Rotax 912 Series User manual

AIRCRAFT ENGINES
ref. no.: IM-912 | part no.: 898643

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 Series
Edition 2/Rev. 0 INTRO
page 1
August 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 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 and 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
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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INSTALLATION MANUAL
BRP-Powertrain
Effectivity: 912 Series
Edition 2/Rev. 0 INTRO
page 2
August 01/2012
NOTES

Effectivity: 912 Series
Edition 2/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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INSTALLATION MANUAL
BRP-Powertrain
Effectivity: 912 Series
Edition 2/Rev. 0 LEP
page 3
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Effectivity: 912 Series
Edition 2/Rev. 0 LEP
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NOTES

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INSTALLATION MANUAL
BRP-Powertrain
Effectivity: 912 Series
Edition 2/Rev. 0 TOA
page 1
August 01/2012
Chapter: TOA
TABLE OF AMENDMENTS
Approval*
The technical content of this document is approved
under the authority of DOA ref. EASA.21J.048
no. chapter page date of
change
remark for
approval
date of approval
from authorities
date of
inclusion signature
0
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10-10-00
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DOA*
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Effectivity: 912 Series
Edition 2/Rev. 0 TOA
page 2
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NOTES

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Effectivity: 912 Series
Edition 2/Rev. 0 TOA
page 3
August 01/2012
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
0
0
0
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all
24-00-00
61-00-00
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New Layout
Graphic change, modify legend
chap. 1.2) Wording of max. moment of inertia
chap. 1.3) Requirements of the fuel system
chap. 2.1.2) Drainage piping to the carburetor
CO-Measurement for configuration with not
GENUINE-ROTAX airbox
chap. 4.1) Note added
chap. 1) Caution added
chap. 4.1) Muffler graphic change

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Effectivity: 912 Series
Edition 2/Rev. 0 TOA
page 4
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NOTES

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INSTALLATION MANUAL
BRP-Powertrain
Effectivity: 912 Series
Edition 2/Rev. 0 00-00-00
page 1
August 01/2012
Chapter: 00-00-00
GENERAL NOTE
Introduction This section describes the installation of engine type ROTAX 912 Series.
NOTE: The ROTAX 912 Series includes all engines such as the
912 A, 912 F, 912 S, 912 UL and 912 ULS.
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 9
Safety notice
Safety information
Instruction
Technical documentation
Page 10
Page 11
Page 13
Page 14

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Effectivity: 912 Series
Edition 2/Rev. 0 00-00-00
page 2
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NOTES

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INSTALLATION MANUAL
BRP-Powertrain
Effectivity: 912 Series
Edition 2/Rev. 0 00-00-00
page 3
August 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 installation and safety information for service work.
Documentation For more detailed information regarding, installation, maintenance,
safety- or flight operation, consult the documentation provided by the air-
craft manufacturer 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 ignition
cover, on the left, opposite the electric starter. See Fig. 1.
Fig. 1 08749
1
cyl. 1 cyl. 3
cyl. 2 cyl. 4

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BRP-Powertrain
Effectivity: 912 Series
Edition 2/Rev. 0 00-00-00
page 4
August 01/2012
2) Type description
e.g. ROTAX 912
version 2
The type description is made up the following.
Designation
Options Available options (optional equipment) for the engine type mentioned
above:
NOTE: Conversion of the configuration 2/4 to configuration 3 may
be accomplished by ROTAX Authorized Distributors or their
Service Center.
Type
(type)
Zulassung
(certification)
Ausführung
(configuration)
ROTAX
Designation Description
Type 912 4-cyl. horizontally opposed, normal aspirated engine.
Certification A Certified to JAR 22 (TC No. EASA.E.121).
F, S Certified to FAR 33 (TC No. E00051 EN)
JAR-E (TC No. EASA.E.121).
UL, ULS 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.
4With prop flange for fix pitch propeller, but prepared for
retro-fit of hydraulic governor for constant speed prop
(not supplied by manufacturer anymore.
External
alternator
Vacuum-
pump
Drive for rev counter/
hour meter Governor
for configuration 2 yes yes yes no
for configuration 3 yes no yes yes
for configuration 4 yes yes yes no

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Effectivity: 912 Series
Edition 2/Rev. 0 00-00-00
page 5
August 01/2012
2.1) Standard version
Serial production - 4 stroke, 4 cyl. horizontally opposed, spark ignition engine, single cen-
tral camshaft hydraulic tappets - push rods - OHV
- Liquid cooled cylinder heads
- Ram air cooled cylinders
- Dry sump forced lubrication
- Dual ignition of breakerless, capacitor discharge design
- 2 constant depression carburetors
- Mechanical fuel pumps
- Electric starter (12 V 0.7 kW), 912 S/ULS (12 V 0.9 kW)
- Integrated AC generator with external rectifier regulator
- Propeller drive via integrated gearbox with mechanical shock absorber
and overload clutch
NOTE: The overload clutch is installed on all serial production
aircraft engines which are certified and non-certified air-
craft engines of the configuration 3.
Optional - Electric starter (12 V 0.9 kW)
- External alternator (12 V 40 A DC)
- Vacuum pump (only for configuration 1, 2 and 4 possible)
- Hydraulic constant speed propeller governor (only for configuration 3)

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Effectivity: 912 Series
Edition 2/Rev. 0 00-00-00
page 6
August 01/2012
Auxiliary equip-
ment tested
NOTE: The following equipment is not included as part of the stan-
dard engine version!
The following auxiliary equipment has been tested on ROTAX engine
type 912 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.
- Airbox
- External alternator
- Engine suspension frame
- Vacuum pump (feasible on configuration 2 and configuration 4 only)
- Drive for rev counter/hour-meter
- Oil cooler with connections
- Coolant radiator
- Coolant overflow bottle
Auxiliary equip-
ment not tested
The following auxiliary equipment has not been tested on ROTAX
engine type 912 for safety and durability to the standards of aviation.
- Exhaust system
- Intake filter
- Flydat
- Mechanical rev counter
- Electric rev counter
- Shock mount
WARNUNG
NOTICE
Any equipment not included as part of the standard en-
gine version and so does not be part of the engine is
not in the scope 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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BRP-Powertrain
Effectivity: 912 Series
Edition 2/Rev. 0 00-00-00
page 7
August 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
rpm Revolutions per minute
912 A see OM (Type designation)
912 F see OM (Type designation)
912 S see OM (Type designation
912 UL see OM (Type designation)
912 ULS see OM (Type designation)
A Ampere
a.c. alternating current
Ah Ampere hour
A/C Aircraft
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 Controller Area Network
CAN/CGSB Canadian General Standards Board
CSA Constant Speed Actuator
CW Clockwise
CCW Counter-clockwise
DCDI Dual Capacitor Discharge Ignition
d.c. direct current
DOT Department of Transport
DOA Design Organisation Approval
EASA European Aviation Safety Agency
iRMT independent ROTAX Maintenance Technician
IM Installation Manual
EGT Exhaust Gas Temperatur

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BRP-Powertrain
Effectivity: 912 Series
Edition 2/Rev. 0 00-00-00
page 8
August 01/2012
INTRO Introduction
EMS Engine Management System
EN European Norm
IPC Illustrated Parts Catalog
FAA Federal Aviation Administration
FAR Federal Aviation Regulation
OM Overhaul Manual
hr. hours
OM Operators Manual
TOC Table of Contents
ISA International Standard Atmosphere
kg kilograms
AD Airworthiness Directive
MS magneto side
MON motor octane number
N new part (only Illustrated Parts Catalog)
nB as necessary (only Illustrated Parts Catalog)
n.a. not available
NDT non-destructive testing
Nm newtonmeter
Rev. Revision
ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG
RON Research Octane Number
RV Record of Revisions
S/N Serial Number
SB Service Bulletin
SI Service Instruction
SL Service Letter
SMD Surface Mounted Devices
part no. Part number
TSN Time Since New
TSNP Time Since New Part
TBO Time Between Overhaul
VVolt
VFR Visual Flight Rules
LEP List of Effective Pages
MM Maintenance Manual
XXX shows the serial component number
Abbreviation Description