Rotax 912 Series User manual

Before starting the engine, read the Operators Manual, as it contains
important safety relevant information. Failure to do so may result in per-
sonalinjuriesincludingdeath.Consulttheoriginalequipmentmanufactur-
ershandbookforadditionalinstructions!
WARNING
Thesetechnicaldataand theinformationembodiedtherein arethepropertyof 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 legendshall beincluded onany reproductionof thesedata,in whole
orin part. The Manualmustremain with the engine/aircraftin case of sale.
Copyright 2016© - all rights reserved.
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.
Otherproduct namesin thisdocumentation areused purelyfor easeof identification
and may be trademarks of the respective company or owner.
Approvaloftranslation has been done to best knowledge and judgement - inany case
theoriginaltextinEnglish languageisauthoritative.

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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 – Standard operation
Chapter 4 – Abnormal operation
Chapter 5 – Performance and Fuel consumption
Chapter 6 – Weights
Chapter 7 – System Description
Chapter 8 – Preservation and storage
Chapter 9 – Supplement

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NOTES

INTRO) Introduction
Topics in this chapter
The structure of the Manual follows whenever it is possible the
structure of the „GAMA Specification #1 for Pilot’s Operating
Handbook“.
Foreword BRP-Rotax GmbH & Co KG (hereinafter “BRP-Rotax”) provides
“Instructions of Continued Airworthiness”, 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-Rotax. This Operator Manual contains
important information about safe operation of the engine,
together with descriptions of the systems 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
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.
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NOTES

LEP) LIST OF EFFECTIVE PAGES
Chapter Page Date
cover
page
INTRO 1 Nov. 01 2016
2 Nov. 01 2016
LEP 1 Nov. 01 2016
2 Nov. 01 2016
TOA 1 Nov. 01 2016
2 Nov. 01 2016
1 1 Nov. 01 2016
2 Nov. 01 2016
3 Nov. 01 2016
4 Nov. 01 2016
5 Nov. 01 2016
6 Nov. 01 2016
7 Nov. 01 2016
8 Nov. 01 2016
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12 Nov. 01 2016
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20 Nov. 01 2016
2 1 Nov. 01 2016
2 Nov. 01 2016
Chapter Page Date
3 Nov. 01 2016
4 Nov. 01 2016
5 Nov. 01 2016
6 Nov. 01 2016
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4 1 Nov. 01 2016
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Chapter Page Date
5 1 Nov. 01 2016
2 Nov. 01 2016
3 Nov. 01 2016
4 Nov. 01 2016
5 Nov. 01 2016
6 Nov. 01 2016
7 Nov. 01 2016
8 Nov. 01 2016
6 1 Nov. 01 2016
2 Nov. 01 2016
7 1 Nov. 01 2016
2 Nov. 01 2016
3 Nov. 01 2016
Chapter Page Date
4 Nov. 01 2016
5 Nov. 01 2016
6 Nov. 01 2016
7 Nov. 01 2016
8 Nov. 01 2016
8 1 Nov. 01 2016
2 Nov. 01 2016
3 Nov. 01 2016
4 Nov. 01 2016
9 1 Nov. 01 2016
2 Nov. 01 2016
rear
page
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TOA) Table of amendments
Approval*
The technical content of this document is approved under the authority of
DOA ref. EASA.21J.048.
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*
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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
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1) General note
Topics in this chapter
1.1 General ................................................................................................2
1.2 Abbreviations and terms ........................................................................3
1.3 Safety ..................................................................................................7
1.4 Safety information ................................................................................. 9
1.5 Technical documentation...................................................................... 12
1.6 Standard version ................................................................................. 14
1.6.1 Auxiliary equipment (optional)................................................................ 14
1.7 Type description.................................................................................. 16
1.8 Engine components, engine views, cylinder
designation ........................................................................................ 17
1.9 Technical data ..................................................................................... 18
1.10 Fuel consumption .............................................................................. 18
1.11 Direction of rotation ........................................................................... 19
Foreword Before operating the engine, carefully read this Operators
Manual. The Manual provides you with basic information on the
safe operation of the engine.
If any passages of the Manual are not clearly understood or in
case of any questions, please contact an 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.
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1.1) General
Purpose The purpose of this Operators Manual is to familiarize the own-
er/user of this aircraft engine with basic operating instructions
and safety information.
Documentation For more detailed information related to aircraft and aircraft/en-
gine installation, maintenance, safety- or flight operation, con-
sult the documentation provided by the aircraft manufacturer
and/or its dealer.
For additional information on engines, 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, as the manufacturer might make modifi-
cations to the engine in the course of product improvement.
The engine serial number is located on the top of the crank-
case, magneto side.
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
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 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
Ah Ampere hour
A/C Aircraft
AR as required (IPC only)
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 Control 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
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
EN European Norm
ETFE Ethylene Tetrafluoroethylene
FAA Federal Aviation Administration
FAR Federal Aviation Regulations
hr. hours
HIC A Harness Interface Connector A
HIC B Harness Interface Connector B
IFR Instrument Flight Rules
INJ 1–8 Injector 1–8
IPC Illustrated Parts Catalog
ips inch per second
iRMT independent ROTAX Maintenance Technician
TOC Table of content
ISA International Standard Atmosphere
kg Kilograms
KNOCK Knock sensor
MAPS 1+2 Manifold Air Pressure Sensor 1+2
MATS 1+2 Manifold Air Temperature Sensor 1+2
MS Magneto Side
MON Motor Octane Number
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N Newton
n.a. not available
NDT Non Destructive Testing
Nm Newtonmeter
NVFR Night Visual Flight Rules
OHM Overhaul Manual
OHV Over Head Valve
OM Operators Manual
OPS Oil Pressure Sensor
OTS Oil Temperature Sensor
PCV Pressure Control Valve
POA Production Organisation Approval
PTFE Polytetrafluoroethylene
PTO Power Take Off
Rev. Revision
ROTAX® is a trademark of BRP-Rotax GmbH & Co KG
RON Research Octane Number
s.v. still valid (only Illustrated Parts Catalog)
S/N Serial Number
SAE Society of Automotive Engineers
SB Service Bulletin
SI Service Instruction
SL Service Letter
SMD Service Mounted Devices
TBO Time Between Overhaul
TC Type certificate
part no. Part number
TOA Table Of Amendment
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
XXX shows the serial component number
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1.3) Safety
Although reading such information does not eliminate any haz-
ards, it promotes the understanding and application the infor-
mation 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.
ATTENTION
Identifies an instruction which, if not followed, may severely
damage the engine or could lead to suspension of warranty.
NOTE
Indicates supplementary information which may be needed to
fully complete or understand an instruction.

ENVIRONMENT NOTE
Environmental notes give you tips on environmental
protection.
A revision bar outside the page margin indicates a change to
text or graphic.
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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 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-Rotax grants no warranty on the suitability of its engines
use on any particular aircraft. Further, BRP-Rotax grants no
warranty on this engines suitability with any other part, com-
ponents 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 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.
Training • Whether you are a qualified pilot or a novice, complete knowl-
edge of the aircraft, its controls and operation is mandatory

before a solo flight. Flying any type of aircraft involves a cer-
tain amount of risk. Be informed and prepared for any situa-
tion or hazard associated with flying.
• A recognized training program and continued education for
piloting an aircraft is absolutely necessary for all aircraft pi-
lots. Make sure you also obtain as much information as possi-
ble about your aircraft, its maintenance and operation from
your dealer.
• Engine-specific training courses are provided by the author-
ized distributors according to manufacturer specifications
(iRMT).
Regulations • Respect all legal requirements or local rules pertaining to
flight operation in your flying area. Only fly when and where
conditions, topography, and airspeeds are safest.
• Consult your aircraft dealer or manufacturer and obtain the
necessary information, especially before flying in new areas.
Instrumentation • Select and use proper aircraft instrumentation. This instru-
mentation is not included in the ROTAX® engine package.
Verification to the latest regulations such as FAR or EASA
has to be conducted by the aircraft manufacturer.
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)
• Since special training, tools and equipment are required, en-
gine servicing shall only be performed by an authorized
ROTAX® aircraft engine distributor or their independent serv-
ice center. BRP-Rotax requires that any service or mainte-
nance work carried out and verified by a technician that has a
current iRMT rating.
• When the engine will not be operated for a longer period pro-
tect the engine and fuel system from contamination and envi-
ronmental exposure.
Engine operation • 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 unat-
tended while the engine is running.
• To eliminate the risk of injury or damage, ensure any loose
equipment or tools are properly secured before starting the
engine.
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