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MAINTENANCE MANUAL

BRP-Powertrain

Effectivity: 912 i Series
Edition 1/Rev. 0

05-50-00

page 8

January 01/2012

- The whole engine must be inspected, repaired or overhauled in accor-

dance with the BRP-Powertrain instructions for continued airworthi-
ness.

- Inspect all systems for correct functioning.

- Detailed inspection of affected engine components.

Cylinder head

A rise in cylinder head temperature above normal operating limits (see
Operators Manual) is a clear signal for a failure in the cooling system.

Cylinder head temperature too high

part

possible cause

Cooling system

not enough coolant
bad venting

Return valve, pressure relief valve

malfunction

Radiator

contaminated
sealing of intercooler to cowling
poor cooling flow

Radiator cap

leaking

Water pump

malfunction

Summary of Contents for 912 iS Sport

Page 1: ...AIRCRAFT ENGINES ref no MML 912 i part no 898742...

Page 2: ...r written permission of BRP Powertrain GmbH Co KG be disclosed in whole or in part to third parties This legend shall be included on any reproduction of these data in whole or in part Copyright 2012 a...

Page 3: ...iation standards The aim is the compat ibility with the aircraft manufacturers documentation which means they must then adapt the documentation to their standard They partially mod ular design offers...

Page 4: ...d05020 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 INTRO page 2 January 01 2012 NOTES...

Page 5: ...6 7 8 9 10 11 12 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 05 10 00 1 2 3 4 5 6 7 8 07 01 2012 01 01 2012 01...

Page 6: ...012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 2012 01 01 201...

Page 7: ...AL OF THE EASA no chapter page date of change remark for approval date of ap proval from authorities date of inclusion signature 0 0 0 0 INTRO LEP TOA 00 00 00 all all all all 01 01 2012 01 01 2012 01...

Page 8: ...d05441 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 TOA page 2 January 01 2012 NOTES...

Page 9: ...y of the relevant amendments in this context but without require ment on completeness current no chapter page date of change comment 1 1 1 04 00 00 05 10 00 05 50 00 1 7 21 07 01 2012 07 01 2012 07 01...

Page 10: ...d05441 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 TOA page 4 January 01 2012 NOTES...

Page 11: ...s includes 912 iSc and 912 iS Table of contents This chapter of the Maintenance Manual contains general and safety information concerning the operation and maintenance of the aircraft engine Subject P...

Page 12: ...d05023 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 00 00 00 page 2 January 01 2012 NOTES...

Page 13: ...ided by the aircraft manufac turer and or dealer For additional information on engines maintenance or parts you can also contact your nearest authorized ROTAX aircraft engine distributor ROTAX Distrib...

Page 14: ...d05023 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 00 00 00 page 4 January 01 2012 NOTES...

Page 15: ...nating current Ah Ampere hour A C Aircraft AD Airworthiness Directive A F Across flat dimension ASB Alert Service Bulletin ACG Austro Control GmbH API American Petrol Institute ASTM American Society f...

Page 16: ...LEP List of Effective Pages MAPS 1 2 Manifold Air Pressure Sensor 1 2 MATS 1 2 Manifold Air Temperature Sensor 1 2 MM Maintenance Manual MON Motor Octane Number MS Magneto Side N new part only Illustr...

Page 17: ...SL Service Letter SMD Surface Mounted Devices S N Serial Number s v still valid only Illustrated Parts Catalog TOA Table of amendments TC Type certificate TOC Table of Contents TSN Time Since New TSN...

Page 18: ...4 5461 dm3 1 dm3 0 26417 gal US 1 gal US 3 7854 dm3 Units of velocity 1 m s 3 6 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 1 kg 2 2046...

Page 19: ...place or discontinue any design specification fea ture or otherwise Measure Specifications are given in the SI metric system with the USA equivalent in parenthesis Symbols used This Manual uses the fo...

Page 20: ...n prevails Warning It is your responsibility to be completely familiar with the safety instructions including warnings and cautions described in this Manual These warnings and cautions advise of speci...

Page 21: ...g locking tab self locking fasteners etc must be installed or replaced with new ones where specified If the efficiency of a locking device is impaired it must be replaced Torque wrench tightening Torq...

Page 22: ...ools Standstill After engine standstill longer than 2 months observe without fail the instructions for engine out of use Protect fuel system against contamination Returning When returning the engine o...

Page 23: ...Mainte nance Chapter 00 05 and 12 The scope of line maintenance consists of removal installation and adjustment of engine components including part wear All procedures in this Manual are to be consid...

Page 24: ...Bulletin Service Bulletin Service Instruction Service Letter Status The status of the Manuals can be determined with the aid of the table of amend ments The first column indicates the revision state T...

Page 25: ...rrange ment They may not represent in full detail or the exact shape of the parts which have the same or similar function Therefore deduction of dimensions or other details from illustrations is not p...

Page 26: ...gulatory safety or durability testing and conform to no aircraft standards These engines are for use in experimental uncertificated aircraft and vehicles only in which an engine failure will not compr...

Page 27: ...descriped in chapter 05 and are a required by the authority in order to ensure the Continued Airworthiness See chapt 05 00 00 Continued Air worthiness Scheduled inspections of the engine including rep...

Page 28: ...d05442 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 04 00 00 page 2 January 01 2012 NOTES...

Page 29: ...er normal working conditions Table of contents In this chapter the maintenance of engine ROTAX 912 i Series is described The description is subdivided into sections and description of function of the...

Page 30: ...d05025 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 05 00 00 page 2 January 01 2012 NOTES...

Page 31: ...of the engine manufacturer Parts and acces sories We particularly emphasize that parts and accessories not supplied as genuine BRP Powertrain parts are not verified for suitability by BRP Pow ertrain...

Page 32: ...o contact BRP Powertrain through its worldwide distribu tion network for information and guidance on any of the tasks outlined herein See chap 00 00 00 section 3 4 Requisite knowledge of the task as a...

Page 33: ...maintain a cur rent status In order to be eligible for the renewal program training the technician must be able to show and declare that they have been working on ROTAX engines during the past 2 years...

Page 34: ...these marks don t ruin them WARNUNG WARNING Non compliance can result in serious injuries or death When carrying out maintenance and service work re spect without fail all safety regulations WARNUNG...

Page 35: ...ubricants cleaning agents and solvents indicated in the mainte nance instructions Failure to comply may result in damage WARNUNG NOTICE In order to avoid mechanical damage always loosen or tighten scr...

Page 36: ...n 1 Rev 0 05 00 00 page 8 January 01 2012 1 4 Trouble shooting General notes In the Operators Manual possible problems are listed At the same time a brief description of the necessary remedial action...

Page 37: ...maintenance work When handling chemicals comply with all the custom ary regulations and specifications of the producer in cluding the expiry date and instructions of use No part no Description Applica...

Page 38: ...and can be subject ed to mechanical loads 13 n a Preservation oil Requirements The preservation oil has excel lent penetrating capabilities and reaches even tiny gaps it s highly effective additives...

Page 39: ...le for local and gradual very fine treatment of steel parts with rust film propeller shaft The MICRONORM abrasive contains no noxious matter is approved by the relevant authorities and guarantees opti...

Page 40: ...urized areas for which there are no separate maintenance and repair instructions Self locking All instructions regarding the securing and lubrication of parts must be observed Adherence to specified t...

Page 41: ...e maintenance is to help avoid and or detect possible engine issues Table of contents This chapter of the Maintenance Manual contains general information regarding TBO and time limits on components Su...

Page 42: ...d05443 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 05 10 00 page 2 January 01 2012 NOTES...

Page 43: ...ertain intervals are based on experience from long test runs and field observations They are intended as precautionary maintenance measures in order to ensure continued trouble free operation of the e...

Page 44: ...Maintenance of operation The TBO values approved by the relevant authorities are based on perfor mance tests and empirical values which have been gathered through operation of the engine and are requi...

Page 45: ...of contaminants Storage period of the engine Observe the storage and preservation directives NOTE The maximum possible storage period of the engine is limited to 24 months If this period is exceeded...

Page 46: ...15 years whichever comes first 1 1 Engine log book 2 Maintenance records of the engine i e all maintenance check lists and reports of operation of maintenance of findings and of oil analyses 3 The en...

Page 47: ...out periodically after every 100 hours of operation or every 12 months whichever comes first See chapt 05 20 00 section 1 WARNUNG NOTICE This time limit must be followed independently and in addition...

Page 48: ...d05443 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 05 10 00 page 8 January 01 2012 NOTES...

Page 49: ...the maintenance and air worthiness of the engine the owner or user should only have the mainte nance work carried out by qualified engineers Documentation required It is the responsibility of the own...

Page 50: ...d05027 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 05 20 00 page 2 January 01 2012 NOTES...

Page 51: ...k a tolerance of 10 hr is permissible but these tolerances must not be exceeded 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 a...

Page 52: ...January 01 2012 25 hr check In order to demonstrate continued airworthiness an engine must be inspected after the first 25 hours of operation The checks performed at the 25 hr inspection are the same...

Page 53: ...oring and warping 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 rep...

Page 54: ...as specified by the cell manu facturer See specifics of manufac turer Cell side attach ment points of en gine suspension as specified by the cell manu facturer See specifics of manufac turer Throttle...

Page 55: ...ting surface condition cleanliness deformation cracks in welding seams or due to material fatigue or stress corrosion and other visually evident damage Fuel Air and Oil lines Cracks dents kinks requir...

Page 56: ...d05027 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 05 20 00 page 8 January 01 2012 NOTES...

Page 57: ...ions The respective check e g 100 hr check must be noted on the top of each page of the maintenance check list All the maintenance work carried out must be initialled in the signa ture area by the air...

Page 58: ...d05027 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 05 20 00 page 10 January 01 2012 NOTES...

Page 59: ...on AIRCRAFT Registration number Aircraft make Aircraft model and S N Time since new Propeller brand Propeller model and S N Governor brand Governor model and S N ENGINE Engine type Engine S N ECU S N...

Page 60: ...nuary 01 2012 MAINTENANCE FACILITY Maintenance workshop Address Telephone Fax E mail Certificate This check is applicable cir cle on 25 hr 50 hr 1 100 hr 200 hr 500 hr 1000 hr 1 leaded fuel more than...

Page 61: ...ct and cooling fins of the cylin ders for obstruction cracks wear and good condition Take note of changes caused by temperature influ ence recommended 50 hr X 12 20 00 sec 2 Visual inspection of the E...

Page 62: ...for secure fit damage and signs of wear X 12 20 00 sec 15 1 2 Magnetic plug Check the magnetic plug X 12 20 00 sec 13 3 Compression check Check the compression by the differential pressure method Tes...

Page 63: ...he heat range desig nation clean check electrode gap and adjust if nec essary Replace as required X 12 20 00 sec 15 2 Replacing spark plugs every 200 hr X 1 12 20 00 sec 15 2 1 use of leaded fuel more...

Page 64: ...ery 1000 hr 12 20 00 sec 16 1 17 Oil change Drain oil from oil tank every 50 hr 1 X 12 20 00 sec 12 2 12 6 Check the oil tank and clean the oil tank if contaminat ed every 200 hr 1 X 12 20 00 sec 12 2...

Page 65: ...Inspect the fuel system for leaks X 12 20 00 sec 12 2 Inspect the fuel system for damages X 22 Engine test run Observe the safety instructions Start the engine and run to operating temperature Limits...

Page 66: ..._____ the________hr Check at______hr TSN___ TSO___ was carried out according to recommendations of the engine manufac turer and was recorded in the Engine Log book Location Date_______________________...

Page 67: ...gine test run and a leakage check must be carried out WARNUNG NOTICE Observe without fail all the specified instructions Subject Page Engine check after propeller strike incidents Propeller gearbox wi...

Page 68: ...d05028 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 05 50 00 page 2 January 01 2012 NOTES...

Page 69: ...craft manufacturer 4 Remove the fuel pump and gearbox Perform a crankshaft out of round ness inspection on PTO side See chapter 72 00 00 Heavy Maintenance If measuring up is inside the value 0 08 mm c...

Page 70: ...d05028 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 05 50 00 page 4 January 01 2012 NOTES...

Page 71: ...short time just prior to the test otherwise there is the risk of the clutch drying out resulting in a higher torque Fig 1 Step Procedure 1 Remove the propeller as per manufacturers instruction 2 Lock...

Page 72: ...er arm L used at the normal distance from it in m N x m Nm Obtained value The value determined must be between 600 and 800 Nm 442 and 590 ft lb If the value is greater or smaller than the limit values...

Page 73: ...ontamination Ignition system shorting cable charging coil ECU FUSE BOX Spark plug malfunction grounding defect wrong spark plug connection loose connection Rough running engine part possible cause Ign...

Page 74: ...ct functioning Detailed inspection of affected engine components Cylinder head A rise in cylinder head temperature above normal operating limits see Operators Manual is a clear signal for a failure in...

Page 75: ...manufacturer must be followed In most cases an overhaul is necessary in this regard send the engine without delay to an authorized ROTAX overhaul facility for inspection If an engine was submerged in...

Page 76: ...ection Read out the ECU data memory and check the data for details of dimin ished functional capability of ECU Perform the corresponding inspections repairs depending on the functional defects found 3...

Page 77: ...e 1 Check that the push rods are straight Step Procedure 1 The whole engine must be inspected repaired or overhauled in accor dance with the BRP Powertrain instructions for continued airworthiness 2 C...

Page 78: ...elevant instructions 135 C 275 F 0 30 min Time Proceed as instructed in table 2 Proceed as instructed in table 1 Operating limit See Operators Manual 912 i Series Temperature exceeded briefly Step Pro...

Page 79: ...onents 4 Check compression by carrying out a differential pressure check 5 All cylinder heads and cylinders must be removed and subjected to a de tailed check including hardness testing See chapt 72 0...

Page 80: ...nent detail Read out the ECU data memory and check the data for details of increased oil temperature Perform the corresponding inspections repairs depending on the functional defects found Graphic Ove...

Page 81: ...for correct functioning 4 Check that oil lines are routed correctly and undamaged 5 Cut oil filter housing and inspect filter mat for foreign matter 6 Carry out oil change 7 Inspect all further syste...

Page 82: ...88 Minimum oil pressure on the ground Oil pressure below minimum oil pressure on the ground If noticed on ground immediately stop the engine and determine the cause Inspect the complete lubrication sy...

Page 83: ...stallation Manual 912 i Series latest is sue 6 If no cause for the low oil pressure is found after the above checks carry out an oil change 7 If after the previous checks and oil change the oil pressu...

Page 84: ...hic Position of the plug screw Fig 5 Oil specification not respected Step Procedure 1 Oil change 2 Remove the lowest positioned banjo screw 1 banjo bolt plug screw or screw socket and drain the remain...

Page 85: ...nued 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 socket and drain the remaini...

Page 86: ...dance with specification Step Procedure 1 Mark position of the spark plugs e g cyl 1 top and remove all spark plugs 2 Inspect the spark plugs for damage formation of melt beads burn off At heavy melt...

Page 87: ...WARNUNG WARNING Risk of electric shock Ignition OFF and system grounded Disconnect negative terminal of aircraft battery Engine runs sluggishly Step Procedure 1 Remove spark plug connector and remove...

Page 88: ...nd Heat damage due to indirect lightning strike Detailed findings will need to be obtained for affected components Always replace components if visible signs of damage are evident or if you are in any...

Page 89: ...3 the manufac turer shall evaluate field information and report to the authority In case of any relevant occurrences that may involve malfunction of the engine the form on the next page should be fill...

Page 90: ...d05028 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 05 50 00 page 24 January 01 2012 Form...

Page 91: ...anation of the maintenance check list See 05 20 00 NOTE For reasons of clarity only headlines and keywords are listed in the Maintenance Schedule Please refer to the following pages for further explan...

Page 92: ...d05029 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 00 00 page 2 January 01 2012 NOTES...

Page 93: ...is chapter covers the steps required to replenish all operating fluids on the engine and also provides an overview of the fill capacities ENVIRONMENT NOTE All operating materials and cleaning products...

Page 94: ...d05030 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 10 00 page 2 January 01 2012 NOTES...

Page 95: ...n Effectivity 912 i Series Edition 1 Rev 0 12 10 00 page 3 January 01 2012 1 General Servicing points on the engine Fig 1 Part Function 1 Expansion tank 2 Radiator cap 3 Oil filter 4 Oil tank 5 Oil ta...

Page 96: ...d05030 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 10 00 page 4 January 01 2012 NOTES...

Page 97: ...rers and types should be avoided The use of additives may re sult in damage System Fill capacity Details about the operating fluids Fuel system Refer to the relevant specifica tions provided by the ai...

Page 98: ...d05030 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 10 00 page 6 January 01 2012 NOTES...

Page 99: ...ow engine to cool down to ambient temper ature before start of any work WARNUNG WARNING Risk of Burns Never open the radiator cap when the cooling system is hot For safety s sake cover cap with a rag...

Page 100: ...the current Operators Manual If necessary replenish with coolant of same composition 5 Tighten the radiator cap by hand NOTE The radiator cap must be tightened until the stop lug is contacted Step Pr...

Page 101: ...oil level check turn the propeller several times by hand in direction of engine rotation to pump all the oil from the engine to the oil tank 2 This process is completed when air flows back to the oil...

Page 102: ...ks on the oil dipstick 8 Fit the oil dipstick and tighten the oil tank cover 1 by hand Step Procedure Step Procedure 1 Check the oil level and top up with oil as required 2 Operate the engine until th...

Page 103: ...king the compression Checking the compression for fault tracing Page 9 Page 11 Engine management ECU Checking ECU Read out the ECU data memory Page 13 Page 13 Page 13 Locking Loosen of the crankshaft...

Page 104: ...l system Flushing the oil circuit Page 35 Page 37 Page 38 Page 38 Page 40 Page 41 Page 43 Page 43 Inspecting the magnetic plug Installation of the magnetic plug Page 45 Page 46 Electric system Check o...

Page 105: ...lamp connections etc by use of compressed air to prevent leakage current ENVIRONMENT NOTE When cleaning the engine the dissolved residues of fuel oil and other environment contaminating agents are rin...

Page 106: ...d05031 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 4 January 01 2012 NOTES...

Page 107: ...enting hoses oil tank Airbox FUSE BOX Engine suspension frame ECU Heat shrink sleeve Fuel lines Sensor technology Fuel pump module Oil cooler Wiring harness Coolant hoses Cooler WARNUNG NOTICE Exactly...

Page 108: ...Definition Corrosion is a natural process which attacks and potentially damages met als via an electro chemical reaction For more detailed information about different types of corrosion and correspon...

Page 109: ...ed inspect the quality of the coolant Fuel lines Inspect fuel lines their connections and screw fasteners Look for scuff ing marks or other damage Complete a detailed visual inspection When checking s...

Page 110: ...see if there are any leaks Oil lines Inspect all oil feed lines from the oil tank to the oil cooler and to the engine Also inspect the oil return line from the crankcase to the oil tank Check the pres...

Page 111: ...engine components WARNUNG WARNING Risk of electric shock Ignition OFF and system grounded Part number Description n a Compressed air approx 6 bar 600 kPa n a 2 pressure gauges n a Orifice jet of 1mm 0...

Page 112: ...NCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 10 January 01 2012 Graphic Checking the compression Fig 2 Part Function 1 Adaptor 2 Manometer Test gauges set 3 Orifice...

Page 113: ...verhaul must be carried out in accordance with the BRP Powertrain instructions for continued airworthiness Detailed inspection of affected engine components Special tools For accomplishment the follow...

Page 114: ...05031 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 12 January 01 2012 Graphic Compression check for fault tracing Fig 3 Part Function 1 Compression teste...

Page 115: ...WARNUNG WARNING Non compliance can result in serious injuries or death When working on the ECU the general safety instruc tion must be observed See chapt INTRO Step Procedure 1 Inspect the ECU 1 and...

Page 116: ...MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 14 January 01 2012 Graphic Engine management ECU Fig 4 Part Function 1 ECU 2 Grounding clip 3 Socket for APM c...

Page 117: ...own to ambient temper ature before start any work Part number Description part no 240880 1 Thread bolt Part Function 1 Thread bolt 1 Step Procedure 1 Remove the plug screw 1 M8x20 and sealing ring fro...

Page 118: ...1 2012 Loosen the crankshaft After completion of work check Graphic Locking Loosen of the crankshaft Fig 6 Step Procedure 1 Remove the thread bolt 2 and refit crankshaft plug screw M8x20 1 along with...

Page 119: ...d by a competent operator Step Procedure 1 Establish fuel supply open fuel cock 2 Throttle lever to idle position 3 Master switch ON 4 Throttle valve approx 10 to take off position 5 Ignition for both...

Page 120: ...of vapour lock in cylinder heads This is necessary to prevent steam locks in the cooling and fuel system after shut down 13 Shut engine down NOTE On switching off the engine switch off ignition and w...

Page 121: ...12 20 00 page 19 January 01 2012 8 Checking the V belt tension General note See Fig 7 and Fig 8 In the case of configurations with additional auxiliary generator inspect attachment and V belt tension...

Page 122: ...djust the belt tension Graphic Fig 8 00353 Step Procedure 1 Loosen the 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 sc...

Page 123: ...Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 21 January 01 2012 9 Air intake system 9 1 General note Overview Fig 9 Part Function 1 Intake manifold 2 Throttle body socket 3 Air filter 4 Air...

Page 124: ...A dirty filter insert will not only reduce the engine per formance but might also promote premature wear of the engine Step Procedure 1 Visual inspection of the air filter 2 Visual inspection of the...

Page 125: ...y 01 2012 Graphic Cleaning of the filter Fig 10 After cleaning NOTE Each filter pleat must be sprayed with oil After 5 to 10 min the filter will be soaked with oil noticeable by the uni form red color...

Page 126: ...se dry type air filters which are specified by the aircraft manufac turer and from ROTAX Fig 12 WARNUNG NOTICE Each air filter must be secured by clamp attachment and a wire securing element See chapt...

Page 127: ...ffectivity 912 i Series Edition 1 Rev 0 12 20 00 page 25 January 01 2012 10 Cooling system 10 1 Checking the cooling system Overview Fig 13 Part Function 1 Coolant hoses 2 Water pump 3 Expansion tank...

Page 128: ...See chapt 12 20 00 section 10 4 10 2 Replacing the coolant General note Procedure To replace the coolant the following steps are necessary WARNUNG WARNING Risk of Burns Hot engine parts Always allow e...

Page 129: ...g with a new sealing ring Tighten to 10 Nm 90 in lb 5 If the coolant is being replaced with a different type conventional coolant waterless coolant the cooling system must be flushed See chapt 12 20 0...

Page 130: ...owly Step Procedure 1 The system is flushed using pure water at a pressure of 2 bar 200 kPa Where water free coolant is used the cooling system must be drained of water correspondingly after flushing...

Page 131: ...and the coolant is sucked back Radiator cap Inspect the rubber seal 3 the pressure spring 4 and the two valves incorporated in the radiator cap for damage and leaks If necessary replace with a new or...

Page 132: ...radiator hoses hose clamps cooling air ducts General note 7 Sealing surface 8 Tube connections 9 Sight glass Part Function Step Procedure 1 Inspect the bottle for damage 2 Check the venting bore 1 in...

Page 133: ...BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 31 January 01 2012 11 Fuel system 11 1 General note Overview Fig 17 Part Function 1 Fuel pump 2 Fuel line 3 Fuel injector 4 Fuel r...

Page 134: ...ions 2 Inspect the fuel lines for sign of chafing 3 Check the insulating flange on the fuel pump for leaks 4 Check the color markings for damage WARNUNG NOTICE All rubber parts must be replaced after...

Page 135: ...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 11 6 Check valv...

Page 136: ...d05031 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 34 January 01 2012 NOTES...

Page 137: ...ertrain Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 35 January 01 2012 12 Lubrication 12 1 General Overview Fig 19 Part Function 1 Oil tank 2 Drain screw M12x12 3 Oil cooler 4 Oil filter IN...

Page 138: ...12 018 must be accomplished See chapt 12 20 00 section 12 5 Replacement of the oil filter and the oil change should be effected quickly and without interruption to prevent a draining of the oil system...

Page 139: ...use brand name oil in accordance with the latest Operators Manual and SI 912 i 001 Selection of suitable operating fluids latest issue WARNUNG NOTICE The engine must not be cranked when the oil system...

Page 140: ...4 12 3 1 Install oil filter General note See Fig 21 WARNUNG WARNING Risk of Burns Hot engine parts Always allow engine to cool down to ambient temper ature before start of any work WARNUNG NOTICE To e...

Page 141: ...ter wrench 2 Clean the contact surface 1 of the oil pump housing 2 with a clean cloth 3 Apply thin film engine oil on the gasket 3 of the oil filter 4 4 Install the oil filter on the engine 5 Screw on...

Page 142: ...g abrasion repair or overhaul the engine in accordance with the BRP Powertrain instructions for continued airworthi ness If the filter mat is clogged by foreign matter the lube oil reaches the bearing...

Page 143: ...on 12 5 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 WARNUNG NOTICE I...

Page 144: ...es 2 Remove the inner parts of the oil tank such as the baffle insert 5 and the par tition 6 3 Clean oil tank 8 and inner parts 5 6 and check for damage WARNUNG NOTICE Incorrect assembly of the oil ta...

Page 145: ...he oil tank Temporary oil lines Temporary oil lines only for flushing must be fitted so that the oil cooler is not connected The return line is routed into a separate clean recepta cle and not back to...

Page 146: ...otherwise air will be sucked in again Step Procedure 1 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 cont...

Page 147: ...ps in low numbers as depicted in Fig 24 can be tolerated if the accumulation is below 3 mm 0 125 in Steel chips in larger numbers If there are larger accumulations of metal chips on the magnetic plug...

Page 148: ...ug acceptable Step Procedure 1 Clean the magnetic plug and oil tank 2 Flush the oil circuit see section 12 6 3 Perform purging of the oil system see section 12 5 4 Install a new oil filter see section...

Page 149: ...n Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 47 January 01 2012 14 Electric system Overview Fig 25 Part Function 1 Spark plug connectors 2 Double ignition 3 Ignition cable 4 FUSE BOX 5 Plu...

Page 150: ...pick up cable electronic module charging and shorting cables for corrosion or damage and replace as required 4 Inspect plug connections between electronic module and ignition coils for cor rosion or...

Page 151: ...ased wear of the spark plugs Reduce renewal intervals accordingly Special tool Ensure that the following spark plugs corresponding to engine type are employed and that the correct spark plug socket is...

Page 152: ...about the operating condition of the engine Electrode gap New Wear limit 0 6 0 7 mm 0 023 0 027 in 0 9 mm 0 035 in Spark plug face Information light coloured to brown plug and calibration of the engin...

Page 153: ...on the cold engine Graphic spark plugs Fig 26 14 3 Fuse unit FUSE BOX General note Check plug connections and fuse plugs WARNUNG WARNING Eyes and skin irritation Rinse off with water in the case of c...

Page 154: ...d05031 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 52 January 01 2012 NOTES...

Page 155: ...ox General note The gearbox must be inspected repaired or overhauled in accordance with the BRP Powertrain instructions for continued airworthiness Detailed inspection of the affected gearbox componen...

Page 156: ...d05031 fm MAINTENANCE MANUAL BRP Powertrain Effectivity 912 i Series Edition 1 Rev 0 12 20 00 page 54 January 01 2012 NOTES...

Page 157: ......

Page 158: ...AIRCRAFT ENGINES www cps parts com 800 247 9653...

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