BRP ROTAX 912 A Maintenance Manual Download Page 23

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BRP-Rotax

MAINTENANCE MANUAL LINE

• This engine may be equipped with a vacuum pump. The safety warning accompanying

the air pump must be given to the owner/operator of the aircraft into which the air pump
has been installed

Engine operation

• The engine must always be operated according to the content of the latest Operators

Manual

• To eliminate the risk of injury or damage, ensure any loose equipment or tools are prop-

erly secured before starting the engine

• The use of propellers and their fastenings which exceed the specified values of moment

of inertia and imbalance is not allowed and releases the engine manufacturer from any
liability

• Improper engine installation, use of unsuitable piping for fuel, cooling and lubrication

system and use of unsuitable wiring for electric and engine management system re-
leases the engine manufacturer from any liability

Effectivity: 912 Series
Rev. 0

00–00–00

Page 11

January 01 2020

Summary of Contents for ROTAX 912 A

Page 1: ...FOR ROTAX ENGINE TYPE 912 SERIES REF NO MML 912 PART NO 899196 MAINTENANCE MANUAL LINE...

Page 2: ...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 Copyright 2020 all rights rese...

Page 3: ...00 00 00 GENERAL NOTE Chapter 04 00 00 AIRWORTHINESS LIMITATIONS Chapter 05 00 00 MAINTENANCE Chapter 05 10 00 TIME LIMITS Chapter 05 20 00 SCHEDULED MAINTENANCE CHECKS Chapter 05 50 00 UNSCHEDULED MA...

Page 4: ...Page 2 January 01 2020 Effectivity 912 Series INTENTIONALLY LEFT BLANK BRP Rotax MAINTENANCE MANUAL LINE...

Page 5: ...aft 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...

Page 6: ...Page 2 January 01 2020 Effectivity 912 Series INTENTIONALLY LEFT BLANK BRP Rotax MAINTENANCE MANUAL LINE...

Page 7: ...uary 01 2020 11 January 01 2020 12 January 01 2020 13 January 01 2020 14 January 01 2020 15 January 01 2020 16 January 01 2020 04 00 00 1 January 01 2020 Chapter Page Date 2 January 01 2020 05 00 00 1...

Page 8: ...2020 18 January 01 2020 19 January 01 2020 20 January 01 2020 21 January 01 2020 Chapter Page Date 22 January 01 2020 23 January 01 2020 24 January 01 2020 25 January 01 2020 26 January 01 2020 27 Ja...

Page 9: ...January 01 2020 30 January 01 2020 31 January 01 2020 32 January 01 2020 33 January 01 2020 Chapter Page Date 34 January 01 2020 35 January 01 2020 36 January 01 2020 37 January 01 2020 38 January 01...

Page 10: ...BRP Rotax MAINTENANCE MANUAL LINE Chapter Page Date Rear page Chapter Page Date LEP Page 4 January 01 2020 Effectivity 912 Series Rev 0...

Page 11: ...HE EASA Edition 4 Rev 0 January 01 2020 Rev no Chapter Pa ge Date of change Remark for approval Date of approval from authorities Date of inclusion Signature 0 INTRO all Jan 01 2020 DOA 0 LEP all Jan...

Page 12: ...mment 0 0 0 0 0 0 all 05 20 00 05 50 00 05 50 00 05 50 00 12 10 00 all 9 16 2 10 11 19 23 33 5 Jan 01 2020 Jan 01 2020 Jan 01 2020 Jan 01 2020 Jan 01 2020 Jan 01 2020 New layout and change of company...

Page 13: ...2 Abbreviations and terms depending on respective engine type 3 Wiring color codes 7 Conversion table 8 Safety notice 9 Safety information 10 Instruction 12 Maintenance Concept 13 Technical documentat...

Page 14: ...ircraft engine installation maintenance safety or flight operation consult the documentation provided by the aircraft manufacturer and or its dealer For additional information on engines their mainten...

Page 15: ...re Temperature Sensor AC alternating current AD Airworthiness Directives Ah Ampere hour A C Aircraft AR as required assy assembly ASB Alert Service Bulletin ACG Austro Control GmbH ACL Anti Collision...

Page 16: ...onnected from aircraft common ground during flight EMC Electromagnetic compatibility EN European Standard ETFE Ethylene Tetrafluoroethylene FAA Federal Aviation Administration FAR Federal Aviation Reg...

Page 17: ...ane Number MAG Magneto Side N Newton n a not available NDT Non Destructive Testing Nm Newtonmeter NVFR Night Visual Flight Rules OAT Organic Acid Additive Technology OHM Overhaul Manual OHV Over Head...

Page 18: ...twisted pair SL Service Letter SMD Surface Mounted Devices TBO Time Between Overhaul TC Type certificate part no part number TOA Table Of Amendments TOC Table of content TPS Throttle Position Sensor...

Page 19: ...BRP Rotax MAINTENANCE MANUAL LINE WIRING COLOR CODES Figure 1 2 Effectivity 912 Series Rev 0 00 00 00 Page 7 January 01 2020...

Page 20: ...km h 1 ft min 0 3048 m min 0 00508 m sec 1 m s 196 85 ft min 1 kt 1 852 km h 1 km h 0 53996 kn Units of mass spec fuel consumption 1 kg 2 2046 lbs 1 lb 0 45359 kg 1 g kWh 0 001644 lb hph 1 lb hph 608...

Page 21: ...pecifications are given in the SI metric system with the imperial and US customary measurement system equivalents in parenthesis Symbols used This Manual uses the following symbols to emphasize partic...

Page 22: ...aircraft manufac turer assembler or owner user 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 aircraf...

Page 23: ...y or damage ensure any loose equipment or tools are prop erly secured before starting the engine The use of propellers and their fastenings which exceed the specified values of moment of inertia and i...

Page 24: ...ed Parts Catalog latest issue for the respective engine type ATTENTION Only use GENUINE ROTAX spare parts Spare parts must meet the require ments defined by the engine manufacturer This can only be gu...

Page 25: ...nance I Line Maintenance Chapter 00 05 and 12 The scope of line maintenance consists of servicing and adjustment of engine compo nents including part wear All procedures in this Manual are to be consi...

Page 26: ...ervice Instruction Parts and Accessories Service Letter Status The status of the Manuals can be determined by checking the table of amendments The first column of this table indicates the revision sta...

Page 27: ...e system and are provided with a consecutive irrelevant number This number e g AE 5iS001 is of no significance for the content Some measurements are given in the drawings these are manufacturing dimen...

Page 28: ...d any aeronautical standards or regulatory safety or durability testing and do not conform to any aircraft standards These engines are meant for use in experimental uncertificated aircraft and vehicle...

Page 29: ...00 provides information about Airworthiness Limitations Airworthiness Limitations NONE For the ROTAX engine type 912 Series the airworthiness limitations are not applicable NOTE Regarding engine opera...

Page 30: ...Page 2 January 01 2020 Effectivity 912 Series INTENTIONALLY LEFT BLANK BRP Rotax MAINTENANCE MANUAL LINE...

Page 31: ...ubleshooting 6 Consumable Materials 7 Acceptable methods techniques and practice 10 Introduction The information given in the Maintenance Manual is based on data and experience which are considered to...

Page 32: ...ions as well as the use of components and auxiliary components not corresponding to the installation instructions exclude any liability of the engine manufacturer Parts and accessories We particularly...

Page 33: ...quired tools and fixtures as outlined in the ROTAX Maintenance Manual ensure reasonable and prudent maintenance practices are utilized ensure the requirements of the applicable regulatory authority re...

Page 34: ...unintentional operation Ignition ON m WARNING Risk of electric shock The ignition is switched on as long as the ground cable P lead is not properly con nected to ground At maintenance work which requi...

Page 35: ...being used on Removed parts Before re using disassembled parts clean check and refit them as per instructions Use clean screws and nuts Always inspect the contact face and thread for damage If un sure...

Page 36: ...es Possible problems are listed in the Operators Manual At the same time a brief description of the necessary remedial action is given See Chapter 4 in the Operators Manual for engine type 912 Series...

Page 37: ...itable for all operating conditions indicated by the manufacturer No part no Description Application Qty B 897651 LOCTITE 243 blue Blue medium duty screw locking agent oil tolerant 10 ml 0 003 gal US...

Page 38: ...fer resistance The greaselike temperature resistant silicon com pound fills cavities between components and the cooling element e g spark plug cylinder head which otherwise do not contribute to heat c...

Page 39: ...h solid blasting strong abrasive material Due to this surface treat ment one does gain a microscopic surface roughness pitting which does allow as a consequence the adhesion of fuel residues These dep...

Page 40: ...s Self locking ATTENTION Self locking nuts cotter pins tab washers and safety wires must be replaced each time they have been removed All instructions regarding the securing and lubrication of parts m...

Page 41: ...ral overhaul TBO 3 Purging the oil system 3 Time Limit 4 Time limit for parts 7 Time limit for fuel pump 7 Time limit for the coolant 7 Annual inspection 7 Introduction The following checks are requir...

Page 42: ...ection An inspection must be done only by certified mechanics who are approved on this engine using permitted procedures to make an analysis of the physical condition and find defects An inspection fo...

Page 43: ...ness Maintenance of operation The TBO values approved by the relevant authorities are based on performance tests and empirical values which have been gathered through operation of the engine and are r...

Page 44: ...possible storage period of the engine is limited to 24 months If this period is exceeded the engine must be sent to a ROTAX authorized overhaul fa cility for inspection Engine Type description Engine...

Page 45: ...whichever comes first1 912 UL from S N 4409716 incl 2000 h or 15 years whichever comes first 912 ULS up to and incl S N 4427532 incl 1200 h or 10 years whichever comes first1 912 ULS from S N 4427533...

Page 46: ...is 3 The engine assembly as per supply volume Additionally all added on parts as in the supply volume such as filters intake silencer fuel pump external generator sensors ignition unit electric starte...

Page 47: ...brication system which are part of the engine supply volume and if they are not in the maintenance schedule of aircraft manufacturer Connecting hose of the air intake system Venting hose of the fuel p...

Page 48: ...Page 8 January 01 2020 Effectivity 912 Series INTENTIONALLY LEFT BLANK BRP Rotax MAINTENANCE MANUAL LINE...

Page 49: ...ss 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 As the party primarily respons...

Page 50: ...eeded This means that if a 100 hr check is actually carried out at 110 hr the next check will be due at 200 hr 10 hr and not at 210 hr 10 hr If maintenance is performed before the prescribed interval...

Page 51: ...ing Danger of overheating Exhaust fixation Re tighten the exhaust fixation on the cylinder head after the first 2 hr of operation Leakage Exhaust Of the exhaust unit where nec essary replaced applicat...

Page 52: ...NACA intake As specified by the aircraft manufacturer See specifics of manufacturer Aircraft attachment points of engine suspension As specified by the aircraft manufacturer See specifics of manufactu...

Page 53: ...rial fatigue or stress corrosion and other visually evident damage Fuel Air and Oil lines and Hoses Cracks dents kinks required flexibility collapsed lines hoses abrasion cleanliness se cure seating a...

Page 54: ...ance check list All the maintenance work carried out must be initialled in the signature area by the air craft mechanic performing the task Maintenance records After maintenance the completed check li...

Page 55: ...rcraft model and S N Time since new Propeller Propeller brand Propeller model and S N Governor brand Governor model and S N ENGINE Engine type Engine S N TSN time since new TSO time since overhaul Use...

Page 56: ...ENANCE FACILITY Maintenance workshop Address Telephone Fax E mail Certificate This check is applica ble circle one 25 hr 50 hr 1 100 hr 200 hr 400 hr 600 hr 1000 hr 1 leaded fuel more than 30 of opera...

Page 57: ...dic maintenance re quirement after the first 25 hours of operation 25 50 100 200 400 600 1000 1 General note All Alert Service Bulletins are com plied with If necessary to perform these and documented...

Page 58: ...than 30 of operation X 3 X 12 20 00 Installation of spark plug 4 Inspecting the magnetic plug Check the magnetic plug X X 12 20 00 Inspecting the mag netic plug 5 Inspecting the oil filter Remove old...

Page 59: ...l ant level replenish as necessary Inspect radiator cap Inspect protec tion rubber on expansion tank base for correct fit X X 12 20 00 Expansion tank radia tor cap Inspect the overflow bottle for dam...

Page 60: ...sors for tight fit damage from heat damage and signs of wear X X Checking the air filter X X 12 20 00 Cleaning the dry air filter Inspect of the GENUINE ROTAX exhaust system included in the standard d...

Page 61: ...the float chamber ventilation impairs engine and carburetor function and must therefore be avoided Check that the passage of the venti lation lines is free and that no kinks can arise X Check for fre...

Page 62: ...ad drain holes is installed and use of leaded fuel more than 30 of operation Inspect overload clutch X 5 X 05 50 00 Checking the overload clutch 12 20 00 Checking the propeller gearbox Checking the pr...

Page 63: ...17 Engine test run Observe the safety instructions Start the engine and run to operating temperature Limits see Operators Manual 912 Series Ignition check at _____ rpm engine speed Speed drop without...

Page 64: ...25 hr 50 hr 100 hr 200 hr 400 hr 600 hr 1000 hr please strike out not applicable intervals maintenance interval was performed Check at______hr TSN___ TSO___ was carried out according to recommendation...

Page 65: ...n 24 Exceeding the max permissible oil temperature 25 Oil pressure below minimum value 26 Oil specification not respected 29 Spark plug not in accordance with specification 31 Non compliance of fuel q...

Page 66: ...r it has been repaired General visual inspection See Chapter 12 20 00 Engine cleaning See Chapter 12 20 00 Carry out an engine test run See Chapter 12 20 00 Remove surrounding assemblies and detach oi...

Page 67: ...e not to damage the bearing point and the oil seal running surface on the roller bearing side of the propeller shaft Figure 5 1 typical 1 Allen screw M8 2 Allen screw M6 Figure 5 2 1 Puller part no 87...

Page 68: ...ight and left of the gearbox housing 2 Install hex screw M6x40 into the pushing jig assy 3 Put the pushing jig assy in the center and fix it with a hex screw M10x20 4 Using the hex screw press the gea...

Page 69: ...12 248 F 3 Turn clockwise left hand threads to loosen hex nut M30x1 5 with sock et wrench SW 41 part no 877445 Figure 5 4 1 Socket wrench SW 41 part no 877445 2 Hex nut M30x1 5 Step Procedure 4 Remove...

Page 70: ...or pressing The drive gear must only be pushed on manually ATTENTION Ensure that the friction washer is in the correct installation position ATTENTION The dog and drive gears are in pairs Only use par...

Page 71: ...o push the drive gear onto the end of the crankshaft If necessary turn it and push it on in another position Step Procedure 2 Secure the hex nut M30x1 5 with LOCTITE 648 and screw it counter clockwise...

Page 72: ...and repeat the measurement Step Procedure 5 Insert 2 dowel pins 6x20 into the crankcase 6 Apply engine assembly grease into the needle bearing and lubricate the crankshaft with LOCTITE Anti Seize NOT...

Page 73: ...d to the sealing surface of the gearbox housing 9 Fit gearbox into position carefully aligning crankshaft dowels and gears NOTE Move the propeller shaft a little to allow the dog gear to engage ATTENT...

Page 74: ...roller bearing may not be in position Figure 5 9 TYPICAL 1 Allen screw M8 2 Allen screw M6 Step Procedure 11 Tighten 2 Allen screws M8x45and 8 Allen screws M6x45 with washers 6 4 diagonally from each...

Page 75: ...kshaft distortion inspection see Chapter 72 00 00 continue as following 7 Remove drive gear from crankshaft in accordance with Chapter 05 50 00 8 Remove and replace the roller bearing in crankcase for...

Page 76: ...n for a short time max 1 day prior to the test otherwise there is the risk of the clutch drying out resulting in a higher torque Step Procedure 1 Remove the propeller as per manufacturers instruction...

Page 77: ...ller flange support of specially prepared lever torque wrench adapter plate Figure 5 11 Side view TYPICAL ATTENTION Danger of damage to the engine suspension Depending on the engine installation e g i...

Page 78: ...red 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 conti...

Page 79: ...gnition system shorting cable Ignition module wiring connectors charging coil ignition switch s Spark plug malfunction grounding defect wrong spark plug connection loose connection Rough running engin...

Page 80: ...tructions for continued airworthiness Inspect all systems for correct functioning Detailed inspection of affected engine components Cylinder head A rise in cylinder head temperature above normal opera...

Page 81: ...cted for cor rosion For accessories e g vacuum pump fuel filter etc the instructions and specifications of the corresponding manufacturer must be followed Complete inspection of these components power...

Page 82: ...h 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...

Page 83: ...ndness and distortion See Chapter 72 00 00 of the latest Heavy Maintenance Manual 4 Inspect all systems for correct functioning 5 Detailed inspection of affected engine components more than 6500 rpm I...

Page 84: ...max admissible cooling system temperature must be en tered by the pilot into the engine log book stating duration extent of excess tem perature and pertinent detail Exceeding of max cylinder head temp...

Page 85: ...or the operating limit for longer than 30 min Check all coolant fittings feed outflow for secure fit Exceeding over 180 C 356 F Table 2 Temperature exceeded 180 C 356 F and or the operating limit for...

Page 86: ...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 exce...

Page 87: ...and or the operating limit for longer than 30 min Check all coolant fittings feed outflow for secure fit Exceeding over 135 C 275 F Table 2 Temperature exceeded 135 C 275 F and or the operating limit...

Page 88: ...ifferent coolant than the former one conventional coolant used then the coolant system has to be flushed See Chapter 12 20 00 section Flushing the cooling system 2 Fill expansion tank with new coolant...

Page 89: ...erature and pertinent detail Proceed as instructed in table 4 Proceed as instructed in table 3 Operating limit See Operators Manual 912 Series 160 C 320 F 0 15 min Time Figure 5 14 Overview and procee...

Page 90: ...uctions for continued airworthiness 2 Inspect all further systems for correct functioning 3 Carry out detailed inspection of the affected engine components 4 The whole oil system oil cooler oil lines...

Page 91: ...912 005 latest issue If the oil pressure falls below the minimum value up to max 0 5 bar 7 25 psi and for max 1 min the cause must be determined Table 5 Oil pressure below minimum permissible oil pre...

Page 92: ...the re installation of the engine the complete lubrication system inclusive oil tank must be flushed Minimum oil pressure in flight more then 0 5 bar 7 25 psi Consequent damage can be expected if the...

Page 93: ...move the lowest positioned banjo screw 1 banjo bolt plug screw or screw socket and drain the remaining oil from the crankcase Re install in banjo bolt or plug screw Tightening torque see Installation...

Page 94: ...Rotax instructions for continued airworthiness 3 Carry out detailed inspection of the affected engine components 4 Oil change 5 Remove the lowest positioned banjo screw banjo bolt plug screw or screw...

Page 95: ...tion Step Procedure 1 Mark position of the spark plugs e g cylinder 1 top and remove all spark plugs 2 Inspect the spark plugs for damage formation of melt beads burn off At heavy melt beads or bad bu...

Page 96: ...OFF and system grounded Disconnect negative terminal of battery Inspection Inspection of smooth performance of the engine should be performed at a temperature about 0 C to 60 C 140 F Engine runs slug...

Page 97: ...the engine Different types of damage can be caused depending on the type of lightning strike Indirect lightning strike Perform the corresponding inspections repairs depending on the functional defects...

Page 98: ...rike Send the engine without delay to an authorized ROTAX overhaul facility for inspection REPORTING General note In case of any relevant occurrences that may involve malfunction of the engine the for...

Page 99: ...BRP Rotax MAINTENANCE MANUAL LINE Figure 5 18 Form Effectivity 912 Series Rev 05 50 00 Page 35 January 01 2020...

Page 100: ...Page 36 January 01 2020 Effectivity 912 Series INTENTIONALLY LEFT BLANK BRP Rotax MAINTENANCE MANUAL LINE...

Page 101: ...s only as a supplement to and further explanation of the maintenance check list See Chapter 05 20 00 NOTE For reasons of clarity only headlines and keywords are listed in the Maintenance Schedule Plea...

Page 102: ...Page 2 January 01 2020 Effectivity 912 Series INTENTIONALLY LEFT BLANK BRP Rotax MAINTENANCE MANUAL LINE...

Page 103: ...nish 4 Lubrication system 7 Oil level check Replenish 7 Introduction The engine should always be in a horizontal position before checking the fill levels ENVIRONMENTAL NOTE All operating materials and...

Page 104: ...VICING POINTS ON THE ENGINE Overview AE_912_0086 2 4 1 5 6 3 Figure 6 1 1 Expansion tank 2 Radiator cap 3 Oil filter 4 Oil tank 5 Oil tank cover without venting 6 Oil dipstick 12 10 00 Page 2 January...

Page 105: ...provided by the aircraft manufacturer Refer to the corresponding chap ter in the Flight Manual Cooling system Approx 1 5 l 0 4 US gal Refer to the corresponding chap ter in the Operators Manual Oil s...

Page 106: ...ke cover cap with a rag and open slowly Sudden opening of the cap could provoke the escape of boiling coolant and result in scalding ENVIRONMENTAL NOTE Coolant and mixtures of coolant and water have t...

Page 107: ...t coolant with densimeter or glycol tester Strongly discolored or thickened coolant must be replaced ATTENTION Use only coolant as recommended in the current Operators Manual Step Procedure 4 If neces...

Page 108: ...ne until the temperatures have stabilized for a period of 5 min engine oil temperature between 50 to 70 C 122 160 F 2 Switch the engine OFF 3 Allow the engine to cool down 4 Check for leaks 5 Check th...

Page 109: ...e propeller several times by hand in direction of engine rotation to pump residual oil from the engine to the oil tank 2 This process is completed when air flows back to the oil tank This air flow can...

Page 110: ...d the latest Service Instruction Selection of suitable operating fluids of the respec tive engine type Step Procedure 6 Replenish oil as required 7 Check oil level Marks on the oil dipstick 8 Fit the...

Page 111: ...il level and top up with oil as required 2 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 3 Switch the engine OFF 4...

Page 112: ...Page 10 January 01 2020 Effectivity 912 Series INTENTIONALLY LEFT BLANK BRP Rotax MAINTENANCE MANUAL LINE...

Page 113: ...ooling system 20 Replacing the coolant 20 Flushing the cooling system 22 Expansion tank radiator cap 23 Overflow bottle 24 Accessories including radiator radiator hoses hose clamps cooling air ducts 2...

Page 114: ...ark plugs 57 Inspection of spark plugs 57 Installation of spark plug 58 Propeller gearbox 60 Checking the propeller gearbox 60 Checking the friction torque in free rotation 60 Introduction This chapte...

Page 115: ...with a high pressure cleaner This is detrimental to the electrical installations and shaft seals Oxidation of the various components and their potential failure may occur ATTENTION Before cleaning al...

Page 116: ...specified fastener Checking the en gine suspension Step Procedure 1 Verify the engine suspension points on the crankcase for tight fit and dam age including cracks 2 Inspect the surroundings of engin...

Page 117: ...until the temperatures have stabilized for a period of 5 min engine oil temperature between 50 to 70 C 122 158 F 3 Switch OFF ignition and secure engine against unintentional operation Secure aircraf...

Page 118: ...l out of the venting tube In case of uncertainty determine the oil amount An oil leak is when after 20 min engine run more than 0 5 ml of oil loss is detected Oil hoses Inspect all oil feed hoses from...

Page 119: ...ifferential pressure check TYPICAL 1 Adaptor 2 Manometer Test gauges set 3 Orifice jet 4 Compressor Special tools To measure the differential pressure the following special tools and equipment are nec...

Page 120: ...this procedure on all 4 cylinder heads Value The maximum permissible pressure drop is 25 e g from 6 to 4 5 bar 87 psi to 65 psi D If the pressure loss is less than 25 then the valve seats and piston...

Page 121: ...dings on all four cylinders and compare results Measurement 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 overh...

Page 122: ...x20 and sealing ring from the crankcase half cyl 2 4 2 Turn crankshaft propeller shaft until the piston of cyl no 1 and no 2 are in TDC position and lock crankshaft in this position with the thread bo...

Page 123: ...gger boss 4 5 Trigger coils 6 Crankshaft 7 Hex screw M16x1 5x40 Loosen of the crankshaft After completion of work check Step Procedure 1 Remove the thread bolt 2 and refit crankshaft Allen screw M8x20...

Page 124: ...ish fuel supply open fuel cock 2 Activate choke 3 Throttle lever to idle position 4 Master switch ON 5 Ignition for both ignition circuits ON 6 Press starter switch for max 10 sec followed by a coolin...

Page 125: ...and ensure the ignition is switched off and engine secured against unintentional opera tion Coolant must not drip through leakage bore located at the base of the ignition housing for a period of 1 mi...

Page 126: ...tions with additional auxiliary generator inspect attachment and V belt tension Checking the V belt tension Figure 7 6 Checking the V belt tension BELT TENSION ADJUSTMENT 00353 2 1 3 Figure 7 7 Overvi...

Page 127: ...e hex screw 1 M10 and the two M8 allen screw 2 and 3 2 Press the alternator upwards and tighten allen screw 3 3 Then tighten hex screw 1 M10 with tightening torque 40 Nm 30 ft lb and allen screw M8 2...

Page 128: ...truction To check the air intake system the following steps are necessary Step Procedure 1 Visual inspection of the air filter 2 Visual inspection of the airbox for mechanical damage cracks leaks con...

Page 129: ...lly C 08864 A B C Figure 7 8 Cleaning the dry air filter After cleaning ATTENTION Never use gear oil diesel or engine oil as they attract humidity Overoiling of the air filter reduces airflow causing...

Page 130: ...Air filter 2 Safety wire 3 Carburetor ATTENTION Each air filter must be secured by clamp attachment and a wire securing element See chapt 05 00 00 section Acceptable methods techniques and practice F...

Page 131: ...otax MAINTENANCE MANUAL LINE COOLING SYSTEM 1 3 08532 2 4 3 3 Figure 7 11 Overview 1 Expansion tank 2 Radiator cap 3 Coolant hose 4 Water pump Effectivity 912 Series Rev 0 12 20 00 Page 19 January 01...

Page 132: ...pect the gasket of the radiator cap 4 and check the pressure release valve and return valve for proper operation See Chapter 12 20 00 section Expansion tank Radiator cap REPLACING THE COOLANT General...

Page 133: ...itioned coolant hose 4 Fit Allen screw stainless steel along with a new sealing ring Tighten to 10 Nm 89 in lb 5 If the coolant is being replaced with a different type the cooling system must be flush...

Page 134: ...flushed using pure alternative is distilled water at a pres sure of 2 bar 29 psi NOTE For the flushing open the lowest located coolant hose either at water pump or radiator 2 Refill newly mixed coolan...

Page 135: ...ens and the coolant can flow into the overflow bottle via the line 5 When the coolant cools down the return valve 2 opens and the coolant is sucked back Radiator cap Inspect the rubber seal 3 the pres...

Page 136: ...eck the venting bore 1 in the screw cap 3 Inspect tab 2 for the safety wire 4 Check hose connection 3 ACCESSORIES INCLUDING RADIATOR RADIATOR HOSES HOSE CLAMPS COOLING AIR DUCTS General note Accessori...

Page 137: ...synchronize when idling the following steps are necessary Step Procedure 1 Detach the resonator hose of the compensating tube to separate the two air intake systems In this condition a slight differen...

Page 138: ...ns clockwise 6 Gently turn each idle mixture screw 6 clockwise until it is fully inserted and then reopen by 1 5 turns counter clockwise 7 Check that the throttle valve opens fully automatically 8 Adj...

Page 139: ...e idle mix ture screw Carry out the above procedure on both carburetors X AE_912_0084 2 4 3 5 1 7 8 6 Figure 7 16 Mechanical synchronization 1 Throttle valve lever 2 Adjustment screw 3 Idle stop posit...

Page 140: ...Possible connection methods Option 1 Step Procedure 1 Remove the compensating tube 2 from the push on angular tube 4 after removing the two clamps 2 Using the push on angular tube 4 and compensating t...

Page 141: ...ter removing the two tension clamp 4 2 Using the push on angular tube 5 and compensating tube 2 install a flexi ble rubber hose 6 leading to the vacuum gauge 1 AE_912_0087 2 5 1 4 3 6 Figure 7 18 Opti...

Page 142: ...crew M6x6 with LOCTITE 243 2 1 4 3 1 2 4 AE_912_0088 Figure 7 19 Option 3 1 Hex screw M6x6 2 Intake manifold 3 Compensation tube 4 Resonator hose Option 4 Step Procedure 1 Remove hex screw M6x6 from i...

Page 143: ...safe area around propel ler during test run Start the engine and verify the idle speed If necessary correct as per Chapter 12 20 00 section Idle speed adjustment Setting of more than 1 2 turn If a se...

Page 144: ...adings If the same reading is not made on both gauges Step Procedure 1 Shut down the engine 2 Check that carburetor actuation effects full travel and that starting carburetors choke are in the full of...

Page 145: ...nsation tube assy on engine in reverse sequence of removal Any minor differences in balance at idle speed will be compensated for Refit the screw plug M3 5 3 and hex screws M6x6 with gasket X AE_912_0...

Page 146: ...floats 4 Remove both floats 5 from the float chamber 5 Accomplishment of section Check of weight of the floats 6 Inspect the float chamber for contamination and corrosion ATTENTION If any contaminati...

Page 147: ...t with fuel Step Procedure 1 Let the floats dry for 1 2 minutes then weigh the floats Only weigh dry floats 2 Check the weight of all affected floats using a calibrated scale Measuring tolerance of th...

Page 148: ...RP Rotax MAINTENANCE MANUAL LINE AE_912_0092 2 4 3 5 1 Figure 7 22 Float chamber 1 Drip tray 2 Spring clip 3 Float chamber 4 Gasket 5 Float 12 20 00 Page 36 January 01 2020 Effectivity 912 Series Rev...

Page 149: ...ssary only if not taken care of at synchronization Step Procedure 1 Close idle mixture screw by turning clockwise to screw in fully and then opening again by 1 5 turns counter clockwise 2 Starting fro...

Page 150: ...n spring or a cable with pull push action would have to be used Se cure the bowden cable sleeves in the adjustment screws e g safety wire m WARNING Risk of life threatening injuries caused by propelle...

Page 151: ...n spring LEAK TESTS General note ATTENTION Avoid over tightening the fasteners Use a suitable torque wrench for all work Instruction To check the following steps are necessary Step Procedure 1 Inspect...

Page 152: ...ANUAL LINE LUBRICATION Overview IN O U T return from engine to oil pump 08238 Figure 7 24 Figure 7 25 1 Oil tank 2 Drain screw M12x12 3 Oil radiator 4 Oil filter 12 20 00 Page 40 January 01 2020 Effec...

Page 153: ...erve ATTENTION Observe the following to prevent possible unintentional voiding of the oil system and damage to the valve drive Draining the suction lines oil cooler and return line is not necessary an...

Page 154: ...rt 4 Dispose of oil filter according to environmental regulations 5 Install oil drain screw with new gasket and safety wire tightening torque 25 Nm 18 ft lb Step Procedure 1 Crank engine slowly by han...

Page 155: ...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 m...

Page 156: ...g special tool taking care not to produce chips Special tools To carry out the procedure the following tools are necessary part number Description part no 877620 1 Oil filter wrench part no 877670 2 C...

Page 157: ...old up and press remaining oil out 5 Unroll and inspect it for metal chips foreign matter contamination and abrasion 6 Pass over matt with a clean magnet and inspect for metal Possible foreign matter...

Page 158: ...the oil filter once more Contaminated ATTENTION If the oil circuit is contaminated replace the oil cooler and flush the oil circuit See chapter 12 20 00 section Flushing the oil circuit Proper judgeme...

Page 159: ...AL LINE AE_912i_0092 2 3 1 4 5 5 from oil pump to bearings Figure 7 27 Oil filter 1 Filter housing 2 Filter cover 3 Gasket ring 4 Anti drain membrane 5 Filter matt Effectivity 912 Series Rev 0 12 20 0...

Page 160: ...n the gasket 3 of the oil filter 4 3 Install the oil filter on the engine 4 Screw on oil filter until oil filter gasket is seated solidly NOTE Mark 270 check mark on oil pump housing to control tighte...

Page 161: ...ure 1 Detach the profile clamp 2 and remove the oil tank cover 3 together with the O ring 4 and the oil lines 2 Remove the inner parts of the oil tank such as the baffle insert 5 and the partition 6 3...

Page 162: ...gure 7 29 Oil tank 1 Hex screw M12x12 2 Profile clamp 3 Oil tank cover assy Metric AN 4 O ring 5 Baffle insert screen 6 Partition 7 Gasket ring 12x18 8 Oil tank 9 Safety wire 12 20 00 Page 50 January...

Page 163: ...pened and voided e g removal of the oil tank or oil cooler replacement of oil lines FLUSHING THE OIL CIRCUIT General note m WARNING Risk of electric shock Ignition OFF and system grounded Disconnect n...

Page 164: ...discovered 2 Control the oil captured during the rinsing process The rinsing process is complete when no more contamination can be discovered 3 Re install cleaned oil lines and oil cooler according to...

Page 165: ...metal chips on the magnetic plug the engine must be repaired or overhauled in accordance with the BRP Rotax instructions for continued airworthiness Unclear findings In the case of unclear findings St...

Page 166: ...llowing steps are necessary Step Procedure 1 Clean the magnetic plug 2 Install the magnetic plug Tightening torque 25 Nm 18 ft lb 3 Secure with safety wire Inspect all systems for correct function Det...

Page 167: ...AE_912_0091 2 4 3 5 1 3 6 7 6 Figure 7 31 Overview 1 Spark plug connectors 2 Dual ignition coil 3 Ignition cable 4 Electronic module 5 Plug connectors 6 Grounding cable 7 Protection hose Effectivity...

Page 168: ...ing and shorting cables for corrosion or damage and replace as required 4 Inspect plug connections between electronic module and ignition coils for corrosion or damage and replace if necessary 5 Veri...

Page 169: ...E THE SPARK PLUGS Remove Remove the spark plugs and store them according to cylinder and position INSPECTION OF SPARK PLUGS Visual check Inspect all spark plugs for mechanical damage Electrode gap NOT...

Page 170: ...r and piston rings white with formation of melt beads Possibly indicates one or more of the following mixture too lean leaking valves INSTALLATION OF SPARK PLUG Figure 7 32 Spark plugs 1 Ground electr...

Page 171: ...of a cylinder and do not interchange spark plugs between cylinders ATTENTION Heat conduction compound at the ground electrode or the head area can lead to ignition problems Apply heat conduction comp...

Page 172: ...when sending the gearbox for repairs or overhaul CHECKING THE FRICTION TORQUE IN FREE ROTATION General note m WARNING Risk of electric shock Ignition OFF and system grounded Test procedure The followi...

Page 173: ...e distance the scale is attached from the center of the pro peller L The friction torque must be between 30 Nm and max 70 Nm 22 to 51 6 ft lb See calculation example ATTENTION If the above mentioned f...

Page 174: ...Page 62 January 01 2020 Effectivity 912 Series INTENTIONALLY LEFT BLANK BRP Rotax MAINTENANCE MANUAL LINE...

Page 175: ...check after propeller strike incidents 2 Engine cleaning 3 Engine submerging in water 17 Examination after engine failure 15 Exceeding of max admissible engine RPM 18 Exceeding of max cooling system t...

Page 176: ...gearbox 2 Remove the spark plugs 57 Replacement of spark plugs 57 Replacing the coolant 20 Replacing the dry air filter 18 Replenishing operating fluids 1 Reporting 34 S Safety 9 Safety information 10...

Page 177: ...Engine serial no Type of aircraft Aircraft registration no Rotax authorized distributor FLYROTAX COM and TM are trademarks of BRP Rotax GmbH Co KG 2020 BRP Rotax GmbH Co KG All rights reserved...

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BRP ROTAX 912 A, Maintenance Manual

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Summary of Contents for ROTAX 912 A

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