BRP Rotax 912 i Series Maintenance Manual
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BRP Rotax 912 i Series Maintenance Manual

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MAINTENANCE
MANUAL LINE
FOR ROTAX ENGINE TYPE 912 i SERIES
REF NO.: MML-912 i | PART NO.: 898743

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  • Page 1 MAINTENANCE MANUAL LINE FOR ROTAX ENGINE TYPE 912 i SERIES REF NO.: MML-912 i | PART NO.: 898743...
  • Page 2 Rotax 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 i Series May 01/2023...
  • 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 i Series May 01/2023...
  • 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. page page chapter date chapter date Cover May 01 2023 page 04-00-00 May 01 2023...
  • Page 8 BRP-Rotax MAINTENANCE MANUAL LINE page page chapter date chapter date May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023...
  • Page 9 BRP-Rotax MAINTENANCE MANUAL LINE page page chapter date chapter date May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023...
  • Page 10 BRP-Rotax MAINTENANCE MANUAL LINE page page chapter date chapter date May 01 2023 May 01 2023 May 01 2023 May 01 2023 May 01 2023 Index Back page Effectivity: 912 i Series Edition 2/Rev. 2 Page 4 May 01/2023...
  • 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 the DOA ref. 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 12 BRP-Rotax MAINTENANCE MANUAL LINE Cur- Chapter Page Date of change Remark Date of Date of Signature rent approval inclusion approval from authori- ties 00-00-00 Febr. 01 2023 DOA* 05-00-00 2,3,4,8- Febr. 01 2023 DOA* 05-10-00 2,4-6 Febr. 01 2023 DOA*...
  • Page 13 BRP-Rotax MAINTENANCE MANUAL LINE Summary of amendments Summary of the relevant amendments in this context, but without requirement on completeness. page comment chapter date of change 00-00-00 Febr. 01 2023 new text 05-00-00 2,3,4,8-12 Febr. 01 2023 text change, PU- glue deleted, new...
  • Page 14 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 4 Effectivity: 912 i Series May 01/2023...

  • Page 15: 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 ..........................8 Conversion table ...........................9 Safety notice ............................10 Safety information ..........................11 Instruction............................13 Maintenance Concept..........................14 Technical documentation........................15 Use for intended purpose ........................17...

  • Page 16: General

    BRP-Rotax MAINTENANCE MANUAL LINE GENERAL In this Manual all ROTAX® 912 i Series engines are described. NOTE ROTAX® 912 i Series includes 912 iS, 912 iS Sport and 912 iSc Sport. Purpose The purpose of this Manual is to provide aircraft manufacturers with technical require- ments (e.g.

  • Page 17: 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 Maintenance Manual Heavy) °C Degrees Celsius (Centigrade) °F...
  • Page 18 BRP-Rotax MAINTENANCE MANUAL LINE Abbreviations Description clockwise counter-clockwise 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 Introduction...
  • Page 19 BRP-Rotax MAINTENANCE MANUAL LINE Abbreviations Description Illustrated Parts Catalog inch per second iRMT independent ROTAX Maintenance Technician International Standard Atmosphere Kilograms KNOCK Knock sensor Lane A System A of Engine Management System Lane B System B of Engine Management System...
  • Page 20 MAINTENANCE MANUAL LINE Abbreviations Description Power Take Off Rev. Revision ROTAX® is a trademark of BRP-Rotax GmbH & Co KG Research Octane Number RON 424 ROTAX® Standard 424 s.v. still valid (only Illustrated Parts Catalog) Serial Number Society of Automotive Engineers...
  • Page 21 BRP-Rotax MAINTENANCE MANUAL LINE Abbreviations Description Connector on Engine Management System wiring harness which serves as an interface for power supply XXXX shows the component serial number Effectivity: 912 i Series 00–00–00 Edition 2/Rev. 2 Page 7 May 01/2023...

  • Page 22: Wiring Color Codes

    BRP-Rotax MAINTENANCE MANUAL LINE WIRING COLOR CODES Figure 1.2 00–00–00 Effectivity: 912 i Series Edition 2/Rev. 2 Page 8 May 01/2023...

  • Page 23: 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 24: 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 25: 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 26 BRP-Rotax MAINTENANCE MANUAL LINE Engine operation • The engine must always be operated according to the content of the latest Operators Manual (OM) • To eliminate the risk of injury or damage, ensure any loose equipment or tools are prop- erly secured before starting the engine •...

  • Page 27: Instruction

    Accessories This engine must only be operated with accessories supplied, recommended and re- leased by BRP-Rotax. Modifications are only allowed after consent of the engine manufacturer. Spare parts See Illustrated Parts Catalog (IPC), latest issue for the respective engine type.

  • Page 28: Maintenance Concept

    BRP-Rotax MAINTENANCE MANUAL LINE MAINTENANCE CONCEPT General note The maintenance functions detailed in this Manual are divided into two categories: • Maintenance I (Line Maintenance) • Maintenance II (Heavy Maintenance) Repairs beyond the levels detailed in Manual I and Maintenance Manual II are not recom- mended as maintenance functions and must be in accordance to the current Overhaul Manual (OHM) for the respective engine type.

  • Page 29: 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 MML, Chapter 05–00–00 section “Author- ized Personnel”) under normal conditions for engine removal and installation.
  • Page 30 BRP-Rotax MAINTENANCE MANUAL LINE This symbol informs you of additional references (data sheets, Manuals, etc.) associated with the given subject. 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.

  • Page 31: 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 32 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 18 Effectivity: 912 i Series May 01/2023...
  • Page 33 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 34 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 912 i Series May 01/2023...
  • Page 35 BRP-Rotax MAINTENANCE MANUAL LINE Chapter: 05–00–00 MAINTENANCE TOPICS IN THIS CHAPTER General note ............................2 Authorized personnel ..........................4 Procedure notes ............................5 Troubleshooting ............................7 Consumable Materials ..........................8 Acceptable methods, techniques and practice ..................12 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 36: 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 37 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE Be sure to use the recommended tightening torque for the specified fastener. NOTE When possible, always apply torque on the nut. NOTE Always torque screws, bolts and/or nuts using a crisscross pattern when multiple fasteners are used to secure a part. Some parts must be torqued according to a specific sequence and torque pattern as detailed in the installation procedure.

  • Page 38: Authorized Personnel

    • ensure the requirements of the applicable regulatory authority regarding running a maintenance organization 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 39: 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 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 40 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 NOTICE In order to avoid mechanical damage, always loosen or tighten screws and nuts with specified tools.

  • Page 41: Troubleshooting

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

  • Page 42: Consumable Materials

    BRP-Rotax MAINTENANCE MANUAL LINE CONSUMABLE MATERIALS General note NOTICE Use only the specified or technically equivalent materials for all maintenance work. NOTICE When handling chemicals, comply with all the customary regulations and specifi- cations of the producer, including the expiry date and instructions of use.
  • Page 43 BRP-Rotax MAINTENANCE MANUAL LINE Part no. Description, application Qty. 897330 LITHIUM-BASE GREASE 250 g Electrical isolating (0.55 lb) n.a. Engine oil For easier assembly of components or for first lubrica- tion before first engine start 899791 LOCTITE 5910 50 ml (0.013 gal...
  • Page 44 BRP-Rotax MAINTENANCE MANUAL LINE Additional materials NOTICE All metal and synthetic parts should be cleaned with suitable cleaning agents. Before using new and unknown cleaning agents, check their compatibility with the materials they are being used on. Part no. Description, application Qty.
  • Page 45 BRP-Rotax MAINTENANCE MANUAL LINE Part no. Description, application Qty. n.a. Valve lapping paste This paste, produced by various manufacturers, is a fine granulate lapping paste for manual lapping of valve seats and valves. The paste is usually available in 3 dif- ferent granulate sizes.

  • Page 46: 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 47 BRP-Rotax MAINTENANCE MANUAL LINE Nut securing When using a self-locking nut, make sure the polyamide insert ring meets the require- ments of DIN 985. Be sure that the securing elements the nut is positioned towards the outside, in accordance with DIN 980.
  • Page 48 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 14 Effectivity: 912 i Series May 01/2023...
  • Page 49 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 ..............................3 Life cycle ..............................3 General overhaul (TBO).........................3 Purging the oil system..........................3 Time Limit..............................4 Time limit for parts ..........................6 Time limit for the coolant ........................6...

  • Page 50: 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 51: Time Limit

    BRP-Rotax MAINTENANCE MANUAL LINE TIME LIMIT Definition Time limits are predetermined time spans and intervals which are based either on calen- dar intervals or the number of engine operating hours. Once the time limits have been reached, the affected parts must either be replaced for a general overhaul, or mainte- nance work must be performed.

  • Page 52: Time Limit

    BRP-Rotax MAINTENANCE MANUAL LINE TIME LIMIT General NOTICE 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 53 BRP-Rotax MAINTENANCE MANUAL LINE Shipment The appropriation for the overhaul must include the following: Engine log book (including date and time of engine removal). Maintenance records of the engine (i.e. all maintenance check lists, and re- ports of operation, of maintenance, of findings and of oil analyses).

  • Page 54: Time Limit For Parts

    BRP-Rotax MAINTENANCE MANUAL LINE TIME LIMIT FOR PARTS General note NOTICE 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 55 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 56: 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 57: 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 58 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 59: 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 60: 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 61: 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 ENGINE Engine type Engine S/N TSN (time since new) TSO (time since overhaul) ECU S/N FUSE BOX Used operating fluids: Coolant •...
  • Page 62 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- 1000 50 hr. 25 hr. 100 hr. 200 hr. 400 hr. 600 hr. ble (circle on)

  • Page 63: 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 Chapter...
  • Page 64 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance re- 1000 quirement after the first 25 hours of operation 3) Inspection of the GENUINE ROTAX fuel filter (on the air frame)
  • Page 65 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance re- 600 1000 quirement after the first 25 hours of operation 6) Inspecting the oil filter Remove old oil filter from engine.
  • Page 66 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance re- 1000 quirement after the first 25 hours of operation Inspect all oil lines for damage, leak- 12–20–00 age, hardening from heat, porosity,...
  • Page 67 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance re- 1000 quirement after the first 25 hours of operation 8) Oil change Drain oil from oil tank. 12–20–00 Oil change, Flushing the...
  • Page 68 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance re- 1000 quirement after the first 25 hours of operation 13) Engine sensors Check all temperature sensors. Check all pressure sensors. Check all exhaust gas temperature sensors.
  • Page 69 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance re- 1000 quirement after the first 25 hours of operation 16) Checking the propeller gear box Check gear set (pittings). See Heavy...
  • Page 70 BRP-Rotax MAINTENANCE MANUAL LINE Interval Operating hours Chapter Signa- Points of Inspection Reference ture * no periodic maintenance re- 1000 quirement after the first 25 hours of operation 18) Engine cleaning Engine cleaning. 12–20–20 Engine cleaning 19) Pre-engine test run – Liquid level check Verify liquid level, replenish as 12–10–00...
  • Page 71 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 Propeller Strike Inspection ........................6 Installation of propeller gearbox ......................11 Checking of the overload clutch ......................15...

  • Page 72: 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 i-001, current edition.
  • Page 73 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE 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: Screw position identification Allen screw M8 Allen screw M6 Figure 5.2...
  • Page 74 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 75: Drive Gear - Removal

    BRP-Rotax MAINTENANCE MANUAL LINE DRIVE GEAR — REMOVAL NOTICE 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 76: Propeller Strike Inspection

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.5 Drive gear Crankshaft Friction washer Hex. nut M30x1.5 PROPELLER STRIKE INSPECTION General note NOTICE Damage to a propeller is serious and can cause the engine to be unairworthy. After any propeller strike the following inspections must be performed before operation can continue.
  • Page 77 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Remove the propeller as per the airframe and propeller manufacturer’s instructions. Inspect the engine for damage. If any damage is detected, inspect, re- pair or overhaul the whole engine in accordance with the relevant Man- ual.
  • Page 78 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.6: Components for inspection Propeller gear assy. Drive gear See latest Illustrated Parts Catalog (IPC) for the respective engine type. Procedure Step Inspect , repair or perform service of the whole gearbox in accordance with Chapter 72-10-00 of the latest Maintenance Manual Heavy (MMH).
  • Page 79 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.7: NDT inspection Dog hub wide Step Procedure If cracks are detected on any these components the parts need to be replaced. These parts need to be replaced 100% in course of a propeller strike inspection.
  • Page 80 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Disassemble overload clutch. See Chapter 72-10-00 Maintenance Man- ual Heavy (MMH). Check all given wear limits about the gearbox assy. See Chapter 72-10- 00 Maintenance Manual Heavy (MMH) section “Inspection” and “Wear Limits”. If a part is not within given limits or has unusual wear or damage, the part needs to be replaced.

  • Page 81: Installation Of Propeller Gearbox

    BRP-Rotax MAINTENANCE MANUAL LINE INSTALLATION OF PROPELLER GEARBOX Preparation NOTICE No hammering or pressing! The drive gear must only be pushed on by hand. NOTICE Ensure that the friction washer is in the correct installation position. NOTICE The dog and drive gears are in pairs.
  • Page 82 BRP-Rotax MAINTENANCE MANUAL LINE 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. If necessary, turn it and push it on in another position.
  • Page 83 BRP-Rotax MAINTENANCE MANUAL LINE See Maintenance Manual Heavy (MMH) for the engine type 912 i Series Chapter 72-10-00 section Wear limits (CS24). NOTE If there is slight vertical run-out, replace the nut and repeat the measurement. Step Procedure Insert 2 dowel pins 6x20 into the crankcase.
  • Page 84 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE If excessive installation force is used, the bearing or vacuum pump gear can be damaged. Step Procedure Tap gently on the gearbox housing with a soft-faced hammer to position the gearbox on the crankcase. 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.

  • Page 85: 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 86 BRP-Rotax MAINTENANCE MANUAL LINE specially prepared lever torque wrench propeller ange support of specially prepared lever 10202 Figure 5.13: Front view torque wrench propeller ange specially pre- adapter plate pared lever support of specially prepared lever 10201 Figure 5.14: Side view 05–50–00...
  • Page 87 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 88: 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 89: 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 90 BRP-Rotax MAINTENANCE MANUAL LINE Complete inspection of these components: • power supply • cooling system • gearbox • valve train system • engine suspension frame • exhaust system • fuel system • lubrication system • cylinder unit • start system In most cases an overhaul is necessary, in this regard the engine has to be overhauled ac- cording to the current Overhaul Manual (OHM) for the respective engine type.

  • Page 91: 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 according to 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 92: Exceeding Of Max. Admissible Engine Rpm

    Step Procedure The whole engine must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. Check that the push-rods are straight. Inspect the crankshaft for out-of-roundness and distortion. See Chapter 72- 00-00 of the latest Maintenance Manual Heavy (MMH).
  • Page 93 If the speed of 6500 rpm was exceeded. Step Procedure The whole engine must be inspected, repaired or overhauled in accordance 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 94: Exceeding Of Max. Coolant Temperature

    BRP-Rotax MAINTENANCE MANUAL LINE EXCEEDING OF MAX. COOLANT TEMPERATURE General note NOTICE If the maximum coolant temperature is exceeded, other limits are also often ex- ceeded, e.g. oil temperature. Please observe the relevant instructions. NOTE Any exceeding of the max. admissible coolant temperature must be entered by the pilot into the engine log book, stating duration, extent of excess temperature and pertinent detail.
  • Page 95 Table 1: Temperature exceeded less than 30 min. Step Procedure The whole cooling system must be inspected, repaired or overhauled in ac- cordance with the BRP-Rotax instructions for continued airworthiness. Table 1: Temperature exceeded less than 30 min. Procedure Step Inspect all further systems for correct functioning.

  • Page 96: Non Compliance With The Coolant Specification

    BRP-Rotax MAINTENANCE MANUAL LINE NON COMPLIANCE WITH THE COOLANT SPECIFICATION General note NOTICE Use only coolant as recommended in the current Operators Manual (OM) and SI- 912 i-001 “Selection of suitable operation fluids“, current issue. Non compliance with the coolant specification...

  • Page 97: Checking Of The Cooling System / Radiator Cap

    BRP-Rotax MAINTENANCE MANUAL LINE CHECKING OF THE COOLING SYSTEM / RADIATOR CAP General Cooling system / radiator cap. check in case of unusual leakage and deposits or exceed- ing of max. cooling system temperature. m WARNING Risk of burns and scalds. Hot engine parts.
  • Page 98 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.16: Special tool Instruction NOTE Perform a visual check of the entire cooling system, check for chafing and coolant residue. Step Procedure Remove one coolant hose at the upper outlet elbow on the cylinder head, hold the hose up and drain the hose and expansion tank.
  • Page 99 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.17: TYPICAL Upper coolant hose Coolant outlet elbow Clean container Step Procedure Seal the open elbow side with a temporary piece of coolant hose, with a plug inserted in the open end. The plug needs to hold a pressure of 2 bar (29 psi).
  • Page 100 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.18: TYPICAL Self compensating clamp 25 part no. water hose part no. 922250 851645 Plug Step Procedure To the open coolant hose, attach an adapter and connect to a manual pump or pressure reduction valve. Use the standard spring clamp to se- cure the hose on the adapter.
  • Page 101 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Remove the connection hose from expansion tank to overflow bottle and install a temporary clear hose. Refill the cooling system at the expansion tank and overflow bottle to standard levels. Apply small amount of coolant to rubber surfaces inside cap (provides lu- brication to prevent binding).
  • Page 102 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE Use only coolant as recommended in the current Operators Manual (OM). Step Procedure Check if the relief pressure lies within following limits for both radiator cap types. • Min. relief pressure: 1.2 bar (17.4 psi) •...
  • Page 103 BRP-Rotax MAINTENANCE MANUAL LINE NOTE To make the entire cooling system check easier, the coolant may be entirely drained, and the system pressurized with air only, up to 1.6 bar (23.2 psi.). Check can be performed with leak detection fluid to locate the leakage.

  • Page 104: Exceeding The Max. Permissible Oil Temperature

    BRP-Rotax MAINTENANCE MANUAL LINE EXCEEDING THE MAX. PERMISSIBLE OIL TEMPERATURE General note NOTICE If the max. permissible oil temperature is exceeded, other limits are often ex- ceeded, too, e.g. the cylinder head temperature and coolant temperature. Please observe the relevant instructions.
  • Page 105 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 106: Oil Pressure Below Minimum Value

    BRP-Rotax MAINTENANCE MANUAL LINE OIL PRESSURE BELOW MINIMUM VALUE General note NOTICE If the oil pressure falls below the minimum value, other limits are often exceeded, e.g. the oil temperature. Please observe the relevant instructions. NOTE Any exceeding of the min. admissible oil pressure must be entered by the pilot in- to the engine log book, stating duration and extent of excessive pressure and per- tinent details.
  • Page 107 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 108: 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 109 Step 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. Carry out an oil change. Remove the lowest positioned banjo screw (banjo bolt, plug screw or screw socket) and drain the remaining oil from the crankcase.

  • Page 110: 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 111: Smooth Performance Of The Engine

    BRP-Rotax MAINTENANCE MANUAL LINE Independent of subsequent following inspections are required: Non compliance with fuel quality Step Procedure Visual inspection of engine. Empty the fuel system according to the instructions of aircraft manufacturer. Flush fuel system. Replace fuel filter Check differential pressure.

  • Page 112: Lightning Strike

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.25: 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 113: 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 114 BRP-Rotax MAINTENANCE MANUAL LINE Figure 5.26: Form 05–50–00 Effectivity: 912 i Series Edition 2/Rev. 2 Page 44 May 01/2023...
  • Page 115 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 116 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 2 Effectivity: 912 i Series May 01/2023...
  • Page 117 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 118: Servicing Points On The Engine

    BRP-Rotax MAINTENANCE MANUAL LINE SERVICING POINTS ON THE ENGINE Overview Figure 6.1 Expansion tank Radiator cap Oil filter Oil tank Radiator cap Oil dipstick Overflow bottle 12–10–00 Effectivity: 912 i Series Edition 2/Rev. 2 Page 2 May 01/2023...

  • Page 119: 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 120: 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 121 BRP-Rotax MAINTENANCE MANUAL LINE Instruction To refill the coolant the following steps are necessary. Procedure Step Open the radiator cap (1) on the expansion tank (2). Visually check the rub- ber seats inside the cap for condition and orientation. Check the coolant level. The coolant level must be filled up to the top (see Figure).
  • Page 122 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 123: 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 124 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE For longer flights replenish oil to max. mark to warrant more oil reserve. NOTICE Only use brand name oil in accordance with the latest Operators Manual (OM) and the latest Service Instruction “Selection of suitable operating fluids“ of the respective engine type.
  • Page 125 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 126 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 10 Effectivity: 912 i Series May 01/2023...
  • Page 127 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 ...................... 11 Engine control unit (ECU) ........................13 Checking ECU ............................13 Read out the ECU data memory ......................13...
  • Page 128 BRP-Rotax MAINTENANCE MANUAL LINE Flushing the oil circuit ..........................45 Inspecting the magnetic plug ........................47 Installation of the magnetic plug......................48 Electric system............................49 Check of wiring............................50 Replacement of spark plugs .........................51 Remove the spark plugs ........................51 Inspection of spark plugs........................51 Installation of spark plug ........................53 Fuse box.............................54...

  • Page 129: 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 130: 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 131: Leakage Check

    BRP-Rotax MAINTENANCE MANUAL LINE LEAKAGE CHECK General note NOTICE 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 132 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.1: Connections and fuel lines Fuel hose assy. (Steel) Pressure regulator Electric fuel pump module Fuel rail 1/3 outlet line Fuel injector Electric fuel Electric fuel pump module remove cover and inspect for leaks. pump module 12–20–00...

  • Page 133: Differential Pressure Check

    BRP-Rotax MAINTENANCE MANUAL LINE DIFFERENTIAL PRESSURE CHECK General note m WARNING Risk of electric shock! Ignition “OFF” and system grounded! m WARNING Danger of life threatening injuries caused by the propeller, rotating and stressed parts of the engine! Engine (and propeller) may suddenly rotate if the piston is not at top dead center.Al- ways secure propeller and keep blade path clear before adding pressurized air to the cylinder.
  • Page 134 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.2: Differential pressure check. TYPICAL Adaptor Manometer/Test gauges set Orifice jet Compressor 12–20–00 Effectivity: 912 i Series Edition 2/Rev. 2 Page 8 May 01/2023...
  • Page 135 BRP-Rotax MAINTENANCE MANUAL LINE Special tools To measure the differential pressure the following special tools and equipment are necessary. Part no. Description n.a. Compressed air approx. 6 bar (80 psi). 2 pressure gauges. Orifice jet*, of 1 mm (0.04 in) inner diameter and 3 mm (0.12 in) length.
  • Page 136 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Place a plastic drift (2) on the rocker arm (1) (directly over the inlet valve stem). See Fig. Valve seat debris removal. Use a hammer to give a slight blow onto the fibre drift to dislodge any for- eign material between the intake valve face and seat.

  • Page 137: Compression Check For Fault-Tracing

    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 138 BRP-Rotax MAINTENANCE MANUAL LINE Special tools For accomplishment the following special tool is required: Figure 7.4: Compression check for fault-tracing. TYPICAL Part no. Description n.a. Compression tester (1) 12–20–00 Effectivity: 912 i Series Edition 2/Rev. 2 Page 12 May 01/2023...

  • Page 139: Engine Control Unit (Ecu)

    BRP-Rotax MAINTENANCE MANUAL LINE ENGINE CONTROL UNIT (ECU) Safety notice m WARNING Non-compliance can result in serious injuries or death! When working on the ECU, the general safety instruction must be observed. See chap- ter „INTRO“. Figure 7.5: Engine control unit (ECU)
  • Page 140 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Connect the decoding unit (Dongle) with ECU data cable to the computer. Select the menu item BUDS in the maintenance software and print out the report. NOTE Connect and disconnect the B.U.D.S. USB-to-CAN Converter only if ECU is OFF.

  • Page 141: 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. For accom- plishment the following special tool is required: Figure 7.6: Special tool...
  • Page 142 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.7: Locking/Loosen of the crankshaft. TYPICAL Plug screw M8x20 Sealing ring Locking pin Crankshaft Loosen of the After completion of work/check: crankshaft Step Procedure Remove the locking pin (4) and refit crankshaft Allen screw M8x20 (1) along with a new sealing ring with a dry torque of 15 Nm (133 in.lb).

  • Page 143: 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 144 BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Shut engine down. NOTE Switch “OFF” lanes, fuel pumps and master switch Inspect rotary seal for leakage. NOTE Due to the design of the rotary seal, the manufacturer tolerates a certain amount of leakage. If the leakage is in excess of the limit ro- tary seal must be renewed.

  • Page 145: 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 7.8: Checking the V-belt tension Effectivity: 912 i Series 12–20–00...

  • Page 146: Belt Tension Adjustment

    BRP-Rotax MAINTENANCE MANUAL LINE BELT TENSION ADJUSTMENT 00353 Figure 7.9: Overview 2, 3 Hex. screw M10 Allen screw M8 Belt tension To adjust the belt tension: Step Procedure Loosen the hex. screw (1) M10 and the two M8 Allen screw (2) and (3).

  • Page 147: Air Intake System

    BRP-Rotax MAINTENANCE MANUAL LINE AIR INTAKE SYSTEM Figure 7.10: Overview Throttle body socket Intake manifold Air filter Airbox Temperature sensor Pressure sensor Effectivity: 912 i Series 12–20–00 Edition 2/Rev. 2 Page 21 May 01/2023...

  • Page 148: Checking Air Intake System

    BRP-Rotax MAINTENANCE MANUAL LINE CHECKING AIR INTAKE SYSTEM General note NOTICE Blocked air filter. In the event of dust formation, clean air filter at correspondingly shorter intervals. If filter mat is damaged, replace air filter. NOTICE A dirty filter insert will not only reduce the engine performance but might also promote premature wear of the engine.
  • Page 149 BRP-Rotax MAINTENANCE MANUAL LINE Cleaning To clean the dry filter the following steps are necessary: 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).

  • Page 150: 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 7.13: Overview. TYPICAL Air filter NOTICE Each air filter must be secured by clamp attachment and a wire securing element.

  • Page 151: Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE COOLING SYSTEM Figure 7.14: Overview Water pump Coolant hoses Expansion tank Radiator cap with gasket Coolant temperature sensor Overflow bottle Effectivity: 912 i Series 12–20–00 Edition 2/Rev. 2 Page 25 May 01/2023...

  • Page 152: 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. m WARNING Non-compliance can result in serious injuries or death! Any of the following conditions require a check of the cooling system/radiator cap check as described in Chapter 05-50-00 Unscheduled Maintenance.

  • Page 153: Replacing The Coolant

    BRP-Rotax MAINTENANCE MANUAL LINE REPLACING THE COOLANT 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 154 BRP-Rotax MAINTENANCE MANUAL LINE Instruction To replace the coolant the following steps are necessary: Figure 7.15: 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 155: Flushing The Cooling System

    BRP-Rotax MAINTENANCE MANUAL LINE Step Procedure Fit radiator cap. NOTE Run the engine briefly and replenish with clean coolant as required. 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.

  • Page 156: Expansion Tank, Radiator Cap

    BRP-Rotax MAINTENANCE MANUAL LINE EXPANSION TANK, RADIATOR CAP Figure 7.16: 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 157: Overflow Bottle

    BRP-Rotax MAINTENANCE MANUAL LINE OVERFLOW BOTTLE General note Figure 7.17: 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 158: Fuel System

    BRP-Rotax MAINTENANCE MANUAL LINE FUEL SYSTEM Figure 7.18: Overview Fuel pump Fuel line (steel) Fuel injector Fuel rail Fuel pressure regulator 12–20–00 Effectivity: 912 i Series Edition 2/Rev. 2 Page 32 May 01/2023...

  • Page 159: Leak Tests

    BRP-Rotax MAINTENANCE MANUAL LINE LEAK TESTS General note NOTICE Avoid over-tightening the fasteners. Use a suitable torque wrench for all work. Instruction To check the following steps are necessary: Step Procedure Inspect all fuel lines, their connections and unions. Inspect the fuel lines for sign of chafing.

  • Page 160: Fuel Pumps

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.19: Fuel pressure regulator Fuel pressure regulator Reference hose connection FUEL PUMPS General note Inspect the fuel pumps in accordance with the manufacturers instructions or the aircraft manufacturers. • Remove the housing • Visual inspection of lines and connections...

  • Page 161: Lubrication

    BRP-Rotax MAINTENANCE MANUAL LINE LUBRICATION Overview 08238 Figure 7.20 Figure 7.21 Oil tank Drain screw M12x12 Oil radiator Oil filter Effectivity: 912 i Series 12–20–00 Edition 2/Rev. 2 Page 35 May 01/2023...
  • Page 162 BRP-Rotax MAINTENANCE MANUAL LINE General note For detailed information see Service Instruction SI-912 i-005 “oil change“, latest issue. m WARNING Risk of burns and scalds. Hot engine parts. Always allow engine to cool down to ambient temperature before starting work.

  • Page 163: 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: NOTICE Counter hold on the hex of the oil tank when loosing and/or torquing the oil drain screw to avoid stress in the soldering.

  • Page 164: Oil Filter Removing

    BRP-Rotax MAINTENANCE MANUAL LINE NOTICE DO NOT use compressed air to blow through the oil system (or oil lines, oil cool- er, oil pump housing, oil bores in the engine). ENVIRONMENTAL NOTE Protect the environment. Do not harm the environment by spilling oil. Dispose of oil in an environmentally friendly manner.
  • Page 165 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.22: Special tool Oil filter wrench part no. 877620* Cutting tool part no. 276275 *or equivalent Procedure To remove the oil filter the following steps are necessary: Step Procedure Remove used oil filter with oil filter wrench.

  • Page 166: 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 167 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 NOTICE If the oil circuit is contaminated, replace the oil cooler and flush the oil circuit.

  • Page 168: 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 169: 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 170 BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.25 Profile clamp Hex. screw M12x12 Oil tank cover assy. Metric/ UNF O-ring Baffle insert (screen) Partition Gasket ring 12x18 Oil tank Safety wire 12–20–00 Effectivity: 912 i Series Edition 2/Rev. 2 Page 44 May 01/2023...

  • Page 171: Purging The Oil System

    BRP-Rotax MAINTENANCE MANUAL LINE PURGING THE OIL SYSTEM General note NOTICE 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 current Installation Manual (IM) for the engine type 912 i Series Chap- ter 79-00-00 section Purging the lubrication system.
  • Page 172 BRP-Rotax MAINTENANCE MANUAL LINE NOTICE 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 173: 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 overhauled according to the BRP-Rotax instructions for continued airworthiness. Unclear findings In the case of unclear findings: Step...

  • Page 174: Installation Of The Magnetic Plug

    BRP-Rotax MAINTENANCE MANUAL LINE Figure 7.26: Overview TYPICAL 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 175: Electric System

    BRP-Rotax MAINTENANCE MANUAL LINE ELECTRIC SYSTEM Figure 7.27: Overview Spark plug connectors Double ignition coils Ignition cable FUSE BOX assy. Plug connectors Crankshaft position sensors Stator assy. Stator Engine Control Unit (ECU) Effectivity: 912 i Series 12–20–00 Edition 2/Rev. 2...

  • Page 176: 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 177: Replacement Of Spark Plugs

    BRP-Rotax MAINTENANCE MANUAL LINE REPLACEMENT OF SPARK PLUGS General note NOTICE 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 178 BRP-Rotax MAINTENANCE MANUAL LINE Spark plug face Spark plug face reveals the following about the operating condition of the engine: Spark plug face Information light tan- colored plug and calibration of the engine are correct velvet black Possibly indicates one or more of the following: •...

  • Page 179: Installation Of Spark Plug

    BRP-Rotax MAINTENANCE MANUAL LINE INSTALLATION OF SPARK PLUG Figure 7.28: Spark plugs Ground electrode Head area Cleaning m WARNING Eyes and skin irritation! Rinse off with water in the case of contact with eyes or skin. May be harmful if swallowed.

  • Page 180: Fuse Box

    BRP-Rotax MAINTENANCE MANUAL LINE Installation NOTICE Always replace both spark plugs of a cylinder and do not interchange spark plugs between cylinders. NOTICE Silicone heat compound at the ground electrode or the head area can lead to igni- tion problems. Apply heat compound sparingly and do not apply to the first three threads.

  • Page 181: Propeller Gearbox

    See Heavy Maintenance Manual Heavy (MMH) for the engine type 912 i Series. 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 Maintenance Manual Heavy (MMH).
  • Page 182 BRP-Rotax MAINTENANCE MANUAL LINE INTENTIONALLY LEFT BLANK Page 56 Effectivity: 912 i Series May 01/2023...
  • Page 183 BRP-Rotax MAINTENANCE MANUAL LINE Index Exceeding of max. coolant temperature ....24 Exceeding the max. permissible oil temperature ..34 Abbreviations............3 Expansion tank ...........30 Acceptable methods, techniques and practice ..12 Extreme climatic conditions........21 Accessories ............31 Air intake system..........21 Airworthiness Limitations ........1 Annual inspection..........6 Fluid capacities .............3...
  • Page 184 BRP-Rotax MAINTENANCE MANUAL LINE Reporting ............43 Maintenance Concept..........14 Maintenance Schedule ..........9 Maintenance schedule procedures ......6 Safety ..............10 Safety information ..........11 Scheduled maintenance ........2 Scheduled maintenance checks ......1–2 Non compliance — coolant specification ....26 Servicing points on the engine........2 Non compliance —...
  • Page 186 Engine serial no. Type of aircraft Aircraft registration no. Rotax® authorized distributor FLYROTAX.COM ® and TM are trademarks of BRP-Rotax GmbH & Co KG. 2023 BRP-Rotax GmbH & Co KG. All rights reserved. ©...

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