OPERATORS MANUAL
Contents
1. 8 Va y 7 11 a 25 7 WOES oxi L ji 2 eto y 7 A o j Jk ROTAX AOTAX Ost olo 5 6 oj o fig 1 me 00337 5 o 5 5 2 5 5 Cyl 2 4 00334 Effectivity 912 Serie BRP Rotax page 7 OM Edition 1 Rev 0 Jan 01 2007 Front view 1 engine serial number 6 2 CD carburetor 7 propeller gear box 8 4 electric starter exhaust flange external alternator vacuum pump or hydraulic governor for constant speed propeller 5 expansion tank with excess pressure valve Effectivity 912 Serie BRP Rotax page 7 4 OM Edition 1 Rev 0 Jan 01 2007 d03931 fm d03932 fm 8 Technical data 8 1 Dimen Description sions Bore 912 UL A F 912 UL ULS 79 5 mm 3 13 in 84 mm 3 31 in Stroke 61 mm 2 40 in 61 mm 2 40 in Disp lacement 1211 mm 73 9 in 1352 mm 82 5 in Compression 8 2 Weigh ratio ts NOTE Weight in kg Ib 9 0 1 10 5 1 The stated weights are dry weights without operating fluids with electric starter carburetors internal generator ignition unit and oil tank without exhaust system radiator airbox 912 UL 912 ULS2. I s 03646 Effectivity 912 Serie BRP Rotax page8 2 OM Edition 1 Rev 0 Jan 01 2007 d03932 fm d03933 fm 9 Description of systems 9 1 Cooling system See fig 4 The cooling system of the ROTAX 912 is designed for liquid cooling of the cylinder heads and ram air cooling of the cylinders The cooling system of the cylinder heads is a closed circuit with an expansion tank The coolant flow is forced by a water pump driven from the camshaft from the radiator to the cylinder heads From the 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 level 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 pres sure valve opens and the coolant will flow via a hose at atmospheric pres sure to the transparent overflow bottle 4 When cooling down the coolant will be sucked back into the cooling circuit NOTE Coolant temperatures are measured by means of tem perature probes installed in cylinder heads 2 and 3 Readings are taken on measuring point of the hottest cylinder head depen ding on engine installation Coolant see Chap
3. Configuration 2 4 overload 57 1 126 with 58 3 128 with clutch overload clutch 55 4 122 56 6 125 without clutch without clutch Configuration 3 59 8 132 61 134 Equipment 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 Serie OM Edition 1 Rev 0 BRP Rotax page 8 1 Jan 01 2007 8 3 Fuel consumption Fuel consumption in l h US gal h 912 UL AF 912 ULS S at take off performance 24 0 6 3 27 0 7 1 at max continuous performance 22 6 5 6 25 0 6 6 at 75 ontinuous performance 16 2 4 3 18 5 4 9 specific consumtion at max 285 g kWh 285 g kWh continuous performance 0 47 Ib hph 0 47 Ib hph 8 4 Direction of rotation Direction of rotation on propeller shaft counter clockwise looking at p t o side of engine NOTE Propeller shouldn t be turned reverse the normal direc tion of engine rotation normal direction of propeller rotation engine
4. A WARNING Reduce engine power setting to the minimum necessary and carry out precautionary landing Any exceeding of the max admissible cylinder head temperature has to be entered by the pilot into the logbook stating duration and extent of over temperature condition 10 4 4 Exceeding of max admissible oil temperature A WARNING Reduce engine power setting to the minimum necessary 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 10 4 5 Oil pressure below minimum during flight A WARNING Reduce engine power setting to the minimum necessary and carry out precautionary landing Check oil system 10 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 quality see section 10 2 3 d03934 fm Effectivity 912 Serie BRP Rotax page 10 20 OM Edition 1 Rev 0 Jan 01 2007 d03935 fm 11 Checks All checks to be carried out as specified in the current Maintenance Manual last revision 4 WARNING Only qualified staff authorized by the Aviation Authorities trained on this particular engine is allowed to carry out maintenance and repair work m CAUTION Carry out all directives of Service Bulletins SB according to their priority 11 1 Engine preservation
5. OPERATORS MANUAL FOR ROTAX ENGINE TYPE 912 SERIES Ref No OM 912 ROTAX 912 015 WITH OPTIONS part no 899371 ZX WARNING Before starting the engine read the Operator s Manual as it contains important safety relevant information Failure to do so may result in per sonal injuries including death Consult the original equipment manufactur ers handbook for additional instructions These technical data and the information embodied therein are the property of BRP Rotax GmbH amp Co KG Austria acc BGBl 1984 no 448 and shall not without prior written permission of BRP Rotax 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 orin part The Manual must remain with the engine aircraft in case of sale Copyright 2006 all rights reserved ROTAX is a trade mark of BRP Rotax GmbH amp Co KG In the following document the short form of BRP Rotax GmbH amp Co KG BRP Rotax 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 originaltextin german language is authoritative d03925ENIVZ fm 1 Table of contents tt tn nn nn trn nnnm 1 3 2 Index iion EE nuni 2 1 3 Introd ction
6. 21 410 9020 E mail berimpex clicknet ro Contact person Dr Cristian Berar Effectivity 912 Serie OM Edition 1 Rev 1 BRP Rotax page 13 1 Febr 01 2008 SLOVAKIA gt TEVESO S R O Skroupova 441 CS 50002 HRADEC KRALOVE Tel 42 0 49 5217 127 Fax 42 0 49 5217 226 E mail motory teveso cz Website www teveso cz Contact person Ing Jiri Samal SLOVENIA PIPISTREL D O O Goriska Cesta 50A 5270 AJDOVSCINA Tel 386 0 5 3663 873 Fax 386 0 5 3661 263 E mail pipistrel siol net Website www pipistrel si Contact person Ivo Boscarol SPAIN PORTUGAL gt AVIASPORT S A Almazara 11 E 28760 TRES CANTOS MADRID Tel 34 0 91 803 77 11 Fax 34 0 91 803 55 22 E mail aviasport aviasport com Website www aviasport com Contact person Roberto Jimenez SWITZERLAND LIECHTENSTEIN gt FRANZ AIRCRAFT ENGINES VERTRIEB GMBH Am Weidengrund la 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 TURKEY gt AIR CONSULT Belediyeevler Mah 368 Sk Vilko Sitesi No 8 01360 Adana Kurttepe TURKEY Tel 90 0 322 248 0746 Fax 90 0 322 248 6927 E Mail sales airconsult com Contact person Peter Girmann 2 AMERICA CANADA gt ROTECH RESEARCH CANADA LTD 6235 Okanagan Landing Rd VERNON B C 1 5 CANADA NORTH MIDDLE SOUTH AMERI
7. Permanent monitoring of cylinder head temperature is necessary 7 Engine start operating temperature ee 50 120 F MIN ak 25 13 F Effectivity 912 ULS S BRP Rotax page 10 5 OM Edition 1 Rev 0 Jan 01 2007 8 Fuel pressure 5 8 psi 2 2 psi A WARNING Exceeding the max admissible fuel pressure will over ride the float valve of the carburetor and to engine fai lure The aircraft engine manufacturer strongly recommends the installation of an additional pump unless this has not been covered by legal obligations so far 9 Power consumption of the hydraulic propeller governor a 600 W 10 Power consumption of the vacuum pump Iur zinku 300 W 11 Power consumption of the external alternator Iur ERSTER 1200 W 12 Deviation from bank angle ui e TE 40 NOTE Up to this value the dry sump lubrication system war rants lubrication in every flight situation Effectivity 912 ULS S BRP Rotax page 10 6 OM Edition 1 Rev 1 Febr 01 2008 d02824 fm d03934 fm 10 1 2 1 Performance graphs for stand conditions ISA 130 130 120 125 110 Drehmoment Torque 100 120 5 5 80 115 max Motorleistung max engine output 110 E g so 105 2 40 4 100 30 Propellerkurve 20 power requirement of
8. propeller 10 o 2500 3000 3500 4000 4500 5000 5500 5800 Drehzahl Engine Speed 1 min 02001 30 Ansaugladedruck 25 manifold pressure 20 15 Werte bezogen auf die Propeller Kurve values along propeller curve Ansaugladedruck manifold pressure in Hg 0 Benzinverbrauch fuel consumption Benzinverbrauch Fuel consumption L h 2500 3000 3500 4000 4500 5000 5500 5800 Drehzahl Engine speed 1 min rpm fig 13 02002 Effectivity 912 ULS S BRP Rotax page 10 7 OM Edition 1 Rev 0 Jan 01 2007 Performance data for variable pitch propeller Engine operation is permitted without restriction between full thrott le performance and power requirement of propeller providing engi ne speed over 5500 r p m is restricted to 5 minutes However for economic reasons it is recommended to run the engi ne in accordance with the following table Engine Power Engine speed Performance Torque Nm Manifold pres Setting rpm kW in HG Take off perform cruising power 7596 65 55 10 1 2 2 Performance graph for non standard conditions The following graph shows the performance drop with in creasing flight altitude The curves show the performance at 5800 5500 5000 4800 and 4300 r p m at full throttle The engine allows operation with fully open throttle valve over the whole r p m range with
9. 912 UL A F OM Edition 1 Rev 0 BRP Rotax page 10 4 Jan 01 2007 d03934 fm d03934 fm 10 1 2 Operating speeds and limits 912 ULS S 1 Speed Take off speed 5800 1 min 5 min Max continuous speed 5500 1 min Idle 1400 1 2 Performance ISA International Standard Atmosphere Take off performance 73 5 kW at 5800 1 min Max continuous performance 69 kW at 5500 1 min 3 Acceleration Limit of engine operation at zero gravity and in negative g conditions NAN 5 seconds at max 0 5 g 4 Oil pressure fa At N 7 bar m CAUTION Fora short period admissible at cold start TUN ender ce A a use 0 8 bar 12 psi below 3500 rpm normal 2 0 5 0 bar 29 73 psi above 3500 rpm 5 temperature eet 130 Carr 266 F Min een co oot Pec exe et 120 normal operating approx 90 110 C 190 230 F 6 Coolant See Operating media Chapter 10 2 1 In use of conventional coolant Coolant temperature coolant exit temperature dome he CAN eas 120 C 248 F Cylinder head temperature A 135 C 275 F Permanent monitoring of coolant temperature and cylinder head temperature is necessary In use of waterless coolant Cylinder head temperature Maenner rn 135 C 275 F
10. Due to the special material of the cylinder wall there is no need for extra pro tection against corrosion At extreme climatic conditions and for long out of service periods we recommend the following to protect the valve guides against corrosion Let engine run until warm then change oil Remove the air intake filters and insert approx 30 cm 1 fl oz of corro sion inhibiting oil into the carburetor throat with the engine running at in creased 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 exhaust end pipe venting tube air filter etc against entry of dirt and humidity Spray all steel external engine parts with corrosion inhibiting oil Engine back to operation Remove all plugs and fasteners Clean spark plugs with plastic brush and solvent If preservation including oil change took place within a year of storage oil renewal will not be necessary For longer storage periods repeat preser vation annually Effectivity 912 Serie BRP Rotax page 11 1 OM Edition 1 Rev 0 Jan 01 2007 NOTES Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 11 2 Jan 01 2007 d03935 fm d03936 fm 12 Trouble shooting A WARNING Only qualified staff authorized by the Aviation Authorities trained on this particular engine is allowed to carry out maintenance and repair work If the following hint
11. The 5 trigger coil 5 is planned for rev counter signal Ignition circuit A U Ignition circuit 00425 Effectivity 912 Serie BRP Rotax page 9 4 OM Edition 1 Rev 0 Jan 01 2007 d03933 fm d03933 fm 9 5 Propeller gearbox See fig 8 For the engine type 912 two reduction ratios are available 2 27 1 crankshaft propeller shaft 243 1 2 43 1 optional Depending on engine type certification and configuration the propeller ge arbox is supplied with or without an overload clutch NOTE The overload clutch is installed on serial production on all certified aircraft engines and on the non certified aircraft engines of configuration 3 S cn f 9 el 02531 NOTE Fig 8 shows a propeller gearbox of configuration 2 with the integrated overload clutch The design incorporates a torsional shock absorber The shock absorbing is based on progressive torsional cushioning due to axial spring load acting on a dog hub On the gearbox version with overload clutch the design incorporates a fric tion damped free play at the dogs to warrant proper engine idling Due to this backlash at the dogs a distinct torsional impact arises at start stop and at sudden load chan
12. Where precise accuracy is not required some conversions are rounded off for easier use This document has been translated from the German language and the original German text shall be deemed authoritative 4 1 Repeating symbols This Manual uses the following symbols to emphasize particular information 4 WARNING Identifies an instruction which if not followed may cause serious injury including the possibility of death CAUTION 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 instruc tion Effectivity 912 Serie BRP Rotax page 4 1 OM Edition 1 Rev 0 Jan 01 2007 4 2 Safety information 4 WARNING Never fly the aircraft equipped with this engine at loca tions airspeeds altitudes or other circumstances from which a successful no power landing cannot be made after sudden engine stoppage Unless correctly equipped to provide enough electrical power for night VFR according latest requirement as ASTM the ROTAX 912 UL ULS ULSFR is restricted to DAY VFR only 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 a
13. speed 10 20 10 4 3 Exceeding of max admissible cyl head temperature 10 20 10 4 4 Exceeding of max admissible oil temperature 10 20 10 4 5 Oil pressure below minimum during flight 10 20 10 4 6 Oil pressure below minimum on ground 10 20 113 CHECKS 11 1 11 1 Engine preservation 11 1 12 Trouble shooting tesa 12 1 12 1 Reporting 2 2 12 4 13 Authorized Distributors for ROTAX Aircraft Engines 13 1 Effectivity 912 Serie BRP Rotax page 1 4 OM Edition 1 Rev 0 Jan 01 2007 d03926ENMIX fm 2 Index A Abnormal operation 10 20 Acceleration 912 UL A F 10 1 Acceleration 912 ULS S 10 5 AVGAS 100LL 10 10 Carburetor 10 14 Certification 7 2 Check of hydraulic propeller governor 10 17 Checks 11 1 Cold start 10 18 Cold weather operation 10 18 Configuration 7 2 Cooling system 9 1 Cruising 10 18 Cylinder head temperature 912 ULS S 10 5 D Daily checks 10 13 Denomination of cylinders 7 3 Description of design 7 1 Description of systems 9 1 Dimensions 8 1 Direction of rotation 8 2 Documentation technical 4 5 E Electric system 9 4 Engine preservation 11 1 Engine serial number 3 1 Engine shut off 10 18 Engine start 10 16 Engine start operating temperatu
14. 0 1 10 1 1 Operating speeds and limits 912 UL 10 1 10 1 1 1 Performance graphs for stand conditions ISA 10 3 10 1 1 2 Performance graph for non standard conditions 10 4 10 1 2 Operating speeds and limits 912 ULS 5 10 5 10 1 2 1 Performance graphs for stand conditions ISA 10 7 10 1 2 2 Performance graph for non standard conditions 10 8 10 2 Operating media nn nn nn nn nn 10 9 10 21 guine e ite EE ern 10 9 10 2 2 Eu8l i eee ISP 10 10 10 23 L bfiCahts 5e eet l 10 11 10 3 Standard 10 13 10 31 ee ae 10 13 10 3 2 Before engine Start 10 14 10 3 3 Pre flight checks essen 10 15 10 3 4 Engine 51 10 16 1035 Prior to take off cv ts Aiea ecce tenes 10 17 10 3 6 Take off us ede merenti 10 17 Effectivity 912 Serie BRP Rotax page 1 3 OM Edition 1 Rev 0 Jan 01 2007 10 37 10 18 d03925ENIVZ fm 10 3 8 Engine shut off 10 18 10 3 9 Cold weather operation 10 18 10 4 Abnormal 10 20 10 4 1 Engine stop Start during 10 20 10 4 2 Exceeding of max admissible engine
15. 02 01 2008 1 1 2 01012007 10 2 02012008 1 3 01012007 10 3 01012007 1 4 01012007 10 4 01012007 10 5 01012007 2 2 1 01012007 10 6 02012008 2 2 0101 2007 10 7 01012007 10 8 01012007 3 3 1 01012007 10 9 01 01 2007 3 2 01 01 2007 10 10 01 01 2007 10 11 0101 2007 4 4 1 0101 2007 10 12 01 01 2007 4 2 0201 2008 10 13 02 01 2008 4 3 0101 2007 10 14 02012008 4 4 01 01 2007 10 15 02 01 2008 4 5 01 01 2007 10 16 01 01 2007 4 6 01012007 10 17 01 01 2007 10 18 01 01 2007 5 5 1 0201 2008 10 19 01 01 2007 5 2 01 01 2007 10 20 01 01 2007 6 6 1 0201 2008 11 01 01 2007 6 2 01 01 2007 01 01 2007 7 7 1 0101 2007 12 12 1 01 01 2007 7 2 0201 2008 12 2 01 01 2007 7 3 01 01 2007 12 3 01 01 2007 7 4 01 01 2007 12 4 01 01 2007 12 5 01 01 2007 8 8 1 01 01 2007 12 6 01 01 2007 8 2 01 01 2007 13 13 1 0201 2008 9 9 1 01012007 13 2 02 01 2008 9 2 01 01 2007 13 3 02012008 9 3 0101 2007 13 4 01012008 9 4 01012007 9 5 01 01 2007 9 6 01 01 2007 Effectivity 912 Serie BRP Rotax page 5 1 Edition 1 Rev 1 01 2008 NOTES Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 5 2 Jan 01 2007 d03929 fm 6 List of amendments Approval The technical content is approved under the authority of DOA Nr EASA 21 J 048 Date Note Date of Date of of of approval insertion modification appr
16. 1 Rev 0 NOTES Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 12 6 Jan 01 2007 d03936 fm d02825 fm 13 Authorized Distributors for ROTAXg Aircraft Engines www rotax aircraft engines com 1 EUROPE AUSTRIA gt HB FLUGTECHNIK GMBH Dr Adolf Sch rf Str 42 A 4053 HAID Tel 43 0 7229 79104 Fax 43 0 7229 79104 15 E mail info hb flugtechnik at Website www hb flugtechnik at Contact person Ing Heino Brditschka BULGARIA gt GERGANOV AIRCRAFT ENGINES LTD 25B Post 20 23 peh Shlp polk Blvd BG 6100 KAZANLAK Tel 359 0 431 27 247 Fax 359 0 431 23 777 E mail gaerotax mbox contact bg Contact person Radosslav D Gerganov CROATIA FORMER YUGOSLAVIA EXEPT SLOVENIA 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 gt TEVESO S R O Skroupova 441 5 50002 HRADEC KRALOVE Tel 42 0 49 5217 127 Fax 42 0 49 5217 226 E mail motory teveso cz Website www teveso cz Contact person Ing Jiri Samal SWEDEN FINLAND NORWAY ESTONIA LATVIA LITHUANIA DENMARK LYCON ENGINEERING H rkeberga SE 74596 ENK PING Tel 46 0 171 414039 Fax 46 0 171 414116 E mail info lycon se Website www lycon se FRANCE BELGIUM MONACO LUXEMBURG MOTEUR AERO DISTRIBUTION 11 Blvd A
17. 2 Serie OM Edition 1 Rev 0 BRP Rotax page 10 10 Jan 01 2007 d03934 fm d03934 fm 10 2 3 Lubricants Oil Motorcycle oil of a registered brand with gear additives If using aircraft engine oil than only blended one CAUTION Atthe selection of suitable lubricants refer to the additional information in the Service Information SI 912 016 latest edition Cil specification Use only oil with API classification SG or higher Due to the high stresses in the reduction gears oils with gear ad ditives such as high performance motor cycle oils are required Because of the incorporated friction clutch oils with friction mo difier additives are unsuitable as this could result in a slipping clutch during normal operation Heavy dury 4 stroke motor cycle oils meet all the requirements These oils are normally no mineral oils but semi or full synthetic oils Oils primarity for Diesel engines are due to insufficient high temperature properties and additives which favour clutch slipping generally unsuitable B CAUTION If the engine is mainly run on AVGAS more fre quent oil changes will be required See Service Information SI 912 016 latest edition Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 10 11 Jan 01 2007 Oil consumption max 0 06 I h 0 13 liq pt h Cil viscosity Use of multi grade oils is recommended NOTE Multi viscosity grade oils are less sensitive to tem
18. 6 fm 82790 aeg aeg ue SI siu MOJEJ e jeuondo nseed OS NS GALLINENS HZANNN INOH43T3L Jaquiny jeues ON Ned 10 awen ued sapnjouy jquiessy LN3NOdWOO 9 129jeq ued ON eves ON 10 DAWN ned 714NOHL ONISNWO jo LHvd 21410345 7 v INVIdH3MOd LAVYOUIV 1viH3s S3IU3S 13I0N U3UNLIVANNVN jueuiued 19ju3 HILNNNOD ON Bay 1HOd3H NOILVINYOSNI 3D1AU3S ob uaWoisno S3NION3 LAVYOUIV VLV 99U811N0EI oj 8 pue asneo XVL a JapUN SPOUEJSUINOIO Y pue Jo UOHJOUNYJEU equoseq SIUSUILIOJ 78 ON 04109 H4dO YOLVNDISAG HOlVH3dO 1019181 WI IEGEOP page 12 5 Jan 01 2007 BRP Rotax Effectivity 912 Serie OM Edition
19. 98 0 21 77105107 Fax 98 0 21 77000030 E mail asmpish asmpish com Contact person Ali Habibi Najafi ISRAEL gt CONDOR AVIATION INDUSTRIES LTD P O Box 1903 14 Topaz st Cesaria 38900 Tel 972 0 4 6265080 Fax 972 0 4 62650 95 E mail condor netvision net il Contact person David Wiernik JAPAN 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 President KOREA IND CO LTD 1104 Biz Center SK Technopark 190 1 Sangdeawon Dong Joongwon Ku Seoungnam City SOUTH KOREA Tel 82 0 31 776 0771 5 Fax 82 0 31 776 0776 E mail johnlee korberco com Contact person John Lee President 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 Al Moalla Effectivity 912 Serie BRP Rotax page 13 3 OM Edition 1 Rev 1 Febr 01 2008 NOTES Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 13 4 Jan 01 2007 d03937 fm ROTAX AIRCRAFT ENGINES Motornummer Engine serial no Flugzeugtype Type of aircraft Flugzeugkennzeichen Aircraft registration no ROTAX Vertriebspartner ROTAX authorized distributor www rotax aircraft engines com and TM are trademarks of BRP Rotax G
20. CA 3 4 gt KODIAK RESEARCH LTD PO 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 AUSTRALIA NEW ZEALAND PAPUA NEW GUINEA gt BERT 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 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 ANGOLA BOTSWANA LESOTHO MADAGASCAR MALAWI MOZAMBIQUE NAMIBIA SOUTH AFRICA SWAZILAND ZAMBIA ZIMBABWE gt AVIATION ENGINES ANDACCESSO RIES PTY LTD Private Bag X10021 Edenvale 1610 SOUTH AFRICA Tel 27 0 11 455 4203 Fax 27 0 11 455 4499 E mail niren aviation engines co za Website www aviation engines co za Contact person Niren Chotoki Tel 1 250 260 6299 Fax 1 250 260 6269 a E mail inguiries rotec com Website www rotec com 9 8 Effectivity 912 Serie BRP Rotax page 13 2 OM Edition 1 Rev 1 Febr 01 2008 d02825 fm GHANA BENIN BURKINA FASO CAMEROON CENTRAL AFRICAN REPUBLIC CONGO GABON GUINEA IVORY COAST MALI MAURITANIA NIGER NIGERIA SENEGAL TOGO gt WAASPS
21. LTD PMB 49 Kotoka International Airport Accra GHANA Tel 233 0 28 5075254 Fax 233 0 217 717 92 E mail info waasps com Website www waasps com Contact person Jonathan Porter 5 ASIA CHINA HONG KONG MACAO gt PEIPORT INDUSTRIES LIMITED Rm 1302 Westlands Centre 20 Westlands Road Ouarry 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 General Director INDIA gt GREAVES COTTON LTD Express Building Annexe 9 10 Bahadur Shah Zafar Marg NEW DELHI 110 002 Tel 91 0 11 23311501 Fax 91 0 11 23702129 E mail anilkumar greavesmail com Website www greavescotton com aeroengines htm Contact person Cdr Kumar Divisional Manager INDONESIA MALAYSIA PHILIP PINES SINGAPORE THAILAND TAIWAN gt BERT FLOOD IMPORTS PTY 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 gt A SEMAN PISHRANEH 13 Km of Babaee Exp Way Cross Telo Road Sepehr Aviation Group Tehran Iran Tel
22. Y let engine cool down at idling at approx 2000 r p m REMEDY cover oil cooler surface maintain the oil temperature prescribed REMEDY use fuel with higher octane rating REMEDY preheat engine fit fully charged battery at cold start a pressure reading of up to around 7 bar 102 psi does not indicate a malfunction too much resistance in the oil suction tube at low temperatu res Stop engine and preheat oil At oil pressure reading too low than 1 bar oils with lower visco sity are to be used See SI 912 016 current issue NOTE Oil pressure must in the idle ope ration with an oil temperature of min 50 C 120 F to be measu red Effectivity 912 Serie BRP Rotax page 12 2 OM Edition 1 Rev 0 Jan 01 2007 d03936 fm d03936 fm NOTES Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 12 3 Jan 01 2007 12 1 Reporting According to the regulation of JAR FAR 21 3 the manfacturer shall evaluate field information and report to the authority In case of any relevant occur rences that may involve malfunction of the engine the form on the next page should be filled out and sent to the responsible authorized ROTAX distribu tor NOTE The form is also available from the official ROTAX AIRCRAFT ENGINES Homepage www rotax aircraft engines com in electronic version Effectivity 912 Serie BRP Rotax page 12 4 OM Edition 1 Rev 0 Jan 01 2007 d0393
23. aeie ker nr sk fun pain 3 1 3 1 Remarks a 3 1 3 2 Engine serial number 3 1 4 Safety aine TN 4 1 4 1 Repeating symbols ener 4 1 4 2 Safety information eese nennen 4 2 4 3 Technical documentation eese 4 5 5 EE unen 5 1 6 List of amendments 6 1 Description of design 7 1 7 1 Type 7 2 7 2 Denomination of cylinders 7 3 8 Technical data eese eene nennen nnne nennen nennen 8 1 8 1 Dimensions 2 8 1 8 2 Weights iei eme 8 1 8 3 Fuel consumption eere eene nnne nenn 8 2 8 4 Direction of rotation 8 2 9 Description of systems eere 9 1 9 1 Cooling system ooroononn nn nn nnne nnn nnns 9 1 9 2 Euel system ehh menie nei egli 9 2 9 3 Lubrication 5 51 9 3 9 4 Electric syst m neLeree rere Me 9 4 9 5 Propeller gearbox nennt nnns 9 5 9 5 1 governor for const speed propeller vacuum pump 9 6 10 Operating instructions 10 1 10 1 General limits of operation eres 1
24. are safest Selectand use proper aircraft instrumentation This instrumentation is not included with the ROTAX engine package Only approved instrumentati on may be installed Effectivity 912 Serie BRP Rotax page 4 2 OM Edition 1 Rev 1 Febr 01 2008 d02820 fm d03928 fm Before flight ensure that all engine controls are operative Make sure all controls can be easily reached in case of an emergency Unless in a run up area never run the engine with the propeller turning while on the ground Do not operate engine if bystanders are close Inthe interest of safety the aircraft must not be left unattended while the engine is running Keep an engine log and respect engine and aircraft maintenance sche dules Keep the engine in top operating condition at all times Do not ope rate any aircraft which is not properly maintained or has engine operating irregularities which have not been corrected Since special tools and eguipment may be reguired engine servicing should only be performed by an authorized ROTAX engine dealer or a gualified trained mechanic approved by the local airworthiness authority To eliminate possible injury or damage ensure any loose equipment or tools are properly secured before starting the engine When in storage protect the engine and fuel system from contamination and exposure Certain areas altitudes and conditions present greater risk than others The engine may require carbur
25. be tween the 50 and the max mark and should never falls below the min mark Prior to long flights oil should be added so that the oil level reaches the mark Avoid oil levels exceeding the max mark since excess oil could be poured out through the venting system Difference between max and min mark 0 45 litre 0 95 lig pt Effectivity 912 Serie BRP Rotax page 10 15 OM Edition 1 Rev 1 Febr 01 2008 10 3 4 Engine start 4 WARNING Do not take the engine into operation if any per son is near the aircraft Fuel open Starting carb activated NOTE If the engine is already in operating tempera ture start the engine without choke Throttle lever set to idle position Master switch on Ignition both circuits switched on Starter button actuate B CAUTION Activate starter for max 10 sec only without in terruption followed by a cooling period of 2 minutes As soon as engine runs adjust throttle to achieve smooth running at approx 2500 r p m Check if oil pressure has risen within 10 seconds and monitor oil pressure Increase of engine speed is only permitted at steady oil pressure readings above 2 bar 30 psi At an engine start with low oil temperature continue to observe the oil pressure as it could drop again due to the increased flow resi
26. cation in the en gine The surplus oil emerging from the points of lubrication accumulates on the bottom of crankcase and is forced back to the oil tank by the blow by gases NOTE The oil circuit is vented via bore 7 on the oil tank NOTE The oil temperature sensor 8 for reading of the oil in let temperature is located on the oil pump housing Lubricants see Chapter 10 2 3 00523 HEIDE Effectivity 912 Serie BRP Rotax page 9 3 OM Edition 1 Rev 0 Jan 01 2007 9 4 Electric system See fig 7 The ROTAX 912 engine is equipped with a dual ignition unit of a breaker less capacitor discharge design with an integrated generator The ignition unit is completely free of maintenance and needs no external power supply Two independent charging coils 1 located on the generator stator supply one ignition circuit each The energy is stored in capacitors 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 Firing order 1 4 2 3 NOTE
27. ch off both ignition circuits and anchor the aircraft Have the cockpit occupied by a compe tent person Operating media A WARNING Carry out pre flight checks on the cold or luke warm engine only Risk of burning and scalds Check for any oil coolant and fuel leaks If leaks are evident rectify before flight B CAUTION The coolant specifications of the section 10 2 Operating media are to be observed Verify coolant level in the overflow bottle replenish as required up to top The coolant level must be between min and max mark or at least 0 2 litre 0 4 liq pt B CAUTION The oil specifications of the section 10 2 Oper ating media are to be observed Check oil level and replenish as required NOTE Propeller shouldn t be turned reverse the nor mal direction of engine rotation Priortooil check turn the propeller by hand in direction of engine rotation several times to pump oil from the engine into the oil tank or let the engine idle for 1 minute It is essential to build up compression in the combustion cham ber Maintain the pressure for a few seconds to let the gas flow via the piston rings into the crankcase The speed of rotation is not important as the pressure and the amount of gas which is transfered into the crankcase This process is finished when air is returning back to the oil tank and can be noticed by a murmur from the open oil tank NOTE The oil level should be in the upper half
28. eed drop with only one ignition circuit must not exceed 300 r p m approx 130 r p m propeller 115r p m approx 50 r p m propeller max difference of speed by use of either circuit A or B NOTE The propeller speed depends on the actual re duction ratio Check of hydraulic propeller governor Check control of the hydraulic propeller governor to specifications of the manufacturer 10 3 6 Take off Climbing with engine running at take off performance is permissible max 5 minutes See Chapter 10 1 10 1 1 and 10 1 2 A WARNING Monitor oil temperature cylinder head tempera ture and oil pressure Limits must not be ex ceeded See Chapter 10 1 Operating Limits m CAUTION Respect cold weather operation recommen dations see Chapter 10 3 9 Effectivity 912 Serie BRP Rotax page 10 17 OM Edition 1 Rev 0 Jan 01 2007 10 3 7 Cruising Set performance as per performance specifications and respect operating limits as per Chapter 10 1 10 1 1 and 10 1 2 Avoid operation below normal operation oil temperature 90 110 C 194 230 F as possible formation of condensation water in the lubrication system badly influences the oil quality To evaporate possibly accumulated condensation water at least once a day 100 C 212 F oil temperature must be reached 10 3 8 Engine shut off Normally the cooling down of the engine during descending and ta xiing will be sufficient to allow the eng
29. etor recalibration or humidity or dust sand preventative equipment or additional maintenance may be required Consult your aircraft dealer or manufacturer and obtain the necessary in formation especially before flying in new areas Never operate the engine and gearbox without sufficient guantities of lu bricating oil Periodically verify level of coolant Never exceed maximum rated r p m Allow the engine to cool at idle for several minutes before turning off the engine This engine may be equipped with an Airborne 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 Serie BRP Rotax page 4 3 OM Edition 1 Rev 0 Jan 01 2007 NOTES Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 4 4 Jan 01 2007 d03928 fm d03928 fm 4 3 Technical documentation These documents form the instructions for continued airworthiness of ROTAX aircraft engines Installation Manual 912 F Installation Manual 912 A Installation Manual 912 UL Installation Manual 912 S Operators Manual Maintenance Manual 912 Series Line and Heavy Maintenance Overhaul Manual 912 A F Illustrated Parts Catalog 912 A F S UL ULS ULSFR Alert Service Bulletins Service Bulletins Service Instructions Service Letters Any reference to a document refers to the latest edition issued b
30. ff 5800 1 min 5 min Max continuous speed 5500 1 min Idle 1400 1 2 Performance ISA International Standard Atmosphere Take off 59 6 kW at 5800 1 min Max continuous performance 58 kW at 5500 1 min 3 Acceleration Limit of engine operation at zero gravity and in negative g condition MAX cei deest eiit tet an n hn 5 seconds at max 0 5 g 4 Oil pressure qu EL 7 bar m CAUTION Fora short period admissible at cold start WAIN RE 0 8 bar 12 psi below 3500 rpm 2 0 5 0 bar 29 73 psi above P 3500 rpm 5 temperature 140 285 F Minze Gries 120 F normal operating temperature approx 90 110 C 190 230 F 6 Coolant See Operating media Chapter 10 2 1 In use of conventional coolant Coolant temperature coolant exit temperature MAX lees 120 C 248 F Cylinder head temperature IMEX ec einer 150 C 300 F Permanent monitoring of coolant temperature and cylinder head temperature is necessary In use of waterless coolant Cylinder head temperature MAX ihe oriee eit a 150 C 300 F Permanent monitoring of cylinder head temperature is necessary Effectivity 912 UL A F BRP Rotax page 10 1 OM Edition 1 Rev 1 Febr 01 2008 7 Engine
31. g media are to be observed Verify coolant level in the expansion tank replenish as required up to top The coolant level must be at least 2 3 of the expansion tank Verify coolant level in the overflow bottle replenish as required The coolant level must be between max and min mark or at least 0 2 litre 0 4 liq pt Effectivity 912 Serie BRP Rotax page 10 13 OM Edition 1 Rev 1 Febr 01 2008 Check of mechanical components Turn propeller by hand in direction of engine rotation several times and observe engine for odd noises or excessive resistance and nor mal compression Gear box Version without overload clutch No further checks are necessary Version with overload clutch Turn the propeller by hand to and fro feeling the free rotation of 15 or 30 before the crankshaft starts to rotate If the propeller can be turned between the dogs with practically no friction at all less than 25 Nm 222 in lb further investiga tion is necessary Carburetor Verify free movement of throttle cable and starting carburetor over the complete range Check from the cockpit Exhaust system Inspect for damages leakage and general condition 10 3 2 Before engine start Carry out pre flight checks d02824 fm Effectivity 912 Serie BRP Rotax page 10 141 OM Edition 1 Rev 1 Febr 01 2008 d02824 fm 10 3 3 Pre flight checks 4 WARNING Ignition OFF Before cranking the propeller swit
32. ges 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 propel ler Alternatively either a vacuum pump or a hydraulic governor for constant speed propeller can be used The drive is in each case via the propeller re duction gear Effectivity 912 Serie BRP Rotax page9 5 OM Edition 1 Rev 0 Jan 01 2007 9 5 1 Hydr governor for const speed propeller vacuum pump Alternatively either a vacuum pump or a hydraulic governor for constant speed propeller can be used The drive is in each case via the propeller reduction gear Gear ratio crankshaft propeller shaft propeller shaft hydraulic governor vacuum pump crankshaft hydraulic governor vacuum pump 1 724 1 1 842 1 NOTE Transmission ratio between crankshaft and hy draulic governor or vacuum pump is either 1 842 or 1 724 i e the speed of the hydraulic governor or vacuum pump is either 0 54 or 0 58 of engine speed Effectivity 912 Serie BRP Rotax page 9 6 OM Edition 1 Rev 0 Jan 01 2007 d03933 fm d02824 fm 10 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 E00051EN JAR E TC No EASA E 121 10 1 General limits of operation 10 1 1 Operating speeds and limits 912 UL 1 Speed Take o
33. ine to be shut off as soon as the aircraft is stopped Atincreased operating temperatures to make an engine cooling run of at minimum 2 minutes 10 3 9 Cold weather operation Generally an engine service should be carried out before the start ofthe cold season Coolant For selection of coolant and mixing ratio see Coolant Chapter 10 2 1 Lubricant For selection of oil see Table of Lubricants Chapter 10 2 3 Cold start With throttle closed and choke activated open throttle renders starting carb ineffective aware no spark below crankshaft speed of 220 rpm propel ler speed of 90 rpm As performance 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 Use multigrade oil with the low end viscosity code of 5 or 10 Gap electrode on spark plug to the minimum or fit new spark plugs Effectivity 912 Serie BRP Rotax page 10 18 OM Edition 1 Rev 0 Jan 01 2007 d03934 fm d03934 fm Preheat engine using hot air Beyond that observe following advices for operation at extremely low temperatures NOTE Distinguish between two kinds of carb icing 1 Icing due to water in fuel 2 Icing because of high air humidity Addendum to note 1 Water in fuel will accumulate at the lower parts of the fuel system and leads to freezing of fuel
34. lbert 1 98000 MONACO Tel 377 0 93 30 17 40 Fax 377 0 93 30 17 60 E mail mad libello com Website www moteuraerodistribution com Contact person Philippe Thys Issue 01 01 2007 GERMANY THE NETHERLANDS gt FLUGMOTOREN FRANZ GMBH Am Weidengrund la 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 GREAT BRITAIN IRELAND ICELAND gt SKYDRIVE LTD Burnside Deppers Bridge SOUTHAM WARWICKSHIRE CV47 2SU 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 HUNGARY gt HALLEY Baktai t 45 P O Box 425 H 3300 EGER Tel 36 0 36 313 830 Fax 36 0 36 320 208 E mail apollo mail datanet hu Contact person Zolt n Moln r ITALY 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 ROMANIA 5 BERIMPEX S R L Str Dr Taranu Grigore No 8 Ap 2 Sector 5 R 76241 BUCHAREST Tel 40 0 21 410 90 03 Fax 40 0
35. lines filters or jets Remedy Use non contaminated fuel filtered through su de Generously sized water separators Fuel lines routing inclined Prevent condensation of humidity i e avoid temperature diffe rences between aircraft and fuel A WARNING Fuels containing alcohol always carry a small amount of water in solution In case of temper ature changes or increase of alcohol content water or a mixture of alcohol and water may set tle and could cause troubles Addendum to note 2 Carburetor icing due to humidity may occur on the venturi and on the throttle valve due to fuel evaporation and leads to performance loss and change in mixture Intake air pre heating is the only effec tive remedy Effectivity 912 Serie BRP Rotax page 10 19 OM Edition 1 Rev 0 Jan 01 2007 10 4 Abnormal operation 4 WARNING At unusual engine behaviour conduct checks as per Chapter 10 4 1 through 10 4 13 below and as per Maintenance Manual Chapter 05 before the next flight NOTE Further checks see Maintenance Manual 10 4 1 Engine stop Start during flight Starting procedure same as on ground however on a warm engine without choke 10 4 2 Exceeding of max admissible engine speed Reduce engine speed Any exceeding of the max admissible engi ne speed has to be entered by the pilot into the logbook stating du ration and extent of overspeed 10 4 3 Exceeding of max admissible cyl head temperature
36. mbH amp Co KG 2008 BRP Rotax GmbH amp KG All rights reserved
37. nd responsibility of the aircraft manufacturer assembler and owner user Due to the varying designs equipment and types of aircraft ROTAX grants no warranty or representation on the suitability of its engine s use on any particular aircraft Further ROTAX grants no warranty or repre sentation of this engine s suitability with any other part component or system which may be selected by the aircraft manufacturer assembler or user for aircraft application Whether you are a qualified pilot or a novice complete knowledge of the aircraft its controls and operation is mandatory before venturing solo Flying any type of aircraft involves a certain amount of risk Be informed and prepared for any situation or hazard associated with flying A recognized training program and continued education for piloting an aircraft is absolutely necessary for all aircraft pilots Make sure you also obtain as much information as possible about your aircraft its mainte nance and operation from your dealer 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 compliance with the maintenance and ope ration and any additional information which may be given to you by your dealer Respectall government or local rules pertaining to flight operation in your flying area Fly only when and where conditions topography and air speeds
38. opeller governor for A3 only optional Effectivity 912 Serie BRP Rotax page 7 1 OM Edition 1 Rev 0 Jan 01 2007 7 1 Type description e g ROTAX 912 2 The type designation is of the following composition ROTAX Type type Baureihe Zulassung certification configuration 02091 Type 912 4 oyl horizontalle opposed normal aspirated engine Certification A certified to JAR 22 TC No EASA E 121 ES certified to FAR 33 TC No E00051 EN JAR E TC No EASA E 121 UL ULS hon certified aircraft engines Configuration 1 A Prop shaft with flange for fixed prop P C D 100 mm NOTE This configuration is not available any lon ger and will be replaced by configuration 2 2 Prop shaft with flange for fixed prop P C D 75 mm P C D 80 mm and 4 P C D 3 propeller P C D 75 mm P C D 80 mm P C D 4 and drive for hydraulic governor for constant speed propeller 4 Prop flange for fixed pitch propeller P C D 75 mm P C D 80 mm P C D 4 and prepared for retrofit of a hydraulic governor for constant speed propeller d02823 fm Effectivity 912 Serie BRP Rotax page 7 2 OM Edition 1 Rev 1 Febr 01 2008 d03931 fm 7 2 Denomination of cylinders
39. out limitation But full throttle performance above 5500 r p m is limited to 5 mi nutes At deviation of temperature conditions from standard at mosphere conditions the engine performance to be ex pected can be calculated from the performance indicated multiplied by standard temperature divided by actual temperature in K 5800 U min Vollast take off performance Pakt standard aktuell 2200 T K t C 273 527 K t C Leistung Performance KW 0 1000 2000 3000 4000 5000 6000 7000 7500 Dichteh he Density Altitude m 05482 Effectivity 912 ULS S BRP Rotax page 10 8 OM Edition 1 Rev 0 Jan 01 2007 d03934 fm d03934 fm 10 2 Operating media 10 2 1 Coolant In principle 2 different types of coolant are permitted Conventional coolant based on ethylene glycol Waterless coolant based on propylene glycol CAUTION Obey the manufacturer s instructions about the coolant mixture ratio designation concentrate water anticorrosion conventional e g BASF Glysantine 50 50 waterless e g EVANS NPG 100 0 Conventional coolant mixed with water has the advantage of a hig her specific thermal capacity than water less coolant NOTE The important advantage of water less coolant is its higher boiling point than a conventional mixture When correctly applied there is sufficient protec
40. oval by authority 0 1 to 13 all 01 01 2007 DOA 1 4 4 2 02 01 2008 DOA 1 5 5 1 02 01 2008 DOA 1 6 6 1 02 01 2008 DOA 1 7 7 2 02 01 2008 DOA 1 10 10 1 02 01 2008 DOA 10 2 02 01 2008 DOA 10 6 02 01 2008 DOA 10 13 0201 2008 DOA 10 14 0201 2008 DOA 10 15 0201 2008 DOA 1 13 13 1 02 01 2008 DOA 13 2 02 01 2008 DOA 13 3 02 01 2008 DOA d02822 fm Effectivity 912 Serie BRP Rotax page 6 1 OM Edition 1 Rev 1 Febr 01 2008 NOTES Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 6 2 Jan 01 2007 d03930 fm d03931 fm 7 Description of design 4 stroke 4 cylinder horizontally opposed spark ignition engine 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 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 configuration 3 Electric starter 12V 0 6 kW Electric starter 12V 0 9 kW optional Integrated AC generator with external rectifier regulator 12V 20A DC External alternator 12V 40A DC optional Vacuum pump only for A1 A2 and A4 possible optional Hydraulic constant speed pr
41. perature 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 Table of lubricants See fig 15 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 Mehrbereichs le climatic i i ans multi grade oils tropisch tropical SAE 20W 40 gem igt temperate S z e lt o arktisch arctic 01176 Effectivity 912 Serie BRP Rotax page 10 12 OM Edition 1 Rev 0 Jan 01 2007 d03934 fm d02824 fm 10 3 Standard operation To warrant reliability and efficiency of the engine meet and carefully obser ve all the operating and maintenance instructions 10 3 1 Daily checks A WARNING Risk of burnings and scalds Conduct checks on the cold engine only A WARNING Ignition OFF Before cranking the propeller switch off both ignition circuits and anchor the aircraft Have the cockpit occupied by a compe tent person CAUTION If established abnormalities e g excessive re sistance of the engine noises etc inspection in accordance with the relevant Maintenance Manual is necessary Do not release the engine into service before rectification Coolant level B CAUTION The coolant specifications of the section 10 2 Operatin
42. re 912 ULS S 10 5 Eguipment 8 1 Exceeding of max admissible cyl head temperature 10 20 Exceeding of max admissible engine speed 10 20 Exceeding of max admissible oil tem perature 10 20 Exhaust system 10 14 F Fuel 10 10 Fuel consumption 8 2 Fuel pressure 912 UL A F 10 2 Fuel pressure 912 ULS S 10 6 Fuel system 9 2 H Hydr governor for const speed propel ler 9 6 Ignition check 10 17 Ignition unit 9 4 Index of pages 5 1 Introduction 3 1 L List of amendments 6 1 Lubricants 10 11 Lubrication system 9 3 M magneto side 7 3 Oil consumption 10 12 Oil pressure 912 UL A F 10 1 Oil pressure 912 ULS S 10 5 Oil pressure below minimum during flight 10 20 Oil pressure below minimum on ground 10 20 Oil specification 10 11 Oil temperature 912 UL A F 10 1 Oil temperature 912 ULS S 10 5 Oil viscosity 10 12 Operating media 10 15 Operating speeds and limits 912 UL A F 10 1 Operating speeds and limits 912 ULS S 10 5 Overload clutch 9 5 Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 2 1 Jan 01 2007 P Performance ISA 912 UL A F 10 1 Performance ISA 912 ULS S 10 5 Performance data 10 4 10 8 Performance graphs for stand conditi ons ISA 10 3 10 7 power take off side 7 3 Pre flight checks 10 15 Propeller gearbox 9 5 Propeller governor 9 6 R Remarks 3 1 Repeating symbols 4 1 Reporting 12 4 5 Safet
43. restriction between full thrott le performance and power requirement of propeller providing engi ne speed over 5500 r p m is restricted to 5 minutes However for economic reasons it is recommended to run the engi ne in accordance with the following table Engine Power Engine speed Performance Torque Nm Manifold pres Setting rpm kW in HG Take off perform full throttle cruising power full throttle 75 27 2 65 26 5 55 26 3 10 1 1 2 Performance graph for non standard conditions The following graph shows the performance drop with in creasing flight altitude The curves show the performance at 5800 5500 5000 4500 and 4000 r p m at full throttle The engine allows operation with fully open throttle valve over the whole r p m range without limitation But full throttle performance above 5500 r p m is limited to 5 mi nutes 5800 1 min Vollast take off performance 2 E o E l 1000 2000 3000 4000 5000 6000 7000 Dichteh he Density Altitude m 00452 At deviation of temperature con ditions from standard atmosphe re conditions the engine perfor mance to be expected can be calculated from the performance indicated multiplied by standard temperature divided by actual temperature in K _P stand T standard Taktuell t C 273 Effectivity
44. rts orders always indicate the engine serial number as the manufacturer makes modifications to the engine for product improve ment The engine serial number should always be used when ordering parts to ensure correct part selection prior to shipment The engine serial number is located on the top of the crankcase magneto side See fig 2 Effectivity 912 Serie BRP Rotax page 3 1 OM Edition 1 Rev 0 Jan 01 2007 NOTES Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 3 2 Jan 01 2007 d03927 fm d03928 fm 4 Safety Although the mere reading of these instructions will not eliminate a hazard the un derstanding and application of the information herein will promote the proper use of the engine The information and components system descriptions contained in this Operator s Manual are correct at the time of publication ROTAX however maintains a policy of continuous improvement of its products without imposing upon itself any obliga tion to install them on its products previously manufactured ROTAX reserves the right at any time to discontinue or change specifications de signs features models or equipment without incurring obligation The illustrations in this Manual show the typical construction They may not repre sent in full detail or the exact shape of the parts which have the same or similar function Specifications are given in the SI metric system with the USA equivalent in paren thesis
45. s tance in the suction line The number of revolutions may be only so far increased that the oil pressure remains steady De activate starting carb CAUTION Since the engine comprises a reduction gear with shock absorber take special care of the fol lowing To prevent impact load start with throttle lever in idle position or at the most up to 10 open For the same reason wait for around 3 sec af ter throttling back to partial load to reach con stant speed before re acceleration For checking the two ignition circuits only one circuit may be switched off and on at times m CAUTION Do not actuate starter button switch as long as the engine is running Wait until complete stop of engine Effectivity 912 Serie BRP Rotax page 10 16 OM Edition 1 Rev 0 Jan 01 2007 d03934 fm d03934 fm 10 3 5 Prior to take off Warming up period Start warming up period at 2000 r p m for approx 2 minutes con tinue at 2500 r p m duration depending on ambient temperature until oil temperature reaches 50 C 120 F Check temperatures and pressures Throttle response Short full throttle ground test consult Aircraft Operator s Manual since engine speed depends on the propeller used m CAUTION After a full load ground test allow a short cooling run to prevent vapour formation in the cylinder head Ignition check Check the two ignition circuits at 4000 r p m approx 1700 r p m propeller Sp
46. s regarding remedy do not solve the pro blem contact an authorized workshop The engine must not be operated until the problem is rectified Engine does not start POSSIBLE CAUSE a b ignition off closed fuel tap or clogged filter no fuel in tank starting speed too low faulty or discharged battery starting speed too low start problems on cold engine REMEDY switch on open tap clean or renew filter check fuel system for leaks refuel fit fully charged battery 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 a starting carb activated Low oil pressure POSSIBLE CAUSE a not enough oil in oil tank REMEDY close starting carb REMEDY check oil return line for free pas sage renew oil seal Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 12 1 Jan 01 2007 Engine keeps running with ignition off POSSIBLE CAUSE a overheating of engine Cil level is increasing POSSIBLE CAUSE a oil too cold during engine ope ration Knocking under load POSSIBLE CAUSE a Octane rating of fuel too low Engine hard to start at low temperature POSSIBLE CAUSE a starting speed too low b low charge battery c high oil pressure d oil pressure too low after cold start REMED
47. start operating temperature 8 Fuel pressure max 0 4 err 0 15 bar A WARNING Exceeding the max admissible fuel pressure will over ride the float valve of the carburetor and to engine fai lure The aircraft engine manufacturer strongly recommends the installation of an additional pump unless this has not been covered by legal obligations so far 9 Power consumption of the hydraulic propeller governor CAPPE AA 600 W 10 Power consumption of the vacuum pump 300 W 11 Power consumption of the external alternator A EN 1200 W 12 Deviation from bank angle MAX FE TT TN NIN 40 NOTE Up to this value the dry sump lubrication system war rants lubrication in every flight situation Effectivity 912 UL A F BRP Rotax page 10 2 OM Edition 1 Rev 1 Febr 01 2008 d02824 fm d03934 fm 10 1 1 1 Performance graphs for stand conditions ISA A max engine output B power reguirement of propeller 00450 3000 4000 5000 5800 rpm 00451 C manifold pressure D fuel consumption in Hg L h Gal h 30 7 93 20 5 28 10 2 64 1 i 1 0 3000 4000 5000 5800 rpm Values along propeller curve Effectivity 912 UL A F BRP Rotax page 10 3 OM Edition 1 Rev 0 Jan 01 2007 Performance data for variable pitch propeller Engine operation is permitted without
48. ter 10 2 1 Ausgleichsgef expansion tank berlaufgef overflow bottle 2 K hler radiator 08111 Effectivity 912 Serie BRP Rotax page 9 1 OM Edition 1 Rev 0 Jan 01 2007 9 2 Fuel system See fig 5 The fuel flows from the tank 1 via a coarse filter 2 the safety cock 3 wa ter drain cock 4 and fine filter 5 to the mechanical fuel pump 6 From the pump fuel passes on to the two carburetors 7 Via the return line 8 surplus fuel flows back to the fuel tank NOTE The return line serves to avoid formation of vapour lock Fuel see Chapter 10 2 2 8 0 zum Tank 6 0 to fuel tank gt o 50 7 Ld zum Manometer to fuel pressure gauge sls 8 7 j cp 00535 Effectivity 912 Serie BRP Rotax page 9 2 OM Edition 1 Rev 0 Jan 01 2007 d03933 fm d03933 fm 9 3 Lubrication system See fig 6 The ROTAX 912 engine is provided with a dry sump forced lubrication sys tem with a main oil pump with integrated pressure regulator 1 and oil pres sure sensor 2 NOTE The oil pump is driven by the camshaft 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 lubri
49. tion against vapor bubble formation freezing or thickening of the coolant within the operating limits Use the coolant specified in the manufacturer s documentation m CAUTION Obey the latest edition of Service Instruction SI 912 016 for the selection of the correct cool ant Effectivity 912 Serie OM Edition 1 Rev 0 BRP Rotax page 10 9 Jan 01 2007 10 2 2 Fuel The following fuels can be used Usage Description 912 UL A F 912 ULS S MOGAS EN 228 Normal 1 European standard EN 228 Super 228 Super 2 EN 228 Super plus EN 228 Super plus 2 Canadian CAN CGSB3 5 CAN CGSB3 5 standard Quality 1 Quality 3 9 US standard ASTM D4814 ASTM D4814 AVGAS US standard AVGAS 100 LL AVGAS 100 LL ASTM D910 ASTM D910 1 min ROZ 90 2 min ROZ 95 3 min AKI 87 4 min AKI 91 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 m CAUTION NOTE m CAUTION Use only fuel suitable for the respective climatic zone Risk of vapour formation if using winter fuel for summer operation Obey the latest edition of Service Instruction SI 912 016 for the selection of the correct fuel Effectivity 91
50. y 4 1 Safety information 4 2 Speed 912 UL A F 10 1 Speed 912 015 5 10 5 Symbols 4 1 T Table of lubricants 10 12 Take off 10 17 Technical data 8 1 Technical documentation 4 5 Throttle response 10 17 Trouble shooting 12 1 Type 7 2 Type description 7 2 V Vacuum pump 9 6 W Warming up period 10 17 Weights 8 1 Effectivity 912 Serie BRP Rotax OM Edition 1 Rev 0 page 2 2 Jan 01 2007 403926 fm d03927 fm 3 Introduction Congratulations on your decision to purchase a ROTAX aircraft engine Before operating the engine carefully read this Operator s Manual The Ma nual provides you with basic information on the safe operation of the engine If any passages of the Manual are not clearly understood or in case of any questions please contact an authorized Distribution or Service Center for ROTAX aircraft engines We wish you much pleasure and satisfaction flying your aircraft with this ROTAX engine 3 1 Remarks The purpose of this Operator s Manual is provided to familiarize the owner user of this aircraft engine with basic operating instructions and safety infor mation For more detailed maintenance safety and flight information consult the do cumentation provided by the aircraft manufacturer and dealer For further information on maintenance and spare parts service contact the nearest ROTAX distribution Center see Chapter 13 3 2 Engine serial number On all enquiries or pa
51. y ROTAX if not stated otherwise NOTE The status of Manuals can be determined by checking the table of amendments of the Manual The 18 column of this table is the revision 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 The information given in the are based on data and experience that are con sidered applicable for professionals under normal conditions The fast technical progress and variations of installation might render pre sent laws and regulations inapplicable or inadequate The illustrations in this Manual are mere sketches and show a typical arran gement They may not represent the actual part in all its details but depict parts of the same or similar function Therefore deduction of dimensions or other details from illustrations is not permitted Effectivity 912 Serie BRP Rotax page 4 5 OM Edition 1 Rev 0 Jan 01 2007 All necessary documentation is available from the ROTAX Distribution and Service Centers see Chapter 13 NOTE The Illustrations in this Operator s 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 Serie OM Edition 1 Rev 0 BRP Rotax page 4 6 Jan 01 2007 d03928 fm d03929 fm 5 Index of pages cover page 10 10 1
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