Home

INSTALLATION MANUAL

1. m IN S Effectivity 912 Series page 67 Edition 1 Rev 0 May 01 2007 NOTE A WARNING BRP Rotax INSTALLATION MANUAL In the serial version of the engine an oil tank is included but no provision is made for attachment of an oil cooler Certification of oil cooler and connections to the latest require ments such as FAR and EASA has to be conducted by the aircraft manufacturer 13 2 Limits of operation A WARNING The lubrication system has to be designed such that operating temperatures will not exceed the specified limits pressure For oil pressure sensor see Fig 88 89 see OM 912 Series section 10 1 Oil temperature Oil temperature sensor see Fig 86 87 see OM 912 Series section 10 1 A WARNING NOTE At operation below nominal oil temperature formation of con densate in the lubrication system might influence oil quality For operation at low temperatures the installation of an oil thermostat parallel to the oil cooler is strongly recommended Advantages safe oil pressure after cold start prevention of fuel and water accumulation in the oil See therefore SL 912 011 Use of an oil thermostat latest issue Effectivity 912 Series Edition 1 Rev 0 page 68 May 01 2007 d04055 404636 BRP Powertrain INSTALLATION MANUAL 13 3 Checking of the lubrication system To cont
2. 31 21 MANS DOR tc ML E Teer 31 9 2 State of TEM 31 Engine 1515 otis ene mere ee ree 31 sius o eiie uem 32 10 Engine suspension and position 33 10 1 Definition of attachment points 34 10 2 Permissible fiting Positions asc ise nel ee ea HS eee Ge 35 10 3 General directives for engine suspension 4 44 40 38 11 EXNALIST SYSTEM T 39 11 1 Requirements the exhaust system 40 11 2 operating Rd sn 41 11 3 General directives for exhaust system 42 11 4 Data for optional components of exhaust 43 12 Cooling SYSIOM Y 47 12 1 Description of the system 47 12 2 Operating 48 Effectivity 912 Series page 3 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 12 3 Coolant TYPOS nel 49 12 4 Check cooling system Efficiency of the cooling 50 12 4 1 Measurement of cylinder head temperature and exit tempera
3. 77 19 8 General notes ON oll COS 77 13 9 Filling capacity serne Lm 77 19 10 Purging Of lubrication system 78 13 11 Inspection for correct priming of hydraulic valve 79 19 12 H placemoent of components cuc Pret Skee 80 18 19 Data for optional components of oil system Nissan 81 14 Fuel Systeri 83 14 1 Description of system und eee ess dinde nine 83 14 2 85 14 3 Requirements Of the fuel system 86 14 4 Connecting dimensions location of joints and directives for installation 87 1441 uel manifold EH 87 14 4 2 Fuel pressure control iii 88 144 3 Check valV6 euni en Amd erri ed PESE ete 89 15 f 91 15 1 Requirements on the Carburetor uoce oin 91 15 1 1 Drainage piping on airbox and drip 5 92 15 2 Connections for Bowden cable actuation and limit load 94 15 3 Requirements on cable actuation 96 15 4 Requirements on the throttle lever 97 Effectivity 912 Series page 4 Edition 1 Rev
4. 12 mm 47 in slip on length max 24mm 94 in tightening torque 25 Nm 18 5 Oil inlet 6 and outlet 7 via standard UNF thread AN 8 optional thread 3 4 16 UNF AN 8 Tightening torque of oil inlet and outlet 25 Nm 18 5 ft lb CAUTION The oil tank cap is additionally marked with the term IN oil inlet 6 from crank case OUT oil outlet 7 to oil cooler oil tank See Fig 48 1x venting nipple 9 outside dia 8 mm 31 in slip on length 15 59 0165 02469 _ Effectivity 912 Series page 75 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 13 6 Feasible position and location of the oil tank See Fig 50 The longitudinal axis 23 to be parallel to z axis of the system of coordinates Tolerated deviation of parallelism 10 NOTE Above notice is valid for both planes The oil tank 1 has to be positioned in its z axis such that the normal oil level 2 is always between 0 and 400 mm 15 75 in on the z axis NOTE The profile clamp of oil tank should be between 0 mm and 360 mm below the center line of the propeller shaft A WARNING At higher location of the oil tank oil might trickle through clearances at bearings into crankcase during longer periods of engine stop If fitted too low it might badly effect the oil circuit Install
5. RE NA BRP Rotax INSTALLATION MANUAL 2 00545 T E EE 17 3 6 Starter relay See Fig 75 nominal voltage 12 V control voltage min 6 V max 18 V switching current max 75 A permanent max 300 A for 1 sec ambient temperature range min 40 C 40 F max 100 C 214 F weight see section 8 current connections 1 M6 screw tightening torque 4 Nm 35 in Ib suitable for ring terminals to DIN 46225 control wiring 2 plug connector 6 3x0 8 suitable for spade connector to DIN 46247 MIL T 7928 PIDG or equivalent grounding via housing CAUTION Activation of start relay limited to short duration Over 09169 Effectivity 912 Series Edition 1 Rev 0 a period of 4 min operation the duty cycle is 25 1 0 039 in page 115 May 01 2007 BRP Rotax INSTALLATION MANUAL 17 3 7 External alternator optional extra See Fig 76 77 and 78 output max 600 W DC at 6000 r p m voltage 14 2 V 14 8 V ambient temperature range min 30 C 22 F max 90 C 194 F weight see section 8 NOTE Voltage regulator is integrated in the alternator Feeding wiring to external alternator 1 located on the outside of propeller gear see Fig 76 plus terminal 2 M6 screw suit
6. 3 Heg 5 05536 J cnc gt 00562 JD NOTE Choose between six possible fitting positions of water inlet bend 5 appropriate to specific installation see Fig 27 The inlet bend is attached to the water pump by two Allen screws M6x20 and lock washers Tighten screws to 10 Nm 90 B CAUTION Utilize total slip on length for hose connection Secure hoses with suitable spring type clamp or screw clamp Effectivity 912 Series page 57 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 12 8 Feasible location of radiator See Fig 29 The expansion tank 1 must always be positioned at the highest point of the cooling system CAUTION _ If necessary the radiator outlet opening 8 may be max 1 5 m 5 ft above or below water inlet bend 5 on water pump see Fig 29 NOTE Onthe standard engine version the expansion tank 1 is fitted on top of the engine see Fig 29 E 1 D e IT 6 23 NOD 222222220 SG 22222222 27777222 5 Ew 8 26 08319 EE Fig 29 For proper operation of the cooling system the expansion tank 1 with pressure cap 2 has to remain for all possible engine positions on the highest point of the cooling circuit A WARNING The radiator has to be planned and installed such that the specified operating temperatures are main
7. CAUTION The oil cooler has to be designed to dissipate approx 8 kW 7 58 BTU s heat energy at take off power NOTE From years of experience we recommend an oil cooler size of at least 160 cm 25 ir provided that air flow is adequate CAUTION The oil cooler must not restrict oil flow Test system as per sec 13 3 Filling capacity quantity without oil cooler and connecting lines min 3 0 8 US gal depending on the respective installation Volume of oil tank up to the MIN mark approx 2 5 0 66 US gal up to the MAX mark approx 3 01 0 8 US gal Perform oil level check and add oil if necessary page 77 May 01 2009 BRP Rotax INSTALLATION MANUAL 13 10 Purging of lubrication system See Fig 51 Verify that oil tank connections are connected correctly and secured and that the oil cooler if fitted is in the suction line 1 between the oil tank and the oil pump inlet Verify that the oil tank is filled up to the maximum level to the top of the flat portion of the dipstick Additional oil up to 0 5 litre may be added to the tank for the purpose of this procedure CAUTION Incorrectly connected oil lines to the oil tank or to the engine will result in severe engine damage Disconnect oil line 2 at the oil tank connection Place the free end 3 of the return oil line into a suitable container 4 below the engine Plug open con
8. NOTE Fig 64 shows the genuine ROTAX airbox 5 8 Effectivity 912 Series page 103 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 16 3 Data for optional components of air intake system air filter See Fig 65 weight see section 8 904058 Effectivity 912 Series Edition 1 Rev 0 page 104 May 01 2007 BRP Powertrain INSTALLATION MANUAL airbox configuration part no 867756 See Fig 66 weight see section 8 107 4 22 in 322 5 12 7 in 456 17 96 in 187 in 360 14 18 in 90 3 55 in 260 2 37 in 410 16 14 in 09174 Effectivity 912 Series page 105 Edition 1 Rev 1 May 01 2009 BRP Powertrain INSTALLATION MANUAL airbox new version part no 667355 in comparison to the old version See Fig 66 1 weight see section 8 Alte Ausf hrung TNr 867756 Old Version 106 3 4 17 in Neue Ausf hrung TNr 667355 CN Aenderungen modification 455 11543 mm 4 53 in New Version d I 128 mm 5 04 in 180 mm 7 09 in d04639 Effectivity 912 Series Edition 1 Rev 1 page 106 May 01 2009 d04059 BRP Rotax INSTALLATION MANUAL 17 Electric system See Fig 67 The engine is supplied with the wiring completed and ready to operate Only the
9. 02050 d04054 Effectivity 912 Series page 63 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 12 11 1 General directives for ducting of the cooling air See Fig 2 3 4 For front installation in a closed fuselage ducting of cooling air to the cylinders is recommended In this case a costly horizontal partitioning baffles can be avoided NOTE The engine remains in this case completely on the warm side of the engine compartment and is very well accessible In special cases a separate cold air supply to the air intake filters has to be provided BRP Powertrain has developed especially for this application a non certified cooling air ducting A WARNING Certification to the latest requirements to FAR or EASA has to be conducted by the aircraft manufac turer The following recommendations should assist the aircraft manu facturer at the planning of a suitable cooling air ducting The cooling air ducting to be adequate to transfer thermal energy of approx 6 kW 5 7 BTU s at take off power required cross section of air duct at least 100 cm 16 in material glass fibre reinforced plastic or heat resistant non inflammable material attachment formlocking on engine case and cylinders NOTE In case formlocking attachment won t be adequate additional attachment is possible on two tapped lugs 8 on top side of engine d04635 Effectivity 912 Series page 64 Edition 1
10. 5 4 p 4 4 f LLLA 05033 09126 x 3 Fig 33 Fig 34 Effectivity 912 Series page 60 Edition 1 Rev 0 May 01 2007 904635 BRP Powertrain INSTALLATION MANUAL 12 9 General directives for the cooling system See Fig 29 BRP Powertrain offers essential parts of the cooling system for this engine such as radiator etc A WARNING Certification to the latest requirements to FAR or EASA has to be conducted by the aircraft manufacturer 4 08320 In an installation as depicted with the radiator 9 in a higher position than the standard supplied expansion tank a water accumulator 10 has to be fitted instead of the expansion tank Additionally a suitable expansion tank 1 has to be installed at the highest point of the cooling circuit CAUTION size and type of radiator should be adequate to transfer thermal energy of approx 25 kW 24 BTU s for ROTAX 912 A F UL or approx 28 kW 26 5 BTU s for ROTAX 912 S ULS at take off power NOTE Assessment data by experience For troublefree operation at good airflow a radiator of at least 500 cm 78 in area has to be used The flow rate of coolant in the cooling system is approx 60 min 16 US gal min at 5800 rpm As reference value for the necessary cooling airflow approx 0 75 m s at full load can assumed The flow resistance of the coolant in the optional ROTAX radiator is properly designed for the cooling sy
11. BRP Powertrain Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer The following recommendations should help the aircraft manufacturer to plan a suitable exhaust system NOTE These recommendations derive from years of experience and the results achieved are generally very good Acommon transversal muffler serving all 4 cylinders and positioned under the engine is favourable NOTE Equal length of pipes from the cylinder to muffler is recom mended for better tuning Distribution of the exhaust gases into 2 separate systems is not recom mended Single mufflers on either side cause power loss andincreased noise emission The 4 ball joints must be used to avoid damage due to vibration Be aware that locked up stresses cause cracks Attachment of exhaust bends by springs Springs to be secured with safety wire to prevent FOD All ball joints have to be greased regularly with heat resistant lubricant e g LOCTITE ANTISEIZE to avoid gripping and seizing of the joints CAUTION Vibrations due to improper installation and maintenance is the most common reason for damage of the exhaust system 904634 Effectivity 912 Series page 42 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL The sketch illustrates a possibility how to interconnect the exhaust springs to prevent the vibration of these springs and thus premature wear It is also recommen
12. INSTALLATION MANUAL FOR ROTAX ENGINE TYPE 912 SERIES Ref No IM 912 ROTAX 912 ULS WITH OPTIONS part no 898642 A WARNING Before starting with engine installation please read the Installation Manual completely as it contains important safety relevant information These technical data and the information embodied therein are the property of BRP Powertrain GmbH amp Co KG Austria acc BGBI 1984 no 448 and shall not without prior written permission of BRP Powertrain GmbH amp 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 2009 all rights reserved ROTAX is a trade mark of BRP Powertrain GmbH amp Co KG In the following document the short form of BRP Powertrain GmbH amp 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 904050 BRP Rotax INSTALLATION MANUAL 1 Table of contents 1 3 2 nna es 7 OMIT M a 9
13. WARNING Connect drainage lines well otherwise emerging fuel from a possible leakage could drip onto the exhaust system RISK OF FIRE The lines have to be routed such that in case of a damage the surplus fuel is drained off suitably Route the lines without kinks and avoid tight bends Route the lines with a continuous decline The lines have to be protected against any kind of blockage e g by formation of ice CAUTION With closed or blocked leakage piping fuel could end up on exhaust system RISK OF FIRE CAUTION float chamber venting lines 3 lines have to be routed into a ram air and vacuum free zone or into the airbox according to the requirements and release of BRP Powertrain See section 16 These lines must not be routed into the slipstream or down the firewall Pressure differences between intake pressure and pressure in the carburetor chambers may lead to engine malfunction due to incorrect fuel supply Connecting nipple 2 for leakage line outside dia 6 mm 1 4 slip on length 17 mm 11 16 Effectivity 912 Series page 92 Edition 1 Rev 1 May 01 2009 d04638 904638 BRP Powertrain INSTALLATION MANUAL 08644 Effectivity 912 Series page 93 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 15 2 Connections for Bowden cable actuation and limit load See Fig 2 3 4 60 and 61 centre position of carburetor socket P1 of the r
14. approx 4 0 kg 8 8 Ib oil radiator itt tease 0 55 kg 1 2 Ib engine MORE uie RUM 2 0 kg 4 4 Ib 8 4 Centre of gravity of engine and standard equipment See Fig 2 3 4 NOTE Dimensions to point of reference P 8 5 Moments of inertia See Fig 2 3 4 engine from serial external hydraulic vacuum production alternator governor pump centre of gravity in x axis mm 316 100 276 255 centre of gravity in y axis mm 5 139 0 0 centre of gravity in z axis mm 83 6 56 56 09182 engine engine version version 2 4 3 moment of inertia around 11 100 11 600 axis x1 x1 kg cm moment of inertia around 10 900 11 390 axis y1 y1 kg cm moment of inertia around 17 400 18 200 axis z1 z1 kg cm 09183 d04052 Effectivity 912 Series page 29 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL NOTES 904052 Effectivity 912 Series page 30 Edition 1 Rev 0 May 01 2007 904633 BRP Powertrain INSTALLATION MANUAL 9 Preparations for engine installation CAUTION The stated directives are measures to pay CAUTION to at engine installation to prevent any accidents and engine damage 9 1 Transport The engine to be lifted by two hooks or straps around the middle A of the intake manifolds See chapter engine views numbering of cylinders and definition of main axes 9 2 State of delivery The engine could be attached with to steel angles
15. hose nipple 3 10 DIN 7642 DUISIOO CIA issues 13 5 mm 53 in Slip on length max 24 mm max 94 in Tightening torque of banjo bolt 4 M16x1 5x28 30 Nm 22 ft Ib Option 2 and 3 connection with screw connection 2 or 5 connection with screw connection 2 thread 3 4 16 UNF AN 8 Tightening torque of oil return line 25 Nm 18 5 ft Ib Tightening torque of screw connection 2 M16x1 5 25 Nm 18 5 ft lb connection with screw connection 5 3 4 16 UNF 8 Tigiienmng torque of oil return line mnc 25 Nm 18 5 ft Ib AGT Aw ae Tightening torque of banjo bolt 4 M16x1 5x28 30 Nm 22 10 DID ala f IY no P 2723 4 pe pond Druckpropeller Zugpropeller pusher config tractor config Fig 47 re 5 8 2 08634 904636 Effectivity 912 Series page 74 Edition 1 Rev 1 May 01 2009 d04055 BRP Rotax INSTALLATION MANUAL 13 5 2 Oil tank See Fig 48 and 49 The oil tank is furnished with 2 screw connections M18x1 5 and with a tapped hole M10x1 Connections for oil circuit engine Oil inlet 6 and outlet 7 standard swivel joint and connecting bend 8 2x connecting bend 90 8 outside dia
16. 5 the oil tank and reconnect the engine return oil line 2 to the oil return port on the oil tank CAUTION Ensure thatthe oil suction line 1 and engine oil return lines 2 are connected to the proper fittings on the oil tank If the oil lines from the engine to the oil tank are incorrectly connected at the oil tank severe engine damage may result Replace spark plugs and restore aircraft to original operation condition Residual oil will have accumulated in the crankcase return it to the oil tank by following the oil check procedures in Operators Manual or SI 27 1997 Oil level check for ROTAX engine type 912 and 914 Series current issue Addoilto engine oil tank to bring the oil level up to the full mark on the dipstick A WARNING Carefully check all lubrication system connections lines and clamps for leaks and security 13 11 Inspection for correct priming of hydraulic valve tappets See Fig 52 The subsequent check procedure describes the correct method to verify adequate priming of hydraulic valve tappets CAUTION Engine has reached operating temperatures here Use priate safety equipment and clothing Remove valve cover on cylinder 1 Turn crankshaft in direction of normal rotation so that the piston on cylinder 1 is on ignition top dead center both valves are closed Press on push rod side of rocker arm with a force F of about 70 15 0 for about 3 sec Approximate f
17. Oil lines 71 Oil pressure 68 Oil pressure sensor 129 Oil tank 75 76 Oil temperature 68 On off switch 112 Operating limits 27 Overflow bottle 59 Position of engine 33 Preface 9 Preservation engine 31 Propeller drive 121 Protective covering 32 R Rectifier regulator 110 Remarks 9 Rev counter drive 130 page 7 May 01 2007 BRP Rotax INSTALLATION MANUAL 5 Safety 11 Safety information 11 Sensor for oil temperature 128 Standard engine design 21 Starter relay 115 State of delivery 31 Symbols 11 T Take off speed 27 Technical data 27 Technical documentation 14 Temperature in airbox 99 Throttle lever 97 Transport 31 Trial run 133 V Vacuum pump 123 Venting line of oil tank 71 W Water inlet bend 57 Wiring diagram electric 108 5 Effectivity 912 Series page 8 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 3 Preface In this Manual the installation of all ROTAX 912 Series engines is described NOTE ROTAX 912 Series includes 912 A 912 F 912 S 912 UL 912 ULS and 912 ULSFR Before starting with the engine installation read this Installation Manual carefully The Manual will provide you with basic information on correct engine installation a requirement for safe engine operation If any passages of the Manual are not completely understood or in case of questions please contact an authorized Distribution or Service Center for ROTAX engines BRP Powertrain Gmb
18. surface covered with metal screen total filter area at least 1400 cm 220 in amin flow rate of 6 23 m3 min 220 cfm 16 2 3 Airbox See Fig 64 volume at least 2 5 66 US gal outline dimension see Fig 64 The airbox is furnished with 2 drain holes 1 at the lowest position possible The holes are necessary to drain fuel from flooding float chambers caused by badly closing float valve Drainage lines A WARNING Connect draining lines without fail otherwise emerg ing fuel could drip onto the exhaust system RISK OF FIRE The lines have to be routed such that in case of damage the surplus fuel is drained away suitably Route the lines without kinks and avoid narrow bends Route the lines with a continuous decline The lines have to be protected against any kind of blockage e g by formation of ice CAUTION With closed or blocked drainage bores fuel could flow into combustion chamber possibly ruining the engine by hydraulic lock or emerging fuel could drip onto the exhaust system RISK OF FIRE Effectivity 912 Series page 101 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL CAUTION The drainage lines 1 lines have to be routed into a ram air and vacuum free or into the airbox according to the requirements and release of BRP Powertrain See also section 15 These lines must not be routed into the slipstream If the drainage lines of the airbox are connected
19. 0 May 01 2007 904050 004631 BRP Powertrain INSTALLATION MANUAL 16 Air intake system e 99 Operating limits mm 99 16 2 Requirements on the air intake system 100 16 2 1 Requirements on the intake air ducting 100 LANE lere 100 16 23 SAUD OX spe 101 16 3 Data for optional components of air intake system 104 17 Electri SYSTEM 107 17 1 Requirements on circuit Wiring 107 17 1 1 Electromagnetic compatibility 108 108 17 3 Technical data and connection the electric components 110 17 31 Integrated generator 110 17 3 2 Rectifier regulator ect 110 172323 Electronic mogdul s frio ricerca ri e dee ee eee asser aie nn 112 17 3 4 Ignition switches MAG switch 112 17 95 Electric Starter e 114 17 39 60 Stairter relay 115 17 3 7 External alternator optional extra ssassn 116 17 3 8 Connection of the electric rev counter tachome
20. 119 05 01 2009 DOA 18 121 05 01 2009 DOA 21 128 129 130 05 01 2009 DOA 131 132 05 01 2009 DOA 8 Effectivity 912 Series page 19 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 1 Rev 0 page 20 May 01 2007 d04051 904052 BRP Rotax INSTALLATION MANUAL 7 Description of design 7 1 Designation of type Basic type e g ROTAX 912 version 2 version 2 with prop flange for fix pitch propeller version 3 with prop flange with drive of hydraulic governor for constant speed propeller version 4 with prop flange for fix pitch propeller but prepared for retro fit of hydraulic governor for constant speed prop not supplied by manufacturer anymore Optional extras to the above stated basic type external vacuum drive for rev counter governor alternator pump hour meter for version 2 for version 3 for version 4 NOTE Conversion of the version 2 4 to version 3 may be accom plished by ROTAX Authorized Distributors or their Service Center 7 2 Standard engine design 4 stroke 4 cyl horizontally opposed spark ignition engine single central camshaft hydraulic tappets push rods OHV liquid cooled cylinder heads ram air cooled cylinders dry sump forced lubrication dual ignition of breakerless capacitor discharge design 2 constant depression carburetors mechanical fuel pumps propdrive via integrated
21. 2007 BRP Powertrain INSTALLATION MANUAL A WARNING Do not bend kink pinch or otherwise improperly stress the wiring harness Use proper routing clamping and strain relief on wiring harnesses 17 1 1 Electromagnetic compatibility Electromagnetic interference EMI and lightning The engine complies with the EMI and lightning requirements per DO 160C sections 18 20 22 as noted in the following paragraphs Emission Conducted RF Interference Narrowband and broadband emissions meet RTCA DO160C Section 21 1 Cat B AZ exceptin the frequency range of 150kHz 2MHz where emissions are up to 20dB higher than allowable limits Radiated RF Interference Narrowband and broadband emissions meet RTCA DO160C Section 21 Fig 21 6 and 21 7 Cat B except in the frequency range of 190kHz 2MHz where emission are up to 35dB higher than allowable limits A WARNING Consult the manufacturer if further interpretation is needed These exceedances do not affect engine operation 17 2 Wiring diagram See Fig 67 Legend to wiring diagram Fig 67 Items 1 9 24 25 are included in the standard volume of supply of the engine Items 10 14 are available as accessory Items 15 23 can t be supplied by BRP Powertrain A WARNING The certification of items components which are not included 2 3 4 5 6 7 8 9 10 12 13 in the standard volume of supply of engine has to be conducted by the aircraft manufacturer to th
22. 3 4 Standard engine version pos neg total 589 5 max dimension in y axis mm 576 0 is mmn 394 0 NOTE Dimensions to point of reference P 09181 8 3 Weight Weight of engine defined to the following conditions Engine dry from serial production with internal alternator with overload clutch see section Description of design ROTAX 912 A 912 F 912 UL Engine weight Version 2 and 4 57 1 kg 125 Ib S e 59 8 kg 132 Ib ROTAX 912 S 912 ULS Engine weight Version 2 and 4 58 3 kg 128 Ib V rsion 3 a 61 0 kg 134 Ib auxiliary equipment Weight of external generator assy 3 0 kg 6 6 Ib overload clutch sua 1 7 kg 3 7 Ib vacuum pump ASS 0 8 kg 1 76 Ib hydraulic governor assy incl drive depending on type approx 2 2 4 8 Ib to 2 7 kg 6 Ib HD starter uiae additional 0 43 kg 1 Ib rectifier regulator 0 3 kg 0 66 Ib starter relais rss 0 145 kg 0 32 Ib radiato Mem EINER UM 1 0 kg 2 2 Ib air quide NOOO ada d RR RI 0 8 kg 1 8 Ib ADO iN EC E 1 3 kg 2 8 Ib 2 SUN ee 0 3 kg 0 7 Ib 5 8 Effectivity 912 Series page 28 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL exhaust system
23. INSTALLATION MANUAL n addition to observing the instructions our Manual general safety and accident preventative measures legal regulations and regulations of any aeronautical authority must be observed Where differences exist between this Manual and regulations provided by any authority the more stringent regulation should be applied This engine may be equipped with an other than the ORIGINAL ROTAX vacuum pump The safety warning accompanying the air pump must be given to the owner operator of the aircraft into which the air pump is installed 4 3 Instruction Engines require instructions regarding their application use operation mainte nance and repair Technical documentation and directions are useful and necessary comple mentary elements for personal instruction but can by no means substitute theoretical and practical instructions These instructions should cover explanation of the technical context advice for operation maintenance use and operational safety of the engine All technical directives relevant for safety are especially emphasized Pass on safety instructions to other users without fail This engine must only be operated with accessories supplied recommended and released by BRP Powertrain Modifications are only allowed after consent by the engine manufacturer M CAUTION Spare parts must meet with the requirements defined by the engine manufacturer This is only warranted by use
24. Series sec 10 1 Manifold pressure see Operators Manual 912 Series sec 10 1 Acceleration see Operators Manual 912 Series sec 10 1 Critical flight level see Operators Manual 912 Series sec 10 1 Oil pressure see Operators Manual 912 Series sec 10 1 Oil temperature see Operators Manual 912 Series sec 10 1 Cyl head temperature see Operators Manual 912 Series sec 10 1 Exhaust gas temperature see section 11 1 Range of starting temperature see Operators Manual 912 Series sec 10 1 10 Ambient temperature for electronic module see section 19 3 11 Fuel pressure see Operators Manual 912 Series sec 10 1 12 Banking of plane deviation from the effective vertical see Operators Manual 912 Series sec 10 1 The engine design is for a conventional non aerobatic fixed wing tractor or pusher type configuration with the oil return port in the optimum position see sec 13 5 With this consideration the engine is properly lubricated in all flight profiles The resulting bank angle B depending on acceleration deceleration may never exceed the max bank angle NOTE Pitch or role angle is not equal with except stabilized condition without acceleration pitch or roll B current bank angle F1 gravity F2 acceleration 8 Fig 6 i Fr result of F1 and F2 Effectivity 912 Series page 27 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 8 2 Installation dimensions See Fig 2
25. all risks possibly arising by utilizing auxiliary equipment The furnishing of proof in accordance to the latest FAR or EASA has to be conducted by the aircraft manufacturer exhaust system intake filter mechanical rev counter electric rev counter shock mount Effectivity 912 Series page 23 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 7 3 Engine components engine views definition of main axes See Fig 2 3 4 5 power take off side MS magneto side A points of attachment for engine transport e centre of gravity P zero reference point for all dimensions NOTE Allow 1 mm on all stated dimensions as manufacturing tolerance x y z axes for system of coordinates Cyl 1 Cylinder 1 Cyl 3 Cylinder 3 Cyl 2 Oylinder2 Cyl 4 Cylinder 4 8 Z 1 engine number 3 ater 2 al zx 2 propeller flange 7 s Smp s edem 3 LEM 3 propeller gear 61 4 vacuum pump KL lt VALAN IE hydraulic governor AS 5 H ET 4 _yq Vi for constan
26. anchored on a timber plate CAUTION attachment screws are only for transport and must not be used in the aircraft 9 3 Engine preservation The engine is preserved at BRP Powertrain thus warranting proper protection against corrosion for at least 12 month after date of delivery from BRP Powertrain This warranty is subject to the following conditions the engine has to be stored in the packing as supplied by BRP Powertrain the covers on various openings must not be removed see section of protective covering engine has to be stored in a suitable place at min 40 C 40 F and max 80 C 176 F If the engine is stored for a period longer than 12 month perform every 3 months the tasks given in the current valid Maintenance Manual section Preservation of a new engine Effectivity 912 Series page 31 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 9 4 Protective covering All openings are protected against ingress of contamination and dampness It is recommended not to remove these plugs until installation of the specific feed line NOTE If the engine will be sent to the manufacturer or distributor reuse transport equipment and replug openings List of protective covering exhaust socket 1x cone plug connection for manifold pressure 1x cap ADO a 2x cap fuel pump 1 connection for
27. appropriate clamps to prevent loss E g with spring type clamps as used already for the water tubes between water pump and cylinder Good field experi ence has been made with this type of clamps NOTE See therefore also SI 912 020 Running modifications latest issue The aircraft manufacturer has to carry out the check of coolant level in the expansion tank and note it in the daily inspection section of his flight manual according latest issue of Operators Manual ROTAX 912 It is recommended to make adequate precautions for accomplishment of these inspections e g a flap or panel on the cowling or a warning instrument in the cockpit for low coolant level Effectivity 912 Series page 55 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 200 10 mm Effectivity 912 Series Edition 1 Rev 0 page 56 May 01 2007 904054 904054 BRP Rotax INSTALLATION MANUAL water inlet bend 5 outside dia 27 mm 1 1 16 slip on length max 19 mm 3 4 2
28. electric rev counter on left side of ignition housing connections 2 flexible cables 0 5 white yellow and blue yellow in insulation wrap length approx 600 mm 24 in starting from ignition housing NOTE CAUTION BRP Powertrain developed especially for this applica tion a non certified electric rev counter Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer See also 51 13 1996 latest issue The graphs depicting output signals have been deter mined and are effective only at the following condi tions Ambient temperature 20 C 68 F Tolerance 5 The pick up for the rev counter generates one pulse per revolution Pulse shape and pulse voltage as per recordings oscillogram speed 500 rpm load 100 speed 500 rpm load 100 kQ V 15 10 E 1 rev 5 V 1 rev V 360 Fig 79 gt 00219 speed 6000 rpm load 100 Q speed 6000 rpm load 100 kQ V V 100 50 0 50 1 rev 360 100 150 1 rev V 360 Effectivity 912 Series Edition 1 Rev 1 page 118 May 01 2009 904640 BRP Powertrain INSTALLATION MANUAL 17 3 9 Battery See Fig 67 CAUTION Towarrantreliable engine start use a battery of atleast 16 Ah capaci
29. following connections to the aircraft have to be established integrated generator external rectifier regulator electronic modules electric starter start relay items conditional for operation like circuit breakers ON OFF switches control lamps relays instrumentation and capacitors Optional extras external alternator as option if the output of the integrated generator is inadequate electric rev counter accessory consumer battery 17 1 Requirements on circuit wiring CAUTION The connections have to be completed by the aircraft manu facturer in accordance to effective certification and wiring diagram Fig 67 The electromagnetic compatibility EMC and electromagnetic interference EMI is greatly affected by the wiring and has to be checked for each installation A WARNING The supply to the various consumers e g battery has to be protected adequately by fuses consult wiring diagram Using fuses too large may result in damage to electric equipment Under no circumstances route consumers cables e g bat tery side by side with ignition cable Induction could cause problems CAUTION Anexcess voltage protection has to be realized by the aircraft manufacturer in accordance to effective regulations A WARNING The certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Effectivity 912 Series page 107 Edition 1 Rev 0 May 01
30. in slip on length max 17 mm 67 in fuel pressure switch connection 9 M10 thread length 9 mm 35 in Tightening torque 15 Nm 135 in Ib and Loctite 221 CAUTION Atloosening or tightening of the banjo bolt 7 tighten ing torque 10 Nm 90 in Ib support the fuel manifold appropriately NOTE The connection nipple 5 is furnished with an orifice Effectivity 912 Series Edition 1 Rev 1 8 0 35 mm 0 014 in essential for operation of the fuel system If the pressure gauge connection 6 is not used anda hose nipple 10 installed the banjo bolt assy 11 marked with a colour dot or marked FUEL is fur nished with an orifice 12 0 35 mm 0 014 in This is essential for operation of the fuel system as it prevents a loss in fuel pressure coordinates mm X axis Z axis clamp block page 87 May 01 2009 fuel pressure sensor connection to carburetor BRP Rotax INSTALLATION MANUAL to fuel tank gt v 09192 09139 Y 14 4 2 Fuel pressure control See Fig 56 and 57 hose connection on fuel pump 1 inlet by slip on joint See fig 56 Fuel intake connection 9 outside dia 9 mm 35 in slip on length max 24 mm 95 in Fuel outlet connection 10 outside dia 6 mm 24 in slip on length max 24 mm 95 in CAUTION Ensure at installation of the supply line to fuel pump t
31. literature a max of 0 1 IPS inches per second at 5000 rpm can be assumed 120 mm 4 72 in 46 gt 09193 Effectivity 912 Series Edition 1 Rev 0 page 122 May 01 2007 d04060 404060 BRP Rotax INSTALLATION MANUAL 19 Vacuum pump 19 1 Technical data See Fig 81 and 82 drive via propeller gear location of the necessary connection on the crankcase see Fig 81 and 82 coordinates x axis y axis z axis connection mm mm mm 206 3 0 51 5 09191 connections thread size M6 Effective thread length max 17 mm 9 16 toothing internal spline 20 40 SMS 1834 NA 14x1 27x30x12 power input max 600 W CAUTION attention to manufacturer s specifications NOTE Speed reduction from crankshaft to hydraulic governor is 1 724 or 1 842 i e the vacuum pump runs with 0 58 or 0 54 of engine speed A WARNING Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer 47 6 1 87 in 62 2 44 in 862 Ul 760 97 08322 1 62 2 44 in Effectivity 912 Series page 123 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 08328 Effectivity 912 Series page 124 Edition 1 Rev 0 May 01 2007 d04060 d04060 BRP Rotax INSTALLATION MANUAL 20 Hyd
32. moment limit 77 39 load in Nm in x y and z axis in x y and z axis A WARNING Tighten all engine suspension screws as specified by the aircraft manufacturer 10 2 Permissible fitting positions See Fig 9 10 11 To simplify the matter reference is made only to the 4 engine attachment points R1 L1 R2 and L2 NOTE All dimensions to point of reference P and the system of coordinates remain unchanged The following details of engine position are with reference to aircraft on ground ready for take off engine suitable for propeller in tractor or pusher arrangement propeller shaft above cylinders See Fig 2 A WARNING For upside down installation of the engine the lubrication system fuel system and the cooling system are unsuitable Longitudinal axis The centre of the attachment points L1 and L2 must be on axis x2 parallel to the x axis Allowable pitch deviation of parallelism of axes max 6 counter clockwise on ground max 10 counter clockwise in operation max 30 clockwise see Fig 9 A WARNING installations with fuel tank located above carburetor level combined with badly closing carb float valve fuel could pass into cylinders at more than 6 decline of propeller shaft axis after longer periods of downtime See FAR 33 17 Effectivity 912 Series page 35 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL To prevent a possible hydraulic shock at engine st
33. of GENU INE ROTAX spare parts and or accessories see Illustrated Parts Catalog They are available only at the authorized ROTAX Distribution and Service Centers The use of anything other than genuine ROTAX spare parts and or accessories will render any warranty relating to this engine null and void see Warranty Conditions A WARNING Engine and gear box are delivered in dry conditions without oil Before putting engine in operation it must be filled with oil Use only oil as specified consult Operators Manual and SI 912 016 Selection of suitable operating fluids current issue Effectivity 912 Series page 13 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL A WARNING Exclusively use tools and supplementary materials as listed in the Illustrated Parts Catalog A WARNING This Manual for engine installation is only part of the Technical Documentation and will be supplemented by the respective Operators Manual Maintenance Manual and Spare Parts List Pay attention to references to other documentation found in various parts of this Manual 4 4 Technical documentation The information given in the Installation Manual Operators Manual Maintenance Manual Line Maintenance Maintenance Manual Heavy Maintenance Overhaul Manual Illustrated Parts Catalog IPC Alert Service Bulletin Service Bulletins Service Informations Service Letter are based on data and experience that are con
34. recommended to use the ROTAX engine suspension frame and the 4 stated attachment points R2 L2 and A WARNING At least 4 of the given anchorage points must be used in a side symmetrical pattern of the left L and right R side d04634 Effectivity 912 Series page 33 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 10 1 Definition of attachment points See Fig 8 08318 V 09187 attachement ae 2 E point mm Li R1 iss jum te re to ro te me R2 414 3 71 0 211 0 max usable L3 thread length R3 L4 R4 L5 R5 564 0 1050 277 0 L6 564 0 105 0 7 0 H6 564 0 105 0 7 0 attachment point up to gearbox S N 28986 2 starting from gearbox S N 28987 A WARNING The engine suspension to be designed by the aircraft or fuselage manufacturer such that it will carry safely the maxi mum occurring operational loads without exceeding the max allowable forces and moments on the engine attachment points d04053 Effectivity 912 Series page 34 Edition 1 Rev 0 May 01 2007 d04053 BRP Rotax INSTALLATION MANUAL max allowable forces attachment point limit load in 09185 in x axis 5 000 max allowable forces limit load in N 5000 4900 in x y and z axis max allowable bending moment limit load in Nm 100 max allowable bending
35. stated limit can lead to an override of the float valve with subsequent engine stop NOTE Readings of the fuel pressure are taken at the pressure gauge connection 6 on the fuel manifold 4 See Fig 55 The engine manufacturer recommends the use of an electrical auxiliary fuel pump if this is not already required by airworthiness requirements The electrical auxiliary fuel pump is not just required in case of a malfunction or defect of the mechanical fuel pump but also provides required fuel supply e g in case of vapour formation at high altitudes and temperatures NOTE If an electrical auxiliary fuel pump is installed the whole fuel system has to be designed to warrant engine operation within the specified pressure limits CAUTION The fuel pressure of an additional auxiliary fuel pump should not exceed 0 3 bar 4 4 psi Effectivity 912 Series page 85 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 14 3 Requirements of the fuel system Delivery rate min 35 I h 8 2 US gal h of mechanical or electric fuel pump Fuellines See Fig 54 A WARNING Fuel lines have to be established to the latest requirements such as FAR or EASA by the aircraft manufacturer Secure fuel hoses with suitable screw clamps or by crimp connection CAUTION For prevention of vapour locks all the fuel lines on the suction side of the fuel pump have to be insulated against heat and fire in the engine compartment a
36. the oil tank free of vibrations and not directly to the engine Oil tank cover 3 and oil drain screw 4 to be easily accessible max 400 gt WU 7 4 5 09162 004055 Effectivity 912 Series page 76 Edition 1 Rev 0 May 01 2007 904636 Effectivity 912 Series Edition 1 Rev 1 13 7 13 8 13 9 BRP Powertrain INSTALLATION MANUAL Feasible position and location of the oil cooler See Fig 50 On principle the oil cooler 5 has to be installed below the oil pump of the engine CAUTION The oilcooler has to be installed with connections upwards i e in positive direction on z axis This will prevent an unintentional draining of the oil cooler at longer engine stop CAUTION This will prevent an unintentional draining of the oil cooler at longer engine stop A WARNING The oil cooler has to be planned and installed such that the specified operating temperatures are maintained and the max values are neither exceeded nor fall below This state has to be warranted for hot day conditions too If need be take appropriate measures like changing size of cooler partial covering of cooler etc General notes on oil cooler BRP Powertrain offers for this engine an oil cooler see Illustrated Parts Catalog latest issue A WARNING Certification of this cooler to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufac turer
37. 0 F The cylinder head temperature is 8 C 46 F higher than the coolant temperature Thus Coolant temperature 120 C 248 F Difference cylinder head and coolant temperature 8 C 46 F 128 C 262 F The highest cylinder head temperature permitted is 128 C 262 F so that the max coolant temperature is kept With this special application safe operation of the engine that prevents boiling of the coolant is possible up to a cylinder head temperature of 128 C 262 F CAUTION This cylinder head temperature with the limit found for this type must be displayed constantly in the cockpit The indicating instrument and the manuals must be changed to cylinder head temperature max 128 C 262 F CAUTION The design of the radiator installation must be changed example cowl modifications if the operating temperature exceeds the specified limits Effectivity 912 Series page 53 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 12 6 Requirements on the cooling system CAUTION A WARNING Coolant hoses All components of the cooling system have to secured suitably The size and layout of the cooling system must be designed to keep the operating temperatures within the specified limits To minimize flow resistance employ radiator with low flow resistance and parallel flow as realized on the original ROTA
38. 05 01 2009 i S 5 20 125 05 01 2007 32 05 01 200 77 05 01 2009 126 05 01 2007 10 33 05 01 2009 i Si 2 21 127 05 01 2007 34 05 01 200 80 05 01 200 128 05 01 2009 35 05 01 200 81 05 01 200 129 05 01 2009 36 05 01 200 82 65 01 200 130 05 01 2009 37 05 01 200 131 05 01 2009 38 05012009 44 83 05 01 200 132 05012009 84 05 01 200 133 05 01 2007 85 05 01 200 134 05 01 2007 86 05 01 200 87 05 01 2009 88 05 01 200 89 05 01 200 90 05 01 200 Effectivity 912 Series page 17 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 1 Rev 0 page 18 May 01 2007 904051 BRP Powertrain INSTALLATION MANUAL 6 Table of amendments Approval The technical content is approved under the authority of DOA Nr EASA 21J 048 00568 chapter page date of remark for date of signature change approval from authorities inclusion 0 10 25 all 05 01 2007 DOA 1 0 2 05 01 2009 DOA 1 5 05 01 2009 DOA 3 9 05 01 2009 DOA 4 11 12 13 05 01 2009 DOA 5 17 05 01 2009 DOA 6 19 05 01 2009 DOA 7 22 05 01 2009 DOA 9 31 05 01 2009 DOA 10 33 38 05 01 2009 DOA 11 42 05 01 2009 DOA 12 47 50 51 55 0501 2009 61 64 05 01 2009 DOA 13 69 74 77 05 01 2009 DOA 14 87 05 01 2009 DOA 15 91 92 93 05 01 2009 DOA 16 99 100 102 103 05 01 2009 DOA 105 106 05 01 2009 DOA 17 108 109 111 0501 2009 DOA 118
39. 1 5 metric for the magnetic plug and M8 for the crankshaft locking screw use always new gasket The pressure in the crankcase at full load must not exceed the prevailing ambient pressure by more than 0 45 bar 6 53 psi at 90 C 194 F oil temperature If both pressure readings are within the specified limits under all operating conditions the lubrication circuit should be working suffi ciently A WARNING Ifthe readings exceed the pressure limits then the flow resistance of the oil from oil sump to oil tank contami nation restrictions of cross section etc is too high This condition is unsafe and must be rectified without delay max 0 45 bar 6 53 psi above at mospheric pressure 08324 Effectivity 912 Series page 70 Edition 1 Rev 0 May 01 2007 d04055 BRP Rotax INSTALLATION MANUAL 13 4 Requirements on the oil and venting lines Oil lines Oil circuit engine Temperature durability mind 140 C 285 F Pressure durability mind 10 bar 145 psi Bending radius mind 70 mm 2 75 in unless otherwise stated by the hose manufacturer Minimum inside dia of oil lines in reference to total length length up to 1m 3 3 min 11 mm e 43 length up to 2 m 6 6 min 12 mm 47 length up to 3 m 10 13 mm o 51 Length of a single oil line max 3 m 118 11 in Vent line of oil tank Route the line without kinks and avoid sha
40. H amp KG hereinafter BRP Powertrain wish you much pleasure and satisfaction flying your aircraft powered by this ROTAX engine 3 1 Remarks This Installation Manual is to acquaint the owner user of this aircraft engine with basic installation instructions and safety information For more detailed information on operation maintenance safety or flight consult the documentation provided by the aircraft manufacturer and dealer For further information on maintenance and spare part service contact the nearest ROTAX distributor see section 3 3 3 2 Engine serial number On all enquiries or spare parts orders always indicate the engine serial number as the manufacturer makes modifications to the engine for further development The engine serial number is on the top of the crankcase magneto side 3 3 ROTAX Authorized Distributors for Aircraft Engines See latest Operators Manual or in the Internet at the official Homepage www rotax aircraft engines com 904632 Effectivity 912 Series page 9 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 1 Rev 0 page 10 May 01 2007 d04051 904632 BRP Powertrain INSTALLATION MANUAL 4 Safety Although the mere reading of these instructions will not eliminate a hazard the understanding and application of the information herein will promote the proper installation and use of the engine The information a
41. Ib hose nipple with union nut 6 straight socket outside Ge 12 0 47 in Slip on length max 24 mm max 0 94 in Tightening torque 25 Nm 18 5 ft Ib Effectivity 912 Series page 81 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 6B 18041 i 9026 yews 96 japu LEE uu 28 OB LOCTITE 243 d04055 Effectivity 912 Series page 82 Edition 1 Rev 0 May 01 2007 904056 BRP Rotax INSTALLATION MANUAL 14 Fuel system 14 1 Description of system See Fig 54 The fuel flows from the tank via a coarse filter water trap 1 to the mechanical fuel pump 2 from the pumps fuel passes on via the fuel manifold 3 to the two carburetors Depending on the configuration of the engine the fuel lines from fuel pump to the carburetors are already installed by the manufacturer optional on some engine The fuel system from tank to the inlet of engine driven fuel pump has to be installed by the aircraft manufacturer Via the return line 5 surplus fuel flows back to the fuel tank and suction side of fuel system The fuel system includes the following items tank coarse filter fine filter water trap fuel shut off valve electrical fuel pump as well as the required fu
42. Remarks T n TEMP 9 ac Engineserial number Re 9 3 3 ROTAX Authorized Distributors for Aircraft 9 Safety rise rat eme sens teens ere tn nent 11 4 1 Repeating 11 42 Safety ee ee 11 ELEC MEM c ee Rt o ne 19 4 4 Technical documentation sedo seno cec 14 5 List of the effective pages ennenen nnmnnn assises 17 6 Table 1 ennnen nennen nna 19 7 Description or design sn sara aaraa band 21 IVAN type eer is 21 7 2 Standard ngine ennemie me 21 7 3 Engine components engine views definition of main axes 24 8 27 Operating irits resres E 27 8 2 Installauon dimensions eme 28 83 Welgi E 28 8 4 Centre of gravity of engine and standard equipment 29 SES ms 29 9 Preparations for engine
43. Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL The stated limit loads are valid only at utilization of min specified thread length and must never be exceeded Depth of thread 18 mm 71 in CAUTION 04876 attachment points max allowable forces limit load in N in x y and z 2 000 axis axis mm axis mm in i attachment points 11 81 in d04054 max allowable bending moment limit load in Nm 50 in x y and z axis min length of thread 15 0 59 in engagement mm 11 81 in 12 12 Data for optional components of cooling system overflow bottle See Fig 37 5 ofr 59 wo ROTA zs 2 E N 8 Ie lt MIN LLL 3 v 21 0 83 in 85 3 35 in Le 106 4 18 in Effectivity 912 Series page 65 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL radiator See Fig 38 weight see section 8 09151 415 16 34 in 150 5 91 in 168 6 62 in 122 4 81 in 380 14 97 in 4 32 1 07 in 27 126 in cooling air baffle See Fig 39 weight see section 8 49 1 93in JL 328 12 91 in 146 5 75 in 09165 78 3 07 in 78 3 07 in NOTE gap between cowling and radiator sh
44. The two throttles have to be controlled by two separate Bowden cables working synchronously Adjust the cables to a free travel of 1 04 in 1 mm 0 04 in 08354 WARNING With throttle lever not connected the carb will remain fully open The default position of the carburetor is full throttle Therefore never start engine without connecting throttle lever first NOTE Route Bowden cable in such a way that carb actuation will not be influenced by any movement of engine or air frame thus possibly falsifying idle speed setting and carb synchronisation Adjust Bowden cable such that throttle and choke can be fully opened and closed Use Bowden cable with minimized friction so that the spring on the throttle can open the throttle completely Otherwise in crease pretension of spring by bending lever flap 1 or fit a stronger return spring 2 or a cable with pull push action would have to be used Secure the bowden cable sleeves 3 in the adjustment screws 4 e g safety wire Effectivity 912 Series page 96 Edition 1 Rev 0 May 01 2007 d04057 904057 BRP Rotax INSTALLATION MANUAL 15 4 Requirements on the throttle lever See Fig 63 Adjustable positive stops for idle and full throttle position are of course required These stops have to be designed such to render adjustibility and to prevent overload of the idle stop on the carburetor The sketch Fig 63 depicts a feasible arran
45. X radiator and use short hoses and pipelines temperature durability min 125 C 257 F pressure durability min 5 bar 73 psi nom inside dia 25 mm 1 bending radius min 175 mm 7 material Suitable for 100 Glycol and antifreeze agents Pay CAUTION to ozone stability CAUTION Hoses exposed to direct heat radiaton of exhaust system to be protected with heat resistant protection tubes NOTE If installation require longer distances use aluminium pipes 25 mm 1 inside dia instead of hoses These should have a bulge 1 in order to prevent coolant hoses becoming loose 09158 904054 Effectivity 912 Series Edition 1 Rev 0 page 54 May 01 2007 904635 BRP Powertrain INSTALLATION MANUAL Expansion tank to overflow bottle hose Hose connecting expansion tank to overflow bottle must be rated for vacuum suction for min 125 C 257 F E g it must be strong enough to withstand high heat and suction during the cooling down period A WARNING A soft walled hose is not suitable as it can collapse and cause coolant system failure 12 7 Size and position of connections See Fig 26 27 28 expansion tank 1 with radiator cap 2 to radiator 3 outside dia 25 mm 1 slip on length max 22 mm 7 8 to overflow bottle 4 outside dia 8 mm 3 8 slip on length max 15 mm 9 16 CAUTION hoses have to be fixed with
46. able for ring terminal to DIN 46225 tightening torque 4 Nm 35 in Ib grounding via engine block mount bracket control wiring field circuit 3 and warning lamp circuit 4 via supplied standard plug Sumitomo 6111 2568 03199 3 lij 04902 XXX Effectivity 912 Series page 116 Edition 1 Rev 0 May 01 2007 904059 BRP Rotax INSTALLATION MANUAL Requirements for correct operation of the integrated rectifier regulator the rectifier regulator has to be protected by a slow blowing fuse or circuit breaker Fuse or circuit breaker rating must be determined by load wire size and length cross section of the main circuit at least 4 mm 10 AWG capacitor Fig 67 Pos 14 of at least 22 000 uF 25 V is necessary to flatten voltage current CAUTION current over speed graph has been determined and is effective only at the following conditions ambient temperature 20 C 68 F voltage permanent 13 5 V tolerance 5 NOTE The speed of the auxiliary generator is 1 24 or 1 32 times crankshaft speed or 3 times the prop speed 1 min rpm n Propeller rpm propeller 00547 2000 3000 4000 5000 6000 7000 8000 Dene Effectivity 912 Series page 117 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 17 3 8 Connection of the electric rev counter tachometer See Fig 67 79 Feeding wiring to
47. apter page date 0 1 05 01 200 11 39 05 01 200 15 91 05 01 2009 2 05 01 2009 40 05 01 200 92 05 01 2009 41 05 01 200 93 05 01 2009 1 3 05 01 200 42 05 01 2009 94 05 01 2007 4 05 01 200 43 05 01 200 95 05 01 2007 5 05 01 2009 44 05 01 200 96 0501 2007 6 05 01 200 45 05 01 200 97 0501 2007 46 05 01 200 98 05 01 2007 2 7 05 01 200 8 05 01 200 12 47 05 01 2009 16 99 0501 2009 48 05 01 200 100 05 01 2009 3 9 05 01 2009 49 05 01 200 101 05 01 2007 10 05 01 200 50 05 01 2004 102 05 01 2009 51 05 01 200d 103 05 01 2009 4 11 05 01 2009 52 05 01 200 104 05 01 2007 12 05 01 2009 53 05 01 200 105 05 01 2009 13 05 01 2009 54 05 01 200 106 05 01 2009 14 05 01 200 55 05 01 2009 15 05 01 200 56 05 01 200 17 107 05 01 2007 16 05 01 200 57 05 01 200 108 05 01 2009 58 05 01 200 109 05 01 2009 5 17 05 01 2009 59 05 01 200 110 05 01 2007 18 05 01 200 60 05 01 200 111 05 01 2009 61 05 01 2009 112 05 01 2007 6 19 05 01 2009 62 05 01 200 113 05 01 2007 20 05 01 200 63 05 01 200 114 0501 2007 64 05 01 2004 115 05012007 7 21 0501200 65 05 01200 116 05012007 22 05012009 66 05 01200 117 05012007 23 0501200 118 05 01 2009 24 05012007 67 05 01 200 119 05 01 2009 25 05 01 200 68 05 01 200 120 05 01 2007 26 05 01 200 T 69 05 01 200d 70 05 01 200 18 121 05 01 2009 8 27 05 01 200 71 05 01 200 122 05 01 2007 28 05 01 200 70 05 01 200 29 05 01 200 73 05 04 200 19 123 05 01 2007 30 05 01 200 T 74 05 01 2009 124 05 01 2007 7 05 012 9 31
48. art ensure proper closing of float valves If in doubt park the aircraft with inclining propeller shaft axis 09136 Propeller axis The centres of attachment points L1 and R1 must be on an axis y2 parallel to y axis 02454 Tolerated roll deviation of parallelism 5 see Fig 10 8 Effectivity 912 Series page 36 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL Vertical axis y axis must be square to the longitudinal axis of the aircraft 02455 Tolerated roll deviation of Yaw tolerance 10 see Fig 11 d04053 Effectivity 912 Series Edition 1 Rev 0 page 37 May 01 2007 BRP Powertrain INSTALLATION MANUAL 10 3 General directives for engine suspension Rubber mounts to be used between engine and aircraft frame to neutralize vibrations Damping elements as generally used in the aircraft industry e g LORD are suitable See Fig 12 NOTE The Fig shows rubber mount Lord J 3608 1 resp J 3608 2 NOTE NOTE A WARNING A WARNING CAUTION A WARNING All elements to balance out vibrations have to be of captive design 07600 With suspension on the 4 top lugs L3 R3 L4 and R4 only the tilting moment due to the pull of the propelle
49. c module marked B for ignition circuit B NOTE Ignition circuit A controls top spark plugs of cylinder 1 and 2 lower spark plugs of cylinder 3 and 4 Ignition circuit B controls top spark plugs of cylinder 3 and 4 lower spark plugs of cylinder 1 and 2 B CAUTION electromagnetic compatibility EMC and electro magnetic interference EMI depends essentially on the wire used See Fig 73 Min section area 2x 0 75 mm 18 AMG shielded flexible cable shielding braid on both ends grounded to prevent EMI e g specification MIL 27500 18 No or insufficient shielded cables can cause engine shut off due to electromagnetic and radio interfer ence The metal base of each ignition switch must be grounded to aircraft frame to prevent EMI 17 3 5 Electric starter See Fig 74 Wire from starter relay to the electric starter cross section of at least 16 mm 6 AWG output 0 7 kW 0 9 kW optional positive terminal 1 M6 screw tightening torque 4 Nm 35 in Ib suitable for ring terminal to DIN 46225 MIL T 7928 PIDG or equivalent grounding via engine block CAUTION Suitable for short starting periods only CAUTION Max 80 176 F temperature range by the electric starter housing Activate starter for max 10 sec without interruption followed by a cooling period of 2 min Effectivity 912 Series Edition 1 Rev 0 page 114 May 01 2007 d04059 d04059 Ooh
50. cording to the installation situation e g shortened or extended For extension an appropriate commercially available cable can be used A resistance cable or similar is not necessary wire gauge stranded wire 0 5 mm AWG 20 cable length 3m 118 in operating temperature range 40 40 F max 125 C 257 F grounding via engine block airframe ground output signal In contrary to the oil pressure sensor offered up to now which was providing the signal on the basis of a sensor resistance variation the new oil pressure sensor 1 operates on basis of a current variation This has to be taken into account for the selection of the appropriate cockpit instrument CAUTION The graph current over pressure has been determined and is Effectivity 912 Series Edition 1 Rev 1 effective at the following conditions only see fig 89 ambient temperature 20 C 68 F tolerance max 3 tightening torque 15 98 and LOCTITE 243 mA 25 Fig 89 9 2 4 6 8 n 08442 page 129 May 01 2009 BRP Powertrain INSTALLATION MANUAL As the instruments need a separate power supply and a different design for the electrical oil pressure sensor the resistance type instrument type VDO which was supplied by BRP Powertrain up to now is not suitable anymore Suitable instruments are offered by various instrument manufacturers e g ROAD or Av
51. ction by a screw M3 5x6 2 CAUTION Flawless operation of the indicating instrument needs the installations of a water trap between engine and instrument for the fuel condensate 904641 Effectivity 912 Series page 131 Edition 1 Rev 1 May 01 2009 BRP Powertrain INSTALLATION MANUAL 21 6 Air temperature in the airbox optional See Fig 93 To take air temperature readings in the airbox a connection is provided This connection is closed on the standard engine by a plug screw connection thread M6 thread length approx 9 mm 3 8 08647 E 8 Effectivity 912 Series page 132 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 22 Preparations for trial run of engine A WARNING Prior to engine start and operation review all instructions stated in the Operators Manual Conduct test run See Operators Manual 912 section 10 3 Verification of the throttle lever detent for max continuous power Performance check in accordance with Operators Manual If nominal performance won t be reached or is in excess of examination of the installation and engine will be necessary Consult Maintenance Manual 912 CAUTION Don t conduct any test flights before fault has been traced and found d04060 Effectivity 912 Series page 133 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Ser
52. ded to fill the springs with high heat silicone for additional damping of vibrations CAUTION Appropriate to the installation a vibration damping support for the exhaust system has to be provided on the airframe manufacturers side Approx 10 mm 4 in stretch SS Ire 08326 11 4 Data for optional components of exhaust system weight see section 8 exhaust elbow assy doughnut See Fig 16 Material thickness of the exhaust components X 15CrNiSi20 12 1 4828 AISI 309 a 1 5 mm 0 059 in A section A A 09164 8 gt 5 Effectivity 912 Series page 43 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL muffler assy See Fig 17 Material thickness of the exhaust components X 6CrNiTi 189 1 4541 stainless a 1 mm 0 039 in 379 14 92 in Le 368 14 49 in 331 13 04 in 37 5 1 48 in lt 145 5 5 73 in gt 09159 40 1 58 in 52 75 2 077 in exhaust elbow tailpipe See Fig 18 Material thickness of the exhaust components 5CrNi 189 1 4301 stainless a 1 mm 0 039 in gt gt 8 e D 2 Z T l 1 1 1 7 y 4 c 250 9 85 in 3 19 AT 4 gt 3 AA o 8 09153 Fig 18 Effectivity 912 Series page 44 Edition 1 Rev 0 May 01 2007 d04053 BRP Rotax INSTALLATION MANUAL ball joint ma
53. e regulator while the engine is running i e the master switch is shut off the capacitor will safely absorb and dissipate the electrical charge produced by the generator Otherwise the regulator would be damaged CAUTION The voltage difference between battery and terminal C of regulator should be less than 0 2 V Use cables in this area as short as possible and with adequate cross section CAUTION Never sever connection between terminal C and B of regulator e g by removal of a fuse while the engine is running Overvoltage and regulator damage can occur Effectivity 912 Series page 111 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL During engine stop break circuit between battery and terminal C to avoid discharge of battery see Fig 67 NOTE A charge indicating lamp 3W 12V Fig 67 pos 18 may be fitted on the instrument panel Current CAUTION graph current over engine speed has been deter mined and is valid only at the following conditions ambient temperature 20 C 68 F voltage permanent 13 5 V tolerance 5 02500 0 1000 2000 3000 4000 5000 6000 1 min 17 3 3 Electronic modules 17 3 4 Ignition switches MAG switch See Fig 4 and 71 Ambient temp for the electronic modules 1 max 80 C 176 F See Fig 71 72 and 73 type two separate suitable
54. e adjustment of the Bowden cable after engine installation has been completed to ensure exact final adjustment WARNING The carburetor flange assembly has to carry the weight of the carburetor and intake system Ensure that the screw of the clamp is positioned on the underside as supplied and the gap between the clamp plates is 8 mm 31 in 15 1 Requirements on the carburetor See Fig 59 The carburetors are positioned above the exhaust sockets Below the carburetors one each drip tray 1 with a draining connection 2 is fitted which serves as a heat shield as well CAUTION A WARNING The float chamber venting lines 3 lines have to be routed into a ram air and vacuum free zone or into the airbox according to the requirements and release of BRP Powertrain See section 16 These lines must not be routed into the slipstream or down the firewall Pressure differences between intake pressure and pressure in the carburetor chambers may lead to engine malfunction due to incorrect fuel supply In the area of the float chamber the temperature limit of the fuel must not be exceeded If necessary install additional insulation or heat shields Certi fication to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer Effectivity 912 Series Edition 1 Rev 1 page 91 May 01 2009 BRP Powertrain INSTALLATION MANUAL 15 1 1 Drainage piping on airbox and drip trays
55. e latest requirements such as FAR or EASA 2 electronic modules A and B plug connection for ignition switch integrated generator external regulator rectifier with plug connections electric starter starter relay with plug connection external alternator with connections electric rev counter Effectivity 912 Series Edition 1 Rev 1 page 108 May 01 2009 904640 BRP Powertrain INSTALLATION MANUAL 14 capacitor 15 2 ignition switches 16 master switch 17 starter switch 18 control lamp 19 battery relay 20 battery 21 bus bar 22 capacitor 23 plug connection for trigger coil assy 24 trigger coil assy tachometer 25 electrical fuel pump 26 starting equipment at the electronic modules 1 9 Wiring symbols to DIN 40712 40713 40716 and 40719 08639 Effectivity 912 Series page 109 Edition 1 Rev 1 May 01 2009 404640 BRP Rotax INSTALLATION MANUAL 17 3 Technical data and connection of the electric components 17 3 1 Integrated generator See Fig 68 Feeding wires 1 from the generator to rectifier regulator on left side of ignition housing see Fig 68 2 flexible cables 1 5 yellow in shielding metal braid length approx 660 mm 26 in starting from ignition housing with on each plug socket 6 3 x 0 8 to DIN 46247 NOTE approx 250W AC output at 5800 r p m For DC output in connection with rectifier regulator s
56. ee section 17 3 2 17 3 2 Rectifier regulator See Fig 69 70 type electronic full wave rectifier regulator effective voltage 14 0 3 V from 1000 250 r p m current limit max 22 A max permissible component temperature 80 C 176 F measured in area 1 weight see section 8 NOTE The performance specifications are given for optimal cooled components If necessary use a separate heat sink for the rectifier regulator d04059 Effectivity 912 Series page 110 Edition 1 Rev 0 May 01 2007 904640 BRP Powertrain INSTALLATION MANUAL Description of connections yellow from generator red to battery positive terminal B battery positive terminal L warning lamp circuit control or field circuit 4 92 3 62 1 gt Eo H fo n 5 106 4 18 in Fig 69 08631 Requirements for flawless operation of the rectifier regulator body of regulator must be grounded with no restance allowed the rectifier regulator has to be protected by a slow blowing 25A fuse wire size of the main circuit of at least 2 5 mm 14 AWG capacitor Fig 67 Pos 25 of at least 22 000 uF 25 V is necessary to protect the correct function of regulator and to flatten voltage The regulator is not designed to store any electrical charge If for any reason the battery or bus system is disconnected from th
57. el lines and connections Effectivity 912 Series Edition 1 Rev 0 page 83 May 01 2007 legend 1 fine filter water trap 2 mechanical fuel pump 3 fuel pressure control 5 return line to tank 4 feeding line from tank 6 1 x check valve 7 electrical fuel pump carburetor fuel p BRP Rotax INSTALLATION MANUAL return line to tank 4 fuel tank coarse filter 7 4 fuel manifold carburetor mechanical fuel pump ressure gauge 3 f drain valve uA RECEN fire cock finefilter watertrap 1 gt 6 check valve 07306 Only the following connections per Fig 54 have to be established Feeding lines to suction side of the mechanical fuel pump 2 lines from pressure side of the mechanical fuel pump to inlet of fuel manifold 3 Returnline from fuel pressure control to fuel tank Effectivity 912 Series Edition 1 Rev 0 page 84 May 01 2007 004056 904056 BRP Rotax INSTALLATION MANUAL 14 2 Operating limits A WARNING Design and layout of the fuel system has to warrant engine operation within the specified limits Fuel pressure See Fig 55 MAX 0 4 bar 5 8 psi i Mr an 0 15 bar 2 2 psi pra 0 3 bar 4 4 psi A WARNING Fuel pressure in excess of
58. engine with the propeller turning while on the ground Do not operate engine if bystanders are close To prevent unauthorized use never leave the aircraft unattended with the engine running Toeliminate possible injury or damage ensure that any loose equipment or tools are properly secured before starting the engine When in storage protect the engine and fuel system from contamination and exposure Never operate the engine and gearbox without sufficient quantities of lubricating oil Never exceed maximum rated r p m and allow the engine to cool at idle for several minutes before turning off the engine The engine should only be installed and placed into operation by persons familiar with the use of the engine and informed with regard to possible hazards Never run the engine without a propeller as this will inevitably cause engine damage and present a hazard of explosion Propeller and its attachment with a moment of inertia in excess of the specified value must not be used and releases engine manufacturer from any liability Improper engine installation and use of unsuitable piping for fuel cooling and lubrication system releases engine manufacturer from any liability Unauthorized modifications of engine or aircraft will automatically exclude any liability of the manufacturer for sequential damage Effectivity 912 Series page 12 Edition 1 Rev 1 May 01 2009 904632 904632 BRP Powertrain
59. ensor wiring spade terminal 6 3 x 0 8 to DIN 46247 grounding via engine block graph of sensor resistance over temperature CAUTION The graph resistance over temperature has been determined andis effective at the following conditions only ambient temperature 20 C 68 F tolerance 10 BRP Powertrain offers non certified temperature indicating instrument Refer to Illustrated Parts Catalog latest issue A WARNING Certification to the latest requirements such as FAR of EASA has to be conducted by the aircraft manufacturer Q 1200 1000 800 600 aan 00227 400 200 20 40 60 80 100 120 140 904641 Effectivity 912 Series page 128 Edition 1 Rev 1 May 01 2009 904641 BRP Powertrain INSTALLATION MANUAL 21 3 Oilpressuresensor See Fig 88 and 89 location oil pump housing wiring connection for instrument The sensor cable is approx 3 long and has 3 leads The Black lead is not to be connected and has no function The Red lead from the sensor has to be connected to the positive bus via a fuse or circuit breaker The White lead output signal has to be connected directly to the instrument See also the relevant instructions of the instrument supplier aircraft manufacturer for correct connection and wiring NOTE The sensor cable can be modified in its length ac
60. ertified technicians authorized by the local airworthiness authorities and trained on this product are qualified to work on these engines A WARNING Never fly the aircraft equipped with this engine at locations airspeeds altitudes of other circumstances from which a suc cessful no power landing cannot be made after sudden engine stoppage Unless correctly equipped to provide enough electrical power for night VFR according latest requirement as ASTM the ROTAX 912 UL ULS is restricted to DAY VFR only Effectivity 912 Series page 11 Edition 1 Rev 1 May 01 2009 BRP Powertrain INSTALLATION MANUAL This engine is not suitable for acrobatics inverted flight etc This engine shall notbe used on rotor wing aircraft helicopters or any similar aircraft t 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 Duetothe varying designs equipment and types of aircraft BRP Powertrain makes no warranty or representation on the suitability of its engine s use on any particular aircraft Further BRP Powertrain makes no warranty representation of this engine s suitability with any other part component or system which may be selected by the aircraft manufacturer assembler or user for aircraft application Unless in a run up area never run the
61. es to inflame NOTE To vent coolant steam from the expansion bottle in case of overheating the plastic cap can be retrofitted with a hose nipple and hose The vent line 5 has to be routed in a way that no coolant can get in contact with the hot exhaust system The venting line must be routed in a continuous decline or furnished with a drain bore at it s lowest point to drain possible condensation The vent line has to be protected from any kind of ice formation from condensation Protection by insulation or routing in a hose with hot air flow or by furnishing the vent line with a bypass opening slot 6 before passing through cowling 7 See Fig 30 4 d 09132 Effectivity 912 Series page 59 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL Unscrew cap 2 from the overflow bottle Bore the existing vent hole from dia 1mm 0 04 in to dia 6mm 0 236 in Apply LOCTITE 603 to the threads of the hose nipple 3 Insert nipple 3 into the vent hole Install nut 1 onto the hose nipple 3 Tightening torque 5 Nm 44 in Ib Screw the cap onto the overflow bottle Steps to attach the hose Attach the hose with a gear type hose clamp 4 Make sure the hose 5 has no kinks Route it overboard and secure gt 222222222220 SS 11 5 57 EQ Eo 1 0 453 EN EH fy ao ae A ee 1 1 lke 1 SE CA
62. espective carburetor NOTE All dimensions to point of reference P limit load on point of reference P2 CAUTION The specified limit loads must never be exceeded 00538 coordinates P1 mm max allowable forces imt Ioas 00 carburetor for in x y and z axis max allowable bending moments cylinder 1 3 in x y and z axis connection 1 for air filter or intake silencer outside dia 50 mm 2 in slip on length 12 mm 47 in connection for throttle actuation 2 connection on throttle lever set screw M 5x12 tightening torque 4 Nm 35 in Ib suitable for 1 5 mm 06 in steel wire action travel 65 mm 2 7 actuating force min 1 5 N 3 Ib max 8 N 1 8 Ib limit load 20 N 4 5 Ib NOTE Throttle opens by spring Effectivity 912 Series page 94 Edition 1 Rev 0 May 01 2007 d04057 904057 BRP Rotax INSTALLATION MANUAL connection for starting carb choke actuation 3 connection on choke lever clamping nipple 6 suitable for 1 5 mm 06 in steel wire action travel 23 mm 7 actuating force min 10 2 2 Ib max 45 N 10 Ib limit load 100 N 22 Ib Directive for choke actuation The choke shaft 3 is marked 4 This mark has to point towards cable engagement 5 00541 Effectivity 912 Series page 95 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 15 3 Requirements on cable actuation See Fig 62
63. f the studs coordinates mm location x axis y axis zaxis ndor 360 cylinder 2 192 196 82 gene 82 438 N 09189 NOTE All dimension to point of reference P max allowable forces limit load in N in x y and z axis max allowable bending limit load in N 40 in x y and z axis 02023 A WARNING The exhaust system has to be designed by the aircraft or fuselage manufacturer such that the limit loads on the points of attachment will not by exceeded Additional support of exhaust system may be necessary Effectivity 912 Series page 39 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 11 1 Requirements on the exhaust system See Fig 13 mean bending radius of exhaust bend 40 mm 1 6 in exhaust bend inside dia min 28 mm 1 1 in muffler volume approx 51 1 32 US gal back pressure at takeoff performance max 0 2 bar 2 9 psi readings taken approx 100 mm 3 93 in from exhaustflange connections The 4 exhaust sockets included in the supply scope have to be used without exception See fig 13 Material of the exhaust sockets X 6 CrNiTi 1810 DIN 1 4541 Tightening torque of the lock nut M8 for the exhaust flange 12 20 Nm 106 177 in lb Pay also attention on SI 05 1997 CAUTION Fit heat shields near carburetors or as required Because of the high temperatures occurring provide suitable protection against uni
64. fuel return 1x plug connection for fuel pressure 1x plug oil supply and oil discharge 1x each cap supply and discharge of coolant 1x each cone plug propshaft on version 3 n ant 1x disk plug carburetor if not equipped with an airbox 2x disk plug A WARNING Protective covering to be utilized for transport and at engine installation only Before engine operation remove these pro tections d04052 Effectivity 912 Series page 32 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 10 Engine suspension and position B CAUTION Atinstallation of engine be aware of engine weight and assure careful handling The engine suspension is determined essentially by the aircraft design Twelve attachment points are provided on the engine 8 on engine and 4 on engine frame The engine can be supplied with a well tried and certified suspension frame for attachment on the fire proof bulk head The airbox is supported on this frame too The installation into the aircraft is as generally practised by captive rubber mounts which ensure also to balance out vibrations and sound from engine to aircraft frame A WARNING If the engine suspension frame supplied by BRP Powertrain is not used or if modified certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer It is
65. gear box with torsional shock absorber and overload clutch optional on configuration UL2 UL4 ULS2 and ULS4 Effectivity 912 Series page 21 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL expansion tank coolant electric starter standard or with extended power output integrated AC generator with external rectifier regulator oil tank external start relay drive of hydraulic governor on version 3 only Auxiliary equipment optional M CAUTION Any equipment not included as part of the standard engine version and thus not a fix component of the engine is not in the volume of supply Components especially developed and tested for this engine are readily available at BRP Powertrain Following auxiliary equipment has been tested on ROTAX engine type 912 for safety and durability to the standards of aviation The furnishing of proof in accordance to the latest FAR or EASA has to be conducted by the aircraft manufacturer airbox external alternator engine suspension frame vacuum pump feasible on version 2 and version 4 only drive for rev counter hour meter oil cooler with connections coolant radiator coolant overflow bottle 904633 Effectivity 912 Series page 22 Edition 1 Rev 1 May 01 2009 904052 BRP Rotax INSTALLATION MANUAL Following equipment has not been tested for safety and durability to the standards of aviation A WARNING Theuserassumes
66. gement Startleistung Take off power Leerlauf Idle 09137 d Effectivity 912 Series page 97 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 1 Rev 0 page 98 May 01 2007 904057 904639 BRP Powertrain INSTALLATION MANUAL 16 Air intake system See Fig 64 The intake system is determined essentially by the demands of engine and of the acceptable noise emission the intake side An airbox can be supplied by BRP Powertrain as an option Performance data as specified and limits of operation can only be warranted by employment of the genuine ROTAX airbox CAUTION performance is given at ISA 15 59 F condition only Engine is equipped with unchanged ROTAX tuned exhaust muffler system and air intake box If it will be necessary to use a different airbox or a modified genuine ROTAX airbox for reasons of installation the certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer NOTE If an airbox or genuine ROTAX airbox is retrofitted ata ROTAX 912 A F UL Series a change in the carb jetting is required See Illustrated Parts Catalog 912 914 chapter 22 and or SB 912 044 Use of the ROTAX supplied airbox latest issue 16 1 Operating limits Fuel mixture distribution Low cold air temperature in the airbox is favourable for engine performance and to reduce
67. hat no additional moments or load will rest on the pump CAUTION Utilize max slip on length Secure hoses with suitable screw clamps or crimp hose connection on fuel pump 2 supplied with fire sleeved lines See fig 57 Fuel intake connection 12 fitting 15 9 16 18 UNF AN 6 Tightening torque 15 Nm 135 in Ib Fuel outlet connection 13 hose nipple 14 3 4 DIN 7642 Effectivity 912 Series page 88 Edition 1 Rev 0 May 01 2007 d04056 904056 BRP Rotax INSTALLATION MANUAL 14 4 3 Check valve Specification opening pressure 0 1 0 15 bar 1 5 psi 2 2 psi permitted pressure in reverse biasing 2 bar 29 psi burst DESSUS nimes 5 bar 72 5 psi Effectivity 912 Series page 89 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 1 Rev 0 page 90 May 01 2007 d04056 904638 15 Carburetor See Fig 58 BRP Powertrain INSTALLATION MANUAL The carburetors on the standard engine are already attached by a flexible flange and connecting hoses on the airbox Only connections of the Bowden cable for pre heating choke and throttle have to be established It is recommended to make th
68. iasport A WARNING Certification to the latest requirements such as FAR of EASA has to be conducted by the aircraft manufacturer 21 4 Mechanical rev counter tach drive See Fig 90 and 91 location ignition housing 1 direction of rotation of the rev counter shaft 2 clockwise see figure below position of rev counter drive installation dimensions see figures above Axes point of x yaxis zaxis engagement mm mm D P 8 2 a 3 TN z O 26 2 reduction ratio i 41 1 4 of engine speed 904641 Effectivity 912 Series page 130 May 01 2009 Edition 1 Rev 1 BRP Powertrain INSTALLATION MANUAL 21 5 Monitoring of the intake manifold pressure See Fig 92 Connection nipple 1 to measure manifold pressure outside dia 6 mm 1 4 slip on length max 17 mm 11 16 CAUTION Utilize the total slip on length on all joints Secure hose by suitable screw clamps or crimp connection A WARNING Protective covering to be utilized for transport and at engine installation only If connection for pressure reading is not employed it has to suitably plugged New style compensating tubes have plugged this conne
69. ic rev counter consult the section 17 21 1 Sensor for cylinder head temperature See Fig 4 84 and 85 NOTE A direct reading of the coolant temperature is not provided for The temperature sensor 1 is directly fitted into cylinder head i e a direct temperature reading of the cylinder head material is taken location in the cylinder head of the cylinders 2 and 3 see Fig 4 connection spade terminal 6 3x0 8 to DIN 46247 grounding via engine block graph of sensor resistance over temperature 04868 Axes x axis axis z axis cylinder head mm mm mm 157 0 157 0 0 1200 1000 800 20 40 60 80 100 120 140 9 CAUTION The graph resistance over temperature has been determined and is effective at the following conditions only ambient temperature 20 C 68 F tolerance 10 Effectivity 912 Series page 127 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 21 2 Sensor for oil temperature See Fig 86 and 87 location oil pump housing marking 2 marked with TO temperature oil on oil pump flange CAUTION To avoid any mix up with indication wiring mark this particular cable also with TO x axis y axis z axis mm mm mm position of the temperature sensor 1 the pump flange Axes 04869 connection of s
70. ies Edition 1 Rev 0 page 134 May 01 2007 d04060 ROTAX AIRCRAFT ENGINES HEINDL WERBEAGENTUR PRIBYL Motornummer Engine serial no Flugzeugtype Type of aircraft Flugzeugkennzeichen Aircraft registration no Vertriebspartner ROTAX authorized distributor www rotax aircraft engines com and TM are trademarks of BRP Powertrain GmbH amp Co KG 2009 BRP Powertrain GmbH amp Co KG All rights reserved
71. inder head temperature is necessary Additional monitoring of the actual coolant temperature is possible but not necessary for waterless coolant Effectivity 912 Series page 49 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL NOTE When using EVANS NPGR NPG or added pure ethylene glycol as a coolant note that these fluids have a flammability rating 1 classification LOW at a scale from 0 to 4 The mentioned coolants are complying according to their material safety data sheet with a flammability classification which has only low danger and a low risk of flammability To date no cases in engine operation or flight operation laboratory conditions or from the field were reported which show unsafe conditions of ROTAX aircraft engines in combination with the relevant coolants Marking of the coolant to be used CAUTION Thecoolantto be used and its concentration percentage water rate must be communicated to the owner in the correct form Waterless coolant must not mix with water as otherwise it will lose the advantages of a high boilling point Example EVANS NPG See Fig 22 1 Warning sticker 2 Radiator cap mh TNA 3 Opening pressure information of radiator cap C3 X 12 4 Check cooling system Efficiency of the cooling system For a measurement of the cooling system the maximum values for coolant exit temperature and cylinder head temperature must be found According to the current s
72. ition 1 Rev 0 May 01 2007 d04055 BRP Rotax INSTALLATION MANUAL 13 13 Data for optional components of oil system oil radiator See Fig 53 weight see section 8 variants of connectors adaptor UNF 1 tredd ere 3 4 16 UNF AN 8 Tightening torque 22 Nm 195 in Ib and Loctite 243 Tightening torque of oil inlet and outlet 25 Nm 18 5 16 CAUTION Counterhold on adaptor at installation of an oil line nipple 2 outside 13 2 mm 0 52 in Slip on length max 21 mm 0 83 in Tightening torque 22 Nm 195 in Ib and Loctite 243 adaptor metric 3 18 1 5 Tightening torque 22 Nm 195 in Ib and Loctite 243 Tightening torque of oil inlet and outlet bend socket or hose nipple e PER 25 Nm 18 5 ft lb CAUTION Counterhold on adaptor at installation of an oil line angular tube 4 90 nipple outside 13 2 0 52 1 Slip on length max 21 mm 0 83 in Tightening torque 22 Nm 195 in Ib and Loctite 243 bent socket 5 90 socket outside dia 12 mm 0 47 in Slip on length max 24 mm max 0 94 in Tightening torque 25 Nm 18 5 ft
73. itting positions 35 Air temperature in the airbox 132 Fuel filter 86 Airbox 101 Airfilter 100 Attachment points 34 Auxiliary equipment 22 B Bank angle 27 Battery 119 Carburetor 91 Coarse filter 86 Connection of electric rev counter 118 Connections cooling system 55 Connections oil circuit 72 Connections carburetor 94 Connections for instrumentation 127 Coolant capacity 63 Cooling system 47 Critical flight level 27 Current pages 17 Cylinder head temperature sensor 127 D Definition of main axes 24 Denomination of cylinders 24 Description of design 21 Designation of type 21 Documentation 14 Drainage lines airbox 101 Drainage piping drip tray 92 Drip tray 91 E Electric fuel pump 87 89 Electric starter 114 Electromagnetic compatibility 108 Electronic modules 112 Elektric system 107 Engine components 24 Engine serial number 9 Engine speed 27 Engine suspension 33 38 Engine views 24 Exhaust system 39 Expansion tank 55 External alternator 116 Effectivity 912 Series Edition 1 Rev 0 Fuel pressure 85 Fuel pressure control 88 Fuel system 83 H Hydraulic governor for constant speed propel ler 125 Ignition switches 112 Instruction 13 Instrumentation connection 127 Intake air ducting 100 Integrated generator 110 L Location of radiator 58 Lubrication system 67 M Main axes 24 Manifold pressure 27 Manifold pressure connector 131 Mechanical rev counter 130 O Oil cooler 77
74. knocking tendency at combustion The certification to the latest requirements such as FAR and EASA has to be conducted by the aircraft manufacturer CAUTION changes on the air intake system e g modification on the airbox etc can affect the flow rate in the air intake system and the fuel mixture ratio In the course of certification the fuel mixture process must be proofed by CO measurement CO Measurement CO Emission min 3 0 CO wide open throttle WOT an rpm of min 5200 1 min needs to be achieved Measurement in original configuration of aircraft e g with installed cowling Measured on each single cylinder Measuring point is the same as the EGT measurement See section Exhaust system Effectivity 912 Series page 99 Edition 1 Rev 1 May 01 2009 BRP Powertrain INSTALLATION MANUAL 16 2 Requirements on the air intake system A WARNING Carb icing is a common reason for engine trouble No imple ments are included in the supply volume for preheating of the intake air If an airbox of not ROTAX origin is used provisions for preheating the intake air have to be made to prevent formation of ice in the intake system Preheating of the intake air will result in performance loss because of the lower air density A WARNING AII items of the air intake have to be secured against loss A WARNING The certification to the latest requirements such as FAR and EASA has
75. le See Fig 19 Material thickness of the exhaust components X 15CrNiSi 20 12 DIN 1 4828 stainless a 1 mm 0 039 in 32 1 26 in 09166 30 1 19 in exhaust tube See Fig 20 Material thickness of the exhaust components X 15CrNiSi 20 12 DIN 1 4828 stainless a 1 mm 0 039 in 09167 800 31 49 in d04053 Effectivity 912 Series page 45 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL NOTES 904053 Effectivity 912 Series page 46 Edition 1 Rev 0 May 01 2007 904635 BRP Powertrain INSTALLATION MANUAL 12 Cooling system 12 1 Description of the system See Fig 21 The cooling system of the ROTAX 912 is designed for liquid cooling of the cylinder heads and ram air cooling of the cylinders The cooling system of the cylinder heads is a closed circuit with an expansion tank and overflow bottle 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 The expansion tank is closed by a pressure cap 3 with pressure relief valve and return valve At temperature rise and expansion of the coolant the pressure relief valve opens and the coolant will flow via a hose at atmo
76. m 18 5 ft Ib um B 09123 904055 Effectivity 912 Series page 72 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL Oil pump inlet nipple 2 outside dia 13 2 mm 0 52 in slip on length max 21 mm 0 83 in 00226 Oil pump inlet 3 thread 3 4 16 UNF AN 8 Tightening torque of inlet line 25 Nm 18 5 ft Ib 09123 8 3 Effectivity 912 Series page 73 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL Oil return CAUTION The engine designisfora conventional non aerobatic fixed wing tractor or pusher type configuration with the oil return port in the optimum position With this consideration the engine is properly lubricated in all flight profiles Aircraft that are not conventional e g airship gyrocopters dive brake equipped aircraft etc that require engine load in steeply incline and decline angles see also sec 8 1 point 12 may require special lubrication considerations According to propeller configuration and oil system layout choose the appropriate connection for the oil return line Position 1 for tractor or position 2 for pusher configuration and connector options 1 2 and 5 See Fig 47 Option 1 connection with slip on connection 1
77. nd components system descriptions contained in this Installation 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 BRP Powertrain reserves the right at any time to discontinue or change specifications designs features models or equipment without incurring obligation The illustrations in this Installation Manual show the typical construction They may not represent in full detail or the exact shape of the parts which have the same or similar function 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 4 1 Repeating symbols This Manual uses the following symbols to emphasize particular information These indications are important and must be respected A WARNING Identifies an instruction which if not followed may cause serious injury including the possibility of death CAUTION Denotes an instruction which if not followed may se verely damage the engine or other component NOTE Indicates supplementary information which may be needed to fully complete or understand an instruction revision bar outside of page margin indicates a change to text or graphic 4 2 Safety information A WARNING Only c
78. nd routed at distance from hot engine components without kinks and protected appropri ately At very critical conditions e g problems with vapour formation the fuel lines could be routed in a hose with cold air flow Fuel filter See Fig 54 Coarse filter on fuel tank as per valid certification Fine filter inthe feed line from tank to the fuel pumps an additional fine filter with meshsize 0 1 mm 004 in has to be provided The filter has to be controllable for service A combination of filter watertrap gascolator is recommended water trap A suitable water trap must be installed at the lowest point of the fuel feed line Fuel temperature In case of temperatures over 45 C 113 F in the vicinity of fuel lines watch for vapour lock If you should encounter problems in this respect during the test period than the affected components such as the supply line to the fuel pumps have to be cooled Effectivity 912 Series page 86 Edition 1 Rev 0 May 01 2007 d04056 904637 BRP Powertrain INSTALLATION MANUAL 14 4 Connecting dimensions location of joints and directives for installa tion 14 4 1 fuel manifold See Fig 2 3 4 and 55 position of 24 axis of the fuel manifold NOTE Dimensions always from point of reference P return line to tank 5 outside dia 7 mm 28 in slip on length max 17 mm 67 in pressure gauge connection 6 outside dia 6 mm 24
79. nder head temperature is important to control the engine cooling and prevents detonation within the operating limits It is also necessary to design the cooling circuit so that under no conditions the coolant does get near its boiling point because a subsequent loss of coolant can quickly cause the engine to overheat The boiling point of the coolant is influenced mainly by the type of coolant the proportion of the mixture percentage water rate the system pressure opening pressure of radiator cap Correlation between coolant temperature and cylinder head temperature There is in principle a regular relationship between coolant temperature and cylinder head temperature The coolant transfers some of the combustion heat to the radiator Thus the coolant temperature is usually lower than the cylinder head temperature Butthe temperature difference between coolant and cylinder head is not constant and can vary with different engine installation cowling or free installation tractor or pusher flight speed etc Effectivity 912 Series page 48 Edition 1 Rev 0 May 01 2007 d04054 d04054 BRP Rotax INSTALLATION MANUAL NOTE The basic requirement for safe operation is that boiling of conventional coolant must be prevented The boiling point of conventional coolant is 120 C 248 F with a 50 50 mixture proportion and a system pressure of 1 2 bar 18 psi 12 3 Coolanttypes In principle 2 different types of coolan
80. nection 5 at the oil tank with suitable air tight cap See Fig 51 Remove the spark plug connectors For easier rotation of engine remove one spark plug from each cylinder CAUTION Prevent entering of foreign substance through spark plug hole Using a compressed air line pressurize the oil tank through its breather connection 6 on the neck of the tank Adjust the compressor outlet regulator so that the air line pressure is between 0 4 6 psi and 1 bar 15 psi Do not exceed 1 bar 15 psi NOTE Oil tank cover is not designed to hold pressure Some air will escape WARNING Do not remove oil tank or cover before ensuring that air pressure has been completely released from the tank The pressure in the oil tank has to be maintained during the following step B CAUTION Itis possible to empty the oil tank and as a result introduce more air into the oil system Pay attention to the oil level and fill tank as required Turnthe engine by hand in direction of normal rotation until the first pressure indication on the oil pressure gauge Normally this will take approx 20 turns Depending on installation it may take up to 60 turns CAUTION Donotusestarterforthis purpose Fit propeller and use itto turn engine Effectivity 912 Series page 78 Edition 1 Rev 0 May 01 2007 d04055 d04055 BRP Rotax INSTALLATION MANUAL Release the pressure from the oil tank Un block the oil return port on
81. ntentional contact CAUTION Secure exhaust system by suitable means according to instal lation 1 18 in 030 00776 d04053 Effectivity 912 Series page 40 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 11 2 operating limits See Fig 14 exhaust gas temperature EGT both ignition circuits active nominal approx 800 C 1470 F max 850 C 1560 F max 880 C 1616 F at take off readings of EGT taken approx 100 mm 3 93 in from exhaust flange connections The exhaust gas temperatures EGT have to measured at the initial engine installation in an aircraft and must be verified in the course of test flights WARNING The exhaust system has to be designed and built such that the operating temperatures are maintained and the max exhaust gas temperatures will never be exceeded CAUTION The listed engine performance is given at ISA 15 59 F conditions only on engine that is equipped with an unmodified ROTAX tuned exhaust muffler system and air intake box 2 Ls b LI ne PERI ae Me 100 mm ROTAX 3 93 in 07131 8 5 Effectivity 912 Series page 41 Edition 1 Rev 0 May 01 2007 BRP Powertrain INSTALLATION MANUAL 11 3 General directives for exhaust system See Fig 15 A exhaust system especially for universal application has been developed by
82. on off switches Fig 67 pos 15 switching voltage min 250 V switching current min 0 5 A Wires from the ignition switches connect to the electronic module see Fig 71 d04059 Effectivity 912 Series page 112 Edition 1 Rev 0 May 01 2007 d04059 BRP Rotax INSTALLATION MANUAL one each flexible wire 0 75 mm 18 AMG brown length approx 35 mm 1 3 8 beginning at electronic module with one each plug socket and insulating sleeve 3 96 mm At the new version the cable grommet and fasten connector are integrated in the 6 pole connector housing See also SI 912 013 latest issue NOTE One each cable grommet 2 and flat pin terminal 3 are supplied loosely packed For correct assembly of the flat pin terminal strip the wire 4 and install the cable grommet in correct position and direction Fix the flat pin terminal and the cable grommet with appropriate crimping pliers The rubber grommet is held by the secondary crimp Fit the flat pin terminal in the free position of the 6 pole connector housing until it is locked in place Check for tight fit 08323 NOTE Faston connector and insulation sheath of the old Effectivity 912 Series Edition 1 Rev 0 version are available as spare part See also SI 912 013 latest issue page 113 May 01 2007 BRP Rotax INSTALLATION MANUAL Wire of top electronic module marked for ignition circuit A Wire of bottom electroni
83. or installation Depending on the achieved maximum values of the cylinder head temperature andthe coolant temperature following action are necessary 08358 maximum values for coolant used for tests Coolant Cylinder head Conventional coolant Waterless coolant temperature temperature less than ioo einen for 135 275 F isplaying coolant temperature is necessary Modifications to the instruments or limit not necessary less than a 135 275 F 150 300 F less than 120 C 248 F 150 C 2 300 F b more than 120 C 248 F Cooling capacity too low th T es F Check of the installation necessary Cooling capacity too low Check on 2 150 gt 300 F c of the installation necessary more than c 135 C 275 F 150 300 F less than 120 C 248 F more than 120 C 248 F 9 engine type 912 ULS S 2 engine type 912 UL A F a Maximum cylinder head temperature is below operating limit Operating with waterless coolant is permissible without modification to the installation b Maximum cylinder head temperature and coolant exit temperature is below operating limit For operating with conventional coolant it is necessary to monitoring constantly cylinder head temperature and coolant exit temperature NOTE For detection of possible indication error an additional monitor ing ofthe cylinder head temperature is nece
84. orce can be verified with a fan belt tester Repeat on other rocker arms Check distance between rocker arm and valve contact surface Max allowable distance 0 5 mm 0 02 in Repeat on all other cylinders CAUTION _ If itis possible to push the valve tappets further than this limit an additional engine run for about 5 min at 3500 rpm after refitting the valve covers To get the hydraulic valve tappets primed this process can be repeated another 2 times Effectivity 912 Series page 79 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 13 12 Replacement of components If a malfunction of hydraulic valve tappet should be found during this check of priming process the relevant hydraulic valve tappet has to be replaced The valve spring support has to be inspected for wear All work has to be performed in accordance with the relevant Maintenance Manual pressure max 1 bar 15 psi 6 appropriate plug 5 to oil pump 1 back from engine 2 d04055 Effectivity 912 Series page 80 Ed
85. ould be covered by x appropriate sealing lips for better efficiency of cooling 5 Effectivity 912 Series page 66 Edition 1 Rev 0 May 01 2007 d04055 BRP Rotax INSTALLATION MANUAL 13 Lubrication system 13 1 Description of the system See Fig 40 The ROTAX 912 engine is provided with a dry sump forced lubrication system with a oil pump with integrated pressure regulator NOTE The oil pump is driven by the camshaft The oil pump sucks the motor oil from the oil tank 1 via the oil cooler 2 and forces it through the oil filter to the points of lubrication lubricates also the propeller governor 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 NOTE The oil circuit is vented via nipple 3 in the oil tank Forthe completion of the lubrication system only the following connections need to be established Cil circuit oil tank outlet to oil cooler oilcooler to oil pump inlet oil return to oil tank inlet oiltank venting line
86. pecifications Effectivity 912 Series page 50 Edition 1 Rev 1 May 01 2009 d04635 904635 BRP Powertrain INSTALLATION MANUAL 12 4 1 Measurement of cylinder head temperature and coolant exit Effectivity 912 Series Edition 1 Rev 1 temperature There are two temperature sensors 1 See Fig 23 on the cylinder 2 and 3 for measuring the cylinder head temperature During flight test the place with the highest cylinder head temperature must be found this can vary with different engine installation cowling or free installation tractor or pusher fight speed etc The measuring of the coolant exit temperature is performed using a separate sensor which has to be installed in the line between expan sion tank 1 and radiator inlet 2 09152 The sensor may be installed in a TEE inline with the fluid hose or the expansion tank may be modified to attach the sensor not supplied by BRP Powertrain WARNING Do not restrict the coolant flow with the sensor devise CAUTION _ It is possible to receive a misleading reading when measuring fluid temperatures If fluid volume is lost and the probe is not fully submerged in the fluid the display could show a lower temperature than actual measuring air temperature instead of fluid tempera ture page 51 May 01 2009 BRP Rotax INSTALLATION MANUAL 12 5 Determination of operating limits Coolant and necessary modifica tion on radiat
87. r A WARNING Never run the engine without a propeller installed as engine would 18 1 suffer severe damage by overspeeding Never fit propeller directly on crankshaft Technical data See Fig 80 direction of rotation of the prop flange counter clockwise looking towards face of flange attachment of propeller on prop shaft flange P C D 75 2 95 6 bolt holes of 8 mm 32 in dia P C D 80 3 15 6 bolt holes of 11 5 mm 45 in dia P C D 101 6 mm 4 6 bolt holes of 13 mm 51 in dia hub diameter 47 mm 1 85 in ratio of gear reduction 2 2727 50 Teeth 22 T 2 4286 51 T 21 T max torque ROTAX 912 UL A for i 2 2727 238 Nm 176 ft lb at propeller ROTAX 912 UL A for i 2 4286 255 Nm 188 ft lb at propeller ROTAX 912 ULS S for i 2 4286 315 Nm 232 ft lb at propeller max moment of inertia normal between 1500 kgcm 3 559 Ib ft and 6000 14 238 Ib ft max moment of inertia on propeller 6000 14 238 Ib ft max permitted static out of balance on a prop max 0 5 gm 043 Ib in max extension of the propeller shaft 120 mm 4 72 in CAUTION No modification of propeller shaft permitted page 121 May 01 2009 NOTE BRP Rotax INSTALLATION MANUAL In the course of certification a vibration analysis of the whole system engine suspension propeller etc should be done If there are no limits found in the technical
88. r will be avoided while if attached on the bottom lugs only the moment of tilting has to be taken care of accordingly A certified engine suspension frame has been developed by BRP Powertrain especially for the magneto side engine at tachment to the fireproof bulk head If the engine suspension frame supplied by BRP Powertrain is not used the engine installation must by ground run tested to the specified loads and for vibration behaviour Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer The rubber mounts to neutralize vibrations and all the engine suspension components not in the supply volume must be ground run tested to the specified loads and for vibration behaviour Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer The engine suspension has to be designed to prevent any excessive engine movement and to minimize noise emission and vibration on air frame side See also SL 912 010 Identifying abnormal vibrations on aircrafts latest issue Effectivity 912 Series Edition 1 Rev 1 page 38 May 01 2009 d04634 d04053 BRP Rotax INSTALLATION MANUAL 11 Exhaust system See Fig 2 3 and 4 The shape and execution of the exhaust system is determined essentially by the free space available in the aircraft For attaching the exhaust system two studs M8x23 are provided on each cylinder Location o
89. raulic governor for constant speed propeller 20 1 Technical data See Fig 83 NOTE See therefore also SB 912 052 Installation Use of governors for Rotax engine type 912 and 914 latest issue drive via prop gear location of the necessary connection on the crankcase see Fig 83 coordinates xaxis y axis z axis connection mm mm 206 3 515 09191 connections mounting pad AND20010 thread size M8 Effective thread length max 14 mm 0 55 in toothing internal spline 20 40 SMS 1834 NA 14x1 27x30x12 direction of rotation of governor drive clockwise looking at mounting pad power input max 600 W operating pressure max 30 bar 435 psi CAUTION attention to manufacturer s specifications NOTE Speed reduction from crankshaft to hydraulic governor is 1 724 or 1 842 i e the vacuum pump runs with 0 58 or 0 54 of engine speed Effectivity 912 Series page 125 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 090 0 126 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04060 BRP Rotax INSTALLATION MANUAL 21 Connections for instrumentation These connections to be established in accordance to certification and or national specifications The certification for connections and connection lines have to be conducted by the aircraft manufacturer to the latest requirements like FAR and EASA For notes regarding the electr
90. rol the proper function of the lubrication system the following readings have to be taken on the running engine as part of the test qualification procedure NOTE The required pressure gauges and connection parts are not included in the BRP Powertrain engine delivery 13 3 1 Measuring of the vacuum Measuring of vacuum in the oil suction line 1 line from oil tank to oil pump via oil cooler ata max distance of 100 mm 4 in from pump inlet 2 At take off performance the indicated vacuum 3 must not be more than 0 3 bar 4 35 psi otherwise the oil hose 1 could collapse and thus blocking the oil supply to the engine Fig 41 A WARNING The vacuum 3 must be verified over the total range of engine operation Specially on cold oil temperature the flow resistance increases so that not enough oil can flow on suction side x 0 1 bar max 0 3 bar 4 35 psi below atmospheric pressure Effectivity 912 Series page 69 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 13 3 2 Measuring of the pressure in the crankcase Measure of the mean crankcase pressure at full load blow by gas pressure responsible for proper oil return from crankcase to oil tank A pressure indicator 4 pressure gauge with incorporated viscous damper may be fitted instead of the magnetic plug 5 or the crankshaft locking screw 6 see Fig 42 NOTE The connecting thread is M12x
91. rp bends NOTE Water is a by product of combustion Most of this water will dissipate from the combustion chamber with the exhaust gases A small amount will reach the crankcase and has to be disposed through the vent line of oil tank via oil return line The venting line must be routed in a continuous decline or furnished with a drain bore at it s lowest point to drain possible condensate The vent line has to be protected from any kind of ice formation in the condensate Protection by insulation or routing in a hose with hot air flow or by furnishing vent line with a bypass opening 1 before passing through cowling 2 See Fig 43 09132 d04055 Effectivity 912 Series page 71 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 13 5 Connecting dimensions and location of connections CAUTION Utilize the full slip on length for hose connections Secure hoses with suitable screw clamp or by crimp connection NOTE The oil pipeline connections are optional as UNF thread AN 8 See 51 912 003 13 5 1 Oil circuit engine See Fig 44 45 46 and 47 Depending on engine certification the oil pump inlet connectors can vary 912 A F S thread M18 optional UNF thread AN 8 912UL ULS inlet nipple optional M18 or UNF thread AN 8 Oil pump inlet 1 thread M18 x 1 5 x 11 NOTE Suitable for use of a swivel joint See Fig 48 Tightening torque of inlet line 25 N
92. sidered applicable for profession als under normal conditions The rapid technical progress and variations of installation might render present laws and regulations inapplicable or inadequate The illustrations in this Manual are mere sketches and show a typical arrange ment 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 Effectivity 912 Series page 14 Edition 1 Rev 0 May 01 2007 904051 d04051 NOTE BRP Rotax INSTALLATION MANUAL The illustrations in this Manual are managed in a graphic data base and are identified by a consecutive non corresponding number This No e g 00277 does not have any meaning concerning the content All necessary documentation is available from the ROTAX Authorized Distributors or their Service Centers Installation drawings and a DMU model for virtual installation analysis are available from the ROTAX Authorized Distributors or their Service Centers Effectivity 912 Series Edition 1 Rev 0 page 15 May 01 2007 BRP Rotax INSTALLATION MANUAL NOTES Effectivity 912 Series Edition 1 Rev 0 page 16 May 01 2007 d04051 904632 BRP Powertrain INSTALLATION MANUAL 5 List of the effective pages 00567 chapter page date chapter page date ch
93. spheric pressure to the transparent overflow bottle 4 When cooling down the coolant will be sucked back into the cooling circuit 09152 The shape size and location of one or more radiators depend mainly on the space available On good installation in the airplane the radiator by BRP Powertrain optional has enough cooling capacity to keep within the normal specified operating limits Also the flow of coolant liquid through the radiator is not restricted and the tube size is sufficient Effectivity 912 Series page 47 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL 12 2 Operating Limits Using conventional coolant Coolant temperature coolant exit temperature AR de de 120 C 248 F Cylinder head temperature ROTAX 912 150 300 ROTAX 912 ULS S me 135 275 F Permanent monitoring of coolant temperature and cylinder head temperature is necessary Using waterless coolant Cylinder head temperature ROTAX 912 UL A F Max 150 C 300 F ROTAX 912 ULS S LAC PR 135 275 F Permanent monitoring of cylinder head temperature is necessary Additional monitoring of the actual coolant temperature is possible but not necessary for waterless coolant WARNING The cooling system has to be designed so that operating temperatures will not be more than the maximum values Monitoring the cyli
94. ssary which shows an exceedingin case of coolant loss The aircraft manufacturer has the option of converting the coolant temperature and the cylinder head temperature to an aircraft specific cylinder head tem perature This is possible by calculating the difference between the head material and the coolant temperature This is done by following the flight test procedure on page 53 Effectivity 912 Series page 52 Edition 1 Rev 0 May 01 2007 d04054 904054 BRP Rotax INSTALLATION MANUAL Once the calculation is made and the indicating instrument re labelled it is acceptable to use the cylinder head temperature as the primary cockpit display instead of installing a sensor in the coolant flow The measurement is based on the maximum coolant temperature and cylinder head temperature according to the current requirement B CAUTION In no case a cylinder head temperature higher than the limit of 150 C 300 F for ROTAX 912 UL A F and 135 C 275 F for ROTAX 912 ULS S can be defined because detonation could not be sufficiently prevented Refer to the flight test example that follows c Cooling capacity of the installation too low Flight test example Calculated values maximum values found for coolant temperature and cylinder head temperature Refer to the current specification of the FAA and or EASA Coolant temperature 102 C 216 F Cylinder head temperature 110 23
95. stem Check flow rate and cooling capacity if other radiators are used Effectivity 912 Series page 61 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL No provision has been made for attachment of the radiator s on the engine CAUTION Install the radiator without distortion or stressand free of vibrations rubber mounts are recommended At installation of a non original ROTAX radiator take care of sufficient cooling capacity See section 12 7 Effectivity 912 Series page 62 Edition 1 Rev 0 May 01 2007 d04054 BRP Rotax INSTALLATION MANUAL 12 10 Coolant capacity 4 cylinder heads 560 cm 34 1 in water DUMP 2 100 cm 6 10 in expansion tank 250 cm 15 2 in 2 m coolant hose 18 mm 71 in inside dia 500 30 5 in total coolant quantity in engine approx 1 51 0 4 gal US 12 11 Cooling air ducting Contrary to the cylinder heads the cylinders are ram air cooled Plan cooling air ducting according to installation requirement A WARNING The cooling air ducting has to be designed and built such that the operating temperatures are kept within the specified limits and maximum values are not exceeded This must also be warranted at hot day conditions Max permissible cylinder wall temperature on cylinder 2 200 C 392 F see Fig 36 Schraube screw M5
96. t L 1 1 E 1 Eh 2514 speed propeller TA e e WIL YS 5 intake manifold E 7 6 ignition housing gt ENS gl 7 ignition cover PUO b o 8 constant depression carb 00502 11 i 2779 9 coolant pump 12 10 expansion tank 18 sensor for oil pressure 11 oil pump 19 sensor for oil temperature 12 connection for oil return line 20 sensor for cylinder head temperature 13 oil filter 21 connection for mechanical rev counter 14 electric starter 22 mechanical fuel pump 15 electronic module 23 oil tank 16 compensation tube 24 external alternator 17 connection for manifold pressure pressu 25 exhaust socket E Effectivity 912 Series page 24 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 904052 Effectivity 912 Series page 25 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL NOTES d04052 Effectivity 912 Series page 26 Edition 1 Rev 0 May 01 2007 BRP Rotax INSTALLATION MANUAL 8 Technical data maintain clarity only data relevant for engine installation and operation will be stated in the Manual NOTE Connecting dimensions filling capacities drive and reduction ratios electric output etc can be found in the respective chapter of engine installation or other relevant engine documentation see section 4 4 8 1 Operating limits 1 m I T me m M 9 Engine speed see Operators Manual 912
97. t are permitted Type 1 Conventional coolant based on ethylene glycol Conventional coolant is recommended as it is commonly available and has a greater thermal heat transfer capability Its limitation is its lower boiling point Conventional coolant should be used with a mixture of 50 concentrate and 50 water NOTE Some conventional coolant is available pre mixed by the manufacturer In this case do not mix with water follow the manufacturers instructions on the container Conventional coolant with a rate of 5096 water cannot boil ata temperature below 120 C 248 F at a pressure of 1 2 bar 18 psi Thus the coolant temperature limit is at max 120 C 248 F Permanent monitoring of coolant temperature and cylinder head temperature is necessary Type 2 Waterless coolant based on propylene glycol Waterless coolant is recommended if the design of the aircraft can not maintain the coolant temperature limit Waterless coolant has a very high boiling point that prevents coolant loss due to boiling over vapor loss but not to prevent detonation which can occur with cylinder head temperatures higher than 150 C 300 F for ROTAX 912 UL A F and 135 C 275 F for ROTAX 912 ULS S It does not require pressure to maintain its boiling point Due to a lower thermal conductivity the engine temperature will typically run about 5 10 C 41 50 F higher with waterless coolant Permanent monitoring of cyl
98. tained and the max values are not exceeded This state has to be warranted for hot day conditions too If need be take appropriate measures like changing size of cooler partial covering of cooler etc Additionally the system needs an overflow bottle 7 where surplus coolant is collected and returned back into the circuit at the cooling down period Effectivity 912 Series page 58 Edition 1 Rev 0 May 01 2007 d04054 904054 BRP Rotax INSTALLATION MANUAL NOTE For proper operation keep hose to overflow bottle as short and small as possible see section 12 6 Expansion tank to overflow bottle hose CAUTION warrant the proper operation of the cooling system the delivery head between overflow bottle and expansion tank must not exceed 250 mm 10 Requirements on the overflow bottle 7 transparent material unaffected by temperatures from 40 C 40 F to 125 C 257 F resistant against 100 Glycol and any other anti freeze agent volume approx 0 5 13 US gal possible to vent 6 diameter 2 5 mm 0 1 in NOTE The overflow bottle ought to be furnished with a label indicating function and content A WARNING Ensure that the overflow bottle will never be empty otherwise air will be sucked into cooling circuit causing cooling system failure B CAUTION Theoverflow bottle and their supply and discharge will never be install direct of the exhaust system coolant can be sometim
99. ter 118 173 9 TE 119 17 3 10 Capacitor option electric fuel pump 119 17 3 11 Starting equipment at the electronic modules optional extra 119 18 Propeller drive e 121 TECHNICAL GALA vss EE 121 19 Vacuum e I 123 eee 123 20 Hydraulic governor for constant speed propeller 125 20 1 Technical data ts cs er P in 125 21 Connections for instrumentation ss 127 21 1 Sensor tor cylinder head temperature vaccessecccxssepseeceaseneraneectemeenvorsaerannecedeiersedeansenetes 127 21 2 Sensor for oil temperature 128 21 3 Oil pressure 129 21 4 Mechanical rev counter tach drive 130 21 5 Monitoring of the intake manifold pressure 131 21 6 Air temperature in the airbox optional 132 22 Preparations for trial run of engine 133 Effectivity 912 Series page 5 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES d04050 Effectivity 912 Series Edition 1 Rev 0 page 6 May 01 2007 904050 BRP Rotax INSTALLATION MANUAL 2 Index A F Acceleration 27 Fine filter 86 Air intake system 99 F
100. to be conducted by the aircraft manufacturer Air intake socket 1 for fresh air or pre heated air intake side outside dia 60 mm 2 3 8 slip on length max 25 mm 1 B CAUTION Utilize the full slip on length on all connection Secure hoses by suitable spring type clamp or screw clamp 16 2 1 Requirements on the intake air ducting max length of ducting 500 mm 20 in min inside dia at least outside dia of the intake socket on airbox min mean bending radius 100 mm 4 High engine performance needs air temperature as low as possible at air intake Therefore the air filter should be located in a recess of the engine cowling or separated from warm air by baffles such that fresh air can be aspirated 16 2 2 Airfilter CAUTION minimum flow rate of 6 23 m min 220 cfm has to be warranted for all conditions The pressure loss must not exceed 2 hPa A WARNING Use only filter elements which will not tend to restrict the flow when in contact with water BRP Powertrain offers an air filter as described below Effectivity 912 Series page 100 Edition 1 Rev 1 May 01 2009 d04639 d04058 BRP Rotax INSTALLATION MANUAL A WARNING The certification to the latest requirement such as FAR and EASA has to be conducted by the aircraft manu facturer The following points should assist the aircraft manufacturer at the choice of a suitable filter four fold cotton fabric
101. ture 50 12 5 Determination of operating limits Coolant and necessary modification grazie rc dant 52 12 6 Requirements on the cooling system 54 12 7 Size and position of CONNECTION nee RR en Un mines 55 12 8 Feasible locaton Of radiator o ceti nee E 58 12 9 General directives for the cooling system 61 12 10 Coolant capa ity E D OO OO OO 63 eet t E 63 12 11 1 General directives for ducting of the cooling air 64 12 12 Data for optional components of cooling system 65 13 Lubrication IM T T 67 13 1 Description of the system 67 13 2 Limits Of operation me T 68 18 3 Checking ofthe l brication Syste 2 69 13 9 1 Measuring the enti 69 13 3 2 Measuring of the pressure in the crankcase 70 13 4 Requirements on the oil and venting lines 71 13 5 Connecting dimensions and location of connections 72 132521 Oil Circuit OMGING nero latest danois ras 72 75 13 6 Feasible position and location of the 2 76 13 7 Feasible position and location of the oil cooler
102. ty 17 3 10 Capacitor Option electrical fuel pump See Fig 67 CAUTION warrant reliable operation of the electrical fuel pump the use of capacitor of at least 22 000 UF 25 V is necessary 17 3 11 Easy start function on the electronic module optional See Fig 67 and 79 1 In order to use the easy start function the relevant connections to the starter relays and ignition switch need to be made The start function can be used for aircraft which have an engine start problem in cold conditions NOTE In addition also a modified fly wheel hub is offered which aids improved starting bl blau blue br braun brown bl bi sw ge gelb yellow gn gr n green sw schwarz black ws weiB white S or orange orange Fig 79 1 viol violett violet 00219 5 Effectivity 912 Series page 119 Edition 1 Rev 1 May 01 2009 BRP Rotax INSTALLATION MANUAL NOTES d04059 Effectivity 912 Series page 120 Edition 1 Rev 0 May 01 2007 904641 Effectivity 912 Series Edition 1 Rev 1 BRP Powertrain INSTALLATION MANUAL 18 Propeller drive The propeller in tractor or pusher arrangement has to be fitted on the propeller flange in accordance to current certification As required utilize one of the three possible pitch circle diameters P C D on the flange Certification of the propeller sizing and arrangement to the latest requirement such as FAR or EASA has to be conducted by the aircraft manufacture
103. with the drainge lines of the drip trays or the carburetors by a T piece these lines must not be routed down the firewall drainage lines of the airbox spearately are allowed Pressure differences between intake pressure and pressure in the carburetor chambers may lead to engine malfunction due to incorrect fuel supply Connecting nipple 1 of drainage line outside dia 6 1 4 Slip on length 17 11 16 Provide connection to take readings of manifold pressure 2 Provide connections for temperature sensor 3 Outside diameter 6 mm 24 in Slip on length 17 mm 67 in Connecting nipple 1 of float chamber venting lines outside dia 6 mm 1 4 slip on 1 max 17 mm 11 16 CAUTION Utilize the complete slip on length Secure hoses by suitable screw clamps or by crimp connection B CAUTION Ifthe engine has been installed without employment of the optional ROTAX engine frame which includes also support of the airbox than provide an appropriately support 5 for the airbox Effectivity 912 Series page 102 Edition 1 Rev 1 May 01 2009 d04639 BRP Powertrain INSTALLATION MANUAL NOTE Make sure that the air intake tubes of the airbox for fresh air and preheated air are connected correctly see Fig 64

INSTALLATION MANUAL

Contents

Download Pdf Manuals

Related Search

Related Contents