Rotax 912 iSc Sport User manual

AIRCRAFT ENGINES
ref. no.: MML-912 i | part no.: 898742

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 2012 © - 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.

d05020.fm
MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 INTRO
page 1
January 01/2012
Chapter: INTRO
GENERAL NOTE
Foreword Before carrying out maintenance work on the engine, read the Mainte-
nance Manual (Line Maintenance) carefully.
If any passages of the Manual are not clearly understood or if you have
any questions, please contact an authorized distributor- or Service Cen-
ter 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 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 an another advantage.
The Maintenance Manual is subdivided into the following chapters:
Subject Chapter
Introduction Chapter INTRO
List of effective pages Chapter LEP
Table of amendments Chapter TOA
General note Chapter 00-00-00
Airworthiness Limitations Chapter 04-00-00
Maintenance Chapter 05-00-00
Time limits Chapter 05-10-00
Scheduled maintenance checks Chapter 05-20-00
Unscheduled maintenance checks Chapter 05-50-00
Maintenance of the systems Chapter 12-00-00
Replenishing operating fluids Chapter 12-10-00
Scheduled maintenance Chapter 12-20-00

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 INTRO
page 2
January 01/2012
NOTES

Effectivity: 912 i Series
Edition 1/Rev. 1
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MAINTENANCE MANUAL
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LEP
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July 01/2012
Chapter: LEP
LIST OF EFFECTIVE PAGES
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Effectivity: 912 i Series
Edition 1/Rev. 1
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d05441.fm
MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 1 TOA
page 1
July 01/2012
Chapter: TOA
TABLE OF AMENDMENTS
*Approval
The technical content of this document is approved
under the authority 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.
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
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1
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DOA*

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Effectivity: 912 i Series
Edition 1/Rev. 0 TOA
page 2
January 01/2012
NOTES

d05441.fm
MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 1 TOA
page 3
July 01/2012
Chapter: TOA
SUMMARY OF AMENDMENTS
Content Summary 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 2012
Airworthiness Limitations: Approval inserted
Time limits for parts: Fuel pressure regulator assy.
inserted
Smooth performance of the engine: change of text

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 TOA
page 4
January 01/2012
NOTES

d05023.fm
MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 1
January 01/2012
Chapter: 00-00-00
GENERAL NOTE
Introduction This section describes this maintenance of engine type ROTAX
912 i Series.
NOTE: The ROTAX 912 i Series 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 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

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BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 2
January 01/2012
NOTES

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 3
January 01/2012
1) General note
Purpose The purpose of this Maintenance Manual is to acquaint maintenance ser-
vice staff (iRMT) approved by the local aviation authorities with some
basic maintenance and safety information for service work.
Documentation For more detailed information regarding, maintenance, safety or flight
operation, consult the documentation provided 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
Distributors
For ROTAX Authorized Distributors for Aircraft Engines see latest Opera-
tors 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 number, as the manufacturer makes modifications to the engine for
product improvement. 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.4
Cyl.2

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BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 4
January 01/2012
NOTES

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 5
January 01/2012
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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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 6
January 01/2012
EN European Norm
FAA Federal Aviation Administration
FAR Federal Aviation Regulation
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
SB Service Bulletin
Abbreviation Description

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 7
January 01/2012
SI Service Instruction
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
TSNP Time Since New Part
TSO Time Since Overhaul
VVolt
VFR Visual Flight Rules
XXX shows the serial component number
Abbreviation Description

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 8
January 01/2012
2.1) Conversion table
Units of length:
1 mm = 0.03937 in
1 in = 25.4 mm
1 ft = 12 in
= 0.3048 m
Units of power:
1 kW = 1.341 hp
1 hp = 0.7457 kW
1 kW = 1.3596 PS
1 PS = 0.7355 kW
Units of area:
1 cm2= 0.155 sq in (in2)
1 sq in (in2) = 6.4516 cm2
Units of temperature:
K = °C - 273,15
°C = (°F - 32) / 1,8
°F = (°C x 1.8) + 32
Units of volume:
1 cm3= 0.06102 cu in (in3)
1 cu in (in3) = 16.3871 cm3 (in3)
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
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 lb
1 lb = 0.45359 kg
spec. fuel consumption:
1 g/kWh = 0.001644 lb/hph
1 lb/hph = 608.277 g/kWh
Density:
1 g/cm3= 0.016018 lb/ft3
1 lb/ft3= 62.43 g/cm3
Units of torque:
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:
1 N = 0.224809 lbf
1 lbf = 4.4482 N
Cable cross-section:
Conversion table - Wire Gauge:
AWG-mm2
Units of pressure:
1 Pa = 1 N/m2
1 bar = 100 000 Pa/1000 hPa/
100 kPa
1 bar = 14.5037 lbf/in2(psi)
1 in Hg = 33.8638 hPa
AWG 4 6 8 10 12 14 16 18 20
mm221 13 8.4 5.3 3.3 2.1 1.3 0.8 0.52

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 9
January 01/2012
3) Safety notice
General note Although the reading of such information does not eliminate the hazard,
understanding the information will promote its correct use. Always use
common workshop safety practice.
The information and components system descriptions contained in this
Manual are correct at the time of publication. BRP-Powertrain, however,
maintains a policy of continuous improvement of its products without
imposing upon itself any obligation to install them on its products previ-
ously manufactured.
Revision BRP-Powertrain reserves the right at any time, and without incurring obli-
gation, to remove, replace 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 following symbols to emphasize particular informa-
tion. This information is important and must be observed.
NOTE: Indicates supplementary information which may be needed
to fully complete or understand an instruction.
A revision bar outside of the page margin indicates a
change to text or graphic.
WARNUNG
WARNING
Identifies an instruction which, if not followed,
may cause serious injury including the possibility
of death.
WARNUNG
CAUTION
Identifies an instruction which, if not followed,
may cause minor or moderate injury.
WARNUNG
NOTICE
Denotes an instruction which, if not followed,
may severely damage the engine or other com-
ponent.
ENVIRONMENTAL NOTE
Environment note gives you tips and behaviors to environmental protec-
tion.

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 10
January 01/2012
3.1) Safety notice
General note This information relates to the preparation and use of ROTAX aircraft
engines and has been utilized safely and effectively by BRP-Powertrain.
However, BRP-Powertrain disclaims liability for all damage and/or injuries
resulting from the improper use of the contents. BRP-Powertrain requires
that any service be carried out and verified by a technician that has a cur-
rent iRMT rating.
See chap. 05-00-00 section 1.2)
Manual This Manual has been prepared as a guide to correctly service and main-
tain all ROTAX 912 i Series engines.
This edition was primarily published to be used by aircraft mechanics who
are already familiar with all service procedures relating to ROTAX aircraft
engines.
This Manual uses technical terms which may be slightly different from the
ones used in the Illustrated Parts Catalog.
It is understood that this Manual may be translated into another language.
In the event of any discrepancy the German version 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 specific operating and servicing methods that, if not
observed, can cause a serious engine malfunction or cause the engine to
lose power in flight which can result in loss of life, injury or damage to
equipment.
It is, however, important to understand that these warnings and cautions
are not exhaustive. BRP-Powertrain could not possibly know, evaluate
and advise the user of all conceivable ways in which service might be
done or of the possible hazardous consequences of each way.
Safety instruc-
tion
In addition to observing the instructions in our Manual, general safety and
accident preventative measures, legal regulations and regulations of any
aeronautical authority must also be observed.
Where differences exist between this Manual and regulations provided by
any authority, the more stringent regulation should be applied.
Illustration The content depicts parts and/or procedures applicable to the particular
product at its time of manufacture. It does not include dealer and manufac-
turer modifications, whether authorized or not by BRP-Powertrain, after
manufacturing the product.