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OPERATORS MANUAL

1. Fig 5 5 g 08629 5 Ut Effectivity 912 Series BRP Powertrain page 1 14 OM Edition 2 Rev 0 April 01 2010 d04944 fm Introduction Table of contents 2 Operating instructions The data of the certified engines are based on type certificate of type 912 A JAR 22 TC No EASA E 121 912 F S FAR 33 TC No E00051 EN JAR E TC No EASA E 121 This chapter of the Operators Manual contains the operating limits that must be observed to ensure the ROTAX aircraft engine and standard systems operate safely Subject Page Operating limits 912 A F UL page 2 2 Performance page 2 2 Speed page 2 2 Acceleration page 2 2 Oil pressure page 2 2 Oil temperature page 2 2 EGT page 2 2 Conventional coolant page 2 3 Waterless coolant page 2 3 Engine start temperature page 2 4 Fuel pressure page 2 4 Power consumption of the hydraulic propeller page 2 4 governor Power consumption of the vacuum pump page 2 4 Power consumption of the external alternator page 2 4 Deviation from bank angle page 2 4 Operating limits 912 S ULS page 2 5 Performance page 2 5 Speed page 2 5 Acceleration page 2 5 Oil pressure page 2 5 Oil temperature page 2 5 EGT page 2 5 Conventional coolant page 2 6 Waterless coolant page 2 6 Engine start temperature page 2 7 Fuel pressure page 2 7 Power consumption of the hydraulic propeller page 2 7 governor Power consumption of the vacuum pump page 2 7 Power cons
2. multi grade oils tropisch tropical SAE 20W 40 gemaBigt temperate o T z e o arktisch arctic Fig 1 01176 Effectivity 912 Series BRP Powertrain page 2 11 OM Edition 2 Rev 0 April 01 2010 NOTES Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 2 12 April 01 2010 d04944 fm d04945 fm Introduction 3 Standard operation To warrant reliability and efficiency of the engine meet and care fully observe all the operating and maintenance instructions Table of content This chapter of the Operators Manual contains expanded operat ing and maintenance instructions Subject Page Daily checks page 3 2 Coolant level page 3 3 Check of mechanical components page 3 4 Gear box page 3 4 Carburetor page 3 4 Exhaust system page 3 4 Before engine start page 3 5 Pre flight checks page 3 5 Operating media page 3 5 Coolant page 3 5 Oil page 3 6 Oil level oil dipstick page 3 6 Engine start page 3 7 Prior to take off page 3 9 Warming up period page 3 9 Throttle response page 3 9 Ignition check page 3 9 Propeller governor page 3 9 Take off page 3 10 Cruising page 3 10 Engine shut off page 3 10 Cold weather operation page 3 11 Effectivity 912 Series BRP Powertrain page 3 1 OM Edition 2 Rev 0 April 01 2010 3 1 Daily checks General note To warrant reliability and efficiency of the engine m
3. AIRCRAFT ENGINES Motornummer Engine serial no Flugzeugtype Type of aircraft Flugzeugkennzeichen Aircraft registration no Fa ROTAX Vertriebspartner ROTAX authorized distributor www rotax aircraft engines com and TM are trademarks of BRP Powertrain GmbH amp Co KG 2010 BRP Powertrain GmbH amp Co KG All rights reserved
4. Firing order 1 4 2 3 Ignition circuit A OH TF tl la Ignition circuit B Part Function 1 charging coils 2 electronic modules 3 trigger coils for ignition signal 4 5 dual ignition coils trigger coils for speed signal Fig 4 00425 Effectivity 912 Series BRP Powertrain page 7 7 OM Edition 2 Rev 0 April 01 2010 7 5 Propeller gearbox General note Reduction ratio Overload clutch Torsional shock See Fig 5 For the engine type 912 two reduction ratios are available Reduction ratio 912 A F UL 912 S ULS crankshaft propeller shaft 2 271 2 431 2 431 optional Depending on engine type certification and configuration the pro peller gearbox is supplied with or without an overload clutch NOTE The overload clutch is installed on serial pro duction on all certified aircraft engines and on the non certified aircraft engines of configura tion 3 i Fig 5 02531 NOTE Fig shows a propeller gearbox of configuration 2 with the integrated overload clutch The design incorporates a torsional shock absorber The shock absorber absorbing is based on progressive torsional cushioning due to axi al spring load acting on a dog hub
5. Performance graph for non standard conditions The following graph shows the performance drop with increasing flight altitude The curves show the performance at 5800 5500 5000 4800 and 4300 rpm at full throttle The engine allows operation with fully open throttle valve over the whole rpm range without limitation But full throttle performance above 5500 rpm is limited to 5 minutes At deviation of temperature conditions from standard atmosphere conditions the engine performance to be expected can be calcu lated from the performance indicated multiplied by standard tem perature divided by actual temperature in K 80 5800 U min Vollast take off performance 70 5800 E 5500 amp eo o 2 5000 a E 50 5 4800 a 40 P 4300 30 al 20 10 0 1000 2000 3000 4000 5000 6000 7000 7500 Dichteh he Density Altitude m stand T ioi T K t C 273 Fig 6 08636 Effectivity 912 S ULS BRP Powertrain page 5 7 OM Edition 2 Rev 0 April 01 2010 NOTES Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 5 8 April 01 2010 d04677 fm d04678 fm 6 Weights Introduction The stated weights are dry weights without operating fluids and are guide values only Further weight information relating to the equipment can be found in the current Installation Manual
6. OPERATORS MANUAL FOR ROTAX ENGINE TYPE 912 SERIES Ref OM 912 ROTAX 912 ULS 3 WITH OPTIONS part no 899374 Introduction Foreword BRP Powertrain provides Instructions for Continued Airworthi ness which are based on the design the tests and certification of the engine and its components These instructions apply only to engines and components sup plied by BRP Powertrain This Operators Manual contains important information about safe operation of the engine together with descriptions of the system andits layout technical data operating media and the operational limits of the engine The specified data apply only to the engine and not to specific ap plications in particular aircraft The aircraft manufacturer s Opera tors Manual is therefore definitive in terms of the operation of the engine as it contains all of the aircraft specific instructions Chapter structure The structure of the Manual follows whenever it is applicable the structure of the GAMA Specification 1 for Pilo s Operating Handbook The Operators Manual is subdivided into following d04670 fm chapters Subject Chapter Introduction Chapter INTRO List of effective pages Chapter LEP Table of amendments Chapter TOA General note Chapter 1 Operating instructions Chapter 2 Standard operation Chapter 3 Abnormal operation Chapter 4 Performance data Chapter 5 Wei
7. 377 0 93 30 17 60 E mail mad libello com Website www moteuraerodistribution com Contact person Philippe Thys GERMANY AUSTRIA BULGARIA HUNGARY LIECHTENSTEIN ROMANIA SWITZERLAND THE NETHERLANDS gt FRANZ AIRCRAFT ENGINES VERTRIEB GMBH Am Weidengrund 1a 83135 Schechen GERMANY Tel 49 0 8039 90350 Fax 49 0 8039 9035 35 E mail info franz aircraft de Website www franz aircraft de Contact person Eduard Franz gt SKYDRIVE LTD Burnside Deppers Bridge SOUTHAM WARWICKSHIRE CV47 250 Tel 44 0 1926 612 188 Fax 44 0 1926 613 781 E mail sales skydrive co uk Website www skydrive co uk Contact person Nigel Beale ITALY CYPRUS GREECE MALTA LIBYA SPAIN PORTUGAL TURKEY gt LUCIANO SORLINI S P A Piazza Roma 1 Carzago di Calvagese Riviera Brescia Italy Tel 39 030 601 033 Fax 39 030 601 463 E mail avio sorlini com Website www sorlini com Contact person Alberto Comincioli POLAND gt FASTON LTD ul Zwirki i Wigury 47 PL 21 040 SWIDNIK Tel 48 0 81 751 2882 Fax 48 0 81 751 5740 E mail faston go2 pl Contact person Mariusz Oltarzewski SLOVENIA gt PIPISTREL D O O AJDOVSCINA Goriska Cesta 50A 5270 AJDOVSCINA Tel 386 0 5 3663 873 Fax 386 0 5 3661 263 E mail info pipistrel si Website www pipistrel si Contact person Leon Brecelj Effectivity 912 Series OM Edition 2 Rev 1 BRP Powertrain d04
8. Bank angle Deviation from bank angle Max 40 Up to this value the dry sump lubrication system warrants lubrication in every flight situation Effectivity 912 A F UL OM Edition 2 Rev 1 BRP Powertra in page 2 4 November 01 2010 d04944 fm d04944 fm 2 2 Operating limits 912 S ULS Performance data relate to ISA International Standard Atmo sphere conditions without Governor external alternator etc Performance Speed Acceleration Oil pressure Oil temperature EGT Take off performance 73 5 kW at 5800 rpm Max continuous performance 69 kW at 5500 rpm Take off speed 5800 rpm max 5 min Max continuous speed 5500 rpm Idle speed min 1400 rpm Limit of engine operation at zero gravity and in negative g con dition Max 5 seconds at max 0 5 g Max 7 bar 102 psi NOTICE For a short period admissible at cold start Min 0 8 bar 12 psi below 3500 rpm Normal 2 0 to 5 0 bar 29 73 psi above 3500 rpm Max 130 C 266 F Min 50 C 120 F normal operating temperature approx 90 to 110 C 190 230 F exhaust gas temperature Max 880 1616 F Effectivity 912 S ULS BRP Powertrain OM Edition 2 Rev 0 page 2 5 April 01 2010 Conventional coolant See also Chapter 2 3 Coolant temperature coolant exit te
9. GUINEA IVORY COAST MALI MAURITANIA NIGER NIGERIA SENEGAL TOGO gt WAASPS LTD PMB KA49 Kotoka International Airport Accra GHANA Tel 4233 0 28 5075254 Fax 233 0 217 717 92 E mail info waasps com Website www waasps com Contact person Jonathan Porter Effectivity 912 Series BRP Powertrain page 9 7 OM Edition 2 Rev 1 November 01 2010 ISRAEL gt CONDOR AVIATION INDUSTRIES LTD P O Box 1903 14 Topaz st 5 ASIA CHINA HONG KONG MACAO PEIPORT INDUSTRIES LTD Rm 1302 Westlands Centre 20 Westlands Road Quarry Bay HONG KONG Tel 852 0 2885 9525 Fax 852 0 2886 3241 E mail admin peiport com hk Website www peiport com Contact person Larry Yeung CIS gt AVIAGAMMA JSCO P O Box 51 125 057 MOSCOW Tel 7 499 158 31 23 Fax 7 499 158 62 22 E mail aviagamma mtu net ru Website www aviagamma ru Contact person Vladimir Andriytschuk INDIA gt GREAVES COTTON LTD Express Building Annexe 9 10 Bahadur Shah Zafar Marg NEW DELHI 110002 Tel 91 0 11 23311501 Fax 91 0 11 23702129 E mail anilkumar ggreavesmail com Website www greavescotton com aeroengines htm Contact person Cdr Anil Kumar INDIA gt VARMAN AVIATION PVT LTD Aviation Complex 16 17 EPIP Whitefield Bangalore 560066 Tel 91 80 28412536 91 80 28412655 56 Fax 91 80 28413559 E mail varman blr vsnl net in Website www varman com Contact
10. Gear box Carburetor Exhaust system Check of mechanical components Step Procedure Turn propeller by hand in direction of engine rotation sev eral times and observe engine for odd noises or excessive resistance and normal compression At excessive resistance of the engine per NOTICE form the relevant unscheduled maintenance check according to Maintenance Manual Line chapter Hard to turn over Version without overload clutch No further checks are necessary Version with overload clutch Step Procedure Turn the propeller by hand to and fro feeling the free rota tion of 30 before the crankshaft starts to rotate If the propeller can be turned between the dogs with prac tically no friction at all less than 25 Nm 19 ft Ib further investigation is necessary Step Procedure Verify free movement of throttle cable and starting carbu retor over the complete range Check from the cockpit Step Procedure Inspect for damages leakage and general condition Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 3 4 April 01 2010 d04945 fm d04945 fm 3 2 Before engine start Carry out pre flight checks 3 3 Pre flight checks Safety Non compliance can result in serious injuries or death Ignition OFF Before moving the propeller Switch off both ignition circuits and anchor compete
11. aircraft Warming up peri od Step Procedure 1 Start warming up period at approx 2000 rpm for approx 2 minutes 2 Continue at 2500 rpm duration depending on ambient temperature until oil temperature reaches 50 C 120 F 3 Check temperatures and pressures Throttle response After a full load ground test allow a short cool NOTICE ing run to prevent vapour formation in the cyl inder head Step Procedure 1 Short full throttle ground test consult Aircraft Operators Manual since engine speed depends on the propeller used Ignition check Check the two ignition circuits at 4000 rpm approx 1700 rpm pro peller Step Procedure 1 Speed drop with only one ignition circuit must not exceed 300 rpm approx 130 rpm propeller 2 115 rpm approx 50 rpm propeller max difference of speed by use of either circuit A or B NOTE The propeller speed depends on the actual reduction ratio Propeller gover Check of hydraulic propeller governor nor Check control of the hydraulic propeller governor to specifications of the manufacturer NOTE Cycling the propeller governor puts a relatively high load on the engine Unnecessary cycling or additional checks should be avoided Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 3 9 April 01 2010 3 6 Take off Safety Climb 3 7 Cruising Performance Oil temperature Non compl
12. is returning back to the oil tank and can be noticed by a murmur from the open oil tank Install oil tank cap Oil level oil dip stick NOTE The oil level should be in the upper half be tween the 75096 and the mark and should never falls below the min mark Prior to long flights oil should be added so that the oil level reaches the max mark Avoid oil levels exceeding the mark since excess oil could be poured out through the venting system Difference between max and min mark 0 45 litre 0 95 liq pt Effectivity 912 Series OM Edition 2 Rev 1 BRP Powertrain page 3 6 November 01 2010 d04945 fm d04945 fm 3 4 Engine start Safety Non compliance can result in serious injuries Do not take the engine into operation if any person is near the aircraft Engine start Step Designation Procedure 1 Fuel valve open 2 Starting carb activated If Then engine in operating tempera start the engine without ture choke Throttle lever set to idle position Master switch on Ignition both circuits switched on Do not actuate starter button switch as NOTICE long as the engine is running Wait until complete stop of engine 6 Starter button actuate Activate starter for max 10 sec only NOTICE without interruption followed by a cool ing period of 2 minutes 7 As soon as engine runs adjust throttle to achiev
13. outside of the page margin in dicates a change to text or graphic Effectivity 912 Series BRP Powertrain page 1 4 OM Edition 2 Rev 0 April 01 2010 d04673 fm d04673 fm 1 4 Safety notice Normal use Non compliance can result in serious injuries Never fly the aircraft equipped with this en gine at locations airspeeds altitudes or oth er 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 dis cretion and responsibility of the aircraft manufacturer assem bler 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 components or system which may be selected by the aircraft manufacturer assemb ler or user for aircraft application Non compliance can result in serious injuries Unless correctly equipped to provide enough electrical power for night VFR according la test requirement as ASTM the ROTAX 912 UL ULS ULSFR is
14. restricted to DAY VFR only Certain areas altitudes and conditions present greater risk than others The engine may require humidity or dust sand preventative equipment or additional maintenance may be re quired You should be aware that any engine may seize or stall at any time This could lead to a crash landing and possible severe injury or death For this reason we recommend strict compli ance with the maintenance and operation and any additional information which may be given to you by your distributor Effectivity 912 Series BRP Powertrain page 1 5 OM Edition 2 Rev 0 April 01 2010 Training Whether you are a qualified pilot or a novice complete know ledge of the aircraft its controls and operation is mandatory before venturing solo Flying any type of aircraft involves a cer tain amount of risk Be informed and prepared for any situation or hazard associated with flying A recognized training program and continued education for pi loting an aircraft is absolutely necessary for all aircraft pilots Make sure you also obtain as much information as possible about your aircraft its maintenance and operation from your dealer Regulation Respect all government or local rules pertaining to flight ope ration in your flying area Fly only when and where conditions topography and airspeeds are safest Consult your aircraft dealer or manufacturer and obtain the ne cessary information especially bef
15. 0 power reguirement of propeller 10 0 2500 3000 3500 4000 4500 5000 5500 5800 Drehzahl Engine Speed 1 min Fig 4 02001 Ansaugladedruck manifold pressure Werte bezogen auf die Propeller Kurve values along propeller curve Ansaugladedruck manifold pressure in Hg Benzinverbrauch fuel consumption Benzinverbrauch Fuel consumption L h 2500 3000 3500 4000 4500 5000 5500 5800 Drehzahl Engine speed 1 min rpm Fig 5 02002 Effectivity 912 S ULS BRP Powertrain page 5 5 OM Edition 2 Rev 0 April 01 2010 d04677 fm Performance data Engine 912 S ULS Performance data for variable pitch propeller Engine speed over 5500 rpm is restricted to 5 minutes Run the engine in accordance with the following table Power Set Engine Perfor Torque Nm Manifold ting speed mance ft Ib pressure rom kW HP in HG Take oli 5800 73 5100 121 0 9924 275 power ft Ib conin E50 69 090 119 8 99 96 27 uous power ft Ib 75 96 5000 51 0 68 97 4 26 65 96 4800 44 6 60 88 7 pie 26 55 4300 38 0 50 84 3 A d 24 NOTE Further essential information regarding engine behavior see Service Letter SL 912 016 latest edition M N 3 Effectivity 912 S ULS BRP Powertrain page 5 6 OM Edition 2 Rev 0 April 01 2010 d04677 fm Performance graph Engine 912 S ULS
16. 10 oa 1101229010 3 2 04 01 2010 98 11 01 2010 3 3 04 01 2010 rear page 3 4 04 01 2010 3 5 04 01 2010 3 6 11 01 2010 3 7 04 01 2010 3 8 04 01 2010 3 9 04 01 2010 3 10 04 01 2010 3 11 04 01 2010 3 12 04 01 2010 Effectivity 912 Series BRP Powertrain page LEP 1 OM Edition 2 Rev 1 November 01 2010 NOTES Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page LEP 2 April 01 2010 d04942 fm d04943 fm TOA Table of amendments Approval The technical content of this document is approved under the authority DOA No EASA 21J 048 current chapter page date of remark for date of approval date of signature no change approval from authorities issue 0 1109 04 01 2010 1 LEP LEP 1 11 01 2010 DOA 1 TOA TOA 1 11 01 2010 DOA 3 1101 2010 DOA TOA 4 11 01 2010 DOA 1 2 2 4 11 01 2010 DOA 2 7 11 01 2010 DOA 2 9 11 01 2010 DOA 1 3 3 6 11 01 2010 DOA 1 4 4 6 11 01 2010 DOA 1 9 9 6 11 01 2010 DOA 9 7 11 01 2010 DOA 9 8 11 01 2010 DOA Effectivity 912 Series BRP Powertrain page TOA 1 OM Edition 2 Rev 1 November 01 2010 NOTES Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page TOA 2 April 01 2010 d04943 fm d04943 fm TOA Summary of changes Content Summary of the relevant amendments in this context but makes no claim to completeness current chapter page
17. 12 V 20 A DC Prop drive via reduction gear with integrated shock absorber and overload clutch NOTE The overload clutch is installed on all serial production aircraft engines which are certified and on non certified aircraft engines of the con figuration 3 Electric starter 12 V 0 9 kW External alternator 12 V 40 A DC Vacuum pump only for A1 A2 and A4 possible Hydraulic constant speed propeller governor for configuration 3 only Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 1 10 April 01 2010 d04673 fm d04673 fm 1 7 Type description e g 912 2 Description The type designation is of the following composition ROTAX LI LI V lt DE 58 55 55 FS o 595 BL 5 52 5 5 2 Description Configuration Type 912 4 cyl horizontally opposed nor mal 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 Prop shaft with flange for fixed prop P C D 100 mm 3 936 in NOTE This configura tion is not available any longer and will be replaced by configuration 2 2 Prop shaft with flange for fixed pitch propeller Prop shaft with flange for constant speed propeller and drive for hy draulic governor for cons
18. 2 Series OM Edition 2 Rev 0 BRP Powertrain page 9 2 April 01 2010 d04949 fm 9 1 Form eyeq leq 0 yere ue pareja SI Lode Siy J MOJEJ e yo9uO jeuondo qns uonipuo euibu3 081 euibu3 NS Ag GALLINENS JequinwN jeues ON Hed 10 Jeunjoejnuej awen duozyeuibu3 sepnjour yey Aquiessy LNANOdWOO ANIONA 9 7 129jeQ ued leues ON Hed 10 HAW 38nouL NISnVO 2 Jo OI3IO3dS S ta3TladOtd v INV IdHdMOd LAVYOUIV K YAHLO H310WINOO HJaWNN 1VI43S SIIY3S IIION U3UNLIVANNVN jueujied 18147 Bay IV 1HOd3H NOLLVIAHOHNI 39IAH3S U uawoisno S3NION3 LAVYOUIV E juanaid pue esneo ejqeqoid ejejs peunooo Y XV L o a Japun Y pue Jo Y equoseg SJUBWWOD 8 ON 011109 H3dO HOLVNDIS3G HOLVHZdO 1014LSIG tuJ 6r6r0Dp page 9 3 April 01 2010 BRP Powertrain Effectivity
19. 912 Series OM Edition 2 Rev 0 d04949 fm NOTES Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 9 4 April 01 2010 d04949 fm 9 2 Authorized Distributor General note See the official ROTAX AIRCRAFT ENGINES Homepage www rotax aircraft engines com List Overview of authorized distributor for ROTAX aircraft engines Subject Page Europe page 9 6 America page 9 7 Australia page 9 7 Africa page 9 7 Asia page 9 8 Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 9 5 April 01 2010 1 EUROPE CROATIA FORMER YUGOSLAVIA EXEPT SLOVENIA Issue 2010 11 01 GREAT BRITAIN IRELAND ICELAND gt SHAFT D O O B L Mandica 161 a HR 54000 OSIJEK Tel 385 0 31 280 046 Fax 385 0 31 281 602 E mail shaft os tel hr Contact person Ing Ivan Vdovjak CZECHIA SLOVAKIA gt TEVESO S R O Skroupova 441 CS 50002 HRADEC KRALOVE Tel 42 049 5217 127 Fax 42 049 5217 226 E mail motory teveso cz Website www teveso cz Contact persons Jiri Samal SWEDEN FINLAND NORWAY ESTONIA LATVIA LITHUANIA DENMARK gt LYCON ENGINEERING AB H rkeberga SE 74596 ENK PING Tel 46 0 171 414039 E mail info lycon se Website www aeronord eu FRANCE ALGERIA BELGIUM LU XEMBURG MAROCCO MONACO TUNESIA gt MOTEUR AERO DISTRIBUTION 11 Blvd Albert 1 98000 MONACO Tel 377 0 93 30 17 40 Fax
20. 949 fm page 9 6 November 01 2010 d04949 fm 2AMERICA CANADA gt ROTECH RESEARCH CANADA LTD 6235 Okanagan Landing Rd VERNON B C VIH 1M5 CANADA Tel 1 250 260 6299 Fax 1 250 260 6269 E mail inquiries rotec com Website www rotec com 3 AUSTRALIA NEW ZEALAND PAPUANEWGUINEA FLOOD IMPORTS LTD P O Box 61 16 17 Chris Drive LILYDALE VICTORIA 3140 Tel 61 0 3 9735 5655 Fax 61 0 3 9735 5699 E mail wal bertfloodimports com au Website www bertfloodimports com au Contact person Mark Lester 4 AFRICA EGYPT gt AL MOALLA P O Box 7787 ABU DHABI Tel 971 0 2 444 7378 Fax 971 0 2 444 6896 E mail almoalla emirates net ae Contact person Hussain AI Moalla NORTH MIDDLE SOUTH AMERICA gt KODIAK RESEARCH LTD P O Box N 658 Bay amp Deveaux Street NASSAU BAHAMAS Tel 1 242 356 5377 Fax 1 242 356 2409 E mail custsupport kodiakbs com Website www kodiakbs com ANGOLA BOTSWANA KENIA LESOTHO MADAGASCAR MALAWI MOZAMBIQUE NAMIBIA SOUTH AFRICA SWAZILAND ZAMBIA ZIMBABWE AVIATION ENGINES AND ACCESSORIES PTY LTD P O Box 15749 Lambton 1414 SOUTH AFRICA Tel 27 0 11 824 3368 Fax 27 0 11 824 3339 E mail niren cometaviationsupplies co za Website www aviation engines co za Contact person Niren Chotoki GHANA BENIN BURKINA FASO CAMEROON CENTRAL AFRICAN REPUBLIC CONGO
21. Effectivity 912 Series BRP Powertrain page 7 8 OM Edition 2 Rev 0 April 01 2010 d04679 fm d04679 fm Backlash On the gearbox version with overload clutch the design incorpo rates a friction damped free play at the dogs to warrant proper en gine idling Due to this backlash at the dogs a distinct torsional impact arises at start stop and at sudden load changes but due to the built in overload clutch it will remain harmless NOTE This overload clutch will also prevent any undue load to the crankshaft in case of ground contact of the propeller See Service Letter SI 912 015 latest edition Vacuum pump or Alternatively either a vacuum pump or a hydraulic governor for hydraulic gover constant speed propeller can be used The drive is in each case nor via the propeller reduction gear Effectivity 912 Series BRP Powertrain page 7 9 OM Edition 2 Rev 0 April 01 2010 NOTES Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 7 10 April 01 2010 d04679 fm d04680 fm 8 Checks Introduction All checks to be carried out as specified in the current Mainte nance Manual last revision NOTICE Non compliance can result in serious injuries or death Only qualified staff authorized by the Avi ation Authorities trained on this particu lar engine is allowed to carry out maintenance and repair work Carry out all directives of Service Bulletins SB according to their pri
22. Manual Abbreviations Abbreviation Description C Degrees Celsius Centigrade F Degrees Fahrenheit A Ampere ACG Austro Control GmbH API American Petrol Institute ASTM American Society for Testing and Materials AKI Anti Knock Index CAN CGSB Canadian General Standards Board Cw Clockwise CCW Counter clockwise DOA Design Organization Approval EASA European Aviation Safety Agency EN European Standard FAR Federal Aviation Regulations h hours IFR Instrument Flight Rules INTRO Introduction ISA International Standard Atmosphere kW Kilowatt LEP List of effective pages Nm Newton meter OM Operators Manual part no Part number RON Research Octane Number ROTAX is a trade mark of BRP Powertrain GmbH amp Co KG rpm Revolutions per minute SAE Society of Automotive Engineers SI Service Instruction SB Service Bulletin SL Service Letter TC Type certificate TOA Table of amendments VFR Visual Flight Rules Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 1 3 April 01 2010 1 3 Safety General note Revision Measuring units Translation Symbols used Although the reading of such information does not eliminate the hazard understandi
23. Performance Performance graphs for stand conditions ISA graphs kw Engine 912 A F UL 60 50 40 30 20 10 0 3000 4000 5000 5800 A max engine output B power requirement of propeller Fig 1 00450 in Hg L h Gal R 30 r Fr mFvn rr 30 2299 20 5 28 10 2 64 0 i i i 0 3000 4000 5000 5800 rpm C manifold pressure D fuel consumption Values along propeller curve Fig 2 00451 Effectivity 912 A F UL BRP Powertrain page 5 2 OM Edition 2 Rev 0 April 01 2010 d04677 fm d04677 fm Performance data Engine 912 A F UL Performance data for variable pitch propeller Engine speed over 5500 rpm is restricted to 5 minutes Run the engine in accordance with the following table Engine Perfor Manifold Torque Nm Power setting speed mance ft Ib pressure rpm kW HP in HG Take off power 5800 59 6 80 98 1 s full throttle max continous 5500 58 0 78 100 7 97 tun throttle power 16 75 5000 43 5 58 83 1 p a 27 2 65 4800 37 7 50 75 0 2 26 5 55 4300 31 9 43 70 8 peu 26 3 NOTE Further essential information regarding engine behavior see Service Letter SL 912 016 latest edition Effectivity 912 A F UL OM Edition 2 Rev 0 BRP Powertrain page 5 3 April 01 2010 Performance data Engine 912 A F UL Performance data variab
24. Table of content This chapter of the Operators Manual contains an extensive list of approved equipment for this engine Subject Page Engine page 6 2 Accessories page 6 2 Effectivity 912 Series BRP Powertrain page 6 1 OM Edition 2 Rev 0 April 01 2010 6 1 Engine with electric starter carburetors internal generator ignition unit and oil tank without exhaust system radiator airbox Configuration 2 912 UL 912A 912F 912 ULS 9125 57 1 kg 126 Ib with overload clutch 57 1kg 57 1kg 55 4 kg 122 Ib without clutch 126 Ib 126 Ib 58 3 kg 128 Ib with overload clutch 58 3 kg 128 Ib 56 6 kg 125 Ib without clutch Configuration 3 912 UL 912A 912F 912 ULS 9125 59 8 kg 132 Ib 61 kg 134 Ib 6 2 Assessories Part Weight External alternator 3 0 kg 6 6 Ib Vacuum pump 0 8 kg 1 8 Ib Overload clutch 1 7 kg 3 7 Ib NOTE The overload clutch is installed on all certified aircraft engines and on non certified aircraft engines of the configuration 3 Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 6 2 April 01 2010 d04678 fm d04679 fm 7 Description of systems Introduction This chapter of the Operator Manual contains the description of cooling system fuel system lubrication system electric system and the propeller gearbox Table of c
25. Water in fuel will accumulate at the lower parts of the fuel system and leads to freezing of fuel lines filters or jets Remedy Use non contaminated fuel filtered through suede Generously sized water separators Fuel lines routing inclined Prevent condensation of humidity i e avoid temperature differ ences between aircraft and fuel Effectivity 912 Series BRP Powertrain page 3 12 OM Edition 2 Rev 0 April 01 2010 d04945 fm d04946 fm 4 Abnormal operation Introduction Non compliance can result in serious injuries At unusual engine behaviour conduct checks as per Maintenance Manual Chapter 05 50 00 before the next flight NOTE Further checks see Maintenance Manual Table of contents This chapter of the Operators Manual contains expanded operat ing and maintenance instruction at abnormal operation Subject Page Start during flight page 4 2 Exceeding of max admissible engine speed page 4 2 Exceeding of max admissible cyl head temperature page 4 2 Exceeding of max admissible oil temperature page 4 2 Oil pressure below minimum during flight page 4 3 Oil pressure below minimum on ground page 4 3 Trouble shooting page 4 4 Effectivity 912 Series BRP Powertrain page 4 1 OM Edition 2 Rev 0 April 01 2010 4 1 Start during flight Engine stop Starting procedure same as on ground however on a warm engine without choke 4 2 Exceeding
26. a the fuel manifold 6 to the two carbure tors Return line Via the return line surplus fuel flows back to the fuel tank and suc tion side of fuel system NOTE The returnline serves to avoid formation of va pour lock Fuel system return line carburetor fuel tank C 1 2 orifice jet RSS pecu gt j F N 1 rain ressure U valve gauge 6 3 5 4 UN carburetor Part 1 fuel tank 2 coarse filter 3 fire cock 4 fine filter 5 mechanical fuel pump 6 fuel manifold 7 electric fuel pump 8 check valve standard configuration Fig 2 07306 Effectivity 912 Series BRP Powertrain page 7 4 OM Edition 2 Rev 0 April 01 2010 d04679 fm d04679 fm 7 3 Lubrication system General note Lubrication Crankcase Oil pump Oil circuit vented Oil temperature sensor See Fig 3 The ROTAX 912 engine is provided with a dry sump forced lubri cation system with a main oil pump with integrated pressure regu lator 1 and oil pressure sensor 2 The oil pump 3 sucks the motor oil from the oil tank 4 via the oil cooler 5 and forces it through the oil filter 6 to the points of lu brication in the engine The surplus oil emerging from the points of lubrication accumula tes on the bottom of crankcase and is forced back to the oil tank by the piston blow by gases The oil pumps are driven by the camshaft The oil circuit is vented via bore 7 on the oil tank The oil t
27. be air filter etc against en try of dirt and humidity Spray all steel external engine parts with corrosion in hibiting oil 8 2 Engine back to operation If preservation including oil change took place within a year of storage oil renewal will not be necessary For longer storage pe riods repeat preservation annually Step Procedure 1 Remove all plugs and caps Clean spark plugs with plastic brush and solvent Reinstall Effectivity 912 Series BRP Powertrain page 8 2 OM Edition 2 Rev 0 April 01 2010 d04680 fm d04949 fm 9 Supplement Introduction According to the regulation of EASA part 21 A 3 FAR 21 3 the manufacturer shall evaluate field information and report to the au thority In case of any relevant occurrences that may involve mal function of the engine the form on the next page should be filled out and sent to the responsible authorized ROTAXg distributor NOTE The form is also available from the official ROTAX AIRCRAFT ENGINES Homepage electronic version www rotax aircraft engines com Register Document type Diverses Table of content This chapter of the Operators Manual contains the form and the list of authorized distributors Subject Page Form page 9 3 Authorized distributors page 9 5 Effectivity 912 Series BRP Powertrain page 9 1 OM Edition 2 Rev 0 April 01 2010 NOTES Effectivity 91
28. d engine use top quality low friction oil allow for sufficient cooling period to counter for performance drop on hot starter pre heat engine Engine idles rough after warm up period smoky exhaust emission Possible cause Remedy Starting carb Choke activat ed close starting carb Choke Engine keeps running with ignition off Possible cause Remedy Overheating of engine let engine cool down at idling at approx 2000 rpm Knocking under load Possible cause Remedy Octane rating of fuel too low use fuel with higher octane rating Low oil pressure Possible cause Remedy Not enough oil in oil tank Check oil return line for free passage renew oil seal Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 4 5 April 01 2010 Oil level Cil level is increasing Possible cause Remedy Oil too cold during engine op cover oil cooler surface maintain the oil eration temperature prescribed Cold engine start Engine hard to start at low temperature Possible cause Remedy Starting speed too low preheat engine Low charge battery fit fully charged battery High oil pressure At cold start a pressure reading of up to around 7 bar 102 psi does not indicate a malfunction Oil pressure too low after cold Too much resistance in the oi
29. date of change comment no 0 1 up to 9 all 04 01 2010 New layout 1 2 2 4 2 7 11 01 2010 Engine start operating temperature description 2 10 11 01 2010 Operating fluids definition 1 9 9 6 7 8 11 01 2010 Overview of authorized distributor Effectivity 912 Series BRP Powertrain page TOA 3 OM Edition 2 Rev 1 November 01 2010 NOTES Effectivity 912 Series OM Edition 2 Rev 1 BRP Powertrain page TOA 4 November 01 2010 d04943 fm d04673 fm Foreword Table of content 1 General note Before operating the engine carefully read this Operators Manu al The Manual provides you with basic information on the safe op eration of the engine If any passages of the Manual are not clearly understood or in case of any questions please contact an authorized Distributor or Service Center for ROTAX aircraft engines We wish you much pleasure and satisfaction flying your aircraft with this ROTAX engines This chapter of the Operators Manual contains general and safety information concerning the operation of the aircraft engine Subject Page General note page 1 1 Abbreviations and terms used in this Manual page 1 3 Safety page 1 4 Safety notice page 1 5 Technical documentation page 1 8 Standard version page 1 10 Type description page 1 11 Denomination of cylinders Engine views page 1 12 Technical data page 1 14 Fuel consumption page 1 14 Direction of rotatio
30. e smooth running at approx 2500 r p m 8 Oil pressure Check if oil pressure has ris en within 10 seconds and monitor oil pressure In crease of engine speed is only permitted at steady oil pressure readings above 2 bar 30 psi 9 At an engine start with low oil tempera NOTICE ture continue to observe the oil pressu re as it could drop again due to the increased flow resistance in the suction line The number of revolutions may be only so far increased that the oil pressu re remains steady 10 Starting carb choke de activate Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 3 7 April 01 2010 To observe Reduction gear with shock absorber Since the engine comprises a reduction gear with shock absorber take special care of the following Step Procedure To prevent impact load start with throttle lever in idle position or at the most up to 10926 open 2 For the same reason wait for around 3 sec af ter throttling back to partial load to reach con stant speed before re acceleration 3 For checking the two ignition circuits only one circuit may be switched off and on at a time Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 3 8 April 01 2010 d04945 fm d04945 fm 3 5 Prior to take off Safety Non compliance can result in serious injuries Do not take the engine into operation if any person is near the
31. e top of the cylinder heads the coolant passes on to the expansion tank 1 Since the standard location of the radiator 2 is below engine le vel the expansion tank located on top of the engine allows for coolant expansion The expansion tank is closed by a pressure cap 3 with excess pressure valve and return valve At temperature rise of the coolant the excess pressure valve opens and the coolant will flow via a hose at atmospheric pressure to the transparent overflow bottle 4 When cooling down the coolant will be sucked back into the cooling circuit 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 Effectivity 912 Series BRP Powertrain page 7 2 OM Edition 2 Rev 0 April 01 2010 d04679 fm d04679 fm Cooling system Part Function 1 expansion tank 2 radiator 3 pressure cap 4 overflow bottle Fig 1 09152 Effectivity 912 Series BRP Powertrain page 7 3 OM Edition 2 Rev 0 April 01 2010 7 2 Fuel system General note See Fig 2 The fuel flows from the tank 1 via a coarse filter 2 the fire cock Fuel 3 and fine filter 4 to the mechanical fuel pump 5 From the pump fuel passes on vi
32. eet and care fully observe all the operating and maintenance instructions NOTICE Risk of burnings and scalds Hot engine parts Conduct checks on the cold engine only Non compliance can result in serious injuries or death Ignition OFF Before moving the propeller switch off both ig nition circuit and secure the aircraft Have the cockpit occupied by a competent person If established abnormalities e g excessive resistance of the engine noise etc inspec tion in accordance with the relevant Mainte nance Manual is necessary Do not release the engine into service before rectification Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 3 2 April 01 2010 d04945 fm d04945 fm Coolant level The coolant specifications of the section NOTICE Chapter 2 3 Operating media are to be ob served Step Procedure 1 Verify coolant level in the expansion tank replenish as re quired up to top The max coolant level must be filled up to the top see Fig 1 2 Verify coolant level in the overflow bottle replenish as re quired The coolant level must be between max and min mark Graphic Expansion tank K hlmittel coolant Part Function 1 radiator cap 2 expansion tank Fig 1 05823 Effectivity 912 Series BRP Powertrain page 3 3 OM Edition 2 Rev 0 April 01 2010 Check of mech components
33. emperature sensor 8 for reading of the oil inlet tempera ture is located on the oil pump housing Effectivity 912 Series BRP Powertrain page 7 5 OM Edition 2 Rev 0 April 01 2010 Oil system OQ Part Function pressure regulator oil pressure sensor oil pump oil tank oil cooler oil filter venting tube O oil temperature sensor Fig 3 08650 Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 7 6 April 01 2010 d04679 fm d04679 fm 7 4 Electric system General note Charging coils See Fig 4 The ROTAX 912 engine is equipped with a dual ignition unit of a breakerless capacitor discharge design with an integrated gene rator The ignition unit needs no external power supply Two independent charging coils 1 located on the generator sta tor supply one ignition circuit each The energy is stored in capa citors of the electronic modules 2 At the moment of ignition 2 each of the 4 external trigger coils 3 actuate the discharge of the capacitors via the primary circuit of the dual ignition coils 4 NOTE The trigger coil 5 is provided for rev counter si gnal
34. following specifications can be used Fuel specifikationen Usage Description Knock resistance 912 A F UL 912 S ULS Min RON 90 Min RON 95 min AKI 87 min AKI 91 Anti Knock Index RON MON 2 Usage Description Mogas 912 A F UL 912 S ULS European EN 228 Normal standard EN 228 Super EN 228 Super plus EN 228 Super EN 228 Super plus AVGAS 100LL places greater stress on the valve seats due to its high lead content and forms increased deposits in the combustion chamber and lead sediments in the oil system Thus it should only be used in case of problems with vapor lock or when other types of gasoline are unavailable Usage Description AVGAS 912 A FIUL 912 S ULS Aviation AVGAS 100 LL AVGAS 100 LL Standard ASTM D910 ASTM D910 Effectivity 912 Series OM Edition 2 Rev 1 BRP Powertrain page 2 9 November 01 2010 2 5 Operating me General note Oil type Oil consumption Oil specification dia Lubricants Obey the manufacturers instructions about the lubricants If the engine is mainly run on AVGAS more frequent oil changes will be required See Service Information 51 912 016 latest edi tion NOTICE Motorcycle oil of a registered brand with gear additives Do not use aircraft engine oil for direct driven engines At the selection of suitable lubricants refer to NOTICE the additional information in
35. ghts Chapter 6 Description of systems Chapter 7 Checks Chapter 8 Supplements Chapter 9 Effectivity 912 Series BRP Powertrain page INTRO 1 OM Edition 2 Rev 0 April 01 2010 NOTES Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page INTRO 2 April 01 2010 d04670 fm d04942 fm LEP List of effective pages Chapter Page Date Chapter Page Date cover page 4 4 1 04 01 2010 INTRO INTRO 1 04 01 2010 0401 2010 INTRO 2 04 01 2010 A 04 01 2010 4 4 04 01 2010 LEP LEP 1 11 01 2010 4 5 04 01 2010 LEP 2 04 01 2010 46 1101 2010 TOA 1 11 01 2010 5 5 1 04 01 2010 TOA 2 04 01 2010 5 2 04 01 2010 TOA 3 11 01 2010 5 3 04 01 2010 TOA 4 11 01 2010 5 4 04 01 2010 1 1 1 04 01 2010 5 5 04 01 2010 1 2 04 01 2010 5 6 04 01 2010 1 3 04 01 2010 5 7 04 01 2010 1 4 04 01 2010 5 8 04 01 2010 1 5 04012010 6 6 1 04 01 2010 1 6 04 01 2010 6 2 04 01 2010 17 04012010 la 1 9 04 01 2010 Pe 00 1 10 04 01 2010 Uu 04 01 2010 1 11 04 01 2010 1 deed 1 12 04 01 2010 gt 04 01 2010 1 13 04 01 2010 ER OA 1 14 04 01 2010 er 4 01 2010 7 8 04 01 2010 2 2 1 04 01 2010 7 9 04 01 2010 2 3 04012010 7 10 04 01 2010 emo s aunt 2 6 04 01 2010 82 04 01 2010 2 7 11 01 2010 9 9 1 04 01 2010 2 8 04 01 2010 9 2 04 01 2010 29 1101 2010 9 3 04 01 2010 2 10 04 01 2010 9 4 04 01 2010 2 11 04 01 2010 9 5 04 01 2010 2 12 04 01 2010 9 6 11 01 2010 3 8 1 04 01 20
36. iance can result in serious injuries Monitor oil temperature cylinder head temperature and oil pressure Limits must not be exceeded See Chapter 2 1 Oper ating limits Respect cold weather operation recommendations see Chapter 3 9 Climbing with engine running at take off performance is permissi ble max 5 minutes see Chapter 2 1 Step Procedure 1 Set performance as per performance specifications Chapter 5 and respect operating limits as per Chapter 2 1 Step Procedure Avoid operation below normal operation oil temperature 90 to 110 194 to 230 F as possible formation of condensation water in the lubrication system badly influ ences the oil quality To evaporate possibly accumulated condensation water at least once a day 100 212 F oil temperature must be reached 3 8 Engine shut off Normally the cooling down of the engine during descending and taxiing will be sufficient to allow the engine to be shut off as soon as the aircraft is stopped General note At increased operating temperatures make an engine cooling run of at least minimum 2 minutes Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 3 10 April 01 2010 d04945 fm d04945 fm 3 9 Cold weather operation General note Generally an engine service should be carried out before the start of the cold season Coolant For selection of coolant and mixi
37. iew Fig 4 00336 Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 1 13 April 01 2010 1 9 Technical data See table Description 912 A F UL 912 S ULS Bore 79 5 mm 3 13 in 84 mm 3 31 in Stroke 61 mm 2 40 in 61 mm 2 40 in Displacement 1211 cm 73 9 in 1352 cm 82 5 in Compression ratio 9 0 1 11 1 1 10 Fuel consumption See table ioni Fuel consumption in I h 912 AIFIUL 912 S ULS US gal h at take off performance 24 0 I h 6 3 gal h 27 0 h 7 1 gal h at max continuous perfor 22 6 1 5 6 gal h 25 0 h 6 6 gal h mance at 75 continuous perfor 16 2 4 3 gal h 18 5 l h 4 9 gal h mance specific consumption at max 285 g kWh 285 g kWh continuous performance 0 47 Ib hph 0 47 Ib hph 1 11 Direction of rotation Direction of rota Direction of rotation on propeller shaft counter clockwise looking tion on propeller at p t o side of engine shaft normal direction of propeller rotation engine 1 5 RS D KON MA UN L LA WE
38. l suction start tube at low temperatures Stop engine and preheat oil At oil pressure reading too low than 1 bar oils with lower viscosity are to be used See 51 912 016 current issue NOTE Oil pressure must be measured at idle at an oil temperature of minimum 50 120 F Be sure the oil pressure does not go below minimum at idle d04946 fm Effectivity 912 Series BRP Powertrain page 4 6 OM Edition 2 Rev 1 November 01 2010 d04677 fm 5 Performance data Introduction The performance tables and performance graphs on the next few pages are intended to show you what kind of performance to ex pect from your engine in terms of power output The indicated power can be achieved by following the procedures laid out in the Operators Manual and ensuring that the engine is well main tained Table of content This chapter of the Operators Manual contains performance table and performance graphs Subject Page Engine type 912 A F UL page 5 2 Performance graphs for stand conditions page 5 2 Performance data for variable pitch propeller page 5 3 Performance graph for non standard conditions page 5 4 Engine type 912 S ULS page 5 5 Performance graphs for stand conditions page 5 5 Performance data for variable pitch propeller page 5 6 Performance graph for non standard conditions page 5 7 Effectivity 912 Series BRP Powertrain page 5 1 OM Edition 2 Rev 0 April 01 2010
39. le pitch propeller The following graph shows the performance drop with increasing flight altitude The curves show the performance at 5800 5500 5000 4500 and 4000 rpm at full throttle The engine allows operation with fully open throttle valve over the whole rpm range without limitation But full throttle performance above 5500 rpm is limited to 5 minutes At deviation of temperature conditions from standard atmosphere conditions the engine performance to be expected can be calcu lated from the performance indicated multiplied by standard tem perature divided by actual temperature in K 5800 1 min Volllast take off performance 5 5500 5000 8 40 2500 m SU o 5 I 30 i 5 n 3 20 1000 2000 3000 4000 5000 6000 7000 Dichteh he Density Altitude m T standard T aktuell T K t C 273 P P stand Fig 3 08635 Effectivity 912 A F UL BRP Powertrain page 5 4 OM Edition 2 Rev 0 April 01 2010 d04677 fm Performance Performance graphs for stand conditions ISA graphs Engine 912 S ULS 130 130 120 125 110 Drehmoment Torque _1 120 _ E Z 8 80 115 9 5 Motorleist 5 En max Motorleistung 5 5 max engine output 110 S 60 a D 50 5 z 105 2 3 n 100 Propellerkurve 2
40. mperature Max 120 C 248 F Cylinder head temperature Max 135 C 275 F Permanent monitoring of coolant temperature and cylinder head temper ature is necessary Waterless coolant Cylinder head temperature Max 135 C 275 F Permanent monitoring of cylinder head temperature is necessary Effectivity 912 S ULS OM Edition 2 Rev 0 BRP Powertrain page 2 6 April 01 2010 d04944 fm d04944 fm Engine start oper ating temperature Max 50 C 120 F ambient temperature Min 25 C 13 F oil temperature Fuel pressure Non compliance can result in serious injuries or death Exceeding the max admissible fuel pressure will override the float valve of the carburetor and to engine failure The aircraft engine manufacturer strongly recommends the instal lation of an additional pump unless this has not been covered by legal obligations so far Propeller gover nor Vacuum pump External alternator Bank angle Max 0 4 bar 5 8 psi Min 0 15 bar 2 2 psi Power consumption of the hydraulic propeller governor Max 600 W Power consumption of the vacuum pump Max 300 W Power consumption of the external alternator Max 1200 W Deviation from bank angle Max 40 NOTE Up to this value the dry sump lubrication system wa
41. n page 1 14 Effectivity 912 Series BRP Powertrain page 1 1 OM Edition 2 Rev 0 April 01 2010 1 1 General note Purpose The purpose of this Operators Manual is provided to familiarize the owner user of this aircraft engine with basic operating instruc tions and safety information Documentation For more detailed information regarding maintenance safety or flight operation consult the documentation provided by the aircraft manufacturer and or dealer For additional information on engines maintenance or parts you can also contact your nearest authorized ROTAX aircraft engine distributor Chapter 9 2 Engine serial num When making inquiries or ordering parts always indicate the en ber gine serial number as the manufacturer makes modifications to the engine for product improvement The engine serial number is located on the top of the crankcase magneto side See Fig 1 Cyl 1 Cyl 3 TIA SSS gt Fu dx Part Function 1 engine serial number Fig 1 00334 Effectivity 912 Series BRP Powertrain page 1 2 OM Edition 2 Rev 0 April 01 2010 d04673 fm d04673 fm 1 2 Abbreviations and terms used in this
42. ng ratio see Coolant Chapter 2 3 Lubricant For selection of oil see table of Lubricants Chapter 2 5 Cold start With throttle closed and choke activated open throttle renders starting carb ineffective Be aware no spark below crankshaft speed of 220 rpm pro peller speed of 90 rpm Asperformance of electric starter is greatly reduced when hot limit starting to periods not much longer than 10 sec With a well charged battery adding a second battery will not improve cold starts Remedy Cold start Step Procedure 1 Use of multigrade oil with the low end viscosity code of 5 or 10 2 Gap electrode on spark plug to the minimum or fit new spark plugs 3 Preheat engine Icing in the air in Icing due to humidity take system Carburetor icing due to humidity may occur on the venturi and on the throttle valve due to fuel evaporation and leads to perfor mance loss and change in mixture Remedy Intake air pre heating is the only effective remedy See Flight Manual supplied by the aircraft manufacturer Effectivity 912 Series BRP Powertrain page 3 11 OM Edition 2 Rev 0 April 01 2010 Icing due to water Icing due to water in fuel in fuel p Fuels containing alcohol always small amount of water in solution In case of tem perature changes or increase of alcohol con tent water or a mixture of alcohol and water may settle and could cause troubles
43. ng the en gine Allow the engine to cool at idle for several minutes before turn ing off the engine Vacuum pump This engine may be equipped with a vacuum pump The safety warning accompanying the vacuum pump must be given to the owner operator of the aircraft into which the vacuum pump is installed Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 1 7 April 01 2010 1 5 Technical documentation General note Documentation Status Revision pages These documents form the instructions for continued airworthi ness of ROTAX aircraft engines The information given is based on data and experience that are considered applicable for professionals under normal conditions The fast technical progress and variations of installation might render present laws and regulations inapplicable or inadequate Installation Manual Operators Manual Maintenance Manual Line and Heavy Maintenance Overhaul Manual Illustrated Parts Catalog Alert Service Bulletins Service Bulletins Service Instructions Service Letters The status of Manuals can be determined by checking the table of amendments of the Manual The 1 column of this table is the re vision status Compare this number to that listed on the ROTAX WebSite www rotax aircraft engines com Updates and current revisions can be downloaded for free Further the Manual is in such a way developed that revision page
44. ng the information will promote its correct use 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 however maintains a policy of continuous im provement of its products without imposing upon itself any obliga tion to install them on its products previously manufactured BRP Powertrain reserves the right at any time and without incur ring obligation 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 Where precise accuracy is not required some conversions are rounded off for easier use This document has been translated from German language and the original German text shall be deemed authoritative This Manual uses the following symbols to emphasize particular information This information is important and must be observed Identifies an instruction which if not fol lowed may cause serious injury including the possibility of death Identifies an instruction which if not fol A CAUTION lowed may cause minor or moderate inju ry Denotes an instruction which if not fol Nonce lowed may severely damage the engine or other component NOTES Indicates supplementary information which may be needed to fully complete or under stand an instruction A revision bar
45. nt person Risk of burnings and scalds Hot engine parts Carry out pre flight checks on the cold or luke warm engine only the aircraft Have the cockpit occupied by a Operating media Step Procedure 1 Check for any oil coolant and fuel leaks If leaks are evident rectify and repair them before next flight Coolant The coolant specifications of the section NOTICE Chapter 2 3 Operating media are to be ob served Step Procedure Verify coolant level in the overflow bottle replenish as re quired up to top The coolant level must be between min and max mark Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 3 5 April 01 2010 Oil The oil specifications of the section Chapter NOTICE 2 5 Operating media are to be observed Step Procedure Check oil level and replenish as required NOTE Propeller shouldn t be turned exces sively reverse the normal direction of engine rotation Remove oil tank cap Prior to oil check turn the propeller by hand in direction of engine rotation several times to pump oil from the engine into the oil tank It is essential to build up compression in the combustion chamber Maintain the pressure for a few seconds to let the pressure flow around the piston rings into the crankcase The speed of rotation is not important for the pressure transfer into the crankcase This process is finished when air
46. of max admissible engine speed Exceeding of max Reduce engine speed Any exceeding of the max admissible engine speed engine speed has to be entered by the pilot into the logbook stating the duration and extend of overspeed 4 3 Exceeding of max admissible cyl head temperature Exceeding of cyl inder head temper Reduce engine power setting to the minimum ature zn necessary to maintain flight and carry out precautionary landing Any exceeding of the max admissible cylinder head tempera ture has to be entered by the pilot into the logbook stating du ration and extent of over temperature condition 4 4 Exceeding of max admissible oil temperature Exceeding of oil temperature Reduce engine power setting to the minimum nz necessary to maintain flight and carry out precautionary landing Any exceeding of the max oil temperature must be entered by the pilot in the logbook stating duration and extent of over temperature condition Effectivity 912 Series BRP Powertrain page 4 2 OM Edition 2 Rev 0 April 01 2010 d04946 fm d04946 fm 4 5 Oil pressure below minimum during flight Oil pressure below minimum Reduce engine power setting to the minimum NOTICE necessary and carry out precautionary land ing Check oil system 4 6 Oil pressure below minimum on ground Immediately stop the engine and check for reason Check oil sys tem Check oil quantity in oil tank Check oil quali
47. on 2 Rev 0 page 2 2 April 01 2010 d04944 fm d04944 fm Conventional See also Chapter 2 3 coolant Coolant temperature coolant exit temperature Max 120 248 F Cylinder head temperature Max 150 300 F Permanent monitoring of coolant temperature and cylinder head temper ature is necessary Waterless coolant See also Chapter 2 3 Cylinder head temperature Max 150 300 F Permanent monitoring of cylinder head temperature is necessary Effectivity 912 A F UL BRP Powertrain page 2 3 OM Edition 2 Rev 0 April 01 2010 Engine start oper ating temperature Max 50 C 120 F ambient temperature Min 25 C 13 F oil temperature Fuel pressure Non compliance can result in serious injuries Exceeding the max admissible fuel pressure will override the float valve of the carburetor and to engine failure The aircraft engine manufacturer strongly recommends the instal lation of an additional pump unless this has not been covered by legal obligations so far Max 0 4 bar 5 8 psi Min 0 15 bar 2 2 psi Propeller gover nor Power consumption of the hydraulic propeller governor Max 600 W Vacuum pump Power consumption of the vacuum pump Max 300 W External alternator Power consumption of the external alternator Max 1200 W
48. ontent As already mentioned in the preface the system descriptions only apply to the engine not to a specific application in a particular air craft The aircraft manufacturers Operators Manual is therefore definitive in terms of the operation of the engine as it contains all the aircraft specific instructions Subject Page Cooling system of engine page 7 2 Coolant page 7 2 Expansions tank page 7 2 Coolant temperature measuring page 7 2 Fuel system page 7 4 Fuel page 7 4 Return line page 7 4 Lubrication system page 7 5 Lubrication page 7 5 Crankcase page 7 5 Oil pump page 7 5 Oil circuit vented page 7 5 Oil temperature sensor page 7 5 Electric system page 7 7 Charging coils page 7 7 Propeller gearbox page 7 8 Reduction ratio page 7 8 Overload clutch page 7 8 Torsional shock absorber page 7 8 Backlash page 7 9 Vacuum pump page 7 9 Effectivity 912 Series BRP Powertrain page 7 1 OM Edition 2 Rev 0 April 01 2010 7 1 Cooling system of the engine General note Cooling Coolant Expansion tank Coolant tempera ture measuring See Fig 1 The cooling system of the ROTAX 912 is designed for liquid coo ling of the cylinder heads and ram air cooling of the cylinders The cooling system of the cylinder heads is a closed circuit with an ex pansion tank The coolant flow is forced by a water pump driven from the cams haft from the radiator to the cylinder heads From th
49. ore flying in new areas Instrumentation Select and use proper aircraft instrumentation This instru mentation is not included with the ROTAX engine package Only approved instrumentation may be installed Engine log book Keep an engine log book and respect engine and aircraft maintenance schedules Keep the engine in top operating condition at all times Do not operate any aircraft which is not properly maintained or has engine operating irregularities which have not been corrected Maintenance Before flight ensure that all engine controls are operative Make sure all controls can be easily reached in case of an emergency Since special tools and equipment may be required engine servicing should only be performed by an authorized ROTAX engine distributor or a qualified trained mechanic approved by the local airworthiness authority When in storage protect the engine and fuel system from con tamination and exposure Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 1 6 April 01 2010 d04673 fm d04673 fm Engine run Never operate the engine without sufficient quantities of oper ating fluids oil coolant fuel Never exceed the maximum permitted operational limits 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 starti
50. ority Observe according Service Instructions SI and Service Letter SL Table of content This chapter of the Operators Manual contains checks of the air craft engines Subject Page Engine preservation page 8 2 Engine back to operation page 8 2 Effectivity 912 Series BRP Powertrain page 8 1 OM Edition 2 Rev 0 April 01 2010 8 1 Engine preservation General note Risk of burnings and scalds Hot engine parts Always allow engine to cool down to ambient temperature before start of any work Due to the special material of the cylinder wall there is no need for extra protection against corrosion for the ROTAX aircraft engi nes At extreme climatic conditions and for long out of service pe riods we recommends the following to protect the valve guides against corrosion Step Procedure Operate the engine until the temperatures have stabi lized for a period of 5 min engine oil temperature be tween 50 to 70 122 to 160 F Switch the engine OFF Allow the engine to cool down Change oil Q A OQ Remove the air intake filters and insert approx 30 cm 1 fl oz of corrosion inhibiting oil into the car buretor throat with the engine running at increased idle speed Shut off engine Drain carburetor float chamber Apply oil to all joints on carburetors Close all openings on the cold engine such as ex haust end pipe venting tu
51. person M M Varman UNITED ARAB EMIRATES gt AL MOALLA P O Box 7787 ABU DHABI Tel 971 0 2 444 7378 Fax 971 0 2 444 6896 E mail almoalla emirates net ae Contact person Hussain AI Moalla Cesaria 38900 Tel 972 0 4 6265080 Fax 972 0 4 6265095 E mail condor netvision net il Contact person David Wiernik JAPAN gt JUA LTD 1793 Fukazawa Gotemba City SHIZUOKA PREF 412 Tel 81 0 550 83 8860 Fax 81 0 550 83 8224 E mail jua shizuokanet ne jp Contact person Yoshihiko Tajika KOREA gt KOREA BUSINESS AIR SERVICE CO LTD 672 4 KBAS Bldg Deungchon dong Kangseo ku Seoul SOUTH KOREA Tel 82 0 2 3664 6644 Fax 82 0 2 2658 6562 E mail sd lim kbas com Contact person Su Dong Lim INDONESIA MALAYSIA PHILIP PINES SINGAPORE THAILAND TAIWAN FLOOD IMPORTS LTD P O Box 61 16 17 Chris Drive LILYDALE VICTORIA 3140 Tel 61 0 3 9735 5655 Fax 61 0 3 9735 5699 E mail wal bertfloodimports com au Website www bertfloodimports com au Contact person Mark Lester IRAN ASEMAN PISHRANEH CO Register Code 149432 13 Km of Babaee Exp Way Cross Telo Road Sepehr Aviation Group Tehran IRAN Tel 98 0 21 77105107 Fax 98 0 21 77000030 E mail asmpish asmpish com Contact person Ali Habibi Najafi Effectivity 912 Series OM Edition 2 Rev 1 BRP Powertrain page 9 8 November 01 2010 d04949 fm ROTAX
52. rrants lubrication in every flight situation Effectivity 912 S ULS OM Edition 2 Rev 1 BRP Powertrain page 2 7 November 01 2010 2 3 Operating media Coolant General note Obey the latest edition of Service Instruction 51 912 016 for the selection of the correct coolant Conventional Conventional coolant mixed with water has the advantage of a coolant higher specific thermal capacity than water less coolant Application When correctly applied there is sufficient protection against vapor bubble formation freezing or thickening of the coolant within the operating limits Use the coolant specified in the manufacturers documentation Mixture Obey the manufacturers instructions about nz the coolant mixture ratio designation concentrate water conventional e g BASF Glysantine 50 50 anticorrosion waterless e g EVANS NPG 100 0 coolant component can be increased up to max 65 Effectivity 912 Series BRP Powertrain page 2 8 OM Edition 2 Rev 0 April 01 2010 d04944 fm 2 4 Operating media Fuel General note Knock resistance MOGAS AVGAS d04944 fm Obey the local codes and the latest edition of Service Instruction SI 912 016 for the selec tion of the correct fuel Use only fuel suitable for the respective cli NOTICE matic zone NOTE NOTICE Risk of vapour formation if using winter fuel for summer operation The fuels with
53. s are offered and the entire document does not have to be ex changed The overview of the valid pages are in the Chapter LEP The current edition and revision is shown in the foot note Reference Any reference to a document refers to the latest edition issued by BRP Powertrain if not stated otherwise Effectivity 912 Series BRP Powertrain page 1 8 OM Edition 2 Rev 0 April 01 2010 d04673 fm d04673 fm Illustrations The illustrations in this Manual are mere sketches and show a ty pical arrangement They may not represent the actual part in all its details but depict parts of the same or similar function There fore deduction of dimensions or other details from illustrations is not permitted NOTE The illustrations in this Operators Manual are stored in a graphic data file and are provided with a consecutive irrelevant number This number e g 00277 is of no significance for the content Effectivity 912 Series BRP Powertrain page 1 9 OM Edition 2 Rev 0 April 01 2010 1 6 Standard version Serial production Optional 4 stroke 4 cylinder horizontally opposed spark ignition engi ne one central cam shaft push rods OHV Liquid cooled cylinder heads Ram air cooled cylinders Dry sump forced lubrication Dual breakerless capacitor discharge ignition 2 constant depression carburetors mechanical fuel pump Electric starter 12 V 0 7 kW Integrated AC generator with external rectifier regulator
54. tant speed propeller Prop flange for fixed pitch propeller and prepared for retrofit of a hy draulic governor for constant speed propeller NOTE This configuration 4 is not available any longer and will be replaced by configuration 3 Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 1 11 April 01 2010 1 8 Denomination of cylinders Engine views components Lateral view Part Function propeller gear box 2 vacuum pump or hydraulic governor for con stant speed propeller Fig 2 00337 Top view Cyl 1 Cyl 3 D 2 g x 2 o 5 a o E o I Cyl 4 Part Function 3 engine serial number 4 CD carburetor 5 electric starter 6 expansion tank with excess pressure valve 7 exhaust flange 8 external alternator Fig 3 00334 Effectivity 912 Series BRP Powertrain page 1 12 OM Edition 2 Rev 0 April 01 2010 d04673 fm d04673 fm Front v
55. the Service Infor mation SI 912 016 latest edition 0 06 I h 0 13 liq pt h Useonly oil with API classification SG or higher Due tothe high stresses in the reduction gears oils with gear additives such as high performance motor cycle oils are requi red Because of the incorporated overload clutch oils with friction modifier additives are unsuitable as this could result in a slip ping clutch during normal operation Heavy duty 4 stroke motor cycle oils meet all the require ments These oils are normally not mineral oils but semi or full synthetic oils Oils primarity for Diesel engines have insufficient high tem perature properties and additives which favour clutch slipping and are generally unsuitable viscosity Use of multi grade oils is recommended NOTE Multi viscosity grade oils are less sensitive to temperature variations than single grade oils They are suitable for use throughout the sea Sons ensure rapid lubrication of all engine com ponents at cold start and get less fluid at higher temperatures Effectivity 912 Series OM Edition 2 Rev 0 BRP Powertrain page 2 10 April 01 2010 d04944 fm d04944 fm Table of lubricants See Fig 1 Since the temperature range of neighboring SAE grades overlap there is no need for change of oil viscosity at short duration of am bient temperature fluctuations Klima mN Mehrbereichs le climatic i i
56. ty See Chapter 2 5 Effectivity 912 Series BRP Powertrain page 4 3 OM Edition 2 Rev 0 April 01 2010 4 7 Trouble shooting Introduction All checks in accordance with the Maintenance Manual current issue revision Non compliance can result in serious injuries or death Only qualified staff authorized by the Avia tion Authorities trained on this particular en gine is allowed to carry out maintenance and repair work If the following hints regarding remedy do not solve the problem contact an authorized workshop The engine must not be operated until the problem is rectified Table of content This chapter of the Operators Manual contains possible cause and in case of trouble shooting Subject Page Starting problems page 4 5 Engine run page 4 5 Oil pressure page 4 5 Oil level page 4 6 Engine hard to start at low temperature page 4 6 Effectivity 912 Series BRP Powertrain page 4 4 OM Edition 2 Rev 0 April 01 2010 d04946 fm d04946 fm Starting problems Engine run Oil pressure Engine does not start Possible cause Remedy Ignition off Switch on Closed fuel valve or clogged filter open valve clean or renew filter check fuel system for leaks No fuel in tank refuel Starting speed too low faulty or discharged battery fit fully charged battery Starting speed too low start problems on col
57. umption of the external alternator page 2 7 Deviation from bank angle page 2 7 Operating fluids page 2 8 Coolant page 2 8 Fuel page 2 9 Lubricants page 2 10 Effectivity 912 Series BRP Powertrain page 2 1 OM Edition 2 Rev 0 April 01 2010 2 1 Operating limits 912 A F UL Performance data relate to ISA International Standard Atmo sphere conditions without Governor external alternator etc Performance Speed Acceleration Oil pressure Oil temperature EGT Take off performance 59 6 kW at 5800 rpm Max continuous performance 58 kW at 5500 rpm Take off speed 5800 rpm max 5 min Max continuous speed 5500 rpm Idle speed min 1400 rpm Limit of engine operation at zero gravity and in negative g con dition Max 5 seconds at max 0 5 g Max 7 bar 102 psi For a short period admissible at cold start NOTICE a Min 0 8 bar 12 psi below 3500 rpm 1 5 bar 22 psi Normal 2 0 to 5 0 bar 29 73 psi above 3500 rpm 1 5 to 5 0 bar 22 73 psi 912 UL to S N 4 402 387 912A 912 F to S N 4 410 266 to S N 4 412 764 Max 140 C 285 F Min 50 C 120 F normal operating temperature approx 90 to 110 C 190 230 F exhaust gas temperature Max 880 C 1616 F Effectivity 912 A F UL BRP Powertrain OM Editi

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