Rotax 912 i series User manual

AIRCRAFT ENGINES
ref. no.: MML-912 i | part no.: 898743

Before starting any maintenance work, please read the Maintenance Manual completely as it
contains important safety relevant information. Failure to do so may result in personal
injuries including death. Consult the orginal equipment manufacturers handbook for
additional instructions!
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.
Copyright 2018 © - all rights reserved.
ROTAX® is a trademark 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.
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.

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Edition 2/Rev. 0 Content
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Table of Content
Chapter INTRO – GENERAL NOTE
Chapter LEP – LIST OF EFFECTIVE PAGES
Chapter TOA – TABLE OF AMENDMENTS
Chapter 00–00–00 – GENERAL NOTE
Chapter 04–00–00 – AIRWORTHINESS LIMITATIONS
Chapter 05–00–00 – MAINTENANCE
Chapter 05–10–00 – TIME LIMITS
Chapter 05–20–00 – SCHEDULED MAINTENANCE CHECKS
Chapter 05–50–00 – UNSCHEDULED MAINTENANCE CHECKS
Chapter 12–00–00 – MAINTENANCE OF THE SYSTEMS
Chapter 12–10–00 – REPLENISHING OPERATING FLUIDS
Chapter 12–20–00 – SCHEDULED MAINTENANCE
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Chapter: INTRO
GENERAL NOTE
Foreword Before carrying out maintenance work on the engine, read this Maintenance Manual
carefully.
If any passages of the Manual are not clearly understood or in case of any questions,
please contact your nearest ROTAX® authorized Aircraft Engines Distributors or their
independent Service Center.
BRP-Rotax wishes you much pleasure and satisfaction flying your aircraft powered by this
ROTAX®-aircraft engine.
The structure of the Manual follows whenever it is possible the structure of the ATA (Air
Transport Association) standards. The aim is the compatibility with the aircraft
manufacturers documentation, which means they must then adapt the documentation to
their standard.
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Chapter: LEP
LIST OF EFFECTIVE PAGES
chapter page date
Rear page
INTRO 1September 01 2018
2 September 01 2018
LEP 1 September 01 2018
2September 01 2018
3 September 01 2018
4September 01 2018
TOA 1 September 01 2018
2September 01 2018
00-00-00 1 September 01 2018
2September 01 2018
3September 01 2018
4September 01 2018
5September 01 2018
6 September 01 2018
7September 01 2018
8September 01 2018
9 September 01 2018
10 September 01 2018
11 September 01 2018
12 September 01 2018
13 September 01 2018
14 September 01 2018
15 September 01 2018
16 September 01 2018
04-00-00 1 September 01 2018
2 September 01 2018
chapter page date
05-00-00 1 September 01 2018
2September 01 2018
3 September 01 2018
4September 01 2018
5September 01 2018
6 September 01 2018
7September 01 2018
8 September 01 2018
9September 01 2018
10 September 01 2018
11 September 01 2018
12 September 01 2018
05-10-00 1 September 01 2018
2September 01 2018
3September 01 2018
4September 01 2018
5September 01 2018
6 September 01 2018
05-20-00 1 September 01 2018
2 September 01 2018
3September 01 2018
4September 01 2018
5September 01 2018
6September 01 2018
7September 01 2018
8September 01 2018
9September 01 2018
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chapter page date
10 September 01 2018
11 September 01 2018
12 September 01 2018
13 September 01 2018
14 September 01 2018
15 September 01 2018
16 September 01 2018
05-50-00 1 September 01 2018
2September 01 2018
3 September 01 2018
4September 01 2018
5September 01 2018
6September 01 2018
7September 01 2018
8 September 01 2018
9September 01 2018
10 September 01 2018
11 September 01 2018
12 September 01 2018
13 September 01 2018
14 September 01 2018
15 September 01 2018
16 September 01 2018
17 September 01 2018
18 September 01 2018
19 September 01 2018
20 September 01 2018
21 September 01 2018
22 September 01 2018
23 September 01 2018
chapter page date
24 September 01 2018
25 September 01 2018
26 September 01 2018
27 September 01 2018
28 September 01 2018
29 September 01 2018
30 September 01 2018
31 September 01 2018
32 September 01 2018
33 September 01 2018
34 September 01 2018
12-00-00 1 September 01 2018
2September 01 2018
12-10-00 1 September 01 2018
2 September 01 2018
3September 01 2018
4September 01 2018
5September 01 2018
6September 01 2018
7September 01 2018
8September 01 2018
9 September 01 2018
10 September 01 2018
12-20-00 1 September 01 2018
2September 01 2018
3September 01 2018
4September 01 2018
5September 01 2018
6 September 01 2018
7September 01 2018
LEP
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chapter page date
8September 01 2018
9September 01 2018
10 September 01 2018
11 September 01 2018
12 September 01 2018
13 September 01 2018
14 September 01 2018
15 September 01 2018
16 September 01 2018
17 September 01 2018
18 September 01 2018
19 September 01 2018
20 September 01 2018
21 September 01 2018
22 September 01 2018
23 September 01 2018
24 September 01 2018
25 September 01 2018
26 September 01 2018
27 September 01 2018
28 September 01 2018
29 September 01 2018
30 September 01 2018
chapter page date
31 September 01 2018
32 September 01 2018
33 September 01 2018
34 September 01 2018
35 September 01 2018
36 September 01 2018
37 September 01 2018
38 September 01 2018
39 September 01 2018
40 September 01 2018
41 September 01 2018
42 September 01 2018
43 September 01 2018
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45 September 01 2018
46 September 01 2018
47 September 01 2018
48 September 01 2018
49 September 01 2018
50 September 01 2018
51 September 01 2018
52 September 01 2018
Index
Rear page
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Chapter: TOA
TABLE OF AMENDMENTS
Approval*
The technical content of this document is approved under the authority of DOA ref. EASA.21J.048
NOTE
THE APPROVAL IS GIVEN TO ALL CHAPTERS EXCEPT THE AIRWORTHINESS LIMITATIONS
SECTION 04-00-00 WHICH IS SUBJECT TO SPECIFIC APPROVAL OF THE EASA.
Cur-
rent
no.
Chapter Page Date of change Remark for
approval
Date of
approval
from
authori-
ties
Date of
inclusion
Signature
0 INTRO all Sept. 01 2018 DOA*
0 LEP all Sept. 01 2018 DOA*
0TOA all Sept. 01 2018 DOA*
0 00-00-00 all Sept. 01 2018 DOA*
0 04-00-00 all Sept. 01 2018 EASA approved
0 05-00-00 all Sept. 01 2018 DOA*
0 05-10-00 all Sept. 01 2018 DOA*
0 05-20-00 all Sept. 01 2018 DOA*
0 05-50-00 all Sept. 01 2018 DOA*
0 12-00-00 all Sept. 01 2018 DOA*
0 12-10-00 all Sept. 01 2018 DOA*
0 12-20-00 all Sept. 01 2018 DOA*
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Summary of amendments
Summary of the relevant amendments in this context, but without requirement on completeness.
no. chapter page date of change comment
0 all all Sept. 01 2018 new layout and change of company name
TOA
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Chapter: 00–00–00
GENERAL NOTE
TOPICS IN THIS CHAPTER
General....................................................................................................................................................2
Type description......................................................................................................................................3
Scope of supply.....................................................................................................................................4
Abbreviations and terms .........................................................................................................................5
Conversion table ...................................................................................................................................9
Safety notice .........................................................................................................................................10
Safety information ............................................................................................................................... 11
Instruction...........................................................................................................................................13
Maintenance Concept..........................................................................................................................14
Technical documentation......................................................................................................................15
Use for intended purpose .....................................................................................................................17
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GENERAL
In this Manual all ROTAX® 912 i Series engines are described.
NOTE
ROTAX® 912 i Series includes 912 iS, 912 iS Sport and 912 iSc Sport.
Purpose For detailed information related to aircraft and aircraft/engine installation, maintenance,
safety- or flight operation, consult the documentation provided by the aircraft manufacturer
and/or dealer.
For additional information on engines, their maintenance or parts, you can also contact
your nearest authorized ROTAX® authorized Aircraft Engine Distributor or their independ-
ent Service Center.
ROTAX®
Distributors
For ROTAX® Authorized Distributors for aircraft engines see latest Operators Manual or
the official website www.FLYROTAX.com.
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 on the top of the crankcase, behind
of the propeller gearbox.
Figure 1.1: Engine serial number
00–00–00
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TYPE DESCRIPTION
The type description consists of the following parts:
e. g. ROTAX 912 iSc Sport 3
type certification configuration additional
designation
Designation
Designation Description
Type 912 4-cyl. horizontally opposed, normal aspirated
engine.
Certification iSc Sport Certified to EASA CS-E (TC No. EASA.E.121).
iS Approved to ASTM F2339
iS Sport Approved to ASTM F2339
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.
Additional
designation
Options Available options (optional equipment) for the engine type mentioned above:
external
alternator
vacuum pump governor exhaust
system
for configura-
tion 2
YES YES NO YES
for configura-
tion 3
YES NO YES YES
NOTE
Conversion of the version 2 to version 3 and vice versa may be accomplished by
BRP-Rotax Authorized Distributors or their Service Center.
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SCOPE OF SUPPLY
Basic • 4- stroke-, 4 cylinder horizontally opposed-, spark ignition engine, single central cam-
shaft push rods – OHV (Over Head Valve)
• Liquid cooled cylinder heads
• Ram air cooled cylinders
• Dry sump forced lubrication
• Fully redundant electronic engine management system (EMS) for controlling fuel injec-
tion, ignition, etc.
• Propeller drive via gearbox with integrated torsional vibration absorber and overload
clutch
• Oil tank
• Electric starter
• Fuel pump assy.
Optional Preparation for hydraulic governor for constant speed propeller: (configuration 3 only)
• Exhaust system
• Cooling air baffle
• Engine suspension frame
00–00–00
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ABBREVIATIONS AND TERMS
Abbreviations Description
* Reference to another section
@center of gravity
The drop symbol indicates use of sealing agents, adhesives or lubri-
cants (only in the Illustrated Parts Catalog).
°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
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
Coil 1–4 Ignition coils 1–4
CPS 1+2 Crankshaft Position Sensor 1+2
CSA Constant Speed Actuator
CTS Cooling Temperature Sensor
CW clockwise
CCW counter-clockwise
CGSB Canadian General Standards Board
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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
EMC Electromagnetic compatibility
EN European Norm
ETFE Ethylene Tetrafluoroethylene
FAA Federal Aviation Administration
FAR Federal Aviation Regulations
FOD Foreign object damage
hr. hours
HIC A Harness Interface Connector A
HIC B Harness Interface Connector B
IAT Inorganic Additive Technology
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 Training
ISA International Standard Atmosphere
kg Kilograms
KNOCK Knock sensor
LOPC Loss of power control
MAPS 1 & 2 Manifold Air Pressure Sensor 1 & 2
00–00–00
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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
Nm Newtonmeter
NVFR Night Visual Flight Rules
OAT Organic Acid (Additive) Technology
OHM Overhaul Manual
OHV Over Head Valve
OM Operators Manual
OPS Oil Pressure Sensor
OTS Oil Temperature Sensor
PCD Pitch Circle Diameters
PCV Pressure Control Valve
PMA Permanent magnet alternator
POA Production Organisation Approval
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® Norm 424
s.v. still valid (only Illustrated Parts Catalog)
S/N Serial Number
SAE Society of Automotive Engineers
SB Service Bulletin
SI Service Instruction
SI-PAC Service Instruction Parts and Accessories
SPST Single pole single throw
STP Shield twisted pair
SL Service Letter
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SMD Surface Mounted Devices
TBO Time Between Overhaul
TC Type certificate
part no. part number
TOA Table Of Amendments
TOC Table of content
TPS Throttle potentiometer
TSN Time Since New
TSNP Time Since New Part
TSO Time Since Overhaul
V Volt
VFR Visual Flight Rules
LEP List of Effective Pages
MM Maintenance Manual
XXXX shows the serial component number
00–00–00
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