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I would like to hear from pilot/mechanics with experience using Constant Speed (CS) propellers fitted to Rotax 9 engines.

I have an electric 4 stage (TO/Climb/Cruise & Feather) CS propeller, fitted to my new Sonex/Rotax 912 ULS - fantastic performance BUT in Cruise mode, oil temperatures are a constant concern.

Oil temp's in TO/Climb mode get to 100-105C, perfectly acceptable, even desirable.

In Cruise temp's will rise to 115C with OAT of 11C (today 3500ft). This is fine for TO/Climb but I would like to see them below 100C in cruise.

When doing circuits, prop in Climb mode, temperatures will be from high 90 - 105C.

Its not quite impossible, to reduce oil temps, with Cruise selected  even with a significant reduction in power) but close to it.

I can reduce oil temperatures by switching to Climb (fine ) mode (5200 rpm) & reducing power, which also reduces air speed significantly.

I have fitted what I believe is the largest Rotax oil cooler. To maximise its performance, it has a separate air circuit in/out, to the under cowl air supply/movement. (Exit air temperatures, for this system, are about 45C during flight).

Cylinder head temps are in the low 90C range during flight.

I do not operate my engine below 5200RPM except during decent & ground opps.

My interpretation of this situation is that the CS is loading the engine in Cruise mode, such that it's generating more heat than the oil cooler can deal with.

My questions, for the experienced CS user, are; 

Have you experienced this problem? - If so what is the solution? (larger oil cooler/second oil cooler)

  • Re: Constant Speed Propeller

    by » 2 years ago


    Those are high oil temps with a relatively low OAT, particularly when you have a large oil cooler. Are you sure that you have an unrestricted flow around the oil circuit? Are there any sharp radii in any of the oil hoses, particularly the one that connects to the oil pump inlet?

    Do you have the correct crankcase pressure to force the oil back to the tank?

    I know someone who operates with a similar prop on a tightly cowled Europa with only a small oil cooler on a 912UL. He doesn't have any oil temperature problems.


  • Re: Constant Speed Propeller

    by » 2 years ago


    If a prop is over pitched regardless of the type it will cause higher oil temps and more stress on the engine. Even if you use a reduced rpm the prop can still be over pitched. If you give it WOT in level flight and the rpm is below 5500 rpm then it's over pitched.


    Roger Lee
    LSRM-A & Rotax Instructor & Rotax IRC
    Tucson, AZ Ryan Airfield (KRYN)
    520-349-7056 Cell


  • Re: Constant Speed Propeller

    by » 2 years ago


    Roger Lee wrote:

    If a prop is over pitched regardless of the type it will cause higher oil temps and more stress on the engine. Even if you use a reduced rpm the prop can still be over pitched. If you give it WOT in level flight and the rpm is below 5500 rpm then it's over pitched.

    Hi Roger,

    The prop manufacturer claims to set the WOT to 50 RPM below Rotax specifications, so MAX Continuous - 5450 rpm  & MAX TO - 5750 rpm.

    I can adjust this in flight by switching to manual and for a more permanent fix also change the manufacturers settings.

    I don't usually fly at WOT in cruise, so usually see 5350 rpm in cruise - I will try WOT in cruise, next flight & report back.


  • Re: Constant Speed Propeller

    by » 2 years ago


    Kevin Stewart wrote:

    Those are high oil temps with a relatively low OAT, particularly when you have a large oil cooler. Are you sure that you have an unrestricted flow around the oil circuit? Are there any sharp radii in any of the oil hoses, particularly the one that connects to the oil pump inlet?

    Do you have the correct crankcase pressure to force the oil back to the tank?

    I know someone who operates with a similar prop on a tightly cowled Europa with only a small oil cooler on a 912UL. He doesn't have any oil temperature problems.

    Hi Kevin,

    To ensure that the return oil lines/pipes do not collapse, I have added an internal spring to the oil line tank/oil cooler pipe and an external spring to the short oil cooler/pump pipe, so there should be no chance of a collapsing oil line.

    The long line from tank has no sharp bends, however the short line from cooler to pump is a 90 degree.

    The oil cooler is new (as is the rest of the engine), however this is no guarantee that its not partially blocked. I have taken steps to ensure that there is no air trapped in it. Not sure that I know how to assess a partial blockage. I guess a back flush, with petrol, may dislodge any loose stuff but if its a fixed obstruction, how would I know?

    Crank case pressure? I get the "Burp" within one slow turn of the prop, so I assume all good.


  • Re: Constant Speed Propeller

    by » 2 years ago


    I have the same engine/propeller on my Europa. It will constantly run at 5750 inTO, 5450 in climb and 5050 in cruise. I’m in the California desert and the airflow (single opening) to the oil cooler is almost closed off and directed to the radiator and it works best with about a 90kts or more of airflow. Think you might be over pitch with the low rpm and low airspeed and probably improve the airflow through your cooling system. It was a bit of experimenting to get it sorted out, but worth it.


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