Rotax 912 Series User manual

Recommended price : ATS 100,--
ROTAX®part no.:899 370 DM 14,--
AIRCRAFT ENGINES
WARNING
Before starting the engine, read the Operator's Manual.Failure to do so may result
in personal injuries including death.
Consulttheoriginal equipment manufacturer's handbook for additional instructions!
The manual must remain with the engine /original equipment in case of sale.
Operator's Manual
for all versions of
ROTAX 912
Engine serial no:_________________________
Type of aircraft:__________________________
Aircraft registration no: ___________________
Edition: 0 of 1998 07 01
These technical data and the information contained therein are property of
ROTAX®GmbH and must not be reproduced, neither in entirety nor partially,
and passed on to third parties without previous consent in writing by ROTAX®
GmbH. This text must be written on every complete or partial reproduction.
Copyright - ROTAX®GmbH

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1) Inhaltsverzeichnis
1) Table of contents......................................................................... 1 - 2
2) Index............................................................................................. 2 - 1
3) Introduction ................................................................................. 3 - 1
3.1) Remarks........................................................................................... 3 - 1
3.2) Engine serial number..................................................................... 3 - 1
4) Safety ........................................................................................... 4 - 1
4.1) Repeating symbols ........................................................................ 4 - 1
4.2) Safety information .......................................................................... 4 - 2
4.3) Technical documentation .............................................................. 4 - 5
5) Index of pages ............................................................................. 5 - 1
6) List of amendments .................................................................... 6 - 1
7) Description of design ................................................................. 7 - 1
7.1) Type description ............................................................................. 7 - 2
7.2) Denomination of cylinders: ........................................................... 7 - 3
8) Technical data ............................................................................. 8 - 1
8.1) Dimensions ..................................................................................... 8 - 1
8.2) Weights ............................................................................................ 8 - 1
8.3) Fuel consumption........................................................................... 8 - 2
8.4) Direction of rotation ....................................................................... 8 - 2
9) Description of systems............................................................... 9 - 1
9.1) Cooling system ............................................................................... 9 - 1
9.2) Fuel system ..................................................................................... 9 - 2
9.3) Lubrication system ........................................................................ 9 - 3
9.4) Electric system ............................................................................... 9 - 4
9.5) Propeller gearbox ........................................................................... 9 - 5
9.5.1) Hydr. governor for const. speed propeller, vacuum pump 9 - 6
10) Operating instructions.............................................................. 10 - 1
10.1)General limits of operation.......................................................... 10 - 1
10.1.1) Operating speeds and limits (912 UL / A / F).................. 10 - 1
10.1.1.1) Performance graphs for stand. conditions (ISA)10 - 3
10.1.1.2) Performance graph for non-standard conditions10 - 4
10.1.2 ) Operating speeds and limits (912 ULS / S) .................... 10 - 5
10.1.2.1) Performance graphs for stand. conditions (ISA)10 - 7
10.1.2.2) Performance graph for non-standard conditions10 - 8
10.2)Operating media ........................................................................... 10 - 9
10.2.1) Coolant............................................................................. 10 - 9
10.2.2) Fuel ................................................................................ 10 - 10
10.2.3) Lubricants ...................................................................... 10 - 11

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10.3) Standard operation ..................................................................... 10 - 14
10.3.1) Daily checks .................................................................. 10 - 14
10.3.2) Before engine start ........................................................ 10 - 15
10.3.3) Pre-flight checks ............................................................ 10 - 15
10.3.4) Engine start .................................................................... 10 - 16
10.3.5) Prior to take-off .............................................................. 10 - 17
10.3.6) Take-off .......................................................................... 10 - 18
10.3.7) Cruising ......................................................................... 10 - 18
10.3.8) Engine shut-off .............................................................. 10 - 18
10.3.9) Cold weather operation ................................................ 10 - 19
10.4) Abnormal operation .................................................................... 10 - 21
10.4.1) Engine stop - Start during flight .................................... 10 - 21
10.4.2) Exceeding of max. admissible engine speed .............. 10 - 21
10.4.3) Exceeding of max. admissible cyl. head temperature.. 10 - 21
10.4.4) Exceeding of max. admissible oil temperature ............ 10 - 21
10.4.5) Oil pressure below minimum - during flight ................. 10 - 21
10.4.6) Oil pressure below minimum - on ground .................... 10 - 21
11) Checks ......................................................................................... 11 - 1
11.1) Engine preservation ..................................................................... 11 - 1
12) Trouble shooting ........................................................................ 12 - 1
12.1) Reporting ....................................................................................... 12 - 3
13) Appendix to Aircraft Manual ...................................................... 13 - 1
13.1) Fuel according to DOT .................................................................. 13 - 1
13.2) Fuel according to FAA .................................................................. 13 - 2
14) ROTAX® authorized Distributors ............................................... 14 - 1
15) Warranty ....................................................................................... 15 - 1
15.1) Warranty Conditions / Warranty Card (912 A / F / S) ................. 15 - 1
15.2) Warranty Conditions / Warranty Card (912 UL / ULS) .............. 15 - 5

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2) Index
A
Abnormal operation 10 - 21
Acceleration (912 UL / A / F) 10 - 1
Acceleration (912 ULS / S) 10 - 5
AVGAS 100 LL 10 - 10
C
Carburetor 10 - 14
Certification 7 - 2
Check of hydraulic propeller
governor 10 - 17
Cold start 10 - 19
Cold weather operation 10 - 19
Configuration 7 - 2
Consumer assistance 15 - 2
Coolant 10 - 9
Cooling system 9 - 1
Cruising 10 - 18
Cylinder head temperature (912 UL / A /
F) 10 - 1
Cylinder head temperature (912 ULS /
S) 10 - 5
D
Daily checks 10 - 14
Denomination of cylinders 7 - 3
Description of design 7 - 1
Description of systems 9 - 1
Direction of rotation 8 - 2
Documentation (technical) 4 - 5
E
Electric system 9 - 4
Engine preservation 11 - 1
Engine serial number 3 - 1
Engine shut-off 10 - 18
Engine start 10 - 16
Engine start, operating temperature
(912UL / A / F 10 - 1
Engine start, operating temperature
(912 ULS / S) 10 - 5
Equipment 8 - 1
Exceeding of max. admissible cyl. head
temperature 10 - 21
Exceeding of max. admissible engine
speed 10 - 21
Exceeding of max. admissible oil
temperature 10 - 21
Exhaust system 10 - 14
F
Fuel 10 - 10
Fuel according to DOT 13 - 1
Fuel according to FAA 13 - 2
Fuel consumption 8 - 2
Fuel pressure (912 UL / A / F) 10 - 1
Fuel pressure (912 ULS / S) 10 - 5
Fuel system 9 - 2
H
Hydr. governor for const. speed
propeller 9 - 6
I
Ignition check 10 - 17
Ignition unit 9 - 4
Index of pages 5 - 1
Introduction 3 - 1
L
List of amendments 6 - 1
Lubricants 10 - 11
Lubrication system 9 - 3
M
magneto side 7 - 3
N
Note of approval 6 - 1
O
Oil capacity 10 - 12
Oil consumption 10 - 12
Oil pressure (912 UL / A / F) 10 - 1
Oil pressure (912 ULS / S) 10 - 5
Oil pressure below minimum - during
flight 10 - 21
Oil pressure below minimum - on
ground 10 - 21
Oil specification 10 - 11

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Oil temperature (912 UL / A / F) 10 - 1
Oil temperature (912 ULS / S) 10 - 5
Oil viscosity 10 - 12
Operating media 10 - 9, 10 - 15
Operating speeds and limits (912 UL / A /
F) 10 - 1
Operating speeds and limits (912 ULS /
S) 10 - 5
Overload clutch 9 - 5
P
Performance (ISA) (912 UL / A / F)
10 - 1
Performance (ISA) (912 ULS / S) 10 - 5
Performance data 10 - 4, 10 - 8
Performance graphs for stand. conditions
(ISA) 10 - 3, 10 - 7
power take-off side 7 - 3
Pre-flight checks 10 - 15
Propeller gearbox 9 - 5
Propeller governor 9 - 6
R
Remarks 3 - 1
Repeating symbols 4 - 1
Reporting 12 - 3
ROTAX® authorized Distributors 14 - 1
S
Safety 4 - 1
Safety information 4 - 2
Speed (912 UL / A / F) 10 - 1
Speed (912 ULS / S) 10 - 5
Symbols 4 - 1
T
Table of lubricants 10 - 12
Take-off 10 - 18
Technical data 8 - 1
Technical documentation 4 - 5
Throttle response 10 - 17
Trouble shooting 12 - 1
Type 7 - 2
Type description 7 - 2
V
Vacuum pump 9 - 6
W
Warming up period 10 - 17
Warranty 15 - 1
Weights 8 - 1
Work performance 15 - 1

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3) Introduction
Congratulations on your decision to purchase a ROTAX®aircraft engine.
Before operating the engine, carefully read this Operator's 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 authorized Distribution- or Service Center for
ROTAX®aircraft engines.
We wish you much pleasure and satisfaction flying your aircraft with this
ROTAX®engine.
3.1) Remarks
ThepurposeofthisOperator'sManualisprovidedtofamiliarizetheowner/
user of this aircraft engine with basic operating instructions and safety
information.
For more detailed maintenance, safety and flight information, consult the
documentation provided by the aircraft manufacturer and dealer.
For further information on maintenance and spare parts service, contact
the nearest ROTAX®distribution Center (see Chapter 14).
3.2) Engine serial number
On all enquiries or parts orders, always indicate the engine serial number,
as the manufacturer makes modifications to the engine for product
improvement. The engine serial number should always be used when
ordering parts to ensure correct part selection prior to shipment.
The engine serial number is located on the top of the crankcase, magneto
side. See ill. 6.

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4) Safety
Although the mere reading of these instructions will not eliminate a hazard, the
understandingandapplicationoftheinformationhereinwillpromotetheproperuse
of the engine.
Theinformationandcomponents-/systemdescriptionscontainedinthisOperator's
Manualare correct at the time of publication.ROTAX®however,maintainsa policy
of continuous improvement of its products without imposing upon itself any
obligation to install them on its products previously manufactured.
ROTAX®reserves the right at any time to discontinue or change specifications,
designs, features, models or equipment without incurring obligation.
The illustrations in this Manual show the typical construction. They may not
representinfulldetailortheexactshapeofthepartswhichhavethesameorsimilar
function.
Specifications are given in the SI metric system with the USA equivalent in
parenthesis. Where precise accuracy is not required, some conversions are
rounded off for easier use.
This document has been translated from the German language and the original
German text shall be deemed authoritative.
4.1) Repeating symbols
This Manual uses the following symbols to emphasize particular
information:
▲WARNING: Identifies an instruction which, if not followed, may
causeseriousinjuryincludingthepossibilityofdeath.
■ATTENTION: Denotes an instruction which, if not followed, may
severely damage the engine or other component.
◆NOTE: Indicates supplementary information which may be
neededtofullycompleteorunderstandaninstruction.

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4.2) Safety information
▲WARNING: Neverflytheaircraftequippedwiththisengineatlocations,
airspeeds, altitudes, or other circumstances from which
a successful no-power landing cannot be made, after
sudden engine stoppage.
Aircraft equipped with this engine must only fly in
DAYLIGHT VFR conditions.
— This engine is not suitable for acrobatics (inverted flight, etc.).
— This engine shall not be used on rotor wing aircraft (helicopters,
gyrocopters, etc.) or any similar aircraft.
— Itshould be clearly understood that the choice, selection and use
ofthis
particularengineonany aircraftisatthesolediscretionandresponsibility
of the aircraft manufacturer, assembler and owner/user.
— Due to the varying designs, equipment and types of aircraft, ROTAX®
grantsno warrantyorrepresentationonthesuitabilityofitsengine’suse
on any particular aircraft. Further, ROTAX®grants no warranty or
representationofthisengine’ssuitabilitywithanyotherpart,component
orsystemwhichmaybeselectedbytheaircraftmanufacturer,assembler
or user for aircraft application.
— Whetheryouare aqualifiedpilotoranovice,completeknowledge ofthe
aircraft, its controls and operation is mandatory before venturing solo.
Flyinganytype of aircraft involves a certain amount of risk. Be informed
and prepared for any situation or hazard associated with flying.
A recognized training program and continued education for piloting an
aircraftis 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.
— Youshouldbeawarethat anyengine mayseizeorstallatanytime. This
could lead to a crash landing and possible severe injury or death. For
thisreason,we recommendstrictcompliancewiththemaintenanceand
operation and any additional information which may be given to you by
your dealer.
— Respect all government or local rules pertaining to flight operation in
your flying area. Fly only when and where conditions, topography, and
airspeeds are safest.
— Select and use proper aircraft instrumentation. This instrumentation is
not included with the ROTAX®engine package. Only approved
instrumentation may be installed.

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— Before flight, ensure that all engine controls are operative. Make sure
all controls can be easily reached in case of an emergency.
— Unless in a run up area, never run the engine with the propeller turning
while on the ground. Do not operate engine if bystanders are close.
— In the interst of safety, the aircraft must not be left unattended while the
engine is running.
— Keep an engine log 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.
Since special tools and equipment may be required, engine servicing
should only be performed by an authorized ROTAX®engine dealer or
a qualified trained mechanic approved by the local airworthiness
authority.
— To eliminate possible injury or damage, ensure any loose equipment or
tools are properly secured before starting the engine.
— Whenin storageprotect theengineand fuelsystemfromcontamination
and exposure.
— Certainareas, altitudes andconditionspresent greater riskthanothers.
The engine may require carburetor recalibration or humidity or dust/
sand preventative equipment, or additional maintenance may be
required.
Consult your aircraft dealer or manufacturer and obtain the necessary
information, especially before flying in new areas.
— Never operate the engine and gearbox without sufficient quantities of
lubricating oil.
— Periodically verify level of coolant.
— Never exceed maximum rated r.p.m.
Allowthe engine to cool at idleforseveralminutes before turning off the
engine.
— This engine may be equipped with an Airborne 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.

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4.3) Technical documentation
The information given in the
☞Installation Manual
☞Operator's Manual
☞Collective Manual
☞Maintenance Manual
☞ICR-Manual (Inspection, Clean and Repair Manual)
☞Overhaul Manual
☞Illustrated Parts Catalog
☞Technical Bulletins
☞Service Information
are based on data and experience that are considered applicable for
professionals under normal conditions.
The fast technical progress and variations of installation might render
present laws and regulations inapplicable or inadequate.
The illustrations in this Manual are mere sketches and show a typical
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.
All necessary documentation is available from the ROTAX Distribution-
and Service Centers (see Chapter 14).
◆NOTE: The Illustrations in this Operator´s Manual are stored in
a graphic data file and are provided with a consecutive
irrelevant number.
This number (e.g. 00277) is of no significance for the
content.

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Chap- Page Date
ter Chap- Page Date ter
5) Index of pages
1 cover page 1 - 1 98 07 01
1 - 2 98 07 01
1 - 3 2002 11 01
1 - 4 98 07 01
2 2 - 1 98 07 01
2 - 2 2002 11 01
3 3 - 1 98 07 01
3 - 2 98 07 01
4 4 - 1 98 07 01
4 - 2 98 07 01
4 - 3 98 07 01
4 - 4 98 07 01
4 - 5 98 07 01
4 - 6
55-1
2004 07 01
5 - 2 98 07 01
6 ACG-approv. 6 - 1 2004 07 01
blank 6 - 2 98 07 01
7 7 - 1 98 07 01
7 - 2 98 07 01
7 - 3 98 07 01
7 - 4 98 07 01
8 8 - 1 98 07 01
8 - 2 2002 11 01
9 9 - 1 98 07 01
9 - 2 98 07 01
9 - 3 98 07 01
9 - 4 98 07 01
9 - 5 98 07 01
9 - 6 98 07 01
10 ACG-approv.10 - 1 2004 07 01
ACG-approv.10 - 2 2002 11 01
ACG-approv.10 - 3 98 07 01
ACG-approv.10 - 4 98 07 01
ACG-approv.10 - 5 2004 07 01
ACG-approv.10 - 6 2002 11 01
ACG-approv.10 - 7 98 07 01
ACG-approv.10 - 8 2004 07 01
ACG-approv.10 - 9 2004 07 01
ACG-approv.10 - 10 98 07 01
ACG-approv.10 - 11 98 07 01
ACG-approv.10 - 12 2003 03 01
blank 10 - 13 98 07 01
ACG-approv.10 - 14 2004 07 01
ACG-approv.10 - 15 2004 07 01
ACG-approv.10 - 16 2004 07 01
ACG-approv.10 - 17 98 07 01
ACG-approv.10 - 18 98 07 01
ACG-approv.10 - 19 98 07 01
ACG-approv.10 - 20 98 07 01
ACG-approv.10 - 21 98 07 01
blank 10 - 22 98 07 01
11 11 - 1 98 07 01
11 - 2 98 07 01
12 12 - 1 98 07 01
12 - 2 98 07 01
12 - 3 2002 11 01
12 - 4 2002 11 01
13 DOT-approv.13 - 1 98 07 01
FAA-approv. 13 - 2 98 07 01
14 14 - 1 2003 03 01
14 - 2 2003 03 01
14 - 3 2003 03 01
14 - 4 98 07 01
00522

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Chap- Page Date
ter Chap- Page Date ter
15 15 - 1 98 07 01
15 - 2 98 07 01
15 - 3 98 07 01
15 - 4 98 07 01
15 - 5 98 07 01
15 - 6 98 07 01
15 - 7 98 07 01
15 - 8 98 07 01
15 - 9 98 07 01
15 - 10 98 07 01

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Currt
no.
Date
of
modification
Chap-
ter
Pages Note
of
approval
Date of
approval by
authority
Date of
insertion
Marks /
Signature
1÷5 all not
0 7÷9 all 98 07 01 98 07 01 AA/HeC
11÷15 all required
0 6,10 all* 98 07 01 english version german 98 07 01 AA/HeC
not required version
1.7.1998
1 1, 2 1 - 3 2002 11 01 2002 11 01
2 - 2 2002 11 01 2002 11 01
5, 6 5 - 1 2002 11 01 2002 11 01
6 - 1 2002 11 01 2002 11 01
8, 10 8 - 2 2002 11 01 2002 11 01
10 - 2 2002 11 01 english version 2002 11 01
10 - 6 2002 11 01 not required 2002 11 01
10 - 14 2002 11 01 2002 11 01
10 - 15 2002 11 01 2002 11 01
12 12 - 3 2002 11 01 2002 11 01
12 - 4 2002 11 01 2002 11 01
2 6 6 - 1 2003 03 01 english version german
10 10 - 12 2003 03 01 not required version
10 - 14 2003 03 01 24.06.2003
10 - 15 2003 03 01
2 5 5 - 1 2003 03 01 not
14 14 - 1 2003 03 01 required
14 - 2 2003 03 01
14 - 3 2003 03 01
3 6 6 - 1 2004 07 01 english version german
14 10 - 1 2004 07 01 not required version
10 - 5 2004 07 01 07.09.2004
10 - 8 2004 07 01
10 - 9 2004 07 01
10 - 11 2004 07 01
10 - 14 2004 07 01
10 - 15 2004 07 01
10 - 16 2004 07 01
3 5 5 - 1 2004 07 01 not
required
6) List of amendments 00521
* The note of approval of the Aviation Authority refers only to the certified engines
of the Type 912 A (TW 8/89), 912 F / S (TW9 - ACG).

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7) Description of design
4-stroke, 4 cylinder horizontally opposed, spark ignition engine, one central
camshaft - push-rods - OHV
Liquid cooled cylinder heads
Ram air cooled cylinders
Dry sump forced lubrication
Dual breakerless capacitor discharge ignition
2 constant depression carburetors
mechanical fuel pump
Prop drive via reduction gear with integrated shock absorber and overload clutch
◆NOTE: The overload clutch is installed on all serial production aircraft
engines which are certified and on non-certified aircraft engines
of the configuration 3.
Electric starter (12V 0,6 kW)
Integrated AC generator with external rectifier-regulator (12V 20A DC)
External alternator (12V 40A DC), optional
Vacuum pump: (only for A1, A2 and A4 possible), optional
Hydraulic constant speed propeller governor: (for A3 only), optional

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Type
(type)
Zulassung
(certification)
Ausführung
(configuration)
ROTAX
7.1) Type description
e.g. ROTAX 912 A 2
◆NOTE: The type designation is of the following composition.
Type: 912......... 4-cyl. horizontalle opposed, normal aspirated
engine
Certification: A ............ certified to JAR 22 (TW 8/89)
F, S ........ certified to FAR 33 (TW9 - ACG)
UL, ULS. non-certified aircraft engines
Configuration: 1 ............. Prop shaft with flange for fixed pitch prop, P.C.D.
100 mm.
◆NOTE: Thisconfigurationisnotavailableanylonger
and will be replaced by configuration 2.
2 ............. Propshaftwithflangeforfixedpitchprop,P.C.D.
75 mm, P.C.D. 80 mm and 4" P.C.D.
3 ............. Prop shaft with flange for constant speed
propeller P.C.D. 75 mm, P.C.D. 80 mm, P.C.D.
4" and drive for hydraulic governor for constant
speed propeller.
4 ............. Prop flange for fixed pitch propeller P.C.D.
75 mm, P.C.D. 80 mm, P.C.D. 4" and prepared
for retrofit of a hydraulic governor for constant
speed propeller.
02091