SERVICE INSTRUCTION
Contents
1. or AVGAS Refer to current Maintenance Manual for more information and instructions On turbocharged engines always conduct a cool down run before shutting down in accordance with the relevant Operators Manual Careful attention to engine operation tips see section 6 31 AUGUST 2011 SI 912 016 R4 SI 914 019 R4 page 2 of 12 Copyright BRP Powertrain GmbH amp CO KG All rights reserved 3 2 Operation with unleaded and low lead fuel less than 0 1 g liter lead content E CAUTION When operating primarily on unleaded fuels or MOGAS the maintenance intervals remain unchanged from the published maintenance schedule found in the currently valid Maintenance Manual for the engine type In case of severe operating conditions the time between maintenance intervals must be generally shorter and in particular the frequency of oil changes must be increased regardless of the type of fuel mainly used MOGAS or AVGAS Use the following oils and observe the oil specification indicated Motor oils tested and released from BRP Powertrain for use with unleaded fuel or MOGAS 09464 Marke f Spezifikation Viskosit t Code brand Bezeichnung description specification viscosity SHELL AeroShell Sport Plus 4 API SL SAE 10 W 40 31 AUGUST 2011 SI 912 016 R4 SI 914 019 R4 Copyright BRP Powertrain GmbH amp CO KG All rights reserved Ege Motor oils recommended from the authorized distributors not tested2. ROTAX 912 914 series of engines are now approved for use with E10 Fuels that contain more than 10 ethanol blend have not been tested by BRP Powertrain and are not permitted for use 5 1 2 Suitability of fuel system components of airframe BRP Powertrain urges owners to confirm with their airframe manufacturer that ethanol blended fuels of up to 10 E10 are compatible with all fuel system components It is the responsibility of the aircraft manufacturer to test their fuel system components and supply any further information on techniques procedures and limitations of using ethanol blended fuel BRP Powertrain recommends that aircraft manufacturer and owner operators read the following FAA Advisory Circular Letter AC 23 1521 2 FAA Special Airworthiness Information Bulletin CE 07 06 EASA Safety Information Bulletin SIB 2009 02 These contain details regarding the use of ethanol alcohol blended fuels and the type certificate requirements It is strongly recommended that also non certified aircraft also conform to the information given in the above documents 5 2 AVGAS fuel additives Additives which aid the scavenging of lead deposits under the names of Decalin and Alcor TCP have not been tested by BRP Powertrain Field experience gained shows that these products have no detrimental effect on the engine when used in the recommended manner Always follow the additive manufacturers instructions especially with regard to health and s
3. Shell l a N 0 property code 09466 2 Semi synthetic aviation oils with gear additives Highly recommended for normal lower than 120 C 248 F and occasionally high oil temperature higher than 120 C 248 F operation using leaded or unleaded fuels 3 Semi synthetic motorcycle oils with gear additives Highly recommended for normal lower than 120 C 248 F and occasionally high oil temperature higher than 120 C 248 F operation using leaded or unleaded fuels 4 Semi synthetic oil Recommended for normal lower than 120 C 248 F and occasionally high oil temperature higher than 120 C 248 F operation using leaded or unleaded fuels 5 Petroleum based oil Recommended for use only when oil temperatures remain below 120 C 248 F and when using leaded fuels The viscosity column is only a guideline Substituting other than that shown is acceptable providing all temperature limitations are respected Example Formula Shell Synthetic Blend SAE 5W 30 is a substitute for 10W 30 The guidelines given here must however be obeyed in all cases using only those oils with which there have already been good operating experiences on ROTAX engine types 912 and 914 series NOTE The coefficient of viscosity indicates the tendency of oil to flow but it is not necessarily a quality code Country specific deviations of the viscosity are possible 31 AUGUST 2011 SI 912 016 R4 SI 914 019 R4 Copyright
4. a specific thermal capacity that is higher than waterless coolant It gives excellent corrosion protection especially for aluminum and protection against freezing NOTE For exact monitoring of the coolant temperature a limit has been set This is necessary because standard coolant based on ethylene glycol such as BASF Glysantin in a 50 50 proportion mixture can boil at a temperature as low as 120 C 248 F Refer to the current Installation Manual for more information and instructions E CAUTION The certification and determination of the correct coolant type must be conducted by the aircraft manufacturer As each aircraft type has different characteristics testing must be done to determine the most suitable coolant and instrumentation for each aircraft type NOTE Coolant should be a low silicate and nitrite free formula Follow coolant manufacturer directions regarding mixture percentages etc From the authorized distributors recommended coolants with a mixture of 50 antifreeze and 50 water not tested from BRP Powertrain NOTE The following list is based on the experiences and local recommendation from the authorized distributors Coolant brands with same designation may vary from one to the other region Please contact the local distributor for a recommendation Marke brand Bezeichnung description 08758 31 AUGUST 2011 SI 912 016 R4 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SI 91
5. 04899 ROTAX AIRCRAFT ENGINES SERVICE INSTRUCTION SELECTION OF SUITABLE OPERATING FLUIDS FOR ROTAX ENGINE TYPE 912 AND 914 SERIES SI 912 016 R4 SI 914 019 R4 Repeating symbols Please pay attention to the following symbols throughout this document emphasizing particular information A WARNING Identifies an instruction which if not followed may cause serious injury or even death M CAUTION Denotes an instruction which if not followed may severely damage the engine or could lead to suspension of warranty NOTE Information useful for better handling A revision bar outside of the page margin indicates a change to text or graphic 1 Planning information 1 1 Engines affected All versions of the engine type 912 Series 914 Series 1 2 Concurrent ASB SB SI and SL In addition to this Service Instruction the following additional Service Bulletin must be observed and complied with SB 912 043 SB 914 029 Change of coolant specification current issue 1 3 Reason Field experience has shown that additional information about the choice of suitable operating fluids such as motor oil coolant and fuel and about oil change and maintenance intervals for ROTAX engine types 912 and 914 is necessary 1 4 Subject Selection of suitable operating fluids for ROTAX engine type 912 and 914 Series This information should help the aircraft builder and operator ensure that the operating conditions an
6. 4 019 R4 page 8 of 12 4 3 Waterless coolant Waterless coolant has advantages to prevent boiling of the cooling system because of its high boiling point However the specific thermal capacity is lower than with conventional coolant resulting in slightly higher running temperatures The cooling system of ROTAX engine types 912 914 is designed for operation with waterless coolant and thus must not be modified i e drainage or ventilation holes must not be closed NOTE With waterless coolant based on propylene glycol such as EVANS NPG it is sufficient to monitor the cylinder head temperature since the boiling point is very high CAUTION The certification and determination of the correct coolant type must be conducted by the aircraft manufacturer As each aircraft type has different characteristics testing must be done to determine the most suitable coolant and instrumentation for each aircraft type Recommended coolant 100 concentrate Marke _ brand Bezeichnung description EVANS EVANS NPGR 07181 E CAUTION EVANS NPGR contraction point is approx 23 C 10 F It will not freeze and expand like conventional coolant Do not use if conditions expose the engine to non operational temperatures below 23 C 10 F 4 3 1 Warnings for operating with waterless coolant Water or coolant containing water must never be added to the cooling system The max water content must not exceed 3 6 it can be tested usi
7. BRP Powertrain GmbH amp CO KG All rights reserved pags Soris 3 4 Motor oils not suitable for engine types 912 914 Series Experience has shown that only some oils are suitable for use in ROTAX engine types 912 914 and careful selection is advised following the recommendations in this Service Instruction BRP Powertrain is aware of formulation changes to some oils previously recommended for use in this Service Instruction As a result BRP Powertrain no longer recommends the following oils and these should not be used anymore Marke brand Bezeichnung description Spezifikation specification Castrol Power 1 API SJ GPS API SG CD MOTUL 5100 Synthetic Blend API SJ 31 AUGUST 2011 Copyright BRP Powertrain GmbH amp CO KG All rights reserved SI 912 016 R4 SI 914 019 R4 page 7 of 12 4 Coolant 4 1 4 2 General All engine types 912 914 have liquid cooled cylinder heads and ram air cooled cylinders The function of the coolant is to protect the cylinder heads from over temperature by means of heat dissipation Protection against corrosion of the engine components and freezing of the coolant is achieved with appropriate additives In principle 2 different types of coolant are permitted Conventional coolant based on ethylene glycol with 50 water content Waterless coolant based on propylene glycol Conventional coolant Conventional coolant with about 50 water content has
8. S fuel we recommend to make a change of engine oil every 25 operating hours More frequent oil changes will assure timely removal of residues and oil sludge thus avoiding increased wear or operating troubles Use the following oils and observe the oil specification indicated Motor oils tested and released from BRP Powertrain for use with leaded AVGAS 09464 Marke a Spezifikation Viskosit t Code Bezeichnung description ae brand specification SHELL AeroShell Sport Plus 4 API SL SAE 10 W 40 31 AUGUST 2011 SI 912 016 R4 SI 914 019 R4 Copyright BRP Powertrain GmbH amp CO KG All rights reserved page 5 of 12 Motor oils recommended from the authorized distributors not tested from BRP Powertrain for use with leaded AVGAS NOTE The following list is based on the experiences and local recommendation from the authorized distributors Oil brand with same designation may vary from one to the other region Please contact the local distributor for the recommendation for its region Spezifikation Viskositat specification viscosity EVVA EVVA C52 Airmax APISJ CF SAE10W 40 3l EVVA EVVA Mehrbereichs l C52 multigrade oil C52 AP SJ CF SAE15W 50 3l MOBIL Mobil 1 Clean 7500 APISM SL saE 10w 30 4l Bezeichnung description A jJ wo Skydrive Skydrive Aerolube tow4ooil apis saE10w 40 2 SHELL _ Advance VSX4 Z O i O _ApisG SAE 10 40 _ Silas Formula Shel sss
9. aded or unleaded fuels 5 Full synthetic oil Recommended for high oil temperature operation higher than 120 C 248 F using only unleaded fuels Bezeichnung description O1 ja Jo The viscosity column is only a guideline Substituting other than that shown is acceptable Example Formula Shell Synthetic Blend SAE 5W 30 is a substitute for 10W 30 The guidelines given here must however be obeyed in all cases using only those oils with which there have already been good operating experiences on ROTAX engine types 912 and 914 series NOTE The coefficient of viscosity indicates the tendency of oil to flow but it is not necessarily a quality code Country specific deviations of the viscosity are possible 31 AUGUST 2011 SI 912 016 R4 SI 914 019 R4 Copyright BRP Powertrain GmbH amp CO KG All rights reserved page 4o12 3 3 Operation with leaded AVGAS fuels If the engine is mainly operated with leaded AVGAS fuels the following maintenance operations are necessary in addition by latest after every 50 operating hours change of oil filter change of engine oil oil level checks etc according to the most recent Maintenance Manual In addition compliance with the following operating conditions is required HM CAUTION The engine is considered to be operated mainly on leaded AVGAS when run for more than 30 of engine operating time on leaded AVGAS fuel NOTE When operating primarily on leaded AVGA
10. afety precautions BRP Powertrain only has field experience with Decalin Runup and Alcor TCP brands Other similar additives are not advised as BRP Powertrain cannot comment on their suitability for the 912 914 engine types 31 AUGUST 2011 SI 912 016 R4 SI 914 019 R4 Copyright BRP Powertrain GmbH amp CO KG All rights reserved page tiporta 5 3 Fuel according to local standards The following fuels can be used Usage Description 912 UL A F 912 ULS S 914 UL F Min RON 90 min AKI 87 Min RON 95 min AKI 91 MOGAS E EN 228 Normal uropean standard EN 228 Super EN 228 Super EN 228 Super plus EN 228 Super plus Canadian CAN CGSB 3 5 Qualitat 1 CAN CGSB 3 5 Qualitat 3 standard R 51105 97 R 51866 2002 R 51105 97 R 51866 2002 Russian Regular 91 92 Regular Euro 92 standard Premium 95 Premium Euro 95 Premium 95 Premium Euro 95 Super 98 Super Euro 98 Super 98 Super Euro 98 US standard ASTM D4814 ASTM D4814 AVGAS AVGAS 100 LL leaded AVGAS 100 LL ASTM D910 ASTMD910 UL91 UL91 unleaded ASTM D7547 ASTM D7547 released brand name HJELMCO AVGAS HJELMCO AVGAS 91 96 UL 91 96 UL HJELMCO AVGAS HJELMCO AVGAS 91 98 UL 91 98 UL 08827 d unleaded mainly available in the Scandinavian area Anti Knock Index RON MON 2 AVGAS 100LL places greater stress on the valve seats due to its high lead content and forms increased deposits in the combustion cha
11. d installation are correct and thereby achieve optimum performance and reliability 1 5 Compliance According Maintenance Manual of engine type ROTAX 912 and 914 Series current issue A WARNING Non compliance with these instructions could result in engine damages personal injuries or death 1 6 Approval The technical content of this document is approved under the authority of DOA ref EASA 21J 048 1 7 References In addition to this technical information refer to current issue of Operators Manual OM Maintenance Manual MM Installation Manual IM NOTE The status of Manuals can be determined by checking the table of amendments of the Manual The 1 column of this table is the revision status Compare this number to that listed on the ROTAX WebSite www rotax aircraft engines com Updates and current revisions can be downloaded for free 31 AUGUST 2011 Current valid documentation see SI 912 016 R4 www rotax aircraft engines com SI 914 019 R4 page 1 of 12 Copyright BRP Powertrain GmbH amp CO KG All rights reserved 2 Material Information 2 1 Material cost and availability None 3 Lubricant 3 1 General Foreign particles formed during combustion are suspended in the motor oil Together with oil components that are not sufficiently resistant to heat these foreign particles can cause parts such as pistons piston rings exhaust valves etc to seize and lead to problems On turbocharged engines failing
12. d up coking can also flake off and block restrict the oil return passage Conclusions If possible operate the listed engine types using unleaded or low lead fuel AVAGS 100 LL is not considered low leaded in this context Use the motor oils tested and released by BRP Powertrain or which are recommended by the local authorized distributor according to sections 3 2 and 3 3 of this Service Instruction Use only oil with API classification SG or higher Due to high stresses in the reduction gears oils with gear additives such as good quality 4 stroke motorcycle oils are highly recommended Because of the incorporated friction clutch oils with friction modifier additives are unsuitable because this could result in clutch slipping during standard operation Heavy duty semi or fully synthetic depending on fuel type used brand name oils offer many advantages and are generally the best choice Avoid oils designed strictly for use in Diesel engines These may not be suitable due to insufficient high temperature properties and additives that may affect the operation of the slipper clutch in the gear box Incase of severe operating conditions i e flight school towing near idle operation over a long period over use of carburetor preheating etc the time between maintenance intervals must be generally shorter and in particular the frequency of oil changes must be increased regardless of the type of fuel mainly used MOGAS
13. from BRP Powertrain for use with unleaded fuel or MOGAS NOTE The following list is based on the experiences and local recommendation from the authorized distributors Oil brands with same designation may vary from one to the other region Please contact the local distributor for the recommendation for the corresponding region 09465 Spezifikation Viskositat specification viscosity Evva Evva C52 Airmax TAP SCF SAE tOW 40 3 IEVVA EVVA Mehrbereichs6l C52 multigrade oil C52 APISJ CF__ SAE15W 50 3 MOBIL Mobil1 AP SCF SAE SS W 30 5 MOBIL Mobilit TP uC SAE 1S W 50 6l Skydrive Skydrive Aerolube 10W40 oil property code 1 Full synthetic motorcycle oil with gear additives Highly recommended for occasionally high oil temperature operation higher than 120 C 250 F using only unleaded fuels 2 Semi synthetic aviation oils with gear additives Highly recommended for normal lower than 120 C 250 F and occasionally high oil temperature higher than 120 C 248 F operation using leaded or unleaded fuels 3 Semi synthetic motorcycle oils with gear additives Highly recommended for normal lower than 120 C 250 F and occasionally high oil temperature higher than 120 C 248 F operation using leaded or unleaded fuels 4 Semi synthetic oil Recommended for normal lower than 120 C 248 F and occasionally high oil temperature higher than 120 C 250 F operation using le
14. mber and lead sediments in the oil system Thus it should only be used in case of problems with vapor lock or when other types of gasoline are unavailable HM CAUTION Use only the correct fuel for the specific climate zones NOTE There is a risk of vapor lock formation if winter fuel is used for summer operation 31 AUGUST 2011 SI 912 016 R4 SI 914 019 R4 Copyright BRP Powertrain GmbH amp CO KG All rights reserved page Morte 6 General engine operation requirements and operating tips 1 Keep the motor oil temperature below 120 C 250 F over most of the operating period 2 Always insure that the oil type used is adequate for climatic conditions and peak engine operating temperatures If operational oil temperatures exceed 120 C 250 F use of a mineral or petroleum based oil is not recommended 3 For turbocharged engines ensure an adequate running cool down period to prevent deposits by coking of oil 4 When operating with unleaded fuels or MOGAS and when engine oil temperatures often exceed 120 C 250 F use of a high quality full synthetic oil is recommended 5 To avoid formation of condensation water in the motor oil the oil temperature must rise at least once every operational day to at least 100 C 212 F 6 When safe and sensible avoid extended use of carburetor air pre heating 7 The type of fuel used operating conditions and the demands of the engine mission profile may need to increase the freque
15. ncy of oil changes to avoid the excessive build up of lead and other residues in the engine oil Always adjust the engine oil change intervals to avoid excessive build up of sludge in the engine oil HM CAUTION Donotuse oil additives and observe the operating limits as per the relevant Operators Manual Excessive engine vibration particularly at low idle speeds can impair the carburetor fuel metering system leading to atoo rich mixture condition This rich mixture condition can further lead to rough engine operation and excessive carbon and lead deposits 7 Summary A WARNING Non compliance with these recommendations could result in engine damage personal injury or death Approval of translation to best knowledge and judgment in any case the original text in the German language and the metric units Sl system are authoritative 31 AUGUST 2011 SI 912 016 R4 SI 914 019 R4 Copyright BRP Powertrain GmbH amp CO KG All rights reserved page 120ta
16. ng a Brix refractometer Any water present in the cooling system is separated out as vapor This can cause the cooling system to fail due to insufficient coolant quantity If EVANS NPG NPGR is not available locally for servicing the cooling system a conventional coolant basedon pure 100 ethylene glycol can be used temporarily However the coolant must be replaced again with EVANS NPG NPGR within the next 15 days HM CAUTION As some conventional coolants are available in a pre mixed formula water added be sure you only add 100 pure ethylene glycol if EVANS NPG NPGR is not available M CAUTION The above warnings are taken from the manufacturers user manual however the original text and description in the user manual is binding 31 AUGUST 2011 SI 912 016 R4 SI 914 019 R4 Copyright BRP Powertrain GmbH amp CO KG All rights reserved pages Ore 5 Fuel For ROTAX aircraft engines different fuel types are available See Operators Manual of the relevant engine type and or the table in chapter 5 3 5 1 Automotive fuels In addition to AVGAS various automotive fuel types with different quality are available Due to various environmental economic and political reasons a number of fuel types with different amount of ethanol blend is available Therefore the maximum amount of ethanol blend is defined as follows 5 1 1 E10 Unleaded gasoline blended with 10 ethanol In addition to AVGAS and unleaded automotive fuel Mogas the
17. to ensure an adequate cool down period prior to shut off may lead to particle deposits and cause damage to bearings and seals Hard oil residues can obstruct parts of the oil system and lead to damage Inaddition to insufficient cool down periods the use of unsuitable oils and not obeying oil change intervals can especially cause such damage Long term operation with an engine that is too cold and or operating too long with an overly rich fuel mixture can cause water and fuel contamination in the oil reducing its lubrication capacity Furthermore long down times with oil that contains water and contaminants can cause corrosion damage especially on the bearings with serious consequential damage The criteria for correct motor oil selection are Correct oil viscosity for cold starts and sufficient oil pressure at high temperatures Good gear wear protection Avoidance of clutch slipping due to use of additives Insufficient oil flow capability so that too much volume remains in the engine leading to low oil level in the external oil tank This can only be detected during testing with an oil level indicator installed on the oil tank Ability to withstand combustion products containing lead which enter the oil during AVGAS operation High oil temperature durability This is especially important for the turbo engine due to the risk of oil carbon build up on the bearing and sealing seats of the turbocharger The oil carbon buil
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