Rotax 912 i series User manual

AIRCRAFT ENGINES
ref. no.: OM-912 i | part no.: 898740

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 manufactur-
ers handbook for additional instructions!
WARNING
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 2014© - 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.

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Introduction
Foreword BRP-Powertrain provides “Instructions of Continued Airworthi-
ness”, which are based on the design, the tests and certification
of the engine and its components. These instructions apply only
to engines and components supplied by BRP-Powertrain.
This Operator Manual contains important information about safe
operation of the engine, together with descriptions of the system
and its layout, technical data, operating media and the operational
limits of the engine.
The specified data apply only to the engine and not to specific ap-
plications in particular aircraft. The aircraft manufacturers Opera-
tors Manual is therefore definitive in terms of the operation of the
engine, as it contains all of the aircraft-specific instructions.
Chapter structure The structure of the Manual follows whenever it is possible the
structure of the „GAMA Specification #1 for Pilot’s Operating
Handbook“. The Operators 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 1)
Operating instructions Chapter 2)
Standard operation Chapter 3)
Abnormal operation Chapter 4)
Performance data Chapter 5)
Weights Chapter 6)
Description of systems Chapter 7)
Checks Chapter 8)
Supplements Chapter 9)

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NOTES

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LEP) List of effective pages
Chapter Page Date
cover page
INTRO INTRO-1
INTRO-2
01 01 2012
01 01 2012
LEP LEP-1
LEP-2
04 01 2014
01 01 2012
TOA TOA-1
TOA-2
TOA-3
TOA-4
04 01 2014
01 01 2012
04 01 2014
01 01 2012
11-1
1-2
1-3
1-4
1-5
1-6
1-7
1-8
1-9
1-10
1-11
1-12
1-13
1-14
01 01 2012
01 01 2012
01 01 2012
01 01 2012
01 01 2012
04 01 2014
01 01 2012
01 01 2012
01 01 2012
01 01 2012
04 01 2014
07 01 2012
01 01 2012
04 01 2014
22-1
2-2
2-3
2-4
2-5
2-6
2-7
2-8
01 01 2012
04 01 2014
04 01 2014
01 01 2012
04 01 2014
01 01 2012
01 01 2012
01 01 2012
33-1
3-2
3-3
3-4
3-5
3-6
3-7
3-8
3-9
3-10
3-11
3-12
3-13
3-14
3-15
3-16
04 01 2014
01 01 2012
01 01 2012
01 01 2012
01 01 2012
04 01 2014
10 01 2013
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
44-1
4-2
4-3
4-4
4-5
4-6
4-7
4-8
4-9
4-10
01 01 2012
07 01 2012
01 01 2012
01 01 2012
01 01 2012
01 01 2012
01 01 2012
04 01 2014
04 01 2014
01 01 2012
55-1
5-2
5-3
5-4
5-5
5-6
01 01 2012
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
66-1
6-2
01 01 2012
01 01 2012
77-1
7-2
7-3
7-4
7-5
7-6
7-7
7-8
7-9
7-10
7-11
7-12
01 01 2012
01 01 2012
01 01 2012
01 01 2012
04 01 2014
04 01 2014
01 01 2012
01 01 2012
01 01 2012
01 01 2012
01 01 2012
01 01 2012
88-1
8-2
04 01 2014
01 01 2012
99-1
9-2
9-3
9-4
9-5
9-6
9-7
9-8
01 01 2012
01 01 2012
01 01 2012
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01 01 2012
01 01 2012
01 01 2012
04 01 2014
rear page
Chapter Page Date

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NOTES

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TOA) Table of amendments
Approval*
The technical content of this documents is approved
under the authority DOA ref. EASA.21J.048
current
no.
chapter page date of
change
remark
for
approval
date of
approvalfrom
authorities
date of
inclu-
sion
signa-
ture
01 up to 9 all 01 01 2012
1
1
1
1
1
LEP
TOA
1
2
4
LEP-1
TOA-1, 3
1-11, 11-12
2-2, 2-3
4-2
07 01 2012
07 01 2012
07 01 2012
07 01 2012
07 01 2012
DOA*
DOA*
DOA*
DOA*
DOA*
2
2
2
2
2
2
2
2
2
2
LEP
TOA
1
2
3
4
5
7
8
9
LEP-1
TOA-1, 3
1-6,1-11,1-14
2-2, 2-3, 2-5
3-1, 3-6,
3-8 to 3-16
4-8, 4-9
5-2 to 5-6
7-5, 7-6
8-1
9-8
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*
DOA*

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NOTES

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TOA) Summary of amendments
Content Summary of the relevant amendments in this context, but without
requirement on completeness.
Current
No.
Chapter Page Date of change Comments
1
1
1
1
1
1
1
2
2
4
1-11
1-12
2-2
2-3
4-2
07 01 2012
07 01 2012
07 01 2012
07 01 2012
07 01 2012
Standard version corrected
Certification supplemented
Oil pressure
Ambient temperature
Available landing site
2
2
2
2
2
2
2
2
1
2
3
4
5
7
8
9
1-11,1-14
2-2, 2-3
2-5
3-8 to 3-16
4-8, 4-9
5-2 - 5-6
7-5, 7-6
8-1
9-8
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
04 01 2014
Standard version corrected, Note added
Notice added,EGT temperature changed,
[psi] values corrected
AVGAS description corrected
Engine Start-, Check-, Take-off-, Shut
down procedure changed/updated
Text corrected, step added
New charts + POWER/ECO description
General note: text added, new grafic
Note added
Distributor for Pakistan added

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NOTES

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1) General note
Foreword Before operating the engine, carefully read this Operators Manu-
al. The Manual provides you with basic information on the safe op-
eration of the engine.
If any passages of the Manual are not clearly understood or in
case of any questions, please contact an authorized Distributor or
Service Center for ROTAX aircraft engines.
We wish you much pleasure and satisfaction flying your aircraft
with this ROTAX aircraft engine.
Table of contents This chapter of the Operators Manual contains general and safety
information concerning the operation of the aircraft engine.
Subject Page
General note Page 1-1
Abbreviations and terms used in this Manual Page 1-3
Safety Page 1-5
Safety notice Page 1-6
Technical documentation Page 1-9
Standard version Page 1-11
Type description Page 1-12
Engine components, engine views, cylinder
designation
Page 1-13
Technical data Page 1-14
Fuel consumption Page 1-14
Direction of rotation Page 1-14

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1.1) General note
Purpose The purpose of this Operators Manual is provided to familiarize
the owner/user of this aircraft engine with basic operating instruc-
tions and safety information.
Documentation For more detailed information regarding, maintenance, safety- or
flight operation, consult the documentation provided by the aircraft
manufacturer and/or dealer.
For additional information on engines, maintenance or parts, you
can also contact your nearest authorized ROTAX-aircraft engine
distributor (Chapter 9.2).
Engine serial num-
ber
When making inquiries or ordering parts, always indicate the en-
gine serial number, as the manufacturer makes modifications to
the engine for product improvement.
The engine serial number is located on the top of the crankcase,
behind of the propeller gearbox. See Fig. 1.
Fig 1
Part Function
1 Engine serial number
Cyl. 1 Cyl. 3
Cyl. 4
Cyl. 2

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1.2) Abbreviations and terms used in this Manual
Abbreviation Abbreviation Description
°C Degrees Celsius (Centigrade)
°F Degrees Fahrenheit
rpm Revolutions per minute
912 iS see OM (Type designation)
912 iSc see OM (Type designation)
A Ampere
A/C Aircraft
ACG Austro Control GmbH
API American Petrol Institute
ASTM American Society for Testing and Materials
ATA Air Transport Association
CAN/CGSB Canadian General Standards Board
CSA Constant Speed Actuator
CS-E Certification Specifications for Engines
CW Clockwise
CCW Counter-clockwise
DOA Design Organisation Approval
EASA European Aviation Safety Agency
ECU Engine Control Unit
EMS Engine Management System
FAA Federal Aviation Administration
FAR Federal Aviation Regulations
h hours
IFR Instrument Flight Rules
INTRO Introduction
iRMT independent ROTAX Maintenance Technician
ISA International Standard Atmosphere
kg kilograms
kW Kilowatt
LANE EMS A+B Lane ECU
LEP List of effective pages
MON Motor octane number
Nm Newton meter
OM Operators Manual
part no. Part number

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RON Research Octane Number
RV Record of Revisions
RON Research Octane Number
ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG
SAE Society of Automotive Engineers
SI Service Instruction
SB Service Bulletin
SL Service Letter
TC Type certificate
TOA Table of amendments
VVolt
VFR Visual Flight Rules
Abbreviation Description

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1.3) Safety
General note Although the reading of such information does not eliminate the
hazard, understanding the information will promote its correct use.
Always use common workshop safety practice.
The information and components-/system descriptions contained
in this Manual are correct at the time of publication.
BRP-Powertrain, however, maintains a policy of continuous im-
provement of its products without imposing upon itself any obliga-
tion to install them on its products previously manufactured.
Revision BRP-Powertrain reserves the right at any time, and without incur-
ring obligation, to remove, replace or discontinue any design,
specification, feature or otherwise.
Measure Specifications are given in the SI metric system with the USA
equivalent in parenthesis.
Translation This document has been translated from German language and
the original German text shall be deemed authoritative.
Symbols used This Manual uses the following symbols to emphasize particular
information. This information is important and must be observed.
NOTES: Indicates supplementary information which
may be needed to fully complete or under-
stand an instruction.
A revision bar outside of the page margin in-
dicates a change to text or graphic.
WARNU
WARNING
Identifies an instruction which, if not fol-
lowed, may cause serious injury including
the possibility of death.
WARNUN
CAUTION
Identifies an instruction which, if not fol-
lowed, may cause minor or moderate inju-
ry.
WARNUNG
NOTICE
Denotes an instruction which, if not fol-
lowed, may severely damage the engine
or other components.
ENVIRONMENT NOTE
Environment note gives you tips and behaviors to environmental
protection.

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1.4) Safety notice
Normal use z
- 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 dis-
cretion and responsibility of the aircraft manufacturer, assem-
bler and owner/user.
- Due to the varying designs, equipment and types of aircraft,
BRP-Powertrain grants no warranty or representation on the
suitability of its engine’s use on any particular aircraft. Further,
BRP-Powertrain grants no warranty or representation of this
engine’s suitability with any other part, components or system
which may be selected by the aircraft manufacturer, assemb-
ler or user for aircraft application.
- 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 re-
quired.
- 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 compli-
ance with the maintenance and operation and any additional
information which may be given to you by your dealer.
WARNU
WARNING
Non-compliance can result in serious injuries
or death!
Never fly the aircraft equipped with this en-
gine at locations, airspeeds, altitudes, or oth-
er circumstances from which a successful no-
power landing cannot be made, after sudden
engine stoppage.
WARNU
WARNING
Non-compliance can result in serious injuries
or death!
For each use of VFR or IFR in an aircraft the
applicable requirements and other existing
regulations must be adhered.

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Training - Whether you are a qualified pilot or a novice, complete know-
ledge of the aircraft, its controls and operation is mandatory
before venturing solo. Flying any type of aircraft involves a cer-
tain amount of risk. Be informed and prepared for any situation
or hazard associated with flying.
- A recognized training program and continued education for pi-
loting an aircraft is absolutely necessary for all aircraft pilots.
Make sure you also obtain as much information as possible
about your aircraft, its maintenance and operation from your
dealer.
- Engine-specific training courses are authorized by the distrib-
utors according to manufacturer specifications (iRMT).
Regulation - Respect all government or local rules pertaining to flight ope-
ration in your flying area. Fly only when and where conditions,
topography, and airspeeds are safest.
- Consult your aircraft dealer or manufacturer and obtain the ne-
cessary information, especially before flying in new areas.
Instrumentation - Select and use proper aircraft instrumentation. This instru-
mentation is not included with the ROTAX engine package.
Only approved instrumentation may be installed.
Engine log book - Keep an engine log book and respect engine and aircraft
maintenance schedules. Keep the engine in top operating
condition at all times. Do not operate any aircraft which is not
properly maintained or has engine operating irregularities
which have not been corrected.
Maintenance
(iRMT)
- Before flight, ensure that all engine controls are operative.
Make sure all controls can be easily reached in case of an
emergency.
- Since special tools and equipment may be required, engine
servicing should only be performed by an authorized ROTAX
engine dealer. BRP-Powertrain requires that any service be
carried out and verified by a technician that has a current iRMT
rating.

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- When in storage protect the engine and fuel system from con-
tamination and exposure.
Engine run - Never operate the engine without sufficient quantities of oper-
ating fluids (oil, coolant, fuel).
- Never exceed the maximum permitted operational limits.
- In the interest of safety, the aircraft must not be left unattended
while the engine is running.
- To eliminate possible injury or damage, ensure any loose
equipment or tools are properly secured before starting the en-
gine.
- Allow the engine to cool at idle for several minutes before turn-
ing off the engine.
Vacuum pump - This engine may be equipped with a 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.
Governor - This engine may be equipped with a governor. The safety
warning accompanying the governor must be given to the
owner/operator of the aircraft into which the governor is in-
stalled.

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1.5) Technical documentation
General note These documents form the instructions ensuring continued air-
worthiness of ROTAX aircraft engines.
The information contained is based on data and experience that
are considered applicable for skilled mechanics under normal
conditions.
Due to the fast technical progress and fulfilment of particular spec-
ifications of the customers it may occur that existing laws, safety
prescriptions, constructional and operational regulations cannot
be transferred completely to the object bought, in particular for
special constructions, or may not be sufficient.
Documentation - Installation Manual
- Operators Manual
- Maintenance Manual (Line and Heavy Maintenance)
- Overhaul Manual
- Illustrated Parts Catalog
- Alert Service Bulletins
- Service Bulletins
- Service Instructions
- Service Letters
Status The status of Manuals can be determined with the aid of the table
of amendments. The first column indicates the revision state.
This figure should be compared with the revision provided on
ROTAX-Aircraft Engines Website: www.FLYROTAX.com.
Amendments and current versions can be downloaded free of
change.
Replacement pag-
es
Furthermore the Manual is constructed in such a way that single
pages can be replaced instead of the complete document. The list
of effective pages is given in the chapter LEP. The particular edi-
tion and revision number is given on the footer of each page.
Reference Any reference to a document refers to the latest edition issued by
BRP-Powertrain if not stated otherwise.

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Illustrationen The illustrations in this Manual are mere sketches and show a typ-
ical arrangement. 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.
NOTE: The Illustrations in this Manual are stored in a
graphic data base system and are provided with
a consecutive irrelevant number.
This number (e.g. 00277) is of no significance
for the content.