Rotax 912 i series User manual

AIRCRAFT ENGINES
ref. no.: IM-912 i | part no.: 898647

These technical data and the information embodied therein are the property of
BRP-Powertrain GmbH&Co. KG, Austria, acc, BGBI 1984 no. 448, and shall not, without
prior written permission of BRP-Powertrain 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.
Copyright 2012© - all rights reserved.
ROTAX®is a trade mark of BRP-Powertrain GmbH&Co. KG. In the following document
the short form of BRP-Powertrain GmbH&Co. KG = BRP-Powertrain is used.
Other product names in this documentation are used purely for ease of identification and
may be trademarks of the respective company or owner.
Approval of translation has been done to best knowledge and judgement - in any case
the original text in german language is authoritative.
Before starting with engine installation, please read the Installation Manual completely as
it contains important safety relevant information.
WARNING

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INSTALLATION MANUAL
BRP-Powertrain
Effectivity: 912 i Series
Edition 1/Rev. 0 INTRO
page 1
January 01/2012
Chapter: INTRO
GENERAL NOTE
Foreword Before starting with the engine installation, read this Installation Manual
carefully. The Manual will provide you with basic information on correct
engine installation, a requirement for safe engine operation.
If any passages of this Manual are not clearly understood or if you have
any questions, please contact an authorized distributor- or Service
Center for ROTAX aircraft engines.
BRP-Powertrain GmbH & Co KG (hereinafter “BRP-Powertrain“) wishes
you much pleasure and satisfaction flying your aircraft powered by this
ROTAX aircraft engine.
Chapter structure The structure of the Manual follows whenever it is possible the structure
of the ATA (Air Transport Association) standards. The aim is the compat-
ibility with the aircraft manufacturer's documentation, which means they
must then adapt the documentation to their standard. The partially modu-
lar design offers an another advantage.
The Installation Manual is subdivided into the following chapters:
Subject Chapter
Introduction Chapter INTRO
List of effective pages Chapter LEP
Table of amendments Chapter TOA
General note Chapter 00-00-00
Storage & Installation Chapter 10-10-00
Electric system Chapter 24-00-00
Propeller drive Chapter 61-00-00
Engine Chapter 72-00-00
Fuel system Chapter 73-00-00
Ignition system Chapter 74-00-00
Cooling system Chapter 75-00-00
Engine management Chapter 76-00-00
Exhaust system Chapter 78-00-00
Lubrication system Chapter 79-00-00
Electric starter Chapter 80-00-00

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Effectivity: 912 i Series
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NOTES

Effectivity: 912 i Series
Edition 1/Rev. 0
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INSTALLATION MANUAL
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LEP
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Chapter: LEP
LIST OF EFFECTIVE PAGES
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Effectivity: 912 i Series
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NOTES

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Effectivity: 912 i Series
Edition 1/Rev. 0 TOA
page 1
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Chapter: TOA
TABLE OF AMENDMENTS
*Approval
*DRAFT
no. chapter page date of
change remark for approval
date of ap-
proval from
authorities
date of
inclusion signature
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NOTES

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Edition 1/Rev. 0
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TOA
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Chapter: TOA
SUMMARY OF AMENDMENTS
Content Summary of the relevant amendments in this context, but without require-
ment on completeness.
Current
No. chapter page date of change Comment

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Effectivity: 912 i Series
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page 4
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NOTES

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Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
page 1
January 01/2012
Chapter: 00-00-00
GENERAL NOTE
Introduction This section describes the maintenance of engine type ROTAX
912 i Series.
NOTE: ROTAX 912 i Series includes 912 iSc and 912 iS.
Table of contents This chapter of the Installation Manual contains general and safety infor-
mation concerning the operation and maintenance of the aircraft engine.
Subject Page
General note Page 3
Type description
Standard version
Page 4
Page 5
Abbreviations and terms used in this Manual
Conversion table
Page 7
Page 10
Safety notice
Safety information
Instruction
Technical documentation
Page 11
Page 12
Page 14
Page 15

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NOTES

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1) General note
Purpose The purpose of this Installation Manual is to acquaint maintenance ser-
vice staff (iRMT) approved by the local aviation authorities with some
basic maintenance and safety information for service work.
Documentation For more detailed information regarding, maintenance, safety- or flight
operation, consult the documentation provided by the aircraft manufac-
turer and/or dealer.
For additional information on engines, maintenance or parts, you can
also contact yout nearest authorized ROTAX-aircraft engine distributor.
ROTAX
Distributors For ROTAX Authorized Distributors for Aircraft Engines see latest Opera-
tors Manual or on the Internet at the official Website
www.FLYROTAX.com.
Engine serial
number When making inquiries or ordering parts, always indicate the engine
serial number, as the manufacturer makes modifications to the engine for
product improvement. The engine serial number (1) is on the top of the
crankcase, behind of the propeller gearbox.
Fig. 1

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Effectivity: 912 i Series
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2) Type description
e.g. 912 iSc 3 The type description is made up the following:
Designation
Options Available options (optional equipment) for the engine type mentioned
above:
Type
(type)
Zulassung
(certification)
Ausführung
(configuration)
ROTAX
Designation Description
Type 912 4-cyl. horizontally opposed, normal aspi-
rated engine
Certification iSc Certified to EASA CS-E
(TC No. EASA.E.XXX)
iS Non-certified aircraft engines
Configuration 2 Prop shaft with flange for fixed prop.
3Prop shaft with flange for constant speed
propeller and drive for hydraulic governor
for constant speed propeller.
external
alternator vacuum pump governor exhaust system
for configuration 2 YES YES NO YES
for configuration 3 YES NO YES YES

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Effectivity: 912 i Series
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2.1) Standard version
Serial production - 4-stroke, 4 cylinder horizontally opposed, spark ignition engine, single
central camshaft push rods - OHV
- Liquid cooled cylinder heads
- Ram air cooled cylinders
- Dry sump forced lubrication
- Fully redundant electronic engine management (EMS) includes fuel
injection, characteristic ignition, etc.
- Propeller drive via integrated gearbox with mechanical shock absorber
and overload clutch
- Oiltank
- Electric starter (12 V 0.8 kW)
Optional - Electric starter (12 V 0.9 kW)
- Preparation for hydraulic governor for constant speed propeller: (con-
figuration 3 only)
- Exhaust system
- Cooling air baffle
- Engine suspension frame
- Fuel pump assy.

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Edition 1/Rev. 0 00-00-00
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January 01/2012
Auxiliary equip-
ment tested NOTE: The following equipment is not included as part of the stan-
dard engine version!
Following auxiliary equipment has been tested on ROTAX engine
type 912 i for safety and durability to the standards of aviation.
The furnishing of proof in accordance to the latest FAR or EASA has to be
conducted by the aircraft manufacturer.
- external alternator
- oil cooler with connections
- coolant radiator
- coolant overflow bottle
Auxiliary equip-
ment not tested Following auxiliary equipment has not been tested on ROTAX engine
type 912 i for safety and durability to the standards of aviation.
- intake filter
- shock mount
WARNUNG
NOTICE
Any equipment not included as part of the standard en-
gine version and thus not a fix component of the en-
gine is not in the volume of supply.
Components especially developed and tested for this
engine are readily available at BRP-Powertrain.
WARNUNG
WARNING
Non-compliance can result in serious injuries or death!
The user assumes all risks possibly arising by utilizing
auxiliary equipment.
The furnishing of proof in accordance to the latest FAR
or EASA has to be conducted by the aircraft manufac-
turer.

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Effectivity: 912 i Series
Edition 1/Rev. 0 00-00-00
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3) Abbreviations and terms used in this Manual
Abbreviations
Abbreviation Description
* Reference to another section
center of gravity
The drop symbol indicates use of sealing agents, adhesives or
lubricants (only in the Illustrated Parts Catalog).
°C Degrees Celsius (Centigrade)
°F Degrees Fahrenheit
912 iS see OM (Type designation)
912 iSc see OM (Type designation)
A Ampere
a.c. alternating current
Ah Ampere hour
A/C Aircraft
AD Airworthiness Directive
A/F Across-flat dimension
ASB Alert Service Bulletin
ACG Austro Control GmbH
API American Petrol Institute
ASTM American Society for Testing and Materials
ATA Air Transport Association
AWG American Wire Gauge
CAN/CGSB Canadian General Standards Board
CPS 1+2 Crankshaft Position Sensor 1+2
CSA Constant Speed Actuator
CTS Cooling Temperature Sensor
CW Clockwise
CCW Counter-clockwise
DCDI Dual Capacitor Discharge Ignition
d.c. direct current
DOA Design Organisation Approval
DOT Department of Transport
EASA European Aviation Safety Agency
ECU Engine Control Unit
EGT Exhaust Gas Temperatur
EMS Engine Management System
EN European Norm
FAA Federal Aviation Administration

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FAR Federal Aviation Regulation
hr. hours
IFR Instrument Flight Rules
IM Installation Manual
INJ 1-8 Injector 1-8
INTRO Introduction
IPC Illustrated Parts Catalog
iRMT independent ROTAX Maintenance Technician
ISA International Standard Atmosphere
kg kilograms
LEP List of Effective Pages
MAPS 1+2 Manifold Air Pressure Sensor 1+2
MATS 1+2 Manifold Air Temperature Sensor 1+2
MM Maintenance Manual
MON Motor Octane Number
MAG Magneto Side
N new part (only Illustrated Parts Catalog)
n.a. not available
nB as necessary (only Illustrated Parts Catalog)
NDT non-destructive testing
Nm newtonmeter
OHM Overhaul Manual
OM Operators Manual
part no. Part number
PTO side power take off side
Rev. Revision
RON Research Octane Number
ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG
rpm Revolutions per minute
SB Service Bulletin
SI Service Instruction
SL Service Letter
SMD Surface Mounted Devices
S/N Serial Number
s.v. still valid (only Illustrated Parts Catalog)
TBO Time Between Overhaul
TOA Table of amendments
TOC Table of Contents
Abbreviation Description