Rotax MML-912 User manual

MAINTENANCE MANUAL
(LINE MAINTENANCE) FOR ROTAX® ENGINE TYPE 912 SERIES
part no.: 899735
ROTAX® 912 ULS 3 WITH OPTIONS

Ref. No.: MML-912

Before starting any maintenance work, please read the Maintenance Manual,
as it contains important safety relevant onformation. 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 2009 © - 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 Series
Edition 2 / Rev. 1 INTRO
page 1
July 01/2010
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
questions, please contact an authorized Distribution or Service Center for
ROTAX-aircraft engines.
Chapter structure The structure of the Manual follows whenever it is applicable the struc-
ture of the ATA (Air Transport Association) standards. 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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BRP-Powertrain
Effectivity: 912 Series
Edition 2 / Rev. 0 INTRO
page 2
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NOTES

Effectivity: 912 Series
Edition 2 / Rev. 1
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MAINTENANCE MANUAL
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LEP
page 1
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Chapter: LEP
LIST OF EFFECTIVE PAGES
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INTRO
Title page
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Effectivity: 912 Series
Edition 2 / Rev. 1
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LEP
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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 Series
Edition 2 / Rev. 1 TOA
page 1
July 01/2010
Chapter: TOA
TABLE OF AMENDMENTS
*Approval
The technical content of this document is approved
under the authority of DOA No. 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
issue signature
0
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0
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INTRO
LEP
TOA
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1
INTRO
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1 04-00-00 all 07 01 2010 EASA approved

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Effectivity: 912 Series
Edition 2 / Rev. 0 TOA
page 2
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NOTES

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MAINTENANCE MANUAL
BRP-Powertrain
Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
page 1
October 01/2009
Chapter: 00-00-00
GENERAL NOTE
Introduction This section describes this maintenance of engine type ROTAX 912
Series.
NOTES: The ROTAX 912 Series includes all engines such as the
912 A, 912 F, 912 S, 912 UL, 912 ULS and 912 ULSFR.
Table of contents This chapter of the Maintenance Manual contains general and safety
information concerning the operation of the aircraft engine.
Subject Page
General note page 3
Abbreviations and terms used in this Manual
Conversion table
page 5
page 7
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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Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
page 2
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NOTES

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BRP-Powertrain
Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
page 3
October 01/2009
1) General note
Purpose The purpose of this Maintenance Manual is to acquaint maintenance ser-
vice staff approved by the local aviation authorities with some basic main-
tenance 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
ROTAX Authorized Distributors for Aircraft Engines.
See latest Operators Manual or on the Internet at the official Homepage
www.rotax-aircraft-engines.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 number (1) is on the ignition cover, on
the left, opposite the electric starter. See Fig. 1.
Fig. 1 07902
1
Cyl. 1 Cyl. 3
Cyl. 2 Cyl. 4

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Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
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NOTES

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Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
page 5
October 01/2009
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
rpm Revolutions per minute
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)
912 ULSFR 912 ULS Version France
914 F see OM (Type designation)
914 UL see OM (Type designation)
A Ampere
A/C Aircraft
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
CAN/CGSB Canadian General Standards Board
CSA Constant Speed Actuator
CW Clockwise
CCW Counter-clockwise
DCDI Dual Capacitor Discharge Ignition
DOT Department of Transport
DOA Design Organisation Approval
EASA European Aviation Safety Agency
IM Installation Manual
ECU Engine Control Unit
EGT Exhaust Gas Temperature
INTRO Introduction
EMS Engine Management System

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BRP-Powertrain
Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
page 6
October 01/2009
EN European Norm
IPC Illustrated Parts Catalog
FAA Federal Aviation Administration
FAR Federal Aviation Regulation
OM Overhaul Manual
hr. hours
OM Operators Manual
TOC Table of Contents
ISA International Standard Atmosphere
kg kilograms
AD Airworthiness Directive
MS magneto side
MON motor octane number
N new part (only Illustrated Parts Catalog)
nB as necessary (only Illustrated Parts Catalog)
n.a. not available
NDT non-destructive testing
Nm newton meter
PSU power supply unit
Rev. Revision
ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG
RON Research Octane Number
RV Record of Revisions
s.v. still valid (only IPC)
S/N Serial Number
SB Service Bulletin
SI Service Instruction
SL Service Letter
SMD Surface Mounted Devices
part no. Part number
TSN Time Since New
TSO Time Since Overhaul
VVolt
VFR Visual Flight Rules
LEP List of Effective Pages
MM Maintenance Manual
XXX shows the serial component number
Abbreviation Description

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BRP-Powertrain
Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
page 7
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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 = 1N/m2
1 bar = 100 000 Pa (1000 hPa)
1 bar = 14.5037 lbf/in2(psi)
1 lbf/in2(psi) = 0,0689 bar
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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Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
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NOTES

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Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
page 9
October 01/2009
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.
NOTES: Indicates supplementary information which may be
needed to fully complete or understand an instruc-
tion.
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 component.

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BRP-Powertrain
Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
page 10
October 01/2009
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 strongly
recommend that any service be carried out and/or verified by a highly
skilled professional mechanic
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 aircraft 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 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 modifications,
whether authorized or not by BRP-Powertrain, after manufacturing the
product.

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Effectivity: 912 Series
Edition 2 / Rev. 0 00-00-00
page 11
October 01/2009
Locking devices Locking devices (e.g. 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 replaced.
Torque wrench
tightening
Torque wrench tightening specifications must be strictly adhered to.
WARNUNG
NOTICE If not specified otherwise, the threads are not lubricat-
ed when fastened.

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Edition 2 / Rev. 0 00-00-00
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3.2) Instruction
General note Engines require instructions regarding their application, use, operation,
maintenance and repair.
Technical documentation and directions are useful and necessary comple-
mentary elements for personal instruction, but can by no means substitute
theoretical and practical instructions.
These instructions should cover explanation of the technical context,
advice for operation, maintenance, use and operational safety of the
engine.
Safety notice In this technical Manual passages concerning safety are especially
marked. Pass on safety warnings to other users!
Accessories This engine must only be operated with accessories supplied, recom-
mended and released by BRP-Powertrain. Modifications are only allowed
after consent by the engine manufacturer.
Spare parts
Tools
Standstill After engine standstill (longer than 2 months) observe without fail the
instructions for engine “out of use”. Protect fuel- and carburetor system
against contamination.
Returning When returning the engine or its components (e.g. propeller gearbox) to
an authorized overhaul or repair company, ensure that the necessary doc-
umentation (log book, maintenance records etc.) are enclosed.
WARNUNG
NOTICE Spare parts must meet with the requirements defined
by the engine manufacturer. This is only warranted by
use of GENUINE ROTAX spare parts and/or accesso-
ries (see IPC) or suitable equivalent in the manufactur-
er’s opinion otherwise, any limited warranty by BRP-
Powertrain is null and void (see Warranty Conditions).
Spare parts are available at the authorized ROTAX
Distribution- and Service Center.
Any warranty by BRP-Powertrain becomes null and
void if spare parts and or accessories other than
GENUINE ROTAX spare parts and/or accessories are
used (see latest Warranty Conditions).
WARNUNG
NOTICE In principle use only tools and appliances which are ei-
ther cited in the Manual or in the Illustrated Parts Cat-
alog.