Rotax MML-912 Maintenance Manual
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Rotax MML-912 Maintenance Manual

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MAINTENANCE MANUAL
FOR ROTAX® ENGINE TYPE 912 SERIES
(LINE MAINTENANCE)
Ref. No.: MML-912
ROTAX ® 912 ULS 3
WITH OPTIONS
part no.: 899735

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  • Page 1 �������� ������� MAINTENANCE MANUAL FOR ROTAX® ENGINE TYPE 912 SERIES (LINE MAINTENANCE) Ref. No.: MML-912 ROTAX ® 912 ULS 3 WITH OPTIONS part no.: 899735...
  • Page 2 BRP-Powertrain 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. Copyright 2009 © - all rights reserved. ROTAX is a trade mark of BRP-Powertrain GmbH&Co KG. In the following document the ®...
  • Page 3 If any passages of the Manual are not clearly understood or if you have questions, please contact an authorized Distribution or Service Center for ROTAX-aircraft engines. The structure of the Manual follows whenever it is applicable the struc- Chapter structure ture of the ATA (Air Transport Association) standards.
  • Page 4 BRP-Powertrain MAINTENANCE MANUAL NOTES INTRO Effectivity: 912 Series Edition 2 / Rev. 0 page 2 October 01/2009...
  • Page 5 BRP-Powertrain MAINTENANCE MANUAL Chapter: LEP LIST OF EFFECTIVE PAGES chapter page date chapter page date Title page 05-10-00 10 01 2009 INTRO 07 01 2010 10 01 2009 10 01 2009 10 01 2009 10 01 2009 07 01 2010 10 01 2009 07 01 2010 10 01 2009...
  • Page 6 BRP-Powertrain MAINTENANCE MANUAL chapter page date chapter page date 05-50-00 10 01 2009 10 01 2009 10 01 2009 10 01 2009 10 01 2009 10 01 2009 10 01 2009 10 01 2009 10 01 2009 10 01 2009 10 01 2009 10 01 2009 10 01 2009...
  • Page 7 BRP-Powertrain MAINTENANCE MANUAL Chapter: TOA TABLE OF AMENDMENTS *Approval The technical content of this document is approved under the authority of DOA No. EASA.21J.048. 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 8 BRP-Powertrain MAINTENANCE MANUAL NOTES Effectivity: 912 Series Edition 2 / Rev. 0 page 2 October 01/2009...

  • Page 9: Table Of Contents

    BRP-Powertrain MAINTENANCE MANUAL Chapter: 00-00-00 GENERAL NOTE This section describes this maintenance of engine type ROTAX 912 Introduction Series. NOTES: The ROTAX 912 Series includes all engines such as the 912 A, 912 F, 912 S, 912 UL, 912 ULS and 912 ULSFR.
  • Page 10 BRP-Powertrain MAINTENANCE MANUAL NOTES 00-00-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 2 October 01/2009...

  • Page 11: General Note

    Documentation operation, consult the documentation provided by the aircraft manufac- turer and/or dealer. For additional information on engines, maintenance or parts, you can also contact your nearest authorized ROTAX-aircraft engine distributor. ROTAX Authorized Distributors for Aircraft Engines. ROTAX Distributors See latest Operators Manual or on the Internet at the official Homepage www.rotax-aircraft-engines.com.
  • Page 12 BRP-Powertrain MAINTENANCE MANUAL NOTES 00-00-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 4 October 01/2009...

  • Page 13: Abbreviations And Terms Used In This Manual

    BRP-Powertrain MAINTENANCE MANUAL 2) Abbreviations and terms used in this Manual Abbreviations Abbreviation Description Reference to another section center of gravity The drop symbol indicates use of sealing agents, adhesives or lubricants. (only in the Illustrated Parts Catalog) °C Degrees Celsius (Centigrade) °F Degrees Fahrenheit Revolutions per minute...
  • Page 14 (only Illustrated Parts Catalog) n.a. not available non-destructive testing newton meter power supply unit Rev. Revision ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG Research Octane Number Record of Revisions s.v. still valid (only IPC) Serial Number Service Bulletin...

  • Page 15: Conversion Table

    BRP-Powertrain MAINTENANCE MANUAL 2.1) 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 1 PS = 0,7355 kW Units of area:...
  • Page 16 BRP-Powertrain MAINTENANCE MANUAL NOTES 00-00-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 8 October 01/2009...
  • Page 17 BRP-Powertrain MAINTENANCE MANUAL 3) Safety notice Although the reading of such information does not eliminate the hazard, General note understanding the information will promote its correct use. Always use common workshop safety practice. The information and components-/system descriptions contained in this Manual are correct at the time of publication.

  • Page 18: Safety Notice

    BRP-Powertrain MAINTENANCE MANUAL 3.1) Safety notice This information relates to the preparation and use of ROTAX aircraft General note engines and has been utilized safely and effectively by BRP-Powertrain. However, BRP-Powertrain disclaims liability for all damage and/or injuries resulting from the improper use of the contents. BRP-Powertrain strongly...
  • Page 19 BRP-Powertrain MAINTENANCE MANUAL Locking devices (e.g. locking tab, self-locking fasteners, etc.) must be Locking devices installed or replaced with new ones, where specified. If the efficiency of a locking device is impaired, it must be replaced. Torque wrench If not specified otherwise, the threads are not lubricat- NOTICE WARNUNG tightening...

  • Page 20: Instruction

    NOTICE WARNUNG by the engine manufacturer. This is only warranted by use of GENUINE ROTAX spare parts and/or accesso- ries (see IPC) or suitable equivalent in the manufactur- er’s opinion otherwise, any limited warranty by BRP- Powertrain is null and void (see Warranty Conditions).

  • Page 21: Maintenance Concept

    BRP-Powertrain MAINTENANCE MANUAL 3.3) Maintenance Concept The maintenance functions detailed in this Manual fall into two catego- General note ries: - Maintenance I (Line Maintenance) - Maintenance II (Heavy Maintenance) Repairs beyond the levels detailed in this Manual are not recommended as maintenance functions and must be done by an authorized overhaul facility.

  • Page 22: Technical Documentation

    The status of the Manuals can be determined with the aid of the table of Status amendments. The first column indicates the revision state. This figure should be compared with the revision provided on ROTAX-WebSite: www.rotax-aircraft-engines.com. Amendments and current versions can be downloaded free of charge.
  • Page 23 BRP-Powertrain MAINTENANCE MANUAL The illustrations in this Manual are mere sketches and show a typical Illustrations arrangement. They may not represent in full detail or the exact shape of the parts which have the same or similar function. Therefore deduction of dimensions or other details from illustrations is not permitted.

  • Page 24: Use For Intended Purpose

    Bursting off parts can cause serious injuries. Never run the engine without propeller. The engine ROTAX 912 A/F/S 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.
  • Page 25 This chapter 04-00-00 provides information about “Airworthiness Limita- Introduction tions“. - NONE Airworthiness Limitations For the ROTAX type engine 912 Series the airworthiness limitations are not applicable. NOTES: Regarding engine operating limitations see the relevant chapter “limits of operation“ in the relevant Operators Man- ual.
  • Page 26 BRP-Powertrain MAINTENANCE MANUAL NOTES 04-00-00 Effectivity: 912 Series EASA approved Edition 2 / Rev. 1 page 2 July 01/2010...
  • Page 27 In this chapter the maintenance of engine ROTAX 912 Series is Table of contents described. The description is subdivided into sections and description of function of the various systems.
  • Page 28 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-00-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 2 October 01/2009...

  • Page 29: Maintenance

    BRP-Powertrain MAINTENANCE MANUAL 1) Maintenance 1.1) General note Safety notice Non-compliance can result in serious injuries or death! WARNUNG WARNING Besides our instructions in the documentation sup- plied, also respect the generally valid safety and acci- dent preventive directives and legal regulations. The procedures and limits in this Manual constitute the manufacturers Procedures and limits...

  • Page 30: Authorized Personnel

    Suitable work environment to prevent contamination or damage to engine parts or modules. Suitable tools and fixtures as outlined in the ROTAX Maintenance Manual. Reasonable and prudent maintenance practices are utilized. And the Requirements of the applicable regulatory authority regarding mainte- nance procedures are met.

  • Page 31: Procedure Notes

    BRP-Powertrain MAINTENANCE MANUAL 1.3) Procedure notes General note Non-compliance can result in serious injuries or death! WARNUNG WARNING When carrying out maintenance and service work, re- spect without fail the safety regulations. Ignition “OFF“ Non-compliance can result in serious injuries or death! WARNUNG WARNING This precautionary measure serves to avoid any inju-...

  • Page 32: Trouble Shooting

    BRP-Powertrain MAINTENANCE MANUAL Tool In order to avoid mechanical damages, never loosen NOTICE WARNUNG or tighten screws and nuts with pliers but only with the specified tools. Safety wiring If during disassembling/reassembling the removal of a NOTICE WARNUNG safety item (e.g. safety wiring, self-locking fastener, etc.) should be necessary, it must be always replaced by a new one.

  • Page 33: Consumable Materials

    LOCTITE 222. If necessary contact the manufacturer con- cerning the comparability. In some cases information can be obtained from the local authorized distributors and ser- vice partners for ROTAX engines. NOTES: Respect the manufacturers instruction concerning the cur- ing time and the expire date of the particular surface seal- ing compound.
  • Page 34 BRP-Powertrain MAINTENANCE MANUAL part no. Description, Application Qty. 897870 Filter oil 14,8 ml (0.004 for optimum filter efficiency and protection gal (US)) against moisture 297368 SILASTIC 732, 310 ml (0.082 multi-purpose one-component silicon-based gal (US)) sealing compound 897186 SILICONE HEAT CONDUCTION COMPOUND 150 g (0.33 lb) Application of the heat conduction compound will reduce heat transfer resistance.
  • Page 35 BRP-Powertrain MAINTENANCE MANUAL part no. Description, Application Qty. n.a. Cleaning agents Use only approved cleaning NOTICE agents (e.g. kerosine, varsol, etc.) for cleaning all metal parts. Do not use lye-based cold cleaner or degreasing agents. Do not clean coolant or oil hoses with aggressive solutions.
  • Page 36 BRP-Powertrain MAINTENANCE MANUAL 1.6) Acceptable methods, techniques and practice All general inspection, maintenance and repair has to be carried out in General note accordance with Advisory Circular AC 43.13 from FAA. This Manual "Advisory Circular" AC describes maintenance methods, Advisory Circu- techniques and practice.
  • Page 37 BRP-Powertrain MAINTENANCE MANUAL Chapter: 05-10-00 TIME LIMITS These checks, related to limited periods of operation, are planned to help Introduction avoid engine troubles by the use of preventive maintenance. This chapter of the Maintenance Manual contains general information Table of contents regarding TBO and time limits on rubber components.
  • Page 38 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-10-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 2 October 01/2009...

  • Page 39: Definition Of Terms

    BRP-Powertrain MAINTENANCE MANUAL 1) Definition of terms 1.1) Operating hours All of the maintenance intervals, such as the 100 hr. inspection and the Definition engine TBO, relate to the number of operating hours of the engine. The operating hours are defined as follows in order to prevent misunder- standings and to ensure safety: - All time during which the engine is running is counted towards the total number of operating hours.

  • Page 40: General Overhaul (Tbo)

    BRP-Powertrain MAINTENANCE MANUAL 1.4) General overhaul (TBO) The time between overhauls (TBO) for all objects (such as the engine, Definition component assemblies, add-on components) is the approved length of operation under normal operating conditions before it becomes mandatory to send in these objects for an overhaul. Normal operating conditions are the conditions which comply with the manufacturer's and the aviation authority’s recommendations for the certi- fication of airworthiness.

  • Page 41: Time Limit

    After reaching this time limit, the engine has to be NOTICE WARNUNG this time limit shipped to an authorized ROTAX overhaul facility. For an overhaul, the engine must be removed from the aircraft, be cleaned, preserved and all openings to be closed to prevent entering of contaminants.
  • Page 42 BRP-Powertrain MAINTENANCE MANUAL Engine engine affected Type description engine S/N Time Between Overhaul 912 A up to and incl. 4,076.191 600 hr. or 10 years, whichever comes first 912 A from 4,076.192 up to and 1000 hr. or 10 years, incl.
  • Page 43 Extension or exceeding of the TBO by 5 % or 6 months is allowed which- Authorized ex- ceeding ever comes first. The shipment to an authorized ROTAX overhaul facility must include the Shipment following: Engine log book. Maintenance records of the engine (i.e. all maintenance check lists, and reports of operation, of maintenance, of findings and of oil analyses).

  • Page 44: Time Limit For Rubber Parts

    BRP-Powertrain MAINTENANCE MANUAL 2.1) Time limit for rubber parts General note This time limit must be followed independently and in NOTICE WARNUNG addition to the visual inspections (see chap. 05-20-00 section: 5.1)) of the respective components. The following components and systems must be replaced every 5 years: Time limit venting hose of the carburetors all rubber hoses of the cooling system...
  • Page 45 BRP-Powertrain MAINTENANCE MANUAL Chapter: 05-20-00 SCHEDULED MAINTENANCE CHECKS The owner and/or user is primarily responsible for the maintenance and Introduction airworthiness of the engine. This includes compliance with all applicable airworthiness directives. This inspection protocol is not intended to be all-inclusive, for no such protocol can replace the knowledge and experience of a certified aircraft mechanic.
  • Page 46 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 2 October 01/2009...
  • Page 47 BRP-Powertrain MAINTENANCE MANUAL 1) Scheduled maintenance checks This section lists the periodic inspections which must be carried out after Definition a specified periods of operation. Periodic inspections are those which must be performed at 50, 100, 200, Intervals 600 hr. intervals in accordance with chap. 05-20-00. section: 5.1).
  • Page 48 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 4 October 01/2009...
  • Page 49 BRP-Powertrain MAINTENANCE MANUAL 2) Unscheduled maintenance checks An inspection of the engine must be performed if the operating limits of Operating limits exceeded the engine have been exceeded (e.g. overspeed, excessive temperature etc.), or if unusual operating conditions have occurred during operation (e.g.
  • Page 50 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 6 October 01/2009...
  • Page 51 BRP-Powertrain MAINTENANCE MANUAL 3) Visual inspection The scope of a visual inspection generally includes, but is not necessarily General note limited to, the following. Normal operating condition, accurate alignment, leak-tightness, cleanli- Moving parts ness, ease of movement, adjustment, mechanical stress, travel, catching, extreme wear, cracks, corrosion, deformation and other visually evident damage.
  • Page 52 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 8 October 01/2009...
  • Page 53 BRP-Powertrain MAINTENANCE MANUAL 4) Maintenance schedule procedures (maintenance check list) All stated checks are visual inspections for damage and wear, unless oth- Inspections erwise stated. All listed work must be carried out within the specified period. Specified period Checks are carried out as per the maintenance check lists, where type Maintenance check lists and volume of maintenance work is outlined in key words.
  • Page 54 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 10 October 01/2009...
  • Page 55 BRP-Powertrain MAINTENANCE MANUAL 5) Check List/Maintenance Schedule Identification AIRCRAFT Registration number Aircraft make Aircraft model and S/N Time since new Propeller brand Propeller model and S/N ENGINE Engine type Engine S/N TSN (time since new) TSO (time since overhaul) Used operating fluids: coolant - mixture ratio fuel...
  • Page 56 BRP-Powertrain MAINTENANCE MANUAL Identification MAINTENANCE FACILITY Maintenance workshop Address Telephone/Fax/E-mail Certificate This check is applicable (circle 25 hr. 50 hr. 100 hr. 200 hr. 600 hr. Next check due at: __________________________________hr. (TS________) (engine hr.) 05-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 12 October 01/2009...
  • Page 57 BRP-Powertrain MAINTENANCE MANUAL 5.1) Maintenance Schedule Perform the following maintenance tasks at the intervals shown in the General note maintenance check list. See chapter 05-20-00 25 hr. check. Legend: do the task blank = no task required NOTES: If the points 1-3 in order to continue with the maintenance schedule.
  • Page 58 BRP-Powertrain MAINTENANCE MANUAL Interval Chapter Points of Inspection Signature Operating hours Reference 100 hr. indicated Inspect all oil lines for damage, leakage, hardening 12-20-00 from heat, porosity, security of connections and at- sec. 4) tachments. Verify routing is free of kinks and restric- tions.
  • Page 59 BRP-Powertrain MAINTENANCE MANUAL Interval Chapter Points of Inspection Signature Operating hours Reference 100 hr. indicated 8.) Checking the carburetors Checking the idle speed. 12-20-00 sec.10.3.1) Checking the ventilation of the float chambers. Any 200 hr. trouble with the float chamber ventilation impairs en- gine and carburetor function and must therefore be avoided.
  • Page 60 BRP-Powertrain MAINTENANCE MANUAL Interval Chapter Points of Inspection Signature Operating hours Reference 100 hr. indicated 12.) Flushing the cooling system Flushing the cooling system where conventional cool- when replacing 12-20-00 ants are used. the coolant sec. 9.3) 13.) Checking the propeller gear box Check the friction torque in free rotation on gearboxes 12-20-00 with overload clutch.
  • Page 61 BRP-Powertrain MAINTENANCE MANUAL Interval Chapter Points of Inspection Signature Operating hours Reference 100 hr. indicated 17.) Engine test run Observe the safety instructions! Start the engine and run to operating temperature. 12-20-00 Limits see Operators Manual 912 series. sec. 8) Ignition check at _____ rpm engine speed.
  • Page 62 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 18 October 01/2009...
  • Page 63 BRP-Powertrain MAINTENANCE MANUAL Chapter: 05-50-00 UNSCHEDULED MAINTENANCE CHECKS Introduction In the course of special checks specify if additional NOTICE WARNUNG checks for components (e.g. hydraulic governor) is ap- plicable. After each special check/repair work, an engine test run and a leakage check must be carried out. Observe without fail all the specified instructions.
  • Page 64 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-50-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 2 October 01/2009...

  • Page 65: Engine Check After Propeller Strike Incidents

    BRP-Powertrain MAINTENANCE MANUAL 1) Engine check after propeller strike incidents A propeller strike is: Definition - Any incident while the engine is stationary or running which makes it necessary to perform repairs on the propeller. See SL-912-015, SL-914-012, SL-2ST-009, current edition. 1.1) Propeller gearbox with integrated overload clutch After any propeller strike the following inspections must be performed...

  • Page 66: Propeller Gearbox Without Integrated Overload

    BRP-Powertrain MAINTENANCE MANUAL 1.2) Propeller gearbox without integrated overload clutch The following inspections must be performed before operation can con- Propeller strike tinue. Step Procedure Inspect the engine for damage. If any damage is detected, inspect, repair or overhaul the whole engine in accordance with the BRP-Powertrain in- structions for continued airworthiness.

  • Page 67: Checking Of The Overload Clutch

    BRP-Powertrain MAINTENANCE MANUAL 2) Checking of the overload clutch In the event of lead deposits and/or if slipping is suspected, it will be nec- General note essary to check the overload clutch. NOTES: Slipping of overload clutch is apparent if at engine speed rise, the propeller speed does not increase at the same rate.
  • Page 68 BRP-Powertrain MAINTENANCE MANUAL Repeat the measurement several times to get a stable value. Measurement The breakaway torque is calculated on the basis of the force (F) measured in N and the length of the lever arm (L) used at the normal distance from it in m (N x m = Nm).

  • Page 69: Examination After Engine Failure

    BRP-Powertrain MAINTENANCE MANUAL 3) Examination after engine failure In order to find possible causes of the failure, it is important to pass on all General note 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 70 BRP-Powertrain MAINTENANCE MANUAL Unintended engine stoppage by seizing part possible cause Camshaft bearings/Conrod bearings rather consequential damage wear (low oil pressure) The entire assembly must be dismantled, inspected and re- NOTICE paired. - The whole engine must be inspected, repaired or overhauled in accor- dance with the BRP-Powertrain instructions for continued airworthi- ness.

  • Page 71: Returning Engine To Service After Submerging

    Flying in areas with extreme climatic conditions or in extreme altitudes requires adjustment of the carburetor jetting and of the cooling system. To do this, it is necessary to contact the aircraft manufacturer and an autho- rized ROTAX distributor. Effectivity: 912 Series 05-50-00 Edition 2 / Rev.

  • Page 72: Exceeding Of Max. Admissible Engine Rpm

    BRP-Powertrain MAINTENANCE MANUAL 3.3) Exceeding of max. admissible engine RPM NOTES: Any exceeding of the max. admissible engine RPM must General note be entered by the pilot into the engine log book stating du- ration extent of overspeeding and pertinent detail. up to 6200 rpm If the limit was exceeded for max.

  • Page 73: Exceeding Of Max. Cylinder Head Temperature

    BRP-Powertrain MAINTENANCE MANUAL 3.4) Exceeding of max. cylinder head temperature General note If the maximum cylinder head temperature is exceed- NOTICE WARNUNG ed, other limits are also often exceeded, e.g. oil tem- perature. Please observe the relevant instructions. NOTES: Any exceeding of the max. admissible cylinder head tem- perature must be entered by the pilot into the engine log book, stating duration extent of excess temperature and pertinent detail.
  • Page 74 BRP-Powertrain MAINTENANCE MANUAL Table 2. Exceeded of over 180 °C Excess temperature of over 180 °C (356 °F) and/or for longer than 30 min. (356 °F) Step Procedure The whole cooling system must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthi- ness.

  • Page 75: Exceeding The Max. Permissible Oil Tempera

    BRP-Powertrain MAINTENANCE MANUAL 3.5) Exceeding the max. permissible oil temperature General note If the max. permissible oil temperature is exceeded, NOTICE WARNUNG other limits are often exceeded, too, e.g. the cylinder head temperature. Please observe the relevant in- structions. NOTES: Any exceeding of the max.
  • Page 76 BRP-Powertrain MAINTENANCE MANUAL Table 4. Exceeding over 160 °C (320 °F) Excess temperature over 160 °C (320 °F) for longer than 15 min. Step Procedure The whole engine must be inspected, repaired or overhauled in accor- dance with the BRP-Powertrain instructions for continued airworthiness. Inspect all further systems for correct functioning.

  • Page 77: Oil Pressure Below Minimum Value

    BRP-Powertrain MAINTENANCE MANUAL 3.6) Oil pressure below minimum value General note If the oil pressure falls below the minimum value, other NOTICE WARNUNG limits are often exceeded, e.g. the oil temperature. Please observe the relevant instructions. NOTES: Any exceeding of the min. admissible oil pressure must be entered by the pilot into the engine log book, stating dura- tion extent of excessive pressure and pertinent details.
  • Page 78 BRP-Powertrain MAINTENANCE MANUAL If the oil pressure falls below the minimum value up to max. 0,5 bar (7.25 Minimum oil pressure falls psi) and for max. 1 min., the cause must be determined. Table 5. below 0.5 bar Oil pressure below minimum permissible oil pressure up to max. 0.5 bar (7.25 psi) max.

  • Page 79: Oil Specification Not Respected

    BRP-Powertrain MAINTENANCE MANUAL 3.7) Oil specification not respected NOTES: An entry by the pilot in the engine log book of all pertinent General note details is required. If by error engine was serviced with oil, which does not correspond with oil specification in the Operators Manual and the engine has been in operation for less than 5 hours, the following measures must be taken: less than 5 hr.
  • Page 80 BRP-Powertrain MAINTENANCE MANUAL If the engine has been operated longer than 5 hours with engine oil not longer than 5 hr. corresponding with specification in the Operators Manual the following work is required. Oil specification not respected Step Procedure Remove propeller gearbox. The gearbox must be inspected, repaired or overhauled in accordance with the BRP-Powertrain instructions for continued airworthiness.

  • Page 81: Spark Plug Not In Accordance With Specification

    If by error any of the spark plugs were installed which are not according General note to specification of the engine manufacturer and/or not genuine ROTAX parts, the following verification will be necessary. Spark plug not in accordance with specification...

  • Page 82: Hard To Turn Over

    BRP-Powertrain MAINTENANCE MANUAL 3.9) Hard to turn over Fig. General note Risk of electric shock! WARNUNG WARNING Ignition “OFF“ and system grounded! Disconnect neg- ative terminal of aircraft battery. Carry out inspection only on cold engine and before 1 start. Inspection Engine runs sluggishly Step...

  • Page 83: Reporting

    ROTAX distributor. NOTES: The form is also available from the official ROTAX AIR- CRAFT ENGINES Homepage in electronic version. www.rotax-aircraft-engines.com Register: Document type/Diverses...
  • Page 84 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-50-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 22 October 01/2009...
  • Page 85 BRP-Powertrain MAINTENANCE MANUAL Form Effectivity: 912 Series 05-50-00 Edition 2 / Rev. 0 page 23 October 01/2009...
  • Page 86 BRP-Powertrain MAINTENANCE MANUAL NOTES 05-50-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 24 October 01/2009...
  • Page 87 BRP-Powertrain MAINTENANCE MANUAL Chapter: 12-00-00 MAINTENANCE OF THE SYSTEMS The section “Maintenance of the systems“ is associated with other sec- Introduction tions. It serves only as a supplement to and further explanation of the maintenance check list (See 05-20-00). NOTES: For reasons of clarity, only headlines and keywords are listed in the Maintenance Schedule.
  • Page 88 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-00-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 2 October 01/2009...
  • Page 89 BRP-Powertrain MAINTENANCE MANUAL Chapter: 12-10-00 REPLENISHING OPERATING FLUIDS The engine should always be in a horizontal position before checking the Introduction fill levels. This chapter covers the steps required to replenish all operating fluids on Table of contents the engine and also provides an overview of the fill capacities. Subject Page General note...
  • Page 90 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-10-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 2 October 01/2009...
  • Page 91 BRP-Powertrain MAINTENANCE MANUAL 1) General Servicing points on the engine Part Function Expansion tank Radiator cap Oil filter Oil tank Oil tank cover Oil dipstick Fig. 1 08522 Effectivity: 912 Series 12-10-00 Edition 2 / Rev. 0 page 3 October 01/2009...
  • Page 92 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-10-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 4 October 01/2009...

  • Page 93: General Note

    BRP-Powertrain MAINTENANCE MANUAL 2) Fluid capacities General note The operation of the engine may be adversely affected NOTICE WARNUNG if non-approved or contaminated fuel, oil or coolant are used. Any mixing of different manufacturers and types should be avoided. The use of additives may result in damage.
  • Page 94 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-10-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 6 October 01/2009...

  • Page 95: Cooling System

    BRP-Powertrain MAINTENANCE MANUAL 3) Cooling system 3.1) Coolant check/replenish General note Risk of Burns! WARNUNG WARNING Hot engine parts! Always allow engine to cool down to ambient temper- ature before start of any work. Risk of Burns! WARNUNG WARNING Never open the radiator cap when the cooling system is hot.
  • Page 96 BRP-Powertrain MAINTENANCE MANUAL Coolant check/replenish Graphic Part Function Radiator cap Expansion tank Fig. 2 08523 12-10-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 8 October 01/2009...

  • Page 97: Lubrication System

    BRP-Powertrain MAINTENANCE MANUAL 4) Lubrication system 4.1) Oil level check/Replenish General note Risk of Burns! WARNUNG WARNING Hot engine parts! Always allow engine to cool down to ambient tempera- ture before start of any work. Risk of electric shock! WARNUNG WARNING Ignition “OFF“...
  • Page 98 BRP-Powertrain MAINTENANCE MANUAL Engine test run is necessary: Engine test run 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). Switch the engine OFF. Allow the engine to cool down.
  • Page 99 BRP-Powertrain MAINTENANCE MANUAL Chapter: 12-20-00 SCHEDULED MAINTENANCE This chapter relates in particular to the maintenance work mentioned in Introduction the Maintenance Schedule for the various engine systems and covers the work in more detail. This chapter contains information which is required to perform scheduled Table of contents servicing on the engine.
  • Page 100 BRP-Powertrain MAINTENANCE MANUAL Subject Page Lubrication system page 47 Oil change page 49 Oil filter replacement page 50 Install oil filter page 51 Inspection of the oil filter insert page 52 Cleaning the oil tank page 54 Purging the oil system page 56 Inspecting the magnetic plug page 57...

  • Page 101: Engine Cleaning

    BRP-Powertrain MAINTENANCE MANUAL 1) Engine cleaning General note Do not use easily inflammable liquids or caustic clean- NOTICE WARNUNG ing agents for cleaning the engine. When cleaning the engine, the dissolved residues of NOTICE WARNUNG fuel, oil and other environment-contaminating agents are rinsed off.
  • Page 102 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 4 October 01/2009...

  • Page 103: Checking The Air Filter

    BRP-Powertrain MAINTENANCE MANUAL 2) Checking air filter General note In the event of dust formation, clean air filter at corre- NOTICE WARNUNG spondingly shorter intervals. If filter mat is damaged, replace air filter. A dirty filter insert will not only reduce the engine per- NOTICE WARNUNG formance but might also promote premature wear of...
  • Page 104 BRP-Powertrain MAINTENANCE MANUAL Cleaning of the filter Graphic Fig. 1 08525 After cleaning Never use gear oil, diesel or engine oil, as they attract NOTICE WARNUNG humidity. NOTES: Each filter pleat must be sprayed with oil. After 5 to 10 min. the filter will be soaked with oil, noticeable by the uniform red coloring.

  • Page 105: Replacing The Dry Air Filter

    Attach new air filter, free of grease, at connection fac- NOTICE WARNUNG es, and wire-secure against loss. Only use dry type air filters which are specified by the aircraft manufac- Graphic turer and from ROTAX. Part Function Air filter Safety wire Carburetor Fig.
  • Page 106 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 8 October 01/2009...

  • Page 107: Visual Inspection

    BRP-Powertrain MAINTENANCE MANUAL 3) Visual inspection General visual inspection of the engine for damage or abnormalities. For General note definition and scope of visual inspection (See chap. 05-20-00 section: 3). Take note of changes caused by temperature influence. Abnormalities During a visual inspection you should focus on the following points in par- ticular: - Exhaust system - Engine suspension frame...

  • Page 108: Corrosion

    BRP-Powertrain MAINTENANCE MANUAL 3.2) Corrosion Corrosion is a natural process which attacks and potentially damages met- Definition als via an electro-chemical reaction. For more detailed information about different types of corrosion and corresponding methods for dealing with corrosion refer to the FAA Advisory Circular AC 43.13. See chapter “AC 43.13-1B Maintenance and Repair“.

  • Page 109: Leakage Check

    BRP-Powertrain MAINTENANCE MANUAL 4) Leakage check General note Leaking connections can lead to engine problems or NOTICE WARNUNG engine failure! Visual inspection of the whole engine for leaks. If leaks are visible, locate the cause and remedy the fault. NOTES: If a leak is suspected, then the following check is possible: Instruction Step...
  • Page 110 BRP-Powertrain MAINTENANCE MANUAL Connections and fuel lines Graphic Part Functions Fuel lines (Steel) Connections (Fittings) Fig. 4 09034 Inspect isolating flange of fuel pump for leaks. Fuel pump Check coolant hoses and connections and fittings for leakage. Examine Coolant hoses the surrounding area to see if there are any leaks! Inspect all oil feed lines from the oil tank to the oil cooler and to the engine.

  • Page 111: Checking The Compression

    BRP-Powertrain MAINTENANCE MANUAL 5) Checking the compression Fig. General note Risk of electric shock! WARNUNG WARNING Ignition “OFF“ and system grounded! To measure the compression pressure the following special tools and Special tools equipment are necessary. Part number Description n.a. Compressed air approx.
  • Page 112 BRP-Powertrain MAINTENANCE MANUAL Checking the compression. Graphic Part Function Adaptor Manometer/Test gauges set Orifice jet Compressor Fig. 5 08529 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 14 October 01/2009...
  • Page 113 BRP-Powertrain MAINTENANCE MANUAL 5.1) Compression check for fault-tracing In the course of fault-tracing a compression check can also be per- General note formed. A compression tester is required to check compression. The compres- sion should be between 9 and 12 bar (130 and 174 psi). Compression check for fault-tracing.
  • Page 114 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 16 October 01/2009...

  • Page 115: Checking The V-Belt Tension

    BRP-Powertrain MAINTENANCE MANUAL 6) Checking the V-belt tension Fig. General note In the case of configurations with additional auxiliary generator, inspect attachment and V-belt tension. To adjust the belt tension: 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).
  • Page 116 BRP-Powertrain MAINTENANCE MANUAL Inspect V-belt tension as per drawing below. Checking the V- belt tension Fig. 8 00354 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 18 October 01/2009...

  • Page 117: Locking The Crankshaft

    BRP-Powertrain MAINTENANCE MANUAL 7) Locking the crankshaft Fig. General note NOTES: The thread bolt for crankshaft locking is part of the stan- dard tool kit supplied with each engine. Locking the Risk of Burns! WARNUNG WARNING crankshaft Hot engine parts! Always allow engine to cool down to ambient tempera- ture before start any work.
  • Page 118 BRP-Powertrain MAINTENANCE MANUAL Locking the crankshaft Graphic Part Function Plug screw M8x20 Thread bolt Trigger boss Trigger coils Crankshaft Hex. screw M16x1,5x40 Fig. 9 08530,08531 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 20 October 01/2009...

  • Page 119: Test Run Of Engine

    BRP-Powertrain MAINTENANCE MANUAL 8) Test run of engine General note Danger of life threatening injuries caused by the pro- WARNUNG WARNING peller, rotating and stressed parts of the engine! Always observe the engine from a safe place while it is running.
  • Page 120 BRP-Powertrain MAINTENANCE MANUAL Engine oil and Risk of Burns! WARNUNG WARNING coolant 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 121: Cooling System

    BRP-Powertrain MAINTENANCE MANUAL 9) Cooling system 9.1) Checking the cooling system Overview Part Function Coolant lines Water pump Expansion tank Radiator cap with gasket Fig. 10 08532 Effectivity: 912 Series 12-20-00 Edition 2 / Rev. 0 page 23 October 01/2009...

  • Page 122: Replacing The Coolant

    BRP-Powertrain MAINTENANCE MANUAL General note Risk of Burns! WARNUNG WARNING Hot engine parts! Always allow engine to cool down to ambient tempera- ture before start of any work. Fig. Carry out visual inspection of all coolant hoses (1) for damage, leaks, Coolant hoses hardening as a result of heat and porosity.
  • Page 123 BRP-Powertrain MAINTENANCE MANUAL Step Procedure If the coolant is being replaced with a different type, (conventional coolant, waterless coolant) the cooling system must be flushed. See chap. 12-20-00 section: 9.3). Refill newly mixed coolant into the expansion tank (highest point of the cooling system).

  • Page 124: Flushing The Cooling System

    BRP-Powertrain MAINTENANCE MANUAL 9.3) Flushing the cooling system General note Hot steam can cause scalds in the face and on hands! WARNUNG WARNING Never open the radiator cap when the cooling system is hot. For safety’s sake, cover cap with a rag and open slowly.

  • Page 125: Expansion Tank, Radiator Cap

    BRP-Powertrain MAINTENANCE MANUAL 9.4) Expansion tank, radiator cap Fig. General note To equalize pressure in the cooling system, an expansion tank is required. If the pressure in the system rises above 1.2 bar (17.4 psi) as the coolant warms up, the pressure relief valve (1) opens and the coolant can flow into the expansion tank via the line (5).
  • Page 126 BRP-Powertrain MAINTENANCE MANUAL Part Function Pressure spring Connection to overflow bottle Opening pressure of the radiator cap Sealing surface Tube connections Fig. 12 08534,07620 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 28 October 01/2009...

  • Page 127: Overflow Bottle

    BRP-Powertrain MAINTENANCE MANUAL 9.5) Overflow bottle Fig. General note Checking overflow bottle. Instruction Step Procedure Inspect the bottle for damage. Check the venting bore (1) in the screw cap (see Service Bulletin SB-912-039, “Modification of the overflow bottle“, latest issue). Inspect bracket (2) for the safety wire.
  • Page 128 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 30 October 01/2009...

  • Page 129: Fuel System

    BRP-Powertrain MAINTENANCE MANUAL 10) Fuel system 10.1) Carburetor synchronization Checking the synchronization at idle speed Idle speed Fig. For smooth idling, synchronization of the throttle valves is necessary. When synchronizing, slacken both bowden cables (throttle lever lies close on the adjustment screw). To synchronize when idling the following steps are necessary.

  • Page 130: Mechanical Synchronization

    BRP-Powertrain MAINTENANCE MANUAL 10.2) Mechanical synchronization Fig. General note Danger of life threatening injuries caused by the pro- WARNUNG WARNING peller, rotating and stressed parts of the engine! Always observe the engine from a safe place while it is running. For synchronous basic throttle adjustment proceed as follows.
  • Page 131 BRP-Powertrain MAINTENANCE MANUAL Step Procedure An idle speed which is too low can result in gearbox wear, NOTICE and if the idle speed is too high, the engine is harder to start. 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 (2).

  • Page 132: Pneumatic Synchronization

    BRP-Powertrain MAINTENANCE MANUAL 10.3) Pneumatic synchronization Fig. 16 to Fig. 19. General note Danger of life threatening injuries caused by the pro- WARNUNG WARNING peller, rotating and stressed parts of the engine! Always observe the engine from a safe place while it is running.
  • Page 133 BRP-Powertrain MAINTENANCE MANUAL Option 2 Step Procedure Remove one end of the compensating tube (2) and tube (3) 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 flexible rubber hose (6) leading to the vacuum gauge (1).
  • Page 134 BRP-Powertrain MAINTENANCE MANUAL Option 3 Step Procedure Remove hex. screw (1) M6x6 from intake manifold (2) and connect the vacuum gauge. Remove the compensating tube (3) with attached tubes (4) (connection be- tween intake manifolds) and plug the fittings in the intake manifolds. After synchronization tightened the screw M6x6 (1) with LOCTITE 221.
  • Page 135 BRP-Powertrain MAINTENANCE MANUAL Option 4 Step Procedure Install the vacuum gauge. Clamp the tube (2) with hose clamping pliers (1). Observe the position! The compensation tube (3) must not removed. Unscrew the screw (4). Install the hose nipple M6 (5) with the sealing ring (6). After synchronization tightened the screw M6x6 (4) with LOCTITE 221.

  • Page 136: Idle Speed Check

    BRP-Powertrain MAINTENANCE MANUAL 10.3.1) Idle speed check Before proceeding, secure the aircraft on the ground using wheel chocks General note and ropes. Risk of life threatening injuries caused by propeller! WARNUNG WARNING Secure the propeller region before test run watch it. Secure a safe area around propeller during test run.

  • Page 137: Operating Range Check

    BRP-Powertrain MAINTENANCE MANUAL 10.3.2) Operating range check Once the proper idling speed has been established, it is necessary to General note check the operating range above the idle speed. First establish that the engine is developing full take-off performance or take-off rpm when selected in the cockpit.
  • Page 138 BRP-Powertrain MAINTENANCE MANUAL Assembly Follow the instructions of the instrument manufacturer. NOTICE WARNUNG - Install compensation tube assy. on engine in reverse sequence of removal. Any minor differences in balance at idle speed will be compen- sated for. - Refit the screw plug M3.5 (3) and hex. screws M6x6 with gasket (pos. 1 Fig.

  • Page 139: Checking Of The Float Chamber

    BRP-Powertrain MAINTENANCE MANUAL 10.4) Checking of the float chamber Fig. General note Risk od Burns! WARNUNG WARNING Hot engine parts! Always allow engine to cool down to ambient tempera- ture before start of any work. To check of the float chamber the following steps are necessary: Instruction Step Procedure...
  • Page 140 BRP-Powertrain MAINTENANCE MANUAL Float chamber Graphic Part Function Drip tray Spring clip Float chamber Gasket Float Fig. 21 08653 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 42 October 01/2009...

  • Page 141: Idle Speed Adjustment

    BRP-Powertrain MAINTENANCE MANUAL 10.5) Idle speed adjustment Fig. General note If satisfactory idle speed adjustment cannot be NOTICE WARNUNG achieved, inspection of the idle jet or additional pneu- matic synchronization will be necessary. See chap. 12-20-00 section: 10.3). Always carry out idle speed adjustment when the engine is warm. Idle adjustment - Basic adjustment of the idle speed is first effected using the idle speed adjustment screw (2) of the throttle valve.

  • Page 142: Checking The Carburetor Actuation

    BRP-Powertrain MAINTENANCE MANUAL 10.6) Checking the carburetor actuation Fig. 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. NOTES: Each carburetor is actuated by two bowden cables.
  • Page 143 BRP-Powertrain MAINTENANCE MANUAL Checking the carburetor actuation Graphic Part Function Connection for throttle valve Connection for choke actuation Return springs Fig. 22 00352 Effectivity: 912 Series 12-20-00 Edition 2 / Rev. 0 page 45 October 01/2009...
  • Page 144 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 46 October 01/2009...
  • Page 145 BRP-Powertrain MAINTENANCE MANUAL 11) Lubrication 11.1) General Overview to oil pump back from engine Part Function Oil tank Drain screw M12x12 Oil cooler Oil filter Fig. 23 05448,08238 Effectivity: 912 Series 12-20-00 Edition 2 / Rev. 0 page 47 October 01/2009...
  • Page 146 BRP-Powertrain MAINTENANCE MANUAL For detailed information see SI-912-010 “oil change“, latest issue, and General note Fig. Risk of Burns! WARNUNG WARNING Hot engine parts! Always allow engine to cool down to ambient tempera- ture before start of any work. Risk of electric shock! WARNUNG WARNING Switch off ignition and remove key! Disconnect nega-...

  • Page 147: Oil Change

    BRP-Powertrain MAINTENANCE MANUAL 11.2) Oil change NOTES: Run engine to warm oil before beginning oil change pro- Procedure cedure. To change the oil the following steps are necessary: Step Procedure Crank engine by hand to transfer the oil from the crankcase. See chap.

  • Page 148: Oil Filter Replacement

    To ensure correct functioning of the oil circuit and the NOTICE WARNUNG forced flow lubrication, use genuine ROTAX oil filter only. Only these filters will ensure correct pressure 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 149: Install Oil Filter

    BRP-Powertrain MAINTENANCE MANUAL 11.4) Install oil filter Fig. General note After test run inspect tight fit of oil filter. NOTICE WARNUNG To mount the oil filter the following steps are necessary: Procedure 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 150: Inspection Of The Oil Filter Insert

    BRP-Powertrain MAINTENANCE MANUAL 11.5) Inspection of the filter insert General note The filter insert must be inspected carefully for metal NOTICE WARNUNG chips. This inspection is important as it allows conclusions to be drawn regarding the internal condition of the engine and provides information about the possible cause of any damage.
  • Page 151 BRP-Powertrain MAINTENANCE MANUAL Contaminated If the oil circuit is contaminated, replace the oil cooler NOTICE WARNUNG and flush the oil circuit. See chap. 12-20-00 section: 13). Proper judgement requires years of experience in repair of piston engines. Oil filter Graphic to bearings from oil pump Part...

  • Page 152: Cleaning The Oil Tank

    BRP-Powertrain MAINTENANCE MANUAL 11.6) Cleaning the oil tank Fig. NOTES: This procedure is optional and requires venting of the oil General note system. See chap. 12-20-00 section: 11.7). It is only necessary to clean the oil tank and the inner parts if there is heavy oil contamination.
  • Page 153 BRP-Powertrain MAINTENANCE MANUAL Cleaning the oil tank Graphic Part Function Drain screw Profile clamp Oil tank cover O-ring Baffle insert Partition Gasket ring Oil tank Fig. 27 05556 Effectivity: 912 Series 12-20-00 Edition 2 / Rev. 0 page 55 October 01/2009...

  • Page 154: Purging The Oil System

    BRP-Powertrain MAINTENANCE MANUAL 11.7) Purging the oil system General note Purging of the oil system is extremely important for op- NOTICE WARNUNG eration and service life of the engine and therefore the procedure must be followed meticulously. It must be carried out in accordance with SI-912-018,“Purging the lubrication system“, latest issue.

  • Page 155: Inspecting The Magnetic Plug

    BRP-Powertrain MAINTENANCE MANUAL 12) Inspecting the magnetic plug Fig. General note NOTES: The magnetic plug is located on the crankcase between cylinder 2 and gearbox. This inspection is important because it allows conclusions to be drawn on the internal condition of the gearbox and engine and reveals information about possible damage.

  • Page 156: Installation Of The Magnetic Plug

    BRP-Powertrain MAINTENANCE MANUAL Inspecting the magnetic plug. Graphic magnetic plug acceptable not acceptable Fig. 28 08565,08566,08564,08563 12.1) Installation of the magnetic plug The following steps are necessary: Install Step Procedure Clean the magnetic plug. Refit the magnetic plug. Tightening torque 25 Nm (18.5 ft.lb). Safety wire the plug.

  • Page 157: Flushing The Oil Circuit

    BRP-Powertrain MAINTENANCE MANUAL 13) Flushing the oil circuit General note Risk of electric shock! WARNUNG WARNING Switch off ignition and remove key! Disconnect nega- tive terminal of aircraft battery. Dismantle and flush oil lines as per instructions of the aircraft manufac- Oil lines turer.
  • Page 158 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 60 October 01/2009...

  • Page 159: Electric System

    BRP-Powertrain MAINTENANCE MANUAL 14) Electric system Overview Part Function Spark plug connectors Dual ignition coil Ignition cable Electronic module Plug connectors Grounding cable Protection hose Fig. 29 08552,08553 Effectivity: 912 Series 12-20-00 Edition 2 / Rev. 0 page 61 October 01/2009...

  • Page 160: Check Of Wiring

    BRP-Powertrain MAINTENANCE MANUAL 14.1) Check of wiring General note Risk of electric shock! WARNUNG WARNING Switch off ignition and remove key! Risk of Burns! WARNUNG WARNING Hot engine parts! Always allow engine to cool down to ambient tempera- ture before start of any work. The following steps have to be carried out: Procedure Step...

  • Page 161: Inspection And Replacement Of Spark Plugs

    BRP-Powertrain MAINTENANCE MANUAL 14.2) Inspection and replacement of spark plugs Fig. General note Use of incorrect spark plugs can result in ignition prob- NOTICE WARNUNG lems and pre-ignition and consequent engine damage. See chap. 05-50-00 section: 3.8). Because of the differing thermal load, particular spark plugs have been specified for each engine type.

  • Page 162: Inspection Of Spark Plugs

    BRP-Powertrain MAINTENANCE MANUAL 14.2.2) Inspection of spark plugs Check heat range and adjust electrode gap correspondingly. Heat range Inspect all spark plugs for mechanical damage. Visual check Electrode gap Electrode gap Wear limit 0,6 - 0,7 mm (0.023 - 0.027 in) 0,9 mm (0.035 in) NOTES: Inspect the electrode gap also on use of new spark plugs.

  • Page 163: Installation Of Spark Plug

    BRP-Powertrain MAINTENANCE MANUAL 14.2.3) Installation of spark plug Cleaning Eyes and skin irritation! WARNUNG WARNING Rinse off with water in the case of contact with eyes or skin. May be harmful if swallowed. Before every installation, the spark plug thread and the spark plug seat at the cylinder head should be cleaned (e.g.
  • Page 164 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 66 October 01/2009...

  • Page 165: Propeller Gearbox

    See calculation example. If the above mentioned friction torque is not achieved, in- NOTICE spect, repair or overhaul the gearbox in accordance with the ROTAX instructions for continued airworthiness. Remove crankshaft locking pin. See chap. 12-20-00 section: Effectivity: 912 Series 12-20-00 Edition 2 / Rev.
  • Page 166 BRP-Powertrain MAINTENANCE MANUAL Checking the friction torque. Graphic Fig. 31 05694 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 68 October 01/2009...

  • Page 167: Checking The Propeller Gearbox

    BRP-Powertrain MAINTENANCE MANUAL 15.2) Checking the propeller gearbox The gearbox must be inspected, repaired or overhauled in accordance General note with the BRP-Powertrain instructions for continued airworthiness. Detailed inspection of the affected gearbox components in accordance chap. 72-00-00 section: 3.9) in the Heavy Maintenance Manual. Crack testing of the propeller shaft is not normally planned, but can be carried out if cracks are suspected.
  • Page 168 BRP-Powertrain MAINTENANCE MANUAL NOTES 12-20-00 Effectivity: 912 Series Edition 2 / Rev. 0 page 70 October 01/2009...
  • Page 170 Motornummer / Engine serial no. Flugzeugtype / Type of aircraft Flugzeugkennzeichen / Aircraft registration no. ROTAX® Vertriebspartner ROTAX® authorized distributor www.rotax-aircraft-engines.com ® and TM are trademarks of BRP-Powertrain GmbH & Co KG. © 2009 BRP-Powertrain GmbH & Co KG. All rights reserved.

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