Rotax OM-912 Operator's Manual
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Rotax OM-912 Operator's Manual

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

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  • Page 1 �������� ������� OPERATORS MANUAL FOR ROTAX® ENGINE TYPE 912 SERIES Ref. No.: OM-912 ROTAX ® 912 ULS 3 WITH OPTIONS part no.: 899371...
  • Page 2 These technical data and the information embodied therein are the property of BRP- Rotax GmbH&Co. KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior written permission of BRP-Rotax GmbH&Co. KG, be disclosed in whole or in part to third parties.

  • Page 3: Table Of Contents

    10.3.1) Daily checks................. 10-13 10.3.2) Before engine start............... 10-14 10.3.3) Pre-flight checks ..............10-15 10.3.4) Engine start................10-16 10.3.5) Prior to take-off ..............10-17 10.3.6) Take-off................10-17 Effectivity: 912 Serie BRP-Rotax page 1 - 3 OM Edition 1 / Rev. 0 Jan.01/2007...
  • Page 4 10.4.6) Oil pressure below minimum - on ground ......10-20 11) Checks ....................11-1 11.1) Engine preservation ............... 11-1 12) Trouble shooting................12-1 12.1) Reporting ................. 12-4 13) Authorized Distributors for ROTAX Aircraft Engines....13-1 ® Effectivity: 912 Serie BRP-Rotax page 1 - 4 OM Edition 1 / Rev.

  • Page 5: Index

    Operating speeds and limits speed 10-20 (912 ULS / S) 10-5 Exceeding of max. admissible oil tem- Overload clutch 9-5 perature 10-20 Exhaust system 10-14 Effectivity: 912 Serie BRP-Rotax page 2 - 1 OM Edition 1 / Rev. 0 Jan.01/2007...
  • Page 6 Technical data 8-1 Technical documentation 4-5 Throttle response 10-17 Trouble shooting 12-1 Type 7-2 Type description 7-2 Vacuum pump 9-6 Warming up period 10-17 Weights 8-1 Effectivity: 912 Serie BRP-Rotax page 2 - 2 OM Edition 1 / Rev. 0 Jan.01/2007...

  • 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 Ma- nual provides you with basic information on the safe operation of the engine. If any passages of the Manual are not clearly understood or in case of any questions, please, contact an authorized Distribution- or Service Center for ROTAX aircraft engines.
  • Page 8 NOTES Effectivity: 912 Serie BRP-Rotax page 3 - 2 OM Edition 1 / Rev. 0 Jan.01/2007...

  • Page 9: Safety

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

  • Page 10: Safety Information

    - Due to the varying designs, equipment and types of aircraft, ROTAX grants no warranty or representation on the suitability of its engine’s use on any particular aircraft.
  • Page 11 Since special tools and equipment may be required, engine servicing should only be performed by an authorized ROTAX engine dealer or a qualified trained mechanic approved by the local airworthiness authority. - To eliminate possible injury or damage, ensure any loose equipment or tools are properly secured before starting the engine.
  • Page 12 NOTES Effectivity: 912 Serie BRP-Rotax page 4 - 4 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 13: Technical Documentation

    - Alert Service Bulletins - Service Bulletins - Service Instructions - Service Letters Any reference to a document refers to the latest edition issued by ROTAX if not stated otherwise. ◆ NOTE: The status of Manuals can be determined by checking the table of amendments of the Manual.
  • Page 14 All necessary documentation is available from the ROTAX Distribution- and Service Centers (see Chapter 13). ◆ NOTE: The Illustrations in this Operator´s Manual are stored in a graphic data file and are provided with a consecutive irrelevant number. This number (e.g. 00277) is of no significance for the content.

  • Page 15: Index Of

    01 01 2007 13-3 02 01 2008 01 01 2007 13-4 01 01 2008 01 01 2007 rear page 01 01 2007 01 01 2007 Effectivity: 912 Serie BRP-Rotax page 5 - 1 OM Edition 1 / Rev. 1 Febr. 01/2008...
  • Page 16 NOTES Effectivity: 912 Serie BRP-Rotax page 5 - 2 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 17: List Of Amendments

    02 01 2008 DOA* 10-15 02 01 2008 DOA* 13-1 02 01 2008 DOA* 13-2 02 01 2008 DOA* 13-3 02 01 2008 DOA* Effectivity: 912 Serie BRP-Rotax page 6 - 1 OM Edition 1 / Rev. 1 Febr. 01/2008...
  • Page 18 NOTES Effectivity: 912 Serie BRP-Rotax page 6 - 2 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 19: Description Of Design

    External alternator (12V 40A DC), optional Vacuum pump: (only for A1, A2 and A4 possible), optional Hydraulic constant speed propeller governor: (for A3 only), optional Effectivity: 912 Serie BRP-Rotax page 7 - 1 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 20: Type Description

    7.1) Type description e.g. ROTAX 912 A 2 ◆ NOTE: The type designation is of the following composition. ROTAX 02091 Type: 4-cyl. horizontalle opposed, normal aspirated engine Certification: certified to JAR 22 (TC No. EASA.E.121) F, S certified to FAR 33 (TC No. E00051 EN) JAR-E (TC No.

  • Page 21: Denomination Of Cylinders

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

  • Page 22: Front View

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

  • Page 23: Technical Data

    1,7 kg (3,7 lb) ◆ NOTE: The overload clutch is installed on all certified aircraft engines and on non-certified aircraft engines of the configuration 3. Effectivity: 912 Serie BRP-Rotax page 8 - 1 OM Edition 1 / Rev. 0 Jan.01/2007...

  • Page 24: Fuel Consumption

    ◆ NOTE: Propeller shouldn’t be turned reverse the normal direc- tion of engine rotation. normal direction of propeller rotation (engine) 03646 Effectivity: 912 Serie BRP-Rotax page 8 - 2 OM Edition 1 / Rev. 0 Jan.01/2007...

  • Page 25: Description Of Systems

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

  • Page 26: Fuel System

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

  • Page 27: Lubrication System

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

  • Page 28: Electric System

    9.4) Electric system See fig. 7. The ROTAX 912 engine is equipped with a dual ignition unit of a breaker- less, 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

    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 re- duction gear. Effectivity: 912 Serie BRP-Rotax page 9 - 5 OM Edition 1 / Rev. 0 Jan.01/2007...

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

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

  • Page 31: Operating Instructions

    - In use of waterless coolant: Cylinder head temperature: max.............150 °C (300 °F) Permanent monitoring of cylinder head temperature is necessary. Effectivity: 912 UL / A / F Effectivity: 912 Serie BRP-Rotax page 10 - 1 OM Edition 1 / Rev. 1 Febr. 01/2008...
  • Page 32 ◆ NOTE: Up to this value the dry sump lubrication system war- rants lubrication in every flight situation. Effectivity: 912 UL / A / F Effectivity: 912 Serie BRP-Rotax page 10 - 2 OM Edition 1 / Rev. 1 Febr. 01/2008...

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

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

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

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

  • Page 35: 2) Operating Speeds And Limits (912 Uls / S)

    Permanent monitoring of cylinder head temperature is necessary. Engine start, operating temperature: max............. 50 °C....(120 °F) min............- 25 °C .....(- 13 °F) Effectivity: 912 ULS / S Effectivity: 912 Serie BRP-Rotax page 10 - 5 OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 36 ◆ NOTE: Up to this value the dry sump lubrication system war- rants lubrication in every flight situation. Effectivity: 912 ULS / S Effectivity: 912 Serie BRP-Rotax page 10 - 6 OM Edition 1 / Rev. 1 Febr. 01/2008...

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

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

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

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

  • Page 39: Operating Media

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

  • Page 40: 2) Fuel

    Risk of vapour formation if using winter fuel for summer operation. ■ CAUTION: Obey the latest edition of Service Instruction SI-912-016 for the selection of the correct fuel. Effectivity: 912 Serie BRP-Rotax page 10 - 10 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 41: 3) Lubricants

    ■ CAUTION: If the engine is mainly run on AVGAS more fre- quent oil changes will be required. See Service Information SI-912-016, latest edition. Effectivity: 912 Serie BRP-Rotax page 10 - 11 OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 42 Klima Mehrbereichs-Öle °C °F (climatic multi-grade oils conditions) tropisch (tropical) gemäßigt (temperate) arktisch (arctic) 01176 fig. 15 Effectivity: 912 Serie BRP-Rotax page 10 - 12 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 43: Standard Operation

    - Verify coolant level in the overflow bottle, replenish as required. The coolant level must be between max. and min. mark or at least 0.2 litre (0.4 liq pt). Effectivity: 912 Serie BRP-Rotax page 10 - 13 OM Edition 1 / Rev. 1 Febr. 01/2008...

  • Page 44: 2) Before Engine Start

    Check from the cockpit. Exhaust system: - Inspect for damages, leakage and general condition. 10.3.2) Before engine start Carry out pre-flight checks. Effectivity: 912 Serie BRP-Rotax page 10 - 14 OM Edition 1 / Rev. 1 Febr. 01/2008...

  • Page 45: 3) Pre-Flight Checks

    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) Effectivity: 912 Serie BRP-Rotax page 10 - 15 OM Edition 1 / Rev. 1 Febr. 01/2008...

  • Page 46: 4) Engine Start

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

  • Page 47: 5) Prior To Take-Off

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

  • Page 48: 7) Cruising

    - Use of multigrade oil with the low end viscosity code of 5 or 10. - Gap electrode on spark plug to the minimum or fit new spark plugs. Effectivity: 912 Serie BRP-Rotax page 10 - 18 OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 49 Intake air pre-heating is the only effec- tive remedy. Effectivity: 912 Serie BRP-Rotax page 10 - 19 OM Edition 1 / Rev. 0 Jan. 01/2007...

  • Page 50: Abnormal Operation

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

  • Page 51: Checks

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

  • Page 53: Trouble Shooting

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

  • Page 56: Reporting

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

  • Page 59: Aircraft Engines

    Authorized Distributors for ROTAX Aircraft Engines ® www.rotax-aircraft-engines.com Issue 01 01 2007 1) EUROPE AUSTRIA: GERMANY / THE NETHERLANDS: ➤HB - FLUGTECHNIK GMBH ➤FLUGMOTOREN FRANZ GMBH Dr. Adolf Schärf Str. 42 Am Weidengrund 1a, 83135 Schechen, Germany A-4053 HAID Tel.: +49 (0) 8039 / 90350, Tel.: +43 (0)7229 / 79104,...
  • Page 60 ➤ROTECH RESEARCH CANADA, LTD. 6235 Okanagan Landing Rd. VERNON, B.C., V1H 1M5, CANADA Tel.: +1 250 / 260-6299, Fax: +1 250 / 260-6269 E-mail: inquiries@rotec.com Website: www.rotec.com Effectivity: 912 Serie BRP-Rotax page 13 - 2 OM Edition 1 / Rev. 1 Febr. 01/2008...
  • Page 61 Tel.: +61 (0) 3 / 9735 5655, Contact person: Hussain Al Moalla Fax: +61 (0) 3 / 9735 5699 E-mail:wal@bertfloodimports.com.au Website: www.bertfloodimports.com.au Contact person: Mark Lester Effectivity: 912 Serie BRP-Rotax page 13 - 3 OM Edition 1 / Rev. 1 Febr. 01/2008...
  • Page 62 NOTES Effectivity: 912 Serie BRP-Rotax page 13 - 4 OM Edition 1 / Rev. 0 Jan. 01/2007...
  • Page 64 Motornummer / Engine serial no. Flugzeugtype / Type of aircraft Flugzeugkennzeichen / Aircraft registration no. ROTAX® Vertriebspartner ROTAX® authorized distributor www.rotax-aircraft-engines.com ® and TM are trademarks of BRP-Rotax GmbH & Co. KG. © 2008 BRP-Rotax GmbH & Co. KG. All rights reserved.

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