Rotax 912 Series User manual

Maintenance Manual
(Line Maintenance)
for
ROTAX®Engine
Type 912 Series
Recommendedprice: ATS400,--
www.rotax-aircraft-engines.com
ROTAX®part no.: 899372
AIRCRAFT ENGINES
00337
▲WARNING
Before starting any maintenance work, please, read the Maintenance
Manual completely as it contains important safety relevant information.
Edition:0of19980901
These technical data and the information contained therein are property of ROTAX®GmbH and
must not be reproduced, neither in entirety nor partially, and passed on to third parties without
previous consent in writing by ROTAX®GmbH. This text must be written on every complete or
partial reproduction. Copyright - ROTAX®GmbH
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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CHAPTER 00
INTRODUCTION
1) Table of contents
CHAPTER 00 00-00-00 / 2
INTRODUCTION 00-00-00 / 2
1) Table of contents ....................................................................................00-00-00 / 2
2) List of chapters.......................................................................................00-00-00 / 4
3) Index.......................................................................................................00-00-00 / 6
4) Introduction ............................................................................................00-00-00 / 8
4.1) Remarks........................................................................................00-00-00 / 8
4.2) Engine serial number ....................................................................00-00-00 / 8
4.3) Conversion table and abbreviations ..............................................00-00-00 / 10
5) Safety notice...........................................................................................00-00-00 / 12
5.1) Repeating symbols........................................................................00-00-00 / 14
5.2) Maintenance Concept ...................................................................00-00-00 / 14
5.3) Technical documentation...............................................................00-00-00 / 15
5.3.1) Use for intended purpose .................................................00-00-00 / 16
5.3.2) Instruction.........................................................................00-00-00 / 17
6) List of the current pages ........................................................................00-00-00 / 18
7) Table of amendments.............................................................................00-00-00 / 20

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2) List of chapters
INTRODUCTION ..............................................00
MAINTENANCE SCHEDULE/ CHECKS.........05
MAINTENANCE ...............................................12

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3) Index
A
Abbreviations 00-00-00 / 11
Air filter 12-00-00 / 7
Authorized personnel 05-00-00 / 4
C
Carburetor synchronization 12-00-00 / 18
CASTROL "Clenvex 2000" 05-00-00 / 11
Cleaning agents 05-00-00 / 11
Climatic conditions 05-50-00 / 6
Consumable materials 05-00-00 / 8
Conversion table and abbreviations 00-00-00 / 10
Cooling system 12-00-00 / 14
D
Differential pressure check 12-00-00 / 9
Documentation (technical) 00-00-00 / 14
E
Electric system 12-00-00 / 36
Engine cleaning 12-00-00 / 4
Engine suspension 12-00-00 / 6
Exceeding of cylinder head temperature 05-50-00 /
8
Exceeding of max. admissible engine RPM 05-50-
00 / 7
Exceeding of the oil temperature 05-50-00 / 9
External alternator 12-00-00 / 10
F
Filter oil 05-00-00 / 9
Friction torque 12-00-00 / 41
G
Gearbox 12-00-00 / 40
General note 05-00-00 / 3, 05-10-00 / 1, 05-20-00
/ 1, 05-50-00 / 1, 12-00-00 / 3
I
Identification 05-20-00 / 4
Idle speed adjustment 12-00-00 / 24
Ignition cables 12-00-00 / 36
Inspection sheet 05-20-00 / 2, 05-20-00 / 4
Instruction 00-00-00 / 16
Intended purpose 00-00-00 / 15
Introduction 00-00-00 / 8
L
Lapping fleece 05-00-00 / 10
Leakage check 12-00-00 / 5
List of sections 00-00-00 / 4
List of the current pages 00-00-00 / 18
Lithium grease 05-00-00 / 9
LOCTITE 05-00-00 / 8
Lubrication system 12-00-00 / 26
M
Maintenance 05-00-00 / 3
Maintenance schedule 05-20-00 / 2, 05-20-
00 / 4
Mechanical synchronization 12-00-00 / 18
MOLYKOTE 05-00-00 / 9
Multi-purpose grease LZ 05-00-00 / 10
N
Nut securing 05-00-00 / 12
O
Oil change 12-00-00 / 27
Oil filter replacement and inspection 12-00-00
/ 30
Oil level check 12-00-00 / 26
Oil pressure 05-50-00 / 10
Oil specification 05-50-00 / 11
Overload clutch 05-50-00 / 3
P
Pneumatic synchronization 12-00-00 / 20
Preservation oil 05-00-00 / 10
Procedure notes 05-00-00 / 5
Propeller ground contact 05-50-00 / 2
R
Remarks 00-00-00 / 8
Repeating symbols 00-00-00 / 13
Rubber parts 05-10-00 / 4
Running behaviour 12-00-00 / 24
S
Safety 00-00-00 / 12
Safety wiring 05-00-00 / 12
Securing elements 05-00-00 / 12
Serial number 00-00-00 / 8
Shorting cables 12-00-00 / 36
SILASTIC 05-00-00 / 10
SILICONE HEAT CONDUCTIVITY PASTE 05-
00-00 / 10
Spark plug 05-50-00 / 12
Spark plugs 12-00-00 / 38
Special checks 05-50-00 / 1, 05-50-00 / 2
Submerging in water 05-50-00 / 6

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T
Table of amendments 00-00-00 / 20
Table of contents 05-00-00 / 1
Technical documentation 00-00-00 / 14
Test run of engine 12-00-00 / 11, 12-00-00 / 12
Time limit for maintenance intervals 05-10-00 / 4
Time limit for rubber parts 05-10-00 / 4
Time limit for the coolant 05-10-00 / 4
Time limits for engine operation 05-10-00 / 2
Trouble shooting 05-00-00 / 6
V
V-belt tension 12-00-00 / 10
Valve lapping paste 05-00-00 / 11
Verification of carburetor actuation 12-00-00 / 25
W
Wiring 12-00-00 / 36

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4) Introduction
We are pleased you decided to purchase a ROTAX®aircraft engine.
In this Manual the maintenance of engine type 912 Series is described.
◆NOTE: 912 Series includes all types of 912 engines like 912 A, 912 F, 912 S,
912 UL, 912 ULS and 912 ULSFR.
Before carrying out maintenance work on the engine, carefully read the Maintenance
Manual.
If any passages of the Manual are not clearly understood or in case of any questions,
please, contact an authorized Distribution- or Service Center for ROTAX®-aircraft
engines.
4.1) Remarks
The purpose of this Manual is to acquaint maintenance service staff approved
by the local aviation authorities with some basic maintenance and safety
information for service work.
For competent maintenance and servicing, please, refer to the documentation
providedintheOperator'sManual,InstallationInstructionsandIllustratedParts
Catalog.
For additional engine-, maintenance- and parts information you may also
contact the nearest ROTAX®-aircraft engine Distribution, or Service Center.
4.2) Engineserialnumber
Onallenquiriesorpartsorders,alwaysindicatetheengineserialnumber(1),as
the manufacturer makes modifications to the engine for product improvement.
The engine serial number is on the top of the ignition housing, left side.
See fig. 1.
magneto side
1
00334
power take off side
fig. 1

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Units of length:
1 mm = 0,03937 in
1 in = 25,4mm
1ft = 12 in
= 0,3048 m
Units of area:
1 cm2= 0,155 sq in (in2)
1 sq in (in2) = 6,4516 cm2
Units of volume:
1 cm3= 0,06102 cu in (in3)
1 cu in (in3) = 16,3871 cm3(in3)
1 dm3=1l
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 mass:
1 kg = 2,2046 lb
1 lb = 0,45359 kg
Density:
1g/cm3= 0,016018 lb/ft3
1lb/ft3= 62,43g/cm3
Units of force:
1 N = 0,224809 lbf
1 lbf = 4,4482 N
Units of pressure:
1 Pa = 1N/m2
1 bar = 100000Pa(1000hPa)
1 bar = 14,5037 lbf/in2 (psi)
1 lbf/in2 (psi) = 0,0689 bar
1 in HG = 33,8638 hPa
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 temperature:
K = °C - 273,15
°C = (°F - 32) / 1,8
°F = (°C x 1,8) + 32
Units of velocity:
1m/s = 3,6km/hr.
1ft/min = 0,3048 m/min
= 18,288 m/sek
1m/s = 0,0555ft/min
1 kn = 1,852km/hr.
1km/hr. = 0,53996 kn
spec. fuel consumtion:
1 g/kWh = 0,001644 lb/hph
1 lb/hph = 608,277 g/kWh
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
Wire Gauge: AWG - mm2
AWG
4 6 8 10 12 14 16 18 20
mm
2
21,2 13,3 8,35 5,27 3,31 2,08 1,31 0,82 0,519
04783
4.3) Conversiontableandabbreviations

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Abbreviations:
* Reference to another section (only
in the illustrated parts catalog)
@at
a drop indicates usage of sealing
adhesive or lubrication compound.
(only in the illustrated parts catalog)
center of gravity
912 A see OM (Type designation)
912 F see OM (Type designation)
912 S see OM (Type designation)
912 UL see OM (Type designation)
912 ULS see OM (Type designation)
912ULSFR ROTAX®912 ULS Version
France
914 F see OM (Type designation)
914 UL see OM (Type designation)
A/C Aircraft
ACG Austro Control GesmbH
AD Airworthiness Directives
A/F across-flat dimension
ASB Alert Service Bulletin
CCW counter-clockwise
CW clockwise
EGT Exhaust gas temperature
EM Engine Manual (Overhaul Manual)
FAA Federal Aviation Administration
FAR Federal Aviation Requirements
hr hours
IM Installation Manual
IPC Illustrated Parts Catalog
ISA International Standard Atmosphere
JAA Joint Aviation Administration
JAR Joint Aviation Requirements
MM Maintenance Manual
MS magneto side
N newly introduced part (only in the
illustrated parts catalog)
n.a. not available
NB as required (only in the illustrated
parts catalog)
NDT non-destructive test
OM Operator’s Manual
O/H Overhaul
p/n part number
PTO power take off
Rev. Revision
rpm revolutions per minute
s.v. still valid (only in the illustrated
parts catalog)
S/N Serial number
SB ServiceBulletin
SI Service Instruction
SL Service Letter
TC Transport Canada
TSN Time Since New
TSO Time Since Overhaul
VFR Visual Flight Rules
XXX on illustrations this sign indicates
the location of the current serial
number or special part coding

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5) Safety notice
ThismanualhasbeenpreparedasaguidetocorrectlyserviceandmaintainallROTAX®
912 aircraft engines.
This edition was primarily published to be used by aircraft mechanics who are already
familiar with all service procedures relating to ROTAX®made aircraft engines.
Pleasenotethatthe instructions willapplyonlyifproper hand toolsandspecialservice
tools are used.
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 is prevail.
The content depicts parts and/or procedures applicable to the particular product at its
timeofmanufacture.Itdoesnotincludedealermodifications,whetherauthorizedornot
by ROTAX, after manufacturing the product.
In addition, the sole purpose of the illustrations throughout the manual, is to assist
identification of the general configuration of the parts. They are not to be interpreted
as technical drawings or exact replicas of the parts.
The use of ROTAX®parts is most strongly recommended when considering replace-
ment of any component. Authorized ROTAX®distributor assistance should be sought
in case of doubt.
Theenginesandthecorrespondingcomponentsidentifiedinthisdocumentshouldnot
be utilized on product(s) other than those mentioned in this document.
Torque wrench tightening specifications must be strictly adhered to. Locking devices
(ex.: 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
renewed.
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. ROTAX®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. Consequently,
Although the mere reading of such information does not eliminate the hazard, your
understandingoftheinformationwillpromoteitscorrectuse.Alwaysusecommonshop
safetypractice.

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ThisinformationrelatestothepreparationanduseofROTAX®aircraftenginesandhas
been utilized safely and effectively by ROTAX®. However, ROTAX®disclaims liability
for all damage and/or injuries resulting from the improper use of the contents. We
strongly recommend that any service be carried out and/or verified by a highly skilled
professional mechanic, see chapter 05-00-00, para 2.2.
SpecificationsaregivenintheSI metricsystemwiththeUSAequivalentinparenthesis.
Where precise accuracy is not required, some conversions are rounded off for easier
use.
Because of our ongoing commitment to product quality and innovation. ROTAX®
reserves the right at any time, and without incuring obligation, to remove, replace or
discontinue any design, specification, feature or otherwise.

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5.1) Repeating symbols
This Manual uses the following symbols to emphasize particular information:
▲WARNING: Identifies an instruction which, if not followed, may cause
serious injury including the possibility of death.
■CAUTION: Denotesaninstructionwhich,ifnotfollowed,mayseverely
damage the engine or other component.
◆NOTE: Indicatessupplementaryinformationwhichmaybeneeded
to fully complete or understand an instruction.
5.2) MaintenanceConcept
The maintenance functions detailed in this manual fall into two categories: Line
MaintenanceandHeavyMaintenance.Repairs beyond the levelsdetailsinthis
manualarenotrecommendedasmaintenancefunctionsandshouldbedoneby
an authorized overhaul facility.
- Line Maintenance (Chapter 00, 05 and 12):
The scope of line maintenance consists of removal, installation and ad-
justment
of engine components (including part wear). All procedures in this manual
are to be considered line maintenance.
- Heavy Maintenance (separate Manual p/n 899 601):
Heavymaintenancedetailsremoval,installationandrepairofcomponentsor
parts normally considered beyond the capabilities of the average line main-
tenance facility.

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5.3) Technical documentation
These documents form the instructions for continued airworthiness of ROTAX®
aircraft engines:
- Installation Manual 912 F
- Installation Manual 912 A
- Installation Manual 912 UL
- Installation Manual 912 S
- Maintenance Manual 912 Series (Line+Heavy MM)
- Operators Manual 912 Series
- Illustrated Parts Catalogue 912 A / F / S / UL / ULS, 914 F / UL
- Overhaul Manual 912 A / F
- Alert Service Bulletins
- Service Bulletins
- Service Instructions
- Service Letters
AnyreferencetoadocumentreferstothelatesteditionissuedbyROTAX®,ifnot
stated otherwise.
The rapid technical progress and variations of installation might render present
lawsandregulationsinapplicable or inadequate.
The illustrations in this Manual are mere sketches and show a typical arrange-
ment. They may not represent the actual part in all its details but depict parts of
thesameorsimilarfunction.Thereforedeductionof dimensionsorotherdetails
from illustrations is not permitted.
- AllnecessarydocumentationisavailablefromtheROTAX®Distribution-and
Service Centers.
- The current documentation is available on SI-912-003 and on the official
homepagewww.rotax-aircraft-engines.com.
Most of the necessary documents are also available as pdf-files. Download
is free of charge.
◆NOTE: The Illustrations and Documents in this Manual are stored in a
document data file/graphic data file and are provided with a
consecutive irrelevant number.
This number (e.g. 00277) is of no significance for the content.
Return shipment:
Ifnecessarytoreturnanengineorcomponentslikegearboxect.toanauthorized
overhaul or repair facility, all required documents (Log book, Maintenance log
etc.) has to be included on that shipment.

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5.3.1) Use for intended purpose
- The engine ROTAX®912 A/F/S is intended for use in certified
aircraft.Incaseofdoubttheregulationsofthenationalauthoritiesor
the respective aviation federations must be observed.
- The certified aircraft engine 912 models A/F/S are tested as per
aeronauticalstandardsforsafetyandtimebetweenoverhaul.Itwas
developed to the latest state of the art and intensively tested.
◆NOTE: The 912 engine models UL/ULS are not certified en-
gines. These engines have not received any aeronau-
ticalstandardsorregulatorysafetyordurabilitytesting,
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 com-
promise safety. However these engines confirm to
ROTAX® quality standards.
The operator assumes all risk of use, and acknowl-
edges by this use that he/she knows this engine is
subject to sudden stoppage.
- Use for intended purpose also means respecting the prescribed
operational-maintenance-andrepairconditions.Thisalsoincreases
the engine time between overhaul efficiency.
▲WARNING: Never run the engine without propeller, this inevitably
causes engine damage and is an explosion hazard.

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5.3.2) Instruction
Enginesrequirespecificinstructionsregardingtheirapplication,opera-
tion, maintenance and repair.
Technical documentation and directions are useful and necessary
complementaryelementsforpersonalinstruction,butcanbynomeans
substitute theoretical and practical instructions. These instructions
shouldcoverexplanationofthetechnicalcontext,adviceforoperation,
maintenance, use and operational safety of the engine.
- This engine must only be operated with accessories supplied,
recommended and released by ROTAX®. Modifications are only
allowed after consent by the engine manufacturer.
- After engine standstill (longer than 2 months) observe without fail
the instructions for engine "out of use". Protect fuel- and carburetor
system against contamination.
■ CAUTION: Spare parts must meet with the requirements defined
bythe engine manufacturer. This is only warranted by
useofGENUINEROTAX®sparepartsand/oraccesso-
ries(seeIPC)orsuitableequivalentinthemanufactuer’s
opinion otherwise, any limited warranty by ROTAX®is
null and void (see Warranty Conditions).
AllSparepartsareavailableattheauthorizedROTAX®
Distribution- and Service centers.

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section page date section page date
02773
00-00-00 1 2002 01 01
2 2002 01 01
3 2002 01 01
4 2002 01 01
5 2002 01 01
6 2002 01 01
7 2002 01 01
8 2002 01 01
9 2002 01 01
10 2002 01 01
11 2002 01 01
12 2002 01 01
13 2002 01 01
14 2002 01 01
15 2002 01 01
16 2002 01 01
17 2002 01 01
18 2002 01 01
19 2002 01 01
ACG-approv. 20 2002 01 01
05-00-00 1 2002 01 01
2 2002 01 01
3 2002 01 01
4 2002 01 01
5 2002 01 01
6 2002 01 01
7 2002 01 01
8 2002 01 01
9 98 09 01
10 98 09 01
11 2002 01 01
12 2002 01 01
05-10-00 ACG-approv. 1 2002 01 01
ACG-approv. 2 2002 01 01
ACG-approv. 3 2002 01 01
ACG-approv. 4 2002 01 01
05-20-00 ACG-approv. 1 2002 01 01
ACG-approv. 2 2002 01 01
ACG-approv. 3 2002 01 01
ACG-approv. 4 2002 01 01
ACG-approv. 5 2002 01 01
ACG-approv. 6 2002 01 01
ACG-approv. 7 2002 01 01
ACG-approv. 8 2002 01 01
ACG-approv. 9 2002 01 01
ACG-approv. 10 2002 01 01
ACG-approv. 11 2002 01 01
ACG-approv. 12 2002 01 01
ACG-approv. 13 2002 01 01
ACG-approv. 14 2002 01 01
05-50-00 ACG-approv. 1 2002 01 01
ACG-approv. 2 2002 01 01
ACG-approv. 3 2002 01 01
ACG-approv. 4 2002 01 01
ACG-approv. 5 2002 01 01
ACG-approv. 6 2002 01 01
ACG-approv. 7 2002 01 01
ACG-approv. 8 2002 01 01
ACG-approv. 9 2002 01 01
ACG-approv. 10 2002 01 01
ACG-approv. 11 2002 01 01
ACG-approv. 12 2002 01 01
6) List of the current pages

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02773
section page date section page date
12-00-00 1 2002 01 01
2 2002 01 01
3 2002 01 01
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date remark for date of date
no. section page of approval approval from of signature
change authorities issue
0 00-00-00 1 up to 22 98 09 01 notrequired 98 09 01 AA/HeC
0 05-00-00 1 up to 12 98 09 01 notrequired 98 09 01
0 05-10-00 1 up to 4 98 09 01 englisch version 98 09 01 AA/HeC
0 05-20-00 1 up to 14 98 09 01 not required 98 09 01
0 05-50-00 1 up to 12 98 09 01 98 09 01
0 12-00-00 1 up to 36 98 09 01 notrequired 98 09 01 AA/HeC
1 00-00-00 1.2,4,6-8,10-20 20020101 notrequired
1 05-00-00 1 up to 6,8,11,12 20020101 notrequired
1 05-10-00 1 up to 4 20020101 englisch version
1 05-20-00 1,2,4 up to 13,14 20020101 not required
1 05-50-00 1up to 12 20020101
1 12-00-00 1 up to 41 20020101 notrequired
02774
7) Table of amendments