Rotax 912 series Operator's Manual
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Rotax 912 series Operator's Manual

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

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  • Page 1 ROTAX GmbH and must not be reproduced, neither in entirety nor partially, ® and passed on to third parties without previous consent in writing by ROTAX ® GmbH. This text must be written on every complete or partial reproduction. Copyright - ROTAX GmbH ®...

  • Page 2: Table Of Contents

    Table of contents ................. 1 - 2 1) Inhaltsverzeichnis Index ..................... 2 - 1 Introduction ................. 3 - 1 3.1) Remarks ................... 3 - 1 3.2) Engine serial number ..............3 - 1 Safety ................... 4 - 1 4.1) Repeating symbols ................ 4 - 1 4.2) Safety information ................
  • Page 3 13.1) Fuel according to DOT ..............13 - 1 13.2) Fuel according to FAA ..............13 - 2 14) ROTAX® authorized Distributors ..........14 - 1 15) Warranty ..................15 - 1 15.1) Warranty Conditions / Warranty Card (912 A / F / S) ....15 - 1 15.2) Warranty Conditions / Warranty Card (912 UL / ULS) ....

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  • Page 5: Index

    2) Index Abnormal operation 10 - 21 Exceeding of max. admissible oil Acceleration (912 UL / A / F) 10 - 1 temperature 10 - 21 Acceleration (912 ULS / S) 10 - 5 Exhaust system 10 - 14 AVGAS 100 LL 10 - 10 Fuel 10 - 10 Carburetor 10 - 14 Fuel according to DOT 13 - 1...
  • Page 6 Propeller governor 9 - 6 Remarks 3 - 1 Repeating symbols 4 - 1 Reporting 12 - 3 ROTAX® authorized Distributors 14 - 1 Safety 4 - 1 Safety information 4 - 2 Speed (912 UL / A / F) 10 - 1...

  • Page 7: Introduction

    3) Introduction Congratulations on your decision to purchase a ROTAX aircraft engine. ® Before operating the engine, carefully read this Operator's Manual. The Manual provides you with basic information on the safe operation of the engine. If any passages of the Manual are not clearly understood or in case of any...
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  • Page 9: Safety

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

  • Page 10: Safety Information

    — Due to the varying designs, equipment and types of aircraft, ROTAX ® grants no warranty or representation on the suitability of its engine’s use on any particular aircraft.
  • Page 11 Since special tools and equipment may be required, engine servicing should only be performed by an authorized ROTAX engine dealer or ®...
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  • Page 13: Technical Documentation

    They may not represent the actual part in all its details but depict parts of the same or similar function. Therefore deduction of dimensions or other details from illustrations is not permitted. All necessary documentation is available from the ROTAX Distribution- and Service Centers (see Chapter 14). NOTE: The Illustrations in this Operator´s Manual are stored in...
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  • Page 15: Index Of

    5) Index of pages 00522 Chap- Page Date Chap- Page Date cover page 1 - 1 98 07 01 ACG-approv.10 - 1 2004 07 01 1 - 2 98 07 01 ACG-approv.10 - 2 2002 11 01 1 - 3 2002 11 01 ACG-approv.10 - 3 98 07 01 1 - 4 98 07 01...
  • Page 16 Chap- Page Date Chap- Page Date 15 - 1 98 07 01 15 - 2 98 07 01 15 - 3 98 07 01 15 - 4 98 07 01 15 - 5 98 07 01 15 - 6 98 07 01 15 - 7 98 07 01 15 - 8 98 07 01 15 - 9 98 07 01...

  • Page 17: List Of Amendments

    6) List of amendments 00521 C h a p - C u r r t P a g e s D a t e D a t e o f D a t e o f M a r k s / N o t e a p p r o v a l b y i n s e r t i o n...
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  • Page 19: Description Of Design

    7) Description of design 4-stroke, 4 cylinder horizontally opposed, spark ignition engine, one central camshaft - push-rods - OHV Liquid cooled cylinder heads Ram air cooled cylinders Dry sump forced lubrication Dual breakerless capacitor discharge ignition 2 constant depression carburetors mechanical fuel pump Prop drive via reduction gear with integrated shock absorber and overload clutch NOTE:...

  • Page 20: Type Description

    7.1) Type description e.g. ROTAX 912 A 2 NOTE: The type designation is of the following composition. ROTAX 02091 Type: 912 ..4-cyl. horizontalle opposed, normal aspirated engine Certification: A .... certified to JAR 22 (TW 8/89) F, S ..certified to FAR 33 (TW9 - ACG) UL, ULS .

  • Page 21: Denomination Of Cylinders

    7.2) Denomination of cylinders: Lateral view fig. 1 00337 Zyl. 1 Zyl. 3 Top view fig. 2 00334 Zyl. 2 Zyl. 4 page 7 - 3 Effectivity: 912 Serie July 01/98 OM initial issue AIRCRAFT ENGINES...
  • Page 22 Bild 3 00336 front view engine serial number exhaust flange CD carburetor external alternator propeller gearbox vacuum pump or hydraulic governor for constant speed electric starter propeller expansion tank with excess pressure valve Effectivity: 912 Serie page 7 - 4 OM initial issue July 01/98 AIRCRAFT ENGINES...

  • Page 23: Technical Data

    8) Technical data 8.1) Dimensions Description 912 UL / A / F 912 ULS / S Bore 79,5 mm (3,13 in) 84 mm (3,31 in) Stroke 61 mm (2,40 in) 61 mm (2,4 in) Displacement 1211 cm3 (13,9 in3) 1352 cm3 (82,5 in3) Compression 9,0 : 1 10,5 : 1...

  • Page 24: Fuel Consumption

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

  • Page 25: Description Of Systems

    Cooling system See fig. 8. The cooling system of the ROTAX 912 A is designed for liquid cooling of the cylinder heads and ram-air cooling of the cylinders. The cooling system of the cylinder heads is a closed circuit with an expansion tank.

  • Page 26: Fuel System

    9.2) Fuel system See fig. 9. The fuel flows from the tank (1) via a coarse filter (2) the safety cock (3), water drain cock (4) and fine filter (5) to the mechanical fuel pump (6). From the pump fuel passes on to the two carburetors (7). Via the return line (8) surplus fuel flows back to the fuel tank and suction side of fuel system.

  • Page 27: Lubrication System

    9.3) Lubrication system See fig. 10. The ROTAX 912 A engine is provided with a dry sump forced lubrication system with a main oil pump with integrated pressure regulator (1) and oil pressure sensor (2). NOTE: The oil pump is driven by the camshaft.

  • Page 28: Electric System

    9.4) Electric system See fig. 11. The ROTAX 912 A engine is equipped with a dual ignition unit of a breakerless, capacitor discharge design, with an integrated generator. The ignition unit is completely free of maintenance and needs no external power supply.

  • Page 29: Propeller Gearbox

    9.5) Propeller gearbox See fig. 8. For the engine type 912 two reduction ratios are available. reduction ratio 912 UL / A / F 912 ULS / S 2,27 : 1 crankshaft : propeller shaft 2,43 : 1 2,43 : 1 02719 (optional) Depending on engine type, certification and configuration the propeller...

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

    9.5.1) Hydr. governor for const. speed propeller, vacuum pump: 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. Gear ratio: gear ratio crankshaft : propeller shaft 2,27 : 1 2,43 : 1...

  • Page 31: Operating Instructions

    10) Operating instructions The data of the certified engines are based on type certificate of type 912 A (TW 8/89), 912 F / S (TW9 - ACG). 10.1) General limits of operation 10.1.1) Operating speeds and limits (912 UL / A / F) Speed: Take-off speed ......
  • Page 32 Power consumption of the hydraulic propeller governor: max..........600 W Power consumption of the vacuum pump: max..........300 W Power consumption of the external alternator: max..........1200 W Deviation from bank angle max..........40° NOTE: Up to this value the dry sump lubrication system warrants lubrication in every flight situation.

  • Page 33: 1) Performance Graphs For Stand. Conditions (Isa)10

    10.1.1.1) Performance graphs for stand. conditions (ISA) A: max. engine output B: power requirement of propeller 00450 fig. 9 3000 4000 5000 5800 rpm C: manifold pressure D: fuel consumption 00451 (Gal/h) in.Hg (7,93) (5,28) (2,64) 3000 4000 5000 5800 rpm Values along propeller curve fig.

  • Page 34: 2) Performance Graph For Non-Standard Conditions10

    Performance data for variable pitch propeller: Engine operation is permitted without restriction between full throttle performance and power requirement of propeller, providing engine speed over 5500 r.p.m. is restricted to 5 minutes. However, for economic reasons it is recommended to run the engine in accordance with the following table: Engine Power- Engine speed...

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

    10.1.2 ) Operating speeds and limits (912 ULS / S) Speed: Take-off speed ......5800 1/min (5 min.) Max. continuous speed ..... 5500 1/min Idle speed ........approx. 1400 1/min Performance (ISA): (International Standard Atmosphere) Take-off performance ....73,5 kW at 5800 1/min Max.
  • Page 36 Power consumption of the hydraulic propeller governor: max..........600 W Power consumption of the vacuum pump: max..........300 W Power consumption of the external alternator: max..........1200 W Deviation from bank angle max..........40° NOTE: Up to this value the dry sump lubrication system warrants lubrication in every flight situation.

  • Page 37: 1) Performance Graphs For Stand. Conditions (Isa)10

    10.1.2.1) Performance graphs for stand. conditions (ISA) Drehmoment Torque max. Motorleistung max. engine output Propellerkurve power requirement of propeller 5800 2500 3000 3500 4000 4500 5000 5500 Drehzahl / Engine Speed [1/min] fig. 12 02001 Ansaugladedruck manifold pressure Werte bezogen auf die Propeller-Kurve values along propeller curve...

  • Page 38: 2) Performance Graph For Non-Standard Conditions10

    Performance data for variable pitch propeller: Engine operation is permitted without restriction between full throttle performance and power requirement of propeller, providing engine speed over 5500 r.p.m. is restricted to 5 minutes. However, for economic reasons it is recommended to run the engine in accordance with the following table: Engine Power- Engine speed...

  • Page 39: Operating Media

    10.2) Operating media 10.2.1) Coolant The following water-free coolant concentrate can be used based on propylene glycol. mixture ratio % designation concentrate water EVANS NPG+ * 07032 or equivalent When correctly applied (100% coolant concentration), there is sufficient protection against vapor bubble formation, freezing or thickening of the coolant within the operating limits.

  • Page 40: 2) Fuel

    10.2.2) Fuel The following fuels* can be used. 912 UL / A / F 912 ULS / S min. RON 90 min. RON 95 EN 228 Regular EN 228 Premium EN 228 Premium EN 228 Premium plus EN 228 Premium plus AVGAS 100 LL AVGAS 100 LL 02724...

  • Page 41: 3) Lubricants

    10.2.3) Lubricants Oil: Motorcycle oil of a registered brand with gear additives. If using aircraft engine oil; than only blonded one. CAUTION: At the selection of suitable lubricants refer to the additional information in the Service Infor- mation SI-18-1997, latest edition. Oil specification —...
  • Page 42 Oil capacity: ....3 l (min. 2 l) (6.4 liq pt, min. 4.2 liq pt) Oil consumption: ... max 0,06 l/h (0.13 liq pt/h) Oil viscosity: Use of multi-grade oils is recommended. NOTE: Multi-viscosity grade oils are less sensitive to temperature variations than single grade oils.
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  • Page 44: Standard Operation

    10.3) Standard operation To warrant reliability and efficiency of the engine, meet and carefully observe all the operating and maintenance instructions. 10.3.1) Daily checks WARNING: Risk of burnings and scalds! Conduct checks on the cold engine only! WARNING: Ignition "OFF". Before cranking the propeller switch off both ignition circuits and anchor the aircraft.

  • Page 45: 2) Before Engine Start

    Carburetor: — Verify free movement of throttle cable and starting carburetor over the complete range. Check from the cockpit. Exhaust system: — Inspect for damages, leakage and general condition. 10.3.2) Before engine start Carry out pre-flight checks. 10.3.3) Pre-flight checks WARNING: Ignition "OFF"...

  • Page 46: 4) Engine Start

    10.3.4) Engine start WARNING! Do not take the engine into operation if any person is near the aircraft. Fuel cock........open Starting carb......activated NOTE: If the engine is already in operating temperature, start the engine without choke. Throttle lever.

  • Page 47: 5) Prior To Take-Off

    10.3.5) Prior to take-off Warming up period: Start warming up period at 2000 r.p.m. for approx. 2 minutes, continue at 2500 r.p.m., duration depending on ambient temperature, until oil temperature reaches 50° C (120° F). — Check temperatures and pressures. Throttle response: —...

  • Page 48: 6) Take-Off

    10.3.6) Take-off Climbing with engine running at take-off performance is permissible (max. 5 minutes). See Chapter 10.1), 10.1.1) and 10.1.2). WARNING: Monitor oil temperature, cylinder head tempera- ture and oil pressure. Limits must not be ex- ceeded! See Chapter 10.1) Operating Limits. ATTENTION: Respect "cold weather operation"...

  • Page 49: 9) Cold Weather Operation

    10.3.9) Cold weather operation Generally, an engine service should be carried out before the start of the cold season. Coolant: For selection of coolant and mixing ratio, see "Coolant", Chapter 10.2.1). Lubricant: For selection of oil, see Table of Lubricants (Chapter 10.2.3). Cold start: —...
  • Page 50 Beyond that observe following advices for operation at extremely low temperatures: NOTE: Distinguish between two kinds of carb icing: 1) Icing due to water in fuel 2) Icing because of high air humidity Addendum to note 1) Water in fuel will accumulate at the lower parts of the fuel system and leads to freezing of fuel lines, filters or jets.

  • Page 51: Abnormal Operation

    10.4) Abnormal operation WARNING: At unusual engine behaviour conduct checks as per Chapter 10.4.1) through 10.4.13) below, and as per Maintenance Manual, Chapter 05) before the next flight. NOTE: Further checks - see Maintenance Manual. 10.4.1) Engine stop - Start during flight Starting procedure same as on ground, however, on a warm engine without choke.
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  • Page 53: Checks

    11)Checks All checks to be carried out as specified in the current Maintenance Manual (last revision). WARNING: Only qualified staff (authorized by the Aviation Authorities) trained on this particular engine, is allowed to carry out maintenance and repair work. ATTENTION: Carry out all directives of Technical Bulletins, according to their priority.
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  • Page 55: Trouble Shooting

    12)Trouble shooting WARNING: Only qualified staff (authorized by the Aviation Authorities) trained on this particular engine, is allowed to carry out maintenance and repair work. If the following hints regarding remedy do not solve the problem, contact an authorized workshop. The engine must not be operated until the problem is rectified.
  • Page 56 Engine keeps running with ignition off POSSIBLE CAUSE: REMEDY: a - overheating of engine let engine cool down at idling at approx. 2000 r.p.m. Oil level is increasing REMEDY: POSSIBLE CAUSE: cover oil cooler surface, maintain a - oil too cold during engine operation the oil temperature prescribed.

  • Page 57: Reporting

    According to the regulation of JAR / FAR 21.3 the manfacturer 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 authorized ROTAX ® distributor.
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  • Page 59: Appendix To Aircraft Manual

    13)Appendix to Aircraft Manual 13.1) Fuel according to DOT 912 UL / A / F 912 ULS / S Canadian CAN/CGSB-3.5 CAN/CGSB-3.5 standard Quality Quality 1 Quality 3 min. AKI * min AKI 87 min AKI 91 AVGAS 100 LL AVGAS 100 LL 02728 * Anti Knock Index, (RON+MON)/2...

  • Page 60: Fuel According To Faa

    13.2) Fuel according to FAA Fuel: ...... Standard Spec. for Automotive Spark-Ignition Engine, Fuel, ASTM D 4814, AVGAS 100 LL Due to higher lead content in AVGAS, the wear of the valve seats and deposits in the combustion chamber will increase. Therefore, use AVGAS only if you encounter problems with vapour lock or if the other fuel types are not available, equivalent fuels according to Chapter 10.2.2).
  • Page 61 Authorized Distributors for ROTAX Aircraft Engines ® www.rotax-aircraft-engines.com 1) E U R O P E Issue 2003 01 09 AUSTRIA: GERMANY: HB - FLUGTECHNIK GES.M.B.H. for postcodes 0-5-6-7-8-9: Dr. Adolf Schärf Str. 42 FRANZ AIRCRAFT ENGINES A-4053 HAID VERTRIEB GMBH Tel.: +43 (0)7229 / 79104, Fax: +43 (0) 7229 / 79104 15...
  • Page 62 2) A M E R I C A ROMANIA: CANADA: S.C. BERIMPEX S.R.L. ROTECH RESEARCH CANADA, LTD. Str. Dr. Taranu Grigore No. 8, Ap. 2, Sector 6235 Okanagan Landing Rd. VERNON, B.C., V1H 1M5, Canada R-76241 BUCHAREST Tel.: +1 250 / 260-6299, Fax: +1 250 / 260-6269 Tel.: +40 (0) 1 / 410 90 03;...
  • Page 63 1011 E-mail:aviation@tpa.com.sg Website: www.tpa.com.sg Contact person: Chan Nyuk Lin IRAN: ASEMAN PISHRANEH CO. Auth. Rotax A/C Engine Distributor & Service Center P.O. Box 16535-433, Tehran, Iran Tel.: +98 (0) 21 731 4107, Fax: +98 (0) 21 731 4130 E-mail: asmpish@iranasoft.net...
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  • Page 65: Warranty

    ROTAX as manufacturer, warrants through their authorized ROTAX distributors ® ® FROM THE DATE OF SALE TO THE FIRST CONSUMER, every ROTAX certified ® aircraft engine, sold as NEW AND UNUSED, and delivered by an authorized ROTAX distributor for a period of the earliest of: ®...
  • Page 66 7) Validity: Warranty will only be valid if the end user completes this registration card as soon as the aircraft engine goes into service, and returns it to the national authorized ROTAX ® distributor (marked with “ ” in section Distributors) of the area in which the aircraft engine is firstly operated.
  • Page 67 1. To be eligible for warranty, this registration card must be returned completed and signed by the end user to the authorized ROTAX distribution partner (see section 14) of the area of the permanent residence of the end user and / or in which the aircraft engine is firstly operated, within 30 days as of date of purchase.
  • Page 68 WARNING! Never fly the aircraft equipped with this engine at locations, airspeeds, altitudes, or other circumstances from which a successful no-power landing cannot be made, after sudden engine stoppage. Aircraft equipped with this engine should only fly in DAYLIGHT VFR conditions. All airworthiness requirements like JAR, FAR in their last applicable version have to be respected.

  • Page 69: Warranty Conditions / Warranty Card (912 Ul / Uls)

    ROTAX as manufacturer, warrants through their authorized ROTAX distributors ® ® FROM THE DATE OF SALE TO THE FIRST CONSUMER, every ROTAX non- ® certified aircraft engine, sold as NEW AND UNUSED, and delivered by an authorized ROTAX distributor for a period of the earliest of: ®...
  • Page 70 7) Validity: Warranty will only be valid if the end user completes this registration card as soon as the aircraft engine goes into service, and returns it to the national authorized ROTAX ® distributor (marked with “ ” in section Distributors) of the area in which the aircraft engine is firstly operated.
  • Page 71 1. To be eligible for warranty, this registration card must be returned completed and signed by the end user to the authorized ROTAX distribution partner (see section 14) of the area of the permanent residence of the end user and / or in which the aircraft engine is firstly operated, within 30 days as of date of purchase.
  • Page 72 DANGER! This engine, by its design, is subject to sudden stoppage! Engine stoppage can result in crash landings. Such crash landings can lead to serious bodily injury or death. Never fly the aircraft equipped with this engine at locations, airspeeds, altitudes, or other circumstances from which a successful no-power landing cannot be made, after sudden engine stoppage.
  • Page 73 1. To be eligible for warranty, this registration card must be returned completed and signed by the end user to the authorized ROTAX distribution partner (see section 14) of the area of the permanent residence of the end user and / or in which the aircraft engine is firstly operated, within 30 days as of date of purchase.

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