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Introduction BRP-Powertrain provides “Instructions for Continued Airworthi- Foreword 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.
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NOTES Effectivity: 912 Serie BRP-Powertrain page INTRO-2 OM Edition 2 / Rev. 0 April 01/2010...
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NOTES Effectivity: 912 Serie BRP-Powertrain page LEP-2 OM Edition 2 / Rev. 0 April 01/2010...
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TOA) Table of amendments Approval* The technical content is approved under the authority DOA No. EASA.21J.048. Current chapter page date of remark for date of date of signature change approval approval from issue authorities 1 to 9 04 01 2010 DOA* Effectivity: 912 Serie BRP-Powertrain...
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NOTES Effectivity: 912 Serie BRP-Powertrain page TOA-2 OM Edition 2 / Rev. 0 April 01/2010...
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.
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For additional information on engines, maintenance or parts, you can also contact your nearest authorized ROTAX-aircraft engine distributor (Chapter 9.2). When making inquiries or ordering parts, always indicate the en-...
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Kilowatt List of effective pages Newton meter Operators Manual part no. Part number Research Octane Number ROTAX is a trade mark of BRP-Powertrain GmbH & Co KG Revolutions per minute Society of Automotive Engineers Service Instruction Service Bulletin Service Letter...
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1.3) Safety Although the reading of such information does not eliminate the General note 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.
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WARNU 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. 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.
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Select and use proper aircraft instrumentation. This instru- Instrumentation mentation is not included with the ROTAX engine package. Only approved instrumentation may be installed. Keep an engine log book and respect engine and aircraft Engine log book maintenance schedules.
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Never operate the engine without sufficient quantities of ope- Engine run 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.
Manual. The 1 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. Further the Manual is in such a way developed that revision pages...
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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.
1.7) Type description The type designation is of the following composition. e.g. 912 A 2 ROTAX Description Description Configuration Type: 4-cyl. horizontally opposed, nor- mal aspirated engine Certification: certified to JAR 22 (TC No. EASA.E.121) F, S certified to FAR 33 (TC No.
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1.8) Denomination of cylinders, Engine views, components Lateral view Part Function propeller gear box vacuum pump or hydraulic governor for con- stant speed propeller Fig. 2 00337 Top view Cyl. 1 Cyl. 3 Cyl. 4 Cyl. 2 Part Function engine serial number CD carburetor electric starter expansion tank with excess pressure valve...
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Front view Fig. 4 00336 Effectivity: 912 Serie BRP-Powertrain page 1-13 OM Edition 2 / Rev. 0 April 01/2010...
1.9) Technical data See table Description 912 A/F/UL 912 S/ULS Bore 79.5 mm (3.13 in) 84 mm (3.31 in) Stroke 61 mm (2.40 in) 61 mm (2.40 in) Displacement 1211 cm (73.9 in 1352 cm (82.5 in Compression ratio. 9.0 : 1 11 : 1 1.10) Fuel consumption See table...
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912 F/S FAR 33 (TC No. E00051 EN), JAR-E (TC No. EASA.E.121). This chapter of the Operators Manual contains the operating limits Table of contents that must be observed to ensure the ROTAX aircraft engine and standard systems operate safely. Subject Page...
2.1) Operating limits (912 A/F/UL) Performance data relate to ISA (International Standard At- Performance mosphere) conditions without Governor, external alternator etc. Take-off performance 59.6 kW at 5800 rpm Max. continuous performance 58 kW at 5500 rpm Speed Take-off speed 5800 rpm (max. 5 min) Max.
See also Chapter 2.3). Conventional coolant Coolant temperature: (coolant exit temperature) Max. 120 °C (248 °F) Cylinder head temperature: Max. 150 °C (300 °F) Permanent monitoring of coolant temperature and cylinder head temper- ature is necessary. See also Chapter 2.3). Waterless coolant Cylinder head temperature: Max.
Engine start, ope- rating temperature Max. 50 °C (120 °F) Min. -25 °C (-13 °F) Non-compliance can result in serious injuries Fuel pressure WARNING WARNU or death! Exceeding the max. admissible fuel pressure will override the float valve of the carburetor and to engine failure.
2.2) Operating limits (912 S/ULS) Performance data relate to ISA (International Standard At- Performance mosphere) conditions without Governor, external alternator etc. Take-off performance 73.5 kW at 5800 rpm Max. continuous performance 69 kW at 5500 rpm Speed Take-off speed 5800 rpm (max. 5 min) Max.
See also Chapter 2.3). Conventional coolant Coolant temperature: (coolant exit temperature) Max. 120 °C (248 °F) Cylinder head temperature: Max. 135 °C (275 °F) Permanent monitoring of coolant temperature and cylinder head temper- ature is necessary. Waterless coolant Cylinder head temperature: Max.
Engine start, ope- rating temperature Max. 50 °C (120 °F) Min. -25 °C (-13 °F) Non-compliance can result in serious injuries Fuel pressure WARNU WARNING or death! Exceeding the max. admissible fuel pressure will override the float valve of the carburetor and to engine failure.
2.3) Operating media-Coolant Obey the latest edition of Service Instruction General note NOTICE WARNUNG SI-912-016 for the selection of the correct coolant. Conventional coolant mixed with water has the advantage of a Conventional coolant higher specific thermal capacity than water-less coolant. When correctly applied, there is sufficient protection against vapor Application bubble formation, freezing or thickening of the coolant within the...
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2.4) Operating media-Fuel Obey the latest edition of Service Instruction General note NOTICE WARNUNG SI-912-016 for the selection of the correct fu- Use only fuel suitable for the respective cli- NOTICE WARNUNG matic zone. NOTE: Risk of vapour formation if using winter fuel for summer operation.
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2.5) Operating media-Lubricants Obey the manufacturers instructions about General note NOTICE WARNUNG the lubricants. If the engine is mainly run on AVGAS more frequent oil changes will be required. See Service Information SI-912-016, latest edi- tion. Motorcycle oil of a registered brand with gear additives. Do Oil type not use aircraft engine oil for direct driven engines.
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See Fig. 1 Table of lubricants Since the temperature range of neighboring SAE grades overlap, there is no need for change of oil viscosity at short duration of am- bient temperature fluctuations. Klima Mehrbereichs-Öle °C °F (climatic multi-grade oils conditions) tropisch (tropical) gemäßigt...
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NOTES Effectivity: 912 Serie BRP-Powertrain page 2-12 OM Edition 2 / Rev. 0 April 01/2010...
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3) Standard operation To warrant reliability and efficiency of the engine, meet and care- Introduction fully observe all the operating and maintenance instructions. This chapter of the Operators Manual contains expanded opera- Table of content ting and maintenance instructions. Subject Page Daily checks page 3-2...
3.1) Daily checks To warrant reliability and efficiency of the engine, meet and care- General note fully observe all the operating and maintenance instructions. Risk of burnings and scalds! WARNING WARNU Hot engine parts! Conduct checks on the cold engine only! Non-compliance can result in serious injuries WARNING WARNU...
Coolant level The coolant specifications of the section NOTICE WARNUNG Operating media are to be ob- Chapter 2.3) served! Step Procedure Verify coolant level in the expansion tank, replenish as re- quired up to top. The max. coolant level must be filled up to the top (see Fig.
Check of mechanical components Check of mech. components Step Procedure Turn propeller by hand in direction of engine rotation sever- al times and observe engine for odd noises or excessive resistance and normal compression. At excessive resistance of the engine per- NOTICE WARNUNG form the relevant unscheduled maintenance...
3.2) Before engine start Carry out pre-flight checks. 3.3) Pre-flight checks Non-compliance can result in serious injuries Safety WARNING WARNU or death! Ignition “OFF”. Before moving the propeller. Switch off both ignition circuits and anchor the aircraft. Have the cockpit occupied by a competent person.
The oil specifications of the section Chapter NOTICE WARNUNG Operating media are to be observed! 2.5) Step Procedure Check oil level and replenish as required. NOTE: Propeller shouldn't be turned exces- sively reverse the normal direction of engine rotation. Remove oil tank. Prior to oil check, turn the propeller by hand in direction of engine rotation several times to pump oil from the engine into the oil tank.
3.4) Engine start Non-compliance can result in serious injuries Safety WARNING WARNU or death! Do not take the engine into operation if any person is near the aircraft. Engine start Step Designation Procedure Fuel valve open Starting carb activated Then engine in operating tempera- start the engine without ture...
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Reduction gear with shock absorber To observe! Since the engine comprises a reduction gear NOTICE WARNUNG with shock absorber, take special care of the following: Step Procedure To prevent impact load, start with throttle lever in idle position or at the most up to 10% open. For the same reason, wait for around 3 sec.
3.5) Prior to take-off Non-compliance can result in serious injuries Safety WARNING WARNU or death! Do not take the engine into operation if any person is near the aircraft. Warming up peri- Step Procedure Start warming up period at approx. 2000 rpm for approx. 2 minutes.
3.6) Take-off Non-compliance can result in serious injuries Safety WARNING WARNU or death! Monitor oil temperature, cylinder head temperature and oil pressure. Limits must not be exceeded! See Ope- Chapter 2.1) rating limits. Respect “cold weather operation” recommendations, see Chapter 3.9). Climbing with engine running at take-off performance is permissi- Climb ble (max.
3.9) Cold weather operation Generally, an engine service should be carried out before the start General note of the cold season. For selection of coolant and mixing ratio, see "Coolant", Coolant Chapter 2.3) For selection of oil, see table of Lubricants Lubricant Chapter 2.5) With throttle closed and choke activated (open throttle renders...
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Icing due to water in fuel Icing due to water in fuel Fuels containing alcohol always carry a small NOTICE WARNUNG amount of water in solution. In case of tem- perature changes or increase of alcohol con- tent, water or a mixture of alcohol and water may settle and could cause troubles.
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4) Abnormal operation Non-compliance can result in serious injuries Introduction WARNING WARNU or death! At unusual engine behaviour conduct checks as per Maintenance Manual, Chapter 05-50- 00 before the next flight. NOTE: Further checks - see Maintenance Manual. This chapter of the Operators Manual contains expanded opera- Table of contents ting and maintenance instruction at abnormal operation.
4.1) Start during flight Starting procedure same as on ground, however, on a warm Engine stop engine without choke. 4.2) Exceeding of max. admissible engine speed Reduce engine speed. Any exceeding of the max. admissible Exceeding of max. engine speed engine speed has to be entered by the pilot into the logbook, stating the duration and extend of overspeed.
4.7) Trouble shooting All checks in accordance with the Maintenance Manual (current Introduction issue/revision). Non-compliance can result in serious injuries WARNING WARNU or death! Only qualified staff (authorized by the Aviati- on Authorities) trained on this particular engi- ne, is allowed to carry out maintenance and repair work.
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Engine does not start Starting problems Possible cause Remedy Ignition off. switch on. Closed fuel valve or clogged open valve, clean or renew filter, check filter. fuel system for leaks. No fuel in tank. refuel. Starting speed too low, faulty fit fully charged battery.
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Oil level is increasing Oil level Possible cause Remedy Oil too cold during engine op- cover oil cooler surface, maintain the oil eration. temperature prescribed. Engine hard to start at low temperature Cold engine start Possible cause Remedy Starting speed too low. preheat engine.
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5) Performance data The performance tables and performance graphs on the next few Introduction pages are intended to show you what kind of performance to ex- pect from your engine in terms of power output. The indicated power can be achieved by following the procedures laid out in the Operators Manual and ensuring that the engine is well-maintai- ned.
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Performance data for variable pitch propeller Performance data Engine 912 A/F/UL Engine speed over 5500 rpm is restricted to 5 minutes. Run the engine in accordance with the following table. Engine Perfor- Manifold Torque (Nm) Power setting speed mance pressure (ft.lb) (rpm) (kW)/(HP)
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Performance data variable pitch propeller Performance data Engine 912 A/F/UL The following graph shows the performance drop with increasing flight altitude. The curves show the performance at 5800, 5500, 5000, 4500 and 4000 rpm, at full throttle. The engine allows operation with fully open throttle valve over the whole rpm range, without limitation.
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Performance data for variable pitch propeller Performance data Engine 912 S/ULS Engine speed over 5500 rpm is restricted to 5 minutes. Run the engine in accordance with the following table. Engine Perfor- Manifold Power set- Torque (Nm) speed mance pressure ting (ft.lb) (rpm)
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Performance graph for non-standard conditions Performance graph The following graph shows the performance drop with increasing Engine 912 S/ULS flight altitude. The curves show the performance at 5800, 5500, 5000, 4800 and 4300 rpm, at full throttle. The engine allows operation with fully open throttle valve over the whole rpm range, without limitation.
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NOTES Effectivity: 912 Serie BRP-Powertrain page 5-8 OM Edition 2 / Rev. 0 April 01/2010...
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6) WEIGHTS The stated weights are dry weights (without operating fluids) and Introduction are guide values only. Further weight information relating to the equipment can be found in the current Installation Manual. This chapter of the Operators Manual contains an extensive list of Table of content approved equipment for this engine.
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6.1) Engine with: electric starter, carburetors, internal generator, ignition unit and oil tank without: exhaust system, radiator, airbox Configuration 2 912 UL 912 A 912 F 912 ULS 912 S 57.1 kg (126 lb) 58.3 kg (128 lb) with overload with overload 57.1 kg 57.1 kg...
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7) Description of systems This chapter of the Operator Manual contains the description of Introduction cooling system, fuel system, lubrication system, electric system and the propeller gearbox. As already mentioned in the preface, the system descriptions only Table of content apply to the engine, not to a specific application in a particular air- craft.
7.1) Cooling system of the engine See Fig. 1. General note The cooling system of the ROTAX 912 is designed for liquid coo- Cooling ling of the cylinder heads and ram-air cooling of the cylinders. The cooling system of the cylinder heads is a closed circuit with an ex- pansion tank.
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Cooling system Part Function expansion tank radiator pressure cap overflow bottle Fig. 1 09152 Effectivity: 912 Serie BRP-Powertrain page 7-3 OM Edition 2 / Rev. 0 April 01/2010...
7.2) Fuel system See Fig. 2 General note The fuel flows from the tank (1) via a coarse filter (2) the fire cock Fuel (3) and fine filter (4) to the mechanical fuel pump (5). From the pump fuel passes on via the fuel manifold (6) to the two carbure- tors.
7.3) Lubrication system See Fig. 3 General note The ROTAX 912 engine is provided with a dry sump forced lubri- cation system with a main oil pump with integrated pressure regu- lator (1) and oil pressure sensor (2). The oil pump (3) sucks the motor oil from the oil tank (4) via the oil...
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Oil system Part Function pressure regulator oil pressure sensor oil pump oil tank oil cooler oil filter venting tube oil temperature sensor Fig. 3 08650 Effectivity: 912 Serie BRP-Powertrain page 7-6 OM Edition 2 / Rev. 0 April 01/2010...
7.4) Electric system See Fig. 4 General note The ROTAX 912 engine is equipped with a dual ignition unit of a breakerless, capacitor discharge design, with an integrated gene- rator. The ignition unit needs no external power supply. Two independent charging coils (1) located on the generator sta- Charging coils tor supply one ignition circuit each.
7.5) Propeller gearbox See Fig. 5 General note For the engine type 912 two reduction ratios are available. Reduction ratio Reduction ratio 912 A/F/UL 912 S/ULS crankshaft: propeller shaft 2.27:1 2.43:1 2.43:1 (optional) Depending on engine type, certification and configuration the pro- Overload clutch peller gearbox is supplied with or without an overload clutch.
On the gearbox version with overload clutch the design incorpo- Backlash rates a friction damped free play at the dogs to warrant proper en- gine idling. Due to this backlash at the dogs a distinct torsional impact arises at start, stop and at sudden load changes, but due to the built-in overload clutch it will remain harmless.
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NOTES Effectivity: 912 Serie BRP-Powertrain page 7-10 OM Edition 2 / Rev. 0 April 01/2010...
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8) Checks All checks to be carried out as specified in the current Mainte- Introduction nance Manual (last revision). Non-compliance can result in serious WARNING WARNU injuries or death! Only qualified staff (authorized by the Aviation Authorities) trained on this par- ticular engine, is allowed to carry out maintenance and repair work.
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Due to the special material of the cylinder wall, there is no need for extra protection against corrosion for the ROTAX aircraft engi- nes. At extreme climatic conditions and for long out of service pe-...
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In case of any relevant occurrences that may involve mal- function of the engine, the form on the next page should be filled out and sent to the responsible authorized ROTAX distributor. ®...
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NOTES Effectivity: 912 Serie BRP-Powertrain page 9-2 OM Edition 2 / Rev. 0 April 01/2010...
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9.1) Form Effectivity: 912 Serie BRP-Powertrain page 9-3 OM Edition 2 / Rev. 0 April 01/2010...
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NOTES Effectivity: 912 Serie BRP-Powertrain page 9-4 OM Edition 2 / Rev. 0 April 01/2010...
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9.2) Authorized Distributor See the official ROTAX AIRCRAFT ENGINES Homepage General note ® www.rotax-aircraft-engines.com Overview of authorized distributor for ROTAX aircraft engines. List Subject Page page 9-6 Europe page 9-7 America Australia page 9-7 Africa page 9-7 page 9-8 Asia...
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1) E U R O P E Issue 2010 02 01 CROATIA / FORMER YUGOSLAVIA GREAT BRITAIN / IRELAND / (EXEPT SLOVENIA): ICELAND: ➤SHAFT D.O.O. ➤SKYDRIVE LTD. B.L. Mandica 161 a Burnside, Deppers Bridge HR-54000 OSIJEK SOUTHAM, WARWICKSHIRE CV47 2SU Tel.: +385 (0) 31 /280-046, Tel.: +44 (0) 1926 / 612 188, Fax: +385 (0) 31 /281-602...
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TURKEY: ➤AIR CONSULT Belediyeevler Mah., 368. Sokak,Vilko Sitesi No. 8 01360 Adana, TURKEY Tel.: +90 (0) 322 / 248 0746; Fax: +90 (0) 322 / 248 6927 E-Mail: info@airconsult.com Contact person: Peter Johannes Girmann 2) A M E R I C A NORTH / MIDDLE / SOUTH AMERICA: ➤KODIAK RESEARCH LTD.
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5) A S I A ISRAEL: ➤CONDOR-AVIATION INDUSTRIES LTD. CHINA / HONG KONG / MACAO: P.O. Box 1903, 14 Topaz st. ➤PEIPORT INDUSTRIES LTD. Cesaria 38900 Rm. 1302, Westlands Centre Tel.: +972 (0) 4 / 6265080, 20 Westlands Road, Quarry Bay Fax: +972 (0) 4 / 62650 95 HONG KONG E-mail: condor@netvision.net.il...
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