BRP 912 Series User manual

FOR ROTAX ENGINE TYPE 912 SERIES
REF NO.: OM-912 | PART NO.: 899700
OPERATORS
MANUAL

Before starting the engine, read the Operators Manual, as it contains
important safety relevant information. Failure to do so may result in per-
sonal injuries including death. Consult the original equipment
manufacturers handbook for additional instructions!
WARNING
These technical data and the information embodied therein are the property of
BRP-Rotax GmbH & CO KG, Austria, acc, BGBI 1984 no. 448, and shall not,
without prior written permission of BRP-Rotax GmbH & Co KG, be disclosed in
whole or in part to third parties. This legend shall be included on any reproduction
of these data, in whole or in part. The Manual must remain with the engine/aircraft
in case of sale.
ROTAX® is a trade mark of BRP-Rotax GmbH & Co KG. In the following
document the short form of BRP-Rotax GmbH & 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.
Copyright 2023 © - all rights reserved.
Translation into other languages might be performed in the course of language
localization but does not lie within ROTAX® scope of responsibility.
In any case the original text in English language and the metric units are
authoritative.

Effectivity: 912 Series
Rev. 1
BRP-Rotax Page Content-1
Ed.4/January 01 2023
Table of Content
Chapter INTRO – Introduction
Chapter LEP – LIST OF EFFECTIVE PAGES
Chapter TOA – Table of amendments
Chapter 1 – General note
Chapter 2 – Operating instructions
Chapter 3 – Abnormal operation
Chapter 4 – Standard operation
Chapter 5 – Performance and Fuel consumption
Chapter 7 – System Description
Chapter 8 – Preservation and storage
Chapter 9 – Supplement

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INTRO) Introduction
Topics in this chapter
Foreword BRP-Rotax GmbH & Co KG (hereinafter “BRP-Rotax”) provides
“Instructions for Continued Airworthiness”, which are based on
the design, tests and certification of the engine and its
components. These instructions apply only to engines and
components supplied by BRP-Rotax.
Before operating the engine, read this Operators Manual (OM)
carefully. If any passages of the Manual are not clearly
understood or in case of any questions, please contact our
ROTAX® Authorized Distributors or their independent Service
Centers.
This Operators Manual (OM) contains important information
about safe operation of the engine together with descriptions of
the systems, technical data, operating media and the
operational limits of the engine.
The specified information and procedures apply only to the
engine and not to specific applications in particular aircraft. The
aircraft manufacturers Operators Manual is therefore definitive
in terms of the operation of the engine, as it contains all of the
aircraft-specific instructions
BRP-Rotax wishes you much pleasure and satisfaction flying
your aircraft powered by this ROTAX® aircraft engine.
Document
structure
The structure of the Manual follows whenever it is possible the
structure of the “GAMA Specification #1 for Pilot’s Operating
Handbook“.
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LEP) LIST OF EFFECTIVE PAGES
Each new revision to the Operators Manual will have a new List of Effective Pages.
Chapter Page Date
cover
page
INTRO 1 January 01 2023
2 January 01 2023
LEP 1 January 01 2023
2 January 01 2023
TOA 1 January 01 2023
2 January 01 2023
1 1 January 01 2023
2 January 01 2023
3 January 01 2023
4 January 01 2023
5 January 01 2023
6 January 01 2023
7 January 01 2023
8 January 01 2023
9 January 01 2023
10 January 01 2023
11 January 01 2023
12 January 01 2023
13 January 01 2023
14 January 01 2023
15 January 01 2023
16 January 01 2023
2 1 January 01 2023
2 January 01 2023
3 January 01 2023
Chapter Page Date
4 January 01 2023
5 January 01 2023
6 January 01 2023
7 January 01 2023
8 January 01 2023
9 January 01 2023
10 January 01 2023
11 January 01 2023
12 January 01 2023
3 1 January 01 2023
2 January 01 2023
3 January 01 2023
4 January 01 2023
5 January 01 2023
6 January 01 2023
7 January 01 2023
8 January 01 2023
4 1 January 01 2023
2 January 01 2023
3 January 01 2023
4 January 01 2023
5 January 01 2023
6 January 01 2023
7 January 01 2023
8 January 01 2023
9 January 01 2023
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Chapter Page Date
10 January 01 2023
11 January 01 2023
12 January 01 2023
5 1 January 01 2023
2 January 01 2023
3 January 01 2023
4 January 01 2023
5 January 01 2023
6 January 01 2023
7 January 01 2023
8 January 01 2023
7 1 January 01 2023
2 January 01 2023
3 January 01 2023
Chapter Page Date
4 January 01 2023
5 January 01 2023
6 January 01 2023
7 January 01 2023
8 January 01 2023
9 January 01 2023
10 January 01 2023
8 1 January 01 2023
2 January 01 2023
3 January 01 2023
4 January 01 2023
9 1 January 01 2023
2 January 01 2023
rear
page
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Rev. 1

TOA) Table of amendments
Approval*
The technical content of this document is approved under the authority of the DOA ref.
EASA.21J.048.
Edition 4/Rev. 0 November 01
2016
Obsolete with Revision 1, which is a complete
re-revision.
Revision 1 January 01 2023
cur-
rent
no.
chap-
ter
page date of
change
remark
for
appro-
val
date of
approval
from
authori-
ties
date of
inclusion
sig-
na-
ture
0 INTRO all Nov. 01 2016 DOA*
0 LEP all Nov. 01 2016 DOA*
0 TOA all Nov. 01 2016 DOA*
0 1 up to 9 all Nov. 01 2016 DOA*
cur-
rent
no.
chap-
ter
page date of
change
remark
for
appro-
val
date of
approval
from
authori-
ties
date of
inclusion
sig-
na-
ture
1 INTRO all Jan. 01 2023 DOA*
1 LEP all Jan. 01 2023 DOA*
1 TOA all Jan. 01 2023 DOA*
1 1 up to 9 all Jan. 01 2023 DOA*
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Summary of amendments
Summary of the relevant amendments in this context, but without any claim to
completeness.
current no. chapter page date of
change
comments
0 1 up to 9 all Nov. 01 2016 New layout and change of
company name
1 1 up to 9 all Jan. 01 2023 New text– Intentionally Left
Blank
1 1 1-2 Jan. 01 2023 New text
1 1 1–14, 1–17 Jan. 01 2023 from Chapter 1 to Chapter 7
1 3, 4 all Jan. 01 2023 Chapter changed
1 6 all Jan. 01 2023 Deleted (part of IM)
1 8 8-2 Jan. 01 2023 New text: Corrosion
1 9 9-2 Jan. 01 2023 New form
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Rev. 1

1) General note
Topics in this chapter
1.1 General ................................................................................................2
1.2 Abbreviations and terms (depending on respective engine
type) ....................................................................................................3
1.3 Safety ..................................................................................................8
1.4 Safety information ............................................................................... 10
1.5 Technical documentation...................................................................... 13
1.6 Type description (912 Series) ................................................................ 15
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1.1) General
Purpose The purpose of this Operators Manual (OM) is to familiarize the
aircraft manufacturers installing this aircraft engine with operat-
ing instructions and safety information.
This document is not intended for use by end customers (pri-
vate aircraft owners, flight schools...) for operating the engine.
Due to various executions of engine installations, only the air-
craft manufacturer is able to provide end customers with opera-
tion and safety information tailored for a specific aircraft.
Nevertheless, all provided information in this Operators Manual
(OM) (such as operating limits, safety information, operation in-
structions...) must be adhered to. The aircraft manufacturer is
obliged to forward this information to the end customer in an
appropriate way (e.g. within the aircraft specific Operators
Manual (OM)).
For detailed information related to aircraft and aircraft/engine in-
stallation, maintenance, safety or flight operation, consult the
documentation provided by the aircraft manufacturer and/or its
dealer. For additional information on engines, their maintenance
or parts, you can also contact your nearest ROTAX® authorized
aircraft engines distributor or their independent Service Center.
Engine serial
number
When making inquiries or ordering parts, always indicate the
engine serial number. Due to continuous product improvement,
engines of the same engine type might require different support
and spare parts. The engine serial number is located on the top
of the crankcase, magneto side.
1
Cyl.1 Cyl.3
Cyl.2 Cyl.4
PTO MAG
Figure 1: Pos. 1: Engine serial number
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1.2) Abbreviations and terms (depending on respective engine
type)
Abbrevia-
tions
Description
* Reference to another section
@center of gravity
The drop symbol indicates use of sealing agents, ad-
hesives or lubricants (only in the Maintenance Man-
ual Heavy)
°C Degrees Celsius (Centigrade)
°F Degrees Fahrenheit
rpm Revolutions per minute
A Ampere
AAPTS Ambient Air Pressure Temperature Sensor
AC alternating current
AD Airworthiness Directives
Ah Ampere hour
A/C Aircraft
AC-DC EMS Modul voltage converter
AR as required
assy. assembly
ASB Alert Service Bulletin
ACG Austro Control GmbH
ACL Anti Collision Light
API American Petrol Institute
ASTM American Society for Testing and Materials
ATA Air Transport Association
AWG American Wire Gauge
CAN Controller Area Network
CCS Camshaft position sensor
Coil 1–4 Ignition coils 1–4
CPS 1+2 Crankshaft Position Sensor 1+2

Abbrevia-
tions
Description
CSA Constant Speed Actuator
CTS Cooling Temperature Sensor
CW clockwise
CCW counter-clockwise
CGSB Canadian General Standards Board
DCDI Dual Capacitor Discharge Ignition
DC direct current
DOA Design Organisation Approval
DOT Department of Transport
EASA European Aviation Safety Agency
IM Installation Manual
ECU Engine Control Unit
EGT Exhaust Gas Temperature
INTRO Introduction
EMS Engine Management System
EMS GND Engine system internal ground reference which is in-
tended to be disconnected from aircraft common
ground during flight
EMC Electromagnetic compatibility
EN European Standard
ETFE Ethylene Tetrafluoroethylene
FAA Federal Aviation Administration
FAR Federal Aviation Regulations
FOD Foreign object damage
FL Flight Level
Fuse box Power conditioning and distribution for the Engine
Management System
hr. hours
HIC A Harness Interface Connector A
HIC B Harness Interface Connector B
IAT Indicated Air Temperature
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Abbrevia-
tions
Description
ICA Instructions for Continued Airworthiness
IFR Instrument Flight Rules
IFSD In-flight-shutdown
INJ 1–8 Injector 1–8
IPC Illustrated Parts Catalog
ips inch per second
iRMT independent ROTAX Maintenance Technician
ISA International Standard Atmosphere
kg Kilograms
KNOCK Knock sensor
Lane A System A of Engine Management System
Lane B System B of Engine Management System
LOPC Loss of power control
MAPS 1 &
2
Manifold Air Pressure Sensor 1 & 2
MATS 1 & 2 Manifold Air Temperature Sensor 1 & 2
MON Motor Octane Number
MAG Magneto Side
N Newton
n.a. not available
NDT Non Destructive Testing
NEW Part must be replaced against NEW (mentioned in
figures)
Nm Newtonmeter
NVFR Night Visual Flight Rules
OAT Outside Air Temperature
OHM Overhaul Manual
OHV Over Head Valve
OM Operators Manual
OPS Oil Pressure Sensor

Abbrevia-
tions
Description
OTS Oil Temperature Sensor
PCD Pitch Circle Diameters
PCV Pressure Control Valve
PMA Permanent magnet alternator
POA Production Organization Approval
PS Power supply
PTFE Polytetrafluoroethylene (Teflon)
PTO Power Take Off
Rev. Revision
ROTAX® is a trademark of BRP-Rotax GmbH & Co KG
RON Research Octane Number
RON 424 ROTAX® Standard 424
s.v. still valid (only Illustrated Parts Catalog)
S/N Serial Number
SAE Society of Automotive Engineers
SEP Single Engine Piston
SB Service Bulletin
SI Service Instruction
SI-PAC Service Instruction Parts and Accessories
SPST Single pole single throw
STP Shielded twisted pair wire
SL Service Letter
SMD Surface Mounted Devices
TBO Time Between Overhaul
TC Type certificate
part no. part number
TOA Table Of Amendments
TOC Table Of Contents
TPS Throttle Position Sensor
TSN Time Since New
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Abbrevia-
tions
Description
TSNP Time Since New Part
TSO Time Since Overhaul
V Volt
VFR Visual Flight Rules
LEP List of Effective Pages
MM Maintenance Manual
MEP Multi Engine Piston
X3 Connector on Engine Management System wiring
harness which serves as an interface for power
supply
XXXX shows the component serial number

1.3) Safety
Although reading such information does not eliminate any haz-
ards, it promotes understanding, and applying the information
will promote correct use of the engine. Always apply common
workshop safety rules.
The information and descriptions of components and systems
contained in this Manual are correct at the time of publication.
BRP-Rotax maintains a policy of continuous improvement of its
products without imposing upon itself any obligation to retrofit
products previously manufactured.
Revisions BRP-Rotax reserves the right to remove, replace or discontinue
any design, specification, feature or other at any time, and with-
out incurring obligation.
Measurement Specifications are given in the SI metric system with the imperi-
al and US customary measurement system equivalents in
parenthesis.
Symbols used This Manual uses the following symbols to emphasize particular
information. This information is important and must be
observed.
mWARNING
Identifies an instruction which, if not followed, may cause seri-
ous injury or even fatal injury.
mCAUTION
Identifies an instruction which, if not followed, may cause mi-
nor or moderate injury.
NOTICE
Identifies an instruction which, if not followed, may severely
damage the engine or could void any warranty.
NOTE
Indicates supplementary information which may be needed to
fully complete or understand an instruction.
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ENVIRONMENTAL NOTE
Environmental notes give you tips on environmental
protection.
A revision bar outside the page margin indicates a change to
text or graphic.

1.4) Safety information
Use for intended
purpose
mWARNING
Non-compliance can result in serious injuries or death!
Never fly the aircraft equipped with this engine at locations, air
speeds, altitudes or in other situations which do not allow a success-
ful no-power landing after sudden engine stoppage.
• This engine is not suitable for acrobatics (inverted flight,
etc.). Flight attitudes outside the permissible limits are not
allowed.
• This engine has exclusively been developed and tested for
gyrocopter, pusher and tractor applications. In case of any
other usage, the OEM is responsible for testing and the cor-
rect function of the engine.
• 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-Rotax grants no warranty on the suitability of its en-
gine’s use on any particular aircraft. Further, BRP-Rotax
grants no warranty on this engine’s suitability with any other
part, components or system which may be selected by the
aircraft manufacturer, assembler or user for aircraft
application.
mWARNING
Non-compliance can result in serious injuries or death!
For each use of DAY VFR, NIGHT VFR or IFR in an aircraft the ap-
plicable legal requirements and other existing regulations must be
adhered to.
• 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
required.
• You should be aware that any engine may seize or stall at
any time. This could lead to a crash landing and possible se-
vere injury or death. For this reason, we recommend strict
compliance with the maintenance and operation and any ad-
ditional information which may be given to you by your
dealer.
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Rev. 1