Rotax 912 i series User manual

AIRCRAFT ENGINES
ref. no.: MMH-912 i | part no.: 898751

Before starting any maintenance work, please read the Maintenance Manual,
as it contains important safety relevant information. Failure to do so may
result in personal injuries including death. Consult the original equipment
manufacturer´s handbook for additional instructions!
WARNING
These technical data and the information embodied therein are the property of
BRP-Powertrain GmbH&Co KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior
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 201© - all rights reserved.
ROTAX®is a trade mark of BRP-Powertrain GmbH&Co KG. In the following document the
short form of BRP-Powertrain GmbH&Co KG = BRP-Powertrain 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.
Approval of translation has been done to best knowledge and judgement - in any case the
original text in german language is authoritative.

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 1 INTRO
Page 1
October 01/2013
Chapter: 00-00-00
GENERAL NOTE
Foreword Before carrying out maintenance work on the engine, please read the
Heavy Maintenance Manual carefully. See also the latest revision of the
corresponding Line Maintenance Manual for the engine type 912 i Series.
If any passages of this Manual are not clearly understood or if you have
any questions, please contact an authorized distributor or Service Center
for ROTAX aircraft engines.
Chapter structure The structure of the Manual follows whenever it is possible the structure
of the ATA (Air Transport Association) standards. The Maintenance
Manual is subdivided into the following chapters:
Subject Chapter
Introduction Chapter 00-00-00
List of effective pages Chapter LEP
Table of amendments Chapter TOA
General note Chapter 00-00-00
Internal alternator Chapter 24-20-00
External alternator Chapter 24-30-00
Vacuum system Chapter 37-00-00
Vacuum pump Chapter 37-10-00
Propeller Chapter 1
Governor Chapter 61-20-00
Power plant Chapter 71-00-00
Engine Chapter 72-00-00
Propeller gearbox Chapter 72-10-00
Engine block Chapter 72-20-00
Cylinder head Chapter 72-30-00
Piston and Cylinder assembly Chapter 72-30-10
Fuel system Chapter 73-00-00
Fuel pump and Distribution Chapter 73-10-00
Ignition system Chapter 74-00-00
Ignition system - partition Chapter 74-20-00
Cooling system Chapter 75-00-00
Engine control Chapter 76-00-00
ECU Chapter 76-10-00
Wiring harness Chapter 76-50-00

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Sensors and actuators Chapter 76-70-00
Exhaust system Chapter 78-00-00
Exhaust Chapter 78-10-00
Lubrication system Chapter 79-00-00
Electric starter Chapter 80-00-00
Subject Chapter

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NOTES

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Edition 1/Rev. 1 TOA
Page 1
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Chapter: TOA
TABLE OF AMENDMENTS
*Approval
The technical content of this document is approved
under the authority DOA ref. EASA.21J.048
no. chapter page date of
change
remark for
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date of ap-
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Chapter: TOA
SUMMARY OF AMENDMENTS
Content Summary of the relevant amendments in this context, but without requi-
rement on completeness.
Current
No. chapter page date of change Comment
1
1
1
00-00-00
24-20-00
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31 - 36
3,7
13,14-20
1-28
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10 01 2013
10 01 2013
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Illustration (special tools) added.
New illustrations, new tooling (see revision bars).
Illustration (special tools) added.
Illustration (special tools) added,
Chapter ECU revision, New Text, New Illustration

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NOTES

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MAINTENANCE MANUAL
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Edition 1/Rev. 0 00-00-00
Page 1
July 01/2012
Chapter: 00-00-00
GENERAL NOTE
Introduction This manual describes maintenance of all ROTAX 912 i Series engines.
NOTE: ROTAX 912 i Series includes 912 iSc and 912 iS.
Table of contents This chapter of the Maintenance Manual contains general and safety informa-
tion concerning a safe operation and maintenance of the aircraft engine.
Subject Page
General note Page 3
Abbreviations and terms used in this manual
Conversion table
Page 5
Page 8
Safety notice
Safety information
Instruction
Maintenance Concept
Technical documentation
Use for intended purpose
Page 9
Page 10
Page 12
Page 13
Page 14
Page 16
Inspection of parts and report of findings Page 17
Classification of parts for maintenance/repair Page 19
Maintenance Page 23

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Page 3
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1) General note
Purpose The purpose of this Maintenance Manual is to acquaint maintenance service
staff (iRMT) approved by the local aviation authorities with some basic mainte-
nance and safety information for service work.
Documentation For more detailed information regarding, maintenance, safety or flight operation,
consult the documentation provided by the aircraft manufacturer and/or dealer.
For additional information on engines, maintenance or parts, you can also con-
tact your nearest authorized ROTAX-aircraft engine distributor.
ROTAX
Distributors
For ROTAX Authorized Distributors for Aircraft Engines see latest Operators
Manual or on the Internet at the official Website
www.FLYROTAX.com.
Engine serial
number
When making inquiries or ordering parts, always indicate the engine serial num-
ber, as the manufacturer makes modifications to the engine for product impro-
vement. The engine serial number (1) is on the top of the crankcase, behind of
the propeller gearbox. See Fig. 1.
Fig. 1
Cyl.1 Cyl.3
Cyl.4Cyl.2

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NOTES

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2) Abbreviations and terms used in this manual
Abbreviations
Abbreviation Description
* Reference to another section
center of gravity
The drop symbol indicates use of sealing agents, adhesives or
lubricants (only in the Illustrated Parts Catalog).
°C Degrees Celsius (Centigrade)
°F Degrees Fahrenheit
912 iS see OM (Type designation)
912 iSc see OM (Type designation)
A Ampere
AAPTS Ambient Air Pressure Temperature Sensor
AC alternating 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 for Testing and Materials
ATA Air Transport Association
AWG American Wire Gauge
CAN/CGSB Canadian General Standards Board
CPS 1+2 Crankshaft Position Sensor 1+2
CSA Constant Speed Actuator
CTS Cooling Temperature Sensor
CS-E Certification Specifications for Engines
CW Clockwise
CCW Counter-clockwise
DCDI Dual Capacitor Discharge Ignition
DC direct current
DOA Design Organisation Approval
DOT Department of Transport
EASA European Aviation Safety Agency
ECU Engine Control Unit
EGT Exhaust Gas Temperature
EMS Engine Management System

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EN European Norm
FAA Federal Aviation Administration
FAR Federal Aviation Regulation
FUSE BOX Fuse box
hr. hours
HIC A Human Interface Connector A
HIC B Human Interface Connector B
IFR Instrument Flight Rules
IM Installation Manual
INJ 1-8 Injector 1-8
INTRO Introduction
IPC Illustrated Parts Catalog
iRMT independent ROTAX Maintenance Technician
ISA International Standard Atmosphere
kg kilograms
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 Illustrated Parts Catalog)
n.a. not available
nB as necessary (only Illustrated Parts Catalog)
NDT Non Destructive Testing
Nm newtonmeter
OHM Overhaul Manual
OM Operators Manual
OPS Oil Pressure Sensor
OTS Oil Temperature Sensor
part no. Part number
POA Production Organisation Approval
PTO power take off side
Rev. Revision
RON Research Octane Number
ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG
rpm Revolutions per minute
SAE Society of Automotive Engineers
Abbreviation Description