshaft.
  • Page 72 BRP-Rotax MAINTENANCE MANUAL LINE 09588 Figure 5.7 Crankshaft (power take off side) Drive gear Crankshaft Hex. nut Friction washer VS-30 Serial number See Maintenance Manual Heavy for the engine type Chapter 72-10-00 section Wear limits (CS24). NOTE If there is slight vertical run-out, replace the nut and repeat the measurement.
  • Page 73 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.8 Dowel pins 6x20 ATTENTION The sealing surface must be free from dirt and oil. Step Procedure Clean both sealing surfaces with LOCTITE 7063 or equivalent cleaner. Apply a thin layer of LOCTITE 5910 surface sealing compound to the sealing surface of the gearbox housing.
  • Page 74 BRP-Rotax MAINTENANCE MANUAL LINE NOTE If there is a large amount of resistance at a gap of approximately 10 mm, the bear- ing rollers of the roller bearing may not be in position. Figure 5.9: TYPICAL Allen screw M8 Allen screw M6...

  • Page 75: Propeller Strike Inspection

    BRP-Rotax MAINTENANCE MANUAL LINE PROPELLER STRIKE INSPECTION General note After any propeller strike the following inspections must be performed before operation can continue. See also Maintenance Manual Heavy for the engine type 1. Inspect the engine for damage. If any damage is detected, inspect, repair or overhaul the whole engine in accordance with the relevant Manual.

  • Page 76: Checking Of The Overload Clutch

    BRP-Rotax MAINTENANCE MANUAL LINE CHECKING OF THE OVERLOAD CLUTCH General note In the event of lead deposits and/or if slipping is suspected, it will be necessary to check the overload clutch. NOTE Slipping of overload clutch is apparent if at engine speed rise, the propeller speed does not increase at the same rate.
  • Page 77 BRP-Rotax MAINTENANCE MANUAL LINE specially prepared lever torque wrench propeller ange support of specially prepared lever 10202 Figure 5.10: Front view TYPICAL torque wrench propeller ange specially pre- adapter plate pared lever support of specially prepared lever 10201 Figure 5.11: Side view TYPICAL...
  • Page 78 Compare the measured value with the limits. If the value is greater or smaller than the limit values, the overload clutch must be inspected, repaired or overhauled in accordance with the BRP-Ro- tax instructions for continued airworthiness. Breakaway torque...

  • Page 79: Examination After Engine Failure

    BRP-Rotax MAINTENANCE MANUAL LINE EXAMINATION AFTER ENGINE FAILURE General note In order to find possible causes of the failure, it is important to pass on all available data. Observations on the aircraft and the engine suspension can also be of help. It is important to pay particular attention to any of the following engine phenomena to facilitate troubleshooting.
  • Page 80 The entire assembly must be dismantled, inspected and repaired. • The whole engine must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. • Inspect all systems for correct functioning. • Detailed inspection of affected engine components.

  • Page 81: Returning Engine To Service After Submerging In Water

    The engine must be marked clearly “Engine submerged in water“. Define if it was fresh water or salt water. An engine which has been submerged in water must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. See current Maintenance Manual of the respective engine type. Inspection •...

  • Page 82: Inspection In Extreme Climatic Conditions

    RETURNING ENGINE TO SERVICE AFTER INFLUENCE BY FIRE General note An engine after influence by fire must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. Inspection • Inspect all systems for correct functioning. NOTE Prior to the detailed inspection, all parts should be cleaned and inspected for burn penetration or melted materials.
  • Page 83 If the speed of 6500 rpm was exceeded. Step Procedure The whole engine must be inspected, repaired or overhauled in accord- ance with the BRP-Rotax instructions for continued airworthiness. Check cylinder differential pressure. Check that the push-rods are straight. Check if piston had contact with valve.

  • Page 84: Exceeding Of Max. Cooling System Temperature

    BRP-Rotax MAINTENANCE MANUAL LINE EXCEEDING OF MAX. COOLING SYSTEM TEMPERATURE General note See SB-912-068, latest issue. ATTENTION If the maximum cooling system temperature is exceeded, other limits are also often exceeded, e.g. oil temperature. Please observe the relevant instructions. NOTE Any exceeding of the max.
  • Page 85 Procedure Step The whole cooling system must be inspected, repaired or overhauled in ac- cordance with the BRP-Rotax instructions for continued airworthiness. Inspect all further systems for correct functioning. Carry out detailed inspection of the affected engine components such as: •...
  • Page 86 BRP-Rotax MAINTENANCE MANUAL LINE Exceeding of max. coolant temperature All engines affected with serial number with Suffix –01. General note See SB-912-068, latest issue. ATTENTION If the maximum coolant temperature is exceeded, other limits are also often ex- ceeded, e.g. oil temperature. Please observe the relevant instructions.
  • Page 87 Step Procedure The whole cooling system must be inspected, repaired or overhauled in ac- cordance with the BRP-Rotax instructions for continued airworthiness. Inspect all further systems for correct functioning. Carry out detailed inspection of the affected engine components such as: •...

  • Page 88: Non Compliance With The Coolant Specification

    BRP-Rotax MAINTENANCE MANUAL LINE NON COMPLIANCE WITH THE COOLANT SPECIFICATION General note ATTENTION Use only coolant as recommended in the current Operators Manual Non compliance with the coolant specification Step Procedure When a different coolant than the former one (conventional coolant) used, then the coolant system has to be flushed.

  • Page 89: Exceeding The Max. Permissible Oil Temperature

    Procedure The whole oil system must be inspected, repaired or overhauled in accord- ance with the BRP-Rotax instructions for continued airworthiness. Inspect oil level in the oil tank. Inspect oil cooler for contamination and check the entire oil circuit for cor- rect functioning.

  • Page 90: Oil Pressure Below Minimum Value

    Step Procedure The whole oil system must be inspected, repaired or overhauled in accord- ance with the BRP-Rotax instructions for continued airworthiness. Inspect all further systems for correct functioning. Carry out detailed inspection of the affected engine components. The whole oil system (oil cooler, oil lines) must be inspected.
  • Page 91 BRP-Rotax MAINTENANCE MANUAL LINE Operating limit Proceed as instructed (See Operators Manual 912 Series) 0.5 bar in table 5 (7.3 psi) Proceed as instructed in table 6 1 min. Time Figure 5.15 Oil pressure below minimum oil pressure on the ground If noticed on ground, immediately stop the engine and determine the cause.
  • Page 92 If after the previous checks and oil change the oil pressure is still too low, repair or overhaul the engine in accordance with the BRP-Rotax instruc- tions for continued airworthiness. Inspect all systems for correct functioning.

  • Page 93: Oil Specification Not Respected

    BRP-Rotax MAINTENANCE MANUAL LINE OIL SPECIFICATION NOT RESPECTED General note NOTE An entry by the pilot in the engine log book of all pertinent details is required. If by error engine was serviced with oil, which does not correspond with oil specification in...
  • Page 94 Procedure Remove propeller gearbox. The gearbox must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. Carry out detailed inspection of the affected engine components. Oil change. Remove the lowest positioned banjo screw (banjo bolt, plug screw or screw socket) and drain the remaining oil from the crankcase.

  • Page 95: Spark Plug Not In Accordance With Specification

    If parts are damaged, the engine must be inspected, re- paired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. Inspect all systems for correct function.

  • Page 96: Non Compliance Of Fuel Quality

    BRP-Rotax MAINTENANCE MANUAL LINE NON COMPLIANCE OF FUEL QUALITY General note The use of unsuitable fuel quality has to be entered in the engine log book. Independent of subsequent following inspections are required: Non compliance with fuel quality Step Procedure Visual inspection of engine.

  • Page 97: Lightning Strike

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.17: Inspection of smooth performance TYPICAL NOTE Always use protection of propeller edge when doing this test. LIGHTNING STRIKE General note An indirect lighting strike is a strike on the aircraft fuselage, the wings or propeller. A direct lighting strike is a strike which acts directly on the engine.

  • Page 98: Reporting

    BRP-Rotax MAINTENANCE MANUAL LINE Heat damage due to indirect lightning strike: Detailed findings will need to be obtained for affected components. Always replace com- ponents if visible signs of damage are evident or if you are in any doubt. Electrical and magnetic damage due to indirect lightning strike: Detailed findings will need to be obtained for affected components.
  • Page 99 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.18: Form Effectivity: 912 Series 05–50–00 Rev. Page 35 January 01 2020...
  • Page 100 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 36 Effectivity: 912 Series January 01 2020...
  • Page 101 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 12–00–00 MAINTENANCE OF THE SYSTEMS TOPICS IN THIS CHAPTER Introduction The section “Maintenance of the systems“ is associated with other sections. It serves only as a supplement to and further explanation of the maintenance check list (See Chapter 05-20-00).
  • Page 102 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 912 Series January 01 2020...
  • Page 103 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 12–10–00 REPLENISHING OPERATING FLUIDS TOPICS IN THIS CHAPTER Servicing points on the engine ........................2 Fluid capacities ............................3 Cooling system ............................4 Coolant check/replenish.........................4 Lubrication system..........................7 Oil level check/Replenish ........................7 Introduction The engine should always be in a horizontal position before checking the fill levels.

  • Page 104: Servicing Points On The Engine

    BRP-Rotax MAINTENANCE MANUAL LINE SERVICING POINTS ON THE ENGINE Overview AE_912_0086 Figure 6.1 Expansion tank Radiator cap Oil filter Oil tank Oil tank cover, without venting Oil dipstick 12–10–00 Effectivity: 912 Series Rev. 0 Page 2 January 01 2020...

  • Page 105: Fluid Capacities

    3.0 l (0.8 US gal.). NOTE BRP-Rotax can give an approx value on the fill capacity depending on aircraft de- sign and positions of radiators and tanks. The volume may differ from this value. Always check the relevant specifications provided by the aircraft manufacturer.

  • Page 106: Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE COOLING SYSTEM General note m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. m WARNING Risk of Burns! Never open the radiator cap when the cooling system is hot. For safety’s sake, cover cap with a rag and open slowly.
  • Page 107 BRP-Rotax MAINTENANCE MANUAL LINE Instruction To refill the coolant the following steps are necessary. Step Procedure Open the radiator cap (1) on the expansion tank (2). Check the coolant level. The coolant level must be filled up to the top (see Sketch).
  • Page 108 BRP-Rotax MAINTENANCE MANUAL LINE Engine test run Engine test run is necessary: Step Procedure Operate the engine until the temperatures have stabilized for a period of 5 min. (engine oil temperature between 50 to 70 °C (122 - 160 °F).

  • Page 109: Lubrication System

    BRP-Rotax MAINTENANCE MANUAL LINE LUBRICATION SYSTEM General note m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. m WARNING Risk of electric shock! Ignition “OFF” and system grounded! Disconnect negative terminal of battery.
  • Page 110 BRP-Rotax MAINTENANCE MANUAL LINE ATTENTION For longer flights replenish oil to max. mark to warrant more oil reserve. ATTENTION Only use brand name oil in accordance with the latest Operators Manual and the latest Service Instruction “Selection of suitable operating fluids“ of the respec- tive engine type.
  • Page 111 BRP-Rotax MAINTENANCE MANUAL LINE Engine test run An engine test run is necessary: Step Procedure Check the oil level and top up with oil as required. Operate the engine until the temperatures have stabilized for a period of 5 min. (engine oil temperature between 50 to 70 °C (122 - 160 °F).
  • Page 112 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 10 Effectivity: 912 Series January 01 2020...
  • Page 113 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 12–20–00 SCHEDULED MAINTENANCE TOPICS IN THIS CHAPTER Engine cleaning............................3 Visual inspection .............................4 Checking the engine suspension ......................4 Corrosion..............................4 Leakage check............................5 Differential pressure check........................7 Compression check for fault-tracing ......................8 Locking/Loosening of the crankshaft ....................10 Test run of engine..........................12 Checking the V-belt tension........................14...
  • Page 114 BRP-Rotax MAINTENANCE MANUAL LINE Flushing the oil circuit ..........................51 Inspecting the magnetic plug ........................53 Installation of the magnetic plug......................54 Electric system............................55 Check of wiring............................56 Replacement of spark plugs .........................57 Remove the spark plugs ........................57 Inspection of spark plugs........................57 Installation of spark plug ........................58 Propeller gearbox ..........................60...

  • Page 115: Engine Cleaning

    BRP-Rotax MAINTENANCE MANUAL LINE ENGINE CLEANING General note ENVIRONMENTAL NOTE When cleaning the engine, the dissolved residues of fuel, oil and other environ- ment-contaminating agents are rinsed off. Collect the residual liquids and dispose of them in an environmentally sound way.

  • Page 116: Visual Inspection

    BRP-Rotax MAINTENANCE MANUAL LINE VISUAL INSPECTION General note General visual inspection of the engine for damage or abnormalities. For definition and scope of visual inspection. See Chapter 05-20-00 section Visual inspection. Abnormalities Take note of changes caused by temperature influence.

  • Page 117: Leakage Check

    BRP-Rotax MAINTENANCE MANUAL LINE LEAKAGE CHECK General note ATTENTION Leaking connections can lead to engine problems or engine failure! Visual inspection of the whole engine for leaks. If leaks are visible, locate the cause and remedy the fault. Water pump Checking water pump for leaks.
  • Page 118 BRP-Rotax MAINTENANCE MANUAL LINE AE 2_0090 Figure 7.1: Connections and fuel lines Fuel lines (steel) Connections (fittings) Fuel pump Inspect fuel pump and isolating flange for leaks. For a period of 1 minute after shut down the engine must not drip oil out of the venting tube, In case of uncertainty determine the oil amount.

  • Page 119: Differential Pressure Check

    BRP-Rotax MAINTENANCE MANUAL LINE DIFFERENTIAL PRESSURE CHECK General note m WARNING Risk of electric shock! Ignition “OFF” and system grounded! Figure 7.2: Differential pressure check. TYPICAL Adaptor Manometer/Test gauges set Orifice jet Compressor Special tools To measure the differential pressure the following special tools and equipment are necessary.

  • Page 120: Compression Check For Fault-Tracing

    If the value is over 25% inspection, repair or overhaul must be carried out in accordance with the BRP-Rotax instructions for continued airworthiness. • Detailed inspection of affected engine components. COMPRESSION CHECK FOR FAULT-TRACING General note...
  • Page 121 Individual readings for the cylinder must not differ by more than 2 bar (29 psi). If the value is below 6 bar (87 psi), inspection, repair or overhaul must be carried out in ac- cordance with the BRP-Rotax instructions for continued airworthiness • Detailed inspection of affected engine components.

  • Page 122: Locking/Loosening Of The Crankshaft

    BRP-Rotax MAINTENANCE MANUAL LINE LOCKING/LOOSENING OF THE CRANKSHAFT Locking of the crankshaft m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. Special tool Do not use a substitute part (such a bolt) it may bend and damage crankcase.
  • Page 123 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.5: Locking/Loosen of the crankshaft. Allen screw M8x20 Thread bolt Trigger boss Trigger coils Crankshaft Hex.screw M16x1.5x40 Loosen of the After completion of work/check: crankshaft Step Procedure Remove the thread bolt (2) and refit crankshaft Allen screw M8x20 (1) along with a new sealing ring with a dry torque of 15 Nm (133 in.lb).

  • Page 124: Test Run Of Engine

    BRP-Rotax MAINTENANCE MANUAL LINE TEST RUN OF ENGINE General note m WARNING Danger of life threatening injuries caused by the propeller, rotating and stressed parts of the engine! Always observe the engine from a safe place while it is running. Check that the cockpit is occupied by a competent operator.
  • Page 125 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure After full-load run, conduct a short cooling run to prevent formation of va- pour lock in cylinder heads. This is necessary to prevent steam locks in the cooling and fuel system after shut-down. Shut engine down.

  • Page 126: Checking The V-Belt Tension

    BRP-Rotax MAINTENANCE MANUAL LINE CHECKING THE V-BELT TENSION General note In the case of configurations with additional auxiliary generator, inspect attachment and V- belt tension. Checking the V- belt tension Figure 7.6: Checking the V-belt tension BELT TENSION ADJUSTMENT 00353 Figure 7.7: Overview...
  • Page 127 BRP-Rotax MAINTENANCE MANUAL LINE Belt tension To adjust the belt tension: Step Procedure Loosen the hex. screw (1) M10 and the two M8 allen screw (2) and (3). Press the alternator upwards and tighten allen screw (3). Then tighten hex. screw (1) M10 with tightening torque 40 Nm (30 ft.lb) and allen screw M8 (2) with tightening torque 22 Nm (16 ft.lb).

  • Page 128: Air Intake System

    BRP-Rotax MAINTENANCE MANUAL LINE AIR INTAKE SYSTEM CHECKING AIR INTAKE SYSTEM General note ATTENTION Blocked air filter. In the event of dust formation, clean air filter at correspondingly shorter intervals. If filter mat is damaged, replace air filter. ATTENTION A dirty filter insert will not only reduce the engine performance but might also promote premature wear of the engine.
  • Page 129 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Lightly tap and brush off surface dirt (A). Spray K&N filter cleaner onto filter surface and leave to soak for approx. 10 min. (B). Rinse air filter with low pressure water from inside to outside and let ele- ment dry naturally (C).

  • Page 130: Replacing The Dry Air Filter

    BRP-Rotax MAINTENANCE MANUAL LINE REPLACING THE DRY AIR FILTER General note Only use dry type air filters which are specified by the aircraft manufacturer and from ROTAX®. Figure 7.10: Air filter Safety wire Air filter Carburetor ATTENTION Each air filter must be secured by clamp attachment and a wire securing element.

  • Page 131: Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE COOLING SYSTEM 08532 Figure 7.11: Overview Expansion tank Radiator cap Water pump Coolant hose Effectivity: 912 Series 12–20–00 Rev. 0 Page 19 January 01 2020...

  • Page 132: Checking The Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE CHECKING THE COOLING SYSTEM General note See Figure Overview. m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. Coolant hoses Carry out visual inspection of all coolant hoses (1) for damage, leaks, hardening as a re- sult of heat and porosity.
  • Page 133 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.12: Replacing the coolant Allen screw M6x35 (stainless) Gasket ring Water pump Step Procedure Open the radiator cap on the expansion tank. Remove the bottom Allen screw (1) (with sealing ring (2) ) of water pump (3).

  • Page 134: Flushing The Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE FLUSHING THE COOLING SYSTEM General note m WARNING Risk of Burns! Never open the radiator cap when the cooling system is hot. For safety’s sake, cover cap with a rag and open slowly. Sudden opening of the cap could provoke the escape of boiling coolant and result in scalding.

  • Page 135: Expansion Tank, Radiator Cap

    BRP-Rotax MAINTENANCE MANUAL LINE EXPANSION TANK, RADIATOR CAP Figure 7.13: Expansion tank, radiator cap Pressure relief valve Return valve Pressure spring Rubber seal Opening pressure of the radiator cap Connection to overflow bottle Sealing surface Tube connections Sight glass General note To equalize pressure in the cooling system, an expansion tank is required.

  • Page 136: Overflow Bottle

    BRP-Rotax MAINTENANCE MANUAL LINE OVERFLOW BOTTLE General note Figure 7.14: Overflow bottle Venting bore Tab for the safety wire Hose connection Instruction Checking overflow bottle. Procedure Step Inspect the bottle for damage. Check the venting bore (1) in the screw cap.

  • Page 137: Fuel System

    BRP-Rotax MAINTENANCE MANUAL LINE FUEL SYSTEM CARBURETOR SYNCHRONIZATION Idle speed Checking the synchronization at idle speed For smooth idling, synchronization of the throttle valves is necessary. When synchroniz- ing, slacken both bowden cables (throttle lever lies close on the adjustment screw).

  • Page 138: Mechanical Synchronization

    BRP-Rotax MAINTENANCE MANUAL LINE MECHANICAL SYNCHRONIZATION General note m WARNING Non-compliance can result in serious injuries or death! Always observe the engine from a safe place while it is running. Check that the cockpit is occupied by a competent operator.

  • Page 139: Pneumatic Synchronization

    BRP-Rotax MAINTENANCE MANUAL LINE ATTENTION An idle speed which is too low can result in gearbox wear, and if the idle speed is too high, the engine is harder to start. Step Procedure Start the engine and verify the idle speed. If the idle speed is too high or too low, adjust accordingly with idle speed adjustment screw.
  • Page 140 BRP-Rotax MAINTENANCE MANUAL LINE NOTE Perform a mechanical synchronization before attempting a pneumatic synchronization. Special tool The two carburetors are adjusted to equal flow rate at idling with a suitable flow meter or vacuum gauge(s). Connection Possible connection methods. Option 1...
  • Page 141 BRP-Rotax MAINTENANCE MANUAL LINE Option 2 Step Procedure Remove one end of the compensating tube (2) and tube from the push on angular tube (5) after removing the two tension clamp (4). Using the push on angular tube (5) and compensating tube (2) install a flexi- ble rubber hose (6) leading to the vacuum gauge (1).
  • Page 142 BRP-Rotax MAINTENANCE MANUAL LINE Option 3 Step Procedure Remove hex. screw M6x6 from intake manifold and connect the vacuum gauge. Remove the compensation hose with attached resonator hose(connection between intake manifolds) and plug the fittings in the intake manifolds. After synchronization, tightened the screw M6x6 with LOCTITE 243.

  • Page 143: Idle Speed Check

    BRP-Rotax MAINTENANCE MANUAL LINE AE_912_0089 Figure 7.20: Option 4 Clamping pliers Tube Compensation tube Screw Hose nipple Sealing ring IDLE SPEED CHECK General note Before proceeding, secure the aircraft on the ground using wheel chocks and ropes. m WARNING Non-compliance can result in serious injuries or death! Secure the propeller region before test run watch it.

  • Page 144: Operating Range Check

    BRP-Rotax MAINTENANCE MANUAL LINE ATTENTION Also check for translucent, jelly-like contamination. Inspect for free passage. OPERATING RANGE CHECK General note Once the proper idling speed has been established, it is necessary to check the operating range above the idle speed.
  • Page 145 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Equal adjustment must be made on both carburetors. Any major adjustments required necessitate replaced verification of all pa- rameters mentioned in this procedure. Assembly ATTENTION Obey the manufacturers instructions! • Install compensation tube assy. on engine in reverse sequence of removal. Any minor differences in balance at idle speed will be compensated for.

  • Page 146: Checking Of The Float Chamber

    BRP-Rotax MAINTENANCE MANUAL LINE CHECKING OF THE FLOAT CHAMBER General note m WARNING Danger of severe burns and scalds! Always allow the engine to cool down to am- bient temperature before starting any work. Instruction To check of the float chamber the following steps are necessary. See Figure: Float chamber.

  • Page 147: Check The Weight Of Floats

    BRP-Rotax MAINTENANCE MANUAL LINE CHECK THE WEIGHT OF FLOATS The weight inspection shows whether the affected floats have absorbed fuel. This is only significant if the floats already had contact with fuel. NOTE This check is not relevant for new spare parts, that were not in contact with fuel.
  • Page 148 BRP-Rotax MAINTENANCE MANUAL LINE AE_912_0092 Figure 7.22: Float chamber Drip tray Spring clip Float chamber Gasket Float 12–20–00 Effectivity: 912 Series Rev. 0 Page 36 January 01 2020...

  • Page 149: Idle Speed Adjustment

    BRP-Rotax MAINTENANCE MANUAL LINE IDLE SPEED ADJUSTMENT General note ATTENTION IF satisfactory idle speed adjustment cannot be achieved, inspection of the idle jet or additional pneumatic synchronization will be necessary. See Chapter 12-20-00 section Pneumatic synchronization. Idle adjustment Always carry out idle speed adjustment when the engine is warm.

  • Page 150: Checking The Carburetor Actuation

    BRP-Rotax MAINTENANCE MANUAL LINE CHECKING THE CARBURETOR ACTUATION General note Route bowden cables in such a way that carburetor actuation will not be influenced by any movement of engine or airframe, thus possibly falsifying idle speed setting and synchronization. NOTE Each carburetor is actuated by two bowden cables.

  • Page 151: Leak Tests

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.23: Checking the carburetor actuation Connection for throttle valve Connection for throttle valve Return spring LEAK TESTS General note ATTENTION Avoid over-tightening the fasteners. Use a suitable torque wrench for all work. Instruction To check the following steps are necessary:...

  • Page 152: Lubrication

    BRP-Rotax MAINTENANCE MANUAL LINE LUBRICATION Overview 08238 Figure 7.24 Figure 7.25 Oil tank Drain screw M12x12 Oil radiator Oil filter 12–20–00 Effectivity: 912 Series Rev. 0 Page 40 January 01 2020...
  • Page 153 BRP-Rotax MAINTENANCE MANUAL LINE m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work. m WARNING Risk of electric shock! Ignition “OFF” and system grounded! Disconnect negative terminal of battery.

  • Page 154: Oil Change

    BRP-Rotax MAINTENANCE MANUAL LINE OIL CHANGE Instruction NOTE Run engine to warm oil before beginning oil change procedure. To change the oil the following steps are necessary: Procedure Step Crank engine slowly by hand to transfer the oil from the crankcase.

  • Page 155: Oil Filter Replacement

    BRP-Rotax MAINTENANCE MANUAL LINE ATTENTION Only use brand name oil in accordance with the latest Operators Manual and the latest Service Instruction “Selection of suitable operating fluids“ of the respec- tive engine type. ATTENTION The engine must not be cranked when the oil system is open. Attention must also be paid to this before first commissioning (e.g.
  • Page 156 BRP-Rotax MAINTENANCE MANUAL LINE ATTENTION To ensure correct functioning of the oil circuit and the forced flow lubrication, use ORIGINAL ROTAX® oil filter only. Only these filters will ensure correct pres- sure in the by-pass valve. At every oil change, unscrew the oil filter and cut open using special tool taking care not to produce chips.

  • Page 157: Inspecting Of The Oil Filter Components

    If an increased amount of metal particles is found, such as brass- or bronze chips or sliver matter from bearing abrasion, repair or overhaul the engine in accordance with the BRP-Rotax in- structions for continued airworthiness. If the filter mat is clogged by foreign matter, the lube oil reaches the bearing points unfiltered via the by-pass valve in the oil filter.
  • Page 158 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Engine test run. See chap. 12-20-00 section: Test run of engine. Inspect the oil filter once more. Contaminated ATTENTION If the oil circuit is contaminated, replace the oil cooler and flush the oil circuit.
  • Page 159 BRP-Rotax MAINTENANCE MANUAL LINE to bearings from oil pump AE_912i_0092 Figure 7.27: Oil filter Filter housing Filter cover Gasket ring Anti-drain membrane Filter matt Effectivity: 912 Series 12–20–00 Rev. 0 Page 47 January 01 2020...

  • Page 160: Installing New Oil Filter

    BRP-Rotax MAINTENANCE MANUAL LINE INSTALLING NEW OIL FILTER Procedure To mount the oil filter the following steps are necessary: Step Procedure Clean the contact surface (1) of the oil pump housing (2) with a clean cloth. Apply thin film engine oil on the gasket (3) of the oil filter (4).

  • Page 161: Cleaning The Oil Tank

    BRP-Rotax MAINTENANCE MANUAL LINE CLEANING THE OIL TANK General note NOTE This procedure is optional and requires purging of the oil system. See Chapter 12–20–00 section Purging the oil system. If using leaded fuel it is required to clean the tank every 200 flight hours. It is only necessary to clean the oil tank and the inner parts if there is heavy oil contamination.
  • Page 162 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.29: Oil tank Profile clamp Hex. screw M12x12 Oil tank cover assy. Metric/ AN O-ring Baffle insert (screen) Partition Gasket ring 12x18 Oil tank Safety wire 12–20–00 Effectivity: 912 Series Rev. 0 Page 50 January 01 2020...

  • Page 163: Purging The Oil System

    BRP-Rotax MAINTENANCE MANUAL LINE PURGING THE OIL SYSTEM General note ATTENTION Purging of the oil system is extremely important for operation and service life of the engine and therefore the procedure must be followed meticulously. See Installation Manual for the engine type 912 Series Chapter 79-00-00 section Purging the lubrication system.
  • Page 164 BRP-Rotax MAINTENANCE MANUAL LINE ATTENTION The oil level in the tank must not drop below the end of suction pipe, otherwise air will be sucked in again. Step Procedure Turn engine by hand in direction of engine rotation to return the oil from the oil from the oil tank into the engine and into the collection container.

  • Page 165: Inspecting The Magnetic Plug

    Steel chips in If there are larger accumulations of metal chips on the magnetic plug, the engine must be larger numbers repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. Unclear findings In the case of unclear findings:...

  • Page 166: Installation Of The Magnetic Plug

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.30: Magnetic plug INSTALLATION OF THE MAGNETIC PLUG Install The following steps are necessary: Step Procedure Clean the magnetic plug. Install the magnetic plug. Tightening torque 25 Nm (18 ft lb.) Secure with safety wire.

  • Page 167: Electric System

    BRP-Rotax MAINTENANCE MANUAL LINE ELECTRIC SYSTEM AE_912_0091 Figure 7.31: Overview Spark plug connectors Dual ignition coil Ignition cable Electronic module Plug connectors Grounding cable Protection hose Effectivity: 912 Series 12–20–00 Rev. 0 Page 55 January 01 2020...

  • Page 168: Check Of Wiring

    BRP-Rotax MAINTENANCE MANUAL LINE CHECK OF WIRING General note m WARNING Risk of electric shock! Ignition “OFF” and system grounded! Disconnect negative terminal of battery. m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work.

  • Page 169: Replacement Of Spark Plugs

    BRP-Rotax MAINTENANCE MANUAL LINE REPLACEMENT OF SPARK PLUGS General note ATTENTION Use of incorrect spark plugs can result in ignition problems and pre-ignition and consequent engine damage. In numerous tests the best possible heat range has been determined to make sure that the spark plug will burn off deposits but will not overheat.

  • Page 170: Installation Of Spark Plug

    BRP-Rotax MAINTENANCE MANUAL LINE Spark plug face Information oily, glossy coating Possibly indicates one or more of the following: • damaged valve stem seal • misfiring • too much oil in combustion chamber • worn cylinder and piston rings white with formation...
  • Page 171 BRP-Rotax MAINTENANCE MANUAL LINE Before every installation, the spark plug thread and the spark plug seat at the cylinder head should be cleaned (e.g. to remove residue of heat conduction compound). Installation ATTENTION Always replace both spark plugs of a cylinder and do not interchange spark plugs between cylinders.

  • Page 172: Propeller Gearbox

    General note See Heavy Maintenance Manual Heavy for the engine type . The gearbox must be inspected, repaired or overhauled in accordance with the BRP-Ro- tax instructions for continued airworthiness. Detailed inspection of the affected gearbox components in accordance chapter 72-00-00 in the Heavy Maintenance Manual.
  • Page 173 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Attach a calibrated spring scale to the propeller in distance (L) from the cen- ter of the propeller. Measure the force required to pull the propeller through the 15 or 30 degree range of free rotation.
  • Page 174 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 62 Effectivity: 912 Series January 01 2020...
  • Page 175 BRP-Rotax MAINTENANCE MANUAL LINE Index Expansion tank ...........23 Extreme climatic conditions........18 Abbreviations............3 Acceptable methods, techniques and practice ..10 Accessories ............24 Air intake system..........16 Fluid capacities .............3 Airworthiness Limitations ........1 Flushing the cooling system .........22 Annual inspection..........7 Flushing the oil circuit ..........51 Authorized personnel ..........3...
  • Page 176 BRP-Rotax MAINTENANCE MANUAL LINE Non compliance — coolant specification ....24 Safety ..............9 Non compliance — fuel quality ......32 Safety information ..........10 Scheduled maintenance ........2 Scheduled maintenance checks ......1–2 Servicing points on the engine........2 Smooth performance of the engine .......32 Oil change ............42...
  • Page 177 Engine serial no. Type of aircraft Aircraft registration no. Rotax® authorized distributor FLYROTAX.COM ® and TM are trademarks of BRP-Rotax GmbH & Co KG. 2020 BRP-Rotax GmbH & Co KG. All rights reserved. ©...

This manual is also suitable for:

Rotax 912 aRotax 912 fRotax 912 sRotax 912 ulRotax 912 ulsRotax 912 ulsfr

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