Rotax SB 912: No revision named, text

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Page 1Open in PDF

d07187.fm ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1 This ASB revises SB-912 i-016 / SB-915 i-016 / SB-916 i-006 dated 16 December 2024

ALERT SERVICE BULLETIN Inspection and/or replacement of oil spray nozzle for ROTAX® Engine Type 912 i, 915 i and 916 i (Series) ATA System: 24-20-00 Internal generator HIGHLY RECOMMENDED*MANDATORY* * This Alert Service Bulletin could be subject to an EASA airworthiness directive (AD).

1) Planning information To obtain satisfactory results, procedures specified in this publication must be accomplished with accepted methods in accordance with prevailing legal regulations.

BRP-Rotax GmbH & Co KG cannot accept any responsibility for the quality of work performed in accomplishing the requirements of this publication.

1.1) Applicability All engines which are not already cleared by accomplishment of the Service Bulletin SB-912 i-016 / SB-915 i-016 / SB-916 i-006 dated 16 December 2024 and all engines of Series 912 iSc Sport, 915 iSc A, 915 iSc C24, 916 iSc A, 916 iSc C24 and 916 iSc B are affected if at least one of following criteria applies:

Criterion A) Engine serial number (S/N):

These engines have been originally delivered from the factory with the possibility of blockage of the oil spray nozzle:

NOTE: Engine S/Ns from the list below with minimum 200 hours of operation are excluded from this Alert Service Bulletin as cooling of the stator is sufficient.

Criterion B) Spare parts:

Further all engines are affected which have been equipped with overhaul kits with engine blocks part no.:

- 893246 OVERHAUL-KIT 912 iS W. ENGINE BLOCK

- 893249 OVERHAUL-KIT 915 iS W. ENGINE BLOCK during engine repair, maintenance or general overhaul, delivered as spare parts from January 1st, 2022 up to October 31st, 2024 included.

Engine type Serial number 912 iSc Sport The serial numbers of the affected engine types are mentioned in Chapter 4) Appendix.

NOTE:

To search for serial numbers, please use the search function (Ctrl+F) in the PDF.

915 iSc A 915 iSc C24 916 iSc A 916 iSc C24 916 iSc B

Page 2Open in PDF

ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

ALERT SERVICE BULLETIN

1.2) Concurrent ASB/SB/SI and SL In addition to this Alert Service Bulletin the following documents must be observed:

- SI-912 i-011 Maintenance information on plug screw M22x1.5 part no. 940520 for ROTAX 912 i Series

- SI 912 i-028, SI-915 i-008 Change of oil cooling of stator for ROTAX® Engine Type 915 i A (Series) and 912 i (Series).

- SI-912 i-001,SI-912-016,SI-914-019,SI-915 i-001,SI-916 i-001 Selection of suitable operating fluids for Rotax Engine Type 916 i (Series), 915 i (Series), 912 i (Series), 912 and 914 (Series).

- in general, all relevant Alert Service Bulletins (ASB), Service Bulletins (SB), Service Instructions (SI), Service Letters (SL), Service Instruction - Parts and Accessories (SI-PAC) with relevance to perform this maintenance, repair or overhaul task.

1.3) Reason Due to a deviation in the manufacturing process, excessive application of LOCTITE at the sprag clutch housing and/or oil spray nozzle may lead to blockage of the nozzle. This could lead to inadequate cooling and possible damage to both of the generators.

The classification of this mandatory Service Bulletin has been changed to a mandatory Alert Service Bulletin due to the fact that the failure mechanism has been re-evaluated to include immediate action as described before flight.

Fig. 1

1.4) Subject Inspection and/or replacement of oil spray nozzle for ROTAX® Engine Type 912 i, 915 i and 916 i (Series).

Page 3Open in PDF

d07187.fm ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

1.5) Compliance

- before each flight verify the availability of the battery backup function, until the oil spray nozzle check has been conducted, see also section 3.3.

- at next scheduled maintenance event but latest within the coming 25 hours of operation carry out the oil spray nozzle check on the engines listed in section 1.1) according to the following instructions in section 3, but at the latest after 1 year (from the date of the initial issue of this Service Bulletin).

- before the initial installation of the engine / spare part

- on undelivered engines / spare parts prior to delivery

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

EASA.21J.048.

1.7) Labor time A labor credit will be provided for work performed by a technician with current applicable iRMT rating.

To apply for labor credit, contact your ROTAX® Authorized Distributor or their independent Service Centers.

1.8) Mass data Change of weight - - - none Moment of inertia - - - unaffected

1.9) Electrical load data No change.

1.10) Software modifications No change.

m WARNUNGmWARNING Non-compliance with these instructions could result in engine damages, personal injuries or death.

Work performed iRMT ratingrequired Laborcredit Inspect oil spray nozzle on aircraft Maintenance Line 1.2 hr per inspection Cleaning of oil spray nozzle on aircraft Maintenance Heavy 7.3 hr per replacement

Page 4Open in PDF

ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

ALERT SERVICE BULLETIN

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

- In general Illustrated Parts Catalog (IPC) and in particular Chapters 72-20-00 & 24-20-00

- In general Operators Manual (OM)

- In general Installation Manual (IM)

- In general Maintenance Manual Line (MML) and in particular Chapter 12-20-00

- In general Maintenance Manual Heavy (MMH) and in particular Chapters 24-20-00, 72-20-00, 75-00-00 & 80-10-00 NOTE: The status of the Manuals can be determined by checking the table of amendments.

The 1st column of this table shows the revision status. Compare this number to the one listed on the ROTAX® website:

www.flyrotax.com. Updates and current revisions can be downloaded for free.

1.12) Other Publications affected None

1.13) Interchangeability of parts None.

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d07187.fm ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

2) Material Information

2.1) Material Price and availability will be provided on request by ROTAX® Authorized Distributors or their independent Service Centers.

2.2) Company support information

- Any possible support by BRP-Rotax will be provided on request by ROTAX ® Authorized Distributors or their independent Service Centers

- This exchange program and cost sharing is valid until December 31st 2025. Up to this date lim - ited reimbursement of costs can be applied for

- Shipping costs, downtime costs, loss of income, telephone costs etc. or costs of conversion to other engine versions or additional work, as for instance simultaneous engine overhauls are not covered in this scope and will not be borne or reimbursed by ROTAX®.

2.3) Material requirement per engine Parts requirement for inspection, see Fig. 2.

Fig. 2 Fig.no. Part no. Qty/engine Description Application 2-1 950141 1 SEALING RING A 8X13 Locking pin bolt 2-2 250057* (1) O-RING - 18X2.5 Plug screw * 2-3 430225** (1) O-RING - 15.9X2.3 Plug screw **

- - AR ENGINE OIL XPS / AEROSHELL SPORT PLUS 4 Oil level check * only applicable to 912i Series ** only applicable to 915i and 916i Series

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ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

ALERT SERVICE BULLETIN Parts requirement for cleaning and replacement, see Fig. 3:

Fig. 3 Fig.no. Part no. Qty/engine Description Application 3-1 831929 1 O-RING 5X2 Ignition housing 3-2 246055 1 WOODRUFF KEY Crankshaft / sprag clutch 3-3 456540 1 OIL SPRAY NOZZLE ASSY. Sprag clutch housing 3-4 230429 1 OIL SEAL Ignition housing 3-5 850983 (1) GASKET Water pump housing 3-6 230415 (1) SEALING RING A 6X10 Water pump drain screw

- i AR ENGINE OIL XPS / AEROSHELL SPORT PLUS 4 Oil level check

- i AR ENGINE COOLANT Coolant level check i See SI-912 i-001,SI-912-016,SI-914-019,SI-915 i-001,SI-916 i-001 Selection of suitable operating fluids for Rotax Engine Type 916 i (Series), 915 i (Series), 912 i (Series), 912 and 914 (Series).

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d07187.fm ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

2.4) Special tooling/lubricants- /adhesives- /sealing compounds Part no. Description Application 240880 LOCKING PIN Crankshaft locking 876010 PULLER ASSY. Ignition housing 877375 PULLER ASSY. Sprag clutch assy.

877419 PROTECTION MUSHROOM Puller assy.

876020 INSERTION JIG Ignition housing, oil seal 976740 TEST TOOL OIL SPRAY NOZZLE ASSY. Blockage test

- FLOW-METER (0 - 10 l/min) digital or analog (for operating medium of compressed air and with an unidirectional flow) Blockage test

- PNEUMATIC PRESSURE REGULATOR (pressure regulation range 0,1 bar to 6 bar) Blockage test

- PNEUMATIC SHUT OFF VALVE Blockage test

- ALLEN SCREW M6x120 Blockage test 897651 LOCTITE 243 BLUE. 10 CC. (B) Oil spray nozzle 899788 LOCTITE 648 GREEN. 5 CC (C) Hex. nut 297438 LOCTITE ANTI SEIZE 8151 400 ML (E) Sprag clutch

- LOCTITE 7063 (F) Cleaner / degreaser for oil spray nozzle

- ENGINE OIL (O) Crankshaft 899791 LOCTITE 5910. 50 ML (P) Ignition housing, oil seal 898570 LOCKING PAINT 20 ML (V) Lock pin, Allen screw 899789 LOCTITE 603 GREEN. 10 CC. (Z) Sprag clutch assy.

Page 8Open in PDF

ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

ALERT SERVICE BULLETIN

3) Accomplishment/Instructions

- ROTAX ® reserves the right to make any amendments to existing documents, which might become necessary due to this standardization, at the time of next revision or issue.

NOTE: Before maintenance, review the entire documentation to make sure you have a com - plete understanding of the procedure and requirements.

Accomplishment All measures must be implemented and confirmed by at least one of the following persons or organizations:

- ROTAX ® - Airworthiness representatives

- ROTAX ® - Authorized Distributors or their independent Service Centers

- Persons approved by the respective Aviation Authorities

- Persons with approved qualifications for the corresponding engine types. Only authorized persons (iRMT, Level Line / Heavy Maintenance) are entitled to carry out this work

- Persons with type-specific training NOTE: Indicates supplementary information which may be needed to fully complete or under - stand an instruction.

General Further material on general inspection, maintenance and repair can also be found in relevant Advisory Circular AC 43.13 from FAA.

Advisory Circular Procedure The Advisory Circular (AC) contains maintenance methods, techniques and practices.

3.1) Illustrated Parts Catalog - related information

3.2) Installation - related information All work has to be performed in accordance with the relevant ROTAX® Instructions for Continued Airworthiness (ICA) of the respective engine type.

Step Procedure 1 Check the criteria given on page 1, section 1.1, if the aircraft engine or spare part is affect - ed by this SB.

2 Check the engine logbook and maintenance documentation, if this SB has already been ac - complished.

See current Illustrated Parts Catalog (IPC) for the respective engine type, Chapters 72-20-00 & 24-20-00.

See current Installation Manual (IM) for the respective engine type.

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d07187.fm ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

3.3) Operation - related information General The Battery Backup Function gives the possibility of providing power supply to the EMS via an alternate path if the internal power supply fails completely. Therefore this path needs to be checked and a sufficient power source/battery capacity needs to be guaranteed.

At engine start - Engage the battery backup system for starting the engine without the provision of any addi - tional starting power source.

- After a short engine run shut off the engine.

- Start again the engine using the common starting procedure which includes the check of the availability of generators A and B. This procedure must be successfully concluded.

- If engine run-up check was not successful, contact the distributor in your area.

During flight - In case of any unusual power performance behavior (e.g. engine alternating, surging or stalling) engage battery backup function.

- In this case land as soon as possible and perform steps beginning from section 3.4.

NOTE: If engine runs on battery backup function, engine running time and current supply to the aircraft is limited by battery capacity.

See current Operators Manual (OM) for the respective engine type.

See also Aircraft Flight Manual (AFM) / Pilot Operating Handbook (POH).

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ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

ALERT SERVICE BULLETIN

3.4) Maintenance (Line) - related information

3.4.1) Inspection of oil spray nozzle See Fig. 4 Fig. 4 Step Procedure 1 Lock the crankshaft.

See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-20-00, Section Locking / loosen of the crankshaft.

2 Loosen plug screw (1 or 2).

3 If equipped, remove the optional generator flange assy. (3).

See current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 72-20-00 and SI-PAC-023.

1 Plug screw 915 i/916 i (Series) 2 Plug screw 912 i (Series) 3 Generator flange assy.

(optional part)

Page 11Open in PDF

d07187.fm ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

See Fig. 5 Fig. 5 Step Procedure 4 Attach a pressure regulator (1), shutoff valve (2) and a flow meter (4 or 5) to the mea - surement adapter tool.

NOTE: For measurement a flow meter is required, either a digital or analog one;

if using an analog type, this one needs to be in vertical position while the measurement is done, otherwise the measurement will be inaccurate.

5 Connect the regulator (1) input to a compressed air source.

6 Open the shutoff valve (2) and set the regulator (1) to 300 mbar (4.35 psi). close the shutoff valve.

1 Pressure regulator 2 Shutoff valve 3 Gauge (with proper scale) 4 Digital flow meter 5 Analog flow meter 6 Test tool oil spray nozzle assy

Page 12Open in PDF

ASB-912 i-016 R1 / ASB-915 i-016 R1 ASB-916 i-006 R1

ALERT SERVICE BULLETIN See Fig. 6 Fig. 6 Step Procedure 7 Carefully insert the measurement adapter tool (1) into the crankshaft, capturing the internal oil nipple (2).

8 Slide the rod (3) into the tool until approximately 25 mm (0.98 in.) is still protruding from the tool.

1 Adapter tool 2 Oil nipple 3 Rod

(e.g. Allen screw M6x120 - not scope of delivery)

Pages 13–24 of 131