BRP Rotax 912 i Series User manual

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

Before starting any maintenance work, please read the Maintenance Manual completely as it
contains important safety relevant information. Failure to do so may result in personal
injuries including death. Consult the orginal equipment manufacturers handbook for
additional instructions!
These technical data and the information embodied therein are the property of BRP-
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.
ROTAX® is a trade mark of BRP-Rotax GmbH & Co KG. In the following document the short form
of BRP-Rotax GmbH & Co KG = BRP-Rotax is used.
Other product names in this documentation are used purely for ease of identification and may be
trademarks of the respective company or owner.
Copyright 2023 © - all rights reserved.
Translation into other languages might be performed in the course of language localization but
does not lie within ROTAX® scope of responsibility.
In any case the original text in English language and the metric units are authoritative.

Effectivity: 912 i Series
Edition 2/Rev. 2 Content
Page 1
May 01/2023
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 – TIME LIMITS
Chapter 05–20–00 – SCHEDULED MAINTENANCE CHECKS
Chapter 05–50–00 – UNSCHEDULED MAINTENANCE CHECKS
Chapter 12–00–00 – MAINTENANCE OF THE SYSTEMS
Chapter 12–10–00 – REPLENISHING OPERATING FLUIDS
Chapter 12–20–00 – SCHEDULED MAINTENANCE
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Chapter: INTRO
GENERAL NOTE
Foreword Before carrying out maintenance work on the engine, read this Maintenance Manual
carefully.
If any passages of the Manual are not clearly understood or in case of any questions,
please contact your nearest 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. The aim is the compatibility with the aircraft
manufacturers documentation, which means they must then adapt the documentation to
their standard.
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Chapter: LEP
LIST OF EFFECTIVE PAGES
Each new revision to the Maintenance Manual Line will have a new List of Effective Pages.
chapter page date
Cover
page
INTRO 1 May 01 2023
2 May 01 2023
LEP 1 May 01 2023
2 May 01 2023
3 May 01 2023
4 May 01 2023
TOA 1 May 01 2023
2 May 01 2023
00-00-00 1 May 01 2023
2 May 01 2023
3 May 01 2023
4 May 01 2023
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17 May 01 2023
chapter page date
18 May 01 2023
04-00-00 1 May 01 2023
2 May 01 2023
05-00-00 1 May 01 2023
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05-20-00 1 May 01 2023
2 May 01 2023
3 May 01 2023
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Edition 2/Rev. 2 LEP
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4 May 01 2023
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05-50-00 1 May 01 2023
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chapter page date
18 May 01 2023
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2 May 01 2023
12-10-00 1 May 01 2023
LEP
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chapter page date
2 May 01 2023
3 May 01 2023
4 May 01 2023
5May 01 2023
6 May 01 2023
7May 01 2023
8 May 01 2023
9 May 01 2023
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19 May 01 2023
20 May 01 2023
21 May 01 2023
chapter page date
22 May 01 2023
23 May 01 2023
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Edition 2/Rev. 2 LEP
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chapter page date
52 May 01 2023
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chapter page date
55 May 01 2023
56 May 01 2023
Index
Back page
LEP
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Edition 2/Rev. 2

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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.
Edition 2 / Rev. 0 September 01 2018
Revision 1 February 01 2023 Obsolete with Revision 2, which is a complete re-revision
Revision 2 May 01 2023
Cur-
rent
no.
Chapter Page Date of change Remark for
approval
Date of
approval
from
authori-
ties
Date of
inclusion
Signature
0INTRO all Sept. 01 2018 DOA*
0 LEP all Sept. 01 2018 DOA*
0 TOA all Sept. 01 2018 DOA*
0 00-00-00 all Sept. 01 2018 DOA*
0 04-00-00 all Sept. 01 2018 EASA approved
0 05-00-00 all Sept. 01 2018 DOA*
0 05-10-00 all Sept. 01 2018 DOA*
0 05-20-00 all Sept. 01 2018 DOA*
0 05-50-00 all Sept. 01 2018 DOA*
0 12-00-00 all Sept. 01 2018 DOA*
0 12-10-00 all Sept. 01 2018 DOA*
0 12-20-00 all Sept. 01 2018 DOA*
Cur-
rent
no.
Chapter Page Date of change Remark
for
approval
Date of
approval
from
authori-
ties
Date of
inclusion
Signature
1 LEP all Febr. 01 2023 DOA*
1 TOA all Febr. 01 2023 DOA*
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Edition 2/Rev. 2 TOA
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Cur-
rent
no.
Chapter Page Date of change Remark
for
approval
Date of
approval
from
authori-
ties
Date of
inclusion
Signature
1 00-00-00 14 Febr. 01 2023 DOA*
1 05-00-00 2,3,4,8-
12
Febr. 01 2023 DOA*
1 05-10-00 2,4-6 Febr. 01 2023 DOA*
1 05-20-00 9-16 Febr. 01 2023 DOA*
1 05-50-00 4,6-
10,12-14
Febr. 01 2023 DOA*
1 05-50-00 20-23,27-
32
Febr. 01 2023 DOA*
1 12-10-00 5Febr. 01 2023 DOA*
1 12-20-00 5,7,9,10 Febr. 01 2023 DOA*
1 12-20-00 23,26,29-
,37-
40,50,55
Febr. 01 2023 DOA*
Cur-
rent
no.
Chapter Page Date of change Remark
for
approval
Date of
approval
from
authori-
ties
Date of
inclusion
Signature
2 LEP all May 01 2023 DOA*
2 TOA all May 01 2023 DOA*
2 04-00-00 1 May 01 2023 DOA*
2 05-10-00 2 May 01 2023 DOA*
TOA
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Summary of amendments
Summary of the relevant amendments in this context, but without requirement on completeness.
no. chapter page date of change comment
1
1
1
1
1
1
1
1
1
1
00-00-00
05-00-00
05-10-00
05-20-00
05-50-00
05-50-00
05-50-00
12-10-00
12-20-00
12-20-00
14
2,3,4,8-12
2,4-6
9-16
4,6-10,12-14
20-23,27-32
36,41,42,43
5
5,7,9,10
23,26,29,37-40,50,55
Febr. 01 2023
Febr. 01 2023
Febr. 01 2023
Febr. 01 2023
Febr. 01 2023
Febr. 01 2023
Febr. 01 2023
Febr. 01 2023
Febr. 01 2023
Febr. 01 2023
new text
text change, PU- glue deleted, new
figure, new text
new text, text change
text change, new text
text change, new text
new attention, text change
text change, new customer service
information report
text change
text change
new special tool, new text, new figure
no. chapter page date of change comment
2 04-00-00 1 May 01 2023 text change
2 05-10-00 2 May 01 2023 text change
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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
Effectivity: 912 i Series
Edition 2/Rev. 2 00–00–00
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BRP-Rotax
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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. interface descriptions and limitations) that must be adhered to when installing
this type of engine into an aircraft or certifying aircraft powered by this engine type. Fur-
thermore it should allow independent ROTAX® Maintenance Technicians (iRMT) to main-
tain this engine in compliance with the relevant maintenance and safety instructions
provided by the engine manufacturer.
For detailed information related to aircraft and aircraft/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 maintenance or parts, you can also contact
your nearest authorized ROTAX® authorized Aircraft Engine Distributor or their independ-
ent Service Center.
ROTAX®
Distributors
For ROTAX® Authorized Distributors for aircraft engines see latest Operators Manual
(OM) or the official website www.FLYROTAX.com.
Engine serial
number
When making inquiries or ordering parts, always indicate the engine serial number. Due to
continuous product improvement, engines of the same engine type might require different
support and spare parts. The engine serial number is on the top of the crankcase, behind
of the propeller gearbox.
Figure 1.1: Engine serial number
00–00–00
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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 Degrees Fahrenheit
rpm Revolutions per minute
A Ampere
AAPTS Ambient Air Pressure Temperature Sensor
AC alternating current
AD Airworthiness Directives
Ah Ampere hour
A/C Aircraft
AC-DC EMS Modul voltage converter
AR as required
assy. assembly
ASB Alert Service Bulletin
ACG Austro Control GmbH
ACL Anti Collision Light
API American Petrol Institute
ASTM American Society for Testing and Materials
ATA Air Transport Association
AWG American Wire Gauge
CAN Controller Area Network
CCS Camshaft position sensor
Coil 1–4 Ignition coils 1–4
CPS 1+2 Crankshaft Position Sensor 1+2
CSA Constant Speed Actuator
CTS Cooling Temperature Sensor
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Abbreviations Description
CW clockwise
CCW counter-clockwise
CGSB Canadian General Standards Board
DCDI Dual Capacitor Discharge Ignition
DC direct current
DOA Design Organisation Approval
DOT Department of Transport
EASA European Aviation Safety Agency
IM Installation Manual
ECU Engine Control Unit
EGT Exhaust Gas Temperature
INTRO Introduction
EMS Engine Management System
EMS GND Engine system internal ground reference which is intended to be dis-
connected from aircraft common ground during flight
EMC Electromagnetic compatibility
EN European Standard
ETFE Ethylene Tetrafluoroethylene
FAA Federal Aviation Administration
FAR Federal Aviation Regulations
FOD Foreign object damage
FL Flight Level
Fuse box Power conditioning and distribution for the Engine Management
System
hr. hours
HIC A Harness Interface Connector A
HIC B Harness Interface Connector B
IAT Indicated Air Temperature
ICA Instructions for Continued Airworthiness
IFR Instrument Flight Rules
IFSD In-flight-shutdown
INJ 1–8 Injector 1–8
00–00–00
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Abbreviations Description
IPC Illustrated Parts Catalog
ips inch per second
iRMT independent ROTAX Maintenance Technician
ISA International Standard Atmosphere
kg Kilograms
KNOCK Knock sensor
Lane A System A of Engine Management System
Lane B System B of Engine Management System
LOPC Loss of power control
MAPS 1 & 2 Manifold Air Pressure Sensor 1 & 2
MATS 1 & 2 Manifold Air Temperature Sensor 1 & 2
MON Motor Octane Number
MAG Magneto Side
N Newton
n.a. not available
NDT Non Destructive Testing
NEW Part must be replaced against NEW (mentioned in figures)
Nm Newtonmeter
NVFR Night Visual Flight Rules
OAT Outside Air Temperature
OHM Overhaul Manual
OHV Over Head Valve
OM Operators Manual
OPS Oil Pressure Sensor
OTS Oil Temperature Sensor
PCD Pitch Circle Diameters
PCV Pressure Control Valve
PMA Permanent magnet alternator
POA Production Organization Approval
PS Power supply
PTFE Polytetrafluoroethylene (Teflon)
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Abbreviations Description
PTO Power Take Off
Rev. Revision
ROTAX® is a trademark of BRP-Rotax GmbH & Co KG
RON Research Octane Number
RON 424 ROTAX® Standard 424
s.v. still valid (only Illustrated Parts Catalog)
S/N Serial Number
SAE Society of Automotive Engineers
SEP Single Engine Piston
SB Service Bulletin
SI Service Instruction
SI-PAC Service Instruction Parts and Accessories
SPST Single pole single throw
STP Shielded twisted pair wire
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 Contents
TPS Throttle Position Sensor
TSN Time Since New
TSNP Time Since New Part
TSO Time Since Overhaul
V Volt
VFR Visual Flight Rules
LEP List of Effective Pages
MM Maintenance Manual
MEP Multi Engine Piston
00–00–00
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