SB 912 079
SB 912 079
SB 912 079
SERVICE BULLETIN
Essential information regarding engine installation, operation,
and maintenance for ROTAX® 912 (Series) Aircraft Engines
ATA System: 72-00-00 Engine
MANDATORY
1) Planning information
To obtain satisfactory results, procedures specified in this publication must be accomplished with
accepted methods in accordance with prevailing legal regulations.
BRP-Rotax GmbH & Co KG cannot accept any responsibility for the quality of work performed in
accomplishing the requirements of this publication.
1.1) Applicability
All versions of ROTAX® engine types:
Engine type Serial number
912 S/ULS (Series) all
1.2) Concurrent ASB/SB/SI and SL
In addition to this Service Bulletin / Service Letter / Service Instruction the following documents
must be observed and complied with:
- SI-912-016 / SI-914-019, “Selection of suitable operating fluids for ROTAX® Engine Type 912 i,
915 i, 912 and 914 (Series)”.
- SL-916 i-009/915 i-011/912 i-005/912-014/914-012, Non-approved modifications or use of
ROTAX® unapproved engine components or accessories for ROTAX® Aircraft Engines.
- SB-912-044 - Use of the ROTAX® supplied airbox for all ROTAX® Engine Types 912 A/F
(Series).
- SI-03-1998 - Engine start at low temperatures at ROTAX® Engine Type 912 and 914 (Series).
- in general, all relevant Alert Service Bulletins (ASB), Service Bulletins (SB), Service Instruc-
tions (SI), Service Letters (SL), Service Instruction - Parts and Accessories (SI-PAC) with rele-
vance to perform this maintenance, repair or overhaul task.
1.3) Reason
Field observations that are carried out as part of our obligations revealed an increased number of
unexplainable engine power losses, engine vibrations, and piston damage. In-depth investigations
on various aircraft models have identified the main contributing factors and causes for the majority
of these occurrences. The findings and insights of these investigations are hereby shared with all
stakeholders. It is also pointed out that these guidelines and requirements must be observed.
1.4) Subject
Essential information regarding engine installation, operation, and maintenance for ROTAX® 912
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1.5) Compliance
A significant part of the SB's content is related to existing requirements that are already in place
and described in the currently valid Instructions for Continued Airworthiness (ICA) documents. The
purpose of these requirements within the SB is to emphasize that these specifications must be
complied with. The content of the SB must therefore be analyzed, understood and checked for
compliance by all stakeholders.
In case of non-compliances, corrective actions must be implemented by the associated stake-
holder to comply with the existing requirements.
OEM / TC-holder requirements:
- Check for compliance with applicable guidelines and requirements in your area of account-
ability as soon as possible and correct any non-compliance at the next possible occasion.
- Any additional specifications, new requirements or limitations that are not yet available in the
existing ICAs must be implemented by the corresponding stakeholder as quickly as possible
but at latest 12 months after publication of this Service Bulletin.
Operators / Pilots requirements:
- Check for compliance with applicable guidelines and requirements in your area of account-
ability - with the next 10 hours. In case of non-compliance or questions contact a ROTAX®
authorized distributor.
Maintenance requirements:
- These maintenance instructions must be considered at any maintenance events, retrofitting,
repair and overhaul.
- Check for compliance with applicable guidelines and requirements in your area of account-
ability and take actions to correct the non-compliance at the next regular maintenance inter-
val.
Non-compliance with these instructions could result in engine damag-
m
m WARNING
WARNUNG es, personal injuries or death.
1.6) Approval
The technical content of this document is approved under the authority of the DOA ref.
EASA.21J.048.
1.7) Labor time
Estimated labor hours:
Engine installed in the aircraft - - - labor time will depend on airframe installation and therefore no
estimate is available from the engine manufacturer.
1.8) Mass data
Change of weight - - - depends on the aircraft installation and installation situation (parts chosen
by the maintenance technician are not considered).
Moment of inertia - - - unaffected
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1.10) Software modifications
No change.
1.11) References
In addition to this technical information refer to current issue of
-In general Operators Manual (OM) and in particular: Chapter 4
-In general Installation Manual (IM) and in particular: Chapter 72-60-00 and 73-00-00
-In general Maintenance Manual Line (MML) and in particular: Chapter 05-20-00
-In general Maintenance Manual Heavy (MMH) and in particular: Chapter 24-20-00, 73-00-00,
74-00-00 and 78-00-00
NOTE: The status of the Manuals can be determined by checking the table of amendments.
The 1st column of this table shows the revision status. Compare this number to the one
listed on the ROTAX® website:
www.flyrotax.com. Updates and current revisions can be downloaded for free.
1.12) Other Publications affected
None.
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2) Material Information
None.
3) Accomplishment/Instructions
- ROTAX® reserves the right to make any amendments to existing documents, which might
become necessary due to this standardization, at the time of next revision or issue.
NOTE: Before maintenance, review the entire documentation to make sure you have a com-
plete understanding of the procedure and requirements.
Accomplish- All measures must be implemented and confirmed by at least one of the following persons or
ment organizations:
OEM requirements:
- Aircraft OEM.
Operator requirements:
- Aircraft operator, pilot, student.
Maintenance requirements:
- Persons with approved qualifications for the corresponding engine types. Only authorized per-
sons (iRMT, Level Line / Heavy Maintenance) are entitled to carry out this work.
- ROTAX® - Authorized Distributors or their independent Service Centers.
- ROTAX® - Airworthiness representatives.
- Persons approved by the respective Aviation Authorities.
NOTE: Indicates supplementary information which may be needed to fully complete or under-
stand an instruction.
All work has to be performed in accordance with the relevant ROTAX® Instructions for
Continued Airworthiness (ICA) of the respective engine type.
General Further material on general inspection, maintenance and repair can also be found in relevant Advi-
sory Circular AC 43.13 from FAA.
Advisory This Manual “Advisory Circular” AC describes maintenance methods, techniques and practice.
Circular These are recognized and authorized for inspection and repairs in non-pressurized areas for which
there are no separate maintenance and repair instructions.
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3.1) Introduction
The identified main contributing factors and causes for the aforementioned occurrences have been
listed below. Each contributing factor and cause is subsequently detailed in the respective subsec-
tion following a common structure:
- Background information
- OEM requirements
- Operator requirements
- Maintenance requirements
Table of contents:
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3.2) Fuel system
NOTE: Due to the technical design and installation conditions (construction of the return line,
etc.) pressure fluctuations at the fuel pump are possible. These pressure fluctuations
within the specified operating limits are not considered a problem.
Low fuel pressure indications are also possible and allowed, but the pressure must
stabilize to the operating limit within 10 seconds. However, low pressure indications
below 0.08 bar (1.16 psi) may only last a maximum of 1 second. If not, the cause must
be determined and rectified.
- It is also advisable to route the fuel line as far away from heat source as possible and to add
thermal isolation around the fuel lines, especially within the engine compartment.
- The electrical fuel pump must be positioned in order to be gravity fed from the fuel (catch)
tank and the hoses between the electrical fuel pump and fuel tank must be self bleeding (No
airtrap).
- Fuel line should also be routed with sufficient bending radius (Follow manufacturer recom-
mendation) in order to prevent the pipe from kinking.
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- In order to reduce the pressure drop along the fuel line, the use of sharp angled adapters or
banjo connectors should be avoided as much as possible.
- The fuel hose on the suction side must be collapse resistant.
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- All the fuel hoses must also be sufficiently supported in order to avoid excessive vibration of
the hose, which would increase the risk of vapor lock.
- When installing other "devices" than the one specified in the Rotax installation manual on the
suction side of the fuel pump, their effect on the fuel system pressure drop must be carefully
investigated at all operating conditions.
- Use appropriate fuel filter (coarse/fine) and water separator/gascolator.
- For prevention of vapor locks: The length of the fuel line on the suction side of the electrical /
mechanical fuel pump (between the fuel tank and the fuel pump) must be kept as short as
possible to minimize vapor formation at high altitudes and high temperatures. High engine
compartment temperatures increase fuel temperature and therefore facilitate vapor forma-
tion of the fuel.
- Fuel temperature: The fuel system must be designed considering vapor lock depending on the
ambient conditions (e.g. pressure and temperature) and the used fuel types (vapor pressure
class). Should problems occur during the test period, the affected components, e.g. the sup-
ply line to the fuel pumps, must be cooled. To avoid too much fuel heating at the fuel pump
inlet, it is obligatory to route the fuel return line from the engine to the main fuel tank, and not
to the electrical fuel pump inlet or header tank, see latest Installation Manual (IM), Chapter
73-00-00.
- Install check valves with appropriate specification (e.g. with sufficient cross section, opening
pressure etc.) parallel to the electrical fuel pumps as indicated in the latest Installation Man-
ual (IM), Chapter 73-00-00.
- Venting lines: The carburetor float chamber venting lines have to be routed into a ram-air and
vacuum free zone or into the GENUINE ROTAX® airbox, according to the requirements and
release of BRP-Rotax GmbH & Co KG. These lines must not be routed into the slipstream. If
the drainage lines of the airbox are connected with the drainage lines of the drip trays or the
carburetors by a T-piece, these lines must not be routed down the firewall (drainage lines of
the airbox separately are allowed).
- At first installation or when doing extensive work on the fuel system or replacing fuel line, the
complete fuel system should be flushed in order to remove all potential contaminant.
- Ensure adequate fuel delivery in accordance with the fuel system requirements in the latest
Installation Manual (IM) of the respective engine type.
- Use ROTAX® genuine airbox (optional).
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- Install venting lines in accordance with the latest Installation Manual (IM) of the respective
engine type.
- Do not install non-approved mixture leaning devices.
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3.3) Exhaust back pressure
The exhaust back pressure measurement has to be performed on a serial production aircraft (not a
development prototype that is subject to change). This also applies to any modifications to the
exhaust system; in this case, the measurements have to be repeated and results updated.
Exhaust back pressure:
Max. 0.2 bar (2.9 psi) at wide open throttle and 5800 en-
gine rpm, ISA conditions, ambient pressure > 950
mbar (28.05 inHg).
Min. 0.08 (1.2 psi) bar at wide open throttle and 5800 en-
gine rpm, ISA conditions, ambient pressure > 950
mbar (28.05 inHg).
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3.3.4) Maintenance requirements
Please check the exhaust system while performing maintenance events.
Pay special attention to:
- Any unauthorized modifications or improper repairs on the exhaust system.
- Damages and cracks due to mechanical impact, e.g. heavy landing.
- When performing repairs to the exhaust system, avoid e.g. excessive welding seams, intro-
ducing kinks, or any other modifications which might limit the available cross-section of the
exhaust system (thus increasing exhaust back-pressure).
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3.4) Engine power setting
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3.4.3) Operator requirements
Use the following graph to determine appropriate MAP and RPM settings depending on fuel type to
ensure maximum margin/robustness for piston damage/pre-ignitions.
Fig. 1
Manifold absolute pressure (MAP) and engine speed settings for ROTAX® 912 S/ULS
for fuel type RON 95 and RON 98*
The red line labeled “carb. heat on inch Hg” represents the limits for both RON 95 and RON 98*
above which piston damage may occur when the carb. heat is on/activated.
The area above the carb. heat on inch Hg line must be avoided at all
m CAUTION
m WARNUNG times when the carb. heat is on/activated.
The blue and orange lines represent the limits for RON 95 and RON 98 respectively above which
piston damage may occur. The areas above the RON 95 inch Hg line and the RON 98 inch Hg line
respectively must be avoided at all times. RON 95 and RON 98 lines are valid for manifold air tem-
perature up to max. 50 °C / 122 °F.
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*for specification of fuel types see Service Instruction SI-912-016 / SI-914-019 / SI-912 i-001 /
SI-915 i-001 / SI-916 i-001, “Selection of suitable operating fluids for ROTAX® Engine
Type 916 i (Series), 915 i (Series), 912 i (Series), 912 and 914 (Series)”.
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In addition to the manifold absolute pressure and engine/propeller speed limitations, adjustment of
the power needs to be performed in a correct way:
- Power increase needs to be led with the propeller control followed by the throttle control as
outlined in the table below.
Step Procedure - Power increase
1 First increase propeller speed [rpm].
2 Then increase MAP with the throttle lever.
Red arrows describe the way it should not be done. Green arrows
m CAUTION
m WARNUNG describe the right way
Fig. 2
Power increase
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- Power reduction needs to be led with the throttle control followed by the propeller control as
outlined in the table below.
Step Procedure - Power reduction
1 First reduce MAP with the throttle.
2 Then decrease propeller speed (rpm).
Red arrows describe the way it should not be done. Green arrows
m CAUTION
m WARNUNG describe the right way
Fig. 3
Power reduction
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3.5) Engine load
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3.6) Intake air heat up - Carb. heat bypass, Airbox temperature, Engine compartment ventilation
NOTE: Air intake Heat up = Air temperature measured in the airbox - Ambient temperature
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ROTAX® strongly recommends additional to minimum required instrumentation the installation as
per latest Installation Manual (IM) of:
- An airbox temperature sensor (see as well section 3.14.2)).
NOTE: This does offer the possibility to constantly monitor the MAT temperature and eventu-
ally identify issues (leaking carb heat, disconnected intake pipes,...) before they will
eventually result into engine damage.
Air Filter:
High engine performance requires air temperature as low as possible at air intake. Therefore the
air filter should be located in a recess of the engine cowling or separated from warm air by baffles
such that fresh air can be aspirated.
- Minimize heat up of intake air (without activated carburetor heat) under cowling by proper
firewall forward design and engine installation (e.g. routing of air hoses away from hot engine
parts and add heat insulation where needed). Inadequate installation could cause exceeding
of limits of operation (e.g. CT and EGT) and thus lead to a higher possibility of engine damage.
NOTE: Proper installations are able to achieve less than 8° C (delta between carburetor en-
trance and ambient temperature) at max. continuous power.
- In case of using a non-ROTAX® genuine airbox, consider the negative effect on mixture distri-
bution. The carburetor float chamber venting lines have to be routed into a ram-air and vac-
uum free zone.
- Avoid improper cowling design that supplies hot air to the engine and/or restricts airflow
causing inadequate cooling.
- Make sure that the air intake tubes of the airbox for fresh air and preheated air are connected
correctly.
- Respect maximum allowable temperatures of engine components in all operating conditions
of flight to avoid operational problems. Always design engine installations to respect all
parameters and limitations.
NOTE: Suitable documentation of airbox temperature measurements will be required in case
of warranty application due to piston damage.
- Verify the correct actuation of the airbox push/pull mechanical linkage, no wear is allowed.
- Check for unauthorized modifications to the air intake.
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3.7) Carburetor heat - Usage, Temperature increase
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3.8) Coolant temperature (CT)
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3.9) Fuel type and quality
- Refrain from using fuels which exceed specified Alcohol content > 10% (E10+).
- Refrain from using non-approved fuel additives.
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- Ensure that the fuel source (airport/landing strip, automotive fuel station) meets the required
quality standards. It is recommended to use the fuel available at the respective airport or
landing strip rather to get fuel supplied from a local automotive fuel station not knowing the
quality of fuel source.
NOTE: Implement procedures to regularly check, track and document the quality of the fuel
used. In case of piston damages, it is mandatory to provide a fuel sample of the fuel
being used during the time of incident.
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3.10) Ignition system - Easy-start activation, Trigger coil gap, Temp. influence
1...starter relay
2...ignition switch
2 1
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Fig. 4
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The easy-start function can be used for aircraft, which have an engine start problem in cold condi-
tions.
NOTE: For more detailed information about the Advanced Start Module (ASM) see SI-912-028.
Analysis of field observations so far have not revealed a malfunction of the Advanced Start Module
(ASM) as a root cause, but pointed mainly to the fuel system and/or fuel type and quality.
Respecting the limits below the ignition system is essentially single fault tolerant:
- High temperatures in the engine compartment.
NOTE: The trigger coils as all other ignition electrics must not be exposed to ambient tem-
peratures higher than 80 °C (176 °F) - see latest Maintenance Manual Heavy (MMH),
Chapter 24-20-00, page 6.
- Gap of trigger coils (IH02), see Fig. 5.
NOTE: Due to the operating principle of the ignition system the gap of the trigger coil has to
be within limits - see latest Maintenance Manual Heavy (MMH), Chapter 24-20-00, page
16.
Intentional activation of the easy-start function is only possible when a minimum voltage of 2.8 V is
applied at the advanced start terminals and they must therefore be grounded when not intended to
be activated.
- Ensure that the engine installation is performed in accordance with the latest installation
manual e.g. grounding of the trigger coil wire and the ignition switch shielding is done cor-
rectly.
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3.10.4) Maintenance requirements
- Check the wiring of the ignition system and make sure that the grounding of the trigger coil
wire and the ignition switch shielding is done correctly.
- Ensure that the trigger coil gaps are not inadvertently changed (e.g. collision with other parts
during installation). The trigger coils have to be within the limits, see latest Maintenance Man-
ual Heavy (MMH) Chapter 24-20-00.
Field observation has shown that some trigger gaps were above speci-
m NOTICE
WARNUNG fied limits. The trigger coil gap is factory preset and within normal usage
there is no need to adjust it.
Fig. 5
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3.11) Spark plugs
Fig. 6
NOTE: Do use correct quantity of heat conduction compound. Excessive use of heat conduction
compound could lead to the effect of contributing to piston damage.
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- Inspect the electrode gap as per latest Maintenance Manual Line (MML) of the respective
engine type:
Fig. 7
NOTE: Due to the curved gap between the center electrode and the ground electrodes, it is
suggested to use a wire type feeler gauge for accurate gap measurement..
Electrode gap
New Wear limit
0.8 - 0.9 mm (0.0031 - 0.0035 in.) 1.1 mm (0.043 in.)
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3.12) Exhaust gas CO measurement
- Measurements are to be taken from each cylinder from the position of EGT measurement.
- Re-test at modification of the exhaust system.
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3.13) Ambient conditions
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3.14) Instrumentation
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3.15) Idle speed setting
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3.16) Engine startup and shutdown procedure and tips
Cold engines
Step Procedure
1 Due to a feature of the carburetor design the throttle must be at idle (fully
closed) when starting a cold engine. This allows for more effective fuel
enrichment.
2 The choke must be fully opened.
3 Soon after starting advance the throttle to around 2000 rpm and slowly
close the choke.
4 Keep engine at around 2200 rpm for warm up period.
.
Hot engines
Step Procedure
1 It is always prudent to park the aircraft with the nose pointing into wind to
aid the cooling after shut down and prevent excessive heat soak under the
engine cowling.
2 Open the throttle a small amount slowly while cranking (choke closed).
Once the engine fires, advance throttle to 1800 / 2000 rpm.
Engines which have not started due to wrong procedure and are “flooded”
Step Procedure
1 Open throttle fully (choke closed).
2 Ignition ON and start the engine.
NOTE: To increase power, put the propeller governor lever to maximum rpm speed, then in-
crease MAP with the throttle lever. Refer also to the pilot operating handbook of the
aircraft manufacturer for relevant power setting.
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NOTE: Allow the engine to cool at idle for several minutes before turning off the engine, as
follows:
Step Procedure
1 It is always prudent to park the aircraft with the nose pointing into wind to
aid the cooling after shut down and prevent excessive heat soak under the
engine cowling.
2 Reduce loading on the propeller and gearbox by adjusting the propeller to
fine pitch (in-flight variable pitch propellers) and move throttle to idle
position.
3 After cooling down run, throttle must be at idle so engine at its minimum
speed, switch ignition off on one circuit for a short time (2-3 seconds) then
switch off the second circuit.
NOTE: To decrease power, first reduce MAP with the throttle, and then decrease rpm
with the propeller control. See also section 3.4.3).
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3.17) Piston differential pressure check
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3.18) Selection of pistons and cylinders
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4) Summary
These instructions (section 3) have to be followed in accordance with the deadlines specified in
section 1.5).
The execution of this Service Bulletin must be confirmed in the logbook.
NOTE: Work on EASA certified parts might affect the EASA Form 1 and does require appropri-
ate documentation by authorized persons. Repairs must be entered into the engine
logbook and also do apply for the EASA Form 1.
A revision bar outside of the page margin indicates a change to text or
graphic.
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.
5) Inquiries
Inquiries regarding this Service Bulletin should be sent to the ROTAX® Authorized Distributor of
your area.
A list of all ROTAX® Authorized Distributors or their independent Service Centers is provided on
https://dealerlocator.flyrotax.com.
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