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.

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

d05150.fm

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

d05150.fm

INSTALLATION MANUAL

BRP-Powertrain

Effectivity: 912 i Series

Edition 1/Rev. 0 INTRO

page 2

January 01/2012

NOTES

Effectivity: 912 i Series

Edition 1/Rev. 0

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INSTALLATION MANUAL

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LEP

page 1

January 01/2012

Chapter: LEP

LIST OF EFFECTIVE PAGES

tchapter page date

Title page

INTRO 1

01 01 2012

LEP 1

01 01 2012

TOA 1

01 01 2012

00-00-00 1

01 01 2012

10-10-00 1

01 01 2012

24-00-00 1

01 01 2012

61-00-00 1

01 01 2012

72-00-00 1

01 01 2012

chapter page date

Effectivity: 912 i Series

Edition 1/Rev. 0

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LEP

page 2

January 01/2012

72-00-00 9

01 01 2012

73-00-00 1

01 01 2012

74-00-00 1

01 01 2012

75-00-00 1

01 01 2012

76-00-00 1

01 01 2012

chapter page date

76-00-00 11

01 01 2012

78-00-00 1

01 01 2012

79-00-00 1

01 01 2012

80-00-00 1

01 01 2012

chapter page date

Effectivity: 912 i Series

Edition 1/Rev. 0

d05151.fm

INSTALLATION MANUAL

BRP-Powertrain

LEP

page 3

January 01/2012

80-00-00 4

Rear page

01 01 2012

chapter page date

d05151.fm

INSTALLATION MANUAL

BRP-Powertrain

Effectivity: 912 i Series

Edition 1/Rev. 0 LEP

page 4

January 01/2012

NOTES

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Effectivity: 912 i Series

Edition 1/Rev. 0 TOA

page 1

January 01/2012

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

INTRO

LEP

TOA

00-00-00

10-10-00

24-00-00

61-00-00

72-00-00

73-00-00

74-00-00

75-00-00

76-00-00

78-00-00

79-00-00

80-00-00

all

01 01 2012

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Effectivity: 912 i Series

Edition 1/Rev. 0 TOA

page 2

January 01/2012

NOTES

Effectivity: 912 i Series

Edition 1/Rev. 0

d05152.fm

INSTALLATION MANUAL

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TOA

page 3

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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

Edition 1/Rev. 0 TOA

page 4

January 01/2012

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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Edition 1/Rev. 0 00-00-00

page 2

January 01/2012

NOTES

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INSTALLATION MANUAL

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Effectivity: 912 i Series

Edition 1/Rev. 0 00-00-00

page 3

January 01/2012

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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page 4

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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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Edition 1/Rev. 0 00-00-00

page 5

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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

page 6

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.

d05153.fm

INSTALLATION MANUAL

BRP-Powertrain

Effectivity: 912 i Series

Edition 1/Rev. 0 00-00-00

page 7

January 01/2012

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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Effectivity: 912 i Series

Edition 1/Rev. 0 00-00-00

page 8

January 01/2012

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

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