29 May 2013 Current valid documentation see: **72-30-00** Revision 2 www.FLYROTAX.com Page 1 of 7
Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved.d05057.fm ASB-912-062R2 ASB-914-044R2 

# ALERT SERVICE BULLETIN **Checking of the cylinder head assy. (2/3) for ROTAX ®**  

# Engine **Type 912 and 914 (Series)**

This ASB revises ASB-912-062/ ASB-914-044 Revision 1 

### ATA System: 72-30- 00 cylinder head



# MANDATORY

**Symbols used:** Please, pay attention to the following symbols throughout this document emphasizing particular information. **General note**

NOTE: Information useful for better handling. A revision bar outside of the page margin indicates a change to text or graphic. To obtain satisfactory results, procedures specif ied in this publication must be accomplished with accepted methods and prevailing govern ment regulations. BRP-Powertrain GmbH & Co KG. cannot be responsible for the quality of work performed in accomplishing the requirements of this publication. 

### 1) Planning information **1.1) Applicability** All versions of the engine type:

# **WARNUNG**

# **WARNING Identifies an instruction which, if not followed, may cause serious in**  **jury or even fatal injury.**



# **WARNUNG**

# **CAUTION Identifies an instruction which, if**  **not followed, may cause minor or moderate injury.** 


# **WARNUNG NOTICE**  **Denotes an instruction which if not followed, may severely damage the engine or could lead to suspension of warranty.** 



### ENVIRONMENT NOTE
Environment note gives you tips and behaviors to environmental protection.

**Engine type Serial number** 912 A from S/N 4,410.965 up to S/N 4,410.976 inclusive 912 F from S/N 4,413.013 up to S/N 4,413.017 inclusived05057.fm ASB-912-062R2 ASB-914-044R2 

# ALERT SERVICE BULLETIN

29 May 2013 **72-30-00** Revision 2 Page 2 of 7 Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved. Additional engine S/N as per ASB-912-062/ASB-914-044 Revision 2:

In addition, also affected, all cylinder head assy. 2/3 part no. 623682 or part no. 623687 from 31 January 2013 up to 28 May 2013 inclusive. **1.2) Concurrent ASB/SB/SI and SL**

none **1.3) Reason** Due to a deviation in the manufacturing process some cylinder heads may have an oil leak in the intake channel in the area of the valve guide. There is a possibility of small machined through holes, which can increase the oil consumption which may result in an engine stoppage. **1.4) Subject** Checking of the cylinder head assy. (2/3) for ROTAX for engine type 912 and 914 (Series). **1.5) Compliance** - before next flight, check of the cylinder head assy. 2/3 part no. 623682 or part no. 623687 of an engine with a serial number (S/N) listed in section 1.1) in accordance with the instructions in section 3. NOTE: If an inspection as per ASB-912-06 2R1/914-044R1 have already been carried out, no further inspection is necessary.

**1.6) Approval** The technical content of this document is approved under the authority of DOA ref. EASA.21J.048. **1.7) Labor time** Estimated labor time: engine installed in the aircraft - - - labor time will depend on inst allation and therefore no estimate is available from the engine manufacturer. **1.8) Mass data** change of weight - - none. moment of inertia- - - unaffected. 912 S from S/N 4,924.468 up to S/N 4,924.491 inclusive 914 F from S/N 4,421.156 up to S/N 4,421.169 inclusive

**Engine type Serial number** 912 A from S/N 4,410.977 up to S/N 4,410.981 inclusive 912 F from S/N 4,413.018 up to S/N 4,413.019 inclusive 912 S from S/N 4,924.492 up to S/N 4,924.543 inclusive 914 F from S/N 4,421.170 up to S/N 4,421.177 inclusive



# **WARNUNG**

# **WARNING** Non-compliance with these instructions could result in engine damages, personal injuries or even fatal injury.d05057.fm

29 May 2013 **72-30-00** Revision 2 Page 3 of 7 Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved. ASB-912-062R2 ASB-914-044R2 

# ALERT SERVICE BULLETIN

**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 - Illustrated Parts Catalog (IPC) - Maintenance Manual (MM)

NOTE: The status of Manuals can be determined by checking the table of amendments of the Manual. The 1 st column of this table is the revision status. Compare this number to that 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** - All defective parts and also spare parts in stock are unservicable and must be returned F.O.B to ROTAX ® Authorized Distributors or their Service Center. 

### 2) Material Information **2.1) Material- cost and availability** Price, availability and any possible suppor t will be provided on request by ROTAX ® Authorized Distributors or their Service Center. **2.2) Company support information** - Replaced parts must be returned F.O.B to ROTAX® Authorized Distributors or their Service Center. - Shipping costs, downtime costs, loss of income, telephone costs et c. or costs of conversion to other engine versions or additional work, as fo r instance simultaneous engine overhaul is not covered in this scope and will not be borne or reim bursed by ROTAX ® . **2.3) Material requirement per engine** parts required if cylinder head change is necessary:

**Fig. no. New part no. Qty/**  **engine Description Old part no. Application**  - - as required spark plug12 897225 912 A, 912 F, - - as required spark plug12 297940 912 S - - as required spark plug12 897257 914 F - - as required cylinder head assy. 2/3 623682 Power section 912 A, 912 F, 914 F - - as required cylinder head assy. 2/3 623687 Power section 912 Sd05057.fm ASB-912-062R2 ASB-914-044R2 

# ALERT SERVICE BULLETIN

29 May 2013 **72-30-00** Revision 2 Page 4 of 7 Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved. **2.4) Material requirement per spare part**

none **2.5) Rework of parts**

none **2.6) Special tooling/lubricant-/adhesives- /sealing compound-Price and availability**  Price and availability will be providedon request by ROTAX ®Authorized Distributors or their Service Centers. parts required if cylinder head change is necessary : - - as required O-ring 6.4x1.8 430205 valve cover - - as required O-ring 105x2.5 250285 valve cover - - as required O-ring 16x5 850930 oil return tube - - as required valve stem seal 230810 cylinder head - - as required O-ring 43x2 230910 intake manifold - - as required O-ring 19x2 950180 bent socket - - as required Lock nut M8 842950 exhaust bend - - as required Lock washer A6 945751 intake manifold

**Fig. no. New part no. Qty/engine Description Old part no. Application** - as required valve spring loading jig assy. 877387 cylinder head


# **WARNUNG NOTICE**  When using these special tools observe the manufacturers specifications.d05057.fm

29 May 2013 **72-30-00** Revision 2 Page 5 of 7 Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved. ASB-912-062R2 ASB-914-044R2 

# ALERT SERVICE BULLETIN
**3) Instructions/Accomplishment** NOTE: Before maintenance, review the entire documentation to make sure you have a complete understanding of the procedure and requirements.**Accomplish ment**  All measures must be taken and confirmed byat least one of the following persons or organization: - ROTAX ® - Airworthiness representative - ROTAX ® - Distributors or their Service Center - Persons approved by the res pective Aviation Authority

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

**3.1) Checking of cylinder head assy. 2/3 3.1.1) Introduction**  This check has to be done in order to establish if there is evidence of excessive oil consumption. New or used engines have to be checked by examining for this evidence as detailed under 3.1.2) Checking of spark plug tip on cylinder 2 and 3.



# **WARNUNG**

# **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 agains t unauthorized operation. Disconnect negative terminal of aircraft battery.

# **WARNUNG**

# **WARNING** Risk of scalds and burns! Allow engine to cool sufficiently and use appropriate safety gear while performing work.



# **WARNUNG NOTICE**  Should removal of a locking device (e .g. lock tabs, self-locking fasteners, etc.) be required when undergoing di sassembly/assembly, always replace with a new one.d05057.fm ASB-912-062R2 ASB-914-044R2 

# ALERT SERVICE BULLETIN

29 May 2013 **72-30-00** Revision 2 Page 6 of 7 Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved. **3.1.2) Checking of spark plug tip on cylinder 2 and cylinder 3** See fig.1.

NOTE: If the cylinder heads 2/3 part no. 623682 or part no. 623687 have already been installed in the course of a repair / an overhaul, carry out an engine test run (a minimum engine running time of 20 minutes is required). This must be done prior to the checking of the spark plug tip. See current issue of Maintenance Manual (Line) of the relevant engine type.

NOTE: Unusual deposits (excessive carbon or oil) on the spark plugs are an indication of a defective cylinder head which must be replaced. Figure 1 shows comparison between a used spark plug in normal condition and one that is not.

**3.1.3) Replacement of the affected cylinder head** If excessive deposits (oil or carbon) are found on the spark plugs the cylinder head must be replaced in accordance with the relevant Maintenance Manual (Heavy) and any relevant aircraft manufacturer instructions.

NOTE: At tightening the cylinder head with 2 collar cap nuts M8 and 2 hex. nuts M8 pay attention to the changed tightening torque. Tighten to 10 Nm (90 in.lb) and then in addition tighten further by applying a 120° rotation. - Install new spark plugs. - Restore aircraft to original operating configuration. - Connect negative terminal of aircraft battery. **3.2) Test run** Conduct test run including ignition check and leakage test **3.3) Summary** These instructions (section 3) have to be conducted in accordance with the time scales specifiedin section 1.5. The execution of the mandatory Alert Service Bulletin must be confirmed in the logbook. Approval of translation to best knowledge and judgement-in any case the original text in German language and the metric units (SI-system) are authoritative. **3.4) Enquiries** Enquiries regard ing this Alert Service Bulletin should be sent to the ROTAX®authorized distributor of your area. A list of all distributors is provided on www.FLYROTAX.com

. **Step Procedure**  1 Visual check of both spark plugs per cylinder (top and bottom).



# **WARNUNG NOTICE**  Affected spark plugs with such deposits shown in chapter 4 Fig. 1, have to be removed and can not be reinstalled.d05057.fm

29 May 2013 **72-30-00** Revision 2 Page 7 of 7 Copyright - BRP-Powertrain GmbH & CO KG. All rights reserved. ASB-912-062R2 ASB-914-044R2 

# ALERT SERVICE BULLETIN
**4) Appendix** The following illustrations/drawings sh ould convey additi onal information:

Fig. 1 09884 spark plug

NOTE: The illustrations in this document sh ow 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. okay normal not okay oil fouled