SAIB NE-05-84

SPECIAL AIRWORTHINESS

INFORMATION BULLETIN

Aircraft Certification Service Washington, DC

U.S. Department of Transportation Federal Aviation Administration

NE-05-84 August 30, 2005 http://www.faa.gov/aircraft/safety/alerts/SAIB This is information only. Recommendations aren’t mandatory.

CORRECTION: August 31, 2005, we have corrected typos in 2 paragraphs of the Background section, and attached the applicable service bulletins. All other information is correct.

Introduction

This Special Airworthiness Information Bulletin alerts you, owners and operators of Bombardier-Rotax 912 A, 912 F, 912 S, and 914F series reciprocating engines, to the correct type of coolant to use in your engine. If you use the incorrect type of coolant, cylinder head temperatures above 120°C can result in loss of coolant and engine overheating. These engines are installed on, but not limited to:

Manufacturer Model Aeromot-Industria Mecanico Metalurgica AMT-200, AMT-200S, AMT-300 Aquila Technische Entwicklungen GmbH AT01 Diamond Aircraft Industries (Canada and Germany) DA20-A1, HK36 TS, HK36 TC, HK36 TTC, HK36 TTC- ECO, HK36 TTS Iniziative Industriali Italiane 650 TC, 650 TCN, 650 TCS, 650 TCNS Stemme GmbH S10-VT

Background

Austro Control, the Austrian airworthiness authority, has advised us of new requirements regarding the type of coolant used in Rotax 912 A, 912 F, 912 S, and 914F Series reciprocating engines. The new coolant requirements apply to these engines if the maximum cylinder head temperature will exceed 120°C during normal operation.

If you use a conventional glycol/water coolant at cylinder head temperatures above 120°C, loss of coolant and engine overheating can occur. These new coolant requirements may not apply to all of these engines because the aircraft installation and operating conditions can affect the cylinder head temperature. The maximum cylinder head temperature limits for these engines remain the same.

Austro Control has published Airworthiness Directive (AD) A-2004-004R1 (attached), as a result of these findings. That AD requires the use of a specific waterless type of coolant if the maximum cylinder head temperature will exceed 120°C during normal operation. That AD also specifies requirements associated with the use of conventional glycol/water coolant if the maximum cylinder head temperature will not exceed 120°C during normal operation. It also provides information about related engine installation and operation manual changes.

Bombardier-Rotax has issued revisions to the installation manuals and operator’s manuals that pertain to engine coolant requirements.

Bombardier-Rotax has also issued service bulletins Nos. SB-912-043 and SB-914-029 (also attached), which provide recommendations for the use of a waterless coolant in the 912 series and 914 series engines.

2 Recommendation

We recommend that you comply with the engine coolant requirements specified in Austro Control AD No. A-2004-004R1, and that you comply with the related information contained in the applicable Bombardier-Rotax installation and operator’s manuals and service bulletins.

For Further Information Contact

Richard Woldan, Aerospace Engineer, FAA Engine Certification Office, ANE-140, 12 New England Executive Park. Burlington, MA 01803; phone: 781-238-7136; fax: 781-238- 7199; email: richard.woldan@faa.gov

Bombardier-Rotax, Gunskirchen, Austria;

phone: (43) 7246-601-423; fax: (43) 7246-601- 760; www.rotax-aircraft-engines.com.

austro Airworthiness Directive No. A-2004-004R1 Reference: FL206-1/132-04 CONTROL Rotax 912 A Series engines Abt. Flugtechnik Rotax 912 F Series engines Registration mark: without Rotax 912 S Series engines Rotax 914 F Series engines Page: 1 Sheet: 3 This Airworthiness Directive is published by ACG as Primary Airworthiness Authority for the affected product on behalf of EASA.

1. Applicability: Rotax 912 A Series engines Rotax 912 F Series engines Rotax 912 S Series engines Rotax 914 F Series engines installed in, but not limited to, certificated products of following manufacturers:

Aero Ltd., Aeromot, Alpi, Aquila, Diamond Aircraft Austria, Diamond Aircraft Canada, Issoire Aviation, Sauper, Scheibe, Sky Arrow, Stemme, Tecnam, WD Flugzeug, and installed in various aircrafts by Supplemental Type Certificates (STC).

This list is not exhaustive.

2. Subject: Replacement of coolant/Reduction of Cylinder Head Temperature Limits

3. Reason: Under certain powerplant installation and operating conditions boiling of conventional glycol/water coolant can occur before reaching maximum permissible cylinder head temperatures (CHT). This can lead to loss of coolant and subsequent engine overheat.

4. Action: To insure safe operation corrective actions have to be performed on aircrafts with affected engines installed within the compliance time stated below.

Corrective Actions have to contain at minimum actions a) and c) or b) and c). Effects of these measures on the powerplant installation and on compliance with aircraft related requirements (e.g. engine cooling, engine operating limitations, a.s.o.) have to be reviewed by the affected aircraft manufacturers in accordance with aircraft related certification requirements before these measures are being introduced.

Therefore affected aircraft manufacturers have to bindingly define if actions, and which actions have to be taken in addition and at the same time to the below listed engine related measures (e.g. alteration of indicator markings, airplane flight manual revisions, a.s.o.).

a) Use of "EVANS NPG+" coolant Glycol/water coolants of any mixing ratio have to be replaced with the waterless coolant EVANS NPG+ (specification in accordance with Rotax SB912-043/914-029, chapter 2, Material Information) in accordance with Rotax SB912-043/914-029, chapter 3.2, Changing the Coolant, and chapter 4, Appendix.

The max. CHT limits of 150°C for the Rotax 912 A/F series engines and 135°C for the Rotax 912 S series and 914 F series engines remain unchanged.

LIE/KEL December 22, 2004

austro Airworthiness Directive No. A-2004-004R1 Reference: FL206-1/132-04 CONTROL Rotax 912 A Series engines Abt. Flugtechnik Rotax 912 F Series engines Registration mark: without Rotax 912 S Series engines Rotax 914 F Series engines Page: 2 Sheet: 3

b) Use of conventional glycol/water coolant (mixing ratio 50/50) Following measures have to be taken if the glycol/water coolant (mixing ratio 50/50) shall remain in use:

i) The open-up pressure of the coolant pressure vessel cap has to be checked. The open-up pressure is marked on the cap.

ii) If a different open-up pressure than "1,2 bar" is marked on the cap, than the cap has to be replaced by a new pressure vessel cap, Rotax P/N 922.070.

iii) Max. CHT limits have to be reduced to following values:

Rotax 912 A/F/S series: max. 120°C Rotax 914 F series: max. 120°C

c) Following changes to the installation and operating manuals have to be considered:

i) Operator's Manuals Rotax 912 A/F series Chapter 10, operating limits CHT Use of EVANS NPG+ . max. 150°C Use of glycol/water- .................. max. 120°C coolant (50/50), and use of a 1,2 bar pressure vessel cap ii) Operator's Manuals Rotax 912 S series und 914 F series Chapter 10, operating limits CHT Use of EVANS NPG+. . max. 135°C Use of glycol/water- max. 120°C coolant (50/50), and use of a 1,2 bar pressure vessel cap iii) Installation Manual Rotax 912 A series Chapter 7.1, operating limits CHT Use of EVANS NPG+ .. max. 150°C Use of glycol/water- .. max. 120°C coolant (50/50), and use of a 1,2 bar pressure vessel cap LIE/KEL December 22, 2004

austro Airworthiness Directive No. A-2004-004R1 Reference: FL206-1/132-04 CONTROL Rotax 912 A Series engines Abt. Flugtechnik Rotax 912 F Series engines Registration mark: without Rotax 912 S Series engines Rotax 914 F Series engines Page: 3 Sheet: 3 iv) Installation Manual Rotax 912 F series Chapter 6.1, operating limits CHT Use of EVANS NPG+ max. 150°C Use of glycol/water- . max. 120°C coolant (50/50), and use of a 1,2 bar pressure vessel cap

v) Installation Manual Rotax 912 S series Chapter 7.1, operating limits CHT Use of EVANS NPG+ .. max. 135°C Use of glycol/water ..... max. 120°C coolant (50/50), and use of a 1,2 bar pressure vessel cap vi) Installation Manual Rotax 914 F series Chapter 8.1, operating limits CHT Use of EVANS NPG+ max. 135°C Use of glycol/water .. max. 120°C coolant (50/50), and use of a 1,2 bar pressure vessel cap Further investigations are ongoing to re-establish the original CHT limits as far as possible. If positive results are attained this airworthiness directive will be revised accordingly.

5. Compliance: Latest December 31, 2005

6. Accomplishment: The required actions have to be accomplished either by the manufacturer, or a licensed/qualified person/organization, depending on national regulations. Accomplishment of the AD has to be confirmed in the aircraft log according to national regulations.

7. Effective Date: Immediately after receipt, replaces AD A-2004-004 LASA-Approval:

This AD is approved under reference EASA No 2004-12534 dated December 22, 2004.

LIE/KEL December 22, 2004

ROTAX

AIRCRAFT ENGINES

SERVICE BULLETIN

CHANGE OF COOLANT SPECIFICATION ON ROTAX ENGINE TYPE 912 AND 914 (SERIES) SB-912-043 SB-914-029

MANDATORY Repeating symbols:

Please, pay attention to the following symbols throughout this document emphasizing particular information.

• WARNING: Identities an instruction, which if not followed, may cause serious injury or even death.

• 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.

1) Planning information

1.1) Engines affected All versions of the engine type:

- 912 A all

- 912 F all

- 912 S all

- 914 F all

1.2) Concurrent ASB/SB/S and SL More to this Service Bulletin the following additional Service Bulletin must be observed and complied with:

- SB 912-039 / SB-914-025 "Modifications of the overflow bottle" current issue

1.3) Reason In some instances conventional coolant (mixture ratio of 50% water and 50% antifreeze) can vaporize or boil before the maximum permissible cylinder head temperature is reached.

1.4) Subject Change of coolant specification on ROTAX engine type 912 (Series) and 914 (Series)

1.5) Compliance

- Within the next 100 operating hours, but at the latest by December 31, 2004, the newly specified coolant specifications are to be observed according to the following Instruction section 3 and applied.

• 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 Nr. MOT. JA-03.

1.7) Manpower Engine installed in the aircraft - - - manpower time will depend on installation and thus, no estimate is available from the engine manutacturer.

1.8) Mass data Change of weight - - - none Moment of inertia - - - unaffected SEPTEMBER 2004 SB-912-043 Initial Issue SB-914-029 page 1 of 5 Copyright - ROTAX®

1.9) Electrical load data No change

1.10) Software accomplishment summary No change

1.11) References In addition to this technical information refer to current issue of

- Operator's Manual (OM)

- Illustrated Parts Catalog (IPC)

- Maintenance Manual (MM)

1.12) Other publications affected The following documentation must be replaced without any delay in accordance with this Service Bulletin and will become invalid.

Description part no. Issue Date Rev. Chapter Page SL-912-009/914-008 n. a. Dec. 2003 The following documentations become effective with this Service Bulletin:

Description part no. Issue Date Rev. Chapter Page Operator's Manual 912 Series 899370 1998 07 01 3 Operator's Manual 914 Series 899641 1998 12 01 Installation Manual 912 A 897860 1997 01 16 1 Installation Manual 912 F 897796 1996 01 23 2 Installation Manual 912 S 899376 1998 09 01 1 Installation Manual 912 UL 897711 2 1997 03 26 Installation Manual 914 F 897816 1996 05 10 1 The replacement pages have to be included without delay into the respective documentation of the aircraft manufacturer.

1.13) Interchangeability of parts Not affected SEPTEMBER 2004 SB-912-043 Initial Issue SB-914-029 page 2 of 5 Copyright - ROTAX®

2) Material Information

2.1) Material - cost and availability Prices and availability can be inquired about at:

EVANS 07014 Evans Cooling Systems www.evanscooling.com USA, Central andSouth America, Australia, Asia and Canada:

Evans Cooling Systems Inc. Sales and Warehous Office PO BOx 434 Parkerford, PA 19457-0434, USA Tel.: 001 610 323 3114 Fax: 001 610 970 0286 email: customerservice@evanscooling.com Contact Cathy or Dave Europe, the Middle East and Africa: Northern Europe (The UK, Holland, Scandinavia etc) RENOX S.n.c. GEARFOX UK Via Bologna, 12 Charterhouse 60019 Senigallia AN, Italy 106 Baker Street, Marylebone, London.

Tel.: +39 071 792 7942 Tel: +44 20 7486 1970/1862 Fax: +39 071 791 0343 Fax: +44 20 7935 3268 email: renox@renox.com email: dan.sargent@gearfox.co.uk Contact Alex Priori Contact: Dan Sargent ... or will be supplied on request by ROTAX Authorized Distributors or their Service Center.

Contact your local ROTAX Authorized Distributor as listed in the Operator's Manual or published on our official web-site at: www.rotax-aircraft-engines.com.

2.2) Company supportinformation None

2.3) Material requirement per engine parts requirement:

Fig.no. New part no. Qty/engine Description Old part no. Application as required NPG+™ coolant liquid cooling system

• NOTE: The required coolant quantity depends on the installation. In case of doubt contact your aircraft manufacturer.

2.5) Rework of parts None

2.6) Special tooling/lubricant-/adhesives-/sealing compound - Price and availability Price and availability will be supplied on request by ROTAX Authorized Distributors or their Service Centers.

Parts requirement:

Fig.no. part no. Qty/engine Description Old part no. Application

(1) 898490 warning sticker radiator cap SEPTEMBER 2004 SB-912-043 Initial Issue SB-914-029 page 3 of 5 Copyright - ROTAX®

3) Accomplishment / Instructions Accomplishment All the measures must be taken and confirmed by the following persons or facilities:

- ROTAX -Airworthiness representative

- ROTAX - Distributors or their Service Centers

- Persons approved by the respective Aviation Authority A WARNING: Proceed with this work only in a non-smoking area and not close to sparks or open flames. Switch off ignition and secure engine against unintentional operation. Secure aircraft against unauthorized operation. Disconnect negative terminal of aircraft battery.

• WARNING: Risk of scalds and burns! Allow engine to cool sufficiently and use appropriate safety equipment while performing work A WARNING: Should removal of a locking device (namely lock tabs, self-locking fasteners) be required when undergoing disassembly/assembly, always replace with a new one.

• NOTE: All work has to be performed in accordance with the relevant Maintenance Manual.

3.1) Coolant specification The coolant specification is to be used according to the corresponding Operators Manual current issue, and according to the time schedules in section 1.5.

• CAUTION: The safety-technical data of the coolant manufacturer must be observed!

3.2) Changing the coolant (see fig. 1) The coolant is to be replaced according to the Maintenance Manual, current issue.

• CAUTION: The manufacturer's data for change/replacement, usage, and operation of the previously described coolant are to be observed. See Appendix section. 4.2.

• NOTE: On the radiator cap (3), to identify the new coolant, the warning label (2) is to be affixed so that the opening pressure data (4) is visible.

• WARNING: Water or water-containing coolant must not be added in any case to the cooling system!

- Restore aircraft to original operating configuration.

- Connect negative terminal of aircraft battery.

3.3) Testrun Conduct test run including ignition check and leakage test.

3.4) Summary These instructions (section 3) have to be conducted in compliance with section 1.5.

Approval of translation to best knowledge and judgment - in any case the original text in the German language and the metric units (SI-system) are authoritative.

SEPTEMBER 2004 SB-912-043 Initial Issue SB-914-029 page 4 of 5 Copyright - ROTAX®

4) Appendix

4.1) Sticker The following drawings should provide additional information: See fig. 1

- For new engine deliveries the sticker will be temporarily attached to the expansion tank.

- The sticker has to be affixed to the radiator cap in accordance to the aircraft manufacturer's instruction.

1 Expansion tank 2 Warning sticker 3 Radiator cap 4 Excess-pressure information 4 DO NOT

ADD WATER

TO THIS SYSTEM STOP! 2 EVANS NPG+

WATERLESS

COOLANT ONLY

REMOVE SLOWL 07012 tig. 1

• NOTE: The illustrations in this document show the typical construction. They may not represent full detail or the exact shape of the parts which have the same or similar function.

Exploded views are not technical drawings and are for reference only. For specific detail, refer to the current documents of the respective engine type.

4.2) Manufacturer Instruction An NPG+ Instruction Manual is included in each scope of supply and also available on the official web-site of the manufacturer and includes detailed instructions about the operation and application of EVANS NPG+.

The coolant system of the ROTAX engine type 912 / 914 is designed for the operation with waterless coolant and therefore has not to be modified. The drain holes /venting holes should not be pluged.

4.2.1) Warning notices for operation with EVANS NPG+

- Water or water-containing coolant must not be added in any case to the cooling system!

- 3,6% water or less in the system is acceptable and may be checked with a brix scale retractometer.

- Residual water, if present, will vent rapidly as steam. This could further lead, by too low cooling level, in a complete failure of the cooling system. Check coolant level in expansion tank (1) as per daily checks (see section 10.3.1 Operators Manual) or equivalent electronic warning system.

- If EVANS NPG+ coolant is not locally available, temporarily top off the system with propylene glycol antifreeze and be sure not to add water. Within 15 days the temporary coolant should be completely drained and the system refilled with EVANS NPG+ coolant.

• CAUTION: The above mentioned warning instructions are excerpts of the manufacturer published Instruction Manual, in any case the original textin the Instruction Manual is authoritative.

SEPTEMBER 2004 SB-912-043 Initial Issue SB-914-029 page 5 of 5 Copyright - ROTAX®