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OPERATORS
MANUAL
FOR ROTAX ENGINE TYPE 912 SERIES
REF NO.: OM-912 | PART NO.: 8997 00
WARNING
Before starting the engine, read the Operators Manual, as it contains important safety relevant information. Failure to do so may result in personal injuries including death. Consult the original equipment manufacturers handbook for additional instructions!
These technical data and the information embodied therein are the property of
BRPRotax GmbH & CO KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior written permission of BRPRotax 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.
ROTAX
®
is a trade mark of BRPRotax GmbH & Co KG. In the following document the short form of BRPRotax GmbH & Co KG = BRPRotax 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.
Copyright 202 3 © - all rights reserved.
Translation into other languages might be performed in the course of language localization but does not lie within ROTAX® scope of responsibility.
In any case the original text in English language and the metric units are authoritative.
Table of Content
5 – Performance and Fuel consumption
Effectivity: 912 Series
Rev. 1
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BRP-Rotax Effectivity: 912 Series
INTRO) Introduction
Topics in this chapter
Foreword
Document structure
BRP-Rotax GmbH & Co KG (hereinafter “BRP-Rotax”) provides
“Instructions for Continued Airworthiness”, which are based on the design, tests and certification of the engine and its components. These instructions apply only to engines and components supplied by BRP-Rotax.
Before operating the engine, read this Operators Manual (OM) carefully. If any passages of the Manual are not clearly understood or in case of any questions, please contact our
ROTAX® Authorized Distributors or their independent Service
Centers.
This Operators Manual (OM) contains important information about safe operation of the engine together with descriptions of the systems, technical data, operating media and the operational limits of the engine.
The specified information and procedures apply only to the engine and not to specific applications in particular aircraft. The aircraft manufacturers Operators Manual is therefore definitive in terms of the operation of the engine, as it contains all of the aircraft-specific instructions
BRP-Rotax wishes you much pleasure and satisfaction flying your aircraft powered by this ROTAX® aircraft engine.
The structure of the Manual follows whenever it is possible the structure of the “GAMA Specification #1 for Pilot’s Operating
Handbook“.
Effectivity: 912 Series
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BRP-Rotax Effectivity: 912 Series
LEP) LIST OF EFFECTIVE PAGES
Each new revision to the Operators Manual will have a new List of Effective Pages.
1
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BRP-Rotax Effectivity: 912 Series
Rev. 1
TOA) Table of amendments
Approval*
The technical content of this document is approved under the authority of the DOA ref.
EASA.21J.048.
Edition 4/Rev. 0
Revision 1
November 01
2016
January 01 2023
Obsolete with Revision 1, which is a complete re-revision.
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chapter
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Rev. 1
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Ed.4/January 01 2023
Summary of amendments
1
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Summary of the relevant amendments in this context, but without any claim to completeness.
current no.
chapter page comments
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BRP-Rotax Effectivity: 912 Series
Rev. 1
1) General note
Topics in this chapter
1.5 Technical documentation...................................................................... 13
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
1.1) General
Purpose
Engine serial number
The purpose of this Operators Manual (OM) is to familiarize the aircraft manufacturers installing this aircraft engine with operating instructions and safety information.
This document is not intended for use by end customers (private aircraft owners, flight schools...) for operating the engine.
Due to various executions of engine installations, only the aircraft manufacturer is able to provide end customers with operation and safety information tailored for a specific aircraft.
Nevertheless, all provided information in this Operators Manual
(OM) (such as operating limits, safety information, operation instructions...) must be adhered to. The aircraft manufacturer is obliged to forward this information to the end customer in an appropriate way (e.g. within the aircraft specific Operators
Manual (OM)).
For detailed information related to aircraft and aircraft/engine installation, maintenance, safety or flight operation, consult the documentation provided by the aircraft manufacturer and/or its dealer. For additional information on engines, their maintenance or parts, you can also contact your nearest ROTAX® authorized aircraft engines distributor or their independent Service Center.
When making inquiries or ordering parts, always indicate the engine serial number. Due to continuous product improvement, engines of the same engine type might require different support and spare parts. The engine serial number is located on the top of the crankcase, magneto side.
Cyl.1 Cyl.3
PTO MAG
1
Cyl.2 Cyl.4
Figure 1: Pos. 1: Engine serial number
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
1.2) Abbreviations and terms (depending on respective engine type)
°C
°F rpm
A
AAPTS
AC
AD
Ah
A/C
AC-DC
AR assy.
ASB
ACG
ACL
API
ASTM
ATA
AWG
CAN
CCS
Coil 1–4
CPS 1+2
Abbreviations
*
@
Description
Reference to another section center of gravity
The drop symbol indicates use of sealing agents, adhesives or lubricants (only in the Maintenance Manual Heavy)
Degrees Celsius (Centigrade)
Degrees Fahrenheit
Revolutions per minute
Ampere
Ambient Air Pressure Temperature Sensor alternating current
Airworthiness Directives
Ampere hour
Aircraft
EMS Modul voltage converter as required assembly
Alert Service Bulletin
Austro Control GmbH
Anti Collision Light
American Petrol Institute
American Society for Testing and Materials
Air Transport Association
American Wire Gauge
Controller Area Network
Camshaft position sensor
Ignition coils 1–4
Crankshaft Position Sensor 1+2
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Ed.4/January 01 2023
EMC
EN
ETFE
FAA
FAR
FOD
FL
Fuse box
Abbreviations
CSA
DOT
EASA
IM
ECU
EGT
CTS
CW
CCW
CGSB
DCDI
DC
DOA
INTRO
EMS
EMS GND
Description hr.
HIC A
HIC B
IAT
Constant Speed Actuator
Cooling Temperature Sensor clockwise counter-clockwise
Canadian General Standards Board
Dual Capacitor Discharge Ignition direct current
Design Organisation Approval
Department of Transport
European Aviation Safety Agency
Installation Manual
Engine Control Unit
Exhaust Gas Temperature
Introduction
Engine Management System
Engine system internal ground reference which is intended to be disconnected from aircraft common ground during flight
Electromagnetic compatibility
European Standard
Ethylene Tetrafluoroethylene
Federal Aviation Administration
Federal Aviation Regulations
Foreign object damage
Flight Level
Power conditioning and distribution for the Engine
Management System hours
Harness Interface Connector A
Harness Interface Connector B
Indicated Air Temperature
BRP-Rotax Effectivity: 912 Series
Rev. 1
Effectivity: 912 Series
Rev. 1
Abbreviations
ICA
IFR
IFSD
INJ 1–8
IPC ips iRMT
ISA kg
KNOCK
Lane A
Lane B
LOPC
Description
Instructions for Continued Airworthiness
Instrument Flight Rules
In-flight-shutdown
Injector 1–8
Illustrated Parts Catalog inch per second independent ROTAX Maintenance Technician
International Standard Atmosphere
Kilograms
Knock sensor
System A of Engine Management System
System B of Engine Management System
Loss of power control
MAPS 1 &
2
Manifold Air Pressure Sensor 1 & 2
MATS 1 & 2 Manifold Air Temperature Sensor 1 & 2
MON
MAG
Motor Octane Number
Magneto Side
N n.a.
NDT
NEW
Newton not available
Non Destructive Testing
Nm
NVFR
OAT
Part must be replaced against NEW (mentioned in figures)
Newtonmeter
Night Visual Flight Rules
Outside Air Temperature
OHM
OHV
OM
OPS
Overhaul Manual
Over Head Valve
Operators Manual
Oil Pressure Sensor
BRP-Rotax
Ed.4/January 01 2023
Ed.4/January 01 2023
Abbreviations
OTS
PCD
PCV
PMA
POA
PS
PTFE
PTO
Rev.
ROTAX®
RON
RON 424 s.v.
STP
SL
SMD
TBO
TC part no.
TOA
TOC
TPS
TSN
S/N
SAE
SEP
SB
SI
SI-PAC
SPST
Description
Oil Temperature Sensor
Pitch Circle Diameters
Pressure Control Valve
Permanent magnet alternator
Production Organization Approval
Power supply
Polytetrafluoroethylene (Teflon)
Power Take Off
Revision is a trademark of BRP-Rotax GmbH & Co KG
Research Octane Number
ROTAX® Standard 424 still valid (only Illustrated Parts Catalog)
Serial Number
Society of Automotive Engineers
Single Engine Piston
Service Bulletin
Service Instruction
Service Instruction Parts and Accessories
Single pole single throw
Shielded twisted pair wire
Service Letter
Surface Mounted Devices
Time Between Overhaul
Type certificate part number
Table Of Amendments
Table Of Contents
Throttle Position Sensor
Time Since New
BRP-Rotax Effectivity: 912 Series
Rev. 1
LEP
MM
MEP
X3
Abbreviations
TSNP
TSO
V
VFR
XXXX
Description
Time Since New Part
Time Since Overhaul
Volt
Visual Flight Rules
List of Effective Pages
Maintenance Manual
Multi Engine Piston
Connector on Engine Management System wiring harness which serves as an interface for power supply shows the component serial number
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
1.3) Safety
Revisions
Measurement
Symbols used
Although reading such information does not eliminate any hazards, it promotes understanding, and applying the information will promote correct use of the engine. Always apply common workshop safety rules.
The information and descriptions of components and systems contained in this Manual are correct at the time of publication.
BRP-Rotax maintains a policy of continuous improvement of its products without imposing upon itself any obligation to retrofit products previously manufactured.
BRP-Rotax reserves the right to remove, replace or discontinue any design, specification, feature or other at any time, and without incurring obligation.
Specifications are given in the SI metric system with the imperial and US customary measurement system equivalents in parenthesis.
This Manual uses the following symbols to emphasize particular information. This information is important and must be observed.
m WARNING
Identifies an instruction which, if not followed, may cause serious injury or even fatal injury.
m CAUTION
Identifies an instruction which, if not followed, may cause minor or moderate injury.
NOTICE
Identifies an instruction which, if not followed, may severely damage the engine or could void any warranty.
NOTE
Indicates supplementary information which may be needed to fully complete or understand an instruction.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
ENVIRONMENTAL NOTE
Environmental notes give you tips on environmental protection.
A revision bar outside the page margin indicates a change to text or graphic.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
1.4) Safety information
Use for intended purpose m WARNING
Non-compliance can result in serious injuries or death!
Never fly the aircraft equipped with this engine at locations, air speeds, altitudes or in other situations which do not allow a successful no-power landing after sudden engine stoppage.
• This engine is not suitable for acrobatics (inverted flight, etc.). Flight attitudes outside the permissible limits are not allowed.
• This engine has exclusively been developed and tested for gyrocopter, pusher and tractor applications. In case of any other usage, the OEM is responsible for testing and the correct function of the engine.
• It should be clearly understood that the choice, selection and use of this particular engine on any aircraft is at the sole discretion and responsibility of the aircraft manufacturer, assembler and owner/user.
• Due to the varying designs, equipment and types of aircraft,
BRP-Rotax grants no warranty on the suitability of its engine’s use on any particular aircraft. Further, BRP-Rotax grants no warranty on this engine’s suitability with any other part, components or system which may be selected by the aircraft manufacturer, assembler or user for aircraft application.
m WARNING
Non-compliance can result in serious injuries or death!
For each use of DAY VFR, NIGHT VFR or IFR in an aircraft the applicable legal requirements and other existing regulations must be adhered to.
Ed.4/January 01 2023
• 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 required.
• 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 compliance with the maintenance and operation and any additional information which may be given to you by your dealer.
BRP-Rotax Effectivity: 912 Series
Rev. 1
Training
Regulations
Instrumentation
Engine log book
Maintenance
(iRMT)
Engine operation
• Whether you are a qualified pilot or a novice, complete knowledge of the aircraft, its controls and operation is mandatory before a solo flight. Flying any type 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 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.
• Engine-specific training courses are provided by the authorized distributors according to manufacturer specifications
(iRMT).
• Respect all legal requirements or local rules pertaining to flight operation in your flying area. Only fly when and where conditions, topography, and airspeeds are safest.
• Consult your aircraft dealer or manufacturer and obtain the necessary information, especially before flying in new areas.
• Select and use proper aircraft instrumentation. This instrumentation is not included in the ROTAX® engine package.
Verification to the latest regulations such as FAR or EASA has to be conducted by the aircraft manufacturer.
• 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.
• Since special training, tools and equipment are required, engine servicing shall only be performed by an authorized
ROTAX® aircraft engine distributor or their independent service center. BRP-Rotax requires that any service or maintenance work be carried out and verified by a technician that has a current iRMT rating.
• When the engine will not be operated for a longer period protect the engine and fuel system from contamination and environmental exposure.
• Never operate the engine without sufficient quantities of operating 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.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
Vacuum pump
• To eliminate the risk of injury or damage, ensure any loose equipment or tools are properly secured before starting the engine.
• Allow the engine to cool at idle for several minutes before turning off the engine.
• 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.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
1.5) Technical documentation
These documents form the instructions ensuring continued airworthiness of ROTAX® aircraft engines.
The information contained herein is based on data and experience that are considered applicable for authorized mechanics
(iRMT, see Maintenance Manual Line (MML)) under normal conditions.
Due to the fast technical progress and fulfillment of particular specifications of the customers it may occur that existing laws, safety prescriptions, constructional and operational regulations may not be sufficient or cannot be transferred completely to the object bought, in particular for special constructions.
Documentation
Status
Replacement pages
Reference
• Installation Manual
• Operators Manual
• Maintenance Manual (Line and Heavy
Maintenance)
• Overhaul Manual
• Illustrated Parts Catalog
• Alert Service Bulletins
• Service Bulletins
• Service Instructions
• Service Instruction–Parts and Accessories
• Service Letters
The status of Manuals can be determined by checking the table of amendments. The first column of this table indicates the revision status which should be compared with the revision provided on the ROTAX®-Website: www.FLYROTAX.com
Amendments and current versions can be downloaded free of change.
Furthermore the Manual is constructed in such a way that single pages can be replaced instead of the complete document. The list of effective pages is given in the chapter LEP. The particular edition and revision number is given on the footer of each page.
Any reference to a document refers to the latest edition issued by BRP-Rotax if not stated otherwise.
This symbol informs you of additional references (data sheets, Manuals, etc.) associated with the given subject.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
Illustrations The illustrations in this Manual are merely sketches and show typical arrangements. They may not represent full detail or the exact shape of the parts but should outline the same or similar function. Therefore deriving dimensions or other details from illustrations is not permitted.
TYPICAL indicates a general view which may not represent exact details..
NOTE
The Illustrations in this Manual are stored in a graphic data base system and are provided with a consecutive irrelevant number.
This number (e.g. AE 5iS001) is of no significance for the content.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
1.6) Type description (912 Series)
The type description consists of the following: e.g.
ROTAX
912 A 2 -01
Designation
Options type certification configuration Suffix
Designation
Type 912
Description
4 –cyl. horizontally opposed, normal aspirated engine
Certified to JAR 22 (TC No. EASA.E.121) Certification
A
F, S Certified to FAR 33 (TC No. E00051 EN) JAR-E
(TC No. EASA.E.121)
Non-certified aircraft engines
Configuration
UL,
ULS
2
3
Prop shaft with flange for fixed pitch propeller.
Suffix –XX
Prop shaft with flange for constant speed propeller and drive for hydraulic governor for constant speed propeller.
Explanation of the type designation suffix, see
SB-912-068
Available options (optional equipment) for the engine type mentioned above: external alternator yes vacuum pump yes drive for rev counter/ hour meter yes governor no for configuration 2 for configuration 3 yes no yes yes
NOTE
Conversion of the configuration 2 to configuration 3 may be accomplished by ROTAX® authorized aircraft engines distributors or their Independent service centers.
Effectivity: 912 Series
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BRP-Rotax Effectivity: 912 Series
2) Operating instructions
Topics in this chapter
2.5 Operating media-Lubricants.................................................................. 11
Introduction
The data of the certified engine are based on the type certificate of type 912 A JAR 22 (TC No. EASA.E.121), 912 F/S
FAR 33 (TC No. E00051 EN), JAR-E (TC No. EASA.E. 121).
The operating limits for certified engines are also given in the type certificate for the relevant engine type.
This chapter of the Operators Manual (OM) contains the operating limits that must be observed and adhered to while operating this type of engine.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
2.1) Operating limits (912 A/F/UL)
Performance Performance data relate to ISA ( I nternational S tandard A tmosphere) conditions without Governor, external alternator etc.
Take-off performance
Max. continuous performance
59.6 kW at 5800 rpm
58 kW at 5500 rpm
Speed
Acceleration
Take-off speed
Max. continuous speed
Idle speed
Speed
5800 rpm (max. 5 min.)
5500 rpm min. 1400 rpm
Limit of engine operation at zero gravity and in negative “g“ condition.
Max: 5 seconds at max. -0.5g.
Oil pressure
Max.
Min.
Normal
Oil pressure
7 bar (102 psi)
0.8 bar (11.6 psi) (below 3500 rpm)
1.5 bar (22 psi) 1
2.0 to 5.0 bar (29–72.5 psi) (above 3500 rpm)
1.5 to 5.0 bar (22 psi-72.5 psi) 1
NOTICE
Oil pressure max. for a short period admissible at cold start.
Oil temperature
Oil temperature
Max.
Min.
140 °C (285 °F)
50 °C (122 °F) normal operating temperature approx. 90 to 110 °C (190-230 °F)
1.
912 UL to S/N 4 402 387/912 A to S/N 4 410 266 /912 F to S/N 4 412 764
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
EGT
Conventional coolant
Waterless coolant
Conventional coolant
Max.
Exhaust gas temperature
880 °C (1616 °F)
Applicable for engine S/N without Suffix -01.
Max.
Coolant temperature: (coolant exit temperature)
120 °C (248 °F)
Cylinder head temperature:
150 °C (302 °F) Max.
Permanent monitoring of coolant temperature and cylinder head temperature is necessary.
Cylinder head temperature:
150 °C (302 °F) Max.
Permanent monitoring of cylinder head temperature is necessary.
Applicable for engine S/N with Suffix -01.
Coolant temperature limit measured in the cylinder head
Max. 120 °C (248 °F)
Engine type
912 A/F/UL
Permanent monitoring of coolant temperature is necessary.
Engine start, operating temperature
Max.
Min.
50 °C (122 °F) (ambient temperature)
-25 °C (-13 °F) (oil temperature)
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
Fuel pressure m WARNING
Non-compliance can result in serious injuries or death!
Fuel pressure in excess of stated limit can lead to an override of the float valve with subsequent engine stop.
The aircraft engine manufacturer strongly recommends the installation of an additional pump, unless this has not been covered by legal obligations so far.
Max.
Min.
Fuel pressure
0.4 bar (5.8 psi)
(0.5 bar (7.26 psi)) 2
0.15 bar (2.2 psi)
NOTE
Low fuel pressure indications are possible and allowed. But the pressure must stabilize to the operating limit within 10 seconds.
If not, the cause should be determined and rectified. Due to the technical design and installation conditions (construction of the return line, etc.) pressure fluctuations, at the fuel pump are possible. These pressure fluctuations within the specified operating limits are not considered a problem.
Propeller governor
Power consumption of the hydraulic propeller governor:
Max.
600 W
Vacuum pump
External alternator
Max.
Power consumption of the vacuum pump:
300 W
Max.
Power consumption of the external alternator:
1200 W
2.
applicable only for fuel pump from S/N 11.0036
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Bank angle
Max.
Deviation from bank angle:
40°
NOTE
Up to this value the dry sump lubrication system warrants lubrication in every flight situation.
2.2) Operating limits (912 S/ULS)
Performance Performance data relate to ISA ( I nternational S tandard A tmosphere) conditions without Governor, external alternator etc.
73.5 kW at 5800 rpm Take-off performance
Max. continuous performance
69 kW at 5500 rpm
Speed
Acceleration
Take-off speed
Max. continuous speed
Idle speed
Speed
5800 rpm (max. 5 min.)
5500 rpm min. 1400 rpm
Limit of engine operation at zero gravity and in negative
„g“ condition.
Max. 5 seconds at max. -0.5 g
Oil pressure
Max.
Min.
Normal
Oil pressure
7 bar (101.5 psi)
0.8 bar (11.6 psi) (below 3500 rpm)
2.0 to 5.0 bar (29-72.5 psi) (above 3500 rpm)
NOTICE
Oil pressure max. for a short period admissible at cold start.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
Oil temperature
Max.
Min.
Oil temperature
130 °C (266 °F)
50 °C (122 °F) normal operating temperature: approx. 90 to 110 °C (190-230 °F)
EGT
Conventional coolant
Waterless coolant
Conventional coolant
Max.
Exhaust gas temperature
880 °C (1616 °F)
See also
.
Applicable for engine S/N without Suffix -01.
Max.
Coolant temperature: (coolant exit temperature)
120 °C (248 °F)
Cylinder head temperature
135 °C (275 °F) Max.
Permanent monitoring of coolant temperature and cylinder head temperature is necessary.
Cylinder head temperature
Max.
135 °C (275 °F)
Permanent monitoring of cylinder head temperature is necessary.
Applicable for engine S/N with Suffix -01.
Coolant temperature limit measured in cylinder head
Engine type
Max. 120 °C (248 °F) 912 S/ULS
Permanent monitoring of coolant temperature is necessary.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Engine start, operating temperature
Max.
Min.
50 °C (122 °F) (ambient temperature)
-25 °C (-13 °F) (Oil temperature)
Fuel pressure
Propeller governor
Vacuum pump m WARNING
Non-compliance can result in serious injuries or death!
Exceeding the max admissible fuel pressure will override the float valve of the carburetor and lead to engine stoppage.
The aircraft engine manufacturer strongly recommends the installation of an additional pump, unless this has not been covered by legal obligations so far.
Max.
Min.
Fuel pressure
0.4 bar (5.8 psi)
(0.5 bar (7.26 psi)) 3
0.15 bar (2.2 psi)
NOTE
Low fuel pressure indications are possible and allowed. But the pressure must stabilize to the operating limit within 10 seconds.
If not, the cause should be determined and rectified. Due to the technical design and installation conditions (construction of the return line, etc.) pressure fluctuations, at the fuel pump are possible. These pressure fluctuations within the specified operating limits are not considered a problem.
Power consumption of the hydraulic propeller governor:
Max.
600 W
Max.
Power consumption of the vacuum pump:
300 W
3.
applicable only for fuel pump from S/N 11.0036
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
External alternator
Bank angle
Max.
Power consumption of the external alternator:
1200 W
Deviation from bank angle:
40° Max.
NOTE
Up to this value the dry sump lubrication system warrants lubrication in every flight situation.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
2.3) Operating media-Coolant
Conventional coolant
Application
NOTICE
Obey the latest edition of Service Instruction SI-912-016, for the selection of the correct operating media.
Conventional coolant mixed with water has the advantage of a higher specific thermal capacity than water-less coolant.
When correctly applied, there is sufficient protection against vapor bubble formation, freezing or thickening of the coolant within the operating limits.
Use the coolant specified in the manufacturer’s documentation.
Mixture
NOTICE
Obey the operating media manufacturer's instructions!
Applicable for engine S/N without Suffix -01.
Designation conventional e.g. BASF
Glysantine anticorrosion waterless e.g. Aero Cool
180°
50*
Mixture ratio %
Concentrate Water
50
100 0
* coolant component can be increased up to max. 65 %.
Applicable for engine S/N with Suffix -01.
Designation conventional e.g. BASF
Glysantine anticorrosion
50*
Mixture ratio %
Concentrate Water
50
* coolant component can be increased up to max. 65 %.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
2.4) Operating media – Fuel
NOTICE
Obey the latest edition of Service Instruction SI-912-016, for the selection of the correct operating media.
Antiknock properties
NOTICE
Use only fuel suitable for the respective climatic zone.
NOTE
Risk of vapour formation if using winter fuel for summer operation.
The fuels with following specifications can be used.
Anti knock properties
Usage/Description
912 A/F/UL
Min. RON 90
(min. AKI 4 87)
912 S/ULS
Min. RON 95
(min. AKI 4 91)
NOTE
For fuels according to ASTM D4814 specifications following
AKI (Anti Knock Index) value has to be observed: e.g. min. AKI
91.
MOGAS
AVGAS
MOGAS
European standard
Usage/Description
912 A/F/UL
EN 228 normal
EN 228 super
EN 228 super plus
912 S/ULS
EN 228 super
EN 228 super plus
AVGAS 100LL places greater stress on the valve seats due to its high lead content and forms increased deposits in the combustion chamber and lead sediments in the oil system.
4.
Anti Knock Index (RON+MON)/2
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
AVGAS
Aviation Standard
Usage/Description
912 A/F/UL
AVGAS 100 LL
(ASTM D910)
912 S/ULS
AVGAS 100 LL
(ASTM D910)
2.5) Operating media-Lubricants
NOTICE
Obey the manufacturer’s instructions about the lubricants.
If the engine is mainly run on AVGAS more frequent oil changes will be required. See Service Information SI-912–016, latest edition.
Oil type
Oil consumption
Oil specification
Oil viscosity
At the selection of suitable lubricants refer to the additional information in the Service Information SI-912-016, latest edition.
Max. 0.06 l/h (0.13 liq pt/h)
• Use only oil with RON 424 classification
NOTE
The ROTAX® Norm 424 (RON 424) is a BRP-Rotax internal standard, which is only available on special request via the
ROTAX® authorized distributor and will not be disclosed to third parties without prior consent.
• Due to the high stresses in the reduction gears, oils with gear additives such as high performance motor cycle oils are required.
• Because of the incorporated overload clutch, oils with friction modifier additives are unsuitable as this could result in clutch slippage during normal operation.
• Heavy duty 4-stroke motor cycle oils meet most of the requirements. These oils are normally not mineral oils but semior full synthetic oils.
• Oils primarily for Diesel engines have insufficient high temperature properties and additives which favour clutch slipping, and are generally unsuitable.
Use of multi-grade oils is recommended.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
Table of lubrication
NOTE
Multi-viscosity grade oils are less sensitive to temperature variations than single grade oils.
They are suitable for use throughout the seasons, ensure rapid lubrication of all engine components at cold start and get less fluid at higher temperatures.
Since the temperature range of neighboring SAE grades overlap, there is no need for change of oil viscosity at short duration of ambient temperature fluctuations.
Figure 1: Temperature range
AE 2_0064
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
3) Abnormal operation
Topics in this chapter
3.2 Exceeding max. admissible engine speed ................................................. 3
3.3.4 Exceeding of max. admissible oil temperature ............................................. 4
3.4.1 Oil pressure below minimum - on ground ................................................... 5
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
Introduction m WARNING
Non-compliance can result in serious injuries or death!
Unless stated otherwise in this chapter, operating an engine with limited airworthiness is not permitted. At unusual engine behavior conduct checks as per Maintenance Manual Line (MML) Chapter 05-
50-00 before the next flight. Only qualified staff (authorized by the
Aviation Authorities) trained on this particular engine, is allowed to carry out maintenance and repair work.
The following description of procedures depends on the respective type of installation in the aircraft and shall therefore only be seen functionally.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
3.1) Re-Start during flight
If the propeller continues to rotate during flight by windmilling, but the speed is not sufficient to start the engine, the electric starter can be used. It is not required to wait until the propeller stops rotating.
3.2) Exceeding max. admissible engine speed
Exceeding engine speed
Reduce the engine speed. Any exceeding of the max. admissible engine speed must be entered by the pilot into logbook, stating the exact time and duration of engine over speed.
• A maintenance inspection should be carried out
3.3) Temperature
NOTICE
Reduce engine power setting to the minimum necessary and carry out precautionary landing.
3.3.1) Exceeding of max. admissible cooling system temperature
NOTICE
Reduce engine power setting to the minimum necessary and carry out precautionary landing.
3.3.2) Exceeding of max. admissible cyl. head temperature
Cylinder head temperature max.
NOTICE
Reduce engine power setting to the minimum necessary and carry out precautionary landing.
Applicable for engine S/N without Suffix -01.
• Any exceeding of the max. admissible cylinder head temperature must be entered by the pilot into the logbook, stating duration and extent of over-temperature condition.
• Carry out an unscheduled maintenance check according to
Maintenance Manual Line (MML) chapter 05-50-00.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
3.3.3) Exceeding of max. admissible coolant temperature
NOTICE
Reduce engine power setting to the minimum necessary and carry out precautionary landing.
Coolant temperature max.
Applicable for engine S/N with Suffix -01.
• Any exceeding of the max. admissible coolant temperature must be entered by the pilot into the logbook, stating duration and extent of over-temperature condition.
• Carry out an unscheduled maintenance check according to
Maintenance Manual Line (MML) chapter 05-50-00.
3.3.4) Exceeding of max. admissible oil temperature
Exceeding oil temperature
3.4) Oil pressure
NOTICE
Reduce engine power setting to the minimum necessary and carry out precautionary landing.
• Any exceeding of the max. oil temperature must be entered by the pilot in the logbook, stating duration and extent of over-temperature condition.
• A maintenance inspection should be carried out.
Oil pressure
NOTICE
Reduce engine power setting to the minimum necessary and carry out precautionary landing.
Oil pressure below minimum - during flight
• Check oil system.
• A maintenance inspection should be carried out.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
3.4.1) Oil pressure below minimum - on ground
Oil pressure too low
Immediately stop the engine and check for reason. Check oil system.
• Check oil quantity in oil tank.
• Check oil quality. See Chapter: Operating media-Lubricants.
• A maintenance inspection should be carried out.
3.4.2) Oil pressure above permitted range at low ambient temperatures
NOTICE
Reduce engine power setting to the minimum necessary and carry out precautionary landing.
Oil pressure too high
• Reduce engine speed and check the oil pressure again once it has reached a higher oil temperature
• A maintenance inspection should be carried out
3.5) Engine on fire or fire in the engine compartment
NOTICE
Carry out emergency procedures as prescribed in the flight manual of the aircraft manufacturer.
• After landing locate the cause of fire and resolve the error before next flight by qualified staff (authorized by the Aviation
Authorities)
• An entry in the logbook must be made
• A maintenance inspection should be carried out
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
3.6) Troubleshooting
m WARNING
Non-compliance can result in serious injuries or death!
Only qualified staff (authorized by the Aviation Authorities) trained on this particular engine, is allowed to carry out maintenance and repair work.
Starting problems
Engine run
NOTICE
If the following hints regarding remedy do not solve the problem, contact an authorized distributor. The engine must not be operated until the problem is rectified.
All checks in accordance with the Maintenance Manual , current issue.
Engine does not start
Possible cause
Ignition OFF
Closed fuel valve or clogged filter.
No fuel in tank.
Starting speed too low, faulty or discharged battery.
Starting speed too low, start problems on cold engine.
Wrong fuel (Jetfuel or
Diesel).
Remedy
Switch ON
Open valve, clean or renew filter, check fuel system for leaks.
Refuel.
Fit fully charged battery.
Use top quality, low friction oil; allow for sufficient cooling period to counter for performance drop on hot starter; preheat engine.
Change of fuel.
Engine keeps running while ignition switch is turned off
Possible cause
Overheating of engine.
Remedy
Let engine cool down at idling at approx. 2000 rpm.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Oil pressure
Oil level
Knocking under load
Possible cause
Octane rating of fuel too low.
Remedy
Use fuel with higher octane rating.
Engine idles rough after warm-up period, smoky exhaust emission.
Possible cause
Starting carb (Choke) activated.
Remedy
Close starting carb (Choke).
Low oil pressure
Possible cause
Not enough oil in oil tank.
Oil too hot.
High oil pressure
Possible cause
Oil too cold.
Wrong viscosity of oil.
Remedy
Refill oil.
Cool down oil.
Remedy
Cover oil cooler or install thermostat.
Change oil to lower viscosity.
Oil level is increasing
Possible cause
Oil too cold during engine operation.
Contamination with diesel fuel.
Remedy
Cover oil cooler surface, maintain the oil temperature prescribed.
Check fuel for diesel contamination and purge entire fuel system if diesel is found.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
Cold engine start Engine hard to start at low temperature
Possible cause Remedy
Starting speed too low.
Preheat engine.
Faulty or discharged battery.
Fit fully charged battery.
High oil pressure.
Oil pressure too low after cold start.
At cold start an oil pressure reading of up to around 7 bar (101.5 psi) does not indicate a malfunction.
Too much resistance in the oil suction system at low temperatures due to cold oil. Stop engine and preheat oil. After a cold start the oil tank must be observed and the oil pressure should be above 1.5 bar (22 psi).
Otherwise, the speed must be lowered again, because not enough cold oil can be sucked. If oil pressure is reading lower than 1 bar (15 psi) oils with lower viscosity are to be used.
See SI-912-001, current issue.
NOTE
Oil pressure must be measured at idle at an oil temperature of minimum 50 °C (122 °F). Be sure the oil pressure does not go below minimum at idle.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
4) Standard operation
Topics in this chapter
Introduction To warrant reliability and efficiency of the engine, meet and carefully observe all the operating and maintenance instructions.
The following description of procedures depends on the respective type of installation in the aircraft and shall therefore only be seen functionally.
NOTE
The control elements mentioned in this chapter are only symbolic and should support the understanding of the procedures. The execution of control elements is in the responsibility of the aircraft manufacturer.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
4.1) Daily checks
Safety To warrant reliability and efficiency of the engine, meet and carefully observe all the operating and maintenance instructions.
m WARNING
Risk of burns and scalds! Hot engine parts!
Conduct checks on cold engine only!
m WARNING
Non-compliance can result in serious injuries or death!
Ignition “OFF” Before moving the propeller switch off both ignition circuit and secure the aircraft. Have the cockpit occupied by a competent person.
NOTICE
If established abnormalities (e.g. excessive resistance of the engine, noise etc.) inspection in accordance with the relevant
Maintenance Manual is necessary. Do not release the engine into service before rectification.
Coolant level
NOTICE
Operating media must be observed.
Inappropriate coolant quantity can lead to serious engine damage.
The specifications given in
must be adhered to when refilling coolant.
Step
1
2
Procedure
Verify coolant level in the expansion tank , replenish as required up to top. The max. coolant level must be flush with the bottom of the filler neck.
Verify coolant level in the overflow bottle , replenish as required. The coolant level must be between max. and min. mark.
ENVIRONMENTAL NOTE
Protect the environment!
Do not harm the environment by spilling coolant. Dispose coolant in an environmentally friendly manner.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Expansion tank 1
2
Overflow bottle
Figure 1: Expansion tank
1 Radiator cap 2 Expansion tank
1
08523
coolant
2
Figure 2: Overflow bottle
1 Overflow bottle 2 Coolant
AE 5iS_0139
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
Mech./electronic components
Gearbox
Check of mechanical/electronic components.
Step
1
2
3
4
Procedure
Turn propeller slowly by hand in direction of engine rotation several times and observe engine for odd noises or excessive resistance and normal compression.
Verify free movement of throttle valve and the complete range.
Inspect for damages, leakage and general condition of exhaust system.
Visual inspection for mechanical and thermal damages of sensor, actuators and the wiring harness.
Version without overload clutch:
No further checks are necessary.
Version with overload clutch:
Step
1
Procedure
Turn the propeller by hand back and forth, feeling the free rotation of 30° before the crankshaft starts to rotate.
If propeller can be turned between the dogs with little force (lower than 25 Nm (19 ft.lb)), further inspection is required.
Carburetor
Step
1
Procedure
Verify free movement of throttle cable and starting carburetor over the complete range. Check from the cockpit.
Exhaust system
Step
1
Procedure
Inspect for damages, leakage and general condition.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
4.2) Before engine start
Carry out pre-flight checks.
4.3) Pre-flight checks
Safety m WARNING
Risk of burns and scalds! Hot engine parts!
Conduct checks on cold engine only!
Operating media
Step
1
Procedure
Check for any oil-, coolant- and fuel leaks. If leaks are evident, rectify and repair them before next flight.
Oil level
NOTICE
Operating media must be observed.
Inappropriate oil quantity can lead to serious engine damage.
The specifications given in
must be adhered to when refilling oil.
Step
1
Procedure
2
3
NOTE
Propeller shouldn't be turned in reverse of the normal direction of engine rotation.
Remove bayonet cap from the oil tank, turn the propeller slowly by hand in direction of engine rotation several times to pump residual oil from the engine into the oil tank.
It is essential to build up compression in the combustion chamber. Maintain the pressure for a few seconds to let the gas flow via the piston rings into the crankcase. The speed of rotation is not important but rather the continuous pressure and the amount of gas which is transferred into the crankcase.
This process is finished when air is returning back to the oil tank and can be noticed by an audible gurgle from the open oil tank.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
4.4) Engine start
Step
4
5
Procedure
Check oil level and add oil if necessary.
The oil level should be in the upper half (between the
“50%“ and the “max“ mark) and should never falls below the “min.“ mark of the oil dipstick. Prior to long flights oil should be added so that the oil level reaches the “max“ mark.
Avoid oil levels exceeding the “max“ mark, since excess oil could be poured out through the venting system.
Difference between max.- and min.- mark = 0.45 litre
(0.95 liq pt). Oil consumption max 0.06 l/h (0.13 liq pt/h).
Re-install bayonet cap.
ENVIRONMENTAL NOTE
Protect the environment.
Do not harm the environment by spilling oil. Dispose of oil in an environmentally friendly manner.
m WARNING
Non-compliance can result in serious injuries or death!
Do not start the engine if any person is near the engine.
Engine start
3
4
5
Step
1
2
Designation
Fuel valve open
Starting carb (choke) activated
Procedure
IF engine in operating temperature
Throttle lever
Master switch
Ignition
Then start the engine without choke.
set on idle position
ON both circuits switched on
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
NOTICE
Do not actuate starter button (switch) as long as the engine is running. Wait until complete stop of engine!
Step
6
Designation
Starter button actuate
Procedure
NOTICE
Activate starter for maximum of 10 consecutive seconds only, followed by a cooling period of 2 minutes.
Step
7
8
Designation
As soon as engine runs
Oil pressure
Procedure adjust throttle to achieve smooth running at approx.
2500 rpm.
check if oil pressure has risen within 10 seconds and monitor oil pressure. Increase of engine speed is only permitted at steady oil pressure readings above 2 bar (30 psi).
NOTICE
At an engine start with low oil temperature, continue to observe the oil pressure as it could drop again due to the increased flow resistance in the suction line. Engine rpm may only be increased so far as the oil pressure re-mains steady.
Step
9
Designation Procedure
Starting carb (choke) de-activate
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
To observe Reduction gear with shock absorber
NOTICE
Since the engine comprises a reduction gear with shock absorber, take special care of the following:
Step
1
2
3
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. after throttling back to partial load to reach constant speed before re-acceleration..
For checking the two ignition circuits, only one circuit may be switched off and on at a time.
4.5) After engine start
m WARNING
Non-compliance can result in serious injuries or death!
Do not start the engine if any person is near the engine.
Warming up period
Step
1
2
3
Procedure
Start warming up period at approx. 2000 rpm for approx.
2 minutes.
Continue at 2500 rpm, duration depending on ambient temperature, until oil temperature reaches 50 °C (122 °
F).
Check temperatures and pressure.
Throttle response
NOTICE
After a full-load ground test allow a cooling run at idle speed to prevent vapour formation in the cylinder head.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Ignition check
Propeller governor
Step
1
Procedure
Full throttle ground test (consult Aircraft Operators Manual (OM) since engine speed depends on the propeller used).
After engine warm – up and prior to take –off, check the two ignition circuits at 4000 rpm (approx. 1700 rpm propeller).
Step
1
2
Procedure
Speed (engine rpm) drop with only one ignition circuit must not exceed 500 rpm (approx. 210 rpm propeller).
150 rpm (approx. 65 rpm propeller) max. difference of speed (engine rpm) by use of either circuit, A or B.
NOTE
The propeller speed depends on the actual reduction ratio.
Check of hydraulic propeller governor:
Check control of the hydraulic propeller governor to specifications of the manufacturer.
NOTE
Cycling the propeller governor puts a relatively high load on the engine. Unnecessary cycling or additional checks should be avoided.
4.6) Take-off
Climb m WARNING
Non-compliance can result in serious injuries or death!
Monitor Operating limits. Limits must not be exceeded.
Climbing with engine running at take-off performance is permissible (max. 5 minutes).
See
4.7) Cruising
Performance
Effectivity: 912 Series
Rev. 1
Step
1
Procedure
Set performance as per performance specifications
and respect operating limits as per
BRP-Rotax
Ed.4/January 01 2023
Oil temperature
Step
1
Procedure
Avoid operation below normal oil temperature (90 to 110
°C / 194 to 230 °F), as possible formation of condensation water in the lubrication system badly influences the oil quality.
To evaporate possibly accumulated condensation water, at least once a day 100 °C (212 °F) oil temperature must be reached.
4.8) Engine shut-off
Normally the cooling down of the engine during descending and taxiing will be sufficient to allow the engine to be shut off as soon as the aircraft is stopped.
At increased operating temperatures make an engine cooling run of at least minimum 2 minutes.
4.9) Cold weather operation
Coolant
Generally, an engine service should be carried out before the start of the cold season.
For selection of coolant and mixing ratio, see
.
Lubricant
Cold start
For selection of oil, see table of Lubricants
• With throttle closed and choke activated (open throttle renders starting carb ineffective)
• Be aware, no spark below crankshaft speed of 220 rpm (propeller speed of 90 rpm)
• As performance of electric starter is greatly reduced when hot, limit starting to periods not much longer than 10 sec.
With a well charged battery, adding a second battery will not improve cold starts
Remedy - Cold start
Step
1
2
3
Procedure
Use of multigrade oil with the low end viscosity code of 5 or 10.
Check electrode gap of spark plugs and if worn fit new spark plugs. See Maintenance Manual Line (MML) of the respective engine type.
Preheat engine.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Icing in the air intake system
Remedy
Icing due to water fuel
Icing due to humidity .
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.
• Carburetor heat is the only effective remedy. See Flight Manual or other operating instructions regarding the carburetor heat supplied by the aircraft manufacturer.
Icing due to water in fuel .
Remedy
NOTICE
Fuels containing alcohol always carry a small amount of water in solution. In case of temperature changes or increase of alcohol content, water or a mixture of alcohol and water may settle and could cause troubles.
Water in fuel will accumulate at the lower parts of the fuel system and leads to freezing of fuel lines, filters or jets.
• Use non-contaminated fuel (filtered through suede)
• Generously sized water separators
• Fuel lines routing inclined and without undrained low points
• Prevent condensation of humidity, i. e avoid temperature differences between aircraft and fuel
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
INTENTIONALLY LEFT
BLANK
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
5) Performance and Fuel consumption
Topics in this chapter
Introduction The performance tables and performance graphs on the next few pages are intended to show you what kind of performance to expect from your engine in terms of power output. The indicated power can be achieved by following the procedures laid out in the Operators Manual (OM) and ensuring that the engine is well-maintained.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
5.1) Performance data
Performance graphs
Engine 912 A/F/UL kW
60
Performance graphs for stand. conditions (ISA) hp
80
50
40
30
20
10
A
B
70
60
20
10
50
40
30
0
3000 4000 5000 5800 rpm
Figure 1: Performance graphs 912 A/F/UL in.Hg
30
A max. engine output B power requirement of propeller
L/h
30
(Gal/h)
(7,93)
C
20
20 (5,28)
D
10 10 (2,64)
0
3000 4000 5000
Figure 2: Values along propeller curve
0
5800 rpm
C manifold pressure D fuel consumption
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Performance data
Engine 912 A/F/UL
Performance data
Engine 912 A/F/UL
Performance data for variable pitch propeller
Engine speed over 5500 rpm is restricted to 5 minutes.
Run the engine in accordance with the following table.
Power setting
Take-off power max. continuous power
75 %
Engine speed
(rpm)
5800
5500
5000
Performance
(kW)/(HP)
59.6 / 80
58.0 / 78
43.5 / 58
65 %
55 %
4800
4300
37.7 / 50
31.9 / 43
Torque
(Nm)/(ft.
lb)
98.1 /
72.35
100.7 /
74.27
83.1 /
61.29
75.0 /
55.32
70.8 /
52.22
Manifold pressure (in.
Hg) full throttle full throttle
27.2
26.5
26.3
NOTE
Further essential information regarding engine behavior see
Service Letter SL-912-016, latest edition.
Performance data variable pitch propeller
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.
At deviation of temperature conditions from standard atmosphere conditions the engine performance to be expected can be calculated from the performance indicated, multiplied by standard temperature, divided by actual temperature in K.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
Figure 3: Performance graphs 912 A/F/UL
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Performance graphs
Engine 912 S/ULS
Performance graphs for standard. conditions (ISA)
Figure 4: Performance graphs Engine 912 S/ULS
Effectivity: 912 Series
Rev. 1
Figure 5: Performance graphs Motor 912 S/ULS
BRP-Rotax
Ed.4/January 01 2023
Performance data
Engine 912 S/ULS
Performance data for variable pitch propeller
Engine speed over 5500 rpm is restricted to 5 minutes.
Run the engine in accordance with the following table.
Power setting
Take-off power
Max. continuos power
75 %
65 %
55 %
Engine speed
(rpm)
5800
5500
5000
4800
4300
Performance (kW)
/ (HP)
73.5 / 100
69.0 / 90
51.0 / 68
44.6 / 60
38.0 / 50
Torque
(Nm) / (ft.
lb)
121.0 /
89.24
119.8 /
88.36
97.4 /
71.84
88.7 /
65.42
84.3 /
62.17
Manifold pressure
(in.Hg)
27.5
27
26
26
24
NOTE
Further essential information regarding engine behavior see
Service Letter SL-912-016, latest edition.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Performance graph
Engine 912 S/ULS
Performance graph for non standard conditions
The following graph shows the performance drop with increasing flight altitude. The curves show the performance at 5800,
5500, 5000, 4800 and 4300 rpm, at full throttle.
At deviation of temperature conditions from standard atmosphere conditions the engine performance to be expected can be calculated from the performance indicated, multiplied by standard temperature, divided by actual temperature in °K.
Figure 6: Performance graph
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
5.2) Fuel consumption
Fuel consumption
At take-off performance
At max. continuous performance
At 75 % continuous performance
Specific consumption at max. continuous performance
912 A/F/UL
24.0 l/h (6.3 gal/h)
22.6 l/h (5.6 gal/h)
16.2 l/h (4.3 gal/h)
285 g/kWh (0.47 lb/ hph)
912 S/ULS
27.0 l/h (7.1 gal/h)
25.0 l/h (6.6 gal/h)
18.5 l/h (4.9 gal/h)
285 g/kWh (0.47 lb/ hph)
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
7) System Description
Topics in this chapter
Introduction This chapter of the Operators Manual (OM) contains information about the general engine specification as well as a description of cooling system, fuel system, lubrication system, electric system and the propeller gearbox.
The system description refers only to the engine and not to a specific application in a particular aircraft. The aircraft manufacturer’s Operators Manual (OM) is therefore definitive in terms of the operation of the engine, as it contains all the aircraft specific instructions.
The design shown in this chapter does not represent a specified execution but should support the understanding of the system.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
7.1) General specification
7.1.1) Basic specification
• 4 stroke, 4 cyl. horizontally opposed, spark ignition engine, single central camshaft hydraulic tappets - push rods - OHV
(Over Head Valve)
• 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 pump
• 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
Optional
NOTE
The overload clutch is installed on all serial production aircraft engines which are certified and non-certified aircraft engines of the configuration 3.
• Electric starter (12 V 0.9 kW)
• External alternator (12 V 40 A DC)
• Vacuum pump drive
• Hydraulic constant speed propeller governor drive
7.1.2) Technical data
Description
Bore
Stroke
Displacement
Compression ratio.
912 A/F/UL
79.5 mm (3.13 in)
61 mm (2.40 in)
1211 cm³ (73.9 in³)
9.0 : 1
912 S/ULS
84 mm (3.31 in)
61 mm (2.40 in)
1352 cm³ (82.5 in³)
10.8 : 1
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
7.1.3) Engine components
2
1
10037
1
Figure 1: Engine components
Propeller gear box 2
Vacuum pump or hydraulic governor for constant speed propeller
7.1.4) Cylinder arrangement
Cyl.1 Cyl.3
4
PTO
8
7
Cyl.2 Cyl.4
Figure 2: Cylinder arrangement
5
MAG
6
3
4
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
7.1.5) Direction of rotation
Direction of rotation on propeller shaft: counter clockwise, viewed from the front.
10039
Figure 3: Normal direction of propeller rotation (engine)
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
7.2) Cooling system
System Overview The cooling system of the engine 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.
Coolant flow The coolant flow is forced by a water pump, driven from the camshaft, from the radiator to the cylinder heads. From the top of the cylinder heads the coolant passes on to the expansion tank. Since the standard location of the radiator is below engine level, the expansion tank located on the top of the engine allows for coolant expansion.
Expansion tank From the expansion tank the coolant is sucked back to the water pump. In common installations the coolant passes a radiator in between. Additionally the expansion tank is closed by a pressure cap (with excess pressure valve and return valve). At temperature rise of the coolant the excess pressure valve opens and the coolant will escape via hose at atmospheric pressure. In common installation this hose is connected to an overflow bottle. This overflow bottle allows the coolant to be sucked back into the cooling circuit as the engine is cooling down.
NOTE
The coolant temperature sensors are located in cylinder head 2 and 3.
2
1
4
3
Figure 4: Cooling system (symbolic)
1 Expansion tank
3 Radiator
2
4
Pressure cap
Overflow bottle
09152
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
7.3) Fuel system
Fuel
Return line
The fuel flows from the tank via a coarse filter the fire cock and fine filter to the mechanical fuel pump. From the pump fuel passes on via the fuel manifold to the two carburetors.
Via the return line surplus fuel flows back to the fuel tank and suction side of fuel system.
NOTE
11
The return line serves to avoid formation of vapor lock.
1
13
10
8
2
12
3
11
7
6
4
5
1 Fuel tank
3 Drain valve
5 Fine filter/water trap
7
Fuel manifold (not standard configuration)
9 1x check valve
11 Carburetor
13
Return line from engine to tank
Figure 5: Fuel system
07306
9
2 Coarse filter
4 Fire cock
6
Mechanical fuel pump
(standard configuration)
8 Electrical fuel pump
10 Fuel pressure gauge
12 Restrictor jet
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
7.4) Lubrication system
Lubrication
Crankcase
Oil pump
Oil circuit vented
Oil temperature sensor
The engines is provided with a dry sump forced lubrication system with a main oil pump with integrated pressure regulator.
The airframe manufacturer is responsible for the main layout and the component selection for the lubrication system.
The main oil pump sucks the motor oil from the oil tank via oil radiator and forces it through the oil filter to the points of lubrication.
NOTE
The oil radiator is optional.
The surplus of oil emerging from the points of lubrication accumulates on the bottom of crankcase and is forced back to the oil tank by the piston blow-by gases.
The oil pump is driven by the camshaft.
The oil circuit is vented via bore on the oil tank.
The oil temperature sensor for reading of the oil inlet temperature is located on the oil pump housing.
7
2 6
8
1
3
4
5
08650
Figure 6: Lubrication system
1 Pressure regulator
3 Oil pump
5 Oil radiator
7 Venting tube
2 Oil pressure sensor
4 Oil tank
6 Oil filter
8 Oil temperature sensor (oil)
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
7.5) Electric system
Charging coils
The ROTAX® 912 engine is equipped with a dual ignition unit of a breakeless, capacitor discharge design, with an integrated generator.
The ignition unit needs no external power supply.
Two independent charging coils located on the generator stator supply one ignition circuit each. The energy is stored in capacitors of the electronic modules. At the moment of ignition 2 each of the 4 external trigger coils actuate the discharge of the capacitors via the primary circuit of the dual ignition coils.
NOTE
An additional trigger coil is provided for rev counter signal.
Firing order: 1 - 4 - 2 - 3
2
Ignition circuit A
4
3
B
3/
4
5
A1
/2
3
4
3
A3/
4
B
1
/2
3
1
2
4
4
10040
1 Charging coils
3
Trigger coils for ignition signal
5
Trigger coil for speed signal
Ignition circuit B
2 Electronic modules
4 Dual ignition coils
Figure 7: Ignition circuit
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
7.6) Propeller gearbox
Reduction ratio For the engine type 912 one reduction ratio is available.
Reduction ratio crankshaft: propeller shaft
912 A/F/UL
2.27:1
912 S/ULS
2.43:1
2.43:1 (option)
Overload clutch Depending on engine type, certification and configuration the propeller gearbox is supplied with or without an overload clutch.
NOTE
This overload clutch will prevent any undue load to the crankshaft in case of ground contact of the propeller.
NOTE
The overload clutch is installed on serial production on all certified aircraft engines and on the non-certified aircraft engines of configuration 3.
Effectivity: 912 Series
Rev. 1
Figure 8: Overload clutch
Fig. shows a propeller gearbox of configuration 2 with the integrated overload clutch.
BRP-Rotax
Ed.4/January 01 2023
Torsional shock absorber
Backlash
Vacuum pump or hydraulic governor
The design incorporates a torsional shock absorber. The shock absorbing is based on progressive torsional cushioning due to axial spring load acting on a dog hub.
On the gearbox version with overload clutch the design incorporates a friction damped free play at the dogs to warrant proper engine 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.
NOTE
This overload clutch will also prevent any undue load to the crankshaft in case of ground contact of the propeller.
See Service Letter SL-912-015
Alternatively either a vacuum pump or a hydraulic governor for constant speed propeller can be used. The drive is in each case via the propeller reduction gear.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
8) Preservation and storage
Topics in this chapter
8.1 Engine preservation and storage ............................................................. 2
Safety All checks to be carried out as specified in the current
Maintenance Manual Line (MML) (last revision).
As well as the maintenance and special checks, see
Maintenance Manual Line (MML) for the engine type 912.
m WARNING
Non-compliance can result in serious injuries or death!
Only qualified staff (authorized by the Aviation Authorities) trained on this particular engine, is allowed to carry out maintenance and repair work.
NOTE
Other useful information for service and airworthiness of your engine you'll find on www.rotax-owner.com
.
NOTICE
Carry out all directives of Service Bulletins (SB), according to their priority. Observe applicable Service Instructions (SI) and
Service Letter (SL).
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
8.1) Engine preservation and storage
General Environmental corrosion (on the external surfaces) is a naturally occurring process which can inevitably affect the continued airworthiness of the engine, engine mounted components and accessories. Susceptibility to corrosion is influenced by a number of factors, including but not limited to, geographical location, season and usage. All general preventive (technical) measures, identification, control and treatment of corrosive attack on aircraft structures and engine materials has to be carried out in accordance with Advisory Circular AC 43-4B from
FAA and also in accordance with the information of the aircraft manufacturer´s Instruction for Continued Airworthiness. Furthermore the preservation procedures for stored and inactive aircraft (engines) provides an effective means for combating and minimizing the corrosion condition and should be adhered to.
Advisory Circular AC 43-4B : This advisory circular (AC) is a summary of the current available data regarding identification and treatment of corrosive attack on aircraft structures and engine materials. Corrosion inspection frequency, corrosion identification, and especially corrosion treatment continues to be the responsibility of the operator. These inspections should be accomplished per this AC, the manufacturer’s recommendations, or the operator’s own maintenance program. The procedures in this AC are an acceptable means, but not the only acceptable means, of corrosion treatment. The information in this AC is applicable to aircraft for which the manufacturer has not published corrosion control information.
m WARNING
Risk of burns and scalds! Hot engine parts!
Conduct checks on cold engine only!
Due to the special material of the cylinder wall, there is no need for extra protection against corrosion for ROTAX® aircraft engines. At extreme climatic conditions and/or for long out of service periods we recommend the following to protect the valve guides against corrosion:
Step Procedure
1 Operate the engine until the temperatures have stabilized for a period of 5 min. (engine oil temperature between 50 to 70 °C (122 to 160 °F).
2
3
Shut-off engine.
Allow the engine to cool down.
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
Step Procedure
4
5
6
7
8
9
Change oil.
Remove the top spark plugs and spray into openings with corrosion inhibiting oil.
Turn the propeller several times by hand in direction of the engine rotation, so that the corrosion inhibiting oil reaches all necessary points.
Install the spark plugs in accordance to the Maintenance
Manual.
Close all openings on the cold engine, such as exhaust end pipe, venting tube, air filter etc. against entry of dirt and humidity.
Spray all steel external engine parts with corrosion inhibiting oil.
Drain carburetor float chambers.
8.2) Engine back to operation
If preservation (including oil change) took place within a year of storage, oil renewal will not be necessary. For longer storage periods repeat preservation annually.
Step Procedure
1
2
3
Remove all plugs and caps.
Clean spark plugs with plastic brush and solvent.
Reinstall.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
INTENTIONALLY LEFT
BLANK
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
9) Supplement
Topics in this chapter
Authorized
Distributor
See Form.
According to the regulation of EASA part 21.A.3 the manufacturer shall evaluate field information and report to the authority. In case of any relevant occurrences that may involve malfunction of the engine, the form on the next page should be filled out and sent to the responsible ROTAX® authorized aircraft engines distributor or their independent Service Center.
NOTE
The form is also available from the official ROTAX® AIRCRAFT
ENGINES Website in electronic version.
Overview of ROTAX® authorized aircraft engines distributor or their independent Service Center.
Refer to the official ROTAX® AIRCRAFT ENGINES Website www.FLYROTAX.com
.
Effectivity: 912 Series
Rev. 1
BRP-Rotax
Ed.4/January 01 2023
9.1) Form
Ed.4/January 01 2023
Figure 1: Form
BRP-Rotax Effectivity: 912 Series
Rev. 1
Index
A
Abbreviations ................................3
Abnormal operation........................1
After engine start ...........................8
F
Fire, Engine, compartment .............5
Form.............................................2
Fuel consumption ..........................8
Fuel system...................................6
B
Basic specification .........................2
Before engine start.........................5
G
General.........................................2
General specification......................2
C
Cold weather operation ................10
Cooling system ..............................5
Cruising ........................................9
cylinder arrangement .....................3
L
List of effective pages.....................1
Lubrication system .........................7
D
Daily checks ..................................2
Direction of rotation ........................4
E
Electric system ..............................8
Engine back to operation ................3
Engine components .......................3
Engine preservation and storage.....2
Engine shut-off ............................10
Engine start ............................... 5–6
Exceeding cylinder head
temperature .................................3
Exceeding engine speed ................3
Exceeding of max. admissible
coolant temperature .....................4
Exceeding of max. admissible
cooling system temperature ..........3
Exceeding oil temperature ..............4
O
Oil pressure............................... 4–5
Oil pressure below minimum -
on ground ....................................5
Operating limits (912 A/F/UL)..........2
Operating limits(912 S/ULS) ...........5
Operating media Fuel...................10
Operating media-Coolant ...............9
Operating media-Lubricants.......... 11
P
Performance data ..........................2
Pre-flight checks ............................5
Propeller gearbox ..........................9
R
Re-Start during flight ......................3
Effectivity: 912 Series
Rev. 1
BRP-Rotax Page Index-3
Ed.4/January 01 2023
S
Safety notice ........................... 8, 10
Start..............................................9
T
Table of amendments .....................1
Take-off.........................................9
Technical data ...............................2
Technical documentation ..............13
Temperature ..................................3
Terms ...........................................3
Trouble shooting ............................6
Type description 912 Series..........15
Page Index-4
Ed.4/January 01 2023
BRP-Rotax Effectivity: 912 Series
Rev. 1
DON’T SETTLE
FOR LESS.
IN A WORLD
FULL OF FAKES,
STAY ORIGINAL.
GENUINE PARTS
ORIGINAL QUALITY. ORIGINAL VALUE. ORIGINAL TRUST.
The high levels of safety, reliability, and performance you decided on when choosing your aircraft engine are also reflected in every single part they are built of. Find your extra peace of mind by using only Rotax Genuine Parts when your engine is serviced.
Rotax Genuine Parts are manufactured to strict quality standards for an exact fit and precise operation. They ensure that your aircraft will continue to perform at maximum levels with minimum downtime and a long service life.
Rotax Genuine Parts meet Design/Production Organisation
Approval (DOA/POA) and quality standards (EASA/ASTM).
All Rotax Genuine Parts come with a coverage for the first
24 consecutive months or the first 100 hours of operation, whichever occurs first.
There is no Rotax warranty on non-genuine parts.
If a non-genuine part causes an event on a Rotax engine, it may nullify any warranty.
* applies to all Rotax engine series except Rotax 582 UL
** This offer only applies if allowed under the applicable law. Some jurisdictions may not allow, or may limit, the validity of some or part of the offer; therefore conditions may vary or not be available in some locations. For more details ask your local distributor.
Engine serial no.
Type of aircraft
Aircraft registration no.
Rotax® authorized distributor
FLYROTAX.COM
® and TM are Trademarks of BRP-Rotax GmbH & Co KG.
© 2023 BRP-Rotax GmbH & Co KG. All rights reserved.
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