Rotax 912 UL Operator's Manual
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Rotax 912 UL Operator's Manual

912 series
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OPERATORS MANUAL
FOR ROTAX® ENGINE TYPE 912 SERIES
ROTAX ® 912 ULS 3
WITH OPTIONS
part no.: 899371

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  • Page 1 �������� ������� OPERATORS MANUAL FOR ROTAX® ENGINE TYPE 912 SERIES ROTAX ® 912 ULS 3 WITH OPTIONS part no.: 899371...
  • Page 2 These technical data and the information embodied therein are the property of 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.

  • Page 3: Table Of Contents

    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 conditions 10 - 4...
  • Page 4 11) Checks ..................11 - 1 11.1) Engine preservation ............... 11 - 1 12) Trouble shooting ............... 12 - 1 12.1) Reporting ..................12 - 4 13) Authorized Distributors for ROTAX aircraft engines ... 13 - 1 Effectivity: 912 Serie page 1 - 4 BRP-Rotax OM Edition 1 / Rev.

  • Page 5: Index

    Fuel consumption 8 - 2 Acceleration (912 UL / A / F) 10 - 1 Fuel pressure (912 UL / A / F) 10 - 2 Acceleration (912 ULS / S) 10 - 5 Fuel pressure (912 ULS / S) 10 - 6...
  • Page 6 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...

  • Page 7: Introduction

    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.

  • Page 8: Om Edition 1 / Rev. 0 Jan.

    NOTES Effectivity: 912 Serie page 3 - 2 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 9: Safety

    The information and components-/system descriptions contained in this Operator's Manual are correct at the time of publication. ROTAX however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on its products previously manufactured.

  • Page 10: Safety Information

    — Due to the varying designs, equipment and types of aircraft, ROTAX grants no warranty or representation on the suitability of its engine’s use on any particular aircraft.
  • Page 11 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.
  • Page 12 NOTES Effectivity: 912 Serie page 4 - 4 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 13: Technical Documentation

    Alert Service Bulletins Service Bulletins Service Instructions Service Letters Any reference to a document refers to the latest edition issued by ROTAX if not stated otherwise. ◆ NOTE: The status of Manuals can be determined by checking the table of amendments of the Manual. The 1 column of this table is the revision status.
  • Page 14 All necessary documentation is available from the ROTAX Distribution- and Service Centers (see Chapter 13). ◆ 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.

  • Page 15: Index Of

    13 - 03 01 01 2007 9 -5 01 01 2007 13 - 04 01 01 2007 9 -6 01 01 2007 rear page Effectivity: 912 Serie page 5 - 1 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 16 NOTES Effectivity: 912 Serie page 5 - 2 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 17: List Of Amendments

    09117 Note Date of Date Currt Chap- Date of Marks / Pages approval insertion Signature approval by authority modification 1÷13 01 01 2007 DOA* Effectivity: 912 Serie page 6 - 1 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 18 NOTES Effectivity: 912 Serie page 6 - 2 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 19: Description Of Design

    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 Effectivity: 912 Serie page 7 - 1 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 20: Type Description

    7.1) Type description e.g. ROTAX 912 A 2 ◆ NOTE: The type designation is of the following composition. ROTAX 02091 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 .

  • Page 21: Denomination Of Cylinders

    7.2) Denomination of cylinders: Lateral view fig. 1 00337 Zyl. 1 Zyl. 3 Top view fig. 2 Zyl. 2 Zyl. 4 00334 Effectivity: 912 Serie page 7 - 3 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 22: Front View

    CD carburetor external alternator propeller gearbox vacuum pump or hydraulic governor for constant speed electric starter propeller expansion tank with excess pressure valve Effectivity: 912 Serie BRP-Rotax page 7 - 4 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 23: Technical Data

    8) Technical data 8.1) Dimensions Description 912 UL / A / F 912 ULS / S Bore 79,5 mm (3,13 in) 84 mm (3,31 in) Stroke 61 mm (2,40 in) 61 mm (2,4 in) Displacement 1211 cm3 (73,9 in3) 1352 cm3 (82,5 in3)

  • Page 24: Fuel Consumption

    8.3) Fuel consumption Fuel consumption in l/h (USgal/h 912 UL / A / F 912 ULS / S at take-off performance 24,0 (6,3) 27,0 (7,1) at max. continuous performance 22,6 (5,6) 25,0 (6,6) at 75 % continuous performance 16,2 (4,3) 18,5 (4,9) specific consumption at max.

  • Page 25: Description Of Systems

    Cooling system See fig. 4. The cooling system of the ROTAX 912 is designed for liquid cooling of the cylinder heads and ram-air cooling of the cylinders. The cooling system of the cylinder heads is a closed circuit with an expansion tank.

  • Page 26: Fuel System

    The return line serves to avoid formation of vapour lock. Fuel, see Chapter 10.2.2). zum Tank to fuel tank zum Manometer / to fuel pressure gauge fig. 5 00535 page 9 - 2 Effectivity: 912 Serie BRP-Rotax Jan. 01/2007 OM Edition 1 / Rev. 0...

  • Page 27: Lubrication System

    9.3) Lubrication system See fig. 6. The ROTAX 912 engine is provided with a dry sump forced lubrication system with a main oil pump with integrated pressure regulator (1) and oil pressure sensor (2). ◆ NOTE: The oil pump is driven by the camshaft.

  • Page 28: Electric System

    9.4) Electric system See fig. 7. The ROTAX 912 engine is equipped with a dual ignition unit of a breakerless, capacitor discharge design, with an integrated generator. The ignition unit is completely free of maintenance and needs no external power supply.

  • Page 29: Propeller Gearbox

    9.5) Propeller gearbox See fig. 8. For the engine type 912 two reduction ratios are available. reduction ratio 912 UL / A / F 912 ULS / S 2,27 : 1 crankshaft : propeller shaft 2,43 : 1 2,43 : 1...

  • Page 30: 1) Hydr. Governor For Const. Speed Propeller, Vacuum Pump

    1,842 or 1,724 i.e. the speed of the hydraulic governor or vacuum pump is either 0,54 or 0,58 of engine speed. page 9 - 6 Effectivity: 912 Serie BRP-Rotax Jan. 01/2007 OM Edition 1 / Rev. 0...

  • Page 31: Operating Instructions

    The data of the certified engines are based on type certificate of type 912 A (TW 8/89), 912 F / S (TW9 - ACG). 10.1) General limits of operation 10.1.1) Operating speeds and limits (912 UL / A / F) Speed: Take-off speed ......5800 1/min (5 min.) Max.

  • Page 32: Propeller Governor

    ..........40° ◆ NOTE: Up to this value the dry sump lubrication system warrants lubrication in every flight situation. Effectivity: 912 UL / A / F BRP-Rotax page 10 - 2 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 33: 1) Performance Graphs For Stand. Conditions (Isa)

    D: fuel consumption 00451 (Gal/h) in.Hg (7,93) (5,28) (2,64) 3000 4000 5000 5800 rpm Values along propeller curve fig. 10 page 10 - 3 BRP-Rotax Effectivity: 912 UL / A / F Jan. 01/2007 OM Edition 1 / Rev. 0...

  • Page 34: 2) Performance Graph For Non-Standard Conditions

    T [K] = t [°C]+273 fig. 11 1000 2000 3000 4000 5000 6000 7000 Dichtehöhe / Density Altitude [m] 00452 Effectivity: 912 UL / A / F BRP-Rotax page 10 - 4 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 35: Operating Speeds And Limits (912 Uls / S)

    Permanent monitoring of cylinder head temperature is necessary. Engine start, operating temperature: max..........50 °C ....(120 °F) min..........- 25 °C ....(- 13 °F) page 10 - 5 Effectivity: 912 ULS / S BRP-Rotax Jan. 01/2007 OM Edition 1 / Rev. 0...
  • Page 36 Deviation from bank angle max..........40° ◆ NOTE: Up to this value the dry sump lubrication system warrants lubrication in every flight situation. Effectivity: 912 ULS / S page 10 - 6 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 37: 1) Performance Graphs For Stand. Conditions (Isa)

    Benzinverbrauch fuel consumption 5800 2500 3000 3500 4000 4500 5000 5500 Drehzahl/Engine speed [1/min / rpm] 02002 fig. 13 page 10 - 7 Effectivity: 912 ULS / S BRP-Rotax Jan. 01/2007 OM Edition 1 / Rev. 0...

  • Page 38: 2) Performance Graph For Non-Standard Conditions

    T [K] = t [°C]+273 5500 5000 4800 4300 7500 1000 2000 3000 4000 5000 6000 7000 Dichtehöhe / Density Altitude [m] 05482 fig. 14 Effectivity: 912 ULS / S page 10 - 8 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 39: Operating Media

    Use the coolant specified in the manufacturer's documentation. ■ CAUTION: Obey the latest edition of Service Instruction SI-912-016 for the selection of the correct coolant. BRP-Rotax page 10 - 9 Effectivity: 912 Serie Jan. 01/2007 OM Edition 1 / Rev. 0...

  • Page 40: 2) Fuel

    10.2.2) Fuel The following fuels can be used. Usage / Description 912 UL / A / F 912 ULS / S MOGAS EN 228 Normal European EN 228 Super EN 228 Super standard EN 228 Super plus EN 228 Super plus Canadian CAN/CGSB-3.5...

  • Page 41: 3) Lubricants

    ■ CAUTION: If the engine is mainly run on AVGAS more frequent oil changes will be required. See Service Information SI-912-016, latest edition. BRP-Rotax page 10 - 11 Effectivity: 912 Serie Jan. 01/2007 OM Edition 1 / Rev. 0...

  • Page 42: Oil Consumption

    Klima Mehrbereichs-Öle °C °F (climatic multi-grade oils conditions) tropisch (tropical) gemäßigt (temperate) arktisch (arctic) fig. 15 01176 Effectivity: 912 Serie page 10 - 12 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 43: Standard Operation

    30° before the crankshaft starts to rotate. If the propeller can be turned between the dogs with practically no friction at all (less than 25Nm = 222 in.lb) further investigation is necessary. BRP-Rotax page 10 - 13 Effectivity: 912 Serie Jan. 01/2007...

  • Page 44: Carburetor

    — Verify free movement of throttle cable and starting carburetor over the complete range. Check from the cockpit. Exhaust system: — Inspect for damages, leakage and general condition. Effectivity: 912 Serie page 10 - 14 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 45: 2) Before Engine Start

    Before longer periods of operation ensure that oil level is at least up to mid-position. Difference between max.- and min.- mark = 0,45 litre (0.95 liq pt) BRP-Rotax page 10 - 15 Effectivity: 912 Serie Jan. 01/2007...

  • Page 46: 4) Engine Start

    ■ CAUTION: Do not actuate starter button (switch) as long as the engine is running. Wait until complete stop of engine! Effectivity: 912 Serie page 10 - 16 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 47: 5) Prior To Take-Off

    Limits must not be exceeded! See Chapter 10.1) Operating Limits. ■ CAUTION: Respect "cold weather operation" recommenda- tions, see Chapter 10.3.9). BRP-Rotax page 10 - 17 Effectivity: 912 Serie Jan. 01/2007 OM Edition 1 / Rev. 0...

  • Page 48: 7) Cruising

    — Use of multigrade oil with the low end viscosity code of 5 or 10. — Gap electrode on spark plug to the minimum or fit new spark plugs. Effectivity: 912 Serie page 10 - 18 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 49 Carburetor icing due to humidity may occur on the venturi and on the throttle valve due to fuel evaporation and leads to performance loss and change in mixture. Intake air pre-heating is the only effective remedy. BRP-Rotax page 10 - 19 Effectivity: 912 Serie Jan. 01/2007...

  • Page 50: Abnormal Operation

    Immediately stop the engine and check for reason. Check oil system. — Check oil quantity in oil tank. — Check oil quality (see section 10.2.3). Effectivity: 912 Serie page 10 - 20 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 51: Checks

    – If preservation including oil change took place within a year of storage, oil renewal will not be necessary. For longer storage periods repeat preser- vation annually. Effectivity: 912 Serie page 11 - 1 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 52 NOTES page 11 - 2 Effectivity: 912 Serie BRP-Rotax Jan. 01/2007 OM Edition 1 / Rev. 0...

  • Page 53: Trouble Shooting

    Low oil pressure POSSIBLE CAUSE: REMEDY: a - not enough oil in oil tank check oil return line for free pas- sage, renew oil seal. Effectivity: 912 Serie page 12 - 1 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 54 See SI-912-016, current issue. ◆ NOTE: Oil pressure must in the idle operation with an oil temperature of min. 50 °C (120°F) to be measured. Effectivity: 912 Serie page 12 - 2 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 55 NOTES Effectivity: 912 Serie page 12 - 3 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 56: Reporting

    ROTAX distributor. ◆ NOTE:...
  • Page 57 Effectivity: 912 Serie page 12 - 5 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 58 NOTES Effectivity: 912 Serie page 12 - 6 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 59: Authorized Distributors For Rotax Aircraft Engines

    Authorized Distributors for ROTAX Aircraft Engines ® www.rotax-aircraft-engines.com Issue 01 01 2007 1) E U R O P E AUSTRIA: GERMANY / THE NETHERLANDS: ➤ ➤ ➤ ➤ ➤ HB - FLUGTECHNIK GMBH ➤ ➤ ➤ ➤ ➤ FLUGMOTOREN FRANZ GMBH Dr.
  • Page 60 ➤ ➤ ➤ ➤ ➤ ROTECH RESEARCH CANADA, LTD. 6235 Okanagan Landing Rd. VERNON, B.C., V1H 1M5, Canada Tel.: +1 250 / 260-6299, Fax: +1 250 / 260-6269 E-mail: inquiries@rotec.com Website: www.rotec.com Effectivity: 912 Serie page 13 - 2 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 61 CAMEROON / CENTRAL AFRICAN ➤ ➤ ➤ ➤ ➤ ASEMAN PISHRANEH CO. REPUBLIC / CONGO / GABON / GUINEA Auth. Rotax A/C Engine Distributor & Service Center / IVORY COAST / MALI / MAURITANIA / P.O. Box 16535-433, Tehran, Iran NIGER/ NIGERIA / SENEGAL / TOGO: Tel.: +98 (0) 21 7731 4107,...
  • Page 62 NOTES Effectivity: 912 Serie page 13 - 4 BRP-Rotax OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 64 Motornummer / Engine serial no. Flugzeugtype / Type of aircraft Flugzeugkennzeichen / Aircraft registration no. ROTAX® Vertriebspartner ROTAX® authorized distributor www.rotax-aircraft-engines.com ® and TM are trademarks of BRP-Rotax GmbH & Co. KG. © 2006 BRP-Rotax GmbH & Co. KG. All rights reserved.

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