Rotax 912 ULS 3 Manuals

Manuals and User Guides for Rotax 912 ULS 3. We have 7 Rotax 912 ULS 3 manuals available for free PDF download: Maintenance Manual, Installation Manual, Operator's Manual

Rotax 912 ULS 3 Maintenance Manual (456 pages)

912/914 Series

Brand: Rotax | Category: Engine | Size: 15 MB

Table of Contents

3
- 2 List of Chapters
  
  5
- 3 Index
  
  7
- 4 List of the Valid Pages
  
  11
- 5 Table of Amendments
  
  19
- 6 General Note
  
  21
- 7 Safety Notice
  
  23
  - Repeating Symbols
    23
- 8 Technical Documentation
  
  25
  - Filling in the Dimension Sheets
    25
  - List of Abbreviations
    26
- 9 Classification of Parts for Maintenance/Repair
  
  27
  - Determination of Actual Wear [%]
    30
- 10 Maintenance
  
  33
  - Trouble Shooting
    33
  - Tightening Torques
    33
  - Consumable Materials
    34
  - Auxiliary Tools
    37
  - Measuring Tools
    39
Table of Contents

47
- 2 System Description
  
  49
  - Description of Design
    49
  - Type Description
    50
- 3 Technical Data
  
  57
  - Operating Limits
    57
  - Operating Fluids / Capacity
    57
  - Weights
    57
  - Engine / Components
    58
- 4 Treatment of Corrosion and Surface Damage
  
  61
  - Propeller Shaft
    61
- 5 Preservation and Returning to Service
  
  63
- 6 Maintenance
  
  65
  - Engine Suspension Frame
    65
    
    1) Engine Suspension Frame Disassembly
    65
    
    2) Engine Suspension Frame Inspection
    66
    
    3) Engine Suspension Frame Assembly
    66
  - Temperature- and Pressure Observation
    68
Systems Description/Maintenance

69
- 2 Systems Description
  
  73
  - Propeller Gearbox
    73
  - Hydraulic Governor
    75
  - Vacuum Pump
    76
  - Connections for Instrumentation
    76
    
    1) Mechanical Rev Counter and Hourmeter (Optional)
    76
- 3 Maintenance
  
  77
  - Removal of the Fly Wheel Hub
    77
  - Vacuum Pump Removal and Inspection
    78
  - Governor Removal and Inspection
    78
  - Ignition Housing Removal and Inspection
    79
  - Ignition Housing Fitting
    82
  - Sprag Clutch
    83
    
    1) Sprag Clutch Removal
    84
    
    2) Sprag Clutch Dismantling
    85
    
    3) Sprag Clutch Installation
    86
  - Reduction Gear for Electric Starter
    88
  - Rev Counter Drive
    89
  - Propeller Gearbox
    90
    
    3) Removal of Roller Bearing for - Series 4
    92
    
    4) Propeller Gearbox Disassembly
    96
    
    5) Propeller Shaft Removal
    98
    
    6) Vacuum Pump Drive Removal
    100
    
    7) Propeller Governor Drive Removal
    101
    
    9) Vacuum Pump Drive Installation
    106
    
    10) Gearbox Components Inspection
    107
    
    11) Toothed Shaft Profiles Inspection
    111
    
    12) Gear Set (Gear Wheels) Inspection
    112
    
    13) Propeller Gearbox Reassembly
    117
    
    14) Disc Spring Pre-Tension Adjustment
    119
    
    15) Propeller Gearbox - Installation
    121
  - Cylinder Head - Removal
    123
  - Cylinder Head - Disassembly
    125
    
    1) Cylinder Head and Studs
    127
    
    2) Reworking of the Sealing Surface to the Exhaust Manifold
    129
    
    3) Valve Guides
    130
    
    4) Valve Seats
    131
    
    5) Valves
    132
    
    6) Valve Springs
    135
    
    7) Washers
    137
    
    8) Rocker Arm and Rocker Arm Shaft
    138
    
    1) Rocker Arm with Plastic Bushing
    139
    
    2) Rocker Arm with Pressed Sinter Bushing
    140
    
    3) Rocker Arm Shaft
    140
  - Cylinder Head Reassembly
    141
  - Cylinder and Piston - Removal
    143
    
    1) Checking Pistons
    145
    
    2) Checking the Piston Ring
    147
    
    3) Piston Pin
    148
    
    4) Cylinders Inspection
    149
  - Hydraulic Valve Tappets
    151
  - Pushrods
    153
    
    1) Hydraulic Valve Tappets Fitting
    154
    
    2) Pistons Fitting
    154
    
    Piston and Cylinder Assembly Fitting
    154
    
    3) Cylinders Fitting
    158
    
    4) Cylinder Head Fitting
    160
    
    Intake Manifold and Compensation Tube Assembly
    163
- 4 Wear Limits
  
  165
  - Cylinder Head
    176
- 5 Form Sheets
  
  185
  - Form Sheet for Material Testing ROTAX 912/914 Series
    185
    
    1) Inspection on Cracks
    185
Systems Description/Maintenance

187
- 2 Systems Description
  
  189
  - Fuel System (on 912 Series)
    189
  - Fuel System (on 914 Series)
    191
  - Fuel Filter
    193
  - Fuel Pump (on 912 Series)
    193
  - Fuel Pump (on 914 Series)
    193
  - Fuel Pressure Regulator (Only on 914 Series)
    194
  - Pressure Connecting Lines (Only on 914 Series)
    196
  - BING Constant Depression Carburetor Type 64-3
    198
  - Handling of Fuel
    201
  - Connections for Instrumentation
    202
    
    1) Airbox Air Temperature Display (Only on 914 Series)
    202
    
    2) Boost Pressure Display
    202
  - Carb Heat System and Winter Operation
    202
- 3 Maintenance
  
  203
  - BING-Constant Depression Carburetor Inspection
    207
    
    2) Float Needle Valve Leakage Test
    208
    
    3) Individual Components of the Carburetor (on the 912 Series)73-00-00
    209
    
    4) Individual Components of the Carburetor (on the 914 Series)73-00-00
    210
    
    5) Diaphragm
    211
    
    6) Jet Needle
    211
    
    7) Float Chamber, Floats
    213
    
    8) Float Brackets
    214
    
    9) Carburetor Jets
    215
    
    10) Float Needle Valve Inspection
    216
  - 11) Starting Carburetor (Choke)
    217
  - 12) Carburetor Assembly
    217
  - 13) Carburetor Synchronization
    219
  - 14) Idle Speed Adjustment
    219
  - 15) Throttle Cable and Linkage
    219
  - General Information on the Fuel System
    220
    
    1) Fuel Pressure (on 912 Series)
    221
    
    2) Fuel Pressure (on 914 Series)
    223
    
    3) Carburetor Sockets
    224
    
    4) Fuel Lines (on 912 Series)
    226
    
    5) Fuel Lines (on 914 Series)
    229
    
    6) Fuel Pressure Regulator (Only on 914 Series)
    230
    
    7) Fuel Pump (on 912 Series)
    231
    
    8) Fuel Pump (on 914 Series)
    233
    
    9) Pressure Connecting Lines (Only on 914 Series)
    235
  - Assembly of Carburetor Sockets, Carburetor and Fuel Lines
    239
    
    1) Carburetors and Carburetor Sockets
    239
    
    2) Fuel Lines (on 912 Series)
    241
    
    3) Fuel Lines (on 914 Series)
    244
  - Intake Manifolds Fitting
    246
  - Engaging the Carburetor Support
    246
  - Connecting Fuel Lines (Tank)
    247
Systems Description/Maintenance / Troubleshooting

249
- 2 Systems Description
  
  251
  - Electric System (Alternators, Ignition)
    251
    
    1) Ignition
    254
    
    2) Allocation of Trigger Coils and Ignition Circuits
    256
    
    3) Firing Order
    257
  - Connections for Instrumentation
    257
    
    1) Electronic Rev Counter
    257
- 3 Maintenance / Troubleshooting
  
  259
  - Treatment of Corrosion and Surface Damage
    259
    
    Electric System
    259
  - Checking the Ignition Unit, Trouble Shooting
    259
  - Spark Plugs
    260
  - Spark Plug Connectors and Ignition Cables
    260
  - Electronic Module, Trigger Coil Kit
    262
  - Charging Coil
    263
  - Generator Coils
    264
  - Dual Ignition Coil
    265
  - Cut-In Speed of Ignition
    266
  - Ignition Timing Control
    267
  - Ignition Circuits Inspection (Ignition Check)
    269
  - Measurement Values for the Ignition Unit
    270
  - Wiring Diagrams
    272
    
    1) Engine Internal (on the 912 Series)
    272
    
    Engine Internal (on the 914 Series)
    278
    
    Engine External (on the 914 Series)
    282
  - Ignition Electric Set Removal
    283
  - Ignition Electric Set Dismantling
    285
    
    Dual Ignition Coils Replacement
    285
  - Ignition Electric Set Reassembly
    289
  - Ignition Electric Set Refitting
    291
  - Trigger Coil Kit Replacement
    294
  - Stator Removal and Refitting
    296
  - Fly Wheel Hub
    297
  - Interference Suppression Box (Only on the 912 Series)
    300
    
    1) Interference Suppression Box Dismantling
    300
    
    2) Interference Suppression Box Wiring Diagram
    301
    
    3) Interference Suppression Box Assembly
    302
    
    4) Interference Suppression Box Fitting
    302
  - Rev Counter and Ignition Trigger Coils
    303
  - External Alternator (Optional on 912/914 Series)
    305
    
    1) Vbelt Pulley Assembly
    305
    
    2) Alternator Assembly
    305
    
    3) V-Belt Tension
    307
- 4 Wear Limits
  
  309
- 5 Form Sheets
  
  311
Table of Contents

313
- 2 Systems Description
  
  315
  - Cooling System
    315
  - Connections for Instrumentation
    316
- 3 Maintenance
  
  317
  - Water Pump Removal and Inspection
    318
  - Water Pump Housing - Dismantling and Inspection
    319
  - Fly Wheel Hub Removal
    321
  - Ignition Housing Removal
    321
  - Water Pump Shaft - Removal
    321
  - Rotary Seal - Removal
    322
  - Rotary Seal - Installation
    322
  - Axial Position of the Water Pump Shaft
    324
  - Ignition Housing Assembly
    325
  - Water Pump Housing - Reassembly
    325
  - Coolant Hoses Fitting
    326
  - Spring Band Hose Clamps
    326
  - Radiator (Optional 912/ 914 Series)
    326
  - Cooling Air Duct (Optional 912/ 914 Series)
    326
  - Expansion Tank
    327
  - Overflow Bottle
    327
  - Temperature Measurement System
    327
  - 1) Cylinder Head Temperature Sensor
    327
- 4 Wear Limits
  
  331
  - Water Pump
    331
Systems Description/Maintenance

333
- 2 Systems Description
  
  335
  - Turbocharger Control (Only on 914 Series)
    335
    
    1) Target Pressure Reduction at Overspeeding
    340
    
    2) Target Pressure Reduction
    340
    
    2) Target Pressure Reduction at Excessive Airbox
    341
    
    3) Target Pressure Reduction by Limiting the Compressor
    342
    
    Pressure Ratio
    342
    
    3) Lamp Output Connections on the TCU
    343
    
    4) Three-Way Solenoid Valve
    344
    
    5) PC Interface
    344
- 3 Maintenance
  
  345
  - Control System of the Turbocharger (Only on 914 Series)
    345
    
    1) Checking the Turbocharger Control Unit (TCU) by Means
    345
    
    1) Functions of the Communication Program
    345
    
    2) Required Items
    345
    
    3) Scope of the Communication Program
    347
    
    4) Application of the Communication Program
    349
    
    6) Checking the Throttle Valve Position
    361
    
    7) Recalibration of the Throttle Position
    363
  - 2) Static Check of the Turbocharger Control
    364
    
    1) Turbo Control Unit (TCU)
    364
    
    2) Caution Lamps
    366
    
    3) Wiring Harness
    367
    
    4) Throttle Potentiometer
    369
    
    5) Resistance Thermometer
    374
    
    6) Pressure Sensors
    376
    
    7) Servo Motor
    382
    
    8) Circuit Breaker for Servo Motor
    384
    
    9) Three-Way Solenoid Valve
    385
  - Wiring Diagrams
    386
  - Engine External (on the 914 Series)
    386
- 4 Form Sheets
  
  387
Systems Description/Maintenance

389
- 2 Systems Description
  
  391
- 3 Maintenance
  
  395

Rotax 912 ULS 3 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

Rotax 912 ULS 3 Maintenance Manual (170 pages)

Brand: Rotax | Category: Engine | Size: 3 MB

Chapter: 00-00-00 General Note

9
- Table of Contents
  9
- General Note
  11
- Abbreviations and Terms Used in this Manual
  13
- Conversion Table
  15
- Safety Notice
  18
- Instruction
  20
- Maintenance Concept
  21
- Technical Documentation
  22
- Use for Intended Purpose
  24
Chapter: 05-00-00 Maintenance

27
- General Note
  29
- Maintenance
  29
- Authorized Personnel
  30
- Procedure Notes
  31
- Trouble Shooting
  32
- Consumable Materials
  33
Chapter: 05-10-00 Time Limits

37
- Definition of Terms
  39
- Life Cycle
  39
- Operating Hours
  39
- Time Limits
  39
- General Overhaul (TBO)
  40
- Time Limit
  41
- Annual Inspection
  44
- Time Limit for Rubber Parts
  44
- Time Limit for the Coolant
  44
Chapter: 05-50-00 Unscheduled Maintenance Checks

63
Chapter: 12-10-00 Replenishing Operating Fluids

89
- Fluid Capacities
  93
- General Note
  93
- Coolant Check/Replenish
  95
- Cooling System
  95
- Lubrication System
  97
- Oil Level Check/Replenish
  97
Effectivity: 912 Series 12-20-00

99
- Engine Cleaning
  101
- Checking the Air Filter
  103
- Cleaning the Dry Air Filter
  103
- Replacing the Dry Air Filter
  105
- Checking the Engine Suspension
  107
- Visual Inspection
  107
- Corrosion
  108
- Leakage Check
  109
- Checking the Compression
  111
- Checking the V-Belt Tension
  115
- Locking the Crankshaft
  117
- Test Run of Engine
  119
- Checking the Cool System
  121
- Cooling System
  121
- Replacing the Coolant
  122
- Flushing the Cooling System
  124
- Expansion Tank, Radiator Cap
  125
- Accessories
  127
- Overflow Bottle
  127
- Carburetor Synchronization
  129
- Fuel System
  129
- Mechanical Synchronization
  130
- Pneumatic Synchronization
  132
- Idle Speed Check
  136
- Operating Range Check
  137
- Checking of the Float Chamber
  139
- Idle Speed Adjustment
  141
- Checking the Carburetor Actuation
  142
- Oil Change
  147
- Oil Filter Replacement
  148
- Install Oil Filter
  149
- Inspection of the Oil Filter Insert
  150
- Cleaning the Oil Tank
  152
- Purging the Oil System
  154
- Inspecting the Magnetic Plug
  155
- Installation of the Magnetic Plug
  156
- Flushing the Oil Circuit
  157
- Electric System
  159
- Check of Wiring
  160
- Inspection and Replacement of Spark Plugs
  161
- Inspection of Spark Plugs
  162
- Installation of Spark Plug
  163
- Checking the Friction Torque in Free Rotation
  165
- Propeller Gearbox
  165
- Checking the Propeller Gearbox
  167

Rotax 912 ULS 3 Installation Manual (136 pages)

Brand: Rotax | Category: Engine | Size: 4 MB

1 Table of Contents

3
2 Index

7
3 Preface

9
4 Safety

11
- Repeating Symbols
  11
- Safety Information
  11
- Instruction
  13
- Technical Documentation
  14
5 List of the Effective

17
6 Table of Amendments

19
7 Description of Design

21
8 Technical Data

27
- Operating Limits
  27
- Installation Dimensions
  28
- Weight
  28
- Centre of Gravity of Engine and Standard Equipment
  29
- Moments of Inertia
  29
9 Preparations for Engine Installation

31
- Transport
  31
- State of Delivery
  31
- Engine Preservation
  31
- Protective Covering
  32
10 Engine Suspension and Position

33
11 Exhaust System

39
12 Cooling System

47
13 Lubrication System

67
14 Fuel System

83
15 Carburetor

91
16 Air Intake System

99
- Operating Limits
  99
- Requirements on the Air Intake System
  100
  - 1) Requirements on the Intake Air Ducting
    100
  - 2) Airfilter
    100
  - 3) Airbox
    101
- Data for Optional Components of Air Intake System
  104
17 Electric System

107
- Requirements on Circuit Wiring
  107
  - 1) Electromagnetic Compatibility (EMC/EMI)
    108
- Wiring Diagram
  108
- Technical Data and Connection of the Electric Components
  110
  - 1) Integrated Generator
    110
  - 2) Rectifier-Regulator
    110
  - 3) Electronic Modules
    112
  - 4) Ignition Switches (MAG Switch)
    112
  - 5) Electric Starter
    114
  - 6) Starter Relay
    115
  - 7) External Alternator (Optional Extra)
    116
  - 8) Connection of the Electric Rev-Counter (Tachometer)
    118
  - 9) Battery
    119
  - 10) Capacitor (Option Electric Fuel Pump)
    119
  - 11) Starting Equipment at the Electronic Modules (Optional Extra)
    119

Rotax 912 ULS 3 Installation Manual (136 pages)

912 Series

Brand: Rotax | Category: Engine | Size: 4 MB

1 Table of Contents

3
2 Index

7
3 Preface

9
4 Safety

11
- Repeating Symbols
  11
- Safety Information
  11
- Instruction
  13
- Technical Documentation
  14
5 List of the Effective

17
6 Table of Amendments

19
7 Description of Design

21
8 Technical Data

27
- Operating Limits
  27
- Installation Dimensions
  28
- Weight
  28
- Centre of Gravity of Engine and Standard Equipment
  29
- Moments of Inertia
  29
9 Preparations for Engine Installation

31
- Transport
  31
- State of Delivery
  31
- Engine Preservation
  31
- Protective Covering
  32
10 Engine Suspension and Position

33
11 Exhaust System

39
12 Cooling System

47
13 Lubrication System

67
14 Fuel System

83
15 Carburetor

91
16 Air Intake System

99
- Operating Limits
  99
- Requirements on the Air Intake System
  100
  - 1) Requirements on the Intake Air Ducting
    100
  - 2) Airfilter
    100
  - 3) Airbox
    101
- Data for Optional Components of Air Intake System
  104
17 Electric System

107
- Requirements on Circuit Wiring
  107
  - 1) Electromagnetic Compatibility (EMC/EMI)
    108
- Wiring Diagram
  108
- Technical Data and Connection of the Electric Components
  110
  - 1) Integrated Generator
    110
  - 2) Rectifier-Regulator
    110
  - 3) Electronic Modules
    112
  - 4) Ignition Switches (MAG Switch)
    112
  - 5) Electric Starter
    114
  - 6) Starter Relay
    115
  - 7) External Alternator (Optional Extra)
    116
  - 8) Connection of the Electric Rev-Counter (Tachometer)
    118
  - 9) Battery
    119
18 Propeller Drive

121
- Technical Data
  121

Rotax 912 ULS 3 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 ULS 3 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

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1 Table of Contents

2 Index

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