maintenance manual - rotax-owner.com · (line maintenance for rotax® engine type 582 ul series...

AIRCRAFT ENGINES

ref. no.: IM-2 Stroke | part no.: 899058

MAINTENANCE Manual(LINE MAINTENANCE for rotax® engIne tYPe 582 UL SERIES

RotaX® 582 ul dCdI Mod. 99 wIth oPtIonS

RotaX® 582 ul dCdI Mod. 17 wIth oPtIonS

picture: rotax® 582 UL DCDI Mod. 99 with options

Before starting any maintenance work, please read the Maintenance Manual completely as it contains important safety relevant information. Failure to do so may result in personal injuries including death. Consult the orginal equipment manufacturers handbook for additional instructions!

These technical data and the information embodied therein are the property of BRP-Rotax GmbH & CO KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior written permission of BRP-Rotax 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. The Manual must remain with the engine/aircraft in case of sale.

Copyright 2018 © - all rights reserved.

ROTAX® is a trade mark of BRP-Rotax GmbH & Co KG. In the following document the short form of BRP-Rotax GmbH & Co KG = BRP-Rotax 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.

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.

Effectivity: 582 ULEdition 1/Rev. 0 Content

Page 1March 01 2018

Table of Content

Chapter INTRO – GENERAL NOTE

Chapter LEP – LIST OF EFFECTIVE PAGES

Chapter TOA – TABLE OFAMENDMENTS

Chapter 00–00–00 – GENERAL NOTE

Chapter 05–00–00 – MAINTENANCE

Chapter 05–10–00 – TIME LIMITS

Chapter 05–20–00 – SCHEDULED MAINTENANCE CHECKS

Chapter 05–50–00 – UNSCHEDULED MAINTENANCE CHECKS

Chapter 12–00–00 – MAINTENANCE OF THE SYSTEMS

Chapter 12–10–00 – REPLENISHING OPERATING FLUIDS

Chapter 12–20–00 – SCHEDULED MAINTENANCE

BRP-RotaxMAINTENANCE MANUAL

d06593

NotesPage 2March 01 2018

Effectivity: 582 ULEdition 1/Rev. 0

NOTES



Chapter: INTROGENERAL NOTE

Foreword Before carrying out maintenance work on the engine, read this Maintenance Manualcarefully.If any passages of the Manual are not clearly understood or in case of any questions,please contact your nearest ROTAX® authorized Aircraft Engines Distributors or theirindependent Service Center.

BRP-Rotax wishes you much pleasure and satisfaction flying your aircraft powered by thisROTAX®-aircraft engine.

The structure of the Manual follows whenever it is possible the structure of the ATA (AirTransport Association) standards. The aim is the compatibility with the aircraftmanufacturers documentation, which means they must then adapt the documentation totheir standard.

Effectivity: 582 ULEdition 1/Rev. 0 INTRO

Page 1March 01 2018



NOTES



Chapter: LEPLIST OF EFFECTIVE PAGES

Chapter Page Date

Coverpage

INTRO 1 March 01 2018

2 March 01 2018

LEP 1 March 01 2018

2 March 01 2018

TOA 1 March 01 2018

2 March 01 2018

00-00-00 1 March 01 2018

2 March 01 2018

3 March 01 2018

4 March 01 2018

5 March 01 2018

6 March 01 2018

7 March 01 2018

8 March 01 2018

9 March 01 2018

10 March 01 2018

11 March 01 2018

12 March 01 2018

13 March 01 2018

14 March 01 2018

05-00-00 1 March 01 2018

2 March 01 2018

3 March 01 2018

4 March 01 2018

5 March 01 2018

6 March 01 2018

7 March 01 2018

8 March 01 2018

9 March 01 2018

Chapter Page Date

10 March 01 2018

11 March 01 2018

12 March 01 2018

05-10-00 1 March 01 2018

2 March 01 2018

3 March 01 2018

4 March 01 2018

5 March 01 2018

6 March 01 2018

05-20-00 1 March 01 2018

2 March 01 2018

3 March 01 2018

4 March 01 2018

5 March 01 2018

6 March 01 2018

7 March 01 2018

8 March 01 2018

9 March 01 2018

10 March 01 2018

11 March 01 2018

12 March 01 2018

05-50-00 1 March 01 2018

2 March 01 2018

3 March 01 2018

4 March 01 2018

5 March 01 2018

6 March 01 2018

7 March 01 2018

8 March 01 2018

12-00-00 1 March 01 2018

Effectivity: 582 ULEdition 1/Rev. 0 LEP

Page 1March 01 2018


Chapter Page Date

2 March 01 2018

12-10-00 1 March 01 2018

2 March 01 2018

12-20-00 1 March 01 2018

2 March 01 2018

3 March 01 2018

4 March 01 2018

5 March 01 2018

6 March 01 2018

7 March 01 2018

8 March 01 2018

9 March 01 2018

10 March 01 2018

Chapter Page Date

11 March 01 2018

12 March 01 2018

13 March 01 2018

14 March 01 2018

15 March 01 2018

16 March 01 2018

17 March 01 2018

18 March 01 2018

19 March 01 2018

20 March 01 2018

Index

Rear page

LEPPage 2March 01 2018



Chapter: TOATABLE OFAMENDMENTS

Approval*The technical content of this document is approved under the authority of DOA ref.

EASA.21J.048

NNOOTTEE

THE APPROVAL IS GIVEN TO ALL CHAPTERS EXCEPT THEAIRWORTHINESS LIMITATIONS SECTION 04-00-00 WHICH IS SUBJECT

TO SPECIFIC APPROVAL OF THE EASA.

Currentno.

Chapter Pa-ge

Date ofchange

Remark forapproval

Date ofapproval fromauthorities

Date ofinclusion

Signature

0 INTRO all March 01 2018 DOA*

0 LEP all March 01 2018 DOA*

0 TOA all March 01 2018 DOA*

0 00-00-00 all March 01 2018 DOA*

0 05-00-00 all March 01 2018 DOA*

0 05-10-00 all March 01 2018 DOA*

0 05-20-00 all March 01 2018 DOA*

0 05-50-00 all March 01 2018 DOA*

0 12-00-00 all March 01 2018 DOA*

0 12-10-00 all March 01 2018 DOA*

0 12-20-00 all March 01 2018 DOA*

Effectivity: 582 ULEdition 1/Rev. 0 TOA

Page 1March 01 2018


Summary of amendments

Summary of the relevant amendments in this context, but without requirement on completeness.

Current no. Chapter Page Date of change Comment

0 all all March 01 2018 new layout and change of company name,add of engine type model year 17

TOAPage 2March 01 2018



Chapter: 00–00–00GENERAL NOTE

TOPICS IN THIS CHAPTER

General....................................................................................................................................................2Type description......................................................................................................................................3Abbreviations and terms .........................................................................................................................4

Conversion table ...................................................................................................................................7Safety notice ...........................................................................................................................................8

Safety information .................................................................................................................................9Instruction...........................................................................................................................................10Maintenance Concept.......................................................................................................................... 11Technical documentation......................................................................................................................12Use for intended purpose .....................................................................................................................14

Effectivity: 582 ULEdition 1/Rev. 0 00–00–00

Page 1March 01 2018


GENERALPurpose The purpose of this Manual is to acquaint (iRMT) trained maintenance service staff with

some necessary technical requirements for maintaining the engine into the aircraft in com-pliance with the relevant installation and safety instructions provided by the enginemanufacturer.

Documentation For more detailed information regarding, installation, maintenance, safety- or flight opera-tion, consult the documentation provided by the aircraft manufacturer and/or dealer.

For additional information on engines, maintenance or parts, you can also contact yournearest authorized ROTAX®-aircraft engine distributor.

ROTAX®Distributors

For ROTAX® Authorized Distributors for Aircraft Engines see latest Operators Manual oron the Internet at the official Website www.FLYROTAX.com.

Engine serialnumber

When making inquiries or ordering parts, always indicate the engine serial number, as themanufacturer might make modifications to the engine in the course of product improve-ment. The engine serial number is on the top of the crankcase, magneto side or ignitioncover.

00–00–00Page 2March 01 2018



TYPE DESCRIPTIONThe type description consists of the following:

e.g.ROTAX 582 UL DCDI

mod. 99/ mod.17

type certification ignition model

Designation Designation Description

Type 582 Two stroke engine, 2 cylinder in line with rotary valveinlet.

Certification UL Approved to ASTM F2339.

Ignition DCDI Dual Capacitor Discharge Ignition

Model mod. 99 /mod. 17

Model year


Page 3March 01 2018


ABBREVIATIONS AND TERMSAbbreviations Description

* Reference to another section

� center of gravity

The drop symbol indicates use of sealing agents, adhesives or lubri-cants (only in the Illustrated Parts Catalog).

°C Degrees Celsius (Centigrade)

°F Degrees Fahrenheit

rpm Revolutions per minute

A Ampere

AC alternating current

Ah Ampere hour

A/C Aircraft

AR as required

assy. assembly

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

CW clockwise

CCW counter-clockwise

CGSB Canadian General Standards Board

DCDI Dual Capacitor Discharge Ignition

DOA Design Organisation Approval

DOT Department of Transport

EASA European Aviation Safety Agency

EN European Norm

FAA Federal Aviation Administration

FAR Federal Aviation Regulations

hr. hours

00–00–00Page 4March 01 2018



IFR Instrument Flight Rules

IM Installation Manual

INTRO Introduction

IPC Illustrated Parts Catalog

ips inch per second

iRMT independent ROTAX Maintenance Technican

ISA International Standard Atmosphere

kg Kilograms

LEP List of Effective Pages

MMH Maintenance Manual Heavy

MML Maintenance Manual Line

MON Motor Octane Number

MAG Magneto Side

N Newtonn.a. not available

NDT Non Destructive Testing

Nm Newton metre

NVFR Night Visual Flight Rules

OHM Overhaul Manual

OHV Over Head Valve

OM Operators Manual

part no. Part number

POA Production Organisation Approval

PTO Power Take Off

Rev. Revision

ROTAX® is a trademark of BRP-Rotax GmbH & Co KG

RON Research Octane Number

S/N Serial Number

SAE Society of Automotive Engineers

SB Service Bulletin

SI Service Instruction

SL Service Letter

SMD Surface Mounted Devices


Page 5March 01 2018


s.v. still valid (only Illustrated Parts Catalog)

TBO Time Between Overhaul

TC Type certificate

TOA Table Of Amendment

TOC Table of content

TSN Time Since New

TSNP Time Since New Part

TSO Time Since Overhaul

V Volt

VFR Visual Flight Rules

XXXX shows the serial component number

00–00–00Page 6March 01 2018



CONVERSION TABLEUnits of length: Units of power:

1 mm = 0.03937 in1 in = 25.4 mm1 ft = 12 in= 0.3048 m

1 kW = 1.341 hp1 hp = 0.7457 kW1 kW = 1.3596 PS1 PS = 0.7355 kW

Units of area: Units of temperature:

1 cm² = 0.155 sq. in (in²)1 sq. in (in²) = 6.4516 cm²

K = °C – 273,15°C = (°F – 32) / 1,8°F = (°C x 1.8) +32

Units of volume: Units of velocity:

1 cm³ = 0.06102 cu in (in³)1 cu in (in³) = 16.3871 cm³

1 dm³ = 1 l1 dm³ = 0.21997 gal (UK)1 gal (UK) = 4.5461 dm³1 dm³ = 0.26417 gal (US)1 gal (US) = 3.7854 dm³

1 m/s = 3.6 km/h1 ft/min = 0.3048 m/min

= 0.00508 m/sec1 m/s = 196.85 ft/min1 kt = 1.852 km/h

1 km/h = 0.53996 kn

Units of mass: spec. fuel consumption:

1 kg = 2.2046 lbs.1 lb. = 0.45359 kg

1 g/kWh = 0.001644 lb/hph1 lb/hph = 608.277 g/kWh

Density: Units of torque:

1 g/cm³ = 0.016018 lb/ft³1 lb/ft³ = 62.43 g/cm³

1 Nm = 0.737 ft lb= 8.848 in lb

1 ft lb = 1.356 Nm1 in lb = 0.113 Nm

Units of force: Cable cross-section: Conversion table-Wire Gauge: AWG-mm²

1 N = 0.224809 lbf1 lbf = 4.4482 N

AWG—> mm²4 —> 216 —> 138 —> 8.410 —> 5.312 —> 3.314 —> 2.116 —> 1.318 —>0.820—> 0.52

Units of pressure:

1 Pa = 1 N/m²1 bar = 100 000 Pa / 1000 hPa / 100 kPa

1 bar = 14.503 lbf/in² (psi)1 in Hg = 33.8638 hPa


Page 7March 01 2018


SAFETY NOTICEAlthough reading such information does not eliminate any hazards, it promotes under-standing and application of the information and will promote correct use of the engine. Al-ways apply common workshop safety rules.

The information and descriptions of components and systems contained in this Manualare correct at the time of publication. BRP-Rotax maintains a policy of continuous im-provement of its products without imposing upon itself any obligation to retrofit productspreviously manufactured.

Revisions BRP-Rotax reserves the right to remove, replace or discontinue any design, specification,feature or other at any time, and without incurring obligation.

Measurement Specifications are given in the SI metric system with the imperial- and US customarymeasurement system equivalents in parenthesis.

Symbols used This Manual uses the following symbols to emphasize particular information. This informa-tion is important and must be observed.

mWARNING

Identifies an instruction which, if not followed, may cause serious injury or evenfatal injury.

m CAUTION

Identifies an instruction which, if not followed, may cause minor or moderateinjury.

ATTENTION

Identifies an instruction which, if not followed, may severely damage the engineor could void any warranty.

NNOOTTEE

Indicates supplementary information which may be needed to fully complete orunderstand an instruction.

ENVIRONMENTAL NOTE

Environmental notes give you tips on environmental protection.

A revision bar outside the page margin indicates a change to text or graphic.

00–00–00Page 8March 01 2018



SAFETY INFORMATIONUse for intendedpurpose

mWARNING

Non-compliance can result in serious injuries or death!The user has to assume all risks possibly arising from utilizing auxiliary equipment.

mWARNING

Non-compliance can result in serious injuries or death!Never fly the aircraft equipped with this engine at locations, air speeds, altitudes or inother situations which do not allow a successful no-power landing after sudden engine

stoppage.

• This engine is not suitable for aerobatics (inverted flight, etc.). Flight attitudes outsidethe permissible limits are not allowed.

• It should be clearly understood that the choice, selection and use of this particular en-gine on any aircraft is at the sole discretion and responsibility of the aircraft manufac-turer, assembler or owner/user.

• Due to the varying designs, equipment and types of aircraft, BRP-Rotax grants no war-ranty on the suitability of its engines use on any particular aircraft. Further, BRP-Rotaxgrants no warranty on this engines suitability with any other part, component or systemwhich may be selected by the aircraft manufacturer, assembler or user for aircraftapplication.

mWARNING

Non-compliance can result in serious injuries or death!For each use of DAY VFR, NIGHT VFR or IFR in an aircraft the applicable legal require-

ments and other existing regulations must be adhered to.

• In addition to observing the instructions in our Manual, general safety and accident pre-cautions, legal regulations and regulations of any aeronautical authority must beobserved.

• Where differences exist between this Manual and regulations provided by any authority,the more stringent regulation shall be applied.

• For continued airworthiness see Maintenance Manual Line.

• Unauthorized modifications of engine or aircraft will automatically exclude any liability ofthe engine manufacturer for sequential damage.


Page 9March 01 2018


INSTRUCTIONEngines require instructions regarding their installation, application, use, operation, main-tenance and repair.Technical documentation and regulations are useful and necessary complementary ele-ments for trainings, but can by no means substitute for theoretical and practicalinstructions.These instructions should cover explanation of the technical context, advice for operation,maintenance, installation, use and operational safety of the engine.

Safety notice In this technical Manual passages concerning safety are especially marked. Pass onsafety warnings to other users!

Accessories This engine must only be operated with accessories supplied, recommended and re-leased by BRP-Rotax. Modifications are only allowed after consent of the enginemanufacturer.

Spare parts See Illustrated Parts Catalog, latest issue.

ATTENTION

Only use genuine ROTAX® spare partsSpare parts must meet the requirements defined by the engine manufacturer.This canonly be guaranteed when using GENUINE-ROTAX®-spare parts and/or accessories

(see IPC). Spare parts are available at ROTAX® Authorized Distributors and their inde-pendent Service Centers. Any warranty by BRP-Rotax will become void if other spareparts and or accessories than GENUINE-ROTAX®-spare parts and/or accessories are

used (see latest Warranty Conditions).

Standard tools /Special tools

ATTENTION

Only use tools and appliances which are suitable for the relevant task accordingto the latest Manuals.

State of delivery

mWARNING

Engine and gearbox are delivered in “dry“ conditions (without fuel, oil andcoolant).

Before putting the engine into operation it must be filled with oil and cooling liquid. Useonly oil and coolant as specified.

00–00–00Page 10March 01 2018



MAINTENANCE CONCEPTGeneral note The maintenance functions detailed in this Manual are divided into two categories:

• Maintenance I (Line Maintenance)

• Maintenance II (Heavy Maintenance)

Repairs beyond the levels detailed in this Manual are not recommended as maintenancefunctions and must be conducted by an authorized service facility.

Maintenance I(LineMaintenance)

Chapter 00,05 and 12

The scope of line maintenance consists of removal, installation and adjustment of enginecomponents (including part wear). All procedures in this Manual are to be considered linemaintenance.

NNOOTTEE

Where applicable, you will be referred to the Heavy Maintenance Manual for workabove and beyond line maintenance.

Maintenance II(HeavyMaintenance)

Separate Manual.

Maintenance Manual II details removal, installation and repair of components or parts nor-mally considered beyond the scope of the "Line Maintenance".

NNOOTTEE

This Manual can only be used in combination with Maintenance Manual I (LineMaintenance), as it builds upon it.


Page 11March 01 2018


TECHNICAL DOCUMENTATIONThese documents form the instructions ensuring continued airworthiness of ROTAX® air-craft engines.The information contained herein is based on data and experience that are considered ap-plicable for authorized mechanics (iRMT, see Maintenance Manual Line) under normalconditions for engine removal and installation. Concerning design of engine installationsin depth knowledge of aircraft design is required.Due to the fast technical progress and fulfillment of particular specifications of the custom-ers it may occur that existing laws, safety prescriptions, constructional and operationalregulations may not be sufficient or cannot be transferred completely to the object bought,in particular for special constructions.

Documentation

• Installation Manual

• Operators Manual

• Maintenance Manual (Line and Heavy Maintenance)

• Illustrated Parts Catalog

• Alert Service Bulletin

• Service Bulletin

• Service Instruction

• Service Letter

Status The status of the Manuals can be determined by checking the table of amendments. Thefirst column of this table indicates the revision status, which should be compared with therevision provided on the ROTAX®-Website: www.FLYROTAX.comAmendments and current versions can be downloaded free of charge.

Replacementpages

Furthermore the Manual is constructed in such a way that single pages can be replacedinstead of the complete document. The list of affected pages is given in the chapter LEP.The particular edition and revision number is given on the footer of each page.

Reference This Manual for maintenance is only part of the technical documentation and will be sup-plemented by the respective Operators Manual, Installation Manual and Illustrated PartsCatalog.

ATTENTION

Pay attention to references to other documentation, found in various parts of thisManual.

If not stated otherwise, any reference to a document refers to the latest edition issued byBRP-Rotax.

Illustrations The illustrations in this Manual are merely sketches and show typical arrangements. Theymay not represent full detail or the exact shape of the parts but should outline the same or

00–00–00Page 12March 01 2018



similar function. Therefore deriving dimensions or other details from illustrations is notpermitted.TYPICAL indicates a general view which may not represent exact details.

NNOOTTEE

The Illustrations in this Manual are stored in a graphic data base system and areprovided with a consecutive irrelevant number.This number (e.g. AE 2ST_001) is of no significance for the content.

Some measurements are given in the drawings, these are manufacturing dimensions andare subject to corresponding tolerances.




USE FOR INTENDED PURPOSE

mWARNING

Explosion hazard.Flying components can cause serious injuries.

Never run an engine without propeller.

Use The engine ROTAX® 582 UL DCDI mod.99 / mod. 17 is intended for use in uncertified air-craft. In case of doubt the regulations of the national authorities or the respective sportivefederations have to be observed.

Never run the engine without propeller, this inevitably causes engine damage and hazardof explosion.

Uncertifiedengines

The engine ROTAX® 582 UL DCDI mod.99 / mod. 17 is uncertified. These engines havenot received any safety or durability testing, and conform to no aircraft standards. Theseengines are meant for use in experimental, uncertified aircraft and vehicles only, in whichan engine failure will not compromise safety.

Engine stoppage In using the engine the operator assumes all risk of use and acknowledges that he/sheknows this engine is subject to sudden stoppage.

Maintenance andrepair conditions

Use for intended purpose also includes observation of the operational, maintenance andrepair conditions prescribed by the manufacturer. This is a crucial factor concerning the re-liability of the engine and can increase the durability of the engine.

00–00–00Page 14March 01 2018



Chapter: 05–00–00MAINTENANCE


General note............................................................................................................................................2Authorized personnel ..............................................................................................................................3Procedure notes ......................................................................................................................................4Trouble shooting .....................................................................................................................................6Consumable Materials.............................................................................................................................7Acceptable methods, techniques and practice...................................................................................... 11

Introduction The information given in the Maintenance Manual is based on data and experience whichare considered to be applicable for a skilled aviation mechanic (iRMT) under normalworking conditions.


Page 1March 01 2018


GENERAL NOTE

mWARNING

Non-compliance can result in serious injuries or death!Besides our instructions in the documentation supplied, also respect generally valid

safety and accident preventive directives and legal regulations.

Procedures andlimits

The procedures and limits in this Manual constitute the manufacturers official recommen-dation for engine maintenance and operation.

Instruction The guidelines given in the Maintenance Manual are useful and necessary supplementsto training. They, however, cannot substitute competent theoretical and practical personalinstruction.

Modifications Non-authorized modifications as well as the use of components and auxiliary componentsnot corresponding to the installation instructions exclude any liability of the enginemanufacturer.

Parts andaccessories

We particularly emphasize that parts and accessories not supplied as genuine BRP-Rotaxparts are not verified for suitability by BRP-Rotax and thus are not authorized for use. In-stallation and/or use of such products may possibly change or negatively influence theconstructive characteristics of the engine. For damages resulting from use of non-genuineparts and accessories manufacturer refuses any liability.

Special tools Maintenance of engines and systems requires special knowledge and special tools. Useonly the special tools recommended by BRP-Rotax when disassembling and assemblingthe engine.

05–00–00Page 2March 01 2018



AUTHORIZED PERSONNELGeneral note It is a requirement that all organizations or individuals possess the required special tool-

ing. Technicians must have type-specific training and keep a recurrent knowledge statusfor the level of work they intend to perform. Technicians may require accreditation fromtheir local aviation authority in addition to any BRP-Rotax requirements.

Requisiteknowledge

Any task outlined herein may be performed if the organization or individual has met the fol-lowing conditions:

Requisite knowledge of the task as a result of:

• Type-specific training (for the applicable ROTAX® aircraft engine) which is approvedby the national aviation authorities and/or BRP-Rotax.

or

• Experience in performing the task or

• Formal instruction from a BRP-Rotax authorized training facility or

• Instruction by an authorized BRP-Rotax Distributor representative.

Technicians must:

• maintain a suitable work environment to prevent contamination or damage to engineparts or modules.

• use the required tools and fixtures as outlined in the ROTAX® Maintenance Manual.

• ensure reasonable and prudent maintenance practices are utilized.

• ensure the requirements of the applicable regulatory authority regarding maintenanceprocedures are met.

For more detailed information, maintenance organizations and individuals are encouragedto contact BRP-Rotax through its worldwide distribution network for information and guid-ance on any of the tasks outlined herein.See Chapter 00-00-00 section Technical Documentation.

Type-specifictraining

Type-specific training:

• Independent ROTAX® Maintenance Technician (iRMT) training can be obtained froma ROTAX® approved training organization. Courses are available in various levels tosuit the requirements of work the technician needs to perform. Each rating is valid fora 2 year period.

Valid time ROTAX® iRMTspecialty ratings are valid for a 2 year period after initial instruction. Recur-rent training is required after 2 years to maintain a current status. In order to be eligible forthe renewal program training, the technician must be able to show and declare that theyhave been working on ROTAX® engines during the past 2 years.


Page 3March 01 2018


PROCEDURE NOTESGeneral note

mWARNING

Non-compliance can result in serious injuries or death!When carrying out maintenance and service work, respect without fail all safety

regulations.

Ignition “OFF“

mWARNING

Non-compliance can result in serious injuries or death!This precautionary measure serves to avoid any injuries in case of an unintentional start

of the engine.

Principally ensure the following at each maintenance event

• Ignition is “OFF” and system grounded,

• Disconnect battery

and secure engine against unintentional operation.

Ignition “ON”

mWARNING

Risk of electric shock!The ignition is switched on, as long as the ground-cable (P lead) is not properly con-

nected to ground.

At maintenance work which requires ignition “ON“ and battery connected, take care of thefollowing:

• Secure the propeller against unintentional turning by hand and

• Secure and observe propeller zone

Handling of oper-ating fluids

mWARNING

Risk of burns and scalds. Hot engine parts.Always allow engine to cool down to ambient temperature before starting work.

At maintenance of cooling, lubricating and fuel system take care without fail that no con-tamination, metal chips, foreign material and/or dirt enters the system.

05–00–00Page 4March 01 2018



Disassembly At disassembly of the engine, mark the components as necessary to avoid any mix-up.Take care of these marks, don’t ruin them.

Tool

ATTENTION

In order to avoid mechanical damage, always loosen or tighten screws and nutswith specified tools.

Safety wiring

ATTENTION

If during disassembling/reassembling the removal of a safety item (e.g. safetywiring, self-locking fastener, etc.) should be necessary, it must always be re-

placed by a new one.

Cleaning of parts

ATTENTION

All metal and synthetic parts should be cleaned with suitable cleaning agents.Before using new and unknown cleaning agents, check their compatibility with

the materials they are being used on.

Removed parts Before re-using disassembled parts, clean, check and refit them as per instructions.Use clean screws and nuts. Always inspect the contact face and thread for damage. If un-sure, use new parts.

Self-securingnuts

Once loosened, always replace self-securing nuts.

mWARNING

Non-compliance can result in serious injuries or death!Exactly observe the tightening torques for screws and nuts. Overtightening or a connec-

tion which is too loose could cause serious engine damage.

Sealing rings, O-rings

At reassembly of the engine, replace all sealing rings, gaskets, securing elements, O-ringsand oil seals.

Re-assembly Before re-assembly check components for missing parts. Only use adhesives, lubricants,cleaning agents and solvents indicated in the maintenance instructions. Failure to complymay result in damage.


Page 5March 01 2018


TROUBLE SHOOTINGGeneral notes Possible problems are listed in the Operators Manual. At the same time, a brief description

of the necessary remedial action is given.See chapter 4 in the Operators Manual for engine type .

05–00–00Page 6March 01 2018



CONSUMABLE MATERIALSGeneral note

ATTENTION

Use only the specified or technically equivalent materials from BRP-Rotax for allmaintenance work. When handling chemicals, comply with all the customary reg-ulations and specifications of the producer, including the expiry date and instruc-

tions of use.

NNOOTTEE

To some extent product descriptions deviate in spite of equivalent technical prop-erties, i.e.: LOCTITE 243. If necessary contact the manufacturer concerning thecomparability. In some cases information can be obtained from the local author-ized distributors and service partners for ROTAX® engines.

NNOOTTEE

Respect the manufacturers instruction concerning the curing time and the expirydate of the particular surface sealing compound.

The materials specified have been tested for a long time and are suitable for all operatingconditions indicated by the manufacturer.

No. part no. Description, Application Qty.

B 897651 LOCTITE 243,bluemedium-duty screw securing agent

10 ml(0.003 gal (US))

C 899788 LOCTITE 648 green,high strength screw securing agent

5 ml(0.001 gal (US))

F xxx LOCTITE 7063For degreasing and cleaning surfaces

AR

H 897870 Filter oilfor optimum filter efficiency and protectionagainst moisture

14.8 ml(0.004 gal (US))

I 897330 Lithium-base greaseElectrical insolating

250 g(0.55 lb)

M 297433 Molykote G-N,for the prevention of fretting corrosion

100 g(0.22 lb)

P 899791 LOCTITE 5910 black,surface sealing compound, can be used insteadLOCTITE 574 and LOCTITE 518

50 ml(0.013 gal (US))


Page 7March 01 2018



V 297386 Locking paint AR

AG 897186 SILICONE HEAT CONDUCTIONCOMPOUND,Application of the heat conduction compoundwill reduce heat transfer resistance. Thegreaselike, temperature-resistant silicon com-pound fills cavities between components andthe cooling element (e.g.: spark plug-cylinderhead), which otherwise do not contribute to heatconduction.

150 g(0.33 lb)

Figure 2.1: Consumable materials

05–00–00Page 8March 01 2018



Additionalmaterials

ATTENTION

Use only approved cleaning agents (e.g. kerosine, varsol, etc.) for cleaning allmetal parts.


1 n.a Cleaning agentsDo not use lye-based cold cleaner or degreasingagents. Do not clean coolant or oil hoses with ag-gressive solutions. Clean off sealing compound res-idue with sealant remover. Soak combustionchamber, piston and cylinder head with cleaningagent and remove combustion residues with abronze brush. Very good results have beenachieved with “Clenvex 2000“. It is a solvent-coldcleaner, free of halogen, on the basis of selectedfuel fractions with tenside and is biologically dispos-able. Never use caustic or corrosive cleaningagents.

AR

2 n.a Preservation oilThis special oil has excellent penetrating capabil-ities and reaches even tiny gaps, its highly effectiveadditives protect against corrosion of metalsurfaces

AR


Page 9March 01 2018



3 n.a Abrasive pad for surface finishing 3M Scotch-Brite Multi Flex - very fine or ultra fineIt sold by the meter and used for manual removal ofsmaller rust spots or oxidation, especially for opti-mum ground connections. It is highly suitable for re-moving LOCTITE from surfaces or threads to makethem metallic clean. Before reapplying LOCTITE,clean surfaces with nitro thinners or degreasingagent (CASTROL ZA 30 or OMV-SOFT SOL).When using solvents, observe the safety regula-tions for persons and environment regarding useand proper disposal.

AR

4 n.a Compressed air blasting using a solid blastingagentThis method is suitable for local and gradual veryfine treatment of steel parts with rust film (propellershaft). The MICRONORM abrasive contains noharmful substances, is approved by the competentauthorities and guarantees optimum cleaning. Thegranulates used are of sizes 40 to 60 μ. The achiev-able surface roughness is between 0.5 to 1μ, whichcorresponds to ultrafine machining of surfaces.

AR

05–00–00Page 10March 01 2018



ACCEPTABLE METHODS, TECHNIQUES AND PRACTICEGeneral note All general inspection, maintenance and repair has to be carried out in accordance with

Advisory Circular AC 43.13 from FAA.

Advisory Circular This Manual "Advisory Circular" AC describes maintenance methods, techniques andpractice. These are recognized and authorized for inspection and repairs in non-pressur-ized areas for which there are no separate maintenance and repair instructions.

Self-locking

ATTENTION

Self-locking nuts, cotter pins, tab washers and safety wires must be replacedeach time they have been removed.

All instructions regarding the securing and lubrication of parts must be observed. Adher-ence to specified torque values is required.

Nut securing When using a self-locking nut, make sure the polyamide insert ring meets the require-ments of DIN 985. Be sure that the securing elements on the nut is positioned towards theoutside, in accordance with DIN 980.

Lock washer NNOOTTEE

When fitting lock washers, the curved-up ends (1) must point towards the screwhead or nut.

Figure 2.2: Lock washer

Safety wiring Safety wiring serves to secure screws or nuts to prevent unintended loosening. The screwor nuts are secured by a 0.8 mm (.0315 in) safety wire twisted 3 to 4 turns per 10 mm (.4in.). The wire must by no means be overstretched.




Figure 2.3: Safety wiring

ATTENTION

As a principle, all external engine components and accessories must be wire-se-cured for safety reasons.

Various typical applications of safety wiring

Figure 2.4

Nut securing When using a self-locking nut, take care that the polyamide insert ring on nuts accordingto DIN 985 as well as the securing element on nuts according to DIN 980 is positioned to-wards outside.

05–00–00Page 12March 01 2018



Chapter: 05–10–00TIME LIMITS


Definition of terms...................................................................................................................................2Operating hours ....................................................................................................................................2Time limit ..............................................................................................................................................2Life cycle ..............................................................................................................................................2General overhaul (TBO).........................................................................................................................2

Time Limit................................................................................................................................................4Time limit for parts .................................................................................................................................5Time limit for the coolant ........................................................................................................................5

Introduction The following checks are required at the times specified. This preventative maintenance isto help avoid and/or detect possible engine issues.


Page 1March 01 2018


DEFINITION OF TERMSOPERATING HOURSDefinition All of the maintenance intervals, such as the 100 hr. inspection and the engine TBO, relate

to the number of operating hours of the engine.The operating hours are defined as follows in order to prevent misunderstandings and toensure safety:

• All time during which the engine is running is counted towards the total number of oper-ating hours.

• The time is counted irrespective of the load factor of the engine, such as idling or take-off power.

NNOOTTEE

A mechanical hour meter is directly coupled to the engine speed, the readingsmay deviate considerably from those given by electronic remitters (e.g. FlyDat).Maintenance and overhaul intervals are always dictated by the readings of theelectronic hour meter.

• The planned inspections to be performed at certain intervals are based on experiencefrom long test runs and field observations. They are intended as precautionary mainte-nance measures in order to ensure continued trouble-free operation of the engine.

TIME LIMITDefinition Time limits are predetermined time spans and intervals which are based either on calen-

dar intervals or the number of engine operating hours. Once the time limits have beenreached, the affected parts must either be replaced for a general overhaul, or mainte-nance work must be performed. These precautionary maintenance measures are de-signed to avoid engine malfunctions or defects and ensure continued airworthiness of theengine.

LIFE CYCLEDefinition The life cycle is always specified as an exact time span and is also quoted in flight hours.

NNOOTTEE

Parts with a limited life cycle must be taken out of operation and overhauled if thespecified time span or number of flight hours is reached (whichever comes first).

GENERAL OVERHAUL (TBO)Definition The time between overhauls (TBO) for all objects (such as the engine, component assem-

blies, add-on components) is the approved length of operation under normal operatingconditions before it becomes mandatory to send in these objects for an overhaul.Normal operating conditions are the conditions which comply with the manufacturer's andthe aviation authority’s recommendations for the certification of airworthiness.

05–10–00Page 2March 01 2018



Maintenance ofoperation

The TBO values approved by the relevant authorities are based on performance tests andempirical values which have been gathered through operation of the engine and are re-quired for the acceptance and certification of airworthiness.

Legal obligationto keep

TBO values for the engine are always shown in operating hours and years. The user mustrecord the operating hours in the engine log book.


Page 3March 01 2018


TIME LIMITGeneral

ATTENTION

A general overhaul is due after a defined period of operation or after a specifiedcalendar life since initial start of operation (whichever comes first).

The time limit for engine operation will be specified by the TBO.

After reachingthis time limit

ATTENTIONAfter reaching this time limit, the engine has to be shipped to an authorized

ROTAX® overhaul facility.

For an overhaul, the engine must be removed from the aircraft, be cleaned, preservedand all openings to be closed to prevent entering of contaminants.

Storage period ofthe engine

Observe the storage and preservation directives!

NNOOTTEE

The maximum possible storage period of the engine is limited to 24 months.

If this period is exceeded, the engine must be sent to an ROTAX® authorized overhaul fa-cility for inspection.

EngineType description

Engine affected engine S/N TBOTime Between Overhaul

582 UL Mod. 99 from S/N 5305902 up to S/N9619115 inclusive

300 h or 5 years, whichevercomes first1

582 UL Mod. 17 from S/N 9619116 300 h or 5 years, whichevercomes first1

For the TBO of the specific engine type/version refer to the table below.

Authorizedexceeding

Extension or exceeding of the TBO by 5% or 6 months is allowed whichever comes first.

Shipment The shipment to an authorized ROTAX® overhaul facility must include the following:

1 Engine log book.

2 Maintenance records of the engine (i.e. all maintenance check lists, and re-ports of operation, of maintenance, of findings and of oil analysis).

05–10–00Page 4March 01 2018



3 The engine assembly as per supply volume. Additionally all added-on partsas in the supply volume such as filters, intake silencer, fuel pump, externalgenerator, sensors, ignition unit, electric starter, oil tank.

4 Indication of total engine operating hours (TSN) and where applicable, en-gine operating hours since a previous overhaul (TSO).

NNOOTTEE

This information must be supplied to allow the service history ofcomponents to be traced.

5 Data about the type of aircraft used.

6 Useful remarks and observations concerning the engine.

TIME LIMIT FOR PARTSGeneral note

ATTENTION

This time limit must be followed independently and in addition to the visual in-spections (see Chapter 05-20-00 section: Visual Inspection) of the respective

components.

Time limit The following components and systems must be replaced every 5 years:

• Venting hose of the carburetors

• Carburetor sockets

• All rubber hoses of the cooling system

• All rubber hoses of the fuel system

• All rubber hoses of the lubrication system which are part of the engine supply volumeand if they are not in the maintenance schedule of aircraft manufacturer

TIME LIMIT FOR THE COOLANTGeneral note Coolant must be replaced as per manufacturers instructions, at the latest during overhaul

or when the engine is replaced.


Page 5March 01 2018



NOTES



Chapter: 05–20–00SCHEDULED MAINTENANCE CHECKS


Scheduled maintenance checks ..............................................................................................................2Unscheduled maintenance checks..........................................................................................................3Visual inspection.....................................................................................................................................4Maintenance schedule procedures (maintenance check list) ..................................................................5Check List/Maintenance Schedule...........................................................................................................6Maintenance Schedule ............................................................................................................................8

Introduction The owner and/or user is primarily responsible for the maintenance and airworthiness ofthe engine. This includes compliance with all applicable airworthiness directives.

This inspection protocol is not intended to be all-inclusive, for no such protocol canreplace the knowledge and experience of a certified aircraft mechanic. As the partyprimarily responsible for the maintenance and airworthiness of the engine, the owner oruser should only have the maintenance work carried out by qualified engineers(corresponding to the iRMT levels).

Documentationrequired

It is the responsibility of the owner and/or user to make sure that the aircraft mechanicperforming the work on the engine has access to the previous Inspection Protocols andany other required documents.


Page 1March 01 2018


SCHEDULED MAINTENANCE CHECKSDefinition This section lists the periodic inspections which must be carried out after a specified peri-

ods of operation.

Intervals Periodic inspections are those which must be performed at 12.5, 100, 150 hr. intervals inaccordance with Chapter 05-20-00 section Maintenance Schedule.This means for example that. every 100 hr of operation a 100 hr. check must be carriedout. Every 200 hr. of operation a 100 hr. and the additional checks for 200 hr. must be car-ried out.

Intervals –hours2 hr 10 hr 25 hr every

12.5hr

every25 hr

every50 hr

every100hr

every150hr

to every300 hr

12.5hr

X

100hr

X X X X

150hr

X X X X

• For the intervals between maintenance work, a tolerance of ±10 hr. is permissible, butthese tolerances must not be exceeded. This means that if a 100 hr. check is actuallycarried out at 110 hr., the next check will be due at 200 hr. ±10 hr. and not at 210 hr. ±10hr.

• If maintenance is performed before the prescribed interval, the next maintenance checkis to be done at the same interval (e.g. if first 100 hr. check is done after 87 hours of op-eration, the next 100 hr. check must be carried out after 187 hours of operation).

• If engine has less than 100 hours of operation during one year a 100 hr. check must becarried out. For the annual inspection a tolerance of ±2 months is given.

Checks • In order to demonstrate continued airworthiness, an engine must be inspected after thefirst mentioned hours of operation.

05–20–00Page 2March 01 2018



UNSCHEDULED MAINTENANCE CHECKSOperating limitsexceeded

An inspection of the engine must be performed if the operating limits of the engine havebeen exceeded (e.g. overspeed, excessive temperature etc.), or if unusual operating con-ditions have occurred during operation (e.g. lightning strike). In such cases the enginemust be inspected in accordance with the applicable unscheduled maintenance checks.

Recommendsinspections

The manufacturer also recommends the following inspections whenever maintenance iscarried out (where not already prescribed by the airframe manufacturer) as possible mal-functions could have negative effects on engine operation.

part inspection possible danger

Exhaust fixation• Re-tighten the exhaust fixationon the cylinder head after thefirst 2 hr. of operation

Leakage

Exhaust• Of the exhaust unit (where nec-essary, replaced application ofMolykote G-N)

Risk of fracture, wear.Rough engine running.

Fuel filter• Of fuel filter on airframe side (forforeign bodies, sealing materialand loose fragmented material)

Engine may misfire.Power loss. Engine run-ning too lean (Enginemalfunction anddamage).

Oil

• For oil contamination

• Analysis of the oil (provides addi-tional information on the condi-tion of the engine)

Possible engine wear

Radiators, Lines• For damage

• Check for discoloration - andcracks.

Danger of overheating

Throttle control • As specified by the cellmanufacturer

See specifics ofmanufacturer.


Page 3March 01 2018


VISUAL INSPECTIONGeneral note The scope of a visual inspection generally includes, but is not necessarily limited to, the

following.

Moving parts Normal operating condition, accurate alignment, leak-tightness, cleanliness, ease ofmovement, adjustment, mechanical stress, travel, catching, extreme wear, cracks, corro-sion, deformation and other visually evident damage.

Parts Secure seating, surface condition, cleanliness, deformation, cracks in welding seams ordue to material fatigue or stress, corrosion and other visually evident damage.

Fuel-, Air- and Oillines and Hoses

Cracks, dents, kinks, required flexibility, collapsed lines/hoses, abrasion, cleanliness, se-cure seating and other visually evident damage.

Wiring General cleanliness; loose, corroded or broken terminals; chafed, broken or worn insula-tion; secure seating, heat damage and other visually evident damage.

Screws and Nuts Surface damage, secure seating, locking wire, securing paint and other visually evidentdamage.

Filter andScreens

Filters and screens must be inspected for contamination and potential blockages, cleanedand replaced as required.

05–20–00Page 4March 01 2018



MAINTENANCE SCHEDULE PROCEDURES(MAINTENANCE CHECK LIST)

Inspections All stated checks are visual inspections for damage and wear, unless otherwise stated.

Specified period All listed work must be carried out within the specified period.

Maintenancecheck lists

Checks are carried out as per the maintenance check lists, where type and volume ofmaintenance work is outlined in key words.

• The lists must be photocopied and filled out for each maintenance check.

Extra inspections • The respective check (e.g. 100 hr. check) must be noted on the top of each page of themaintenance check list.

• All the maintenance work carried out must be initialled in the "signature" area by the air-craft mechanic performing the task.

Maintenancerecords

After maintenance, the completed check lists must be entered in the maintenance records.The maintenance must be confirmed in the log book.

Discrepancies/re-medial action

All discrepancies and remedial action must be recorded in a report of findings to be gener-ated and maintained by the company authorized to carry out maintenance work. It is theresponsibility of the aircraft operator to store and keep the records.

Replacement ofequipment

Replacement of equipment (e.g. fuel pump, ...) and execution of SB (LTA) must be enteredin the engine log book, TSN and date.


Page 5March 01 2018


CHECK LIST/MAINTENANCE SCHEDULEIdentification

AIRCRAFTRegistration number

Aircraft make

Aircraft model and S/N

Time since new

Propeller

Propeller brand

Propeller model and S/N

ENGINEEngine type

Engine S/N

TSN (time since new)

TSO (time sinceoverhaul)

Used operating fluids:

Coolant

• mixture ratio

Fuel

Oil

• type

• viscosity

05–20–00Page 6March 01 2018



Identification

AIRCRAFT OPERATORName

Contact

Address

Telephone/Fax

E-mail

MAINTENANCE FACILITYMaintenance workshop

Address

Telephone/Fax

E-mail

Certificate

)1leaded fuel more than 30% of operation

Next check due at: hr.

(TSN__________) (engine hr.)


Page 7March 01 2018


MAINTENANCE SCHEDULEPerform the following maintenance tasks at the intervals shown in the maintenance check list.See Chapter 05-20-00 section 25 hr. check.

Legend: X = do the task

blank = no task required

NNOOTTEE

If the table section 1) 2) and 3) are correct (see check list below) then continue with the maintenanceschedule.If one of the section 1) 2) or 3) is not within specification, the engine must be checked and repaired inaccordance with the BRP-Rotax instructions for continued airworthiness.

Points ofInspection

Interval Operating hours Chap-ter

Refer-ence

Signa-ture

*no periodicmaintenance (re-quirement exclu-sive after thementioned hoursof operation)

2 10* 25* every12.5

every25

every50

every100

every150

every300

1) General note

All (Alert) ServiceBulletins are com-plied with. If nec-essary to performthese anddocumented.

X X

2) Spark plug

Check and cleaninside of sparkplug connectors.

X X(2 12-20-00

Remove all sparkplugs and checkfor spark plug de-fects (deposits,melting....).

X X(2 12-20-00

>>

05–20–00Page 8March 01 2018



Points ofInspection


Refer-ence

Signa-ture


2 10* 25* every12.5

every25

every50

every100

every150

every300

Check if GENU-INE-ROTAX®-spark plugs areused on mod. 17.

X 12-20-00

Replace sparkplugs

X X(2 12-20-00

(2 only for mod. 17

3) Checking gearbox oil level

Checking gearboxoil level

X 12-20-00

4) Oil change

Replace gearboxoil

X X 12-20-00

Replace rotaryvalve lubricationoil

X 12-20-00

5) Check and adjust gearbox

Check and adjustgearbox, preloadof springs (type Bgearbox)

X 12-20-00

6) Check carburetors

Check, if neces-sary clean carbu-retor(s) and re-adjust (idle speed,cable tension,..)

X X 12-20-00

Replace jet needleand needle jet X

12-20-00


Page 9March 01 2018


Points ofInspection


Refer-ence

Signa-ture


2 10* 25* every12.5

every25

every50

every100

every150

every300

7) Check fuel pump

Check fuel pump(measure fuelpressure)

X 12-20-00

8) Exhaust system

Retorque exhaustmanifold screws

X X 12-20-00

Lubricate balljoints

X 12-20-00

Replace exhaustmuffler springs

X 12-20-00

9) Clean and oil air filter

Clean and oil airfilter.

X 12-20-00

10) Fuel filter

Check fuel filter X 12-20-00

Replace fuel filter X 12–20–00

11) Check rewind starter rope

Check rewindstarter rope

X 12-20-00

12) Check electric starter gear

Check electricstarter gear

X seeMMH

13) Check ignition system

Check ignitionsystem

X 12-20-00

05–20–00Page 10March 01 2018



Points ofInspection


Refer-ence

Signa-ture


2 10* 25* every12.5

every25

every50

every100

every150

every300

14) Check cylinder head and piston crown

Inspect cylinderhead and pistoncrown

X seeMMH

15) Piston inspection

Inspect pistonrings for freemovement

X seeMMH

Check pistondiameter

X(1 X seeMMH

Piston ring: Checkgap

X(1 X seeMMH

Piston ring (rec-tang. Ring): Checkaxial clearance

X(1 X seeMMH

(1 if used in very dusty atmosphere

16) Piston pin inspection

Inspect piston pinand bearing

X seeMMH

17) Cylinder inspection

Check cylinderdiameter

X(1 X seeMMH

Cylinder: Checkfor roundness

X(1 X seeMMH





Points ofInspection


Refer-ence

Signa-ture


2 10* 25* every12.5

every25

every50

every100

every150

every300

18) Gasket exchange

Replace cylinderhead-, cylinderbase- and exhaust-gasket

X(1 X seeMMH


19) Outer seals crankshaft

Inspect crankshaftand replace outerseals if necessary.

X seeMMH

20) Overhaul of engine

General overhaulof engine

X(2 seeMMH

(2 to be carried out every 5 years or every 300 hours whatever comes first.

05–20–00Page 12March 01 2018



Chapter: 05–50–00UNSCHEDULED MAINTENANCE CHECKS


Engine check after propeller strike incidents ..........................................................................................2Examination after engine failure..............................................................................................................3

Returning engine to service after submerging in water..............................................................................4Inspection in extreme climatic conditions.................................................................................................5Returning engine to service after influence by fire ....................................................................................5Required inspections after limits of operation have been exceeded ...........................................................6Reporting..............................................................................................................................................6

Introduction Special checks must be carried out immediately in the event of an engine fault (e.g.abnormal operation as defined in the Operators Manual) which impairs the airworthinessof the engine.

ATTENTION

In the course of special checks specify if additional checks for components (e.g.hydraulic governor) is applicable. After each special check/repair work, an

engine test run and a leakage check must be carried out.

ATTENTION

Observe without fail all the specified instructions.


Page 1March 01 2018


ENGINE CHECK AFTER PROPELLER STRIKE INCIDENTSDefinition A propeller strike is:

• Any incident while the engine is stationary or running which makes it necessary to per-form repairs on the propeller.

SL-2ST-009, current edition.

05–50–00Page 2March 01 2018



EXAMINATION AFTER ENGINE FAILUREGeneral note In order to find possible causes of the failure, it is important to pass on all available data.

Observations on the aircraft and the engine suspension can also be of help. It is importantto pay particular attention to any of the following engine phenomena to facilitatetroubleshooting.

Engine Engine runs erratically and misfires

part possible cause

Fuel system fuel supplyvapour lockscontamination

Ignition system (shorting cable, chargingcoil, Spark plug

malfunctiongrounding defectwrong spark plug connectionloose connection

Rough runningengine

Rough running engine

part possible cause

Ignition wiring (assignment fault)

Engine engine temperature too lowwrong intake air

Carburetor fuel supply inadequatecontamination in float chamber or floatneedle valvefloat chamber ventingfalse air intake due to defective carburetorflangeincorrect synchronization of the carburetor


Page 3March 01 2018


Engine stoppage

ATTENTION

Should one of the above mentioned items occur even for a short time then a de-tailed check of the engine is necessary. The fault needs to be located and

corrected.

Unintended engine stoppage by seizing

part possible cause

Oil systemCarburetorsGaskets/Seals

oil shortagecontaminationincorrect ventingincorrect oil typeincorrect carburetor settingleaking seals

Oil pump defect

ATTENTION

The entire assembly must be dismantled, inspected and repaired.

• The whole engine must be inspected, repaired or overhauled in accordance with theBRP-Rotax instructions for continued airworthiness.

• Inspect all systems for correct functioning.

• Detailed inspection of affected engine components.

RETURNING ENGINE TO SERVICE AFTER SUBMERGING IN WATERGeneral note

ATTENTION

The engine must be marked clearly “Engine submerged in water“. Define if it wasfresh water or salt water.

An engine which has been submerged in water must be inspected, repaired or overhauledin accordance with the BRP-Rotax instructions for continued airworthiness. See currentMaintenance Manual of the respective engine type.

Inspection • Inspect all systems for correct functioning.

NNOOTTEE

Prior to the detailed inspection, all parts should be cleaned and inspected for cor-rosion. For accessories (e.g. vacuum pump, fuel filter etc.) the instructions andspecifications of the corresponding manufacturer must be followed.

05–50–00Page 4March 01 2018



Complete inspection of these components:

• power supply • cooling system

• gearbox • exhaust system

• fuel system • start system

• cylinder unit

In most cases an overhaul is necessary, in this regard send the engine without delay to anauthorized ROTAX® overhaul facility for inspection.

If an engine was submerged into water, all electrical components(e. g.: ignition coils, spark plugs, spark plug connectors must be replaced.

NNOOTTEE

Discoloration or corrosion are signs of submerging in water.

INSPECTION IN EXTREME CLIMATIC CONDITIONSGeneral note

ATTENTION

Every 25 hr. checks of air filter, coolant radiator and oil cooler are necessary.

Flying in deserts or areas with heavily contaminated or dusty air causes increased wearon all components. For this reason, shorter maintenance intervals are recommended.

Flying in areas with extreme climatic conditions or in extreme altitudes requires adjust-ment of the cooling system. To do this, it is necessary to contact the aircraft manufacturerand an authorized ROTAX® aircraft engines distributor.

RETURNING ENGINE TO SERVICE AFTER INFLUENCE BY FIREGeneral note An engine after influence by fire must be inspected, repaired or overhauled in accordance

with the BRP-Rotax instructions for continued airworthiness.

Inspection • Inspect all systems for correct functioning.

NNOOTTEE

Prior to the detailed inspection, all parts should be cleaned and inspected for weldpenetration or melted materials.

If an engine was influenced by fire, first a visual inspection of all parts has to be done andthen a hardness test of all mechanical parts must be performed(e. g.: crankcase, cylinder, cylinder heads etc.).


Page 5March 01 2018


In most cases an overhaul is necessary, in this regard send the engine without delay to anauthorized ROTAX® overhaul facility for inspection.

REQUIRED INSPECTIONS AFTER LIMITS OF OPERATION HAVE BEEN EXCEEDEDExceeding of max. permissible engine speedRemove the cylinders and inspect the pistons for seizure.

Exceeding of max. permissible cylinder head temperatureRemove the cylinders and inspect the pistons for seizure and piston crown for crushes.

Exceeding of max. permissible exhaust gas temperatureRemove the cylinders and inspect the pistons for seizure.

Fuel pressure below specified valueRemove the cylinders and inspect the pistons for seizure. Also inspect crankshaft endseals for leakage.

REPORTINGGeneral note According to the regulation of EASA part 21A.3 / FAR 21.3 the manufacturer shall evalu-

ate field information and report to the authority. In case of any relevant occurrences thatmay involve malfunction of the engine, the form on the next page should be filled out andsent to the responsible ROTAX® Authorized Aircraft engines distributor or their independ-ent Service Center.

NNOOTTEE

The form is also available from the official ROTAX® AIRCRAFT ENGINES Web-site in electronic version.wwwwww..FFLLYYRROOTTAAXX..ccoomm

05–50–00Page 6March 01 2018



Figure 5.1: Form


Page 7March 01 2018



NOTES



Chapter: 12–00–00MAINTENANCE OF THE SYSTEMS


Introduction The section “Maintenance of the systems“ is associated with other sections. It serves onlyas a supplement to and further explanation of the maintenance check list (See 05-20-00).

NNOOTTEE

For reasons of clarity, only headlines and keywords are listed in the MaintenanceSchedule. Please refer to the following pages for further explanation if needed. Asfar as possible, the content has been arranged according to system.


Page 1March 01 2018



NOTES



Chapter: 12–10–00REPLENISHING OPERATING FLUIDS


Fluid capacities .......................................................................................................................................2

Introduction The engine should always be in a horizontal position before checking the fill levels.

ENVIRONMENTAL NOTE

All operating materials and cleaning products endanger the environment byimproper disposal.

Dispose of the operating materials in an environmentally sound way!


Page 1March 01 2018


FLUID CAPACITIESGeneral note

ATTENTION

The operation of the engine may be adversely affected if non-approved or conta-minated fuel, oil or coolant are used. Any mixing of different manufacturers and

types should be avoided. The use of additives may result in damage.

System Overview

System Fill capacity Details about the operatingfluids

Fuel system Refer to the relevant specificationsprovided by the aircraftmanufacturer.

Refer to the corresponding chap-ter in the Flight Manual.

Coolingsystem

Approx. 1.5 l (0.4 US gal.). Refer to the corresponding chap-ter in the Operators Manual.

NNOOTTEE

BRP-Rotax can give an approx value on the fill capacity depending on aircraft de-sign and positions of radiators and tanks. The volume may differ from this value.Always check the relevant specifications provided by the aircraft manufacturer.

12–10–00Page 2March 01 2018



Chapter: 12–20–00SCHEDULED MAINTENANCE


Spark plugs .............................................................................................................................................2Check and clean inside of spark plug connectors .....................................................................................2Inspection of spark plugs........................................................................................................................2Replacement of spark plugs ...................................................................................................................6

Propeller gearbox....................................................................................................................................8Checking the propeller gearbox ..............................................................................................................8Oil change ............................................................................................................................................9

Carburetor ............................................................................................................................................. 11Clean carburetor and check for wear..................................................................................................... 11Replace jet needle and needle jet ......................................................................................................... 11

Fuel pump .............................................................................................................................................12Exhaust system.....................................................................................................................................13

Retorque of exhaust manifold screws....................................................................................................13Lubricate ball joints..............................................................................................................................13Replace exhaust muffler springs...........................................................................................................13

Air filter .................................................................................................................................................15Cleaning the air filter ............................................................................................................................15Application of new air filters ..................................................................................................................16

Fuel filter ...............................................................................................................................................17Check and replacement of fuel filter ......................................................................................................17

Rewind starter .......................................................................................................................................18Check of ignition system.......................................................................................................................20

Introduction This chapter relates in particular to the maintenance work mentioned in the MaintenanceSchedule for the various engine systems and covers the work in more detail.


Page 1March 01 2018


SPARK PLUGSCHECK AND CLEAN INSIDE OF SPARK PLUG CONNECTORSInstruction Step Procedure

1 Inspect spark plug connector for cracks, burn-off, dampness and fouling.Check connection with ignition cable and fitting of rain protection cover.

2 The resistance value of the standard plug connector is 4.5 – 5.5 kΩ.

Mod. 99 only For various applications radio interference suppression plug connectors must be used ac-cording to respective regulations. These are more prone to troubles than the standard re-sistor type connector, due to the metal shielding.Resistance of these connectors is 0.8 – 1.2 kΩ.

Never pull off spark plug connector on a running engine.Clean contact surfaces in the spark plug connectors as required.

Mod. 99 only

ATTENTION

On engine installation with spark plugs down, it is highly recommended to addi-tionally secure spark plug caps.

Figure 7.1: Spark plug connector for mod. 99 (left) and mod. 17 (right)

INSPECTION OF SPARK PLUGSSpark plugs for mod. 99:

Visual check Inspect all spark plugs for mechanical damage.

Due to varying fuel properties etc., check according to maintenance schedule. Replace asrequired or annually: Provided that spark plug heat range and the carburetor calibrationare correct, the spark plugs will have a brownish tinge at the electrodes of both spark

12–20–00Page 2March 01 2018



plugs after full load operation. In numerous tests the best possible heat range has beendetermined to make sure that the spark plug will burn off deposits but will not overheat.

On engines with single carburetor, one sooty spark plug usually indicates a bad plug orfault ignition system. If both plugs are sooty with oil deposits, carburetor and air systemshould be checked. On engines with two carburetors you should switch the carburetor totrace the problem.

Spark plugs for mod. 17:Due to the curved gap between the center electrode and the ground electrodes, it is sug-gested to use a wire type feeler gauge for accurate gap measurement.

All versions:

ATTENTION

Do not induce forces to the center electrode of the spark plug. These might dam-age the spark plug.

Electrode gap NNOOTTEE

Spark plugs are already gapped upon delivery. No adjustment of the gap is neces-sary nor allowed.If gap measurement is over permissible limit, the spark plug must be replaced.

Electrode gap

Mod. 99 0.4 - 0.5 mm (0.016 - 0.020 in.), wear limit:0.5 mm (0.020 in.)

Mod. 17 0.8 - 0.9 mm (0.031 - 0.035 in.), wear limit:1.1 mm (0.043 in.)


Page 3March 01 2018


Figure 7.2: Spark plug dimensions

Spark plug face Spark plug face reveals the following about the operating condition of the engine:

Spark plug face Information

light colored to brown plug and calibration of the engine are correct

velvet black Possibly indicates one or more of the following:

• mixture to rich

• insufficient air intake (clogged air filter)

• engine operating temperature too low

oily, glossy coating Possibly indicates one or more of the following:

• damaged valve stem seal

• misfiring

• too much oil in combustion chamber

• worm cylinder and piston rings

white with formationof melt beads

Possibly indicates one or more of the following:

• mixture too lean

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Tips • If both plugs have "white" electrodes with "melt" droplets, first suspect lean mixture. Ifcalibration is correct and there is no evidence of manifold leaks, lack of fuel, or incorrectfloat settings, don't change the plugs to a colder range. Check if cooling system is oper-ating correctly.

• Heavy oil deposits on the electrodes and insulator may cause engine problems, ex-change regularly according to maintenance schedule, or at any indications of trouble.

• If after cleaning or changing the spark plugs, you still have an ignition problem, check ifonly one cylinder is affected or both. Some thought to what is common to both systemsor only one will isolate the problem more efficiently. If no external fault is found, the igni-tion unit must be checked.


Page 5March 01 2018


REPLACEMENT OF SPARK PLUGSGeneral note NNOOTTEE

To avoid spark plug damage, make sure to use a correct wrench/socket. Oldspark plugs (mod. 99) = A/F 21 / hex. 21 mm (0.83 in.), new spark plugs (mod.17) = hex. 16 mm (0.62 in.).

ATTENTION

Use of incorrect spark plugs can result in ignition problems and pre-ignition andconsequent engine damage.

ATTENTION

Always change both plugs. Never interchange plugs from one cylinder to theother.

Figure 7.3

1 Terminal nut inseparable on connectionthread 2 Connection thread

3 Leakage current barrier 4 Insulator (AI2 O3)

5 Conductive enamel 6 Terminal stud

7 Upset- and heat-shrinkage zone 8 Captive sealing ring

9 Insulator nose 10 Center electrode

11 Ground electrode

12–20–00Page 6March 01 2018



NNOOTTEE

The spark plug can be distinguished by the part no. and by the designation.

Spark plug mod. 99:

Step Procedure

1 Apply a small amount of heat-conducting compound to spark plug threads.

2 Tighten the spark plugs to 27 Nm (20 ft. lb), only on cold engine.

Spark plug mod. 17:

Step Procedure

1 Apply a small amount of heat-conducting compound to spark plug threads.

2 Tighten the spark plugs to 16 Nm (142 in. lb), only on cold engine.


Page 7March 01 2018


PROPELLER GEARBOXCHECKING THE PROPELLER GEARBOXB-type gearbox Place gearbox on a suitable support under hand press. See Figure: Gearbox “B” type.

Step Procedure

1 Place the mounting yoke, part no. 876880 on the dog gear (1)

2 Place angular ring (2) upside down (with “L” shape downwards) on propshaft to facilitate reading of the distance A.

3 Apply a load of 16 kN (3600 lbs) on the dog gear via the mounting yoke.With this load, disk spring will be completely compressed.

ATTENTION

Do not exceed maximum load of 16 kN (3600 lbs), otherwise cover or dog gearwill be damaged.

Step Procedure

4 With spring in compressed state, measure A, the distance from top side ofangular ring to lower edge of groove.See Figure: Gearbox “B” type.

5 Relieve pressure, remove all items from prop shaft and compensate dis-tance A, by placing appropriate shims (3) under distance ring (4).

6 Shims are available as spare parts in the size 0.1 / 0.2 / 0.3 / 0.5 and 1.0mm (0.0039 / 0.0079 / 0.0118 / 0.019 and 0.039 in.).

12–20–00Page 8March 01 2018



Figure 7.4: Gearbox “B” type

OIL CHANGE

ENVIRONMENTAL NOTE

Protect the environment.Do not harm the environment by spilling oil. Dispose of oil in an environmentally friendly

manner.

ATTENTION

Only use brand name oil in accordance with the latest Operators Manual.

Instruction Renewing of the rotary valve lubrication oil.

NNOOTTEE

To change the oil the following steps are necessary:

Step Procedure

1 Drain oil completely: For complete emptying, the engine must be inclined.

2 Afterwards refill the oil tank. Allow some time for setting.

3 Fill tank to max. mark and after a short trail run verify the oil level again.

Instruction Check gearbox oil level, replace gearbox oil.


Page 9March 01 2018


Step Procedure

1 For draining the oil, remove drain plug. See Figure: Gearbox “B” type.

2 Replenish oil, until oil emerges at the respective lower oil level plug.

ATTENTION

The two large ventilation bores on both sides have to remain always open to warrantdissipation of heat at gearbox type “C” and “E”.

Step Procedure

3 Wire-secure vent screw, oil level plugs and drain plugs.

NNOOTTEE

Illustration shows “B” type gearbox.

Figure 7.5: Gearbox “B” type

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CARBURETORCLEAN CARBURETOR AND CHECK FORWEAR

• Stop engine at raised speed and verify float level

• Inspect carburetor assy. for leakage

• Check float valve for easy operation

• Inspect clip of jet needle for wear

• Inspect sieve sleeve

• Clean the carburetor with fuel as required

REPLACE JET NEEDLE AND NEEDLE JETThe needle jet and jet needle must only be exchanged by a mechanic with experience ontwo-stroke engines and in accordance with the relevant Maintenance Manual Heavy.




FUEL PUMPGeneral note Inspect the fuel pump in accordance with the manufacturers or the aircraft manufacturers

instructions.

• Inspect the fuel pump

• Verify the fuel pressure: 0.2 – 0.5 bar (3 – 7 psi)

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EXHAUST SYSTEMRETORQUE OF EXHAUST MANIFOLD SCREWS

The screws of the exhaust manifold must be retightened to the specified torque:22 Nm (195 in. lb)

Figure 7.6

LUBRICATE BALL JOINTSCheck exhaust system prior to every flight for tightness, physical damage or changes insound pattern. Especially inspect springs and hooks.The muffler has to be supported on vibration damping blocks. All ball joints have to begreased regularly with heat resistant lubricant (e.g. Molykote G-N, 297 433) to avoid grip-ping or seizing of joints and consequent breaking of exhaust components.

REPLACE EXHAUST MUFFLER SPRINGSRemoving thetension springs

See Figure: Exhaust muffler spring.

Step Procedure

1 Remove the lock tabs from tension spring.

2 Inspect exhaust system for cracks and staining. Replace exhaust systemwith new if any external cracks are found. Do not weld cracks.




ATTENTION

Take care to use suitable protective equipment as disassembly .may result incracking of the tension spring.

Step Procedure

3 Detach tension springs with suitable tools one by one.

4 Clean ball joint with appropriate cleaning agent (dry rag or equivalent) andinspect for wear.

Inspecting of thetension springs

An affected (faulty) tension spring can be identified by black, bright surfaces.

Qualitatively flawless tension springs show dark brown, dull surfaces.

ATTENTION

After prolonged operation, due to high operating temperatures, there may be nodistinct distinguishing features left as described that could aid in discerning the

tension springs.Replace the tension springs in case of doubt.

Installation of thetension springs

Step Procedure

1 Lubricate ball joint with heat-resistant lubricant (Molykote G-N orequivalent).

2 Install new tension springs with appropriate tools.

3 Exhaust springs shall be secured against loss and vibrations with wire.

Figure 7.7: Exhaust muffler spring

12–20–00Page 14March 01 2018



AIR FILTERCLEANING THE AIR FILTERGeneral note

ATTENTION

Never use gasoline, steam, caustic liquids, strong detergents, particle cleaningagents or high pressure cleaners during this step.

ATTENTION

Do not dry over open flame, with compressed air or with hot air gun.

Cleaning To clean the dry filter the following steps are necessary:

Step Procedure

1 Lightly tap and brush off surface dirt and wet with cold water.

2 Roll filter in filter cleaning and degreasing fluid.

3 The level of the cleaning fluid should be approx. 3/4 of the height of corru-gations. Dirty fluid must not run inside of filter. Allow at least 5 minutes todissolve the dirt.

4 Rinse air filter with cold water from inside to outside. Shake off and let it dryin free air.

Figure 7.8: Cleaning the air filter




APPLICATION OF NEWAIR FILTERSGeneral note For a higher life-span and optimal engine protection the filter corrugations have to be

moisturized with oil. Unoiled filters lose their effectiveness against dirt and dust.Every corrugation of the filter has to be oiled. After 5 - 10 minutes the filter mat will besoaked with oil, noticeable on the uniform red colouring

ATTENTION

Never use gear oil, diesel or engine oil, as they attract humidity.

NNOOTTEE

If necessary, apply filter oil on sealing face, but don’t oil clamp connection area offilter.

Figure 7.9: Overview

12–20–00Page 16March 01 2018



FUEL FILTERCHECK AND REPLACEMENT OF FUEL FILTERGeneral The flow through the filter may be restricted due to the long term build up of dirt. A more

serious type of blockage, which can occur quite rapidly is caused by a reaction betweendetergents in certain two-stroke oils and water in the fuel.

Both types of blockage may be difficult to detect visually. If blockage is suspected, renewfuel filter or filter element. Subsequently avoid water contamination of fuel.




REWIND STARTERInstruction Check and replacement of the rewind starter. See Figure: Rewind starter.

Step Procedure

1 Remove the rewind starter assembly from the engine.

2 Remove the snap ring (1), loop spring (2), circlip (3) , pawl lock (4) and thepawl (5).

3 Check starter rope condition according to maintenance schedule. Replaceif worn or frayed.

Instruction To change the starter rope

Step Procedure

1 Pull out the starter rope fully to the end, hold starter housing (6) and ropesheave (7) together in their position. There is an opening in the ropesheave.

2 The key clamp (8) visible in the opening must be pushed out in the oppositesense of the pulling direction.

3 Pull the rope out of the rope sheave.

12–20–00Page 18March 01 2018



mWARNING

Do not remove spring container (9), this might cause injuries.Do not operate theengine if the rewind starter is defective.

Figure 7.10: Rewind starter

1 Snap ring 2 Loop spring

3 Circlip 4 Pawl lock

5 Pawl 6 Starter housing

7 Rope sheave 8 Key clamp

9 Spring container

Instruction Installation of the rewind starter

Step Procedure

1 Insert the new starter rope sheave, fit the key clamp in the same position asit was before.

2 Refit the parts pawl (5), pawl lock (4), circlip (3), loop spring (2) and snapring (1).




CHECK OF IGNITION SYSTEMGeneral Verify all electrical connections for good contact and ensure they are free of corrosion.

Inspect the wiring for wear, damage and corrosion.

Before flight the function of the two ignition circuits must be checked. For checking theignition unit the engine must be operated at 3000 to 3500 rpm and alternately ignition cir-cuit 1 and 2 must be switched off.The rpm-drop must not exceed at 300 rpm.

12–20–00Page 20March 01 2018


Effectivity: 582 ULEdition 1/Rev. 0 Index

Page 1March 01 2018

IndexAAbbreviations........................................................4Acceptable methods, techniques and practice ....... 11Air filter...............................................................15Application of new air filters..................................16Authorized personnel ............................................3

CCarburetor .......................................................... 11Check and replacement of fuel filter ......................17Check List/Maintenance Schedule..........................6Check of ignition system ......................................20Check spark plug connectors .................................2Checking the propeller gearbox..............................8Cleaning, Air filter................................................15Consumable Materials...........................................7Conversion table ...................................................7

DDefinition of terms .................................................2

EEngine check after propeller strike incidents............2Engine submerging in water...................................4Examination after engine failure .............................3Exhaust system ..................................................13Extreme climatic conditions....................................5

FFluid capacities .....................................................2Fuel filter ............................................................17Fuel pump ..........................................................12

GGeneral ................................................................2General overhaul, TBO..........................................2

IInfluence by fire.....................................................5

Inspection of spark plugs .......................................2Instruction ..........................................................10

LLife cycle ..............................................................2List of effective pages ............................................1Lubricate ball joints..............................................13

MMaintenance Concept.......................................... 11Maintenance Schedule ..........................................8Maintenance schedule procedures .........................5

OOil change ............................................................9Operating hours ....................................................2

PProcedure notes ...................................................4Propeller gearbox..................................................8

RReplace of exhaust muffler springs .......................13Replacement of spark plugs...................................6Replacing the rewind starter.................................18Replenishing operating fluids .................................1Reporting .............................................................6

SSafety ..................................................................8Safety information .................................................9Scheduled maintenance ........................................1Scheduled maintenance checks ......................... 1–2Spark plugs ..........................................................2

TTable of amendments ............................................1Technical documentation .....................................12


Effectivity: 582 ULEdition 1/Rev. 0 Index

Page 2March 01 2018

Terms...................................................................4Time limit..............................................................2Time Limit.............................................................4Time limit for the coolant ........................................5Time limit, parts.....................................................5Time limits ............................................................1Trouble shooting ...................................................6Type description....................................................3

UUnscheduled maintenance checks ..................... 3, 1Use for intended purpose.....................................14

VVisual inspection ...................................................4


Before starting any maintenance work, please read the Maintenance Manual completely as it contains important safety relevant information. Failure to do so may result in personal injuries including death. Consult the orginal equipment manufacturers handbook for additional instructions!

These technical data and the information embodied therein are the property of BRP-Rotax GmbH & CO KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior written permission of BRP-Rotax 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. The Manual must remain with the engine/aircraft in case of sale.

Copyright 2018 © - all rights reserved.

ROTAX® is a trade mark of BRP-Rotax GmbH & Co KG. In the following document the short form of BRP-Rotax GmbH & Co KG = BRP-Rotax 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.

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.

AIRCRAFT ENGINES

__________________________________________________________Engine serial no.

__________________________________________________________Type of aircraft

__________________________________________________________Aircraft registration no.

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