Rotax 912 ULS 3 User manual


OPERATORS MANUAL
FOR ROTAX® ENGINE TYPE 912 SERIES
ROTAX® 912 ULS 3 WITH OPTIONS
part no.: 899374
Ref. No.: OM-912

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 2010 © - 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 for 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 sup-
plied by BRP-Powertrain.
This Operators 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 manufacturer’s 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 applicable the
structure of the „GAMA Specification #1 for Pilot’s Operating
Handbook“. The Operators Manual is subdivided into 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
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Chapter Page Date

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NOTES

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TOA) Table of amendments
Approval*
The technical content is approved under the authority
DOA No. EASA.21J.048.
Current
no.
chapter page date of
change
remark for
approval
date of
approval from
authorities
date of
issue
signature
01 to 9 all 04 01 2010 DOA*

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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 engines.
Table of content 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 1-4
Safety notice page 1-5
Technical documentation page 1-8
Standard version page 1-10
Type description page 1-11
Denomination of cylinders, Engine views page 1-12
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,
magneto side. See Fig. 1.
Fig. 1 00334
Part Function
1 engine serial number
1
Cyl. 1 Cyl. 3
Cyl. 4
Cyl. 2

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1.2) Abbreviations and terms used in this Manual
Abbreviations Abbreviation Description
°C Degrees Celsius (Centigrade)
°F Degrees Fahrenheit
A Ampere
ACG Austro Control GmbH
API American Petrol Institute
ASTM American Society for Testing and Materials
AKI Anti Knock Index
CAN/CGSB Canadian General Standards Board
CW Clockwise
CCW Counter-clockwise
DOA Design Organization Approval
EASA European Aviation Safety Agency
EN European Standard
FAR Federal Aviation Regulations
h hours
IFR Instrument Flight Rules
INTRO Introduction
ISA International Standard Atmosphere
kW Kilowatt
LEP List of effective pages
Nm Newton meter
OM Operators Manual
part no. Part number
RON Research Octane Number
ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG
rpm Revolutions per minute
SAE Society of Automotive Engineers
SI Service Instruction
SB Service Bulletin
SL Service Letter
TC Type certificate
TOA Table of amendments
VFR Visual Flight Rules

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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, spe-
cification, feature or otherwise.
Measuring units 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.
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.
WARN
U
WARNING Identifies an instruction which, if not fol-
lowed, may cause serious injury including
the possibility of death.
WARNU
N
CAUTION Identifies an instruction which, if not fol-
lowed, may cause minor or moderate inju-
ry.

WARNUN
G
NOTICE Denotes an instruction which, if not fol-
lowed, may severely damage the engine
or other component.

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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 distributor.
WARN
U
WARNING Non-compliance can result in serious injuries
or death!
Never fly the aircraft equipped with this engi-
ne at locations, airspeeds, altitudes, or other
circumstances from which a successful no-
power landing cannot be made, after sudden
engine stoppage.
WARN
U
WARNING Non-compliance can result in serious injuries
or death!
Unless correctly equipped to provide enough
electrical power for night VFR (according la-
test requirement as ASTM), the ROTAX
912 UL/ULS/ULSFR is restricted to DAY VFR
only.

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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.
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 - 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 distributor or a qualified trained mechanic approved by
the local airworthiness authority.
- When in storage protect the engine and fuel system from con-
tamination and exposure.

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Engine run - Never operate the engine without sufficient quantities of ope-
rating 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.

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1.5) Technical documentation
General note These documents form the instructions for continued airworthi-
ness of ROTAX aircraft engines.
The information given is 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.
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 by checking the table of
amendments of the Manual. The 1st column of this table is the re-
vision status.
Compare this number to that listed on the ROTAX WebSite:
www.rotax-aircraft-engines.com.
Updates and current revisions can be downloaded for free.
Revision pages Further the Manual is in such a way developed that revision pages
are offered and the entire document does not have to be ex-
changed. The overview of the valid pages are in the Chapter LEP.
The current edition and revision is shown in the foot note.
Reference Any reference to a document refers to the latest edition issued by
BRP-Powertrain if not stated otherwise.

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Illustrations The illustrations in this Manual are mere sketches and show a ty-
pical arrangement. They may not represent the actual part in all
its details but depict parts of the same or similar function. There-
fore deduction of dimensions or other details from illustrations is
not permitted.
NOTE: The illustrations in this Operators 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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1.6) Standard version
Serial production - 4-stroke, 4 cylinder horizontally opposed, spark ignition engi-
ne, one central cam-shaft - 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
- Electric starter (12 V 0.7 kW)
- Integrated AC generator with external rectifier-regulator (12 V
20 A DC)
- 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 con-
figuration 3.
Optional - Electric starter (12 V 0.9 kW)
- External alternator (12 V 40 A DC)
- Vacuum pump (only for A1, A2 and A4 possible)
- Hydraulic constant speed propeller governor (for configuration
3 only)

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1.7) Type description
e.g. 912 A 2 The type designation is of the following composition.
Description
Type
(type)
Zulassung
(certification)
Baureihe
(configuration)
ROTAX
Description Configuration
Type: 912 4-cyl. horizontally opposed, nor-
mal 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: 1 Prop shaft with flange for fixed
prop, P.C.D 100 mm (3.936 in.).
NOTE: This configuration is not available any longer
and will be replaced by configuration 2.
2Prop shaft with flange for fixed
pitch propeller.
3Prop shaft with flange for constant
speed propeller and drive for hy-
draulic governor for constant
speed propeller.
4Prop flange for fixed pitch propeller
and prepared for retrofit of a hy-
draulic governor for constant
speed propeller.
NOTE: This configuration 4 is not available any longer
and will be replaced by configuration 3.

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1.8) Denomination of cylinders, Engine views, components
Lateral view
Fig. 2 00337
Top view
Fig. 3 00334
Part Function
1 propeller gear box
2 vacuum pump or hydraulic governor for con-
stant speed propeller
2
1
Part Function
3 engine serial number
4 CD carburetor
5 electric starter
6 expansion tank with excess pressure valve
7 exhaust flange
8 external alternator
3
Cyl. 3
Cyl. 1
Cyl. 2 Cyl. 4
5
4
4
7
8
6
MS magneto side
PTO power take of side