Rotax 912 ULS 3 Installation Manual
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Rotax 912 ULS 3 Installation Manual

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Ref. No.: IM-912
898642

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Summary of Contents for Rotax 912 ULS 3

  • Page 1 Ref. No.: IM-912 898642...
  • Page 2 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. Copyright 2009 © - all rights reserved. ROTAX is a trade mark of BRP-Powertrain GmbH&Co. KG. In the following document ®...

  • Page 3: Table Of Contents

    2) Index ........................7 3) Preface ........................9 3.1) Remarks ........................9 3.2) Engine serial number ....................9 3.3) ROTAX Authorized Distributors for Aircraft Engines ............ 9 4) Safety ........................11 4.1) Repeating symbols ....................11 4.2) Safety information ..................... 11 4.3) Instruction .........................
  • Page 4 BRP-Rotax INSTALLATION MANUAL 12.3) Coolant types ......................49 12.4) Check cooling system - Efficiency of the cooling system .......... 50 12.4.1) Measurement of cylinder head temperature and exit temperature ...... 50 12.5) Determination of operating limits, Coolant and necessary modification on radiator installation ....................
  • Page 5 BRP-Powertrain INSTALLATION MANUAL 16) Air intake system ....................99 16.1) Operating limits ......................99 16.2) Requirements on the air intake system ..............100 16.2.1) Requirements on the intake air ducting .............. 100 16.2.2) Airfilter ......................... 100 16.2.3) Airbox ........................101 16.3) Data for optional components of air intake system ..........104 17) Electric system ....................
  • Page 6 BRP-Rotax INSTALLATION MANUAL NOTES page 6 Effectivity: 912 Series May 01/2007 Edition 1 / Rev. 0...

  • Page 7: Index

    BRP-Rotax INSTALLATION MANUAL 2) Index Acceleration 27 Fine filter 86 Air intake system 99 Fitting positions 35 Air temperature in the airbox 132 Fuel filter 86 Airbox 101 Fuel pressure 85 Airfilter 100 Fuel pressure control 88 Attachment points 34...
  • Page 8 BRP-Rotax INSTALLATION MANUAL Safety 11 Safety information 11 Sensor for oil temperature 128 Standard engine design 21 Starter relay 115 State of delivery 31 Symbols 11 Take-off speed 27 Technical data 27 Technical documentation 14 Temperature in airbox 99 Throttle lever 97...

  • Page 9: Preface

    In this Manual the installation of all ROTAX 912 Series engines is described. ◆ NOTE: ROTAX 912 Series includes 912 A, 912 F, 912 S, 912 UL, 912 ULS and 912 ULSFR. Before starting with the engine installation, read this Installation Manual carefully. The Manual will provide you with basic information on correct engine installation, a requirement for safe engine operation.
  • Page 10 BRP-Rotax INSTALLATION MANUAL NOTES Effectivity: 912 Series page 10 Edition 1 / Rev. 0 May 01/2007...

  • Page 11: Safety

    Unless correctly equipped to provide enough electrical power for night VFR (according latest requirement as ASTM), the ROTAX 912 UL/ULS is restricted to DAY VFR only. Effectivity: 912 Series page 11 Edition 1 / Rev. 1...
  • Page 12 BRP-Powertrain INSTALLATION MANUAL This engine is not suitable for acrobatics (inverted flight, etc.). This engine shall not be used on rotor wing aircraft (helicopters) or any similar aircraft. 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.

  • Page 13: Instruction

    Where differences exist between this Manual and regulations provided by any authority, the more stringent regulation should be applied. This engine may be equipped with an other than the ORIGINAL-ROTAX vacuum pump. The safety warning accompanying the air pump must be given to the owner/operator of the aircraft into which the air pump is installed.

  • Page 14: Technical Documentation

    BRP-Rotax INSTALLATION MANUAL ▲ WARNING: Exclusively use tools and supplementary materials as listed in the Illustrated Parts Catalog. ▲ WARNING: This Manual for engine installation is only part of the Technical Documentation and will be supplemented by the respective Operators Manual, Maintenance Manual and Spare Parts List.
  • Page 15 All necessary documentation is available from the ROTAX Authorized Distributors or their Service Centers. Installation drawings and a DMU-model for (virtual) installation analysis are available from the ROTAX Authorized Distributors or their Service Centers. Ersatz fuer Ersatz fuer OPTIONAL ALTERNATOR...
  • Page 16 BRP-Rotax INSTALLATION MANUAL NOTES Effectivity: 912 Series page 16 Edition 1 / Rev. 0 May 01/2007...

  • Page 17: List Of The Effective

    BRP-Powertrain INSTALLATION MANUAL 5) List of the effective pages 00567 chapter page date chapter page date chapter page date 05 01 2007 05 01 2009 05 01 2007 05 01 2009 05 01 2009 05 01 2007 05 01 2009 05 01 2007 05 01 2007 05 01 2007...
  • Page 18 BRP-Rotax INSTALLATION MANUAL NOTES Effectivity: 912 Series page 18 Edition 1 / Rev. 0 May 01/2007...

  • Page 19: Table Of Amendments

    BRP-Powertrain INSTALLATION MANUAL 6) Table of amendments Approval* The technical content is approved under the authority of DOA Nr. EASA.21J.048. 00568 chapter page date of remark for date of approval date of signature change approval from authorities inclusion 0 - 25 05 01 2007 DOA* 05 01 2009...
  • Page 20 BRP-Rotax INSTALLATION MANUAL NOTES Effectivity: 912 Series page 20 Edition 1 / Rev. 0 May 01/2007...

  • Page 21: Description Of Design

    4 08116 ◆ NOTE: Conversion of the version 2 / 4 to version 3 may be accom- plished by ROTAX Authorized Distributors or their Service Center. 7.2) Standard engine design 4 stroke, 4 cyl. horizontally opposed, spark ignition engine, single central...

  • Page 22: Auxiliary Equipment

    Components especially developed and tested for this engine are readily available at BRP-Powertrain. Following auxiliary equipment has been tested on ROTAX engine type 912 for safety and durability to the standards of aviation. The furnishing of proof in accordance to the latest FAR or EASA has to be conducted by the aircraft manufacturer.
  • Page 23 BRP-Rotax INSTALLATION MANUAL Following equipment has not been tested for safety and durability to the standards of aviation. ▲ WARNING: The user assumes all risks possibly arising by utilizing auxiliary equipment. The furnishing of proof in accordance to the latest FAR or EASA has to be conducted by the aircraft manufacturer.

  • Page 24: Engine Components, Engine Views, Definition Of Main Axes

    BRP-Rotax INSTALLATION MANUAL 7.3) Engine components, engine views, definition of main axes See Fig. 2/3/4/5. power take off side magneto side points of attachment (for engine transport) centre of gravity zero reference point for all dimensions ◆ NOTE: Allow ±1 mm on all stated dimensions as manufacturing tolerance.
  • Page 25 BRP-Rotax INSTALLATION MANUAL Fig. 3 00503 cyl. 4 cyl. 3 cyl. 2 cyl. 1 Fig. 5 09147 00504 Fig. 4 Effectivity: 912 Series page 25 Edition 1 / Rev. 0 May 01/2007...
  • Page 26 BRP-Rotax INSTALLATION MANUAL NOTES Effectivity: 912 Series page 26 Edition 1 / Rev. 0 May 01/2007...

  • Page 27: Technical Data

    BRP-Rotax INSTALLATION MANUAL 8) Technical data To maintain clarity, only data relevant for engine installation and operation will be stated in the Manual. ◆ NOTE: Connecting dimensions, filling capacities, drive and reduction ratios, electric output etc. can be found in the respective chapter of engine installation or other relevant engine documentation.

  • Page 28: Installation Dimensions

    Engine dry from serial production with internal alternator, with overload clutch (see section Description of design) ROTAX 912 A, 912 F, 912 UL: Engine weight ..Version 2 and 4: ........57,1 kg (125 lb) Version 3: ..........59,8 kg (132 lb) ROTAX 912 S, 912 ULS: Engine weight ..

  • Page 29: Centre Of Gravity Of Engine And Standard Equipment

    BRP-Rotax INSTALLATION MANUAL exhaust system ......approx. 4,0 kg (8.8 lb) oil radiator .......... 0,55 kg (1.2 lb) engine mount ........2,0 kg (4.4 lb) 8.4) Centre of gravity of engine and standard equipment See Fig. 2/3/4. ◆ NOTE: Dimensions to point of reference (P).
  • Page 30 BRP-Rotax INSTALLATION MANUAL NOTES Effectivity: 912 Series page 30 Edition 1 / Rev. 0 May 01/2007...

  • Page 31: Preparations For Engine Installation

    BRP-Powertrain INSTALLATION MANUAL 9) Preparations for engine installation ■ CAUTION: The stated directives are measures to pay CAUTION to at engine installation to prevent any accidents and engine damage. 9.1) Transport The engine to be lifted by two hooks or straps around the middle (A) of the intake manifolds.

  • Page 32: Protective Covering

    BRP-Rotax INSTALLATION MANUAL 9.4) Protective covering All openings are protected against ingress of contamination and dampness. It is recommended not to remove these plugs until installation of the specific feed line. ◆ NOTE: If the engine will be sent to the manufacturer or distributor reuse transport equipment and replug openings.

  • Page 33: Engine Suspension And Position

    FAR or EASA has to be conducted by the aircraft manufacturer. It is recommended to use the ROTAX engine suspension frame and the 4 stated attachment points R2, L2, R3 and L3 .

  • Page 34: Definition Of Attachment Points

    BRP-Rotax INSTALLATION MANUAL 10.1) Definition of attachment points See Fig. 8. Fig. 8 08318 Axes 09187 attachement x axis y axis z axis attachment point point -200,8 71,0 -211,0 09186 L1 R1 L2 R2 L3 R3 L4 -200,8 -71,0 -211,0...

  • Page 35: Permissible Fitting Positions

    BRP-Rotax INSTALLATION MANUAL attachment point 09184 L5 R5 L6 R6 max. allowable forces attachment point (limit load) in (N) 5 000 in x axis 09185 L1 R1 L2 R2 L3 R3 L4 R4 in y axis 2 000 in z axis 3 000 max.
  • Page 36 BRP-Rotax INSTALLATION MANUAL To prevent a possible hydraulic shock at engine start, ensure proper closing of float valves. If in doubt, park the aircraft with inclining propeller shaft axis. 6° 6° Fig. 9 09136 30° Propeller axis: The centres of attachment points L1 and R1 must be on an axis y2 parallel to y-axis.
  • Page 37 BRP-Rotax INSTALLATION MANUAL Vertical axis: y-axis must be square to the longitudinal axis of the aircraft. Fig. 11 02455 Tolerated roll deviation of Yaw tolerance: ± 10° (see Fig. 11) Effectivity: 912 Series page 37 Edition 1 / Rev. 0...

  • Page 38: General Directives For Engine Suspension

    BRP-Powertrain INSTALLATION MANUAL 10.3) General directives for engine suspension Rubber mounts to be used between engine and aircraft frame to neutralize vibrations. Damping elements as generally used in the aircraft industry (e.g. LORD) are suitable. See Fig. 12. ◆ NOTE: Zelle Stützscheibe The Fig.

  • Page 39: Exhaust System

    BRP-Rotax INSTALLATION MANUAL 11) Exhaust system See Fig. 2, 3 and 4. The shape and execution of the exhaust system is determined essentially by the free space available in the aircraft. For attaching, the exhaust system two studs M8x23 are provided on each cylinder.

  • Page 40: Requirements On The Exhaust System

    BRP-Rotax INSTALLATION MANUAL 11.1) Requirements on the exhaust system See Fig. 13. mean bending radius of exhaust bend : min. 40 mm (1.6 in.) exhaust bend, inside dia.: min. 28 mm (1.1 in.) muffler volume: approx. 5 l (1.32 US gal) back pressure at takeoff performance: max.

  • Page 41: Operating Limits

    ■ CAUTION: The listed engine performance is given at ISA ((15 °C) (59 °F)) conditions only on engine that is equipped with an unmodified ROTAX tuned exhaust muffler system and air intake box. ~100 mm (3.93 in.) 07131 Fig.

  • Page 42: General Directives For Exhaust-System

    BRP-Powertrain INSTALLATION MANUAL 11.3) General directives for exhaust-system See Fig. 15. A exhaust system, especially for universal application has been developed by BRP-Powertrain. Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer. The following recommendations should help the aircraft manufacturer to plan a suitable exhaust system.

  • Page 43: Data For Optional Components Of Exhaust System

    BRP-Rotax INSTALLATION MANUAL The sketch illustrates a possibility how to interconnect the exhaust springs to prevent the vibration of these springs and thus premature wear. It is also recommended to fill the springs with high heat silicone for additional damping of vibrations.
  • Page 44 BRP-Rotax INSTALLATION MANUAL muffler assy. See Fig. 17. Material/thickness of the exhaust components: X 6CrNiTi 189 (1.4541) (stainless) a= 1 mm (0.039 in.) 09159 Fig. 17 exhaust elbow (tailpipe) See Fig. 18. Material/thickness of the exhaust components: X 5CrNi 189 (1.4301) (stainless) a= 1 mm (0.039 in.) 09153 Fig.
  • Page 45 BRP-Rotax INSTALLATION MANUAL ball joint, male See Fig. 19. Material/thickness of the exhaust components: X 15CrNiSi 20,12 (DIN 1.4828) (stainless) a= 1 mm (0.039 in.) 09166 Fig. 19 exhaust tube See Fig. 20. Material/thickness of the exhaust components: X 15CrNiSi 20,12 (DIN 1.4828) (stainless) a= 1 mm (0.039 in.) 09167 Fig.
  • Page 46 BRP-Rotax INSTALLATION MANUAL NOTES Effectivity: 912 Series page 46 Edition 1 / Rev. 0 May 01/2007...

  • Page 47: Cooling System

    12.1) Description of the system See Fig. 21. 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 and overflow bottle.

  • Page 48: Operating Limits

    12.2) Operating Limits Using conventional coolant: Coolant temperature: (coolant exit temperature) max............120 °C (248 °F) Cylinder head temperature: ROTAX 912 UL/A/F: max...........150 °C (300 °F) ROTAX 912 ULS/S: max...........135 °C (275 °F) Permanent monitoring of coolant temperature and cylinder head temperature is necessary.

  • Page 49: Coolant Types

    150 °C (300 °F) (for ROTAX 912 UL/A/F) and 135 °C (275 °F) (for ROTAX 912 ULS/ S). It does not require pressure to maintain its boiling point. Due to a lower thermal conductivity the engine temperature will typically run about 5-10 °C (41-...

  • Page 50: Check Cooling System - Efficiency Of The Cooling System

    To date, no cases in engine operation or flight operation, laboratory conditions or from the field were reported, which show unsafe conditions of ROTAX aircraft engines in combination with the relevant coolants. Marking of the coolant to be used ■...
  • Page 51 BRP-Powertrain INSTALLATION MANUAL 12.4.1) Measurement of cylinder head temperature and coolant exit temperature There are two temperature sensors (1) (see Fig. 23) on the cylinder 2 and 3 for measuring the cylinder head temperature. During flight test the place with the highest cylinder head temperature must be found, this can vary with different engine installation (cowling or free installation, tractor or pusher, fight speed etc.).

  • Page 52: Determination Of Operating Limits, Coolant And Necessary Modification On Radiator Installation

    BRP-Rotax INSTALLATION MANUAL 12.5) Determination of operating limits, Coolant and necessary modifica- tion on radiator installation Depending on the achieved maximum values of the cylinder head temperature and the coolant temperature following action are necessary. 08358 maximum values for coolant used for tests...
  • Page 53 ■ CAUTION: In no case a cylinder head temperature higher than the limit of 150 °C (300 °F) (for ROTAX 912 UL/A/F) and 135 °C (275 °F) (for ROTAX 912 ULS/S) can be defined because detonation could not be sufficiently prevented.

  • Page 54: Requirements On The Cooling System

    ▲ WARNING: The size and layout of the cooling system must be designed to keep the operating temperatures within the specified limits. To minimize flow resistance employ radiator with low flow resistance and parallel flow as realized on the original ROTAX radiator and use short hoses and pipelines. Coolant hoses: temperature durability: min.

  • Page 55: Size And Position Of Connections

    The aircraft manufacturer has to carry out the check of coolant level in the expansion tank and note it in the daily inspection section of his flight manual according latest issue of Operators Manual ROTAX 912. It is recommended to make adequate precautions for accomplishment of these inspections, e.g.
  • Page 56 BRP-Rotax INSTALLATION MANUAL 200± 10 mm 252± 5 mm 07136 Fig. 26 Effectivity: 912 Series page 56 May 01/2007 Edition 1 / Rev. 0...

  • Page 57: Water Inlet Bend

    BRP-Rotax INSTALLATION MANUAL water inlet bend (5): outside dia. 27 mm (1 1/16") slip-on length max. 19 mm (3/4") 110° 105° 70° 75° Fig. 28 05536 Fig. 27 00562 ◆ NOTE: Choose between six possible fitting positions of water inlet bend (5) appropriate to specific installation (see Fig.

  • Page 58: Feasible Location Of Radiator

    BRP-Rotax INSTALLATION MANUAL 12.8) Feasible location of radiator See Fig. 29. The expansion tank (1) must always be positioned at the highest point of the cooling system. ■ CAUTION: If necessary, the radiator outlet opening (8) may be max. 1,5 m (5 ft) above or below water inlet bend (5) on water pump (see Fig.

  • Page 59: Overflow Bottle

    BRP-Rotax INSTALLATION MANUAL ◆ NOTE: For proper operation keep hose to overflow bottle as short and small as possible (see section 12.6 Expansion tank to overflow bottle hose ). ■ CAUTION: To warrant the proper operation of the cooling system the delivery head between overflow bottle and expansion tank must not exceed 250 mm (10").
  • Page 60 BRP-Rotax INSTALLATION MANUAL Unscrew cap (2) from the overflow bottle. Bore the existing vent hole from dia. 1mm (0.04 in.) to dia. 6mm (0.236 in.) Apply LOCTITE 603 to the threads of the hose nipple (3). ® Insert nipple (3) into the vent hole.

  • Page 61: General Directives For The Cooling System

    ■ CAUTION: The size and type of radiator should be adequate to transfer thermal energy of approx. 25 kW (24 BTU/s) (for ROTAX 912 A/F/UL) or approx. 28 kW (26,5 BTU/s) (for ROTAX 912 S/ULS) at take-off power. ◆ NOTE: Assessment data by experience.
  • Page 62 No provision has been made for attachment of the radiator(s) on the engine. ■ CAUTION: Install the radiator without distortion or stressand free of vibrations (rubber mounts are recommended). At installation of a non-original ROTAX radiator take care of sufficient cooling capacity. See section 12.7 Effectivity: 912 Series page 62 May 01/2007 Edition 1 / Rev.

  • Page 63: Coolant Capacity

    BRP-Rotax INSTALLATION MANUAL 12.10)Coolant capacity 4 cylinder heads: ......560 cm (34.1 in water pump: ......... 100 cm (6.10 in expansion tank: ......250 cm (15.2 in 2 m coolant hose (18 mm (.71 in) inside dia.) : ..500 cm (30.5 in...

  • Page 64: 1)General Directives For Ducting Of The Cooling Air

    BRP-Powertrain INSTALLATION MANUAL 12.11.1)General directives for ducting of the cooling air See Fig. 2/3/4. For front installation in a closed fuselage, ducting of cooling air to the cylinders is recommended. In this case a costly horizontal partitioning (baffles) can be avoided. ◆...

  • Page 65: Data For Optional Components Of Cooling System

    BRP-Rotax INSTALLATION MANUAL ■ CAUTION: The stated limit loads are valid only at utilization of min specified thread length, and must never be exceeded. Depth of thread 18 mm (.71 in). attachment points 04876 04864 Axes max. allowable forces (limit...
  • Page 66 BRP-Rotax INSTALLATION MANUAL radiator See Fig. 38. weight: see section 8. 09151 Fig. 38 cooling air baffle See Fig. 39. weight: see section 8. 09165 Fig. 39 ◆ NOTE: The gap between cowling and radiator should be covered by appropriate sealing lips for better efficiency of cooling.

  • Page 67: Lubrication System

    13) Lubrication system 13.1) Description of the system See Fig. 40. The ROTAX 912 engine is provided with a dry sump forced lubrication system with a oil pump with integrated pressure regulator. ◆ NOTE: The oil pump is driven by the camshaft.

  • Page 68: Limits Of Operation

    BRP-Rotax INSTALLATION MANUAL ◆ NOTE: In the serial version of the engine an oil tank is included, but no provision is made for attachment of an oil cooler. ▲ WARNING: Certification of oil cooler and connections to the latest require- ments such as FAR and EASA has to be conducted by the aircraft manufacturer.

  • Page 69: Checking Of The Lubrication System

    BRP-Powertrain INSTALLATION MANUAL 13.3) Checking of the lubrication system To control the proper function of the lubrication system the following readings have to be taken on the running engine as part of the test/qualification procedure. ◆ NOTE: The required pressure gauges and connection parts are not included in the BRP-Powertrain engine delivery.

  • Page 70: 2) Measuring Of The Pressure In The Crankcase

    BRP-Rotax INSTALLATION MANUAL 13.3.2) Measuring of the pressure in the crankcase Measure of the mean crankcase pressure at full load (blow-by gas pressure) responsible for proper oil return from crankcase to oil tank. A pressure indicator (4) (pressure gauge with incorporated viscous damper) may be fitted instead of the magnetic plug (5) or the crankshaft locking screw (6) (see Fig.

  • Page 71: Requirements On The Oil- And Venting Lines

    BRP-Rotax INSTALLATION MANUAL 13.4) Requirements on the oil- and venting lines Oil lines Oil circuit, engine Temperature durability: mind. 140 °C (285 °F) Pressure durability: mind. 10 bar (145 psi.) Bending radius: mind. 70 mm (2.75 in) * * unless otherwise stated by the hose manufacturer Minimum inside dia.

  • Page 72: Connecting Dimensions And Location Of Connections

    BRP-Rotax INSTALLATION MANUAL 13.5) Connecting dimensions and location of connections ■ CAUTION: Utilize the full slip-on length for hose connections. Secure hoses with suitable screw clamp or by crimp connection. ◆ NOTE: The oil pipeline connections are optional as UNF-thread (AN- See SI-912-003.
  • Page 73 BRP-Rotax INSTALLATION MANUAL Oil pump inlet nipple (2): outside dia ..13,2 mm (0.52 in.) slip-on length...max. 21 mm (0.83 in.) Fig. 45 00226 Oil pump (inlet) (3) ....thread 3/4-16 UNF (AN-8) Tightening torque of inlet line: .. 25 Nm (18.5 ft.lb) Fig.
  • Page 74 BRP-Powertrain INSTALLATION MANUAL Oil return ■ CAUTION: The engine design is for a conventional, non-aerobatic, fixed wing tractor or pusher type configuration with the oil return port in the optimum position. With this consideration the engine is properly lubricated in all flight profiles.

  • Page 75: 2) Oil Tank

    BRP-Rotax INSTALLATION MANUAL 13.5.2) Oil tank See Fig. 48 and 49. The oil tank is furnished with 2 screw connections M18x1,5 and with a tapped hole (M10x1). Connections for oil circuit (engine) - Oil inlet (6) and outlet (7) via standard swivel joint and connecting bend (8): 2x connecting bend 90°...

  • Page 76: Feasible Position And Location Of The Oil Tank

    BRP-Rotax INSTALLATION MANUAL 13.6) Feasible position and location of the oil tank See Fig. 50. The longitudinal axis z3 to be parallel to z-axis of the system of coordinates. Tolerated deviation of parallelism: ± 10° ◆ NOTE: Above notice is valid for both planes.

  • Page 77: Feasible Position And Location Of The Oil Cooler

    BRP-Powertrain INSTALLATION MANUAL 13.7) Feasible position and location of the oil cooler See Fig. 50. On principle the oil cooler (5) has to be installed below the oil pump of the engine. ■ CAUTION: The oil cooler has to be installed with connections upwards i.e. in positive direction on z-axis.

  • Page 78: Purging Of Lubrication System

    BRP-Rotax INSTALLATION MANUAL 13.10) Purging of lubrication system See Fig. 51. Verify that oil tank connections are connected correctly and secured, and that the oil cooler (if fitted) is in the suction line (1) between the oil tank and the oil pump inlet.

  • Page 79: Inspection For Correct Priming Of Hydraulic Valve Tappets

    Operators Manual (or SI-27-1997 Oil level check for ROTAX engine type 912 and 914 (Series), current issue). Add oil to engine oil tank to bring the oil level up to the full mark on the dipstick.

  • Page 80: Replacement Of Components

    BRP-Rotax INSTALLATION MANUAL 13.12)Replacement of components If a malfunction of hydraulic valve tappet should be found during this check of priming process, the relevant hydraulic valve tappet has to be replaced. The valve spring support has to be inspected for wear.

  • Page 81: Data For Optional Components Of Oil System

    BRP-Rotax INSTALLATION MANUAL 13.13)Data for optional components of oil system oil radiator See Fig. 53. weight: see section 8. variants of connectors: adaptor UNF (1): thread ........3/4-16 UNF (AN-8) Tightening torque:..... 22 Nm (195 in.lb) and Loctite 243. Tightening torque of oil inlet and outlet: ..... 25 Nm (18.5 ft.lb) ■...
  • Page 82 BRP-Rotax INSTALLATION MANUAL 04910 Fig. 53 B: LOCTITE 243 Effectivity: 912 Series page 82 Edition 1 / Rev. 0 May 01/2007...

  • Page 83: Fuel System

    BRP-Rotax INSTALLATION MANUAL 14) Fuel system 14.1) Description of system See Fig. 54. The fuel flows from the tank via a coarse filter/water trap (1) to the mechanical fuel pump (2), from the pumps fuel passes on via the fuel manifold (3) to the two carburetors.
  • Page 84 BRP-Rotax INSTALLATION MANUAL legend: (1) fine filter / water trap (2) mechanical fuel pump (3) fuel pressure control (4) feeding line from tank (5) return line to tank (6) 1 x check valve (7) electrical fuel pump return line to tank...

  • Page 85: Operating Limits

    BRP-Rotax INSTALLATION MANUAL 14.2) Operating limits ▲ WARNING: Design and layout of the fuel system has to warrant engine operation within the specified limits. Fuel pressure: See Fig. 55. max................. 0,4 bar (5.8 psi.) min................0,15 bar (2.2 psi.) normal ..............

  • Page 86: Requirements Of The Fuel System

    BRP-Rotax INSTALLATION MANUAL 14.3) Requirements of the fuel system Delivery rate: min. 35 l/h (8,2 US gal/h) of mechanical or electric fuel pump. Fuel lines: See Fig. 54. ▲ WARNING: Fuel lines have to be established to the latest requirements such as FAR or EASA by the aircraft manufacturer.

  • Page 87: Connecting Dimensions, Location Of Joints And Directives For Installation

    BRP-Powertrain INSTALLATION MANUAL 14.4) Connecting dimensions, location of joints and directives for installa- tion 14.4.1) fuel manifold See Fig. 2, 3, 4 and 55. position of z4 axis of the fuel manifold: ◆ NOTE: Dimensions always from point of reference (P). return line to tank (5): outside dia.

  • Page 88: 2) Fuel Pressure Control

    BRP-Rotax INSTALLATION MANUAL to fuel pressure gauge to fuel tank to fuel tank fuel pressure fuel pressure sensor connection sensor connection to carburetor to carburetor to carburetor to carburetor from fuel pump from fuel pump Fig. 55 09139 09192 14.4.2) Fuel pressure control See Fig.

  • Page 89: 3) Check Valve

    BRP-Rotax INSTALLATION MANUAL Fig. 56 Fig. 57 00537 02064 14.4.3) Check valve Specification: opening pressure ........0,1-0,15 bar (1,5 psi. - 2,2 psi.) permitted pressure in reverse-biasing ..2 bar (29 psi.) burst pressure ........... 5 bar (72,5 psi.) Effectivity: 912 Series page 89 Edition 1 / Rev.
  • Page 90 BRP-Rotax INSTALLATION MANUAL NOTES Effectivity: 912 Series page 90 Edition 1 / Rev. 0 May 01/2007...

  • Page 91: Carburetor

    BRP-Powertrain INSTALLATION MANUAL 15) Carburetor See Fig. 58. The carburetors on the standard engine are already attached by a flexible flange (and connecting hoses on the airbox). Only connections of the Bowden cable for pre- heating, choke and throttle have to be established. It is recommended, to make the adjustment of the Bowden cable after engine installation has been completed, to ensure exact final adjustment.

  • Page 92: 1) Drainage Piping On Airbox And Drip Trays

    BRP-Powertrain INSTALLATION MANUAL 15.1.1) Drainage piping on airbox and drip trays ▲ WARNING: Connect drainage lines well, otherwise emerging fuel from a possible leakage could drip onto the exhaust system. RISK OF FIRE! The lines have to be routed such that in case of a damage the surplus fuel is drained off suitably.
  • Page 93 BRP-Powertrain INSTALLATION MANUAL Fig. 59 08644 Effectivity: 912 Series page 93 Edition 1 / Rev. 1 May 01/2009...

  • Page 94: Connections For Bowden-Cable Actuation And Limit Load

    BRP-Rotax INSTALLATION MANUAL 15.2) Connections for Bowden-cable actuation and limit load. See Fig. 2, 3, 4, 60 and 61. centre position of carburetor socket (P1) of the respective carburetor: ◆ NOTE: All dimensions to point of reference (P) limit load on point of reference P2 ■...
  • Page 95 BRP-Rotax INSTALLATION MANUAL connection for starting carb (choke) actuation (3) connection on choke lever: clamping nipple 6 (suitable for 1,5 mm (.06 in.) steel wire) action travel: 23 mm ( ") actuating force: min.10 N (2,2 lb) max. 45 N (10 lb)

  • Page 96: Requirements On Cable Actuation

    BRP-Rotax INSTALLATION MANUAL 15.3) Requirements on cable actuation See Fig. 62. The two throttles have to be controlled by two separate Bowden cables working synchronously. Adjust the cables to a free travel of 1 mm (.04 in). (0.04 in.) 08354 Fig.

  • Page 97: Requirements On The Throttle Lever

    BRP-Rotax INSTALLATION MANUAL 15.4) Requirements on the throttle lever See Fig. 63. Adjustable positive stops for idle- and full throttle position are of course required. These stops have to be designed such to render adjustibility and to prevent overload of the idle stop on the carburetor.
  • Page 98 BRP-Rotax INSTALLATION MANUAL NOTES Effectivity: 912 Series page 98 Edition 1 / Rev. 0 May 01/2007...

  • Page 99: Air Intake System

    ROTAX tuned exhaust muffler system and air intake box. If it will be necessary to use a different airbox or a modified genuine ROTAX airbox for reasons of installation the certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer.

  • Page 100: Requirements On The Air Intake System

    If an airbox of not ROTAX origin is used provisions for preheating the intake air have to be made to prevent formation of ice in the intake system.

  • Page 101: 3) Airbox

    BRP-Rotax INSTALLATION MANUAL ▲ WARNING: The certification to the latest requirement such as FAR and EASA has to be conducted by the aircraft manu- facturer. The following points should assist the aircraft manufacturer at the choice of a suitable filter:...
  • Page 102 ■ CAUTION: If the engine has been installed without employment of the optional ROTAX engine frame which includes also support of the airbox, than provide an appropriately support (5) for the airbox. Effectivity: 912 Series page 102 Edition 1 / Rev.
  • Page 103 Make sure that the air intake tubes of the airbox for fresh air and preheated air are connected correctly (see Fig. 64). ◆ NOTE: Fig. 64 shows the genuine ROTAX airbox. Effectivity: 912 Series page 103 Edition 1 / Rev. 1...

  • Page 104: Data For Optional Components Of Air Intake System

    BRP-Rotax INSTALLATION MANUAL 16.3) Data for optional components of air intake system air filter See Fig. 65. weight: see section 8. 09149 Fig. 65 Effectivity: 912 Series page 104 Edition 1 / Rev. 0 May 01/2007...
  • Page 105 BRP-Powertrain INSTALLATION MANUAL airbox (configuration part no. 867756) See Fig. 66. weight: see section 8. 09174 Fig. 66 Effectivity: 912 Series page 105 Edition 1 / Rev. 1 May 01/2009...
  • Page 106 BRP-Powertrain INSTALLATION MANUAL airbox (new version part no. 667355 in comparison to the old version) See Fig. 66-1. weight: see section 8. Fig. 66-1 Effectivity: 912 Series page 106 Edition 1 / Rev. 1 May 01/2009...

  • Page 107: Electric System

    BRP-Rotax INSTALLATION MANUAL 17) Electric system See Fig. 67. The engine is supplied with the wiring completed and ready to operate. Only the following connections to the aircraft have to be established. - integrated generator - external rectifier-regulator - electronic modules...

  • Page 108: 1) Electromagnetic Compatibility (Emc/Emi)

    BRP-Powertrain INSTALLATION MANUAL ▲ WARNING: Do not bend, kink, pinch or otherwise improperly stress the wiring harness. Use proper routing, clamping and strain relief on wiring harnesses. 17.1.1) Electromagnetic compatibility (EMC/EMI) Electromagnetic interference (EMI) and lightning: The engine complies with the EMI and lightning requirements per DO- 160C, sections 18, 20-22 as noted in the following paragraphs.
  • Page 109 BRP-Powertrain INSTALLATION MANUAL capacitor 2 ignition switches master switch starter switch control lamp battery relay battery bus bar capacitor plug connection for trigger coil assy. trigger coil assy. (tachometer) electrical fuel pump starting equipment at the electronic modules 08639 Fig. 67 Effectivity: 912 Series page 109 Edition 1 / Rev.

  • Page 110: Technical Data And Connection Of The Electric Components

    BRP-Rotax INSTALLATION MANUAL 17.3) Technical data and connection of the electric components 17.3.1) Integrated generator See Fig. 68 Feeding wires (1) from the generator to rectifier-regulator on left side of ignition housing (see Fig. 68). 2 flexible cables, 1,5 mm yellow (in shielding metal braid) length approx.
  • Page 111 BRP-Powertrain INSTALLATION MANUAL Description of connections: yellow - from generator red - to battery, positive terminal +B = battery positive terminal G G R warning lamp circuit control or field circuit Fig. 69 08631 Requirements for flawless operation of the rectifier-regulator body of regulator must be grounded with no restance allowed the rectifier-regulator has to be protected by a slow blowing 25A fuse.

  • Page 112: 3) Electronic Modules

    BRP-Rotax INSTALLATION MANUAL During engine stop break circuit between battery and terminal C to avoid discharge of battery! (see Fig. 67) ◆ NOTE: A charge-indicating lamp 3W/12V (Fig. 67, pos. (18) may be fitted on the instrument panel. Current: ■ CAUTION: The graph current over engine speed has been deter- mined and is valid only at the following conditions.
  • Page 113 BRP-Rotax INSTALLATION MANUAL one each flexible wire 0,75 mm (18 AMG), brown length approx. 35 mm (1 3/8") beginning at electronic module with one each plug socket and insulating sleeve 3,96 mm. At the new version the cable grommet and fasten connector are integrated in the 6-pole connector housing.

  • Page 114: 5) Electric Starter

    BRP-Rotax INSTALLATION MANUAL Wire of top electronic module (marked "A") for ignition circuit A. Wire of bottom electronic module (marked "B") for ignition circuit B. ◆ NOTE: Ignition circuit A controls: top spark plugs of cylinder 1 and 2; lower spark plugs of cylinder 3 and 4.

  • Page 115: 6) Starter Relay

    BRP-Rotax INSTALLATION MANUAL 00545 Fig. 74 17.3.6) Starter relay See Fig. 75. nominal voltage: 12 V control voltage: min. 6 V max. 18 V switching current: max. 75 A (permanent) max. 300 A (for 1 sec.) ambient temperature range: min. – 40 °C (-40 °F) max.

  • Page 116: 7) External Alternator (Optional Extra)

    BRP-Rotax INSTALLATION MANUAL 17.3.7) External alternator (optional extra) See Fig. 76, 77 and 78. output: max. 600 W DC at 6000 r.p.m. voltage: 14,2 V – 14,8 V ambient temperature range: min. - 30 °C (-22 °F) max. +90 °C (194 °F) weight: see section 8.
  • Page 117 BRP-Rotax INSTALLATION MANUAL Requirements for correct operation of the integrated rectifier-regulator: the rectifier-regulator has to be protected by a slow blowing fuse or circuit breaker. Fuse or circuit breaker rating must be determined by load, wire size and length. cross section of the main circuit at least 4 mm (10 AWG) a capacitor (Fig.

  • Page 118: 8) Connection Of The Electric Rev-Counter (Tachometer)

    BRP-Powertrain INSTALLATION MANUAL 17.3.8) Connection of the electric rev-counter (tachometer) See Fig. 67/79. Feeding wiring to electric rev counter on left side of ignition housing. connections: 2 flexible cables 0,5 mm , white/yellow and blue/ yellow (in insulation wrap) length approx. 600 mm (24 in) starting from ignition housing. ◆...

  • Page 119: 9) Battery

    BRP-Powertrain INSTALLATION MANUAL 17.3.9) Battery See Fig. 67. ■ CAUTION: To warrant reliable engine start use a battery of at least 16 Ah capacity. 17.3.10) Capacitor (Option electrical fuel pump) See Fig. 67. ■ CAUTION: To warrant reliable operation of the electrical fuel pump the use of capacitor of at least 22 000 μF / 25 V is necessary.
  • Page 120 BRP-Rotax INSTALLATION MANUAL NOTES page 120 Effectivity: 912 Series May 01/2007 Edition 1 / Rev. 0...

  • Page 121: Propeller Drive

    2,2727 (50 Teeth/22 T) 2,4286 (51 T/21 T) max. torque: ROTAX 912 UL, A, F for i=2,2727: 238 Nm (176 ft.lb.) (at propeller) ROTAX 912 UL, A, F for i=2,4286: 255 Nm (188 ft.lb.) (at propeller) ROTAX 912 ULS, S for i=2,4286: 315 Nm (232 ft.lb.) (at propeller)
  • Page 122 BRP-Rotax INSTALLATION MANUAL ◆ NOTE: In the course of certification a vibration analysis of the whole system (engine, suspension, propeller etc.) should be done. If there are no limits found in the technical literature, a max. of 0.1 IPS (inches per second) at 5000 rpm can be assumed.

  • Page 123: Vacuum Pump

    BRP-Rotax INSTALLATION MANUAL 19) Vacuum pump 19.1) Technical data See Fig. 81 and 82 drive via propeller gear location of the necessary connection on the crankcase: see Fig. 81 and 82 coordinates x axis y axis z axis connection -206,3...
  • Page 124 BRP-Rotax INSTALLATION MANUAL Fig. 82 08328 page 124 Effectivity: 912 Series Edition 1 / Rev. 0 May 01/2007...

  • Page 125: Hydraulic Governor For Constant Speed Propeller

    20.1) Technical data See Fig. 83 ◆ NOTE: See therefore also SB-912-052 "Installation / Use of governors for Rotax engine type 912 and 914", latest issue. drive via prop gear location of the necessary connection on the crankcase: see Fig. 83...
  • Page 126 BRP-Rotax INSTALLATION MANUAL Fig. 83 08179 page 126 Effectivity: 912 Series Edition 1 / Rev. 0 May 01/2007...

  • Page 127: Connections For Instrumentation

    BRP-Rotax INSTALLATION MANUAL 21) Connections for instrumentation These connections to be established in accordance to certification and/or national specifications. The certification for connections and connection lines have to be conducted by the aircraft manufacturer to the latest requirements like FAR and EASA.

  • Page 128: Sensor For Oil Temperature

    BRP-Powertrain INSTALLATION MANUAL 21.2) Sensor for oil temperature See Fig. 86 and 87 location: oil pump housing marking (2): marked with "TO" (temperature oil) on oil pump flange ■ CAUTION: To avoid any mix-up with indication wiring, mark this particular cable also with "TO".

  • Page 129: Oil Pressure Sensor

    BRP-Powertrain INSTALLATION MANUAL 21.3) Oil pressure sensor See Fig. 88 and 89. location: oil pump housing wiring connection for instrument: The sensor cable is approx. 3 m long and has 3 leads. The Black lead is not to be connected and has no function. The Red lead from the sensor has to be connected to the positive bus via a fuse or circuit breaker.

  • Page 130: Mechanical Rev Counter (Tach Drive)

    BRP-Powertrain INSTALLATION MANUAL As the instruments need a separate power supply and a different design for the electrical oil pressure sensor, the resistance type instrument (type VDO), which was supplied by BRP-Powertrain up to now, is not suitable anymore. Suitable instruments are offered by various instrument manufacturers (e.g.

  • Page 131: Monitoring Of The Intake Manifold Pressure

    BRP-Powertrain INSTALLATION MANUAL 21.5) Monitoring of the intake manifold pressure See Fig. 92. Connection nipple (1) to measure manifold pressure: outside dia. ø ....6 mm (1/4") slip-on length . max. 17 mm (11/16") ■ CAUTION: Utilize the total slip-on length on all joints. Secure hose by suitable screw clamps or crimp connection.

  • Page 132: Air Temperature In The Airbox (Optional)

    BRP-Powertrain INSTALLATION MANUAL 21.6) Air temperature in the airbox (optional) See Fig. 93. To take air temperature readings in the airbox a connection is provided. This connection is closed on the standard engine by a plug screw. connection: thread M6 thread length approx.

  • Page 133: Preparations For Trial Run Of Engine

    BRP-Rotax INSTALLATION MANUAL 22) Preparations for trial run of engine ▲ WARNING: Prior to engine start and operation review all instructions stated in the Operators Manual. Conduct test run: See Operators Manual 912 section 10.3 Verification of the throttle lever detent for max. continuous power: Performance check in accordance with Operators Manual.
  • Page 134 BRP-Rotax INSTALLATION MANUAL NOTES page 134 Effectivity: 912 Series Edition 1 / Rev. 0 May 01/2007...
  • Page 136 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-Powertrain GmbH & Co KG. © 2009 BRP-Powertrain GmbH & Co KG. All rights reserved.

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