OPERATORS MANUAL

FOR ROTAX ENGINE TYPE 912 SERIES

Ref. No.: OM-912

ROTAX 912 ULS 3 WITH OPTIONS

part no.: 899374

WARNING
Before starting the engine, read the Operators Manual, as it contains
important safety relevant information. Failure to do so may result in personal injuries including death. Consult the original equipment manufacturers handbook for additional instructions!

These technical data and the information embodied therein are the property of BRP-Powertrain
GmbH&Co KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior
written permission of BRP-Powertrain GmbH&Co KG, be disclosed in whole or in part to
third parties. 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 2010 - all rights reserved.
ROTAX is a trade mark of BRP-Powertrain GmbH&Co KG. In the following document the
short form of BRP-Powertrain GmbH&Co KG = BRP-Powertrain is used.
Other product names in this documentation are used purely for ease of identification
and may be trademarks of the respective company or owner.
Approval of translation has been done to best knowledge and judgement - in any case
the original text in german language is authoritative.

Introduction
Foreword

BRP-Powertrain provides Instructions for Continued Airworthiness, which are based on the design, the tests and certification
of the engine and its components.
These instructions apply only to engines and components supplied by BRP-Powertrain.
This Operators Manual contains important information about safe
operation of the engine, together with descriptions of the system
and its layout, technical data, operating media and the operational
limits of the engine.
The specified data apply only to the engine and not to specific applications in particular aircraft. The aircraft manufacturers Operators Manual is therefore definitive in terms of the operation of the
engine, as it contains all of the aircraft-specific instructions.

Chapter structure

The structure of the Manual follows whenever it is applicable the

structure of the GAMA Specification #1 for Pilots Operating
Handbook. The Operators Manual is subdivided into following
chapters:
Subject

Chapter

Chapter INTRO
Chapter LEP)

Table of amendments

Chapter TOA)

General note

Chapter 1)

Operating instructions

Chapter 2)

Standard operation

Chapter 3)

Abnormal operation

Chapter 4)

Performance data

Chapter 5)

Weights

Chapter 6)

Description of systems

Chapter 7)

Checks

Chapter 8)

Supplements

Chapter 9)

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Introduction
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LEP) List of effective pages

Chapter

Page

Date

cover page

Chapter

Page

Date

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INTRO-1
INTRO-2

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LEP

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TOA

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TOA) Table of amendments

Approval*
The technical content is approved under the authority
DOA No. EASA.21J.048.

chapter

page

date of
change

remark for
approval

1 to 9

all

04 01 2010

DOA*

date of
approval from
authorities

date of
issue

signature

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1) General note
Foreword

Before operating the engine, carefully read this Operators Manual. The Manual provides you with basic information on the safe operation of the engine.
If any passages of the Manual are not clearly understood or in
case of any questions, please, contact an authorized Distributor or
Service Center for ROTAX aircraft engines.
We wish you much pleasure and satisfaction flying your aircraft
with this ROTAX engines.

Table of content

This chapter of the Operators Manual contains general and safety

information concerning the operation of the aircraft engine.
Subject

Page

page 1-1

Abbreviations and terms used in this Manual

page 1-3

Safety

page 1-4

Safety notice

page 1-5

Technical documentation

page 1-8

Standard version

page 1-10

Type description

page 1-11

Denomination of cylinders, Engine views

page 1-12

Technical data

page 1-14

Fuel consumption

page 1-14

Direction of rotation

page 1-14

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1.1) General note

Purpose

The purpose of this Operators Manual is provided to familiarize

the owner/user of this aircraft engine with basic operating instructions and safety information.

Documentation

For more detailed information regarding, maintenance, safety- or

flight operation, consult the documentation provided by the aircraft
manufacturer and/or dealer.
For additional information on engines, maintenance or parts, you
can also contact your nearest authorized ROTAX-aircraft engine
distributor (Chapter 9.2).

Engine serial number

When making inquiries or ordering parts, always indicate the engine serial number, as the manufacturer makes modifications to
the engine for product improvement.
The engine serial number is located on the top of the crankcase,
magneto side. See Fig. 1.
Cyl. 1

Cyl. 3

Cyl. 2
Part
1

Cyl. 4
Function

engine serial number

Fig. 1

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1.2) Abbreviations and terms used in this Manual

Abbreviations

Abbreviation

Description

Degrees Celsius (Centigrade)

Degrees Fahrenheit

Ampere

ACG

Austro Control GmbH

API

American Petrol Institute

ASTM

American Society for Testing and Materials

AKI

Anti Knock Index

CAN/CGSB

Canadian General Standards Board

CW

Clockwise

CCW

Counter-clockwise

DOA

Design Organization Approval

EASA

European Aviation Safety Agency

EN

European Standard

FAR

Federal Aviation Regulations

hours

IFR

Instrument Flight Rules

INTRO

Introduction

ISA

International Standard Atmosphere

kW

Kilowatt

LEP

List of effective pages

Nm

Newton meter

OM

Operators Manual

part no.

Part number

RON

Research Octane Number

ROTAX

is a trade mark of BRP-Powertrain GmbH & Co KG

rpm

Revolutions per minute

SAE

Society of Automotive Engineers

SI

Service Instruction

SB

Service Bulletin

SL

Service Letter
Type certificate

TOA

Table of amendments

VFR

Visual Flight Rules

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TC

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1.3) Safety
General note

Although the reading of such information does not eliminate the

hazard, understanding the information will promote its correct use.
Always use common workshop safety practice.
The information and components-/system descriptions contained
in this Manual are correct at the time of publication.
BRP-Powertrain, however, maintains a policy of continuous improvement of its products without imposing upon itself any obligation to install them on its products previously manufactured.

Revision

BRP-Powertrain reserves the right at any time, and without incurring obligation, to remove, replace or discontinue any design, specification, feature or otherwise.

Measuring units

Specifications are given in the SI metric system with the USA

equivalent in parenthesis. Where precise accuracy is not required,
some conversions are rounded off for easier use.

Translation

This document has been translated from German language and

the original German text shall be deemed authoritative.

Symbols used

This Manual uses the following symbols to emphasize particular

information. This information is important and must be observed.

WARNU
WARNING

Identifies an instruction which, if not followed, may cause serious injury including
the possibility of death.
Identifies an instruction which, if not fol-

WARNUN lowed, may cause minor or moderate injuCAUTION

ry.

Denotes an instruction which, if not fol-

WARNUNGlowed, may severely damage the engine

NOTICE
or other component.

NOTES:

Indicates supplementary information which

may be needed to fully complete or understand an instruction.

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A revision bar outside of the page margin indicates a change to text or graphic.

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1.4) Safety notice

Normal use

WARNU
WARNING

Non-compliance can result in serious injuries

or death!
Never fly the aircraft equipped with this engine at locations, airspeeds, altitudes, or other
circumstances from which a successful nopower landing cannot be made, after sudden
engine stoppage.

This engine is not suitable for acrobatics (inverted flight etc.).

This engine shall not be used on rotorcrafts with an in-flight

driven rotor (e.g. helicopters).

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.

Due to the varying designs, equipment and types of aircraft,

BRP-Powertrain grants no warranty or representation on the
suitability of its engines use on any particular aircraft. Further,
BRP-Powertrain grants no warranty or representation of this
engines suitability with any other part, components or system
which may be selected by the aircraft manufacturer, assembler or user for aircraft application.

WARNU
WARNING

Non-compliance can result in serious injuries

or death!
Unless correctly equipped to provide enough
electrical power for night VFR (according latest requirement as ASTM), the ROTAX
912 UL/ULS/ULSFR is restricted to DAY VFR
only.

Certain areas, altitudes and conditions present greater risk

than others. The engine may require humidity or dust/sand
preventative equipment, or additional maintenance may be required.

You should be aware that any engine may seize or stall at any
time. This could lead to a crash landing and possible severe
injury or death. For this reason, we recommend strict compliance with the maintenance and operation and any additional
information which may be given to you by your distributor.

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Whether you are a qualified pilot or a novice, complete knowledge of the aircraft, its controls and operation is mandatory
before venturing solo. Flying any type of aircraft involves a certain amount of risk. Be informed and prepared for any situation
or hazard associated with flying.

A recognized training program and continued education for piloting an aircraft is absolutely necessary for all aircraft pilots.
Make sure you also obtain as much information as possible
about your aircraft, its maintenance and operation from your
dealer.

Respect all government or local rules pertaining to flight operation in your flying area. Fly only when and where conditions,
topography, and airspeeds are safest.

Consult your aircraft dealer or manufacturer and obtain the necessary information, especially before flying in new areas.

Instrumentation

Select and use proper aircraft instrumentation. This instrumentation is not included with the ROTAX engine package.
Only approved instrumentation may be installed.

Engine log book

Keep an engine log book and respect engine and aircraft

maintenance schedules. Keep the engine in top operating
condition at all times. Do not operate any aircraft which is not
properly maintained or has engine operating irregularities
which have not been corrected.

Maintenance

Before flight, ensure that all engine controls are operative.

Make sure all controls can be easily reached in case of an
emergency.

Since special tools and equipment may be required, engine

servicing should only be performed by an authorized ROTAX
engine distributor or a qualified trained mechanic approved by
the local airworthiness authority.

When in storage protect the engine and fuel system from contamination and exposure.

Training

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Regulation

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Engine run

Never operate the engine without sufficient quantities of operating fluids (oil, coolant, fuel).

Never exceed the maximum permitted operational limits.

In the interest of safety, the aircraft must not be left unattended

while the engine is running.

To eliminate possible injury or damage, ensure any loose

equipment or tools are properly secured before starting the engine.

Allow the engine to cool at idle for several minutes before turning off the engine.

This engine may be equipped with a vacuum pump. The safety

warning accompanying the vacuum pump must be given to the
owner/operator of the aircraft into which the vacuum pump is
installed.

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Vacuum pump

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1.5) Technical documentation

General note

These documents form the instructions for continued airworthiness of ROTAX aircraft engines.
The information given is based on data and experience that are
considered applicable for professionals under normal conditions.
The fast technical progress and variations of installation might
render present laws and regulations inapplicable or inadequate.

Documentation

Installation Manual

Operators Manual

Maintenance Manual (Line and Heavy Maintenance)

Overhaul Manual

Illustrated Parts Catalog

Alert Service Bulletins

Service Bulletins

Service Instructions

Service Letters

Status

The status of Manuals can be determined by checking the table of

amendments of the Manual. The 1st column of this table is the revision status.
Compare this number to that listed on the ROTAX WebSite:
www.rotax-aircraft-engines.com.
Updates and current revisions can be downloaded for free.
Further the Manual is in such a way developed that revision pages
are offered and the entire document does not have to be exchanged. The overview of the valid pages are in the Chapter LEP.
The current edition and revision is shown in the foot note.

Reference

Any reference to a document refers to the latest edition issued by

BRP-Powertrain if not stated otherwise.

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Illustrations

The illustrations in this Manual are mere sketches and show a typical arrangement. They may not represent the actual part in all
its details but depict parts of the same or similar function. Therefore deduction of dimensions or other details from illustrations is
not permitted.
NOTE:

The illustrations in this Operators Manual are

stored in a graphic data file and are provided
with a consecutive irrelevant number.

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This number (e.g. 00277) is of no significance

for the content.

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1.6) Standard version

Serial production

4-stroke, 4 cylinder horizontally opposed, spark ignition engine, one central cam-shaft - push-rods - OHV

Liquid cooled cylinder heads

Ram air cooled cylinders

Dry sump forced lubrication

Dual breakerless capacitor discharge ignition

2 constant depression carburetors

mechanical fuel pump

Electric starter (12 V 0.7 kW)

Integrated AC generator with external rectifier-regulator (12 V

20 A DC)

Prop drive via reduction gear with integrated shock absorber

and overload clutch

NOTE:

Electric starter (12 V 0.9 kW)

External alternator (12 V 40 A DC)

Vacuum pump (only for A1, A2 and A4 possible)

Hydraulic constant speed propeller governor (for configuration

3 only)

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Optional

The overload clutch is installed on all serial

production aircraft engines which are certified
and on non-certified aircraft engines of the configuration 3.

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1.7) Type description

e.g. 912 A 2

The type designation is of the following composition.

Description

Description

Baureihe
(configuration)

Type
(type)

Zulassung
(certification)

ROTAX

Configuration

Type:

912

4-cyl. horizontally 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. EASA.E.121)

UL, ULS

non-certified aircraft engines

Prop shaft with flange for fixed

prop, P.C.D 100 mm (3.936 in.).

Configuration:

NOTE:
2

Prop shaft with flange for fixed

pitch propeller.

Prop shaft with flange for constant

speed propeller and drive for hydraulic governor for constant
speed propeller.

Prop flange for fixed pitch propeller

and prepared for retrofit of a hydraulic governor for constant
speed propeller.

This configuration 4 is not available any longer

and will be replaced by configuration 3.

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NOTE:

This configuration is not available any longer

and will be replaced by configuration 2.

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1.8) Denomination of cylinders, Engine views, components

Lateral view
2

Part

Function

propeller gear box

vacuum pump or hydraulic governor for constant speed propeller

Fig. 2

00337

Top view
Cyl. 1

Cyl. 3

6
3

7
Cyl. 4

Cyl. 2
Part

Function
engine serial number

CD carburetor

electric starter

expansion tank with excess pressure valve

exhaust flange

external alternator

Fig. 3

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MS magneto side

PTO power take of side

Front view

Fig. 4

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1.9) Technical data

See table

Description
Bore

912 A/F/UL

912 S/ULS

79.5 mm (3.13 in)

84 mm (3.31 in)

Stroke

61 mm (2.40 in)

61 mm (2.40 in)

Displacement

1211 cm3 (73.9 in3)

1352 cm3 (82.5 in3)

Compression ratio.

9.0 : 1

11 : 1

1.10) Fuel consumption

See table

Fuel consumption in l/h

(US gal/h)

912 A/F/UL

912 S/ULS

at take-off performance

24.0 l/h (6.3 gal/h) 27.0 l/h (7.1 gal/h)

at max. continuous performance

22.6 l/h (5.6 gal/h) 25.0 l/h (6.6 gal/h)

at 75 % continuous performance

16.2 l/h (4.3 gal/h) 18.5 l/h (4.9 gal/h)

specific consumption at max.

continuous performance

285 g/kWh
(0.47 lb/hph)

285 g/kWh
(0.47 lb/hph)

1.11) Direction of rotation

Direction of rotation on propeller
shaft

Direction of rotation on propeller shaft: counter clockwise, looking

at p.t.o side of engine.

Fig. 5

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normal direction of propeller rotation (engine)

2) Operating instructions
Introduction

The data of the certified engines are based on type certificate of

type 912 A JAR 22 (TC No. EASA.E.121),
912 F/S FAR 33 (TC No. E00051 EN),
JAR-E (TC No. EASA.E.121).

Table of contents

This chapter of the Operators Manual contains the operating limits

that must be observed to ensure the ROTAX aircraft engine and
standard systems operate safely.
Subject

Page

Operating limits (912 A/F/UL)

Performance
Speed
Acceleration
Oil pressure
Oil temperature
EGT
Conventional coolant
Waterless coolant
Engine start temperature
Fuel pressure
Power consumption of the hydraulic propeller
governor
Power consumption of the vacuum pump
Power consumption of the external alternator
Deviation from bank angle
Operating limits (912 S/ULS)
Performance
Speed
Acceleration
Oil pressure
Oil temperature
EGT
Conventional coolant
Waterless coolant
Engine start temperature
Fuel pressure
Power consumption of the hydraulic propeller
governor
Power consumption of the vacuum pump
Power consumption of the external alternator
Deviation from bank angle

page 2-2
page 2-2
page 2-2
page 2-2
page 2-2
page 2-2
page 2-2
page 2-3
page 2-3
page 2-4
page 2-4
page 2-4

Operating fluids:
Coolant
Fuel
Lubricants

page 2-8
page 2-8
page 2-9
page 2-10

page 2-4
page 2-4
page 2-4
page 2-5
page 2-5
page 2-5
page 2-5
page 2-5
page 2-5
page 2-5
page 2-6
page 2-6
page 2-7
page 2-7
page 2-7

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2.1) Operating limits (912 A/F/UL)

Performance

Speed

Acceleration

Performance data relate to ISA (International Standard Atmosphere) conditions without Governor, external alternator etc.
Take-off performance

59.6 kW at 5800 rpm

Max. continuous performance

58 kW at 5500 rpm

Take-off speed

5800 rpm (max. 5 min)

Max. continuous speed

5500 rpm

Idle speed

min. 1400 rpm

Limit of engine operation at zero gravity and in negative g condition.

Max.

Oil pressure

5 seconds at max. -0.5 g

Max.

NOTICE

7 bar (102 psi)

For a short period admissible at cold start.

Min.

0.8 bar (12 psi) (below 3500 rpm)

* 1.5 bar (22 psi)

Normal

2.0 to 5.0 bar (29-73 psi) (above

3500 rpm)
* 1.5 to *5.0 bar (22-73 psi)
* 912 UL to S/N 4,402.387
912 A to S/N 4,410.266
912 F to S/N 4,412.764

Oil temperature

EGT

Max.

140 C (285 F)

Min.

50 C (120 F)

normal operating temperature

approx. 90 to 110 C (190 - 230 F)

exhaust gas temperature

880 C (1616 F)

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Max.

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Conventional
coolant

See also Chapter 2.3).

Coolant temperature: (coolant exit temperature)
Max.

120 C (248 F)
Cylinder head temperature:

Max.

150 C (300 F)

Permanent monitoring of coolant temperature and cylinder head temperature is necessary.

Waterless coolant

See also Chapter 2.3).

Cylinder head temperature:
Max.

150 C (300 F)

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Permanent monitoring of cylinder head temperature is necessary.

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Engine start, operating temperature

Max.

50 C (120 F)

Min.

-25 C (-13 F)

Fuel pressure

WARNU
WARNING

Non-compliance can result in serious injuries

or death!
Exceeding the max. admissible fuel pressure
will override the float valve of the carburetor
and to engine failure.

The aircraft engine manufacturer strongly recommends the installation of an additional pump, unless this has not been covered by
legal obligations so far.
Max.

0.4 bar (5.8 psi)

Min.

0.15 bar (2.2 psi)

Propeller governor

Power consumption of the hydraulic propeller governor:

Max.

Vacuum pump

600 W

Power consumption of the vacuum pump:

Max.

External alternator

300 W

Power consumption of the external alternator:

Max.

Bank angle

1200 W

Deviation from bank angle:

Max.

Up to this value the dry sump lubrication system

warrants lubrication in every flight situation.

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NOTE:

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2.2) Operating limits (912 S/ULS)

Performance

Performance data relate to ISA (International Standard Atmosphere) conditions without Governor, external alternator etc.

Speed

Acceleration

Take-off performance

73.5 kW at 5800 rpm

Max. continuous performance

69 kW at 5500 rpm

Take-off speed

5800 rpm (max. 5 min)

Max. continuous speed

5500 rpm

Idle speed

min. 1400 rpm

Limit of engine operation at zero gravity and in negative g condition.

Max.

Oil pressure

Max.

NOTICE

Oil temperature

EGT

5 seconds at max. -0.5 g

7 bar (102 psi)

For a short period admissible at cold start.

Min.

0.8 bar (12 psi) (below 3500 rpm)

Normal

2.0 to 5.0 bar (29-73 psi) (above 3500

rpm)

Max.

130 C (266 F)

Min.

50 C (120 F)

normal operating temperature

approx. 90 to 110 C (190-230 F)

exhaust gas temperature

880 C (1616 F)

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Max.

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Conventional
coolant

See also Chapter 2.3).

Coolant temperature: (coolant exit temperature)
Max.

120 C (248 F)
Cylinder head temperature:

Max.

135 C (275 F)

Permanent monitoring of coolant temperature and cylinder head temperature is necessary.

Waterless coolant

Cylinder head temperature:

Max.

135 C (275 F)

d04674.fm

Permanent monitoring of cylinder head temperature is necessary.

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page 2-6
April 01/2010

Engine start, operating temperature

Fuel pressure

Max.

50 C (120 F)

Min.

-25 C (-13 F)

WARNU
WARNING

Non-compliance can result in serious injuries

or death!
Exceeding the max. admissible fuel pressure
will override the float valve of the carburetor
and to engine failure.

The aircraft engine manufacturer strongly recommends the installation of an additional pump, unless this has not been covered by
legal obligations so far.
Max.

0.4 bar (5.8 psi)

Min.

0.15 bar (2.2 psi)

Propeller governor

Power consumption of the hydraulic propeller governor:

Max.

Vacuum pump

600 W

Power consumption of the vacuum pump:

Max.

External alternator

300 W

Power consumption of the external alternator:

Max.

Bank angle

1200 W

Deviation from bank angle:

Max.

Up to this value the dry sump lubrication system

warrants lubrication in every flight situation.

d04674.fm

NOTE:

40

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2.3) Operating media-Coolant

General note

Obey the latest edition of Service Instruction

WARNUNGSI-912-016 for the selection of the correct

NOTICE
coolant.

Conventional
coolant

Conventional coolant mixed with water has the advantage of a

higher specific thermal capacity than water-less coolant.

Application

When correctly applied, there is sufficient protection against vapor

bubble formation, freezing or thickening of the coolant within the
operating limits.
Use the coolant specified in the manufacturers documentation.

Mixture

Obey the manufacturers instructions about

WARNUNGthe coolant.
NOTICE

mixture ratio %
designation

concentrate

water

conventional e.g. BASF Glysantine

anticorrosion

50*

50

waterless e.g. EVANS NPG+

100

d04674.fm

* coolant component can be increased up to max. 65%.

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page 2-8
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2.4) Operating media-Fuel

General note

Obey the latest edition of Service Instruction

WARNUNGSI-912-016 for the selection of the correct fuNOTICE

el.

Use only fuel suitable for the respective cli-

WARNUNGmatic zone.
NOTICE
NOTE:

Mogas

Risk of vapour formation if using winter fuel for

summer operation.

The following fuels can be used:

Usage/Description
Mogas
European
standard

912 S/ULS

1)

EN 228 Normal

EN 228 Super 1)

EN 228 Super 2)

EN 228 Super plus 1)

EN 228 Super plus 2)

Canadian stan- CAN/CGSB-3.5

dard
Quality 13)

CAN/CGSB-3.5
Quality 34)

ASTM D4814 3)

ASTM D4814 4)

US standard
1)
2)
3)
4)
AVGAS

912 A/F/UL

min. RON 90
min. RON 95
min. AKI 87
min. AKI 91

AVGAS 100LL places greater stress on the valve seats due to its
high lead content and forms increased deposits in the combustion
chamber and lead sediments in the oil system. Thus it should only
be used in case of problems with vapor lock or when other types
of gasoline are unavailable.
Usage/Description
AVGAS

AVGAS 100 LL
(ASTM D910)

912 S/ULS
AVGAS 100 LL
(ASTM D910)

d04674.fm

Aviation
Standard

912 A/F/UL

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2.5) Operating media-Lubricants

General note

Obey the manufacturers instructions about

WARNUNGthe lubricants.
NOTICE

If the engine is mainly run on AVGAS more

frequent oil changes will be required. See
Service Information SI-912-016, latest edition.

Oil type

Motorcycle oil of a registered brand with gear additives. Do

not use aircraft engine oil for direct driven engines.
At the selection of suitable lubricants refer to

WARNUNGthe additional information in the Service InforNOTICE

mation SI-912-016, latest edition.

Oil consumption

Max. 0.06 l/h (0.13 liq pt/h).

Oil specification

Use only oil with API classification "SG" or higher!

Due to the high stresses in the reduction gears, oils with gear
additives such as high performance motor cycle oils are required.

Because of the incorporated overload clutch, oils with friction

modifier additives are unsuitable as this could result in a slipping clutch during normal operation.

Heavy duty 4-stroke motor cycle oils meet all the requirements. These oils are normally not mineral oils but semi- or full
synthetic oils.

Oils primarity for Diesel engines have insufficient high temperature properties and additives which favour clutch
slipping, and are generally unsuitable.

Oil viscosity

Use of multi-grade oils is recommended.

NOTE:

Multi-viscosity grade oils are less sensitive to

temperature variations than single grade oils.

d04674.fm

They are suitable for use throughout the seasons, ensure rapid lubrication of all engine components at cold start and get less fluid at higher
temperatures.

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Table of lubricants

See Fig. 1
Since the temperature range of neighboring SAE grades overlap,
there is no need for change of oil viscosity at short duration of ambient temperature fluctuations.
Klima
F

40

100

multi-grade oils

30

60
10
40

(temperate)
0

20

SAE 5W-50
SAE 5W-40

80
20

gemigt

Mehrbereichs-le

SAE 10W-40

tropisch
(tropical)

SAE 20W-50
SAE 20W-40
SAE 15W-50
SAE 15W-40

(climatic
conditions)

10

arktisch
(arctic)

20

30

Fig. 1

20

d04674.fm

01176

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d04674.fm

NOTES

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3) Standard operation
Introduction

To warrant reliability and efficiency of the engine, meet and carefully observe all the operating and maintenance instructions.

Table of content

This chapter of the Operators Manual contains expanded operating and maintenance instructions.
Subject

Page
page 3-2
page 3-3
page 3-4
page 3-4
page 3-4
page 3-4

Before engine start

page 3-5

Pre-flight checks
Operating media
Coolant
Oil
Oil level (oil dipstick)

page 3-5
page 3-5
page 3-5
page 3-6
page 3-6

Engine start

page 3-7

Prior to take-off
Warming up period
Throttle response
Ignition check
Propeller governor

page 3-9
page 3-9
page 3-9
page 3-9
page 3-9

Take-off

page 3-10

Cruising

page 3-10

Engine shut-off

page 3-10

Cold weather operation

page 3-11

d04675.fm

Daily checks
Coolant level
Check of mechanical components
Gear box
Carburetor
Exhaust system

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page 3-1
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3.1) Daily checks

General note

To warrant reliability and efficiency of the engine, meet and carefully observe all the operating and maintenance instructions.

WARNU
WARNING

Risk of burnings and scalds!

Hot engine parts!
Conduct checks on the cold engine only!

WARNU
WARNING

Non-compliance can result in serious injuries

or death!
Ignition OFF
Before moving the propeller switch off both
ignition circuit and secure the aircraft. Have
the cockpit occupied by a competent person.
If established abnormalities (e.g. excessive

WARNUNGresistance of the engine, noise etc.) inspecNOTICE

d04675.fm

tion in accordance with the relevant Maintenance Manual is necessary. Do not release
the engine into service before rectification.

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page 3-2
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Coolant level

The coolant specifications of the section

WARNUNGChapter 2.3) Operating media are to be obNOTICE

served!

Step

Graphic

Procedure

Verify coolant level in the expansion tank, replenish as required up to top. The max. coolant level must be filled up
to the top (see Fig. 1).

Verify coolant level in the overflow bottle, replenish as required.

The coolant level must be between max. and min. mark.

Expansion tank
1

Part

Function

radiator cap

expansion tank

Fig. 1

d04675.fm

05823

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Check of mech.
components

Check of mechanical components

Step
1

Procedure
Turn propeller by hand in direction of engine rotation several times and observe engine for odd noises or excessive
resistance and normal compression.

At excessive resistance of the engine per-

WARNUNGform the relevant unscheduled maintenance

NOTICE
check according to Maintenance Manual
(Line), chapter Hard to turn over.

Gear box

Version without overload clutch:

No further checks are necessary.
Version with overload clutch:
Step
1

Procedure
Turn the propeller by hand to and fro, feeling the free rotation of 30 before the crankshaft starts to rotate.
If the propeller can be turned between the dogs with practically no friction at all (less than 25 Nm = 19 ft.lb) further
investigation is necessary.

Carburetor

Step
1

Exhaust system

Procedure
Verify free movement of throttle cable and starting carburetor over the complete range. Check from the cockpit.

Step

Procedure
Inspect for damages, leakage and general condition.

d04675.fm

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3.2) Before engine start

Carry out pre-flight checks.

3.3) Pre-flight checks

Safety

WARNU
WARNING

Non-compliance can result in serious injuries

or death!
Ignition OFF. Before moving the propeller.
Switch off both ignition circuits and anchor
the aircraft. Have the cockpit occupied by a
competent person.

WARNU
WARNING

Risk of burnings and scalds!

Hot engine parts!
Carry out pre-flight checks on the cold or luke
warm engine only!

Operating media

Step
1

Coolant

Procedure
Check for any oil-, coolant- and fuel leaks.
If leaks are evident, rectify and repair them before next
flight.

The coolant specifications of the section

WARNUNGChapter 2.3) Operating media are to be obNOTICE

served!

Step

Procedure
Verify coolant level in the overflow bottle, replenish as required up to top.
The coolant level must be between min. and max. mark.

d04675.fm

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BRP-Powertrain

page 3-5
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Oil

The oil specifications of the section Chapter

WARNUNG2.5) Operating media are to be observed!

NOTICE
Step

Procedure

Check oil level and replenish as required.

NOTE:

Propeller shouldn't be turned excessively reverse the normal direction of

engine rotation.

Remove oil tank. Prior to oil check, turn the propeller by

hand in direction of engine rotation several times to pump
oil from the engine into the oil tank.

Oil level (oil dipstick)

It is essential to build up compression in the combustion

chamber. Maintain the pressure for a few seconds to let the
pressure flow around the piston rings into the crankcase.
The speed of rotation is not important for the pressure
transfer into the crankcase.

This process is finished when air is returning back to the oil

tank and can be noticed by a murmur from the open oil
tank.

Install oil tank cap.

NOTE:

The oil level should be in the upper half (between the 50% and the max mark) and
should never falls below the min mark. Prior to
long flights oil should be added so that the oil
level reaches the max mark.

Avoid oil levels exceeding the max mark, since excess oil could
be poured out through the venting system.

d04675.fm

Difference between max.- and min.- mark = 0.45 litre (0.95 liq pt)

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page 3-6
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3.4) Engine start

Safety

WARNU
WARNING

Engine start

Step

Non-compliance can result in serious injuries

or death!
Do not take the engine into operation if any
person is near the aircraft.

Designation

Procedure

Fuel valve

open

Starting carb

activated

If
engine in operating temperature

Then
start the engine without
choke

Throttle lever

set to idle position

Master switch

on

Ignition

both circuits switched on

NOTICE

Do not actuate starter button (switch) as

long as the engine is running. Wait until
complete stop of engine!

Starter button

NOTICE

actuate
Activate starter for max. 10 sec. only (without interruption), followed by a cooling
period of 2 minutes!

As soon as engine runs

adjust throttle to achieve

smooth running at approx.
2500 r.p.m

Oil pressure

Check if oil pressure has risen within 10 seconds and

monitor oil pressure. Increase of engine speed is only
permitted at steady oil pressure readings above 2 bar
(30 psi).

At an engine start with low oil temperature, continue to observe the oil pressure as it could drop again due to the
increased flow resistance in the suction
line. The number of revolutions may be
only so far increased that the oil pressure remains steady.

Starting carb (choke)

de-activate

d04675.fm

10

NOTICE

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To observe!

Reduction gear with shock absorber

Since the engine comprises a reduction gear

WARNUNGwith shock absorber, take special care of the

NOTICE
following:

Step

Procedure
To prevent impact load, start with throttle lever
in idle position or at the most up to 10% open.

For the same reason, wait for around 3 sec. after throttling back to partial load to reach constant speed before re-acceleration.

For checking the two ignition circuits, only one

circuit may be switched off and on at a time.

d04675.fm

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BRP-Powertrain

page 3-8
April 01/2010

3.5) Prior to take-off

Safety

WARNU
WARNING

Warming up period

Throttle response

Non-compliance can result in serious injuries

or death!
Do not take the engine into operation if any
person is near the aircraft.

Step

Procedure

Start warming up period at approx. 2000 rpm for approx. 2

minutes.

Continue at 2500 rpm, duration depending on ambient

temperature, until oil temperature reaches 50 C (120 F).

Check temperatures and pressures.

After a full-load ground test allow a short coo-

WARNUNGling run to prevent vapour formation in the cylNOTICE

inder head.

Step
1

Ignition check

Procedure
Short full throttle ground test (consult Aircraft Operators
Manual since engine speed depends on the propeller
used).

Check the two ignition circuits at 4000 rpm (approx. 1700 rpm propeller).
Step

Procedure

Speed drop with only one ignition circuit must not exceed
300 rpm (approx. 130 rpm propeller).

115 rpm (approx. 50 rpm propeller) max. difference of

speed by use of either circuit, A or B.
NOTE:

Propeller governor

The propeller speed depends on

the actual reduction ratio.

Check of hydraulic propeller governor:

Check control of the hydraulic propeller governor to specifications
of the manufacturer.
Cycling the propeller governor puts a relatively
high load on the engine. Unnecessary cycling or
additional checks should be avoided.

d04675.fm

NOTE:

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3.6) Take-off
Safety

WARNU
WARNING

Non-compliance can result in serious injuries

or death!

Monitor oil temperature, cylinder head temperature and oil

pressure. Limits must not be exceeded! See Chapter 2.1) Operating limits.

Respect cold weather operation recommendations, see

Chapter 3.9).

Climb

Climbing with engine running at take-off performance is permissible (max. 5 minutes) (see Chapter 2.1).

3.7) Cruising
Performance

Step

Procedure

Set performance as per performance specifications

Chapter 5) and respect operating limits as per Chapter

2.1).

Oil temperature

Step
1

Procedure
Avoid operation below normal operation oil temperature
(90 to 110 C / 194 to 230 F), as possible formation of
condensation water in the lubrication system badly influences the oil quality.
To evaporate possibly accumulated condensation water,
at least once a day 100 C (212 F) oil temperature must
be reached.

3.8) Engine shut-off

General note

Normally the cooling down of the engine during descending and

taxiing will be sufficient to allow the engine to be shut off as soon
as the aircraft is stopped.

d04675.fm

At increased operating temperatures make an engine cooling run

of at least minimum 2 minutes.

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3.9) Cold weather operation

General note

Generally, an engine service should be carried out before the start

of the cold season.

Coolant

For selection of coolant and mixing ratio, see "Coolant",

Chapter 2.3)

Lubricant

For selection of oil, see table of Lubricants Chapter 2.5).

Cold start

With throttle closed and choke activated (open throttle renders

starting carb ineffective).

Be aware, no spark below crankshaft speed of 220 rpm (propeller speed of 90 rpm).

As performance of electric starter is greatly reduced when hot,

limit starting to periods not much longer than 10 sec. With a
well charged battery, adding a second battery will not improve
cold starts.

Remedy - Cold start

Step

Procedure

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.

Preheat engine.

Icing in the air intake system

Icing due to humidity

Remedy

Carburetor icing due to humidity may occur on the venturi and on

the throttle valve due to fuel evaporation and leads to performance loss and change in mixture.

d04675.fm

Intake air pre-heating is the only effective remedy. See Flight

Manual supplied by the aircraft manufacturer.

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Icing due to water

in fuel

Icing due to water in fuel

Fuels containing alcohol always carry a small

WARNUNGamount of water in solution. In case of temNOTICE

perature changes or increase of alcohol content, water or a mixture of alcohol and water
may settle and could cause troubles.

Water in fuel will accumulate at the lower parts of the fuel system
and leads to freezing of fuel lines, filters or jets.
-

Use non-contaminated fuel (filtered through suede)

Generously sized water separators

Fuel lines routing inclined

Prevent condensation of humidity, i.e avoid temperature differences between aircraft and fuel.

d04675.fm

Remedy

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page 3-12
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4) Abnormal operation
Introduction

WARNU
WARNING

NOTE:
Table of contents

Non-compliance can result in serious injuries

or death!
At unusual engine behaviour conduct checks
as per Maintenance Manual, Chapter 05-5000 before the next flight.

Further checks - see Maintenance Manual.

This chapter of the Operators Manual contains expanded operating and maintenance instruction at abnormal operation.
Subject

Page

page 4-2

Exceeding of max. admissible engine speed

page 4-2

Exceeding of max. admissible cyl. head temperature

page 4-2

Exceeding of max. admissible oil temperature

page 4-2

Oil pressure below minimum - during flight

page 4-3

Oil pressure below minimum - on ground

page 4-3

Trouble shooting

page 4-4

d04676.fm

Start during flight

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4.1) Start during flight

Engine stop

Starting procedure same as on ground, however, on a warm

engine without choke.

4.2) Exceeding of max. admissible engine speed

Exceeding of max.
engine speed

Reduce engine speed. Any exceeding of the max. admissible

engine speed has to be entered by the pilot into the logbook,
stating the duration and extend of overspeed.

4.3) Exceeding of max. admissible cyl. head temperature

Exceeding of cylinder head temperature

Reduce engine power setting to the minimum

WARNUNGnecessary to maintain flight and carry out

NOTICE
precautionary landing.

Any exceeding of the max. admissible cylinder head temperature has to be entered by the pilot into the logbook, stating duration and extent of over-temperature condition.

4.4) Exceeding of max. admissible oil temperature

Exceeding of oil
temperature

Reduce engine power setting to the minimum

WARNUNGnecessary to maintain flight and carry out

NOTICE
precautionary landing.

Any exceeding of the max. oil temperature must be entered by

the pilot in the logbook, stating duration and extent of overtemperature condition.

d04676.fm

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4.5) Oil pressure below minimum - during flight

Oil pressure below
minimum

Reduce engine power setting to the minimum

WARNUNGnecessary and carry out precautionary lanNOTICE

ding.

Check oil system.

4.6) Oil pressure below minimum - on ground

Immediately stop the engine and check for reason. Check oil system.
Check oil quantity in oil tank.

Check oil quality. See Chapter 2.5).

d04676.fm

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page 4-3
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4.7) Trouble shooting

Introduction

All checks in accordance with the Maintenance Manual (current

issue/revision).

WARNU
WARNING

Non-compliance can result in serious injuries

or death!
Only qualified staff (authorized by the Aviation Authorities) trained on this particular engine, is allowed to carry out maintenance and
repair work.
If the following hints regarding remedy do not

WARNUNGsolve the problem, contact an authorized

NOTICE

workshop. The engine must not be operated

until the problem is rectified.

Table of content

This chapter of the Operators Manual contains possible cause

and remedy in case of trouble shooting.
Subject

Page
page 4-5

Engine run

page 4-5

Oil pressure

page 4-5

Oil level

page 4-6

Engine hard to start at low temperature

page 4-6

d04676.fm

Starting problems

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Starting problems

Engine does not start

Possible cause

Engine run

Remedy

Ignition off.

switch on.

Closed fuel valve or clogged

filter.

open valve, clean or renew filter, check

fuel system for leaks.

No fuel in tank.

refuel.

Starting speed too low, faulty

or discharged battery.

fit fully charged battery.

Starting speed too low, start

problems on cold engine.

use top quality, low friction oil; allow for

sufficient cooling period to counter for
performance drop on hot starter; preheat engine.

Engine idles rough after warm-up period, smoky exhaust

emission
Possible cause
Starting carb (Choke) activated.

Remedy
close starting carb (Choke).

Engine keeps running with ignition off

Possible cause
Overheating of engine.

Remedy
let engine cool down at idling at approx.
2000 rpm.

Knocking under load

Possible cause
Octane rating of fuel too low.

Oil pressure

Remedy
use fuel with higher octane rating.

Low oil pressure

Possible cause

Check oil return line for free passage,

renew oil seal.

d04676.fm

Not enough oil in oil tank.

Remedy

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Oil level

Cold engine start

Oil level is increasing

Possible cause

Remedy

Oil too cold during engine operation.

cover oil cooler surface, maintain the oil

temperature prescribed.

Engine hard to start at low temperature

Possible cause

Remedy

Starting speed too low.

preheat engine.

Low charge battery.

fit fully charged battery.

High oil pressure.

At cold start a pressure reading of up to

around 7 bar (102 psi) does not indicate
a malfunction.

Oil pressure too low after cold

start.

Too much resistance in the oil suction

tube at low temperatures. Stop engine
and preheat oil.
At oil pressure reading too low than 1
bar oils with lower viscosity are to be
used.
See SI-912-016, current issue.

NOTE:

Oil pressure at idle must be a minimum of

50 C (120 F) to be measured accurately.

d04676.fm

Be sure the oil pressure does not go below

minimum at idle.

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5) Performance data
Introduction

The performance tables and performance graphs on the next few

pages are intended to show you what kind of performance to expect from your engine in terms of power output. The indicated
power can be achieved by following the procedures laid out in the
Operators Manual and ensuring that the engine is well-maintained.

Table of content

This chapter of the Operators Manual contains performance table

and performance graphs.
Subject

Page

page 5-2
page 5-2
page 5-3
page 5-4

Engine type 912 S/ULS

Performance graphs for stand. conditions
Performance data for variable pitch propeller
Performance graph for non-standard conditions

page 5-5
page 5-5
page 5-6
page 5-7

d04677.fm

Engine type 912 A/F/UL

Performance graphs for stand. conditions
Performance data for variable pitch propeller
Performance graph for non-standard conditions

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Performance
graphs
Engine 912 A/F/UL

Performance graphs for stand. conditions (ISA)

kW
60

hp
80
70

50

60

40

50
30

40

30
20

20
10

10
0
3000

4000

5000

5800 rpm

A: max. engine output

B: power requirement of propeller

Fig. 1

00450
L/h (Gal/h)
30 (7,93)

in.Hg
30

C
20 (5,28)

20

D
10 (2,64)

10

3000

4000

5000

0
5800 rpm

C: manifold pressure
D: fuel consumption
Values along propeller curve

Fig. 2

d04677.fm

00451

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page 5-2
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Performance data
Engine 912 A/F/UL

Performance data for variable pitch propeller

Engine speed over 5500 rpm is restricted to 5 minutes.
Run the engine in accordance with the following table.
Power setting

Engine
speed
(rpm)

Performance
(kW)/(HP)

Torque (Nm)
(ft.lb)

Take-off power

5800

59.6

80

98.1

72.35
ft.lb

full throttle

max. continous
power

5500

58.0

78

100.7

74.27
ft.lb

full throttle

75 %

5000

43.5

58

83.1

61.29
ft.lb

27.2

65 %

4800

37.7

50

75.0

55.32
ft.lb

26.5

55 %

4300

31.9

43

70.8

52.22
ft.lb

26.3

Further essential information regarding engine

behavior see Service Letter SL-912-016, latest
edition.

d04677.fm

NOTE:

Manifold
pressure
(in.HG)

Effectivity: 912 A/F/UL

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BRP-Powertrain

page 5-3
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Performance data
Engine 912 A/F/UL

Performance data variable pitch propeller

The following graph shows the performance drop with increasing
flight altitude. The curves show the performance at 5800, 5500,
5000, 4500 and 4000 rpm, at full throttle.
The engine allows operation with fully open throttle valve over the
whole rpm range, without limitation. But full throttle performance
above 5500 rpm is limited to 5 minutes.
At deviation of temperature conditions from standard atmosphere
conditions the engine performance to be expected can be calculated from the performance indicated, multiplied by standard temperature, divided by actual temperature in K.

Fig. 3

d04677.fm

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Performance graphs for stand. conditions (ISA)

Fig. 4

02001

Ansaugladedruck / manifold pressure [in.Hg]

30

30

Ansaugladedruck
manifold pressure

25

25

20

15

20

Werte bezogen auf die

Propeller-Kurve
values along propeller
curve

15

10

10

Benzinverbrauch
fuel consumption
5

0
2500

Benzinverbrauch / Fuel consumption [L/h]

Performance
graphs
Engine 912 S/ULS

0
3000

3500

4000

4500

5000

5500

5800

Drehzahl/Engine speed [1/min / rpm]

Fig. 5

d04677.fm

02002

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Performance data
Engine 912 S/ULS

Performance data for variable pitch propeller

Engine speed over 5500 rpm is restricted to 5 minutes.
Run the engine in accordance with the following table.
Power setting

Engine
speed
(rpm)

Performance
(kW)/(HP)

Take-off
power

5800

73.5/100

121.0

89.24
ft.lb

27.5

max. continuous power

5500

69.0/90

119.8

88.36
ft.lb

27

75 %

5000

51.0/68

97.4

71.84
ft.lb

26

65 %

4800

44.6/60

88.7

65.42
ft.lb

26

55 %

4300

38.0/50

84.3

62.17
ft.lb

24

Manifold
pressure
(in.HG)

Further essential information regarding engine

behavior see Service Letter SL-912-016, latest
edition.

d04677.fm

NOTE:

Torque (Nm)
(ft.lb)

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page 5-6
April 01/2010

Performance
graph
Engine 912 S/ULS

Performance graph for non-standard conditions

The following graph shows the performance drop with increasing
flight altitude. The curves show the performance at 5800, 5500,
5000, 4800 and 4300 rpm, at full throttle.
The engine allows operation with fully open throttle valve over the
whole rpm range, without limitation. But full throttle performance
above 5500 rpm is limited to 5 minutes.
At deviation of temperature conditions from standard atmosphere
conditions the engine performance to be expected can be calculated from the performance indicated, multiplied by standard temperature, divided by actual temperature in K.

Fig. 6

d04677.fm

08636

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d04677.fm

NOTES

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page 5-8
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6) WEIGHTS
Introduction

The stated weights are dry weights (without operating fluids) and
are guide values only.
Further weight information relating to the equipment can be found
in the current Installation Manual.

Table of content

This chapter of the Operators Manual contains an extensive list of

approved equipment for this engine.
Subject

Page

page 6-2

Accessories

page 6-2

d04678.fm

Engine

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6.1) Engine
-

with: electric starter, carburetors, internal generator, ignition

unit and oil tank

without: exhaust system, radiator, airbox

Configuration 2
912 UL

912 A

57.1 kg (126 lb)

with overload
clutch

912 F

912 ULS

912 S

58.3 kg (128 lb)

with overload
57.1 kg 57.1 kg
clutch
58.3 kg (128 lb)
(126 lb) (126 lb)
56.6 kg (125 lb)
without clutch

55.4 kg (122 lb)

without clutch

Configuration 3
912 UL

912 A

59.8 kg (132 lb)

912 F

912 ULS

912 S

61 kg (134 lb)

6.2) Assessories
Part

Weight

External alternator

3.0 kg (6.6 lb)

Vacuum pump

0.8 kg (1.8 lb)

Overload clutch

1.7 kg (3.7 lb)

The overload clutch is installed on all certified

aircraft engines and on non-certified aircraft
engines of the configuration 3.

d04678.fm

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7) Description of systems
Introduction

This chapter of the Operator Manual contains the description of

cooling system, fuel system, lubrication system, electric system
and the propeller gearbox.

Table of content

As already mentioned in the preface, the system descriptions only

apply to the engine, not to a specific application in a particular aircraft. The aircraft manufacturers Operators Manual is therefore
definitive in terms of the operation of the engine, as it contains all
the aircraft specific instructions.
Subject

Page

page 7-2
page 7-2
page 7-2
page 7-2

Fuel system
Fuel
Return line

page 7-4
page 7-4
page 7-4

Lubrication system
Lubrication
Crankcase
Oil pump
Oil circuit vented
Oil temperature sensor

page 7-5
page 7-5
page 7-5
page 7-5
page 7-5
page 7-5

Electric system
Charging coils

page 7-7
page 7-7

Propeller gearbox
Reduction ratio
Overload clutch
Torsional shock absorber
Backlash
Vacuum pump

page 7-8
page 7-8
page 7-8
page 7-8
page 7-9
page 7-9

d04679.fm

Cooling system of engine

Coolant
Expansions tank
Coolant temperature measuring

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7.1) Cooling system of the engine

General note

See Fig. 1.

Cooling

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.

Coolant

The coolant flow is forced by a water pump, driven from the camshaft, from the radiator to the cylinder heads. From the top of the
cylinder heads the coolant passes on to the expansion tank (1).
Since the standard location of the radiator (2) is below engine level, the expansion tank located on top of the engine allows for
coolant expansion.

Expansion tank

The expansion tank is closed by a pressure cap (3) (with excess

pressure valve and return valve). At temperature rise of the
coolant the excess pressure valve opens and the coolant will flow
via a hose at atmospheric pressure to the transparent overflow
bottle (4). When cooling down, the coolant will be sucked back into
the cooling circuit.

Coolant temperature measuring

Readings are taken on measuring point of the hottest cylinder

head, depending on engine installation.
The temperature sensors are located in cylinder
head 2 and 3.

d04679.fm

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Cooling system

3
1

Part

Function

expansion tank

radiator

pressure cap

overflow bottle

Fig. 1

d04679.fm

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7.2) Fuel system

General note

See Fig. 2

Fuel

The fuel flows from the tank (1) via a coarse filter (2) the fire cock
(3) and fine filter (4) to the mechanical fuel pump (5). From the
pump fuel passes on via the fuel manifold (6) to the two carburetors.

Return line

Via the return line surplus fuel flows back to the fuel tank and suction side of fuel system.
NOTE:

The returnline serves to avoid formation of vapour lock.

Fuel system
return line
fuel tank
1

carburetor

2
orifice jet

7
drain
valve

pressure
gauge
6

3
5

carburetor

Part

Function

fuel tank

coarse filter

fire cock

fine filter

mechanical fuel pump*

fuel manifold*

electric fuel pump

check valve

Fig. 2

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00535

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page 7-4
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d04679.fm

* standard configuration

7.3) Lubrication system

General note

See Fig. 3
The ROTAX 912 engine is provided with a dry sump forced lubrication system with a main oil pump with integrated pressure regulator (1) and oil pressure sensor (2).
The oil pump (3) sucks the motor oil from the oil tank (4) via the oil
cooler (5) and forces it through the oil filter (6) to the points of lubrication in the engine.

Crankcase

The surplus oil emerging from the points of lubrication accumulates on the bottom of crankcase and is forced back to the oil tank
by the piston blow-by gases.

Oil pump

The oil pumps are driven by the camshaft.

Oil circuit vented

The oil circuit is vented via bore (7) on the oil tank.

Oil temperature
sensor

The oil temperature sensor (8) for reading of the oil inlet temperature is located on the oil pump housing.

d04679.fm

Lubrication

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Oil system

6
1
4
5

Part

Function

pressure regulator

oil pressure sensor

oil pump

oil tank

oil cooler

oil filter

venting tube

oil temperature sensor

Fig. 3

d04679.fm

08650

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7.4) Electric system

General note

See Fig. 4
The ROTAX 912 engine is equipped with a dual ignition unit of a
breakerless, capacitor discharge design, with an integrated generator.
The ignition unit needs no external power supply.

Charging coils

Two independent charging coils (1) located on the generator stator supply one ignition circuit each. The energy is stored in capacitors of the electronic modules (2). At the moment of ignition 2
each of the 4 external trigger coils (3) actuate the discharge of the
capacitors via the primary circuit of the dual ignition coils (4).
NOTE:

The trigger coil (5) is provided for rev counter signal.

Firing order: 1-4-2-3.

Ignition circuit A
2

B3
/4

A1/2

/2

A3/4

B1

4
1

4
Ignition circuit B
Part

Function

charging coils

electronic modules

trigger coils for ignition signal

dual ignition coils

trigger coils for speed signal

Fig. 4
d04679.fm

00425

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7.5) Propeller gearbox

General note

See Fig. 5

Reduction ratio

For the engine type 912 two reduction ratios are available.
Reduction ratio

912 A/F/UL

crankshaft: propeller shaft

2.27:1
2.43:1 (optional)

Overload clutch

2.43:1

Depending on engine type, certification and configuration the propeller gearbox is supplied with or without an overload clutch.
NOTE:

The overload clutch is installed on serial production on all certified aircraft engines and on
the non-certified aircraft engines of configuration 3.

Fig. 5
NOTE:

02531

Fig. shows a propeller gearbox of configuration

2 with the integrated overload clutch.

The design incorporates a torsional shock absorber. The shock

absorbing is based on progressive torsional cushioning due to axial spring load acting on a dog hub.

d04679.fm

Torsional shock
absorber

912 S/ULS

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page 7-8
April 01/2010

Backlash

On the gearbox version with overload clutch the design incorporates a friction damped free play at the dogs to warrant proper engine idling. Due to this backlash at the dogs a distinct torsional
impact arises at start, stop and at sudden load changes, but due
to the built-in overload clutch it will remain harmless.
NOTE:

Alternatively either a vacuum pump or a hydraulic governor for

constant speed propeller can be used. The drive is in each case
via the propeller reduction gear.

d04679.fm

Vacuum pump or
hydraulic governor

This overload clutch will also prevent any undue

load to the crankshaft in case of ground contact
of the propeller. See Service Letter SI-912-015,
latest edition.

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April 01/2010

d04679.fm

NOTES

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page 7-10
April 01/2010

8) Checks
Introduction

All checks to be carried out as specified in the current Maintenance Manual (last revision).

WARNU
WARNING

Non-compliance can result in serious

injuries or death!
Only qualified staff (authorized by the
Aviation Authorities) trained on this particular engine, is allowed to carry out
maintenance and repair work.
Carry out all directives of Service Bulletins

WARNUNG(SB), according to their priority.

NOTICE

Observe according Service Instructions (SI)

and Service Letter (SL).

Table of content

This chapter of the Operators Manual contains checks of the aircraft engines.
Subject

Page

page 8-2

Engine back to operation

page 8-2

d04680.fm

Engine preservation

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page 8-1
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8.1) Engine preservation

General note

WARNU
WARNING

Risk of burnings and scalds!

Hot engine parts!
Always allow engine to cool down to ambient
temperature before start of any work.

Due to the special material of the cylinder wall, there is no need

for extra protection against corrosion for the ROTAX aircraft engines. At extreme climatic conditions and for long out of service periods we recommends the following to protect the valve guides
against corrosion:
Step

Procedure

Operate the engine until the temperatures have stabilized for a period of 5 min (engine oil temperature between 50 to 70 C (122 to 160 F).

Switch the engine OFF.

Allow the engine to cool down.

Change oil.

Remove the air intake filters and insert approx.

30 cm (1 fl oz) of corrosion inhibiting oil into the carburetor throat with the engine running at increased
idle speed. Shut off engine.

Drain carburetor float chamber.

Apply oil to all joints on carburetors.

Close all openings on the cold engine, such as exhaust end pipe, venting tube, air filter etc. against entry of dirt and humidity.

Spray all steel external engine parts with corrosion inhibiting oil.

8.2) Engine back to operation

If preservation (including oil change) took place within a year of
storage, oil renewal will not be necessary. For longer storage periods repeat preservation annually.
Step
1

Procedure
Remove all plugs and caps.
Clean spark plugs with plastic brush and solvent.

Reinstall.

d04680.fm

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April 01/2010

9) Supplement
Introduction

According to the regulation of EASA part 21 A.3 / FAR 21.3 the

manufacturer shall evaluate field information and report to the authority. In case of any relevant occurrences that may involve malfunction of the engine, the form on the next page should be filled
out and sent to the responsible authorized ROTAX distributor.
NOTE:

The form is also available from the official

ROTAX AIRCRAFT ENGINES Homepage in
electronic version.
www.rotax-aircraft-engines.com
Register: Document type/Diverses

Table of content

This chapter of the Operators Manual contains the form and the
list of authorized distributors.
Subject

Page

page 9-3

Authorized distributors

page 9-5

d04681.fm

Form

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d04681.fm

NOTES

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page 9-2
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ROTAX

MANUFACTURER

MFG. Model or Part No.

Engine TSN

Engine/Comp. Name

Engine TSO

Manufacturer

Serial No.

Engine Condition

Model or Part No.

6. ENGINE COMPONENT (Assembly that includes part)

Part Name

Muster

MODEL/SERIES

A/C Reg. No.

ATA Code
1.

5. SPECIFIC PART (of component) CAUSING TROUBLE

PROPELLER

4.

POWERPLANT

3.

AIRCRAFT

2.

Enter pertinent data

CUSTOMER
SERVICE INFORMATION REPORT

AIRCRAFT ENGINES

A-Z

7.

Date Sub.

Serial Number

Part/Defect Location

SERIAL NUMBER

1.

Accident; Date

Incident; Date

Check a box below, if this report is related to an aircraft

Optional Information:

8. Comments (Describe the malfunction or defect and the circumstances under which
it occurred. State probable cause and recommendations to prevent recurrence.)

OPERATOR
DESIGNATOR
SUBMITTED BY:

OPER. Control No.

DISTRICT
OFFICE
COMMUTER OTHER
ACG
MFG
AIR TAXI
MECH
OPER
REP. STA

BRP-Powertrain

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TELEPHONE NUMBER: (

d04681.fm

9.1) Form

page 9-3
April 01/2010

d04681.fm

NOTES

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page 9-4
April 01/2010

9.2) Authorized Distributor

General note

See the official ROTAX AIRCRAFT ENGINES Homepage

www.rotax-aircraft-engines.com
List

Overview of authorized distributor for ROTAX aircraft engines.

Subject

Page

page 9-6

America
Australia
Africa

page 9-7
page 9-7
page 9-7

Asia

page 9-8

d04681.fm

Europe

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page 9-5
April 01/2010

1) E U R O P E

Issue 2010 02 01

CROATIA / FORMER YUGOSLAVIA

(EXEPT SLOVENIA):
SHAFT D.O.O.
B.L. Mandica 161 a
HR-54000 OSIJEK
Tel.: +385 (0) 31 /280-046,
Fax: +385 (0) 31 /281-602
E-mail: [email protected]
Contact person: Ing. Ivan Vdovjak

SKYDRIVE LTD.
Burnside, Deppers Bridge
SOUTHAM, WARWICKSHIRE CV47 2SU
Tel.: +44 (0) 1926 / 612 188,
Fax: +44 (0) 1926 / 613 781
E-mail: [email protected]
Website: www.skydrive.co.uk
Contact person: Nigel Beale

CZECHIA / SLOVAKIA:

ITALY / CYPRUS / GREECE / MALTA /

LIBYA :

TEVESO S.R.O.
Skroupova 441
CS-50002 HRADEC KRALOVE
Tel.: +42 049 / 5217 127,
Fax: +42 049 / 5217 226
E-mail: [email protected]
Website: www.teveso.cz
Contact persons: Ing. Jiri Samal

LUCIANO SORLINI S.P.A.

Piazza Roma, 1
Carzago di Calvagese Riviera (Brescia), Italy
Tel.: +39 030 / 601 033,
Fax: +39 030 / 601 463
E-mail: [email protected]
Website: www.sorlini.com
Contact person: Alberto Comincioli

LYCON ENGINEERING AB
Hrkeberga, SE-74596 ENKPING
Tel.: +46 (0) 171 / 414039,
E-mail: [email protected]
Website: www.aeronord.eu

FRANCE / ALGERIA / BELGIUM / LUXEMBURG / MAROCCO /

MONACO / TUNESIA:
MOTEUR AERO DISTRIBUTION
11 Blvd Albert 1
98000 MONACO
Tel.: +377 (0) 93 30 17 40,
Fax: +377 (0) 93 30 17 60
E-mail: [email protected]
Website: www.moteuraerodistribution.com
Contact person: Philippe Thys

GERMANY / AUSTRIA / BULGARIA /

HUNGARY / LIECHTENSTEIN /
ROMANIA / SWITZERLAND /
THE NETHERLANDS:
FRANZ AIRCRAFT ENGINES VERTRIEB
GMBH
Am Weidengrund 1a, 83135 Schechen,
GERMANY
Tel.: +49 (0) 8039 / 90350,
Fax: +49 (0) 8039 / 9035-35
E-mail: [email protected]
Website: www.franz-aircraft.de
Contact person: Eduard Franz

POLAND:
FASTON LTD.
ul. Zwirki i Wigury 47
PL-21-040 SWIDNIK
Tel.: +48 (0) 81/ 751-2882;
Fax: +48 (0) 81 / 751-5740
E-mail: [email protected]
Contact person: Mariusz Oltarzewski

SLOVENIA:
PIPISTREL D.O.O. AJDOVSCINA
Goriska Cesta 50A
5270 AJDOVSCINA
Tel.: +386 (0) 5 / 3663 873,
Fax: +386 (0) 5 / 3661 263
E-mail:[email protected]
Website:www.pipistrel.si
Contact person: Leon Brecelj

SPAIN / PORTUGAL:
AVIASPORT S.A.
Almazara 11
E-28760 TRES CANTOS (MADRID)
Tel.: +34 (0) 91 / 803 77 11,
Fax: +34 (0) 91 / 803 55 22
E-mail: [email protected]
Website: www.aviasport.com
Contact person: Roberto Jimenez

BRP-Powertrain

d04681.fm

SWEDEN / FINLAND / NORWAY /

ESTONIA / LATVIA / LITHUANIA /
DENMARK:

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GREAT BRITAIN / IRELAND /

ICELAND:

page 9-6
April 01/2010

TURKEY:
AIR CONSULT
Belediyeevler Mah., 368. Sokak,Vilko Sitesi No. 8
01360 Adana, TURKEY
Tel.: +90 (0) 322 / 248 0746;
Fax: +90 (0) 322 / 248 6927
E-Mail: [email protected]
Contact person: Peter Johannes Girmann

2) A M E R I C A
CANADA:

NORTH / MIDDLE / SOUTH AMERICA:

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: [email protected]
Website: www.rotec.com

KODIAK RESEARCH LTD.

P.O. Box N 658
Bay & Deveaux Street
NASSAU, BAHAMAS
Tel.: +1 242 / 356 5377,
Fax: +1 242 / 356 2409
E-mail: [email protected]
Website: www.kodiakbs.com

3) A U S T R A L I A /
NEW ZEALAND/
P A P U A N E W G U I N E A:
BERT FLOOD IMPORTS PTY. LTD.
P.O. Box 61, 16-17 Chris Drive
LILYDALE, VICTORIA 3140
Tel.: +61 (0) 3 / 9735 5655,
Fax: +61 (0) 3 / 9735 5699
E-mail: [email protected]
Website: www.bertfloodimports.com.au
Contact person: Mark Lester

4) A F R I C A
EGYPT:
AL MOALLA
P.O. Box 7787, ABU DHABI
Tel.: +971 (0) 2/ 444 7378,
Fax: +971 (0) 2/444 6896
E-mail: [email protected]
Contact person: Hussain Al Moalla

ANGOLA / BOTSWANA / LESOTHO/

MADAGASCAR / MALAWI /
MOZAMBIQUE/ NAMIBIA / SOUTH
AFRICA / SWAZILAND/ ZAMBIA / ZIMBABWE:
AVIATION ENGINES ANDACCESSORIES
(PTY) LTD
P.O. Box 15749, Lambton 1414,
SOUTH AFRICA
Tel.: +27 (0) 11 / 455 4203,
Fax: +27 (0) 11 / 455 4499
E-mail: [email protected]
Website: www.aviation-engines.co.za
Contact person: Niren Chotoki

d04681.fm

GHANA / BENIN / BURKINA FASO / CAMEROON / CENTRAL AFRICAN

REPUBLIC / CONGO / GABON / GUINEA / IVORY COAST / MALI /
MAURITANIA / NIGER/ NIGERIA / SENEGAL / TOGO:
WAASPS LTD
PMB KA49, Kotoka International Airport, Accra, GHANA
Tel.: +233 (0) 28 5075254,
Fax: +233 (0) 217 717 92
E-mail:[email protected]
Website:www.waasps.com
Contact person: Jonathan Porter

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5) A S I A
CHINA / HONG KONG / MACAO:
PEIPORT INDUSTRIES LTD.
Rm. 1302, Westlands Centre
20 Westlands Road, Quarry Bay
HONG KONG
Tel.: +852 (0) 2885 / 9525,
Fax: +852 (0) 2886 / 3241
E-mail: [email protected]
Website: www.peiport.com
Contact person: Larry Yeung

CIS:

ISRAEL:
CONDOR-AVIATION INDUSTRIES LTD.
P.O. Box 1903, 14 Topaz st.
Cesaria 38900
Tel.: +972 (0) 4 / 6265080,
Fax: +972 (0) 4 / 62650 95
E-mail: [email protected]
Contact person:David Wiernik

JAPAN :

AVIAGAMMA JSCO.
P.O. Box 51, 125 057 MOSCOW
Tel.: +7 499 / 158 31 23,
Fax: +7 499 / 158 62 22
E-mail: [email protected]
Website: www.aviagamma.ru
Contact person: Vladimir Andriytschuk
General Director

JUA, LTD.
1793 Fukazawa, Gotemba City
SHIZUOKA PREF 412
Tel.: +81 (0) 550 / 83 8860,
Fax: +81 (0) 550 / 83 8224
E-mail: [email protected]
Contact person:Yoshihiko Tajika
President

INDIA:

KOREA:

GREAVES COTTON LTD.

Express Building Annexe
9-10, Bahadur Shah Zafar Marg
NEW DELHI - 110002
Tel.: +91 (0) 11 / 23311501
Fax: +91 (0) 11 / 23702129
E-mail: [email protected]
Website: www.greavescotton.com/aeroengines.htm
Contact person: Cdr.Anil Kumar
Divisional Manager

INDONESIA / MALAYSIA / PHILIPPINES / SINGAPORE / THAILAND /

TAIWAN:
BERT FLOOD IMPORTS PTY. LTD.
P.O. Box 61, 16-17 Chris Drive LILYDALE,
VICTORIA 3140
Tel.: +61 (0) 3 / 9735 5655,
Fax: +61 (0) 3 / 9735 5699
E-mail:[email protected]
Website: www.bertfloodimports.com.au
Contact person: Mark Lester

KORBER IND. CO. LTD.

#1104, Biz Center, SK Technopark, 190-1
Sangdeawon-Dong, Joongwon-Ku,
Seoungnam City, SOUTH KOREA
Tel.: +82 (0) 31 / 776 0771/5
Fax: +82 (0) 31 / 776 0776
E-mail: [email protected]
Contact person: John Lee, President

UNITED ARAB. EMIRATES:

AL MOALLA
P.O. Box 7787
ABU DHABI
Tel.: +971 (0) 2 / 444 7378,
Fax: +971 (0) 2 / 444 6896
E-mail: [email protected]
Contact person: Hussain Al Moalla

IRAN:

d04681.fm

ASEMAN PISHRANEH CO.

Register Code: 149432
13 Km of Babaee Exp. Way, Cross Telo Road,
Sepehr Aviation Group, Tehran, IRAN
Tel.: +98 (0) 21 77105107,
Fax: +98 (0) 21 77000030
E-mail: [email protected]
Contact person:Ali Habibi Najafi

Effectivity: 912 Serie

OM Edition 2 / Rev. 0

BRP-Powertrain

page 9-8
April 01/2010

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. 2010 BRP-Powertrain GmbH & Co KG. All rights reserved.