Rotax OM-912, Operator'S Manual

Page 1: ...OPERATORS MANUAL FOR ROTAX ENGINE TYPE 912 SERIES ROTAX 912 ULS 3 WITH OPTIONS part no 899371 Ref No OM 912...

Page 2: ...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 cas...

Page 3: ...system 9 3 9 4 Electric system 9 4 9 5 Propeller gearbox 9 5 9 5 1 Hydr governor for const speed propeller vacuum pump 9 6 10 Operating instructions 10 1 10 1 General limits of operation 10 1 10 1 1...

Page 4: ...light 10 20 10 4 2 Exceeding of max admissible engine speed 10 20 10 4 3 Exceeding of max admissible cyl head temperature 10 20 10 4 4 Exceeding of max admissible oil temperature 10 20 10 4 5 Oil pres...

Page 5: ...temperature 912 ULS S 10 5 Equipment 8 1 Exceeding of max admissible cyl head temperature 10 20 Exceeding of max admissible engine speed 10 20 Exceeding of max admissible oil tem perature 10 20 Exhaus...

Page 6: ...off side 7 3 Pre flight checks 10 15 Propeller gearbox 9 5 Propeller governor 9 6 R Remarks 3 1 Repeating symbols 4 1 Reporting 12 4 S Safety 4 1 Safety information 4 2 Speed 912 UL A F 10 1 Speed 912...

Page 7: ...se of this Operator s Manual is provided to familiarize the owner user of this aircraft engine with basic operating instructions and safety infor mation For more detailed maintenance safety and flight...

Page 8: ...Effectivity 912 Serie BRP Rotax page 3 2 OM Edition 1 Rev 0 Jan 01 2007 d03927 fm NOTES...

Page 9: ...obligation The illustrations in this Manual show the typical construction They may not repre sent in full detail or the exact shape of the parts which have the same or similar function Specifications...

Page 10: ...with any other part component or system which may be selected by the aircraft manufacturer assembler or user for aircraft application Whether you are a qualified pilot or a novice complete knowledge...

Page 11: ...ified trained mechanic approved by the local airworthiness authority To eliminate possible injury or damage ensure any loose equipment or tools are properly secured before starting the engine When in...

Page 12: ...Effectivity 912 Serie BRP Rotax page 4 4 OM Edition 1 Rev 0 Jan 01 2007 d03928 fm NOTES...

Page 13: ...OTE 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 WebSit...

Page 14: ...sary documentation is available from the ROTAX Distribution and Service Centers see Chapter 13 NOTE The Illustrations in this Operator s Manual are stored in a graphic data file and are provided with...

Page 15: ...4 2 02 01 2008 10 13 02 01 2008 4 3 01 01 2007 10 14 02 01 2008 4 4 01 01 2007 10 15 02 01 2008 4 5 01 01 2007 10 16 01 01 2007 4 6 01 01 2007 10 17 01 01 2007 10 18 01 01 2007 5 5 1 02 01 2008 10 19...

Page 16: ...Effectivity 912 Serie BRP Rotax page 5 2 OM Edition 1 Rev 0 Jan 01 2007 d03929 fm NOTES...

Page 17: ...ate of modification Note of approval Date of approval by authority Date of insertion Marks Signa ture 0 1 to 13 all 01 01 2007 DOA 1 1 1 1 1 1 4 5 6 7 10 13 4 2 5 1 6 1 7 2 10 1 10 2 10 6 10 13 10 14...

Page 18: ...Effectivity 912 Serie BRP Rotax page 6 2 OM Edition 1 Rev 0 Jan 01 2007 d03930 fm NOTES...

Page 19: ...retors mechanical fuel pump Prop drive via reduction gear with integrated shock absorber and overload clutch NOTE The overload clutch is installed on all serial production aircraft engines which are c...

Page 20: ...A 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 Configuration 1 Prop shaft with flange for fixed prop P C D 100 mm 2 Prop shaft with flange...

Page 21: ...Serie BRP Rotax page 7 3 OM Edition 1 Rev 0 Jan 01 2007 d03931 fm 7 2 Denomination of cylinders 3 8 00337 fig 1 Lateral view 2 2 4 1 6 7 00334 fig 2 Cyl 3 Cyl 2 Cyl 4 magneto side Cyl 1 Top view powe...

Page 22: ...2007 d03931 fm 1 engine serial number 6 exhaust flange 2 CD carburetor 7 external alternator 3 propeller gear box 8 vacuum pump or hydraulic governor for constant speed propeller 4 electric starter 5...

Page 23: ...4 mm 3 31 in Stroke 61 mm 2 40 in 61 mm 2 40 in Displacement 1211 mm3 73 9 in3 1352 mm3 82 5 in3 Compression ratio 9 0 1 10 5 1 with electric starter carburetors internal generator ignition unit and o...

Page 24: ...NOTE Propeller shouldn t be turned reverse the normal direc tion of engine rotation Fuel consumption in l h US gal h 912 UL A F 912 ULS S at take off performance 24 0 6 3 27 0 7 1 at max continuous pe...

Page 25: ...adiator 2 is below engine level the expansion tank located on top of the engine allows for coolant expansion The expansion tank is closed by a pressure cap 3 with excess pressure valve and return valv...

Page 26: ...ety cock 3 wa ter drain cock 4 and fine filter 5 to the mechanical fuel pump 6 From the pump fuel passes on to the two carburetors 7 Via the return line 8 surplus fuel flows back to the fuel tank NOTE...

Page 27: ...ucks 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 en gine The surplus oil emerging from the points of lubrication a...

Page 28: ...rnal power supply 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 igni...

Page 29: ...ck absorbing is based on progressive torsional cushioning due to axial spring load acting on a dog hub On the gearbox version with overload clutch the design incorporates a fric tion damped free play...

Page 30: ...d The drive is in each case via the propeller reduction gear Gear ratio NOTE Transmission ratio between crankshaft and hy draulic governor or vacuum pump is either 1 842 or 1 724 i e the speed of the...

Page 31: ...cceleration Limit of engine operation at zero gravity and in negative g condition max 5 seconds at max 0 5 g 4 Oil pressure max 7 bar CAUTION For a short period admissible at cold start min 0 8 bar 12...

Page 32: ...d to engine fai lure The aircraft engine manufacturer strongly recommends the installation of an additional pump unless this has not been covered by legal obligations so far 9 Power consumption of the...

Page 33: ...ISA 5800 rpm 5000 4000 3000 0 10 20 30 40 50 kW 60 A B 10 20 30 60 70 hp 80 50 40 A max engine output B power requirement of propeller 00450 fig 9 5800 rpm 5000 4000 3000 0 10 20 in Hg 30 10 20 L h 30...

Page 34: ...th fully open throttle valve over the whole r p m range without limitation But full throttle performance above 5500 r p m is limited to 5 mi nutes At deviation of temperature con ditions from standard...

Page 35: ...N For a short period admissible at cold start min 0 8 bar 12 psi below 3500 rpm normal 2 0 5 0 bar 29 73 psi above 3500 rpm 5 Oil temperature max 130 C 266 F min 50 C 120 F normal operating temperatur...

Page 36: ...engine manufacturer strongly recommends the installation of an additional pump unless this has not been covered by legal obligations so far 9 Power consumption of the hydraulic propeller governor max...

Page 37: ...Drehm om ent Torque 5800 Leistung Perfom ance KW m ax Motorleistung m ax engine output Propellerkurve power requirem ent of propeller 0 5 10 15 20 25 30 2500 3000 3500 4000 4500 5000 5500 0 5 30 Benzi...

Page 38: ...ion with fully open throttle valve over the whole r p m range without limitation But full throttle performance above 5500 r p m is limited to 5 mi nutes At deviation of temperature conditions from sta...

Page 39: ...ific thermal capacity than water less coolant NOTE The important advantage of water less coolant is its higher boiling point than a conventional mixture When correctly applied there is sufficient prot...

Page 40: ...por lock or when other types of gasoline are unavailable CAUTION Use only fuel suitable for the respective climatic zone NOTE Risk of vapour formation if using winter fuel for summer operation CAUTION...

Page 41: ...ils with gear ad ditives such as high performance motor cycle oils are required Because of the incorporated friction clutch oils with friction mo difier additives are unsuitable as this could result i...

Page 42: ...apid lubrication of all engine com ponents at cold start and get less fluid at higher temperatures Table of lubricants See fig 15 Since the temperature range of neighboring SAE grades overlap there is...

Page 43: ...ckpit occupied by a compe tent person CAUTION If established abnormalities e g excessive re sistance of the engine noises etc inspection in accordance with the relevant Maintenance Manual is necessary...

Page 44: ...sary Version with overload clutch Turn the propeller by hand to and fro feeling the free rotation of 15 or 30 before the crankshaft starts to rotate If the propeller can be turned between the dogs wit...

Page 45: ...quired NOTE Propeller shouldn t be turned reverse the nor mal direction of engine rotation Prior to oil check turn the propeller by hand in direction of engine rotation several times to pump oil from...

Page 46: ...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...

Page 47: ...the two ignition circuits at 4000 r p m approx 1700 r p m propeller Speed drop with only one ignition circuit must not exceed 300 r p m approx 130 r p m propeller 115 r p m approx 50 r p m propeller...

Page 48: ...t is stopped At increased operating temperatures to make an engine cooling run of at minimum 2 minutes 10 3 9 Cold weather operation Generally an engine service should be carried out before the start...

Page 49: ...se non contaminated fuel filtered through su de Generously sized water separators Fuel lines routing inclined Prevent condensation of humidity i e avoid temperature diffe rences between aircraft and f...

Page 50: ...ING Reduce engine power setting to the minimum necessary and carry out precautionary landing Any exceeding of the max admissible cylinder head temperature has to be entered by the pilot into the logbo...

Page 51: ...commend the following to protect the valve guides against corrosion Let engine run until warm then change oil Remove the air intake filters and insert approx 30 cm 1 fl oz of corro sion inhibiting oil...

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Page 53: ...warm up period smoky exhaust emission Low oil pressure POSSIBLE CAUSE REMEDY a ignition off switch on b closed fuel tap or clogged filter open tap clean or renew filter check fuel system for leaks c...

Page 54: ...ring engine ope ration cover oil cooler surface maintain the oil temperature prescribed POSSIBLE CAUSE REMEDY a Octane rating of fuel too low use fuel with higher octane rating POSSIBLE CAUSE REMEDY a...

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Page 56: ...ate field information and report to the authority In case of any relevant occur rences that may involve malfunction of the engine the form on the next page should be filled out and sent to the respons...

Page 57: ...ENT Assembly that includes part Engine Comp Name Manufacturer Model or Part No Serial Number Engine TSN Engine TSO Engine Condition 7 Date Sub 8 Comments Describe the malfunction or defect and the cir...

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Page 59: ...0 31 281 602 E mail shaft os tel hr Contact person Ing Ivan Vdovjak HUNGARY HALLEY Baktai t 45 P O Box 425 H 3300 EGER Tel 36 0 36 313 830 Fax 36 0 36 320 208 E mail apollo mail datanet hu Contact per...

Page 60: ...x 34 0 91 803 55 22 E mail aviasport aviasport com Website www aviasport com Contact person Roberto Jimenez 4 AFRICA EGYPT AL MOALLA P O Box 7787 ABU DHABI Tel 971 0 2 444 7378 Fax 971 0 2 444 6896 E...

Page 61: ...MOSCOW Tel 7 499 158 31 23 Fax 7 499 158 62 22 E mail aviagamma mtu net ru Website www aviagamma ru Contact person Vladimir Andriytschuk General Director JAPAN JUA LTD 1793 Fukazawa Gotemba City SHIZ...

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Page 64: ...mer Engine serial no Flugzeugtype Type of aircraft Flugzeugkennzeichen Aircraft registration no ROTAX Vertriebspartner ROTAX authorized distributor and TM are trademarks of BRP Rotax GmbH Co KG 2008 B...