Rotax 912-UL Manuals

Manuals and User Guides for Rotax 912-UL. We have 5 Rotax 912-UL manuals available for free PDF download: Maintenance Manual, Operator's Manual, Repair Manual

Rotax 912-UL Maintenance Manual (126 pages)

Brand: Rotax | Category: Engine | Size: 7 MB

1 Table of Contents Table of Contents

2
- Table of Contents
  2
2 Index

6
3 List of the Current

8
4 Table of Amendments

10
5 Introduction

13
6 Safety

13
- Repeating Symbols
  13
7 Technical Documentation

13
8 General

13
9 Auxiliary Equipment

13
10 Description of Design

13
11 Maintenance

15
- General Note
  15
- Version
  15
- Procedure Notes
  15
- Auxiliary Tools
  16
- Measuring Tools
  17
- Special Tools and Devices
  18
- Consumable Materials
  24
  - Motor Oil
    26
  - Lithium Grease
    26
  - Multi-Purpose Grease LZ
    26
  - 4) Corrosion Inhibiting Oil Mobil®Arma 524
    26
  - Silastic 743 Rtv
    26
  - Loctite® Antiseize 15378
    26
  - LOCTITE® "574 Orange
    26
  - 8) LOCTITE® "380 Black
    27
  - 9) LOCTITE® "648 Green
    27
  - 10) LOCTITE® "221 Violet
    27
  - 11) LOCTITE® "243 Blue
    27
  - 12) LOCTITE® "603 Green
    27
  - 13) MICRONORM Shot Blasting Abrasive
    27
  - 14) Lapping Fleece SR 4600 a - very Fine Grading
    28
  - 15) Cleaning Agents
    28
  - 16) Valve Lapping Paste
    28
  - 17) MOLYKOTE® 44 Medium
    28
  - 18) Grease MOLYKOTE® GN
    28
  - 19) K&N® Filteroil 99 - 1131
    28
- Securing Elements
  29
  - Safety Wiring
    29
  - 2) Nut Securing
    30
- Tightening Torques
  31
- Treatment of Corrosion and Surface Damages
  32
- Engine Preservation and Engine Back to Operation
  32
  - 1) Preservation of a New Engine
    33
  - 2) Engine Back to Operation
    33
12 Periodic Maintenance

34
13 Maintenance of the Systems

35
- Fuel System
  35
  - 1) Removal of Carburetors and Carburetor Flange
    35
  - BING Constant Depression Carburetor: Check and Maintenance
    36
    
    1) Leakage Test of Float Needle Valve
    36
    
    2) Diaphragm
    37
    
    3) Jet Needle
    37
    
    4) Jets
    38
    
    5) Float Chamber
    38
    
    6) Float Suspension
    39
    
    7) Check of Float Needle Valve
    39
    
    8) Starting Carburetor (Choke)
    40
  - Check of the Fuel System
    41
    
    1) General Notes on Fuels
    41
    
    2) Fuel Pressure
    42
  - Carburetor Flange
    44
  - Fuel Pump
    45
  - 6) Fuel Tubes
    46
  - 7) Carburetor Flange, Carburetor
    47
- Lubricating System
  48
  - 1) Oil Pump Removal
    48
  - 2) Oil Pump Checking
    48
  - 3) Oil Pump Reassembly
    49
  - Magnetic Plug
    50
  - Drain Screw
    50
- Cooling System
  51
  - 1) Water Pump Removal
    51
  - 2) Water Pump Housing Disassembly and Inspection
    51
  - Magneto Hub
    52
  - Ignition Housing Disassembly and Inspect
    52
  - 5) Water Pump Shaft Disassembly
    55
  - 6) Rotary Seal Disassembly
    55
  - Rotary Seal Reassembly
    56
  - 8) Crosssection of Water Pump
    57
  - Ignition Housing Reassembly
    58
  - 10) Water Pump Housing Reassembly
    59
  - 11) Hose Clamps
    60
  - 12) Cooling Air Baffle
    60
- Ignition System
  61
- Temperature- and Pressure Measuring System
  77
14 Maintenance of Components

80
- Electric Starter
  80
- Sprag Clutch
  82
- Rev. Counter Drive
  86
- Propeller Gearbox
  86
- Cylinder Head Removal
  103
  - Cylinder Head Disassembly
    104
  - 2) Valve Guides
    105
  - 3) Valve Seats
    105
  - Valves
    106
  - Valve Springs
    106
  - 6) Rocker Arm
    107
  - 7) Cylinder Head Hardness Test
    107
  - 8) Cylinder Heads Reassembly
    108
- Cylinder and Piston Disassembly
  109
  - Piston Check
    110
  - 2) Piston Rings Check
    111
  - 3) Dimensions of Pistons and Piston Rings
    111
  - Piston Pin
    112
  - Cylinder Check
    112
- Hydraulic Valve Tappets
  113
- Push Rods
  113
- Displacement Parts Reassembly
  114
  - Hydraulic Valve Tappets
    114
  - 2) Piston Fitting
    114
  - 3) Fitting of Cylinder
    116
  - 4) Fitting of Cylinder Head
    116
- Fitting of Coolant Hoses
  118
- Fitting of Intake Manifolds
  118
- Fitting of an Extra Carburetor Support
  118
- Connecting of the Fuel Lines
  119
15 Wear Limits Sheets

120
- Wear Limits for ROTAX® 912 UL/A/F
  120
- Wear Limits for ROTAX 912 S/ULS
  122
16 Form Sheets

123

Rotax 912-UL Maintenance Manual (104 pages)

Brand: Rotax | Category: Engine | Size: 2 MB

Table of Contents

2
- Chapter 0 Introduction 00-00-00
  4
- List of Chapters
  4
- Index
  6
- Introduction
  8
  - Remarks
    8
  - Engine Serial Number
    8
  - Conversion Table and Abbreviations
    10
- Safety Notice
  12
  - Repeating Symbols
    14
  - Maintenance Concept
    14
  - Technical Documentation
    15
    
    1) Use for Intended Purpose
    16
    
    2) Instruction
    17
- Table of Amendments
  20
Table of Contents

21
- CHAPTER 0 5 TIME LIMITS / MAINTENANCE SCHEDULE 1) Table of Contents .................................................................................... 05-00-00 / 1
  23
- Maintenance
  23
  - General Note
    23
  - Authorized Personnel
    24
  - Procedure Notes
    25
  - Trouble Shooting
    26
  - Consumable Materials
    28
  - Acceptable Methods, Techniques and Practices
    32
    
    1) Nut Securing
    32
- General Note
  33
- Time Limits
  33
- Time Limits for Engine Operation
  34
- Annual Inspection
  36
- Time Limit for Rubber Parts
  36
- Time Limit for the Coolant
  36
- General Note
  37
  - Maintenance Schedule Procedures
    38
- Scheduled Maintenance Checks
  37
- Inspection Sheet/Maintenance Schedule
  40
  - Identification
    40
  - Maintenance Schedule
    42
    
    1) Engine Cleaning
    42
    
    2) Visual Inspection of the Engine
    42
    
    3) Verification of Engine Suspension
    44
    
    4) Engine External Parts
    44
Table of Contents

63
- Chapter 12 -00
  63
- Table of Contents
  63
- General Note
  65
  - Engine Cleaning
    66
  - Leakage Check
    67
  - Check of the Engine Suspension
    68
  - Check of the Air Filter
    69
  - Check of Compression
    71
  - Check of V-Belt Tension
    72
  - Locking of the Crankshaft
    73
  - Test Run of Engine
    74
- Cooling System
  76
  - Check of the Cooling System
    76
  - Renewal of the Coolant
    77
  - Flushing of the Cooling System
    77
  - Expansion Tank, Radiator Cap
    78
  - Overflow Bottle
    79
  - Equipment
    79
    
    Cooling Air Guide)
    79
- Fuel System
  80
- Lubrication System
  88
- Electric System
  98
  - Check of Wiring
    98
  - Verification or Replacement of Spark Plugs
    100
- Propeller Gearbox
  102
  - Checking of the Friction Torque
    103

Rotax 912-UL Operator's Manual (84 pages)

912 Series

Brand: Rotax | Category: Engine | Size: 1 MB

1) General Note

9
- Table of Contents
  9
- Technical Documentation
  16
- Standard Version
  18
- Type Description
  19
- Technical Data
  22
- Fuel Consumption
  22
- Direction of Rotation
  22
2) Operating Instructions

23
- Operating Limits (912 A/F/UL)
  24
  - Performance
    24
  - Speed
    24
  - Acceleration
    24
  - Oil Pressure
    24
  - Oil Temperature
    24
  - Egt
    24
  - Conventional Coolant
    25
  - Waterless Coolant
    25
  - Fuel Pressure
    26
  - Power Consumption of the Hydraulic Propeller
    26
  - Power Consumption of the Vacuum Pump
    26
  - Power Consumption of the External Alternator
    26
  - Deviation from Bank Angle
    26
- Operating Limits (912 S/ULS)
  27
  - Performance
    27
  - Speed
    27
  - Acceleration
    27
  - Oil Pressure
    27
  - Oil Temperature
    27
  - Egt
    27
  - Conventional Coolant
    28
  - Waterless Coolant
    28
  - Fuel Pressure
    29
  - Power Consumption of the Hydraulic Propeller
    29
  - Power Consumption of the Vacuum Pump
    29
  - Power Consumption of the External Alternator
    29
  - Deviation from Bank Angle
    29
  - Coolant
    30
3) Standard Operation

35
- Daily Checks
  36
  - Coolant Level
    37
  - Check of Mechanical Components
    38
  - Gear Box
    38
  - Carburetor
    38
  - Exhaust System
    38
- Fully Observe All the Operating and Maintenance Instructions
  36
- Before Engine Start
  39
- Pre-Flight Checks
  39
  - Operating Media
    39
  - Coolant
    39
  - Oil
    40
  - Oil Level (Oil Dipstick)
    40
- Engine Start
  41
- Prior to Take-Off
  43
  - Warming up Period
    43
  - Throttle Response
    43
  - Ignition Check
    43
  - Propeller Governor
    43
- Cruising
  44
- Engine Shut-Off
  44
- Take-Off
  44
- Cold Weather Operation
  45
Warnu

47
7) Description of Systems

63
- Cooling System of Engine
  64
  - Expansions Tank
    64
  - Coolant Temperature Measuring
    64
- Fuel System
  66
  - Return Line
    66
- Lubrication System
  67
  - Oil Pump
    67
  - Oil Circuit Vented
    67
  - Oil Temperature Sensor
    67
- Electric System
  69
  - Charging Coils
    69
- Propeller Gearbox
  70
  - Reduction Ratio
    70
  - Overload Clutch
    70
  - Torsional Shock Absorber
    70
  - Vacuum Pump
    71

Rotax 912-UL Operator's Manual (64 pages)

912 Series

Brand: Rotax | Category: Engine | Size: 1 MB

Table of Contents
3
1 ) Table of Contents

5
2 Index

5
3 Introduction

7
- Remarks
  7
- Engine Serial Number
  7
- OM Edition 1 / Rev. 0 Jan.
  8
4 Safety

9
- Repeating Symbols
  9
- Safety Information
  10
- Technical Documentation
  13
5 Index of

15
6 List of Amendments

17
7 Description of Design

19
- Type Description
  20
- Denomination of Cylinders
  21
  - Top View
    21
  - Front View
    22
8 Technical Data

23
- Dimensions
  23
- Weights
  23
- Fuel Consumption
  24
- Direction of Rotation
  24
9 Description of Systems

25
- Cooling System
  25
- Fuel System
  26
- Lubrication System
  27
- Electric System
  28
- Propeller Gearbox
  29
  - 1) Hydr. Governor for Const. Speed Propeller, Vacuum Pump
    30
10 Operating Instructions

31
100 C

44
- Carburetor
  44
11 Checks

51
- Engine Preservation
  51
12 Trouble Shooting

53
- Reporting
  56
13 Authorized Distributors for ROTAX Aircraft Engines

59

Rotax 912-UL Repair Manual (83 pages)

Brand: Rotax | Category: Engine | Size: 10 MB

Table of Contents
3
Assembly of Cylinder Head
30
Overrunningclutch 1N
30
Ignition Cover
31
Removal of Water Pump
31
Fitting of Rotary Seal and Installation of Water Pump
32
Water Pump Housing
34
Drive for Mechanical Rev Counter
34
Magneto Housing
34
Reduction Gearbox
34
Dis-Assembly of Oil Pump
40
- 1) Oil Circuit
  41
- T6.2) Venting of the Lubrication System
  41
Drive of Vacuum Pump
42
Ignition Unit
42
Generator
46
Check-Circuit for Rectifier-Regu1Ator
47
- 1) DC Output
  47
- 2) Circuit with Main Switch at Battery
  48
- Instruments
  51
- Electric Starter
  52
- Reduction Gear for Electric Starter
  56
- Ignition Cover
  57
- Electric Starter
  57
- Watcr Pump Housing
  57
- BING Constant Depression Carburetor Type 64.3
  61
  - 1) Description of Carburetor
    61
  - 2) Attachment
    61
  - 3) Fuel Supply Control
    61
  - 4> Main Regulating System with Pressure Control
    63
  - 5) Idling System
    66
  - 6) Staning Carburator (Choke)
    67
- Carburetor Actuation
  68
  - 1) Pneumatic Synchronization
    68
  - 2) Mechanical Synchronization
    68
- Actuating of Starting Carburetor
  68
Tightening Torque Specification for Bolts and Nuts
70
Dimension Sheets
74
Distribution- and Service Partners for Rotax Engines
79

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Rotax 912-UL Manuals

Rotax 912-UL Maintenance Manual (126 pages)

Table of Contents

1 Table of Contents Table of Contents

2 Index

3 List of the Current

4 Table of Amendments

5 Introduction

6 Safety

7 Technical Documentation

8 General

9 Auxiliary Equipment

10 Description of Design

11 Maintenance

12 Periodic Maintenance

13 Maintenance of the Systems

14 Maintenance of Components

15 Wear Limits Sheets

16 Form Sheets

Rotax 912-UL Maintenance Manual (104 pages)

Table of Contents

Table of Contents

Table of Contents

Table of Contents

Rotax 912-UL Operator's Manual (84 pages)

Table of Contents

1) General Note

2) Operating Instructions

3) Standard Operation

Warnu

7) Description of Systems

Rotax 912-UL Operator's Manual (64 pages)

Table of Contents

1 ) Table of Contents

2 Index

3 Introduction

4 Safety

5 Index of

6 List of Amendments

7 Description of Design

8 Technical Data

9 Description of Systems

10 Operating Instructions

100 C

11 Checks

12 Trouble Shooting

13 Authorized Distributors for ROTAX Aircraft Engines

Rotax 912-UL Repair Manual (83 pages)

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