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Installation Manual 912 Series

1. Part Function Oil tank Oil drain screw Oil filter Oil cooler A l po a Fig 1 08650 1 2 Operating limits General note Non compliance can result in serious injuries or death AWARNING The lubrication system must be designed such that the permissible operating temperatures and maximum val ues are not exceeded Operation limits Manual Oil pressure See OM 912 Series section 2 1 Oil temperature See OM 912 Series section 2 1 Non compliance can result in serious injuries or death AWARNING At operation below nominal temperature formation of condensate in the oil system might negatively affect oil quality Effectivity 912 Series 79 00 00 Edition 2 Rev 0 page 4 August 01 2012 d04927 fm d04927 fm Low temperatu res BRP Powertrain INSTALLATION MANUAL NOTE When operating at low temperatures installation of an oil thermostat parallel to the oil cooler is highly recommend ed A WARNING Non compliance can result in serious injuries or death If an oil thermostat is being used and the ambient temperature is low there is a possibility that the oil may congeal briefly when in a steep descent Pay ex tra attention to
2. NOTE All dimensions from zero reference points P Sinaad External Hydraulic Vacuum cange alternator governor pump version 3 centre of gravity on x axis 316 100 276 255 mm 12 44 in 3 94 in 10 87 in 10 04 in centre of gravity on y axis 5 0 20 in 139 0 0 mm 5 47 in centre of gravity on z axis 83 3 27 in 6 0 24 in 56 56 mm 2 20 in 2 20 in Moments of inertia See Fig 3 Engine Engine version 2 4 version 3 moment of inertia around 11100 11600 axis x1 x1 kg cm 26 341 Ib ft 27 527 Ib ft moment of inertia around 10900 11390 axis y1 y1 kg cm 25 866 Ib ft 27 029 Ib ft moment of inertia around 17400 18200 axis z1 z1 kg cm 41 291 Ib ft 43 190 Ib ft Effectivity 912 Series Edition 2 Rev 0 72 00 00 page 8 August 01 2012 d04922 fm d04922 fm BRP Powertrain INSTALLATION MANUAL 3 Operating limits Manuals Documentation overview Operating limits Manual Engine speed See Operators Manual 912 Series chap 2 1 Acceleration See Operators Manual 912 Series chap 2 1 Oil pressure See Operators Manual 912 Series chap 2 1 Oil temperature See Operators Manual 912 Series chap 2 1 Coolant temperature See Operators Manual 912 Series chap 2 1 Exhaust gas temperature See chap 78 00 00 section Operating limits Ambient temperature for start up See Operators Manu
3. 5 i A ih 3 A Part Function 15 Mechanical fuel pump 16 Exhaust socket 17 Intake manifold 18 Electronic module 19 Electric starter 20 Ignition housing 21 Engine number 22 Expansion tank 23 Connection for manifold pressure 24 External alternator 00504 Effectivity 912 Series Edition 2 Rev 0 72 00 00 page 5 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 72 00 00 page 6 August 01 2012 d04922 fm d04922 fm BRP Powertrain INSTALLATION MANUAL 2 Technical data General note To maintain clarity only data relevant for engine installation and opera tion will be stated in the Manual NOTE Connecting sizes capacities gear and reduction ratios electric power permissible temperatures etc can be found in the respective section of engine installation or oth er relevant engine type documentation 2 1 Weight General note The engine weight is defined by the following conditions Engine dry from serial production with internal alternator with over load clutch see chapter Description of design Version ROTAX 912 A 912 F 912 UL Version Weight Version 2 and 4 57 1 kg 125 Ib Version 3 59 8 kg 132 Ib ROTAX 912 S 912 ULS Version Weight Version 2 and
4. Coordinates Connection x Axis mm y Axis mm z Axis mm 206 3 mm 8 12 in O 51 5 mm 2 03 in Graphic Attachment flange 47 6 1 87 in 62 2 44 in ul py Z 8 ES ul 76 0 92v 1 62 2 44 in Part Function 1 Connection for Vacuum pump 2 Attachment flange Fig 3 08322 c ti P onnection NOTICE Pay attention to manufacturers specifications Speed reduction NOTE Speed reduction from crankshaft to hydraulic governor is 1 724 or 1 842 i e the vacuum pump runs with 0 58 or 0 54 of engine speed Effectivity 912 Series 2 Edition 2 Rev 0 61 00 00 page 5 August 01 2012 BRP Powertrain INSTALLATION MANUAL Connections Thread size M6 Effective thread length Max 17 mm 9 16 Governor drive Internal spline 20 40 SMS 1834 NA 14x1 27x30x12 Power consumption Max 600 W Graphic Vacuum pump Part Function 1 Vacuum pump Attachment flange Gasket Fig 4 08328 Effectivity 912 Series Edition 2 Rev 0 61 00 00 page 6 August 01 2012 d04921 fm d04921 fm BRP Powertrain INSTALLATION MANUAL 3 Hydraulic governor for constant speed propeller 3 1 Technical data for connections General note See Fig 5 NOTE See therefore also SB 912 052 Installation Use of gover nors for ROTAX engine type 912 and 914 latest issue Drive Dr
5. Airbox See Fig 15 Airbox new version part no 667355 in comparison to the old version Weight See also chap 72 00 00 section Technical data Graphic Airbox part no 667355 Alte Ausf hrung TNr 867756 Neue Ausf hrung TNr 667355 Old Version New Version y Aenderungen _ modification 5 vee gt sil Ge gee A Or ry sy T s E 3 29 mm 1 14 in i 439 3 mm 17 28 in 180 mm 7 09 in K 8 08646 amp Fig 15 08646 S S S D Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 29 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 30 August 01 2012 d04923 fm 04924 fm General note Table of con tents BRP Powertrain INSTALLATION MANUAL Chapter 75 00 00 COOLING SYSTEM The shape size and position of the radiator s depends mainly on the space available in the aircraft When correctly installed in the aircraft the optionally available BRP Pow ertrain radiator has enough cooling capacity to keep within the standard specified operating limits The flow resistance of the radiator coolant is correctly adjusted to the cooling system The tube size must be sufficient The size shape orientation of all cooling components must not compro mise the engine cooling under all operation conditions This section of the Installation Manual contains system description oper ating limits and requi
6. Max 24 mm 95 in Sleeved lines Fuel intake connection 5 Fitting 8 9 16 18 UNF AN 6 Tightening torque 15 Nm 135 in lb Fuel outlet connection 6 Hose nipple 7 3 4 DIN 7642 Hose connection on fuel pump 2 supplied with fire sleeved lines Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 9 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Fuel pump STB 7 5 o Part Function 1 2 Fuel pump 3 5 Fuel intake connection 4 6 Fuel outlet connection 7 Hose nipple 8 Fitting Fig 5 00537 02064 1 4 3 Check valve Specification Opening pressure 0 1 bar 0 15 bar 1 5 psi 2 2 psi Permitted pressure in reverse biasing 2 bar 29 psi Burst pressure 5 bar 72 5 psi Effectivity 912 Series 7 B Edition 2 Rev 0 13 00 00 page 10 August 01 2012 d04923 fm d04923 fm BRP Powertrain INSTALLATION MANUAL 2 Carburetor General note See Fig 6 Non compliance can result in serious injuries or death AWAPNING The carburetor flange assembly has to carry the weight of the carburetor and intake system Ensure that the screw of the clamp is positioned on the under side as supplied and the gap between the clamp pl
7. N i lt A Eg AN 4 v A LOF Ay i FOR ROTAX ENGINE TYPE 912 SERIES A WARNING Before starting with engine installation please read the Installation Manual completely as it contains important safety relevant information These technical data and the information embodied therein are the property of BRP Powertrain GmbH amp Co KG Austria acc BGBI 1984 no 448 and shall not without prior written permission of BRP Powertrain GmbH amp 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 2012 all rights reserved ROTAX is a trade mark of BRP Powertrain GmbH amp Co KG In the following document the short form of BRP Powertrain GmbH amp Co KG BRP Powertrain 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 Approval of translation has been done to best knowledge and judgement in any case the original text in german language is authoritative d04915 fm Foreword Chapter structure BRP Powertrain INSTALLATION MANUAL Chapter INTRO GENERAL NOTE Before starting with the engine installation read this Installation Manual carefully The Manual will provide you with basic information on correct engine installation a requirement for safe engin
8. Part Function 1 Expansion tank 2 Radiator cap 3 Radiator outlet Effectivity 912 Series E Edition 2 Rev 0 195 00 00 page 19 August 01 2012 BRP Powertrain INSTALLATION MANUAL Part Function 4 Water inlet elbow 5 Overflow bottle 6 Purging Fig 9 08319 3 2 1 Overflow bottle General note See Fig 10 The system also needs an overflow bottle in which surplus coolant is col lected and returned to the coolant circuit during the cooling down period NOTICE To ensure proper operation of the cooling system the suction height between overflow bottle and expansion tank must not exceed 250 mm 10 in NOTE For proper operation ensure that the hose to the overflow bottle is as short as possible Overflow bottle Transparent material requirements Temperature resistant from 40 C to 130 C 40 F to 266 F 100 resistant to glycol and suitable for all other antifreeze agents Volume approx 0 51 13 USgal With vent 6 diameter 2 5 mm 0 1 in NOTE See also SB 912 039 Modification of the overflow bottle latest issue NOTE The overflow bottle should be furnished with a label indicat ing function and content Capacity Non compliance can result in serious injuries or death The overflow bottle must never be empty otherwise air will be sucked into the cooling circuit this can have a negative effect on the safe operation of the engine Installation NOT
9. A revision bar outside of the page margin indicates a change to text or graphic Effectivity 912 Series 00 00 00 Edition 2 Rev 0O page 10 August 01 2012 d04918 fm d04918 fm BRP Powertrain INSTALLATION MANUAL 4 1 Safety information Use for intended Non compliance can result in serious injuries or purpose death Only certified technicians iIRMT see also Mainte nance Manual Line and trained on this product are qualified to work on these engines _A WARNING Non compliance can result in serious injuries or death Never fly the aircraft equipped with this engine at lo cations airspeeds altitudes of other circumstances from which a successful no power landing cannot be made after sudden engine stoppage This engine is not suitable for acrobatics inverted flight etc This engine shall not be used on rotorcrafts with an in flight driven rotor e g helicopters It should be clearly understood that the choice selection and use of this particular engine on any aircraft is at the sole discretion and responsibility of the aircraft manufacturer assembler and owner user Due to the varying designs equipment and types of aircraft BRP Powertrain grants no warranty or representation on the suitability of its engine s use on any particular aircraft Further BRP Powertrain grants no warranty or representation of this engine s suitability with any other part component or system which ma
10. 1 Electric starter G on eneral note NOTICE Suitable for short starting periods only Max 80 C 176 F ambient temperature by the elec tric starter housing Activate starter for max 10 sec without interruption followed by a cooling period of 2 minutes 1 1 Power supply wires from starter relay to the electric starter Cross section At least 16 mm 2 48 in Output 0 7 kW 0 9 kW optional Connection See Fig 2 Plus terminal 2 M6 screw connection tightening torque 4 Nm 36 in lb suitable for cable terminals according to DIN 46225 MIL T7928 PIDG or equivalent Graphic Connection Part Function 1 Electric starter 2 Plus terminal Fig 2 00545 Grounding Grounding cable via engine block Effectivity 912 Series Z s Edition 2 Rev 0 80 00 00 page 3 August 01 2012 BRP Powertrain INSTALLATION MANUAL 1 2 Starter relay assy technical data General note Nominal voltage Control voltage Switching current Ambient tempera ture range Weight Connections Grounding See Fig 3 NOTICE Activation of starter relay limited to short duration The duty cycle over an interval of 4 minutes is 25 12 V DC Min 6 V Max 18V Max 75 A 8 permanent Max 300 A 1 sec short duration Ambient temperature range Min 40 C 40 F Max 100 C 212 F See chap 72 00 00 section Technical data Main c
11. Connector option Option 2 and 3 BRP Powertrain INSTALLATION MANUAL See Fig 8 The engine design is for a conventional non aerobat ic tractor or pusher configuration with the oil return port in the optimum position Assuming these points are taken into consideration the engine will be proper ly lubricated in all flight profiles Aircraft that are not conventional e g airships gyrocopters dive brake equipped aircraft etc that require engine load at steep inclination angles may have special lubrication requirements Select the appropriate connection for the oil return line according to the propeller configuration and oil system layout Position 1 for tractor or position Position 2 for pusher configuration Connector option 1 2 and 5 See Fig 8 Option 1 Connection with slip on connection Connection with slip on connection 1 Hose nipple 3 10 DIN 7642 Outside dia 13 5 mm 53 in Slip on length Max 24 mm max 94 in Tightening torque of banjo bolt 4 M16x1 5x28 30 Nm 22 ft lb Option 2 and 3 Connection with adaptor 2 or 5 Connection with adaptor 2 Thread 3 4 16 UNF AN 8 Tightening torque of oil return line 25 Nm 18 5 ft lb Tightening torque of screw connection 2 M16x1 5 25 Nm 18 5 ft lb Connection with screw connection 5 Thread 3 4 16 UNF AN 8 Tightening torquet
12. Fig 12 09163 05448 Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 25 August 01 2012 BRP Powertrain INSTALLATION MANUAL 3 4 Checking the hydraulic valve tappet for correct purging See Fig 13 A WARNING Risk of burns and scalds Hot engine parts General note Instruction Always allow engine to cool down to ambient temper ature before starting work The following check procedure describes the correct method for purging the hydraulic valve tappet The following work procedures must be carried out Step Procedure Remove valve cover on cylinder 1 Turn crankshaft in direction of normal rotation so that cylinder 1 is set to top dead centre ignition both valves are closed Push down the rocker arm on the push rod side with a force F of around 70 N 15 74 Ib force for about 3 seconds You can using a belt tester for example to check approximately how much force is being exerted Re peat on other rocker arms Check the size of the gap between the rocker arm and the valve contact surfaces Max permitted gap 0 5 mm 0 02 in If it is possible to push the hydraulic valve tappet NOTICE further than this limit an additional engine run for about 5 min at 3500 rpm after refitting the valve co vers is required In order to vent the hydraulic valve tappet this process can be repeated another 2 times Repeat on all other cylinders Effect
13. If you should encounter problems in this respect during the test period than the affected components such as the supply line to the fuel pumps have to be cooled 1 4 Connecting dimensions location of joints and directives for instal lation 1 4 1 Fuel manifold Return line See Fig 4 Return line 1 to tank Outside dia 7 mm 28 in Slip on length Max 17 mm 67 in Pressure gauge Pressure gauge connection 2 Outside dia 6 mm 24 in Slip on length Max 17 mm 67 in Fuel pressure Fuel pressure switch connection 3 switch Thread M10 Thread length Max 9 mm 35 in Tightening torque 15 Nm 135 in lb und LOCTITE 221 Banjo bolt NOTICE At loosening or tightening of the banjo bolt 4 tighten ing torque 10 Nm 90 in lb support the fuel manifold appropriately Effectivity 912 Series Edition 2 Rev 0 13 00 00 page 7 August 01 2012 Connection nip ple Coordinates Graphic BRP Powertrain INSTALLATION MANUAL NOTE The connection nipple 5 is furnished with an orifice 6 0 35 mm 0 014 in essential for operation of the fuel system If the pressure gauge connection 2 is not used and a hose nipple 7 installed the banjo bolt assy 4 marked with a colour dot or marked FUEL is furnished with an orifice 8 0 35 mm 0 014 in This is essential for op eration of the fuel system as it prevent a lo
14. BRP Powertrain INSTALLATION MANUAL 4 Safety notice General note Revision Measure Symbols used Although the reading of such information does not eliminate the hazard it promotes the understanding and application of the information contained in for correct use of the engine Always use common workshop safety practice The information and components system descriptions contained in this Manual are correct at the time of publication BRP Powertrain maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on its products previously manufac tured BRP Powertrain reserves the right at any time and without incurring obli gation to remove replace or discontinue any design specification feature or otherwise Specifications are given in the SI metric system with the USA equivalent in parenthesis This Manual uses the following symbols to emphasize particular informa tion This information is important and must be observed Identifies an instruction which if not followed may cause serious injury including the possibility of death AXCAUTION Identifies an instruction which if not followed may cause minor or moderate injury NOTICE Denotes an instruction which if not followed may severely damage the engine or other component NOTE Indicates supplementary information which may be needed to fully complete or understand an instruction
15. NOTE Water is a by product of the combustion of fuel Most of this water will dissipate from the combustion chamber with the exhaust gases A small amount will reach the crankcase and must be dis posed of through the purging line The purging line must be routed in a continuous decline or furnished with a drain bore at its lowest point to drain any condensate The purging line must be protected from any kind of ice formation from condensation e g insulation protection or routing in a hose with hot air flow and furnishing the vent line with a bypass opening 1 before the cowling outlet 2 Effectivity 912 Series 79 00 00 Edition 2 Rev 0 page 9 August 01 2012 Graphic Purging line Fig 4 BRP Powertrain INSTALLATION MANUAL f Part Function Bypass opening Outlet through the cowling 04874 Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 10 August 01 2012 d04927 fm d04927 fm BRP Powertrain INSTALLATION MANUAL 2 Connecting sizes and position of connections General note NOTICE Utilize the full slip on length for all connections Se cure hoses with suitable screw clamps or crimp con nections NOTE The oil line connections are optionally available as UNF threads AN 8 2 1 Oil circuit engine General note See Fig 5 Depending on engine configuration the oil feed line connectors may vary 912 A F S Thread M18 optional UNF threa
16. Nipple optional BRP Powertrain INSTALLATION MANUAL Oil feed line and outlet have UNF thread AN 8 optional Screw connection optional Thread 3 4 16 UNF AN 8 Tightening torque of oil inlet and outlet 25 Nm 18 5 ft Ib The oil tank cover is also marked with the designa NOTICE Hone IN oil return line from crankcase OUT outlet to oil cooler oil pump Purging nipple Purging nipple Outer dia 8 mm 31 in Slip on length Max 15 mm 59 in part no 956580 Bent socket 90 M18x1 5 Outer dia 12 mm 0 47 in Slip on length max 24 mm 0 94 in Tightening torque 25 Nm 18 44 ft lb part no 956610 Nipple with cap nut straight Outer dia 12 mm 0 47 in Slip on length max 24 mm 0 94 in Tightening torque 25 Nm 18 44 ft lb Effectivity 912 Series Edition 2 Rev O 79 00 00 page 16 August 01 2012 d04927 fm d04927 fm BRP Powertrain INSTALLATION MANUAL Graphic Oll tank o 4 08799 3 s Part Function Oil tank Bayonet cap M12x12 hex screw C12x18 gasket ring Oil dipstick M10x1 plug screw A10x14 gasket ring Profile clamp 163 Oil tank cover assy UNF 3 4 16 Oil tank cover assy metric M18x1 5 CO l Nj o Oy By Cy N A o Fig 10 08799 NOTICE If the lines are co
17. d04918 fm d04918 fm BRP Powertrain INSTALLATION MANUAL 3 Abbreviations and terms used in this Manual Abbreviations Abbreviation Description Reference to another section S center of gravity b The drop symbol indicates use of sealing agents adhesives or lubricants only in the Illustrated Parts Catalog C Degrees Celsius Centigrade F Degrees Fahrenheit rpm Revolutions per minute 912A see OM Type designation 912 F see OM Type designation 912S 912 UL see OM Type designation 912 ULS see OM Type designation see OM Type designation A Ampere a c alternating current Ah Ampere hour A C Aircraft A F Across flat dimension 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 CAN Controller Area Network CAN CGSB Canadian General Standards Board CSA Constant Speed Actuator CW Clockwise CCW Counter clockwise DCDI Dual Capacitor Discharge Ignition d c direct current DOT Department of Transport DOA Design Organisation Approval EASA European Aviation Safety Agency iRMT independent ROTAX Maintenance Technician IM I
18. s for ROTAX 912 S ULS at take off power In an installation as depicted with the radiator 1 in a higher position than the standard supplied expansion tank a water accumulator 2 has to be fitted instead of the expansion tank Additionally a suitable expansion tank 3 has to be installed at the highest point of the cooling circuit NOTE Experience has shown that with good airflow a radiator with an area of 500 cm 77 5 in is required for troublefree op eration Radiator Part Function 1 Radiator 2 Water accumulator 3 Expansion tank Fig 11 08320 Effectivity 912 Series 7 5 00 00 Edition 2 Rev 0 page 23 August 01 2012 Flow rate Flow resistance Installation of the radiator BRP Powertrain INSTALLATION MANUAL The flow rate in the coolant circuit is approx 60 l min 15 85 USgal min at 5800 rpm At full throttle an approximate value of around 0 75 m s 28 59 cu ft sec can be assumed for the required cooling air flow The flow resistance of the coolant in the optional ROTAX radiator is cor rectly adjusted for the cooling system If using other radiators check the flow rate and cooling capacity No provision has been made for attachment of the radiator s on the engine rubber mounts are recommended The radiator must be installed without distortion or NOTICE stress and free of vibrations If a GENUINE ROTAX radiator is not being installed ensure suffi
19. tional damping of vibrations Fig 2 08326 Effectivity 912 Series 78 00 00 Edition 2 Rev 0 page 4 August 01 2012 d04926 fm d04926 fm BRP Powertrain INSTALLATION MANUAL 2 Exhaust system requirements General note NOTICE Install heat shields in required areas fuel oil coolant hoses or tubes and or on the electronic components Because of the high temperatures provide suitable protection against accidental contact NOTICE Secure exhaust system by suitable means according to installation requirements Lockwire heat resistant silicone to dampen the exhaust spring etc 2 1 Technical data See Fig 3 Average radius of exhaust manifold at least 40 mm 1 57 in Inner diameter of manifold pipe at least 28 mm 1 10 in Volume of damping element approx 5 1 82 USgal Back pressure at maximum power max 0 2 bar 2 9 psi measured in each case approx 100 mm 3 94 in beyond the end of the exhaust flange 2 2 If a GENUINE ROTAX exhaust is not used General note The four prefitted exhaust sockets with exhaust flange and lock nuts must be used Exhaust sockets material X6CrNiTi 1810 DIN 1 4541 Tightening torque of M8 lock nuts 15 Nm 133 in Ib NOTE The exhaust flange does not touch the cylinder head Graphic Fig 3 08810 Effectivity 912 Series 78 00 00 Edition 2 Rev 0 page 5 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effect
20. 0 INTRO page 2 August 01 2012 d04915 fm d04916 fm BRP Powertrain INSTALLATION MANUAL Chapter LEP LIST OF EFFECTIVE PAGES chapter page date chapter page date Title page 24 00 00 1 08012012 INTRO 1 08012012 WE LEP 1 0801 2012 P SRo 2 0801 2012 S See 3 08012012 C Seeeh ee 4 08012012 S Oe 9 08012012 TOA 1 08012012 10 0801 2012 2 0801 2012 11 0801 2012 3 08012012 12 0801 2012 4 08012012 13 0801 2012 14 08012012 S TORUN els 16 0801 2012 Si ee ele 17 0801 2012 O80 a01 18 0801 2012 2 Ce Oheote 19 08012012 SEOTI 20 0801 2012 7 0801 2012 8 0801 2012 61 00 00 1 08012012 9 0801 2012 2 08012012 10 08012012 3 08012012 11 0801 2012 4 0801 2012 12 08012012 5 0801 2012 13 0801 2012 6 08012012 14 0801 2012 7 08012012 15 0801 2012 8 08012012 16 08012012 72 00 00 1 08012012 10 10 00 1 08012012 2 08012012 2 08012012 3 08012012 3 08012012 4 08012012 4 08012012 5 08012012 5 08012012 6 08012012 6 08012012 7 08012012 7 08012012 8 08012012 8 08012012 9 08012012 9 08012012 10 0801 2012 10 08012012 11 0801 2012 12 08012012 13 0801 2012 14 0801 2012 Effectivity 912 Series Edition 2 Rev O LEP page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL chapter page date chapter page date 73 00 00 1 08 01 2012 75 00 00 17
21. 01 2012 27 08 01 2012 28 08 01 2012 29 08 01 2012 30 08 01 2012 31 08 01 2012 32 08 01 2012 80 00 00 1 08 01 2012 2 08 01 2012 3 08 01 2012 4 08 01 2012 5 08 01 2012 6 08 01 2012 Rear page Effectivity 912 Series Edition 2 Rev 0 LEP page 3 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 LEP page 4 August 01 2012 d04916 fm d04917 fm BRP Powertrain INSTALLATION MANUAL Chapter TOA TABLE OF AMENDMENTS Approval The technical content of this document is approved under the authority of DOA ref EASA 21J 048 date of remark for date of approval date of ue Snaprar page change approval from authorities inclusion Signatura 0 INTRO all 08 01 2012 DOA 0 LEP all 08 01 2012 DOA 0 TOA all 08 01 2012 DOA 0 00 00 00 all 08 01 2012 DOA 0 10 10 00 all 08 01 2012 DOA 0 24 00 00 all 08 01 2012 DOA 0 61 00 00 all 08 01 2012 DOA 0 72 00 00 all 08 01 2012 DOA 0 73 00 00 all 08 01 2012 DOA 0 75 00 00 all 08 01 2012 DOA 0 76 00 00 all 08 01 2012 DOA 0 78 00 00 all 08 01 2012 DOA 0 79 00 00 all 08 01 2012 DOA 0 80 00 00 all 08 01 2012 DOA Effectivity 912 Series Edition 2 Rev O TOA page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 TOA page 2
22. 08 01 2012 2 08 01 2012 18 08 01 2012 3 08 01 2012 19 08 01 2012 4 08 01 2012 20 08 01 2012 5 08 01 2012 21 08 01 2012 6 08 01 2012 22 08 01 2012 7 08 01 2012 23 08 01 2012 8 08 01 2012 24 08 01 2012 9 08 01 2012 25 08 01 2012 10 08 01 2012 26 08 01 2012 11 08 01 2012 27 08 01 2012 12 08 01 2012 28 08 01 2012 13 08 01 2012 15 08 01 2012 2 08 01 2012 16 08 01 2012 3 08 01 2012 17 08 01 2012 4 08 01 2012 18 08 01 2012 5 08 01 2012 19 08 01 2012 6 08 01 2012 20 08 01 2012 7 08 01 2012 21 08 01 2012 8 08 01 2012 22 08 01 2012 9 08 01 2012 33 OS Orao 10 08 01 2012 A ARTALIE 78 00 00 1 08012012 25 08 01 2012 5 Ie O20 26 08 01 2012 5 AE 27 08 01 2012 A anes 2012 28 08 01 2012 5 EOE 29 08 01 2012 A e0 30 08 01 2012 EE 75 00 00 1 08 01 2012 8 08 01 2012 4 0o Or2012 11 08 01 2012 osdi adi 12 08 01 2012 So 9001 2012 79 00 00 1 08012012 Ti eee cote 2 0801 2012 Si a PROAI 3 08012012 30 08101 2012 4 08012012 11 08 01 2012 3 08 02042 12 08 01 2012 08 01 2012 14 08 01 2012 5 pa 012012 15 08 01 2012 10 08 01 2012 16 08 01 2012 11 08 01 2012 Effectivity 912 Series Edition 2 Rev 0 LE P page 2 August 01 2012 d04916 fm d04916 fm BRP Powertrain INSTALLATION MANUAL chapter page date 79 00 00 12 08 01 2012 13 08 01 2012 14 08 01 2012 15 08 01 2012 16 08 01 2012 17 08 01 2012 18 08 01 2012 19 08 01 2012 20 08 01 2012 21 08 01 2012 22 08 01 2012 23 08 01 2012 24 08 01 2012 25 08 01 2012 26 08
23. Obey the manufacturers instructions Table of contents This section of the Installation Manual describes the engine management of the aircraft engines Subject Page Connections for instrumentation Page 3 Sensor for cylinder head temperature Page 3 Sensor for oil temperature Page 4 Oil pressure sensor Page 6 Mechanical rev counter tach drive Page 8 Monitoring of the intake manifold pressure Page 9 Air temperature in the airbox optional Page 10 Effectivity 912 Series 76 00 00 Edition 2 Rev 0 page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 76 00 00 page 2 August 01 2012 d04925 fm d04925 fm BRP Powertrain INSTALLATION MANUAL 1 Connections for instrumentation General note NOTICE These connections to be established in accordance to certification and or national specifications The certification for connections and connection lines have to be conducted by the aircraft manufacturer to the latest requirements like FAR and EASA For notes regarding the electric rev counter consult the chap Electric system 1 1 Sensor for cylinder head temperature General note See Fig 1 NOTE A direct reading of the coolant temperature is not provided for Technical data The temperature sensor 1 is directly fitted into cylinder head i e a direct temperature reading of the cylinder
24. TO Temperature Oel on oil pump flange To avoid any mix up with indication wiring mark this HSIN particular cable also with TO Position Position of the temperature sensor 1 on the oil pump flange Axes Point of support x axis y axis z axis 115 0 mm 4 53 in 46 0 mm 1 81 in 150 0 mm 5 92 in d04925 fm Effectivity 912 Series 76 00 00 Edition 2 Rev 0 page 4 August 01 2012 d04925 fm Technical data Graph resistance Graphic BRP Powertrain INSTALLATION MANUAL Anschl sse f r Oltemperaturgeber Location Oil pump housing Connection of sensor wiring Spade terminal 6 3x0 8 DIN 46247 Grounding Via engine block Graph of sensor resistance over temperature See Fig 2 NOTICE The graph resistance over temperature has been de termined and is effective at the following conditions only Ambient temperature 20 C 68 F Tolerance Max 10 Sensor for oil temperature 1 Q 1200 N ME NS O O 1000 SEA EA a eerste E a Seems l Aa e A O Y O 600 ZN AE sete Y be pe hl kA ee T ec eee Uw 400 sesefesss olXe jones a ko 200 a 20 40 60 80 100 120 140 160 Fa C 3 Part Function Sensor for oil temperature 2 TO marking Graph resistance over temperature Fig 2 00227 00327 Effectivity 912 Series Edition 2 Rev 0 76 00 00
25. Using conventional coolant Coolant temperature coolant exit temperature Max 120 C 248 F Cylinder head temperature 912 A F UL Max 150 C 300 F 912 S ULS Max 135 C 275 F Permanent monitoring of coolant temperature and cylinder head tem perature is necessary Using waterless coolant Cylinder head temperature 912 A F UL Max 150 C 300 F 912 S ULS Max 135 C 275 F Permanent monitoring of cylinder head temperature is necessary Additional monitoring of the actual coolant temperature is possible but not necessary for waterless coolant Effectivity 912 Series Edition 2 Rev 0 75 00 00 page 5 August 01 2012 Coolant temper ature and cylin der head temperature BRP Powertrain INSTALLATION MANUAL Correlation between coolant temperature and cylinder head tempera ture There is in principle a regular relationship between coolant temperature and cylinder head temperature The coolant transfers some of the com bustion heat to the radiator Thus the coolant temperature is usually lower than the cylinder head temperature But the temperature difference between coolant and cylinder head is not constant and can vary with dif ferent engine installation cowling or free installation tractor or pusher flight speed etc NOTE The basic requirement for safe operation is that boiling of conventional coolant must be prevented
26. engine start and operation review all instruc tions stated in the Operators Manual 3 1 Conduct test run Instruction See Operators Manual 912 chapter 3 3 2 Verification of the throttle lever detent for max continuous power Instruction Performance check in accordance with Operators Manual If nominal performance won t be reached or is in excess of examination of the installation and engine will be necessary Don t conduct any test flights before fault has been WSS traced and found Effectivity 912 Series 10 10 00 Edition 2 Rev 0 page 14 August 01 2012 d04919 fm d04920 fm BRP Powertrain INSTALLATION MANUAL Chapter 24 00 00 ELECTRIC SYSTEM Intro The engine is supplied with the wiring completed and ready to operate Only the following connections to the aircraft have to be established integrated generator external rectifier regulator electronic modules electric starter start relay items conditional for operation like circuit breakers ON OFF switches control lamps relays instrumentation and capacitors Optional extras external alternator as option if the output of the integrated generator is inadequate electric rev counter accessory cosumer battery Table of contents This section contains information about electronic modules electric starter and wiring diagram of the engine Subject Page Requirements for the circuit wiring
27. in the carburetor chambers may lead to engine malfunction due to incorrect fuel supply Effectivity 912 Series Edition 2 Rev 0O 73 00 00 page 24 August 01 2012 d04923 fm d04923 fm 3 2 5 Technical data See Fig 12 NOTICE NOTICE General note Connecting nip ple Manifold pres sure Temperature sen sor Connecting nip ple BRP Powertrain INSTALLATION MANUAL Utilize the complete slip on length Secure hoses by suitable screw clamps or by crimp connection If the engine has been installed without employment of the optional ROTAX engine frame which includes also support of the airbox than provide an appropriately support 6 for the airbox Connecting nipple 2 of drainage line Outside dia 6 mm 1 4 Slip on length Max 17 mm 11 16 Provide connection to take readings of manifold pressure 3 Provide connections for temperature sensor 4 Outside dia 6 mm 24 in Slip on length Max 17 mm 67 in Connecting nipple 5 of float chamber venting lines Outside dia 6 mm 1 4 Slip on length Max 17 mm 11 16 Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 25 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Air intake system NOTE Make sure that the air intake tubes of the airbox for fresh air and preheated air are connected corre
28. not connected the throttle valve will remain fully open The starting position of the throttle valve is there fore full throttle Therefore never start the engine without connecting the throttle lever first Non compliance can result in serious injuries or death AWAPNING The cable actuations being used must not be affected at all by vibrations emanating from the engine or the airframe Bowden cable The two throttles have to be controlled by two separate Bowden cables working synchronously Adjust the cables to a free travel of 1 mm 04 in Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 17 August 01 2012 Graphic Cable actuation Fig 10 BRP Powertrain INSTALLATION MANUAL aes n SS fan K A d OEN PON Q DLN ge ia pe i mAP O R K A OW Part Function 1 Lever flap 2 Return spring 3 Cable sleeves 4 Adjustment screws 08338 08354 Adjust Bowden cable such that throttle and choke can be fully opened and closed Use Bowden cable with minimized friction so that the spring on the throttle can open the throttle completely Otherwise increase pretension of spring by bending lever flap 1 or fit a stronger return spring 2 ora cable with pull push action would have to be used Secure the bowden cable sleeves 3 in the adjustment screws 4 e g safety wire 2 4 Requirements on the thr
29. of oil return line 25 Nm 18 5 ft lb Tightening torque of banjo bolt 4 M16x1 5x28 30 Nm 22 ft lb Effectivity 912 Series Edition 2 Rev O 19 00 00 page 13 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Connection Or pos 2 pos 1 Druckpropeller Zugpropeller pusher config config AQ 5 ay 4 82 Part Function Slip on connection Adaptor 3 4 16 UNF AN 8 Hose nipple 10 DIN 7642 Banjo bolt M16x1 5x28 oly A j N Screw connection Fig 8 08634 Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 14 August 01 2012 d04927 fm d04927 fm 2 2 Connection Graphic BRP Powertrain INSTALLATION MANUAL Oil tank See Fig 9 and Fig 10 NOTICE Only use the oil tank provided in the scope of delivery as its design has changed compared with older tanks NOTE Optional extra Nipple either straight or with 90 elbow Metric M18x1 5 or UNF 3 4 16 thread Check what type of thread or connection there is on ES the supplied oil tank Connections for oil circuit engine se joa Part Function 1 Oil feed line 2 Oil outlet Purging nipple Fig 9 08246 Effectivity 912 Series 79 00 00 Edition 2 Rev O page 15 August 01 2012 UNF thread Purging nipple Bent socket 90 optional
30. page 5 August 01 2012 BRP Powertrain INSTALLATION MANUAL 1 3 Oil pressure sensor General note Technical data Output signal Wiring connec tion See Fig 3 NOTICE Certification to the latest requirements such as FAR of NOTICE EASA has to be conducted by the aircraft manufactur er As the instruments need a separate power supply and a different design for the electrical oil pressure sensor the resistance type instrument type VDO which was supplied by BRP Powertrain up to now is not suitable anymore Suitable instruments are offered by various instrument manu facturers e g ROAD or Aviasport Oil pressure sensor Location Oil pump housing Wire gauge Standard wire 0 5 mm AWG 20 Cable length 3m 118 in Operating temperature range Min 40 C 40 F Max 125 C 257 F Grounding Via engine block airframe ground Tightening torque 15 Nm 98 in Ib and LOCTITE 243 In contrary to the oil pressure sensor offered up to now which was pro viding the signal on the basis of a sensor resistance variation the new oil pressure sensor 1 operates on basis of a current variation This has to be taken into account for the selection of the appropriate cockpit instru ment Wiring connection for instrument NOTE The sensor cable can be modified in its length according to the installation situation e g shortened or extended For extension an appropriate com
31. performance needs air temperature as low as possible at air intake Therefore the air filter should be located in a recess of the engine cowling or separated from warm air by baffles such that fresh air can be aspirated Max length of ducting 500 mm 20 in Inside dia Min inside dia at least outside dia of the intake socket on airbox Min mean bending radius 100 mm 4 Airfilter BRP Powertrain offers an air filter as described below A WARNING Non compliance can result in serious injuries or death Use only filter elements which will not tend to restrict the flow when in contact with water NOTICE The certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer A minimum flow rate of 220 m h 260 yd h has to be NOTICE warranted for all conditions The pressure loss must not exceed 2 hPa The following points should assist the aircraft manufacturer at the choice of a suitable filter four fold cotton fabric surface covered with metal screen total filter area at least 1400 cm 217 in amin flow rate of 6 23 m min 220 yd h 3 2 4 Airbox General note Volume at least 2 5 Liter 66 US gal Outline dimension see Fig 12 Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 23 August 01 2012 Requirements BRP Powertrain INSTALLATION MANUAL The airbox is furnished with 2 drain holes 2
32. permissible loads and bending moments on the points of attach ment are not exceeded The exhaust system may re quire additional support Table of contents This section of the Installation Manual contains information on the exhaust system of the aircraft engines Subject Page General notes on the exhaust system Page 3 Exhaust system requirements Page 5 Technical data Page 5 Attaching of the exhaust system Page 7 Operating limits Page 9 Data for optional components of exhaust system Page 10 Effectivity 912 Series Z Edition 2 Rev 0 18 00 00 page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL Overview Exhaust system Part Function Muffler Tension spring Exhaust tube A O N EGT temperature sensor Fig 1 06303 Effectivity 912 Series Edition 2 Rev 0 78 00 00 page 2 August 01 2012 d04926 fm d04926 fm BRP Powertrain INSTALLATION MANUAL 1 General notes on the exhaust system Certification An exhaust system especially designed for universal application has been developed by BRP Powertrain Certification according to the latest regulations such as FAR or EASA must be conducted by the aircraft or fuselage manufacturer NOTICE Vibrations due to improper installation and mainte nance is the most common reason for damage of the exhaust system 1 1 The following recommendations should help the airc
33. propeller in tractor or pusher arrangement must be fitted on the pro peller flange in accordance with applicable regulations As required utilize one of the three possible pitch circle diameters P C D on the flange The propeller design must be certified in accordance with applicable reg ulations such as FAR or EASA by the aircraft manufacturer 1 1 Technical data Direction of rota tion Graphic Transmission Vibration analy sis See Fig 1 Direction of rotation of the propeller flange left counter clockwise looking towards face of flange Direction of rotation Fig 1 08629 Gear transmission j 2 2727 50 Teeth 22 T i 2 4286 51 Teeth 21 T NOTE Vibration analysis of the whole system engine suspen sion propeller etc should be carried out as part of the certification process If no limits are available in the technical literature a max of 1 0 IPS inches per second at 5000 rpm can be as sumed Effectivity 912 Series 61 00 00 Edition 2 Rev 0 page 3 August 01 2012 Propeller shaft flange Graphic BRP Powertrain INSTALLATION MANUAL See Fig 2 Attachment of propeller on prop shaft flange Pitch circle diameter 75 mm 2 95 in 6x through holes 8 mm 0 31 in Pitch circle diameter 80 mm 3 15 in 6x
34. protected by fuses Using in correctly rated fuses may result in destruction of the equipment Under no circumstances must consumer cables e g battery be routed alongside the ignition cable There is a risk of electromagnetic interference or damage NOTICE Do not bend kink pinch or otherwise improperly stress the wiring harness Use proper routing clamping and strain relief on wiring harnesses Effectivity 912 Series 24 00 00 Edition 2 Rev 0 page 3 August 01 2012 BRP Powertrain INSTALLATION MANUAL 1 1 Electromagnetic compatibility EMC EMI Electromagnet ic interference Emission Electromagnet ic compatibility Electromagnetic interference EMI and lightning The engine complies with EMI and lightning requirements as per DO 160C sections 18 20 22 as detailed in the following paragraphs Emission Conductive radio interference Narrowband and broadband emissions meet RTCA DO160C Section 21 2 Cat B AZ requirements except in the frequency range of 150 kHz 2 MHz where emissions are up to 20 dB higher than allowable limits Radiated radio interference Narrowband and broadband emissions meet RTCA DO160C Section 22 item 21 6 and 21 7 Cat B requirements except in the frequency range of 190 kHz 2 MHz where emissions are up to 35 dB higher than allowable limits NOTE Consult the aircraft manufacturer if further interpretation is needed The exceeded limits do not affect the operation
35. respective installation Volume of oil tank Up to the MIN mark 2 5 0 66 US gal Up to the MAX mark 3 0 I 0 8 US gal Perform oil level check and add oil if necessary Effectivity 912 Series F _ Edition 2 Rev 0 19 00 00 page 22 August 01 2012 d04927 fm d04927 fm BRP Powertrain INSTALLATION MANUAL 3 3 Purging the lubrication system Safety See Fig 12 AWARNING Risk of burns and scalds Hot engine parts Always allow engine to cool down to ambient temper ature before starting work Introduction Ensure that oil lines are connected correctly and secured and that the oil cooler if fitted is in the suction line 1 between the oil tank and the oil pump Verify that the oil tank is filled up to the maximum level to the top of the flat portion of the dipstick Additional oil up to 0 5 litre 0 13 USgal may be added to the tank for the purpose of this procedure Instruction The following work procedures must be carried out NOTICE Incorrectly connected oil lines to the oil tank or to the engine will result in severe engine damage Step Procedure 1 Disconnect oil return line 2 from the oil tank 2 Place the free end 3 of the return line into a suitable container 4 below the engine 3 Plug open connection 5 on oil tank with suitable air tight cap 4 Remove the spark plug connectors 5 For easier rotation of engine remove one spark plug from each cylin
36. single cylinder Measuring point is the same as the EGT measurement See chap 78 00 00 section Exhaust system 3 2 Requirements on the air intake system meee ASWARINING NOTICE NOTICE Non compliance can result in serious injuries or death Carb icing is acommon reason for engine trouble No implements are included in the supply volume for preheating of the intake air If an airbox of not ROTAX origin is used provisions for preheating the intake air have to be made to prevent formation of ice in the intake system Preheating of the intake air will result in performance loss because of the lower air density The certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer All items of the air intake have to be secured against loss 3 2 1 Air intake socket for fresh air or pre heated intake side General note See Fig 12 NOTICE Utilize the full slip on length on all connection Secure hoses by suitable spring type clamp or screw clamp Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 22 August 01 2012 d04923 fm fm d04923 Air intake socket 3 2 2 Technical data 3 2 3 General note Choice of a suit able filter BRP Powertrain INSTALLATION MANUAL Air intake socket 1 Outside dia 60 mm 2 3 8 Slip on length Max 25 mm 1 Requirements on the intake air ducting High engine
37. suitable crimping pliers 4 to fit the fasten connector B 4 The rubber grommet is held by the secondary crimp 5 Push the faston connector in the corresponding slot 4 of the connector recep tacle until it is locked in place C 6 Check for tight fit 7 Press the pin holder white downwards using the long nose pliers NOTE Faston connector and insulation sheath of the old version are available as spare part See also SI 912 013 latest is sue NOTE The pin holder must not be pressed with excessive force Effectivity 912 Series Edition 2 Rev 0 24 00 00 page 11 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Assembly of the flat pin terminal Part Function Cable grommet Flat pin terminal Wiring airframe Crimping pliers Oo A j N Position in the connector housing Fig 6 08323 Effectivity 912 Series Edition 2 Rev 0 24 00 00 page 12 August 01 2012 d04920 fm d04920 fm BRP Powertrain INSTALLATION MANUAL 2 5 External alternator optional extra General note See Fig 7 2 5 1 Technical data General note NOTE The voltage regulator is integrated in the alternator Output Output Max 600 W DC at 6000 r p m Output Voltage Output Voltage 14 2 V 14 8 V Ambient temper Ambient temperature Min 30 C 22 F aure range Max 90 C 194 F Weight See chap 72 00 00 section Technical d
38. the engine AWARNING Non compliance can result in serious injuries or death The vacuum 3 pressure gauge with liquid damping must be verified over the complete engine operation range If the oil is cold the flow resistance increases which means that not enough oil will flow on the suc tion side Effectivity 912 Series 79 00 00 Edition 2 Rev 0 page 7 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Measuring of the vacuum max 100 mm i or 4 inch ao Function Part Suction oil line 2 Oil pump 3 Pressure gauge Fig 3 08324 Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 8 August 01 2012 d04927 fm d04927 fm BRP Powertrain INSTALLATION MANUAL 1 5 Oil and purging line requirements Oil lines Oil circuit engine main oil pump Temperature durability min 140 C 284 F Pressure durability min 10 bar 73 psi Bending radius min 70 mm 2 76 in unless otherwise stated by the hose manufacturer Minimum inner dia of oil lines in relation to total length up to 1 m 39 37 in inner diameter minimum 11 mm 0 43 in up to 2 m 78 74 in inner diameter minimum 12 mm 0 47 in up to 3 m 118 11 in inner diameter minimum 13 mm 0 51 in Length of individual oil line max 3 m 9 84 ft Purging line Purging line of oil tank See Fig 4 Route the line without kinks and avoid sharp bends
39. the oil pressure and oil temperature during these abnormal conditions If necessary re vert to a cruising or climb situation Advantages safe oil pressure after cold start prevention of fuel and water accumulation in the oil See SL 912 011 Use of an oil thermostat latest issue 1 3 Checking the oil circuit General note Measurement of crankcase pres sure NOTE The required pressure gauges and connection parts are not included in the BRP Powertrain delivery To check the oil circuit for correct function the following readings have to be taken with the engine running See Fig 2 Measurement of the mean crankcase pressure at full throttle this ensures correct oil return from crankcase blow by gas Do not remove the magnetic plug for prolonged peri OS ods nor during flight operations A pressure sensor 1 pressure gauge with liquid damping can be fitted instead of the magnetic plug 2 or the crankshaft locking screw 3 The magnetic plug 2 or the crankshaft locking screw 3 is removed and the pressure sensor 1 is fitted Effectivity 912 Series 79 00 00 Edition 2 Rev O page 5 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Measurement of crankcase pressure 3 2 Part Function Pressure indicator 2 Magnetic plug 3 Crankshaft locking screw Fig 2 09161 Magnetic plug NOTE The thread for the magnetic pl
40. through holes 11 5 mm 0 45 in Pitch circle diameter 101 6 mm 4 6x through holes 13 mm 0 51 in Hub diameter 47 mm 1 85 in Propeller shaft flange Fig 2 02581 09193 1 2 Operating limits Torque Max moment of inertia Extension of propeller shaft Out of balance NOTICE Modification of the propeller shaft is not permitted Max torque ROTAX 912A F UL for i 2 2727 238 Nm 176 ft lb at propeller ROTAX 912A F UL for i 2 4286 255 Nm 188 ft lb at propeller ROTAX 912 S ULS for i 2 4286 315 Nm 232 ft lb at propeller Max permissible moment of inertia on propeller 6000 kg cm 14 238 Ib ft Normal between 1500 kg cm and 6000 kg cm 3 559 Ib ft and 14 238 Ib ft2 Max extension of the propeller shaft 120 mm 4 72 in Dynamic balancing of the proppeller as specified by the propeller manu facturer must be carried out Effectivity 912 Series 61 00 00 Edition 2 Rev O page 4 August 01 2012 d04921 fm d04921 fm BRP Powertrain INSTALLATION MANUAL 2 Vacuum pump 2 1 Technical data General note See Fig 3 NOTICE Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufactur er Drive Drive via propeller gear Location of the necessary connection 1 on the crankcase
41. 2 d04918 fm d04918 fm Reference Illustrations Installation draw ings BRP Powertrain INSTALLATION MANUAL This Manual for engine installation is only part of the Technical Documentation and will be supplemented by the respective Operators Manual Maintenance Manu al and Illustrated Parts Catalog Pay attention to references to other documentation found in various parts of this Manual Any reference to a document refers to the latest edition issued by BRP Powertrain if no stated othrwise The illustrations in this Manual are mere sketches and show a typical arrangement They may not represent in full detail or the exact shape of the parts which have the same or similar function Therefore deduction of dimensions or other details from illustrations is not permitted NOTE The Illustrations in this Manual are stored in graphic data base system and are provided with a consecutive irrele vant number This number e g 00277 is of no signifi cance for the content Installation drawings and a DMU model for virtual installation analysis are available from the ROTAX Authorized Distributors or their Service Centers Effectivity 912 Series 00 00 00 Edition 2 Rev 0 page 15 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Installation drawing Fig 2 09171 09170 Effectivity 912 Series Edition 2 Rev 0 00 00 00 page 16 August 01 2012 d04918
42. 4 58 3 kg 128 Ib Version 3 61 0 kg 134 Ib Accessories Overview Accessories Weight External alternator assy 3 0 kg 6 6 Ib Overload clutch 1 7 kg 8 7 Ib Vacuum pump assy 0 8 kg 1 76 Ib Hydraulic governor assy incl drive approx 2 2 4 8 Ib to 2 7 kg 6 Ib depending on type HD starter additional 0 43 kg 1 Ib Rectifier regulator 0 3 kg 0 66 Ib Starter relais 0 145 kg 0 32 Ib Radiator 1 0 kg 2 2 Ib Air guide hood 0 36 kg 0 79 Ib Airbox 1 3 kg 2 8 Ib 2 air filter 0 3 kg 0 66 Ib Oil radiator 0 55 kg 1 21 Ib Effectivity 912 Series Edition 2 Rev 0 12 00 00 page 7 August 01 2012 2 2 Standard en gine version 2 3 BRP Powertrain INSTALLATION MANUAL Accessories Weight Exhaust system approx 4 0 kg 8 8 Ib Engine mount 2 0 kg 4 4 Ib Installation dimensions See Fig 3 NOTE All dimensions from zero reference points P Standard engine version Pos Neg Total max dimension along x axis mm 8 5 0 33 in 581 22 87 in 589 5 23 21 in max dimension along y axis mm 288 11 34 in 288 11 34 in 576 22 68 in max dimension along z axis mm 118 4 65 in 276 10 87 in 394 15 51 in Centre of gravity See Fig 3 2 4 Moments of in ertia Centre of gravity of engine and standard accessories
43. 5x12 Tightening torque 4 Nm 3 32 Ib ft suitable for 1 5 mm 06 in steel wire Action travel 65 mm 2 56 in Actuating force Min 1 5 N 3 Ib Max 8 N 1 8 Ib Limit load 20 N 4 5 Ib force NOTE Throttle opens by spring Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 15 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Coordinates P1 and Reference point P2 Part Function Connection for air filter or intake silencer Connection for throttle actuation Fig 8 08339 Starting carb See Fig 9 Connection for starting carb choke actuation 1 Connection on choke lever Clamping nippel 6 suitable for 1 5 mm 06 in steel wire Action travel 23 mm 15 16 Actuating force Min 10 N 2 2 Ib Max 45 N 10 Ib Limit load 100 N 22 Ib Directive for choke actuation The choke shaft 1 is marked 2 This mark has to point towards cable engagement 3 Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 16 August 01 2012 d04923 fm d04923 fm BRP Powertrain INSTALLATION MANUAL Graphic Choke actuation Part Function 1 Choke shaft 2 Marking 3 Cable engagement Fig 9 00541 2 3 Requirements on cable actuation General note See Fig 10 Non compliance can result in serious injuries or death AWARNING With throttle lever
44. August 01 2012 d04917 fm d04917 fm BRP Powertrain INSTALLATION MANUAL Chapter TOA SUMMARY OF AMENDMENTS Content Summary of the relevant amendments in this context but without require ment on completeness Current date of No chapter page change Comment 0 all all 08 01 2012 New Layout 0 24 00 00 6 08 01 2012 Graphic change modify legend 0 61 00 00 4 08 01 2012 chap 1 2 Wording of max moment of inertia 0 73 00 00 6 08 01 2012 chap 1 3 Requirements of the fuel system 0 73 00 00 14 08 01 2012 chap 2 1 2 Drainage piping to the carburetor 0 73 00 00 22 08 01 2012 CO Measurement for configuration with not GENUINE ROTAX airbox 0 75 00 00 24 08 01 2012 chap 4 1 Note added 0 78 00 00 3 08 01 2012 chap 1 Caution added 0 78 00 00 11 08 01 2012 chap 4 1 Muffler graphic change Effectivity 912 Series TO A Edition 2 Rev 0 page 3 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 TOA page 4 August 01 2012 d04917 fm d04918 fm Introduction Table of contents BRP Powertrain INSTALLATION MANUAL Chapter 00 00 00 GENERAL NOTE This section describes the installation of engine type ROTAX 912 Series NOTE The ROTAX 912 Series includes all engines such as the 912 A 912 F 912 S 912 UL and 912 ULS This chapter of the Installation Manual contains general and safety infor mation concerning the opera
45. BRP Powertrain These lines must not be routed into the slipstream or any other location that is subject to ram air or vacuum during flight or ground operations Pressure differences between intake pressure in the carburetor float chamber may lead to engine malfunc tion due to incorrect fuel supply Effectivity 912 Series 73 00 00 Edition 2 Rev O page 14 August 01 2012 d04923 fm d04923 fm BRP Powertrain INSTALLATION MANUAL 2 2 Connections for Bowden cable actuation and permissible load General note See Fig 8 The specified permissible loads must never be HALE exceeded 2 2 1 Technical data Coordinates P1 Centre position of carburetor socket P1 of the respective carburetor Coordinates P1 mm Carburetor for x axis y axis z axis Cylinder 1 3 521 mm 180 mm 25 mm 20 52 in 7 1 in 0 988 in Cylinder 2 4 553 mm 180 mm 25 mm 21 772 in 7 1 in 0 988 in Reference point Limit load on point of reference P2 Pa Reference point P2 Max allowable forces limit load in N 60 N 44 ft lb in x y and z axis Max allowable bending moments limit 4 Nm 3 32 Ib ft load in Nm in x y and z axis Connection Connection 1 for air filter or intake silencer Outside dia 50 mm 2 in Slip on length 12 mm 47 in Connection 2 for throttle actuation Connection on throttle lever Set screw M
46. Below the carburetors one each drip tray 2 with a draining connection 3 is fitted which serves as a heat shield as well Graphic Drip tray and draining connection Part Function 1 Float chamber venting lines 2 Drip tray 3 Draining connection Fig 7 08644 Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 12 August 01 2012 fm d04923 d04923 fm BRP Powertrain INSTALLATION MANUAL 2 1 1 Drainage piping on airbox and drip trays General note See Fig 7 Non compliance can result in serious injuries or death WARNING Connect drainage lines well otherwise emerging fuel from a possible leakage could drip onto the exhaust system RISK OF FIRE Drainage piping Requirements on the drainage piping NOTICE With closed or blocked leakage piping fuel could end NOTICE up on exhaust system RISK OF FIRE The lines have to be routed such that in case of damage the surplus fuel is drained off suitably Route the lines without kinks and avoid tight bends Route the lines with a continuous decline The lines have to be protected against any kind of blockage e g by for mation of ice Float chamber Float chamber venting lines 1 venting lines NOTICE The float chamber venting lines 1 have to be routed into a ram air and vacuum free zone or into the airbox according to the requirements and release of BRP Powertrain See chapter air intake system These lines m
47. ICE The overflow bottle and its supply and discharge must not be installed close to the exhaust system as emerg ing coolant can be flammable under certain conditions Effectivity 912 Series 75 00 00 Edition 2 Rev 0 page 20 August 01 2012 04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL 3 3 ROTAX overflow bottle optional extra If the optional ROTAX overflow bottle is used the purging system must be arranged as shown below General note Work instruction NOTE To vent coolant steam from the overflow bottle in case of overheating the plastic cap can be retrofitted with a hose nipple and hose The purging line 5 must be routed so that coolant cannot come in contact with the hot exhaust system The vent line must be routed in a continuous decline or furnished with a drain bore at its lowest point to drain any condensation The line must be protected from any kind of ice formation from condensation e g insulation protection or routing in a hose with hot air flow and furnishing the line with a bypass opening before the cowling outlet See Fig 10 Procedure for attaching the hose nipple Step Procedure 1 Unscrew the plug screw 2 from the overflow bottle 2 Bore the existing purging hole from dia 2 5 mm 0 10 in to dia 6 mm 0 236 in 3 Apply LOCTITE 603 to the threads of the hose nipple 3 4 Insert hose nipple 3 with the thread first into the
48. Instruction The design of the fuel system is the responsibility of EE the aircraft manufacturer The fuel system must be designed to ensure that the engine is supplied with sufficient fuel at the correct pressure in every operational situation Operating limits must be adhered to Table of contents This section of the Installation Manual contains information on the aircraft engine fuel system Subject Page Fuel system Page 3 Description of system Page 3 Operating limits Page 5 Fuel pressure Page 5 Electrical fuel pump Page 6 Requirements of the fuel system Page 6 Connecting dimensions location of joints and directives for in Page 7 stallation Fuel manifold Page 7 Fuel pump Page 9 Check valve Page 10 Carburetor Page 11 Requirements on the carburetor Page 11 Drainage piping on airbox and drip trays Page 13 Drainage piping on carburetor Page 14 Connections for Bowden cable actuation and permissible load Page 15 Technical data Page 15 Requirements on cable actuation Page 17 Requirements on the throttle lever Page 18 Air intake system Page 21 Operating limits Page 21 Requirements on the air intake system Page 22 Air intake socket for fresh air or pre heated air Page 22 Requirements on the intake air ducting Page 23 Airfilter Page 23 Airbox Page 23 Technical data Page 25 Data for optional components of air intake system Page 27 Effectivity 912 Series Edition 2 Rev 0 13 00 00 page 1 Au
49. ON MANUAL Part Function Expansion tank Pressure cap Radiator A l po a Overflow bottle 09152 Effectivity 912 Series Edition 2 Rev 0 75 00 00 page 4 August 01 2012 d04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL 1 2 Operating Limits AWARNING Non compliance can result in serious injuries or death The cooling system must be designed so that operat ing temperatures will not exceed the maximum values General note Optional radia tor Boiling point of the coolant Coolant temper ature When correctly installed in the aircraft the optionally available BRP Pow ertrain radiator has enough cooling capacity to keep within the standard specified operating limits The flow resistance of the radiator coolant is correctly adjusted to the cooling system The tube size must be sufficient Monitoring the cooling system is important for controlling engine cooling and prevent knocking combustion within the operating limits It is important that the coolant circuit is designed so that the coolant does not reach boil ing point under any conditions If the temperature exceeds the boiling point the engine can quickly overheat due to loss of coolant The boiling point of the coolant is mainly influenced by the type of coolant mixture ratio percentage water rate the system pressure opening pressure of radiator cap
50. Page 3 Electromagnetic compatibility EMC EMI Page 4 Technical data and connection of the electric components Page 5 Integrated generator Page 5 Rectifier regulator Page 6 Requirements for flawless operation of the rectifier regu Page 7 lator Electronic modules Page 8 Ignition switches MAG switch Page 9 Connection Page 9 Assembly of the flat pin terminal Page 11 External alternator optional extra Page 13 Technical data Page 13 Connection Page 13 Requirements for correct operation of the integrated rec Page 14 tifier regulator Connection of the electric rev counter tachometer Page 16 Technical data Page 16 Connection Page 17 Effectivity 912 Series Edition 2 Rev 0 24 00 00 page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL Subject Page Battery Page 17 Capacitor Option electrical fuel pump Page 17 Easy start function on the electronic module optional Page 17 Wiring diagram Page 18 Effectivity 912 Series Edition 2 Rev O 24 00 00 page 2 August 01 2012 d04920 fm d04920 fm BRP Powertrain INSTALLATION MANUAL 1 Requirements for the circuit wiring General note NOTICE The connections have to be made by the aircraft man ufacturer in accordance with applicable regulations and the enclosed wiring diagram See chap 24 00 00 section Switch requirements NOTICE The power supply to the various consumers e g bat tery must be adequately
51. RICATION SYSTEM General note See Fig 1 The ROTAX 912 Series is fitted with a dry sump forced lubrication system with a main oil pump with integrated pressure regulator and oil pressure sensor Table of contents This section of the Installation Manual describes the system operating limits and requirements for the lubrication system Subject Page Lubrication system oil system Page 3 System description Page 3 Operating limits Page 4 Checking the oil circuit Page 5 Measuring of the vacuum Page 7 Oil and purging line requirements Page 9 Connecting sizes and position of connections Page 11 Oil circuit Page 11 Oil tank Page 15 Permissible position and location of the oil tank Page 18 General notes on the oil cooler Page 21 Permissible position and location of the oil Page 21 cooler Capacity Page 22 Purging the lubrication system Page 23 Checking the hydraulic valve tappet for correct Page 26 purging Replacement of components Page 27 Data for optional components of lubrication system Page 29 Oil cooler Page 29 Variants of connectors Page 29 Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 2 August 01 2012 d04927 fm d04927 fm BRP Powertrain INSTALLATION MANUAL 1 Lubrication system oil system 1 1 System description Drive Purging C
52. Series Edition 2 Rev 0 78 00 00 page 8 August 01 2012 d04926 fm d04926 fm BRP Powertrain INSTALLATION MANUAL 4 Operating limits Safety notes See Fig 4 AWAPNING Non compliance can result in serious injuries or death The exhaust system must be designed and built such that the permissible operating temperatures are main tained and the max exhaust gas temperatures are not exceeded The performance specifications relate to ISA 15 C 59 F conditions and are only achieved if the engine is equipped with an unmodified GENUINE ROTAX exhaust system and airbox NOTICE Readings of EGT The exhaust gas temperatures EGT have to measured at the initial engine installation in an aircraft and must be verified in the course of test flights Readings of EGT taken approx 100 mm 3 93 in from exhaust flange connections Graphic Readings of EGT 100 mm 3 94 in Fig 4 07131 Effectivity 912 Series 78 00 00 Edition 2 Rev 0 page 9 August 01 2012 BRP Powertrain INSTALLATION MANUAL Values Exhaust gas temperature EGT both ignition circuits active Nominal exhaust gas temperature 800 C 1470 F max 850 C 1560 F At take off max 880 C 1616 F 4 1 Data for optional components of exh
53. The boiling point of conventional coolant is 120 C 248 F with a 50 50 mix ture proportion and a system pressure of 1 2 bar 18 psi Effectivity 912 Series 75 00 00 Edition 2 Rev 0 page 6 August 01 2012 d04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL 1 3 Coolant types General note Conventional coolant Waterless cool ant Mixing ratio Boiling point In principle 2 different types of coolant are permitted Description 1 Conventional coolant based on ethylene glycol 2 Waterless coolant based on propylene glycol When selecting a suitable coolant the information in Service Instruction SI 912 016 latest issue must be observed Conventional coolant is recommended as it commonly available and has a greater thermal heat transfer capability Its limitation is its lower boiling point Waterless coolant is recommended if the design of the aircraft can not maintain the coolant temperature limit The manufacturers instructions regarding the coolant HES must be observed Mixing ratio Description Concentrate Water Conventional coolant 50 50 Some conventional coolant is available pre mixed by the manufacturer In this case do not mix with water instead follow the manufacturers instructions Waterless coolant 100 0 Conventional coolant Conventional coolant with a rate of 50 water cannot boil at a tempe
54. a 27 mm 1 1 16 Slip on length Max 19 mm 3 4 NOTE See therefore also SI 912 020 Running modifications la test issue Effectivity 912 Series 75 00 00 Edition 2 Rev 0 page 16 August 01 2012 04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL Graphic Connecting dimension 200 10 mm Fig 7 ww 0L Zet Part Function Expansion tank Radiator cap gt O N Connection to the radiator Connection to the overflow bottle 07136 Effectivity 912 Series Edition 2 Rev 0 75 00 00 page 17 August 01 2012 BRP Powertrain INSTALLATION MANUAL Connecting dimension 1107 i 70 Nios 752 j A AN O y aa WY T PIP OQO 28 G WPIP Part Function 5 Water inlet elbow Fig 8 08788 05536 Water inlet el NOTICE Utilize total slip on length for the water inlet elbow and bow expansion tank Secu
55. al 912 Series chap 2 1 Ambient temperature for electronic See chap 24 00 00 section Electronic module module Fuel pressure See Operators Manual 912 Series chap 2 1 Governor See Operators Manual 912 Series chap 2 1 External alternator See Operators Manual 912 Series chap 2 1 Deviation from the apparent per See Operators Manual 912 Series chap 2 1 pendicular 3 1 Deviation from the apparent perpendicular General note See Fig 5 The engine design is for a conventional non aerobatic tractor or pusher configuration with the oil return port in the optimum position Assuming these points are taken into consideration the engine will be properly lubricated in all flight profiles Bank angle The resulting bank angle B depending on acceleration deceleration may never exceed the max bank angle NOTE Pitch or role angle a is not equal with B except stabilized condition without acceleration Effectivity 912 Series Z Edition 2 Rev 0 12 00 00 page 9 August 01 2012 Graphic Bank angle Fig 5 BRP Powertrain INSTALLATION MANUAL a Bank or rotation F1 Gravity B Bank angle F2 Acceleration Fr Result of F1 and F2 07191 08325 Effectivity 912 Series Edition 2 Rev 0 72 00 00 page 10 August 01 2012 d04922 fm d04923 fm BRP Powertrain INSTALLATION MANUAL Chapter 73 00 00 FUEL SYSTEM
56. at the lowest position possi ble The holes are necessary to drain fuel from flooding float chambers caused by badly closing float valve Drainage lines Non compliance can result in serious injuries or death Connect draining lines without fail otherwise emerg ing fuel could drip onto the exhaust system RISK OF FIRE Observe the following requirements NOTICE With closed or blocked drainage bores fuel could flow into combustion chamber possibly ruining the engine by hydraulic lock or emerging fuel could drip onto the exhaust system RISK OF FIRE Step Procedure The lines have to be routed such that in case of damage the surplus fuel is drained away suitably 2 Route the lines without kinks and avoid narrow bends 3 Route the lines with a continuous decline 4 The lines have to be protected against any kind of blockage e g by formation of ice NOTICE NOTICE The drainage lines 2 have to be routed into a ram air and vacuum free or into the airbox according to the requirements and release of BRP Powertrain See also chap Carburetor These lines must not be routed into the slipstream If the drainage lines of the airbox are connected with the drainge lines of the drip trays or the carburetors by a T piece these lines must not be routed down the firewall drainage lines of the airbox separately are allowed Pressure differences between intake pressure and pressure
57. ata 2 5 2 Connection Power supply Power supply wires to external alternator 1 located on the outside of pro wires peller gear Positive terminal Positive terminal 2 M6 screw connection suitable for cable terminal acording to DIN 46225 tightening torque 4 Nm 35 in lb Grounding Via engine block Control wiring Control wiring field circuit 3 Via supplied standard plug Sumitomo 6111 2568 and 6 3 x 0 8 Fasten connectors Effectivity 912 Series 24 00 00 Edition 2 Rev 0 page 13 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic External alternator Teil Funktion 1 External alternator 2 Positive terminal 3 Control wiring Fig 7 03199 02764 00547 2 6 Requirements for correct operation of the integrated rectifier regu lator Fuse The rectifier regulator must be protected by a slow blowing fuse or circuit breaker Fuse or circuit breaker rating must be determined by load wire size and length Cross section Wire size of the main circuit at least 4 mm 0 006 in Capacitor A capacitor of at least 22000 uF 25 V is necessary to flatten voltage Effectivity 912 Series 24 00 00 Edition 2 Rev 0 page 14 August 01 2012 d04920 fm d04920 fm BRP Powertrain INSTALLATION MANUAL Amperage T NOTICE The current over speed graph was determined and is only effective under the following cond
58. ates is 8 mm 31 in The carburetors on the standard engine are already attached by a flexible flange and connecting hoses on the airbox Only connections of the Bowden cable for preheating choke and throttle have to be established It is recommended to make the adjustment of the Bowden cable after engine installation has been completed to ensure exact final adjustment Graphic Carburetor socket Fig 6 05794 2 1 Requirements on the carburetor General note See Fig 7 Non compliance can result in serious injuries or death AWARNING In the area of the float chamber the temperature limit of the fuel must not be exceeded If necessary install additional insulation or heat shields Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 11 August 01 2012 BRP Powertrain INSTALLATION MANUAL The float chamber venting lines 1 lines have to be routed into a ram air and vacuum free zone or into the airbox according to the requirements and release of BRP Powertrain See chapter air intake system These lines must not be routed into the slipstream or down the firewall NOTICE Pressure differences between intake pressure and pressure in the carburetor chambers may lead to engine malfuction due to incorrect fuel supply Drip tray The carburetors are positioned above the exhaust sockets
59. aust system Weight See also chap 72 00 00 Graphic Exhaust elbow Material thickness X 15 CrNiSi20 12 DIN 1 4828 stainless steel a 1 5 mm 0 06 in Fig 5 09164 Effectivity 912 Series 78 00 00 Edition 2 Rev 0 page 10 August 01 2012 d04926 fm d04926 fm BRP Powertrain INSTALLATION MANUAL Graphic Muffler assy A 397 5 15 65 in 4 373 5 14 71 in 331 13 04 in i 37 5 1 48 in 52 75 2 077 in Material thickness X 6CrNiTi 189 DIN 1 4541 stainless steel a 1 mm 0 04 in Fig 6 09159 Graphic Exhaust elbox tailpipe 40 1 57 in Material thickness X 5CrNi 189 DIN 1 4301 stainless steel a 1mm 0 04 in Fig 7 09153 Effectivity 912 Series Edition 2 Rev 0 78 00 00 page 11 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Ball joint male 232 1 26 in 30 1 19 in Material thickness X 15CrNiSi 20 12 DIN 1 4828 stainless steel a 1 mm 0 04 in Fig 8 09166 Graphic Exhaust tube 230 1 18 in 800 31 49 in Material starke X 15CrNiSi 20 12 DIN 1 4828 stainless steel a 1 mm 0 04 in Fig 9 09167 Effectivity 912 Series 78 00 00 Edition 2 Rev 0 page 12 August 01 2012 d04926 fm d04927 fm BRP Powertrain INSTALLATION MANUAL Kapitel 79 00 00 LUB
60. c Easy start function bl blau blue br braun brown bl bl sw ge gelb yellow gn griin green sw schwarz black ws weil3 white or orange orange viol violett violet Fig 10 08556 2 11 Wiring diagram General note See Fig 11 Scope of deliv Items components which are not included in the stan ery dard engine scope of delivery must be certified the air craft or fuselage manufacturer in accordance with the latest regulation such as FAR or EASA Position Supply 1 9 Are included in the standard volume of supply of the engine 22 24 Are included in the standard volume of supply of the engine 10 14 Are available as accessory 15 22 Can t be supplied by BRP Powertrain 25 Can t be supplied by BRP Powertrain Effectivity 912 Series Edition 2 Rev 0 24 00 00 page 18 August 01 2012 d04920 fm d04920 fm BRP Powertrain INSTALLATION MANUAL Graphic Wiring diagram f jaiisuo J YNLIQIIA Effectivity 912 Series s Edition 2 Rev 0 24 00 00 page 19 August 01 2012 BRP Powertrain INSTALLATION MANUAL Legend to wiring diagram Fig 11 Part Function Part Function 1 2 Electronic modules A 17 Starter switch and B 2 3 Plug connection for igni 18 Control lamp tion switch 4 Integrated generator 19 Battery relay 5 6 External regulator recti 20 Battery fier with plug connec tions 7 Electric s
61. can result in serious injuries or death A soft walled hose is not suitable as it can collapse and cause cooling system failure The hose from the expansion tank to the overflow bottle must be rated for vacuum suction for min 125 C 257 F e g it must be strong enough to withstand high temperatures and vacuum suction during the cooling down period The aircraft manufacturer must give the possibility to the pilots to check the coolant level in the expansion tank Also it is necessary to inform the pilots about the daily inspection of the coolant level in the aircraft manufac turers operators pilots manual or an adequate link to the ROTAX 912 Series Operators Manual It is recommended that adequate measures are taken for carrying out these inspections e g a flap or panel on the cowling or a warning instru ment in the cockpit for low coolant level 3 1 Connecting size and position of connections General note See Fig 7 and Fig 8 NOTICE The hoses must be fixed with appropriate clips to pre vent loss e g with spring type hose clips such as those used for the coolant hoses between the water pump and cylinder Clips of this type have performed well in the field Expansion tank 1 with radiator cap 2 to radiator 3 Outside dia 25 mm 1 Slip on length Max 22 mm 7 8 to overflow bottle 4 Outside dia 8 mm 3 8 Slip on length Max 15 mm 9 16 water inlet elbow 5 Outside di
62. cient cooling capacity 4 1 Coolant capacity 4 cylinder heads cccscccceeesssseeeeeeeeeees 560 cm 0 02 cu ft Coolant DUMP cstasccticstssssassnansnrtaeceanaananectons 100 cm 0 004 cu ft Expansion tank sss cscsccdcedancascniiernienadeonsanssd 250 cm 0 008 cu ft Overflow bottle yi andinnminaiinninnas approx 0 5 0 13 USgal 2 m coolant hose inner 18 mm 500 cm 0 018 cu ft Total coolant quantity for engine approx 1 5 0 4 USgal Effectivity 912 Series 75 00 00 Edition 2 Rev O page 24 August 01 2012 d04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL 4 2 Cooling air ducts optional General note Cooling air ducts are not required if the oil and coolant temperatures are within the prescribed operating limits Otherwise following measurement must be performed for the first installation of an aircraft type not in serial production Hot day condi See Fig 12 p In contrast to the cylinder heads the cylinders are ram air cooled Plan the cooling air ducts according to installation requirement AWARNING Non compliance can result in serious injuries or death The cooling air ducts must be designed and built such that the operating temperatures are within the speci fied limits and maximum values ar
63. ctly Fig shows the GENUINE ROTAX airbox Part Function Air intake socket Connecting nipple of drainage line Connection for manifold pressure Connection for temperature sensor Connection for float chamber venting lines Oo Oo A j N Rubber puffer Fig 12 08645 02051 Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 26 August 01 2012 d04923 fm d04923 fm BRP Powertrain INSTALLATION MANUAL 3 3 Data for optional components of air intake system Air filter See Fig 13 Weight See chap 72 00 00 section Technical data Graphic Air filter Fig 13 09149 Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 27 August 01 2012 Airbox Graphic See Fig 14 Airbox configuration part no 867756 Weight BRP Powertrain INSTALLATION MANUAL See also chap 72 00 00 section Technical data Airbox part no 867756 217 8 54 in 106 4 18 in D 42 5 4 18 in lt Suet 322 5 12 7 in 456 17 96 in 180 7 09 in 252 2 05 in 360 14 18 in 260 2 37 in 410 16 14 in Fig 1 09174 Effectivity 912 Series Edition 2 Rev 0O 73 00 00 page 28 August 01 2012 d04923 fm BRP Powertrain INSTALLATION MANUAL
64. d AN 8 912 UL ULS Inlet nipple optional M18 or UNF thread AN 8 Oil pump inlet Connection variant 1 Oil pump inlet Thread M18x1 5x11 Tightening torque of inlet line 25 Nm 18 5 ft lb NOTE Suitable for use of a swivel joint Graphic Oil pump inlet Part Function 1 Oil pump inlet Fig 5 09123 Effectivity 912 Series 79 00 00 Edition 2 Rev 0 page 11 August 01 2012 BRP Powertrain INSTALLATION MANUAL Oil pump inlet Connection variant 2 nipple Oil pump inlet Inlet nipple 2 outside dia 13 2 mm 0 52 in Slip on length Max 21 mm 0 83 in Graphic Oil pump inlet nipple oe l 2 2 Part Function 2 Inlet nipple Fig 6 08633 Oil pump inlet Connection variant 3 Oil pump inlet Thread 3 3 4 16 UNF AN 8 Tightening torque of inlet line 25 Nm 18 5 ft lb Graphic Oil pump inlet Se eee iid Part Function Oil pump inlet Fig 7 08633 d04927 fm Effectivity 912 Series F B Edition 2 Rev 0 19 00 00 page 12 August 01 2012 d04927 fm Oil return
65. d with accessories supplied recom mended and released by BRP Powertrain Modifications are only allowed after consent by the engine manufacturer NOTICE Spare parts must meet with the requirements defined NOTICE by the engine manufacturer This is only warranted by use of GENUINE ROTAX spare parts and or acces sories see IPC or suitable equivalent in the manu facturer s opinion otherwise any limited warranty by BRP Powertrain is null and void see Warranty Condi tions Spare parts are available at the authorized ROTAX Distributor and their Service Center Any warranty by BRP Powertrain becomes null and void if spare parts and or accessories other than GENUINE ROTAX spare parts and or accessories are used see latest Warranty Conditions NOTICE In principle use only tools and appliances which are NOTICE either cited in the Manual or in the Illustrated Parts Catalog Engine and gearbox are delivered in dry conditions _A WARNING without oil Before putting engine in operation it must be filled with oil Use only oil as specified consult Op erators Manual and SI 912 016 Selection of suitable operating fluids current issue Effectivity 912 Series 00 00 00 Edition 2 Rev O page 13 August 01 2012 4 3 General note BRP Powertrain INSTALLATION MANUAL Technical documentation These documents form the instructions ensuring continued airworthiness of ROTAX aircraft engi
66. der Prevent any foreign objects entering through spark NOTICE plug hole 6 Using a compressed air line pressurise the oil tank through its purging connection 6 on the neck of the tank Adjust the compressor outlet reg ulator so that the air line pressure is between 0 4 bar 5 8 psi and 1 bar 14 5 psi Do not exceed 1 bar 14 5 psi AWAPRNING Non compliance can result in serious injuries or death Do not remove the oil tank cover before ensuring that air pressure has been completely released from the tank Effectivity 912 Series Z Edition 2 Rev 0 19 00 00 page 23 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTE The oil tank cover is not pressure tight some air can es cape The pressure in the oil tank has to be maintained during the following steps NOTICE The oil tank may empty and as a result introduce air into the oil system Pay attention to the oil level and fill tank as required Do not use the starter for this purpose Fit propeller HALES and use it to turn the engine 7 Turn the engine by hand in direction of normal rotation until the first pres sure indication appears on the oil pressure gauge Normally this will take approx 20 turns Depending on installation it may take up to 60 turns 8 Stop the pressurisation 9 Open the cap 5 for the oil return line on the oil tank and reconnect the en gine oil return line 2 to the tank NOTICE Ensure
67. dule marked B for ignition circuit B NOTE Ignition circuit A controls top spark plugs of cylinder 1 and 2 lower spark plugs of cylinder 3 and 4 NOTE Ignition circuit B controls top spark plugs of cylinder 3 and 4 lower spark plugs of cylinder 1 and 2 Wire Part Function 1 Wire for ignition circuit A 2 Wire for ignition circuit B Fig 5 07602 One each flexible wire 0 75 mm 18 AMG brown Length approx 35 mm 1 3 8 beginning at electronic module with one each plug socket and insulating sleeve 3 96 mm At the new version the cable grommet and fasten connector are integrated in the 6 pole connec tor housing See also SI 912 013 latest issue Effectivity 912 Series 24 00 00 Edition 2 Rev 0 page 10 August 01 2012 d04920 fm d04920 fm BRP Powertrain INSTALLATION MANUAL 2 4 2 Assembly of the flat pin terminal General note See Fig 6 NOTE One each cable grommet 1 and flat pin terminal 2 are supplied loosely packed Special tools The following special tools and equipment are necessary for fitting the Faston connector Part number Description n a MOLEX Crimping pliers 64016 0035 n a MOLEX Disassembly total 63813 1500 Procedure Assembly of the flat pin terminal Step Procedure 1 Strip cable 3 as required 2 Install the cable grommet 1 in correct position and direction A 3 Use
68. e filter Fine filter water trap Fuel shut off valve Electrical fuel pump Manometer Return line from tank to engine with integrated adapter sleeve as well as the required fuel lines and connections Effectivity 912 Series Edition 2 Rev 0 13 00 00 page 3 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Fuel system return line to tank carburetor ae tank b 9 2 P _ restrictor jet 7 fuel pressure C C O en gauge mechanical fuel e pum 5 4 O Pa carburetor 8 Part Function 1 Fuel tank 2 Coarse filter 3 Fire cock 4 Fine filter water trap 5 Mechanical fuel pump 6 Fuel pressure control 7 Electrical fuel pump 8 1x check valve 9 Return line from tank to engine with integrat ed adapter sleeve Standard version Fig 2 07306 Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 4 August 01 2012 d04923 fm d04923 fm BRP Powertrain INSTALLATION MANUAL 1 2 Operating limits General note NOTICE The design and layout of the entire fuel system must ensure engine operation within the specified operat ing limits See 912 Series Operators Manual section 2 1 Operating Limits 1 2 1 Fuel pressure General note See Fig 3 AWARNING Non compliance can result in serious injuries or death Fuel pressure in excess of stated limit can lead to an override of the fl
69. e not exceeded This must also apply to Hot day condition Max permitted cylinder wall temperature on hottest cylinder 200 C 392 F NOTE If this temperature is exceeded appropriate measures e g cooling air ducts modifications to cowling etc must be taken to bring it within limits again NOTE As long as the oil and coolant temperatures are within the operating limits no cooling air ducts are necessary Graphic Cooling air duct dine x r N A j YANNI o iNO o ZE O L ff sul lt Yo U f R P pai A i 5 SSahvaube fasten M5 Fig 12 02050 Effectivity 912 Series 7 5 00 00 Edition 2 Rev O page 25 August 01 2012 BRP Powertrain INSTALLATION MANUAL 4 3 General notes on the cooling air ducts Non compliance can result in serious injuries or death AWARNING Certification according to the latest regulations such as FAR or EASA must be conducted by the aircraft or fuselage manufacturer For front installation in a closed fuselage ducting of cooling air to the cylin ders is recommended This removes the need for costly horizontal parti Front installa tion Selecting cool ing air ducts tioning baffles NOTE It also means that the engine remains completely on the warm side of the engine compartment and is very easy to access In special cases a separate cold air supply to the air filters must be provided BRP Powertrain has developed a non certified coolin
70. e operation If any passages of this Manual are not clearly understood or if you have any questions please contact an authorized distributor or Service Center for ROTAX aircraft engines BRP Powertrain GmbH amp Co KG hereinafter BRP Powertrain wishes you much pleasure and satisfaction flying your aircraft powered by this ROTAX aircraft engine The structure of the Manual follows whenever it is possible the structure of the ATA Air Transport Association standards The aim is the compat ibility with the aircraft manufacturer s documentation which means they must then adapt the documentation to their standard The Installation Manual is subdivided into the following chapters Subject Chapter Introduction Chapter INTRO List of effective pages Chapter LEP Table of amendments Chapter TOA General note Chapter 00 00 00 Storage and Installation Chapter 10 10 00 Electric system Chapter 24 00 00 Propeller drive Chapter 61 00 00 Engine Chapter 72 00 00 Fuel system Chapter 73 00 00 Cooling system Chapter 75 00 00 Engine management Chapter 76 00 00 Exhaust system Chapter 78 00 00 Lubrication system Chapter 79 00 00 Electric starter Chapter 80 00 00 Effectivity 912 Series Edition 2 Rev O INTRO page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev
71. e views cylinder designation Page 3 Side view Page 3 Front view Page 4 Top view Page 5 Technical data Page 7 Weight Page 7 Installation dimensions Page 8 Centre of gravity of engine and standard accesso Page 8 ries Moments of inertia Page 8 Operating limits Page 9 Deviation from the apparent perpendicular Page 9 Effectivity 912 Series Z Edition 2 Rev 0 12 00 00 page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL Overview Engine Part Function Airbox 2 Carburetor 3 Mechanical fuel pump Fig 1 09170 Effectivity 912 Series Edition 2 Rev 0 72 00 00 page 2 August 01 2012 d04922 fm d04922 fm BRP Powertrain INSTALLATION MANUAL 1 Engine components engine views cylinder designation General note See Fig 2 PTO power take off side MS magneto side A points of attachment for engine transport centre of gravity P zero reference point for all dimensions NOTE Allow 1 mm on all stated dimensions as manufacturing tolerance X y Z axes for system of coordinates Cyl 1 Cylinder 1 Cyl 3 Cylinder 3 Cyl 2 Cylinder 2 Cyl 4 Cylinder 4 Side view 4 Z 2 3 1 A ha TI aco X al mi a iL a
72. ements Safety Coolant hoses Graphic Non compliance can result in serious injuries or death AWARNING The cooling system must be designed so that the op erating limits are not exceeded To minimize flow resistance use radiators that have both a parallel flow and have a low flow resistance A prime example would be the GENUINE ROTAX radia tors Be sure to use short hoses and pipelines All components of the cooling system must be suitably pees secured See Fig 6 Hoses exposed to direct heat radiation from the ex haust system must be suitably protected with heat re sistant protection tubes for example NOTE Aluminium tubes with an inner diameter of 25 mm 0 98 in can be used instead of longer hoses These must have a bulge 1 in order to prevent coolant hoses working loose Note as well that this will double the number of hose clips required Temperature resistance min 125 C 257 F Pressure durability min 5 bar 72 psi Inner diameter 25 mm 1 Bending radius min 175 mm 6 89 in except moulded hoses Material 100 resistant to glycol antifreeze and ozone Drawing aluminium tube POI E Cy Fig 6 09158 Effectivity 912 Series 7 5 00 00 Edition 2 Rev O page 15 August 01 2012 BRP Powertrain INSTALLATION MANUAL Hose connect Hose from expansion tank to overflow bottle ing expansion 7 Bar g tank A WARNING Non compliance
73. er as the manufacturer makes modifications to the engine for product improvement The engine serial number 1 is on the ignition cover on the left opposite the electric starter See Fig 1 cyl 1 cyl 3 cyl 2 cyl 4 Fig 1 08749 Effectivity 912 Series 00 00 00 Edition 2 Rev O page 3 August 01 2012 2 Type description e g ROTAX 912 version 2 BRP Powertrain INSTALLATION MANUAL The type description is made up the following ROTAX _ Oa DT DT S38 SS s zo QS 8 SS BS ot 8D Ng 25 Designation Designation Description Type 912 4 cyl horizontally opposed normal aspirated engine Certification A Certified to JAR 22 TC No EASA E 121 F S Certified to FAR 33 TC No E00051 EN JAR E TC No EASA E 121 UL ULS Non certified aircraft engines Configuration 2 Prop shaft with flange for fixed prop 3 Prop shaft with flange for constant speed propeller and drive for hydraulic governor for constant speed propeller 4 With prop flange for fix pitch propeller but prepared for retro fit of hydraulic governor for constant speed prop not supplied by manufacturer anymore Options Available options optional equipment for the engine type mentioned above External Vacuum Drive for rev counter Governor alternator pump hour meter for configuration 2 yes yes yes no for configura
74. ertrain Fig 11 mii 7 NVA Part Function Oil tank Oil level Oil tank cover Oil drain screw oy By j N Oil cooler 09162 Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 19 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 20 August 01 2012 d04927 fm d04927 fm BRP Powertrain INSTALLATION MANUAL 3 General notes on oil cooler General note An oil cooler is available for this engine from BRP Powertrain see Illus trated Parts Catalog AWARNING Non compliance can result in serious injuries or death Certification according to the latest regulations such as FAR or EASA must be conducted by the aircraft or fuselage manufacturer NOTICE The oil cooler must be designed to dissipate approx NOTICE 10 kW 7 58 BTU s of the
75. ertrain INSTALLATION MANUAL Conversion table Units of length 1mm 0 03937 in Tin 25 4mm 1ft 12in 0 3048 m Units of power 1 kW 1 341 hp 1hp 0 7457 kw 1 kW 1 3596 PS 1PS 0 7355 kw Units of area 1cm 0 155 sq in in 1 sq in in 6 4516 cm Units of temperature K C 273 15 C F 32 1 8 F C x 1 8 32 Units of volume 1cm 0 06102 cu in in 1 cuin in3 16 3871 cm in3 1dm 11 1 dm 0 21997 gal UK 1 gal UK 4 5461 dm 1 dm 0 26417 gal US 1 gal US 3 7854 dm Units of velocity 1 m s 3 6 km h 1 ft min 0 3048 m min 0 00508 m sec 1 m s 196 85 ft min 1 kt 1 852 km h 1 km h 0 53996 kn Units of mass 1kg 2 2046 Ib 1 Ib 0 45359 kg spec fuel consumption 1 g kWh 0 001644 Ib hph 1 Ib hph 608 277 g kWh Density 1 g cm 0 016018 lb ft 1 lb ft 62 43 g cm Units of torque 1Nm 0 737 ft lb 8 848 in lb 1 ftlb 1 356 Nm 1inlb 0 113 Nm Units of force 1N 0 224809 Ibf 1 lbf 4 4482 N Units of pressure 1 Pa 1N m 1 bar 100000 Pa 1000 hPa 100 kPa 1 bar 14 5037 Ibf in psi 1 inHg 33 8638 hPa Cable cross section Conversion table Wire Gauge AWG mm2 AWG 4 6 8 10 12 14 16 18 20 mm2 21 13 8 4 5 3 3 3 2 1 1 3 0 8 0 52 Effectivity 912 Series Edition 2 Rev 0 00 00 00 page 9 August 01 2012
76. ertrain INSTALLATION MANUAL 2 7 2 Connection General note Feeding wiring Connections NOTICE BRP Powertrain developed especially for this applica tion a non certified electric rev counter Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer See also SI 13 1996 latest issue Feeding wiring to electric rev counter on left side of ignition housing Length approx 600 mm 24 in starting from ignition housing 2 flexible cables 0 5 mm white yellow and blue yellow in insulation wrap 2 8 Battery General note See Fig 11 To warrant reliable engine start use a battery of at least SSS 16 Ah capacity 2 9 Capacitor Option electrical fuel pump General note See Fig 11 NOTICE To warrant reliable operation of the electrical fuel pump the use of capacitor of at least 22 000 uF 25 V is necessary 2 10 Easy start function on the electronic module optional General note See Fig 10 In order to use the easy start function the relevant connections to the starter relays and ignition switch need to be made The start function can be used for aircraft which have an engine start problem in cold conditions NOTE In addition also a modified fly wheel hub is offered which aids improved starting Effectivity 912 Series 24 00 00 Edition 2 Rev O page 17 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphi
77. essary to monitoring constantly cylinder head temperature and coolant exit temperature NOTE For detection of possible indication error an additional mo nitoring of the cylinder head temperature is necessary which shows an exceeding in case of coolant loss Flight test The aircraft manufacturer has the option of converting the coolant temper ature and the cylinder head temperature to an aircraft specific cylinder head temperature This is possible by calculating the difference between the head material and the coolant temperature This is done by following the flight test procedure on page page 14 Once the calculation is made and the indicating instrument re labelled it is acceptable to use the cylinder head temperature as the primary cockpit display instead of installing a sensor in the coolant flow Effectivity 912 Series E Edition 2 Rev 0 15 OO 00 page 13 August 01 2012 BRP Powertrain INSTALLATION MANUAL The measurement is based on the maximum coolant temperature and cyl inder head temperature according to the current requirement NOTICE Inno case a cylinder head temperature higher than the limit of 150 C 300 F for ROTAX 912 A F UL and 135 C 275 F for ROTAX 912 S ULS can be de fined because detonation could not be sufficiently pre vented Refer to the flight test example that follows c Cooling capacity of the installation too low Flight testexam Calculated values maximum va
78. et ring 14 2 18 2 Nipple 13 2 9 5 M18x1 5 M14x1 5 screw socket Bent socket assy M14x1 5 angular tube Hose nipple with cap nut OO NI aj A O P 3 4 16 UNF M14x1 5 screw socket 08900 Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 32 August 01 2012 d04927 fm d04928 fm BRP Powertrain INSTALLATION MANUAL Chapter 80 00 00 ELECTRIC STARTER General note A WARNING Non compliance can result in serious injuries or death When working on the electric starter assy there is a risk of short circuit and electrical fault All installation work on the electric starter assy must be carried out with engine switched off and the battery negative terminal disconnected Ignition main switches must be set to OFF Table of contents This section of the Installation Manual contains the electric starter of the aircraft engine Subject Page Electric starter Page 3 Power supply wires from starter relay to the Page 3 electric starter Starter relay assy technical data Page 4 Effectivity 912 Series Z Edition 2 Rev 0 80 00 00 page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL Overview Electric starter Part Function 1 Electric starter Fig 1 05900 Effectivity 912 Series 80 00 00 Edition 2 Rev 0 page 2 August 01 2012 d04928 fm d04928 fm BRP Powertrain INSTALLATION MANUAL
79. fm d04919 fm Introduction Table of contents BRP Powertrain INSTALLATION MANUAL Chapter 10 10 00 STORAGE AND INSTALLATION NOTICE The stated directives are measures that must be ob served during every engine installation to prevent any accidents and engine damage This section of the Installation Manual contains state of delivery trans port storage and aircraft engine installation Subject Page Preparations for engine installation Page 3 State of delivery Page 3 Unpacking handling of the engine Page 3 Preservation and storage of the engine Page 4 Protective coverings Page 5 Engine suspension and installation position Page 6 Engine suspension instructions Page 6 Attachment points Page 8 Definition of attachment points Page 9 Permissible installation positions Page 12 Preparations for trial run of engine Page 14 Conduct test run Page 14 Verification of the throttle lever detent for max Page 14 continuous power Effectivity 912 Series Edition 2 Rev 0 10 10 00 page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 10 10 00 page 2 August 01 2012 d04919 fm d04919 fm BRP Powertrain INSTALLATION MANUAL 1 Preparations for engine installation 1 1 State of delivery Attachment NOTICE Risk of consequential damage to engine and aircraft as a result of corrosion and damage Under no circumstances
80. g air duct especially for this application The following recommendations should assist the aircraft or fuselage man ufacturer in selecting suitable cooling air ducts Cooling capacity The cooling air ducts must be designed such that they transfer thermal energy of approx 6 kW 5 7 BTU s at take off performance Cross section of air duct Cross section of air duct under the airflow baffle min 100 cm 15 50 in Material Glass fibre reinforced plastic or heat and fire resistant ma terial Attachment options Formlocking on engine block and mounting above the cyl inder and the crankcase NOTE If formlocking attachment is not suffi cient additional attachment is possi ble using two M8 threaded lugs on the top of the engine block NOTICE The stated maximum permissible loads per screw NOTICE are valid only if using the minimum specified thread length and must never be exceeded Thread height 18 mm 0 71 in Effectivity 912 Series Edition 2 Rev 0 75 00 00 page 26 August 01 2012 d04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL Permissible loads per screw x axis y axis z axis Attachment points 300 mm 11 81 in 30 mm 1 18 in 14 mm 0 55 in 300 mm 11 81 in 30 mm 1 18 in 14 mm 0 55 in Attachment points Max permissible force safe load in N on x y and z a
81. gine and fuel system from contamination and exposure Never operate the engine and gearbox without sufficient quantities of lubricating oil Never exceed the maximum permitted operational limits Allow the engine to cool at idle for several minutes before turning off the engine Propeller and its attachment with a moment of inertia in excess of the specified value must not be used and releases engine manufacturer from any liability Improper engine installation and use of unsuitable piping for fuel cool ing and lubrication system releases engine manufacturer from any lia bility Effectivity 912 Series 00 00 00 Edition 2 Rev 0 page 12 August 01 2012 d04918 fm d04918 fm BRP Powertrain INSTALLATION MANUAL 4 2 Instruction General note Safety notice Accessories Spare parts Tools State of delivery Engines require instructions regarding their installation application use operation maintenance and repair Technical documentation and directions are useful and necessary com plementary elements for personal instruction but can by no means sub stitute theoretical and practical instructions These instructions should cover explanation of the technical context advice for operation maintenance use and operational safety of the engine In this technical Manual passages concerning safety are especially marked Pass on safety warnings to other users This engine must only be operate
82. gust 01 2012 BRP Powertrain INSTALLATION MANUAL Overview Fuel system Part Function 1 Fuel pump 2 Fuel hose assy Fig 1 08825 Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 2 August 01 2012 d04923 fm d04923 fm BRP Powertrain INSTALLATION MANUAL 1 Fuel system 1 1 Description of system General note See Fig 2 NOTE The fuel system from tank to the inlet of engine driven fuel pump has to be installed by the aircraft manufacturer Fuel The fuel flows from the tank 1 via a coarse filter and fire cock 3 con tinue to water trap fine 4 to the mechanical fuel pump 5 from the pumps fuel passes on via the fuel manifold 3 to the two carburetors Fuel lines Depending on the configuration of the engine the fuel lines from fuel pump to the carburetors are already installed by the manufacturer optional on some engine Only the following connections per Fig 2 have to be established Feeding lines to suction side of the mechanical fuel pump 5 Lines from pressure side of the mechanical fuel pump to inlet of fuel manifold 6 Returnline from fuel pressure control to fuel tank Return line Via the return line 5 surplus fuel flows back to the fuel tank and suction side of fuel system NOTE The return line prevents malfunctions caused by the for mation of vapor lock Components The fuel system includes the following items Tank Coars
83. haft 2 Reduction ratio Installation dimensions i 4 i e 1 4 of engine speed See figures above Position mechanical rev counter Position Axes point of engage x axis y axis z axis ment P4 465 0 mm 18 31 in 87 0 mm 3 43 in 160 0 mm 6 3 in Graphic Mechanical rev counter a P4_ Misa S 2 LOR Oy m IN zi eh ln peL D S PHHH ie ad 1 O Part Function 1 Ignition housing 2 Rev counter shaft fm 00560 00562 Fig 4 d04925 Effectivity 912 Series 76 00 00 Edition 2 Rev 0 page 8 August 01 2012 d04925 fm BRP Powertrain INSTALLATION MANUAL 2 Monitoring of the intake manifold pressure General note See Fig 5 NOTICE Utilize the total slip on length on all joints Secure hose by suitable screw clamps or crimp connection Connection nip Connection nipple 1 to measure manifold pressure pis Outside dia 6 mm 174 Slip on length Max 17 mm 11 16 NOTICE Protective covering to be utilized for transport and at engine installation only If connection for pressure reading is not employed it has to suitabl
84. he aircraft in parked position aircraft on ground ready for take off Engine suitable for propeller in tractor or pusher arrangement Installation only with propeller shaft above cylinders The centres of attachment points L1 and R1 must be on a y2 axis parallel to the y axis Permissible deviation from parallelism 5 Fig 4 02454 Effectivity 912 Series 10 10 00 Edition 2 Rev 0 page 12 August 01 2012 d04919 fm d04919 fm BRP Powertrain INSTALLATION MANUAL Vertical axis The y axis must be perpendicular to the longitudinal axis of the aircraft Permissible deviation from perpendicular 10 anat oom Ens F Co es gt es ra RE P Fig 5 00515 Effectivity 912 Series Z Edition 2 Rev 0 1 O 1 O 00 page 13 August 01 2012 BRP Powertrain INSTALLATION MANUAL 3 Preparations for trial run of engine General note A WARNING Non compliance can result in serious injuries or death Prior to
85. head material is taken Location In the cylinder head of the cylinder 2 and 3 Connection Spade terminal 6 3x0 8 DIN 46247 Grounding Via engine block Position Position temperature sensor Axes Cylinder head x axis y axis z axis 2 200 0 mm 7 88 in 241 0 mm 9 49 in 157 0 mm 6 18 in 3 387 0 mm 15 24 in 241 0 mm 9 49 in 157 0 mm 6 18 in Graph resistance Graph of sensor resistance over temperature See Fig 1 NOTICE The graph resistance over temperature has been de termined and is effective at the following conditions only Ambient temperature 20 C 68 F Tolerance Max 10 Effectivity 912 Series 76 00 00 Edition 2 Rev 0 page 3 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Sensor for cylinder head temperature 9 1200 1000 800 600 0 Pe 20 40 60 80 100 120 140 ey 2 Part Function Sensor for cylinder head temperature 2 Graph resistance over temperature Fig 1 00227 00327 1 2 Sensor for oil temperature General note See Fig 2 NOTICE Certification to the latest requirements such as FAR of EASA has to be conducted by the aircraft manufactur er BRP Powertrain offers a non certified temperature indicating instrument Refer to Illustrated Parts Catalog latest issue Marking Marking 2 Marked with
86. is a corroded or damaged engine to be installed in an aircraft The attachment screws are only for transport and SES must not be used in the aircraft The engine can be attached with steel angles anchored on a timber plate When the engine is delivered check that the GENUINE ROTAX pack ing is not damaged If the packing is damaged contact the authorised sales and service partner for ROTAX aircraft engines 1 2 Unpacking handling of the engine Unpacking the To unpack a new engine proceed as follows engine Step Procedure 1 Remove the wooden cover 2 Remove the protective packaging 3 Remove the protective film around the engine After unpacking To check the state of delivery proceed as follows Step Procedure 1 Check that the serial number and engine type designation on the type plate are identical to those shown on the delivery note 2 Check the engine for damage or corrosion If everything is deemed OK the engine can be accepted Suspension point The engine to be lifted by two hooks or straps around the middle A of the intake manifolds See chapter engine views numbering of cylinders and definitions of main axes Effectivity 912 Series Z Edition 2 Rev 0 1 0 1 O 00 page 3 August 01 2012 BRP Powertrain INSTALLATION MANUAL 1 3 Preservation and storage of the engine General note Warranty Storage The engine is preserved at BRP Power
87. itions Ambient temperature 20 C 68 F Voltage constant 13 5 V Tolerance max 5 NOTE The speed of the external generator is 1 24 times the crank shaft speed or 3 times the propeller speed Graphic E Lee 1 min rpm 1309 2090 Torn propeller 2000 3000 4000 5000 6000 7000 8000 Generator Fig 8 00547 Effectivity 912 Series 24 00 00 Edition 2 Rev 0 page 15 August 01 2012 BRP Powertrain INSTALLATION MANUAL 2 7 Connection of the electric rev counter tachometer General note See Fig 9 2 7 1 Technical data Output signal NOTICE The graphs depicting output signals have been deter mined and are effective only at the following condi tions Ambient temperature 20 C 68 F Tolerance Max 5 NOTE The pick up for the rev counter generates one pulse per revolution Pulse shape and pulse voltage as per record ings oscillogram Graphic Oscillogram speed 500 rpm load 100 9 speed 500 rpm load 100 kQ V V 3 15 2 10 1 5 0 0 1 5 2 10 3 15 4 V 1 Umar rev V s gt speed 6000 rpm load 100 Q speed 6000 rpm load 100 KQ V V A 10 100 5 50 0 0 5 50 10 100 V 1 ee 150 Too g 1 Umar rev y mgs ev Fig 9 Ig 00219 S S 5 Effectivity 912 Series F _ Edition 2 Rev 0 24 00 00 page 16 August 01 2012 d04920 fm BRP Pow
88. ive via propeller gearbox Position of the propeller connection 1 on the governor flange Axes Point of support x Axis mm y Axis mm z Axis mm 206 3 mm 8 12 in 0 51 5 mm 2 03 in Graphic Crankcase flange Part Function 1 Connection for hydraulic governor 2 Governor flange Fig 5 00256 08179 Effectivity 912 Series 61 00 00 Edition 2 Rev 0 page 7 August 01 2012 BRP Powertrain INSTALLATION MANUAL d04921 fm Connections Pay attention to manufacturers specifications NOTICE y p Gear ratio NOTE Gear ratio from crankshaft to hydraulic governor is 1 842 i e the propeller governor runs at 0 54 times engine speed Mounting pad AND20010 Thread M8 Thread length Max 14 mm 0 55 in Governor drive Internal spline 20 40 SMS 1834 NA 14x1 27x30x12 Power consumption Max 600 W Operating pressure Max 30 bar 435 psi Effectivity 912 Series 61 00 00 Edition 2 Rev 0 page 8 August 01 2012 d04922 fm BRP Powertrain INSTALLATION MANUAL Chapter 72 00 00 ENGINE Introduction NOTICE Certification in accordance with the latest regulations NOTICE such as FAR or EASA must be carried out by the air craft or fuselage manufacturer Table of contents This section of the Installation Manual contains views of the aircraft engine technical data and installation dimensions of the engine Subject Page Engine components engin
89. ivity 912 Series Edition 2 Rev O 79 00 00 page 26 August 01 2012 d04927 fm d04927 fm BRP Powertrain INSTALLATION MANUAL Graphic Hydraulic valve tappet Fig 13 08800 3 5 Replacement of components General note If an hydraulic valve tappet still malfunctions after several engine runs it must be replaced and the valve spring support must be inspected for wear Work procedures All work has to be performed in accordance with the relevant Mainte nance Manual Effectivity 912 Series 79 00 00 Edition 2 Rev 0 page 27 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 28 August 01 2012 d04927 fm d04927 fm BRP Powertrain INSTALLATION MANUAL 4 Data for optional components of lubrication system 4 1 Oil cooler General note See Fig 14 Weight See also chap 72 00 00 sectiont weight 4 1 1 Variants of connectors General note i i NOTICE ea hold screw sockets when securing the oil UNF screw socket UNF screw socket Thread 3 4 16 UNF AN 8 Tightening torque 22 Nm 16 23 ft lb and LOCTITE 648 Tightening torque of oil feed line 25 Nm 18 5 ft lb and outlet Nipple 13 2 9 2 Nipple Outer dia 13 2 mm 0 52 in Slip on length max 21 mm 0 83 in Tightening torque 22 Nm 16 23 ft lb and LOCTITE 243 Metric screw socket NOTICE al hold screw soc
90. ivity 912 Series Edition 2 Rev 0 78 00 00 page 6 August 01 2012 d04926 fm d04926 fm BRP Powertrain INSTALLATION MANUAL 3 Attaching of the exhaust system General note See Fig 4 The shape and configuration of the exhaust system is essentially deter mined by the free space available in the aircraft Two M8x23 studs are provided on each cylinder for attaching the exhaust system Location of the NOTE All dimensions from zero reference point P studs z Coordinates Location x axis mm in y axis mm in z axis mm in Cylinder 1 160 mm 6 3 in 196 mm 7 72 in 82 mm 3 23 in 160 mm 6 3 in 212 mm 8 35 in 113 mm 4 45 in Cylinder 2 192 mm 7 56 in 196 mm 7 72 in 82 mm 3 23 in 192 mm 7 56 in 212 mm 8 35 in 113 mm 4 45 in Cylinder 3 408 mm 16 06 in 196 mm 7 72 in 82 mm 3 23 in 408 mm 16 06 in 212 mm 8 35 in 113 mm 4 45 in Cylinder 4 438 mm 17 24 in 196 mm 7 72 in 82 mm 3 23 in 438 mm 17 24 in 212 mm 8 35 in 113 mm 4 45 in Attachment points Max permissible forces safe load in N Ib 1000 N 224 81 force on x y and z axis Max permissible bending moment safe load 40 Nm 30 ft lb in Nm on x y and z axis Effectivity 912 Series 78 00 00 Edition 2 Rev 0 page 7 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912
91. kets when securing the oil Metric screw socket Thread M18x1 5 Tightening torque 22 Nm 16 23 ft lb and LOCTITE 648 Tightening torque of oil feed line 25 Nm 18 5 ft lb and outlet bent socket or hose nipple Effectivity 912 Series Z Edition 2 Rev 0 19 00 00 page 29 August 01 2012 Angular tube BRP Powertrain INSTALLATION MANUAL Angular tube 90 Outer dia 13 2 mm 0 52 in Slip on length max 21 mm 0 83 in Tightening torque 22 Nm 16 23 ft lb and LOCTITE 648 Bent socket Bent socket 90 Outer dia 12 mm 0 47 in Slip on length max 24 mm max 0 94 in Tightening torque 25 Nm 18 5 ft lb Hose nipple with cap nut straight nipple Hose nipple with union nut Outer dia 12 mm 0 47 in Slip on length max 24 mm max 0 94 in Tightening torque 25 Nm 18 5 ft lb d04927 fm Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 30 August 01 2012 d04927 fm BRP Powertrain INSTALLATION MANUAL Graphic Connection variants B LOCTITE 243 C LOCTITE 648 82 mm 3 23 in mittel medium 95 mm 3 74 in Klein small Effectivity 912 Series Edition 2 Rev 0 79 00 00 page 31 August 01 2012 Fig 14 BRP Powertrain INSTALLATION MANUAL Part Function Oil cooler M22x1 5 hex nut Gask
92. l rE ae mg P ff i i E A ZED x NIN _A KIEZE A EA xX AS a fe m Je ms PTO ff I lt i lle Gad LG HO W Y L i eet y teh e oT SE 5 LF a De i 2 NA S ze X 3 BOOS 5 D a Q a D 7 8 Part Function Propeller flange Propeller gear Vacuum pump or hydraulic governor for con stant speed propeller Constant depression carb 5 Ignition cover Effectivity 912 Series Edition 2 Rev 0 12 00 00 page 3 August 01 2012 Fig 2 BRP Powertrain INSTALLATION MANUAL Part Function 6 Connection for mechanical rev counter 7 Coolant pump 8 Connection for oil return line 00502 Front view Fig 3 Part Function 9 Oil filter 10 Sensor for oil temperature 11 Oil pump 12 Sensor for oil pressure 13 Compensation tube 14 Sensor for cylinder head temperature 00503 Effectivity 912 Series Edition 2 Rev 0 72 00 00 page 4 August 01 2012 d04922 fm d04922 fm Top view Fig 4 BRP Powertrain INSTALLATION MANUAL I ya Us Hih q 10 at
93. lues found for coolant temperature and ple cylinder head temperature Refer to the current specification of the FAA and or EASA Coolant temperature cccceceeeeeeeeees 102 C 216 F Cylinder head temperature 065 110 C 230 F The cylinder head temperature is 8 C 46 F higher than the coolant tem perature Thus Coolant temperature ccccccceeceeeeeeeeeeee cessteteaeeeeees 120 C 248 F Difference cylinder head and coolant temperature 8 C 46 F Te ball i ease nen nanimatiomed aehencataen sas 128 C 262 F The highest cylinder head temperature permitted is 128 C 262 F so that the max coolant temperature is kept With this special application safe operation of the engine that prevents boiling of the coolant is possible up to a cylinder head temperature of 128 C 262 F NOTICE This cylinder head temperature with the limit found for NOTICE this type must be displayed constantly in the cockpit The indicating instrument and the Manuals must be changed to cylinder head temperature max 128 C 262 F geandert werden The design of the radiator installation must be changed example cowl modifications if the operating temper ature exceeds the specified limits NOTICE Effectivity 912 Series 75 00 00 Edition 2 Rev 0 page 14 August 01 2012 d04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL 3 Cooling system requir
94. m 04924 fm 2 1 BRP Powertrain INSTALLATION MANUAL cation on radiator installation Maximum values Determination of operating limits Coolant and necessary modifi Depending on the achieved maximum values of the cylinder head temper ature and the coolant temperature following action are necessary Maximum values for Coolant used for tests 120 C 248 F 135 C 275 F 150 C 300 F for displaying coolant temperature is neces sary b more than 120 C 248 F less than 135 C 275 F 150 C 300 F 120 C 248 F less than more than 120 C 248 F 135 C 150 C 300 F more than more than 135 C 275 F 150 C 300 F Cooling capacity too low Check of the in stallation necessary c Coolant Cylinder head Conventional Waterless coolant temperature temperature coolant less than less than Additional instruments Modifications to the in struments or limit not necessary a Cooling capacity too low Check of the instal lation necessary c 1 engine type 912 S ULS 2 engine type 912 A F UL a Maximum cylinder head temperature is below operating limits Opera ting with waterless coolant is permissible without modification to the installation b Maximum cylinder head temperature and coolant exit temperature is below operating limit For operating with conventional coolant it is nec
95. mercially available ca ble can be used A resistance cable or similar is not nec essary The sensor cable is approx 3 m 118 in long and has 3 leads The Black lead is not to be connected and has no function The Red lead from the sensor has to be connected to the positive bus via a fuse or circuit breaker The White lead output signal has to be connected directly to the inst rument Effectivity 912 Series 76 00 00 Edition 2 Rev 0 page 6 August 01 2012 d04925 fm d04925 fm BRP Powertrain INSTALLATION MANUAL See also the relevant instructions of the instrument supplier aircraft man ufacturer for correct connection and wiring Graph current See Fig 3 over pressure NOTICE The graph current over pressure 2 has been deter mined and is effectiva at the following conditions only Ambient temperature 20 C 68 F Tolerance Max 3 Graphic Oil pressure sensor mA 25 bar Part Function Oil pressure sensor Graph current over pressure sensor Fig 3 08379 08442 Effectivity 912 Series Edition 2 Rev 0 76 00 00 page 7 August 01 2012 BRP Powertrain INSTALLATION MANUAL 1 4 Mechanical rev counter tach driver optional General note See Fig 4 Technical data Mechanical rev counter Ignition housing 1 Location Right Clockwise Direction of rotation of the rev counter s
96. n x y and z axis L1 5000 N 196 85 in 77 Nm 56 8 ft lb R1 L2 5000 N 196 85 in 77 Nm 56 8 ft Ib R2 L3 5000 N 196 85 in 77 Nm 56 8 ft lb R3 L4 1900 N 74 80 in 39 Nm 28 8 ft lb R4 max permissible forces max permissible bending moment secure load in N in secure load in Nm attach ment x axis y axis z axis xX y and z axis points L5 5000 N 2000 N 3000 N 100 Nm 73 75 ft lb R5 196 85 in 78 74 in 118 11 in L6 R6 Effectivity 912 Series Edition 2 Rev 0 10 10 00 page 10 August 01 2012 d04919 fm d04919 fm BRP Powertrain INSTALLATION MANUAL thread max usable thread attachment point size length mm in L1 M10 25 mm 0 98 in R1 L2 M10 25 mm 0 98 in R2 L3 M10 25 mm 0 98 in R3 L4 M10 19 mm 0 75 in R4 16 mm 0 63 in 1 up to gearbox S N 28986 2 starting from gearbox S N 28987 Effectivity 912 Series Edition 2 Rev O 10 10 00 page 11 August 01 2012 BRP Powertrain INSTALLATION MANUAL 2 4 Permissible installation positions General note Installation posi tions Propeller axis See Fig 4 NOTICE The oil system fuel system and the cooling system are NOTICE unsuitable for upside down inverted installation of the engine NOTE Dimensions are always from zero reference point and the coordinate system position remains unchanged The following installation position details refer to t
97. nes The information contained is based on data and experience that are con sidered applicable for authorized mechanics iRMT see Maintenance Manual Line under normal conditions Due to the fast technical progress and fulfilment of particular specifications of the customers it may occur that existing laws safety prescriptions con structional and operational regulations cannot be transferred completely to the object bought in particular for special constructions or may not be suf ficient Documentation Installation Manual Status Replacement pages Operators Manual Maintenance Manual Line and Heavy Maintenance Overhaul Manual Illustrated Parts Catalog Alert Service Bulletin Service Bulletin a E Service Instruction H Service Letter m E The status of the Manuals can be determined with the aid of the table of amendments The first column indicates the revision state This figure should be compared with the revision provided on ROTAX Air craft Engines Website www FLYROTAX com Amendments and current versions can be downloaded free of charge Furthermore the Manual is constructed in such a way that single pages can be replaced instead of the complete document The list of effective pages is given in the chapter LEP The particular edition and revision num ber is given on the footer of each page Effectivity 912 Series 00 00 00 Edition 2 Rev 0O page 14 August 01 201
98. nnected incorrectly the engine will not be lubricated and the engine will be damaged very quickly Effectivity 912 Series 2 Edition 2 Rev 0 19 00 00 page 17 August 01 2012 BRP Powertrain INSTALLATION MANUAL 2 3 Permissible position and location of the oil tank Position and lo cation See Fig 11 The longitudinal axis z3 must be parallel to z axis of the system of coor dinates Permissible deviation from parallel 10 NOTE This applies to both planes AWARNING Non compliance can result in serious injuries or death If the oil tank is located higher oil might trickle through bearing clearances into the crankcase during longer periods of engine stop If fitted too low it might damage the oil circuit The oil tank 1 must be positioned on its z axis such that the normal oil level 2 is always between 0 and 400 mm 15 75 in on the y axis NOTE If the profile clamp of the oil tank is 360 mm 14 17 in be low the propeller shaft then the oil in the oil tank is at the same level as the oil pump This is the ideal position for the oil tank Install the oil tank free of vibrations and not directly to the engine Oil tank cover 3 and oil drain screw 4 must be easily accessible Effectivity 912 Series 79 00 00 Edition 2 Rev O page 18 August 01 2012 d04927 fm d04927 fm Graphic Position and location of the oil tank and oil cooler INSTALLATION MANUAL BRP Pow
99. nstallation Manual EGT Exhaust Gas Temperatur Effectivity 912 Series Edition 2 Rev 0 00 00 00 page 7 August 01 2012 BRP Powertrain INSTALLATION MANUAL Abbreviation Description INTRO Introduction EMS Engine Management System EN European Norm IPC Illustrated Parts Catalog FAA Federal Aviation Administration FAR Federal Aviation Regulation OM Overhaul Manual hr hours OM Operators Manual TOC Table of Contents ISA International Standard Atmosphere kg kilograms AD Airworthiness Directive MS magneto side MON motor octane number N new part only Illustrated Parts Catalog nB as necessary only Illustrated Parts Catalog n a not available NDT non destructive testing Nm newtonmeter Rev Revision ROTAX is a trade mark of BRP Powertrain GmbH amp Co KG RON Research Octane Number RV Record of Revisions S N Serial Number SB Service Bulletin Sl Service Instruction SL Service Letter SMD Surface Mounted Devices part no Part number TSN Time Since New TSNP Time Since New Part TBO Time Between Overhaul V Volt VFR Visual Flight Rules LEP List of Effective Pages MM Maintenance Manual XXX shows the serial component number Effectivity 912 Series Edition 2 Rev 0 00 00 00 page 8 August 01 2012 d04918 fm d04918 fm BRP Pow
100. oat valve with subsequent engine stop NOTE Readings of the fuel pressure are taken at the pressure gauge connection on the fuel manifold Operating limits Fuel pressure Max 0 4 bar 0 5 bar 7 26 psi Min 0 15 bar 2 2 psi applicable only for fuel pump from S N 11 0036 Graphic Fuel pressure Ng to fuel tank fuel pressure sensor connection to carburetor to carburetor lt from fuel pump y Fig 3 09139 Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 5 August 01 2012 BRP Powertrain INSTALLATION MANUAL 1 2 2 Electrical fuel pump General note The engine manufacturer recommends the use of an electrical auxiliary fuel pump if this is not already required by airworthiness requirements The electrical auxiliary fuel pump is not just required in case of a malfunc tion or defect of the mechanical fuel pump but also provides required fuel supply e g in case of vapour formation at high altitudes and tempera tures Operating limits NOTE If an electrical auxiliary fuel pump is installed the whole fuel system has to be designed to warrant engine opera tion within the specified pressure limits The fuel pressure of an additional auxiliary fuel pump Ts should not exceed 0 3 bar 4 4 psi 1 3 Requirements of the fuel system Delivery rate Electric or mechanical fuel pump Min 35 I h 8 2 US gal h Fuel lines See Fig 2 NOTICE Fuel line
101. of the engine Electromagnetic compatibility EMC The engine complies with the electromagnetic interference and lightning strike requirements of DO 160C section 18 20 22 and IEC 801 2 The following EMC tests have been carried out Radio frequency RF sensitivity conducted Radio frequency RF sensitivity radiated Audio frequency sensitivity Lightning strike sensitivity Conducted radio frequency RF interference Radiated radio frequency RF interference Effectivity 912 Series 24 00 00 Edition 2 Rev 0 page 4 August 01 2012 d04920 fm d04920 fm BRP Powertrain INSTALLATION MANUAL 2 Technical data and connection of the electric components 2 1 Internal generator General note NOTE Approx 250 W AC output at 5800 rpm For DC output in connection with rectifier regulator See chap 24 00 00 sec tion 3 Connection See Fig 1 Feeding wires 1 from the generator to rectifier regulator on left side of ignition housing 2 flexible cables 1 5 mm yellow in shielding metal braid length approx 660 mm 26 in starting from ignition housing with on each plug socket 6 3 x 0 8 to DIN 46247 Graphic Connection Part Function 1 Feeding wires yellow Fig 1 02498 Effectivity 912 Series 24 00 00 Edition 2 Rev 0 page 5 August 01 2012 BRP Powertrain INSTALLATION MANUAL 2 2 Rectifier regulator Type Output voltage Cur
102. omponent tem Component temp for the electronic modules 1 max 80 C 176 F perature Effectivity 912 Series 24 00 00 Edition 2 Rev 0 page 8 August 01 2012 d04920 fm d04920 fm BRP Powertrain INSTALLATION MANUAL 2 4 Ignition switches MAG switch Type Two separate suitable on off switches Fig 11 pos 15 Switching volt Min 250 V age Switching cur Min 0 5 A rent 2 4 1 Connection Wires See Fig 4 Wires from the ignition switches connect to the electronic module 1 Graphic Electronic modules Part Function 1 Electronic modules Fig 4 02501 Wire See Fig 5 NOTICE The electromagnetic compatibility EMC and electro magnetic interference EMI depends essentially on the wire used Min section area 2x 0 75 mm 18 AMG shielded flexible cable shielding braid on both ends grounded to prevent EMI e g specification MIL 27500 18 Effectivity 912 Series 24 00 00 Edition 2 Rev 0 page 9 August 01 2012 Wire A Wire B Ignition circuit A Ignition circuit B Graphic Flexible wire BRP Powertrain INSTALLATION MANUAL NOTICE No or insufficient shielded cables can cause engine shut off due to electromagnetic and radio interference The metal base of each ignition switch must be grounded to aircraft frame to prevent EMI Wire of top electronic module marked A for ignition circuit A Wire of bottom electronic mo
103. onnections See Fig 1 NOTE The oil pump is driven by the camshaft The main oil pump sucks the engine oil from oil tank 1 via the oil cooler 4 and forces it through the oil filter to the individual points of lubrication also lubricates the propeller governor The surplus oil emerging from the points of lubrication accumulates on the bottom of the crankcase and is forced back to the oil tank by the crankcase blow by gases NOTE The oil circuit is vented via nipple in the oil tank A WARNING Non compliance can result in serious injuries or death The oil cooler and its connections must be certified according to the latest regulations such as FAR and EASA by the aircraft or fuselage manufacturer Only the following connections need to be established to complete the lubrication system oil system Oil circuit engine main oil pump Oil tank outlet to oil cooler Oil cooler to oil pump inlet Connections from Oil return to oil tank inlet Oil tank to purging line NOTE An oil tank is included with the standard engine version No provision has been made for attachment of an oil cool er on the engine Effectivity 912 Series 79 00 00 Edition 2 Rev O page 3 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Oil system
104. ottle lever Mechanical stops See Fig 11 Adjustable positive stops for idle and full throttle position are of course required These stops have to be designed such to render adjustibility and to pre vent overload of the idle stop on the carburetor Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 18 August 01 2012 04923 fm d04923 fm BRP Powertrain INSTALLATION MANUAL Graphic The sketch depicts a feasible arrangement Startleistung Take off power Leerlauf Idle Fig 11 09137 Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 19 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 20 August 01 2012 d04923 fm d04923 fm BRP Powertrain INSTALLATION MANUAL 3 Air intake system General note See Fig 12 The performance is given at ISA 15 C 59 F condition only Engine is equipped with unchanged GENUINE ROTAX tuned exhaust muffler system and air intake box The intake system is determined essentially by the demands of engine and of the acceptable noise emission on the intake side An airbox can be supplied by BRP Powertrain as an option Performance data as specified and limits of operation can only be war ranted by employment of the GENUINE ROTAX airbox Installation note If it will be necessary to use a different airbox or a modified genuine ROTAX airbox for reasons of ins
105. quip ment not tested NOTE BRP Powertrain INSTALLATION MANUAL The following equipment is not included as part of the stan dard engine version NOTICE Any equipment not included as part of the standard en gine version and so does not be part of the engine is not in the scope of supply Components especially developed and tested for this engine are readily available at BRP Powertrain The following auxiliary equipment has been tested on ROTAX engine type 912 for safety and durability to the standards of aviation The furnishing of proof in accordance to the latest FAR or EASA has to be conducted by the aircraft manufacturer Airbox External alternator Engine suspension frame Vacuum pump feasible on configuration 2 and configuration 4 only Drive for rev counter hour meter Oil cooler with connections Coolant radiator Coolant overflow bottle The following auxiliary equipment has not been tested on ROTAX engine type 912 for safety and durability to the standards of aviation Non compliance can result in serious injuries or death The user assumes all risks possibly arising by utilizing auxiliary equipment The furnishing of proof in accordance to the latest FAR or EASA has to be conducted by the aircraft manufac turer Exhaust system Intake filter Flydat Mechanical rev counter Electric rev counter Shock mount Effectivity 912 Series Edition 2 Rev 0 00 00 00 page 6 August 01 2012
106. r Protective cover List of protective covering ing Installation place Number Exhaust socket 1x cone plug Connection for manifold pressure 1x cap Airbox 2x cap Fuel pump inlet 1x cap Connection for fuel return 1x plug Connection for fuel pressure 1x plug Oil supply and oil discharge 1x each cap Supply and discharge of coolant 1x each cone plug Propshaft on configuration 3 1x disk plug Carburetor if not equipped with an airbox 2x disk plug Effectivity 912 Series 1 0 1 0 00 Edition 2 Rev 0 page 5 August 01 2012 BRP Powertrain INSTALLATION MANUAL 2 Engine suspension and installation position General note Engine suspen sion Engine suspen sion frame NOTICE During engine installation take into account the total engine weight and ensure careful handling The engine suspension is essentially determined by the aircraft design Eight attachment points are provided 4 on engine and 4 on engine frame If the engine suspension frame is not used or if modi fied certification in accordance with the latest regula tions such as FAR or EASA must be conducted by the aircraft manufacturer The engine is supplied with a tested and certified suspension frame for the fireproof bulk head Installation in the aircraft is carried out using standard captive rubber mounts which also isolate vibration and noise from the air craft frame 2 1 Engine suspension inst
107. ra ture below 120 C 248 F at a pressure of 1 2 bar 18 psi The max coolant temperature limit is therefore 120 C 248 F Permanent monitoring of coolant temperature and cylinder head tempera ture is necesssary Effectivity 912 Series 7 5 00 00 Edition 2 Rev O page 7 August 01 2012 Marking BRP Powertrain INSTALLATION MANUAL Waterless coolant Waterless coolant has a very high boiling point that prevents coolant loss due to boiling over vapor loss but not to prevent detonation which can occur with cylinder head temperatures higher than 150 C 300 F for ROTAX 912 A F UL and 135 C 275 F for ROTAX 912 S ULS It does not require pressure to maintain its boiling point Due to a lower thermal conductivity the engine temperature will typically run about 5 10 C 41 50 F higher with waterless coolant Permanent monitoring of cylinder head temperature is necessary Additional monitoring of the actual coolant temperature is possible but not necessary for waterless coolant NOTE When using EVANS NPGR NPG or added pure ethylene glycol as a coolant note that these fluids have a flammabi lity rating 1 classification LOW at a scale from 0 to 4 The mentioned coolants are complying according to their mate rial safety data sheet with a flammability classification which has only low danger and a low risk of flammability To date no cases in engine operation or flight operation labo
108. raft or fuse lage manufacturer to select a suitable exhaust system Damping element Distribution of the exhaust sys tem Ball joints Vibration The ideal is a common transversal damping element serving all 4 cylin ders positioned under the engine NOTE Equal length of pipes from the cylinder to damping ele ment is recommended for better tuning Distribution of the exhaust system into 2 separate systems is not recom mended Individual mufflers on either side cause power loss and increased engine noise The 4 ball joints must be used to avoid damage due to vibration NOTICE Be aware that locked up stresses cause cracks All ball joints have to greased regularly with heat resistant lubricant e g LOCTITE ANTISEIZE to avoid gripping and seizing of the joints NOTICE Appropriate to the installation a vibration damping sup NOTICE port for the exhaust system has to be provided on the airframe manufacturers side Springs to be secured with safety wire to prevent FOD See Fig 2 The sketch illustrates a possibility how to interconnect the exhaust springs to prevent the vibration of these springs and thus premature wear Effectivity 912 Series 78 00 00 Edition 2 Rev 0 page 3 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Exhaust spring stretch approx 10 mt in It is also recommended to fill the springs with high heat silicone for addi
109. ratory conditions or from the field were reported which show unsafe conditions of ROTAX aircraft engines in com bination with the relevant coolants See Fig 3 Marking of the coolant to be used NOTICE The coolant to be used and its concentration percent age water rate must be correctly communicated to the owner Waterless coolant must not mix with water as other wise it will lose the advantages of a high boiling point d04924 fm Effectivity 912 Series 75 00 00 Edition 2 Rev 0O page 8 August 01 2012 d04924 fm BRP Powertrain INSTALLATION MANUAL Graphic Marking STOP 1 VANS NTG Part Function 1 Warning sticker 2 Radiator cap 3 Opening pressure information of radiator cap Fig 3 08809 Effectivity 912 Series _ s Edition 2 Rev 0 15 00 00 page 9 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 75 00 00 page 10 August 01 2012 d04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL 2 Checking the efficiency of the cooling system General note The maximum coolant temperature must be determined in order to check the efficiency of the cooling system Cylinder head See Fig 4 tompearature There are two temperature sensors 1 on the cylinder 2 and 3 for measur ing the cylinder head temperature During flight te
110. re hoses with suitable spring or screw clamp NOTE Choose between six possible installation positions of water inlet elbow 5 appropriate to specific installation see illus tration Use two M6x20 Allen screws and lock washers to attach the water inlet elbow Tighten screws to 10 Nm 90 in Ib Effectivity 912 Series Edition 2 Rev 0 75 00 00 page 18 August 01 2012 d04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL 3 2 Requirements permissible location and installation position of the radiator expansion tank overflow bottle Radiator See Fig 9 AWARNING Non compliance can result in serious injuries or death The radiator must be designed and installed such that the permissible operating temperatures are main tained and the max values are not exceeded This must also apply to Hot day conditions NOTICE If required the radiator outlet 3 may be located max NOTICE 1 5 m 4 92 ft underneath the inlet elbow 4 of the water pump and no higher than the expansion tank 1 see Fig 9 Expansion tank To ensure proper operation of the cooling system the expansion tank 1 with pressure cap 2 in the main operating systems must be installed on the highest point of the cooling circuit NOTE The expansion tank 1 is fitted on top of the engine Graphic Permissible position max 250mm max 9 84 in max 59 05 in max 1 5 m
111. rements for the aircraft engine cooling system Subject Page Cooling system Page 3 System description Page 3 Operating limits Page 5 Coolant types Page 7 Checking the efficiency of the cooling system Page 11 Determination of operating limits Coolant and nec Page 13 essary modification on radiator installation Requirements on the cooling system Page 15 Connecting size and position of connection Page 16 Feasible location of radiator expansion tank over Page 19 flow bottle General notes for the cooling system Page 23 Coolant capacity Page 24 Cooling air duct Page 25 General notes on the cooling air ducts Page 26 Data for optional components of cooling system Page 27 Effectivity 912 Series Edition 2 Rev 0 75 00 00 page 1 August 01 2012 Overview Cooling system BRP Powertrain INSTALLATION MANUAL Fig 1 Part Function Expansion tank Radiator cap Water tube HB ow N Water pump 08532 Effectivity 912 Series Edition 2 Rev 0 75 00 00 page 2 August 01 2012 04924 fm d04924 fm BRP Powertrain INSTALLATION MANUAL 1 Cooling system 1 1 System description Cooling Coolant Expansion tank Shape size and location Measuring the coolant temp Radiator See Fig 2 The engine cooling system is designed for liquid cooling of the cylinder heads and ram air cooling of the cylinders The cooling sy
112. rent limit Component tem perature Weight Graphic Electronic full wave rectifier regulator 14 2 V 0 3 from 1000 250 rpm Current limit Max 22 A Max permissible component temperature 80 C 176 F measured in area 1 NOTE The performance specifications are given for optimal cooled components If necessary use a separate heat sink for the rectifier regulator See chap 72 00 00 section weight Connection 80 3 15 in 62 2 44 in 92 3 62 in 106 4 18 in fa 40 1 48 in Part Function 1 Area component temperature 2 Description of connections G yellow from generator R red to battery positive terminal B battery positive terminal L warning lamp circuit C control or field circuit Fig 2 08631 Effectivity 912 Series Edition 2 Rev 0 24 00 00 page 6 August 01 2012 d04920 fm d04920 fm BRP Powertrain INSTALLATION MANUAL 2 2 1 Requirements for flawless operation of the rectifier regulator General note Body of regula tor Fuse Wire size Capacitor Amperage NOTICE The voltage difference between battery and terminal C of regulator should be less than 0 2 V Use cables in this area as short as possible and with adequate cross section NOTICE Never sever connection between terminal C and B of regulator e g by removal of a fuse while
113. rmal energy at take off per formance The oil cooler must not restrict oil flow Test system as pore per chap 79 00 00 section 1 3 NOTE Experience has shown that an oil cooler of at least 160 cm 25 in is required provided that air flow is ade quate 3 1 Permissible position and location of the oil cooler Installation See Fig 11 A WARNING Non compliance can result in serious injuries or death The oil cooler must be designed and installed such that the permissible operating temperatures are main tained and that these do no exceed or fall below the maximum values This must also apply to hot day conditions If need be take appropriate measures such as chang ing the size of the oil cooler partially covering the cooler etc The oil cooler should always be installed below the engine oil pump NOTICE The oil cooler must be installed with the radiator caps NOTICE pointing upwards i e in positive direction on the z axis Effectivity 912 Series Z Edition 2 Rev 0 19 00 00 page 21 August 01 2012 BRP Powertrain INSTALLATION MANUAL If this position is not practical also install the oil cooler with the radiator caps pointing upwards i e in positive direction on the z axis This will prevent unintentional draining of the oil cooler rs during longer periods of engine stop 3 2 Capacity Oil tank Capacity without oil cooler and connecting lines min 3 0 8 USgal depending on the
114. ructions General note Noise emmision and vibration The rubber mounts for neutralising vibrations and all engine suspension components not in the scope of de livery must be ground run tested at the specified loads and tested for vibration behaviour Certification to the latest regulations such as FAR and EASA must be conducted by the aircraft manufactur er NOTICE The engine suspension must be designed to prevent excessive engine movement and to minimise noise NOTICE emission and vibration on the airframe If the GENUINE ROTAX engine suspension frame is not being used a vibration test must be carried out See SL 912 010 NOTICE Effectivity 912 Series 10 10 00 Edition 2 Rev O page 6 August 01 2012 d04919 fm d04919 fm Graphic Vibration neutral isation Damping ele ments Vertical axis Deviation BRP Powertrain INSTALLATION MANUAL NOTE With suspension on the 4 top lugs L3 R3 L4 and R4 only the tilting moment due to the pull of the propeller will be avoided while if attached on the bottom lugs only the mo ment of tilting has to be taken care of accordingly Standard aircraft industry damping elements e g Lord are suitable See Fig 1 Engine suspension NOTE The illustration shows Lord J 3608 1 or J 3608 2 rubber mounts Consult the manufacturer for the dimensions of the rubber mounts Fig 1 07600 The vibration and aco
115. s have to be established to the latest require ments such as FAR or EASA by the aircraft manufac turer For prevention of vapour locks all the fuel lines on the suction side of the fuel pump have to be insulated against heat in the engine compartment and routed at distance from hot engine components without kinks and protected appropriately At very critical conditions e g problems with vapour formation the fuel lines could be routed in a hose with cold air flow Secure fuel hoses with suitable screw clamps or by crimp connection Fuel return line NOTICE The engine manufacturere requires the use of a fuel return line The fuel pressure can be adjusted using different adapter sleeve Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 6 August 01 2012 d04923 fm d04923 fm BRP Powertrain INSTALLATION MANUAL Fuel filter See Fig 2 Fuel filter Coarse fil On fuel tank as per valid certification ter Fine filter In the feed line from tank to the fuel pumps an additional fine filter with meshsize 0 1 mm 004 in has to be provided The filter has to be controllable for service A combination of filter water trap gascolator is recommended Water trap A suitable water trap must be installed at the lowest point of the fuel feed line Fuel temperature To avoid vapour locks keep the temperature of the fuel lines float cham ber and related deviced below 45 C 113 F
116. serious injuries or death The aircraft or fuselage manufacturer must design the engine suspension so that it can safely carry the max imum occurring operational loads without exceeding the max allowable forces and bending moments on the engine housing and attachment points Tighten all engine suspension screws as specified by the aircraft manufacturer Graphic Attachment points Fig 3 08318 Effectivity 912 Series 1 0 1 0 00 Edition 2 Rev 0 page 9 August 01 2012 BRP Powertrain INSTALLATION MANUAL attachment points m n ait ai L1 200 8 7 90 in 71 0 2 80 in 211 0 8 31 in R1 200 8 7 90 in 71 0 2 80 in 211 0 8 31 in L2 414 3 16 31 in 71 0 2 80 in 211 0 8 31 in R2 414 3 16 31 in 71 0 2 80 in 211 0 8 31 in L3 414 3 16 31 in 75 0 2 96 in 22 0 0 87 in R3 414 3 16 31 in 75 0 2 96 in 22 0 0 87 in L4 128 3 5 05 in 87 0 3 43 in 0 R4 128 3 5 05 in 87 0 3 43 in 0 L5 564 0 22 20 in 105 0 4 13 in 277 0 10 91 in R5 564 0 22 20 in 105 0 4 13 in 277 0 10 91 in L6 564 0 22 20 in 105 0 4 13 in 7 0 0 28 in R6 564 0 22 20 in 105 0 4 13 in 7 0 0 28 in aehan max permissible forces max permissible bending mo points secure load in N in ment secure load in Nm xX y and z axis i
117. ss in fuel pres sure Position of z4 axis of the fuel manifold NOTE Dimensions always from point of reference P Coordinates mm x axis y axis z axis Fuel manifold 385 0 mm 50 0 mm approx 110 mm 15 16 in 1 97 in 4 33 in Fuel manifold A 4 2 i fuel pressure sensor connection to carburetor fuel pressure sensor connection to carburetor sa 5 gt to fuel tank Effectivity 912 Series Edition 2 Rev 0 73 00 00 page 8 August 01 2012 d04923 fm d04923 fm Fig 4 BRP Powertrain INSTALLATION MANUAL Part Function Fuel manifold Pressure gauge connection Fuel pressure switch connection Banjo bolt Connection nipple Orifice 0 35 mm 0 014 in Hose nipple l NI o oF A Ol N Orifice 0 35 mm 0 014 in 09192 09139 1 4 2 Fuel pump See Fig 5 General note NOTICE NOTICE Ensure at installation of the supply line to fuel pump that no additional moments or load will rest on the pump Utilize max slip on length Secure hoses with suitable screw clamps or crimp Slip on joint Hose connection on fuel pump 1 inlet by slip on joint Fuel intake connection 3 Outside dia 9 mm 35 in Slip on length Max 24 mm 95 in Fuel outlet connection 4 Outside dia 6 mm 24 in Slip on length
118. st the place with the highest cylinder head temperature must be found this can vary with differ ent engine installation cowling or free installation tractor or pusher fight speed etc Graphic Temperature sensors Fig 4 00327 Effectivity 912 Series 7 5 00 00 Edition 2 Rev 0 page 11 August 01 2012 BRP Powertrain INSTALLATION MANUAL Coolant exit See Fig 5 temperature AWARNING Non compliance can result in serious injuries or death Do not restrict the coolant flow with the sensor It is possible to record a false measurement when measuring fluid temperatures If fluid volume is lost and the sensor is not fully submerged in the liquid the indicating instrument could incorrectly display a lower temperature by measuring the air temperature instead of the coolant temperature The measuring of the coolant exit temperature is performed using a sepa rate sensor which has to be installed in the line between expansion tank 1 and radiator inlet 2 Graphic Measurement of cylinder head temperature and coolant exit temperature 1 Part Function Expansion tank 2 Radiator inlet Fig 5 09152 Installation The sensor may be installed in a TEE inline with the fluid hose or the expansion tank may be modified to attach the sensor not supplied by BRP Powertrain Effectivity 912 Series 7 B Edition 2 Rev 0 15 00 00 page 12 August 01 2012 d04924 f
119. stem of the cylinder heads is a closed circuit with an expan sion tank and overflow bottle The coolant flow is forced by a water pump driven from the camshaft from the radiator to the individual cylinder heads The coolant flows from the top of the cylinder heads to the expansion tank 1 Since the standard location of the radiator 3 is below engine level the expansion tank located on top of the engine allows for coolant expansion The expansion tank is closed with a pressure cap 2 with pressure relief valve and return valve As the coolant heats up and expands the pres sure relief valve opens and the coolant flows via a thin hose at atmo spheric pressure to the transparent overflow bottle 4 As it cools down the coolant is sucked back into the cooling circuit The shape size and position of the radiator s depends mainly on the space available in the aircraft Readings are taken on measuring point of the hottest cylinder head depending on engine installation NOTE The temperature sensors are located in cylinder head 2 and 3 If a GENUINE ROTAX radiator is being used then an oil water heat exchanger must not be present The radiator is dimensioned to cater for the heat of the coolant and cannot cope with the additional heat generated by the oil system Effectivity 912 Series 7 5 00 00 Edition 2 Rev O page 3 August 01 2012 Graphic Cooling system Fig 2 BRP Powertrain INSTALLATI
120. tallation the certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer Airbox retrofitted NOTE If an airbox or GENUINE ROTAX airbox is retrofitted at a ROTAX 912 A F UL Series a change in the carb jetting is required See Illustrated Part Catalog 912 914 chapter 22 and or SB 912 044 Use of the ROTAX supplied air box latest issue 3 1 Operating limits Fuel mixture dis Fuel mixture distribution mibuilon Low cold air temperature in the airbox is favourable for engine perfor mance and to reduce knocking tendency at combustion The certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manfacturer NOTICE Any changes on the air intake system e g modifica tion on the airbox etc can affect the flow rate in the air intake system and fuel mixture ratio In the course of certification the fuel mixture process must be proofed by a CO measurement Effectivity 912 Series Edition 2 Rev 0 13 00 00 page 21 August 01 2012 BRP Powertrain INSTALLATION MANUAL CO Measurement CO Measurement for configuration with not GENUINE ROTAX air box CO Measurement 912 A F UL Min 2 CO 912 S ULS Min 3 0 CO wide open throttle WOT an rpm of min 5200 1 min needs to be achieved Measurement in original configuration of aircraft e g with installed cowl ing Measured on each
121. tarter 21 Bus Bar 8 9 Starter relay with plug 22 Capacitor connection 10 11 External alternator with 23 Plug connection for 12 connection trigger coil assy 13 Electric rev counter 24 Trigger coil assy tachometer 14 2 capacitor 25 Electrical fuel pump 22000 UF 15 2 ignition switches 26 Starting equipment at the electronic modules 16 Masterswitch 08639 Effectivity 912 Series Edition 2 Rev 0 24 00 00 page 20 August 01 2012 d04920 fm d04921 fm BRP Powertrain INSTALLATION MANUAL Chapter 61 00 00 PROPELLER DRIVE Instruction AWARNING Danger of explosion Never operate the engine without propeller as this re sults in serious engine damage from overspeeding Never fit the propeller directly on the crankshaft Table of contents This section of the Installation Manual contains information on the engine propeller component Subject Page Propeller drive Page 3 Technical data Page 3 Operating limits Page 4 Vacuum pump Page 5 Technical data Page 5 Hydraulic governor for constant speed propeller Page 7 Technical data for connections Page 7 Effectivity 912 Series 2 Z Edition 2 Rev 0 61 00 00 page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 61 00 00 pages 2 August 01 2012 d04921 fm d04921 fm BRP Powertrain INSTALLATION MANUAL 1 Propeller drive General note The
122. that the suction oil line 1 and oil return lines 2 are connected to the proper fittings on the oil tank If the oil lines from the engine to the oil tank are incorrectly connected severe engine damage may result 10 Refit the spark plug Restore aircraft to original operating condition 11 Residual oil may have accumulated in the crankcase Return it to the oil tank by following the oil level check procedure in the relevant Operators Manual 12 Fill the oil in the tank up to the full mark on the dipstick Carefully check all lubrication system connections E lines and clamps for leaks and tightness d04927 fm Effectivity 912 Series F _ Edition 2 Rev 0 19 00 00 page 24 August 01 2012 d04927 fm BRP Powertrain INSTALLATION MANUAL Graphic Lubrication system Purging connection To oil pump Part Function 1 Suction line 2 Oil return line 3 Free end 4 Tank 5 Plug 6 7 8 Return from engine
123. the engine is running Overvoltage and regulator damage can occur During engine stop break circuit between battery and terminal C to avoid discharge of battery see Fig 11 NOTE A charge indicating lamp 3 W 12 V see Fig 11 pos 18 may be fitted on the instrument panel Body of regulator must be grounded with no restance allowed The rectifier regulator has to be protected by a slow blowing 25 A fuse Wire size of the main circuit of at least 2 5 mm 14 AWG A capacitor see Fig 11 pos 14 of at least 22000 uF 25 V is necessary to protect the correct function of regulator and to flatten voltage The regula tor is not designed to store any electrical charge If for any reason the bat tery or bus system is disconnected from the regulator while the engine is running i e the master switch is shut off the capacitor will safely absorb and dissipate the electrical charge produced by the generator Otherwise the regulator would be damaged NOTICE The graph current over engine speed has been deter NOTICE mined and is valid only at the following conditions Ambient temperature 20 C 68 F Voltage permanent 13 5 V Tolerance max 5 Effectivity 912 Series 24 00 00 Edition 2 Rev O page 7 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Current 1000 2000 3000 4000 5000 6000 1 min Fig 3 02500 2 3 Electronic modules See Fig 4 C
124. tion 3 yes no yes yes for configuration 4 yes yes yes no NOTE Conversion of the configuration 2 4 to configuration 3 may be accomplished by ROTAX Authorized Distributors or their Service Center Effectivity 912 Series B _ Edition 2 Rev 0 OO 00 00 page 4 August 01 2012 d04918 fm d04918 fm BRP Powertrain INSTALLATION MANUAL 2 1 Standard version Serial production Optional 4 stroke 4 cyl horizontally opposed spark ignition engine single cen tral camshaft hydraulic tappets push rods OHV Liquid cooled cylinder heads Ram air cooled cylinders Dry sump forced lubrication Dual ignition of breakerless capacitor discharge design 2 constant depression carburetors Mechanical fuel pumps Electric starter 12 V 0 7 kW 912 S ULS 12 V 0 9 kW Integrated AC generator with external rectifier regulator Propeller drive via integrated gearbox with mechanical shock absorber and overload clutch NOTE The overload clutch is installed on all serial production aircraft engines which are certified and non certified air craft engines of the configuration 3 Electric starter 12 V 0 9 kW External alternator 12 V 40 A DC Vacuum pump only for configuration 1 2 and 4 possible Hydraulic constant speed propeller governor only for configuration 3 Effectivity 912 Series 00 00 00 Edition 2 Rev 0 page 5 August 01 2012 Auxiliary equip ment tested Auxiliary e
125. tion and maintenance of the aircraft engine Subject Page General note Page 3 Type description Page 4 Standard version Page 5 Abbreviations and terms used in this Manual Page 7 Conversion table Page 9 Safety notice Page 10 Safety information Page 11 Instruction Page 13 Technical documentation Page 14 Effectivity 912 Series 00 00 00 Edition 2 Rev 0 page 1 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 00 00 00 page 2 August 01 2012 d04918 fm d04918 fm BRP Powertrain INSTALLATION MANUAL 1 General note Purpose Documentation ROTAX Distributors Engine serial number The purpose of this Installation Manual is to acquaint maintenance ser vice staff IRMT approved by the local aviation authorities with some basic installation and safety information for service work For more detailed information regarding installation maintenance safety or flight operation consult the documentation provided by the air craft manufacturer and or dealer For additional information on engines maintenance or parts you can also contact yout nearest authorized ROTAX aircraft engine distributor For ROTAX Authorized Distributors for Aircraft Engines see latest Opera tors Manual or on the Internet at the official Website www FLYROTAX com When making inquiries or ordering parts always indicate the engine serial numb
126. train thus guaranteeing proper pro tection against corrosion damage for at least 24 months after the date of delivery from BRP Powertrain This warranty is subject to the following conditions The engine must be stored in the GENUINE ROTAX packing as sup plied by BRP Powertrain The covers on various openings must not be removed The engine must be stored in a suitable place at min 40 C 40 F and max 80 C 176 F The flat bag blue surrounding the engine must not be damaged or removed as it protects the engine from corrosion and oxidation If the engine is stored for a period longer than 12 months not stored in the GENUINE ROTAX packing then maintenance tasks must be carried out every 3 months as per the currently valid Maintenance Manual section Preservation of a new engine Effectivity 912 Series 10 10 00 Edition 2 Rev 0 page 4 August 01 2012 d04919 fm d04919 fm BRP Powertrain INSTALLATION MANUAL 1 4 Protective covering General note NOTICE Protective coverings are only for use during transport and engine installation They must be removed before the engine is operated All openings are protected against ingress of contamination and damp ness It is recommended to leave the protective plugs in place until instal lation of the specific feed line NOTE The transport equipment and plugs must be reattached if the engine will be sent to the manufacturer or distributo
127. ug 2 must be M12x1 5 met ric and M8 for the crankshaft locking screw 3 use always new gasket Pressure values The pressure in the crankcase at full throttle must not exceed the prevail ing ambient pressure by more than 0 45 bar 6 53 psi at 90 C 194 F oil temperature Non compliance can result in serious injuries or death AWARNING If the readings exceed the pressure limits then the flow resistance in the oil return line from oil sump to oil tank is too high in the current engine installation con tamination restrictions of cross section etc This condition is unsafe and must be rectified immediately If crankcase pressure and measuring pressure of the vacuum readings and all operational data flight attitude temperatures etc are within the specified limits then it can be assumed that the oil circuit is working cor rectly Effectivity 912 Series 79 00 00 Edition 2 Rev 0 page 6 August 01 2012 d04927 fm d04927 fm BRP Powertrain INSTALLATION MANUAL 1 4 Measuring of the vacuum Measuring ofthe See Fig 3 meee Measure the vacuum in the suction oil line 1 from the oil tank via the oil cooler to the engine oil pump at a distance of max 100 mm 4 in from the oil pump suction connector 2 At full throttle the indicated vacuum 3 upstream of the oil pump must not be less than 0 3 bar 4 35 psi otherwise the oil hose 1 could col lapse and block the oil supply to
128. urrent connections 1 M6 screw connection tightening torque 4 Nm 36 in Ib suitable for cable terminals according to DIN 46225 MIL T 7928 PIDG or equiva lent Control wiring 2 6 3x0 8 plug connector suitable for Faston connector female according to DIN 46247 MIL T 7928 PIDG or equivalent The starter relay must be isolated from the aircraft NOTICE ground Effectivity 912 Series 80 00 00 Edition 2 Rev 0 page 4 August 01 2012 d04928 fm d04928 fm Graphic Starter relay BRP Powertrain INSTALLATION MANUAL Fig 3 Part Function Main current connections Control wiring Ground Effectivity 912 Series Edition 2 Rev 0 80 00 00 page 5 August 01 2012 BRP Powertrain INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 2 Rev 0 80 00 00 page 6 August 01 2012 d04928 fm ROTAX AIRCRAFT ENGINES Motornummer Engine serial no Flugzeugtype Type of aircraft Flugzeugkennzeichen Aircraft registration no ROTAX Vertriebspartner ROTAX authorized distributor and TM are trademarks of BRP Powertrain GmbH amp Co KG 2011 BRP Powertrain GmbH amp Co KG All rights reserved
129. ust not be routed into the slipstream or down the firewall Pressure differences between intake pressure and pressure in the carburetor chambers may lead to engine malfunction due to incorrect fuel supply Connecting nip Connecting nipple 3 for leakage line ii l akage Outside dia 6 mm 1 4 Slip on length Max 17 mm 11 16 Effectivity 912 Series 73 00 00 Edition 2 Rev 0 page 13 August 01 2012 BRP Powertrain INSTALLATION MANUAL 2 1 2 Drainage piping on carburetor General note Drainage piping The primary function of the carburetor float chamber venting lines is to provide ambient air pressure to the float bowl chambers However it is possible for fuel to be expelled from these lines Normally these lines are connected to fitting on the ROTAX airbox to provide the ideal ambient air pressure and away of draining any expelled fuel overboard If an airbox is not installed the vent lines will need to be routed according to the following instructions The lines have to be routed such that in case of fuel being expelled it is drained off suitably Route the lines without kinks and avoid tight bends Route the lines with a continuous decline The lines have to be protected against any kind of blockage e g by for mation of ice NOTICE The carburetor float chamber venting lines have to be routed into a ram air and vacuum free zone or into the airbox according to the release of
130. ustic insulation factor is dependent on the cell man ufacturer Perform the determination as described in SL 912 010 NOTICE oo for neutralising vibrations must be cap The y axis must be perpendicular to the longitudinal axis of the aircraft Permissible deviation from perpendicular 10 See Fig 2 Effectivity 912 Series 1 0 1 0 00 Edition 2 Rev O page 7 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Deviation A M Pi N eo Fig 2 00515 2 2 Attachment points General note See Fig 3 NOTICE The hex screws M10x60 in the attachment points are for transport only and must not be used for engine suspension It is recommended that the 4 stated attachment points R2 L2 R3 and L3 of the engine suspension frame are used NOTICE A minimum of 4 attachement points must be used NOTICE These must be distributed symmetrically between the left L and right R sides Effectivity 912 Series 10 10 00 Edition 2 Rev 0 page 8 August 01 2012 d04919 fm d04919 fm BRP Powertrain INSTALLATION MANUAL 2 3 Definition of attachment points General note See Fig 3 A WARNING Non compliance can result in
131. vent hole 5 Fix M6 hex nut 1 onto the hose nipple 3 Tightening torque 5 Nm 3 69 Ibft 6 Screw the plug screw onto the overflow bottle Steps for attaching the hose Step Procedure 1 Secure the hose with a gear type hose clip 4 or spring type hose clip 2 Secure and route the hose 5 without kinks Effectivity 912 Series Edition 2 Rev 0 75 00 00 page 21 August 01 2012 BRP Powertrain INSTALLATION MANUAL Graphic Hose nipple 2 g 7 Eeo Eo 4 EQIEE pae SSS H se A S KA 1 2 3 Part Function 1 Nut M6 2 Cap 3 Hose nipple 4 Gear type hose clamp 5 Hose 6 Bypass opening slot 7 Cowlin S Fig 10 09132 05033 09126 S 5 Effectivity 912 Series 7 B Edition 2 Rev 0 15 00 00 page 22 August 01 2012 d04924 fm BRP Powertrain INSTALLATION MANUAL 4 General notes on the cooling system General note Radiator Graphic Non compliance can result in serious injuries or death AWARNING Certification according to the latest regulations such as FAR or EASA must be conducted by the aircraft or fuselage manufacturer Essential parts of the cooling system such as radiator etc are available for this engine from BRP Powertrain See Fig 11 The size and type of radiator should be adequate to transfer thermal energy of approx 25 kW 24 BTU s for ROTAX 912 A F UL or approx 28 kW 26 5 BTU
132. xis 2000 N 449 62 Ib force Max permissible bending moment safe load in Nm in x y and z axis 50 Nm 36 89 Ibft Min length of thread mm 15 mm 0 59 in 4 4 Data for optional components of cooling system Overflow bottle See Fig 13 and Fig 15 A 0 C MAX 3 A z s s o D z ROTAX 2 aI 2 A B D o 2 2 MN o C C A 31 0 83 in 85 3 35 in gt PE 0 83 in p 106 4 18 in gt Fig 13 09148 Effectivity 912 Series Edition 2 Rev O 75 00 00 page 27 August 01 2012 BRP Powertrain INSTALLATION MANUAL Radiator Weight see also chap 72 00 00 section 2 1 z 78 Sfo o 2 By F 2 8 g ae 150 t2 5 91 in z 17 5 3 0 69 in lt 4 22 601m _ N gt n H 9 as 5 7 age eT S sias K hlfl che 4 5dm2 A pe cooling surface 4 5dm TOR 23 leg Sr T Y i Ny j F T p 4175 t3 0 69 in lt 415 4 16 34 in Al Fig ld 08791 Cooling air baf Weight see also chap 72 00 00 section 2 1 fle 328 12 91 in 146 5 75 in 78 3 07 in fm Fig 15 09165 04924 Effectivity 912 Series 7 B Edition 2 Rev 0 15 OO 00 page 28 August 01 2012 d04925 fm BRP Powertrain INSTALLATION MANUAL Chapter 76 00 00 ENGINE MANAGEMENT Introducti i ions ntroduction NOTICE
133. y be selected by the aircraft manufacturer assembler or user for aircraft application A WARNING Non compliance can result in serious injuries or death Unless correctly equipped to provide enough electri cal power for night IFR according latest requirement as ASTM the ROTAX 912 UL ULS is restricted to DAY VFR only In addition to observing the instructions in our Manual general safety and accident preventative measures legal regulations and regulations of any aeronautical authority must be observed Where differences exist between this Manual and regulations provided by any authority the more stringent regulation should be applied Effectivity 912 Series Z Edition 2 Rev 0 OO 00 00 page 11 August 01 2012 Engine run BRP Powertrain INSTALLATION MANUAL For continuing airworthiness see Maintenance Manual Line Unauthorized modifications of engine or aircraft will automatically exclude any liability of the manufacturer for sequential damage This engine may be equipped with an other than the GENUINE ROTAX vacuum pump The safety warning accompanying the air pump must be given to the owner operator of the aircraft into which the air pump is installed In the interest of safety the aircraft must not be left unattended while the engine is running To eliminate possible injury or damage ensure any loose equipment or tools are properly secured before starting the engine When in storage protect the en
134. y plugged New style compensating tubes have plugged this connec tion by a screw M3 5x6 2 NOTICE Flawless operation of the indicating instrument needs the installations of a water trap between engine and in strument for fuel condensate Graphic Monitoring of the intake manifold pressure Part Function Connection nipple 2 Screw M3 5x6 Fig 5 02051 Effectivity 912 Series 2 s Edition 2 Rev 0 16 00 00 page 9 August 01 2012 BRP Powertrain INSTALLATION MANUAL 2 1 Air temperature in the airbox optional General note See Fig 6 To take air temperature readings in the airbox a connection is provided This connection is closed on the standard engine by a plug screw Plug screw Connection Thread M6 Thread length approx 9 mm 3 8 Graphic Airbox 3 F Part Function 1 Plug screw Fig 6 08647 d04925 fm Effectivity 912 Series B Edition 2 Rev 0 76 00 00 page 10 August 01 2012 d04926 fm BRP Powertrain INSTALLATION MANUAL Chapter 78 00 00 EXHAUST SYSTEM General note See Fig 1 NOTICE The exhaust system must be designed by the aircraft or fuselage manufacturer such that the

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