BRP ROTAX 912 Series User manual

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

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.
Copyright 2020 © - all rights reserved.
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.
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.

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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 January 01 2020
2 January 01 2020
LEP 1 January 01 2020
2 January 01 2020
3 January 01 2020
4 January 01 2020
TOA 1 January 01 2020
2 January 01 2020
00-00-00 1 January 01 2020
2 January 01 2020
3 January 01 2020
4 January 01 2020
5January 01 2020
6 January 01 2020
7January 01 2020
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9 January 01 2020
10 January 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 January 01 2020
2 January 01 2020
3 January 01 2020
4 January 01 2020
5January 01 2020
6 January 01 2020
7January 01 2020
8 January 01 2020
9 January 01 2020
10 January 01 2020
05-10-00 1 January 01 2020
2 January 01 2020
3 January 01 2020
4 January 01 2020
5January 01 2020
6 January 01 2020
7January 01 2020
8 January 01 2020
05-20-00 1 January 01 2020
2 January 01 2020
3 January 01 2020
4 January 01 2020
5January 01 2020
6 January 01 2020
7January 01 2020
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Chapter Page Date
8 January 01 2020
9 January 01 2020
10 January 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
05-50-00 1 January 01 2020
2 January 01 2020
3 January 01 2020
4 January 01 2020
5January 01 2020
6 January 01 2020
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8 January 01 2020
9 January 01 2020
10 January 01 2020
11 January 01 2020
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13 January 01 2020
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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 January 01 2020
28 January 01 2020
29 January 01 2020
30 January 01 2020
31 January 01 2020
32 January 01 2020
33 January 01 2020
34 January 01 2020
35 January 01 2020
36 January 01 2020
12-00-00 1 January 01 2020
2 January 01 2020
12-10-00 1 January 01 2020
2 January 01 2020
3 January 01 2020
4 January 01 2020
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6 January 01 2020
7January 01 2020
8 January 01 2020
9 January 01 2020
10 January 01 2020
12-20-00 1 January 01 2020
2 January 01 2020
3 January 01 2020
LEP
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Chapter Page Date
4 January 01 2020
5January 01 2020
6 January 01 2020
7January 01 2020
8 January 01 2020
9 January 01 2020
10 January 01 2020
11 January 01 2020
12 January 01 2020
13 January 01 2020
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33 January 01 2020
Chapter Page Date
34 January 01 2020
35 January 01 2020
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Index
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Chapter Page Date
Rear page
Chapter Page Date
LEP
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Chapter: TOA
TABLE OF AMENDMENTS
Approval*
The technical content of this document is approved under the authority of DOA ref. EASA.21J.048.
This document is part of the ICA for product as specified in this manual.
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 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
0INTRO all Jan. 01 2020 DOA*
0 LEP all Jan. 01 2020 DOA*
0 TOA all Jan. 01 2020 DOA*
0 00-00-00 all Jan. 01 2020 DOA*
0 04-00-00 all Jan. 01 2020 EASA approved
0 05-00-00 all Jan. 01 2020 DOA*
0 05-10-00 all Jan. 01 2020 DOA*
0 05-20-00 all Jan. 01 2020 DOA*
0 05-50-00 all Jan. 01 2020 DOA*
0 12-00-00 all Jan. 01 2020 DOA*
0 12-10-00 all Jan. 01 2020 DOA*
0 12-20-00 all Jan. 01 2020 DOA*
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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
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 name
Change of maintenance schedule
New: Removal, Installation of the gearbox. Change
of text.
Change of text
Change of graphic
TOA
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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.................................................................................................................................7
Conversion table ...................................................................................................................................8
Safety notice ...........................................................................................................................................9
Safety information ...............................................................................................................................10
Instruction...........................................................................................................................................12
Maintenance Concept..........................................................................................................................13
Technical documentation......................................................................................................................14
Use for intended purpose .....................................................................................................................16
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GENERAL
In this Manual all ROTAX® 912 Series engines are described.
NOTE
ROTAX® 912 Series includes 912 A, 912 F, 912 S, 912 UL, 912 ULS and 912
ULSFR.
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 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 number is on the ignition cover, on the left, opposite
the electric starter.
Figure 1.1: Engine serial number
1Engine 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 Illustrated Parts Catalog).
°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
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
Coil 1–4 Ignition coils 1–4
CPS 1+2 Crankshaft Position Sensor 1+2
CSA Constant Speed Actuator
CTS Cooling Temperature Sensor
CW clockwise
CCW counter-clockwise
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Abbreviations Description
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
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
IPC Illustrated Parts Catalog
ips inch per second
00–00–00
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Abbreviations Description
iRMT independent ROTAX Maintenance Training
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
Nm Newtonmeter
NVFR Night Visual Flight Rules
OAT Organic Acid (Additive) Technology
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 Organisation Approval
PS Power supply
PTFE Polytetrafluoroethylene (Teflon)
PTO Power Take Off
Rev. Revision
ROTAX® is a trademark of BRP-Rotax GmbH & Co KG
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Abbreviations Description
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
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
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
X3 Connector on Engine Management System wiring harness which
serves as an interface for power supply
XXXX shows the serial component number
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WIRING COLOR CODES
Figure 1.2
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CONVERSION TABLE
Units of length: Units of power:
1 mm = 0.03937 in
1 in = 25.4 mm
1 ft = 12 in
= 0.3048 m
1 kW = 1.341 hp
1 hp = 0.7457 kW
1 kW = 1.3596 PS
1 PS = 0.7355 kW
Units of area: Units of temperature:
1 cm² = 0.155 sq. in (in²)
1 sq. in (in²) = 6.4516 cm²
K = °C – 273,15
°C = (°F – 32) / 1,8
°F = (°C x 1.8) +32
Units of volume: Units of velocity:
1 cm³ = 0.06102 cu in (in³)
1 cu in (in³) = 16.3871 cm³
1 dm³ = 1 l
1 dm³ = 0.21997 gal (UK)
1 gal (UK) = 4.5461 dm³
1 dm³ = 0.26417 gal (US)
1 gal (US) = 3.7854 dm³
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: spec. fuel consumption:
1 kg = 2.2046 lbs.
1 lb. = 0.45359 kg
1 g/kWh = 0.001644 lb/hph
1 lb/hph = 608.277 g/kWh
Density: Units of torque:
1 g/cm³ = 0.016018 lb/ft³
1 lb/ft³ = 62.43 g/cm³
1 Nm = 0.737 ft lb
= 8.848 in lb
1 ft lb = 1.356 Nm
1 in lb = 0.113 Nm
Units of force: Cable cross-section: Conversion table-
Wire Gauge: AWG-mm²
1 N = 0.224809 lbf
1 lbf = 4.4482 N
AWG —> mm²
4 —> 21
6 —> 13
8 —> 8.4
10 —> 5.3
12 —> 3.3
14 —> 2.1
16 —> 1.3
18 —>0.8
20—> 0.52
Units of pressure:
1 Pa = 1 N/m²
1 bar = 100 000 Pa / 1000 hPa / 100 kPa
1 bar = 14.503 lbf/in² (psi)
1 in Hg = 33.8638 hPa
00–00–00
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