Rotax 912 ULS 3 Installation Manual Download Page 136

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Motornummer / Engine serial no.

Flugzeugtype / Type of aircraft

Flugzeugkennzeichen / Aircraft registration no.

ROTAX® Vertriebspartner

ROTAX® authorized distributor

��

and TM are trademarks of BRP-

Powertrain

GmbH & Co KG. © 200

BRP-

Powertrain

Summary of Contents for 912 ULS 3

Page 1: ...45 5 0 6 03 305 9 5 1 4 3 4 QBSU OP 898642 305 9 6 4 8 5 015 0 4 2 2 4 3 Ref No IM 912...

Page 2: ...Copyright 2009 all rights reserved ROTAX is a trade mark of BRP Powertrain GmbH Co KG In the following document the short form of BRP Powertrain GmbH Co KG BRP Powertrain is used Other product names...

Page 3: ...main axes 24 8 Technical data 27 8 1 Operating limits 27 8 2 Installation dimensions 28 8 3 Weight 28 8 4 Centre of gravity of engine and standard equipment 29 8 5 Moments of inertia 29 9 Preparation...

Page 4: ...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 13 5 1 Oil circuit engine 72 13 5 2 Oil tank 75 13 6 Feasi...

Page 5: ...3 4 Ignition switches MAG switch 112 17 3 5 Electric starter 114 17 3 6 Starter relay 115 17 3 7 External alternator optional extra 116 17 3 8 Connection of the electric rev counter tachometer 118 17...

Page 6: ...page 6 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04050 INSTALLATIONMANUAL BRP Rotax NOTES...

Page 7: ...ectric 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 Exha...

Page 8: ...r 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...

Page 9: ...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 instruct...

Page 10: ...page 10 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04051 INSTALLATION MANUAL BRP Rotax NOTES...

Page 11: ...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 part...

Page 12: ...authorized use never leave the aircraft unattended with the engine running To eliminate possible injury or damage ensure that any loose equipment or tools are properly secured before starting the engi...

Page 13: ...hese 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 especiall...

Page 14: ...ation Manual Operators Manual Maintenance Manual Line Maintenance Maintenance Manual Heavy Maintenance Overhaul Manual Illustrated Parts Catalog IPC Alert Service Bulletin Service Bulletins Service In...

Page 15: ...0 8 2 c 6 c c 19 5 10 M 87 87 30 c c 409 576 25 c 82 2 4 1 3 124 0 156 708 476 0 Ersatz fuer Ersatz fuer L K J I H G F E D C B A L K J I H G F E D C B A 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 16 15 14 13...

Page 16: ...page 16 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04051 INSTALLATION MANUAL BRP Rotax NOTES...

Page 17: ...1 2009 56 05 01 2007 57 05 01 2007 58 05 01 2007 59 05 01 2007 60 05 01 2007 61 05 01 2009 62 05 01 2007 63 05 01 2007 64 05 01 2009 65 05 01 2007 66 05 01 2007 13 67 05 01 2007 68 05 01 2007 69 05 01...

Page 18: ...page 18 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04051 INSTALLATION MANUAL BRP Rotax NOTES...

Page 19: ...5 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 05 01 2009 DOA 61 64 05 01 2009 DOA 13 69 74 77 05 01 2009 DOA 14...

Page 20: ...page 20 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04051 INSTALLATION MANUAL BRP Rotax NOTES...

Page 21: ...ion 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 s...

Page 22: ...nd 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 equipmen...

Page 23: ...afety and durability to the standards of aviation WARNING The user assumes all risks possibly arising by utilizing auxiliary equipment The furnishing of proof in accordance to the latest FAR or EASA h...

Page 24: ...inates Cyl 1 Cylinder 1 Cyl 3 Cylinder 3 Cyl 2 Cylinder 2 Cyl 4 Cylinder 4 1 engine number 2 propeller flange 3 propeller gear 4 vacuum pump or hydraulic governor for constant speed propeller 5 intake...

Page 25: ...Edition 1 Rev 0 d04052 page 25 May 01 2007 BRP Rotax INSTALLATIONMANUAL A A x x y y P x1 y1 y1 x1 P z1 y1 y1 z1 z z y y cyl 1 cyl 3 cyl 4 cyl 2 Fig 3 Fig 4 Fig 5 00504 00503 09147 19 16 23 24 6 15 22...

Page 26: ...page 26 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04052 INSTALLATIONMANUAL BRP Rotax NOTES...

Page 27: ...ors Manual 912 Series sec 10 1 5 Oil pressure see Operators Manual 912 Series sec 10 1 6 Oil temperature see Operators Manual 912 Series sec 10 1 7 Cyl head temperature see Operators Manual 912 Series...

Page 28: ...ator 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 lb Version 3 59 8 kg 132 lb ROTAX 912 S 912 ULS Engine weight Version 2 a...

Page 29: ...ity in z axis mm 83 6 56 56 engine version 2 4 engine version 3 moment of inertia around axis x1 x1 kg cm 11 100 11 600 moment of inertia around axis y1 y1 kg cm 10 900 11 390 moment of inertia around...

Page 30: ...page 30 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04052 INSTALLATIONMANUAL BRP Rotax NOTES...

Page 31: ...ate CAUTION The 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 agains...

Page 32: ...ort equipment and replug openings List of protective covering exhaust socket 1x cone plug connection for manifold pressure 1x cap airbox 2x cap fuel pump inlet 1x cap connection for fuel return 1x plu...

Page 33: ...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 an...

Page 34: ...0 8 71 0 211 0 R1 200 8 71 0 211 0 L2 414 3 71 0 211 0 R2 414 3 71 0 211 0 L3 414 3 75 0 22 0 R3 414 3 75 0 22 0 L4 128 3 87 0 0 R4 128 3 87 0 0 L5 564 0 105 0 277 0 R5 564 0 105 0 277 0 L6 564 0 105...

Page 35: ...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...

Page 36: ...x P L1 R1 L2 R2 x2 6 30 6 09136 To prevent a possible hydraulic shock at engine start ensure proper closing of float valves If in doubt park the aircraft with inclining propeller shaft axis Propeller...

Page 37: ...n 1 Rev 0 d04053 page 37 May 01 2007 BRP Rotax INSTALLATION MANUAL x y y P x 10 10 Fig 11 02455 Vertical axis y axis must be square to the longitudinal axis of the aircraft Tolerated roll deviation of...

Page 38: ...certified engine suspension frame has been developed by BRP Powertrain especially for the magneto side engine at tachment to the fireproof bulk head WARNING If the engine suspension frame supplied by...

Page 39: ...y axis z axis 160 196 82 160 212 113 192 196 82 192 212 113 408 196 82 408 212 113 438 196 82 438 212 113 cylinder 4 coordinates mm cylinder 1 cylinder 2 cylinder 3 points of attachment max allowable...

Page 40: ...9 psi readings taken approx 100 mm 3 93 in fromexhaustflangeconnections The 4 exhaust sockets included in the supply scope have to be used without exception See fig 13 Material of the exhaust sockets...

Page 41: ...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 exha...

Page 42: ...sal 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...

Page 43: ...springs and thus premature wear It is also recommended to fill the springs with high heat silicone for additional damping of vibrations CAUTION Appropriate to the installation a vibration damping supp...

Page 44: ...NUAL BRP Rotax 09153 Fig 18 Fig 17 muffler assy See Fig 17 Material thickness of the exhaust components X 6CrNiTi 189 1 4541 stainless a 1 mm 0 039 in 09159 exhaust elbow tailpipe See Fig 18 Material...

Page 45: ...ION MANUAL 09167 Fig 20 09166 Fig 19 ball joint male See Fig 19 Material thickness of the exhaust components X 15CrNiSi 20 12 DIN 1 4828 stainless a 1 mm 0 039 in exhaust tube See Fig 20 Material thic...

Page 46: ...page 46 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04053 INSTALLATION MANUAL BRP Rotax NOTES...

Page 47: ...r 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 t...

Page 48: ...r 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 coo...

Page 49: ...ontainer Conventionalcoolantwitharateof50 watercannotboilatatemperaturebelow 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 o...

Page 50: ...ntagewater 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 Fig 23 00327 1 12 4 Ch...

Page 51: ...er 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 The sensor ma...

Page 52: ...der head temperature is necessary 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...

Page 53: ...lant 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 C 230 F The cylinder head tempera...

Page 54: ...w as realized on the original ROTAX radiator and use short hoses and pipelines Coolant hoses temperature durability min 125 C 257 F pressure durability min 5 bar 73 psi nom inside dia 25 mm 1 bending...

Page 55: ...22 mm 7 8 to overflow bottle 4 outside dia 8 mm 3 8 slip on length max 15 mm 9 16 CAUTION The hoses have to be fixed with appropriate clamps to prevent loss E g with spring type clamps as used already...

Page 56: ...page 56 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04054 INSTALLATION MANUAL BRP Rotax Fig 26 x x y y P 200 10 mm 427 10 mm 252 5 mm 27 60 3 07136...

Page 57: ...een 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...

Page 58: ...n max 1 5 m max 59 05 in Fig 29 08319 1 6 8 2 4 5 7 3 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...

Page 59: ...tion and content WARNING Ensure that the overflow bottle will never be empty otherwise air will be sucked into cooling circuit causing cooling system failure CAUTION Theoverflowbottleandtheirsupplyand...

Page 60: ...34 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...

Page 61: ...le expansion tank 1 has to be installed at the highest point of the cooling circuit CAUTION The size and type of radiator should be adequate to transfer thermal energy of approx 25 kW 24 BTU s for ROT...

Page 62: ...ax 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 installati...

Page 63: ...in engine approx 1 5 l 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 WARNING The...

Page 64: ...train has developed especially for this application a non certified cooling air ducting WARNING Certification to the latest requirements to FAR or EASA has to be conducted by the aircraft manufac ture...

Page 65: ...71 in Fig 37 09148 04864 04876 Axes x axis mm in y axis mm in z axis mm in 300 11 81 in 30 1 18 in 14 0 55 in 300 11 81 in 30 1 18 in 14 0 55 in attachment points attachment points max allowable forc...

Page 66: ...NSTALLATION MANUAL BRP Rotax Fig 39 09165 Fig 38 09151 radiator See Fig 38 weight see section 8 cooling air baffle See Fig 39 weight see section 8 NOTE The gap between cowling and radiator should be c...

Page 67: ...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...

Page 68: ...hat operating temperatures will not exceed the specified limits Oil 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 s...

Page 69: ...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 at a max distance of 100 mm 4 in from pump inlet 2 At take off performance t...

Page 70: ...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...

Page 71: ...3 m 118 11 in Vent line of oil tank Route the line without kinks and avoid sharp bends NOTE Water is a by product of combustion Most of this water will dissipate from the combustion chamber with the...

Page 72: ...ection NOTE The oil pipeline connections are optional as UNF thread AN 8 See SI 912 003 13 5 1 Oil circuit engine See Fig 44 45 46 and 47 Depending on engine certification the oil pump inlet connector...

Page 73: ...73 May 01 2007 BRP Rotax INSTALLATION MANUAL Oil pump inlet 3 thread 3 4 16 UNF AN 8 Tightening torque of inlet line 25 Nm 18 5 ft lb Oil pump inlet nipple 2 outside dia 13 2 mm 0 52 in slip on length...

Page 74: ...tion and oil system layout choose the appropriate connection for the oil return line Position1fortractororposition2forpusherconfigurationandconnector options 1 2 and 5 See Fig 47 Option 1 connection w...

Page 75: ...cting bend 90 8 outside dia 12 mm 47 in slip on length max 24 mm 94 in tightening torque 25 Nm 18 5 ft lb Oil inlet 6 and outlet 7 via standard UNF thread AN 8 optional thread 3 4 16 UNF AN 8 Tighteni...

Page 76: ...s 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 propel...

Page 77: ...need be take appropriate measures like changing size of cooler partial covering of cooler etc 13 8 General notes on oil cooler BRP Powertrain offers for this engine an oil cooler see Illustrated Parts...

Page 78: ...n 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 conn...

Page 79: ...arefully 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 desc...

Page 80: ...3 back from engine 2 to oil pump 1 max 0 5 mm 0 02 in Fig 51 Fig 52 13 12 Replacement of components If a malfunction of hydraulic valve tappet should be found during this check of priming process the...

Page 81: ...3 in Tightening torque 22 Nm 195 in lb and Loctite 243 adaptor metric 3 thread M18x1 5 Tightening torque 22 Nm 195 in lb and Loctite 243 Tightening torque of oil inlet and outlet bend socket or hose n...

Page 82: ...01 2007 Effectivity 912 Series Edition 1 Rev 0 d04055 INSTALLATION MANUAL BRP Rotax klein small 82 mm 3 23 in mittel medium 95 mm 3 74 in gro big 131 mm 5 16 in B B B B B 04910 Fig 53 1 2 3 4 5 6 B L...

Page 83: ...e 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...

Page 84: ...owing 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 Returnl...

Page 85: ...essure 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 requirement...

Page 86: ...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 filt...

Page 87: ...ion 9 thread M10 thread length max 9 mm 35 in Tightening torque 15 Nm 135 in lb and Loctite 221 CAUTION At loosening or tightening of the banjo bolt 7 tighten ing torque 10 Nm 90 in lb support the fue...

Page 88: ...ne to fuel pump that 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 wit...

Page 89: ...89 May 01 2007 BRP Rotax INSTALLATION MANUAL Fig 57 02064 2 12 Fig 56 00537 1 9 10 14 4 3 Check valve Specification opening pressure 0 1 0 15 bar 1 5 psi 2 2 psi permitted pressure in reverse biasing...

Page 90: ...page 90 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04056 INSTALLATION MANUAL BRP Rotax NOTES...

Page 91: ...Requirements on the carburetor See Fig 59 Thecarburetorsarepositionedabovetheexhaustsockets Belowthecarburetors one each drip tray 1 with a draining connection 2 is fitted which serves as a heat shie...

Page 92: ...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 The float chambe...

Page 93: ...Effectivity 912 Series Edition 1 Rev 1 d04638 page 93 May 01 2009 BRP Powertrain INSTALLATION MANUAL Fig 59 08644 2 1 3...

Page 94: ...ncer 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 lb suitablefor1 5mm 06in steelwire...

Page 95: ...ke actuation 3 connection on choke lever clamping nipple 6 suitablefor1 5mm 06in steelwire action travel 23 mm 15 16 actuating force min 10 N 2 2 lb max 45 N 10 lb limit load 100 N 22 lb Directive for...

Page 96: ...hrottle 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 synchro...

Page 97: ...e 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...

Page 98: ...page 98 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04057 INSTALLATION MANUAL BRP Rotax NOTES...

Page 99: ...e ROTAX airbox is retrofitted at a 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...

Page 100: ...et 1 for fresh air or pre heated air intake side outside dia 60 mm 2 3 8 slip on length max 25 mm 1 CAUTION Utilize the full slip on length on all connection Secure hoses by suitable spring type clamp...

Page 101: ...d 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 WARNING Connect draining li...

Page 102: ...ferences between intake pressure and pressureinthecarburetorchambersmayleadtoengine malfunction due to incorrect fuel supply Connecting nipple 1 of drainage line outside dia 6 mm 1 4 slip on length ma...

Page 103: ...9 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 NOTE Fig 64 shows the genuine ROTAX airbo...

Page 104: ...ffectivity 912 Series Edition 1 Rev 0 d04058 INSTALLATION MANUAL BRP Rotax 16 3 Data for optional components of air intake system air filter See Fig 65 weight see section 8 09149 Fig 65 116 100 52 90...

Page 105: ...Effectivity 912 Series Edition 1 Rev 1 d04639 page 105 May 01 2009 BRP Powertrain INSTALLATION MANUAL 09174 Fig 66 airbox configuration part no 867756 See Fig 66 weight see section 8...

Page 106: ...06 May 01 2009 Effectivity 912 Series Edition 1 Rev 1 d04639 INSTALLATION MANUAL BRP Powertrain airbox new version part no 667355 in comparison to the old version See Fig 66 1 weight see section 8 Fig...

Page 107: ...rcuit 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 ele...

Page 108: ...tion 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 WARNING Consult the manufacturer if further interpretation is ne...

Page 109: ...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 Fig 67 08639 Wiring...

Page 110: ...ing 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 see section 17 3 2 ge ge Cyl 1 Cyl 3 Cyl 2 Cyl 4 Fig 6...

Page 111: ...capacitor Fig 67 Pos 25 of at least 22 000 F 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...

Page 112: ...ent 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 max 5 1 0 10 20 1000 2000 3000 4000 5000 6000...

Page 113: ...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 p...

Page 114: ...elding 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 b...

Page 115: ...nt 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 lb suitable for ring terminals to DIN 46...

Page 116: ...ght 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 suitable f...

Page 117: ...main circuit at least 4 mm2 10 AWG a capacitor Fig 67 Pos 14 of at least 22 000 F 25 V is necessary to flatten voltage current CAUTION The current over speed graph has been determined and is effective...

Page 118: ...er Certification to the latest requirements such as FAR or EASA has to be conducted by the aircraft manufacturer See also SI 13 1996 latest issue CAUTION The graphs depicting output signals have been...

Page 119: ...ation of the electrical fuel pump the use of capacitor of at least 22 000 F 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...

Page 120: ...page 120 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04059 INSTALLATION MANUAL BRP Rotax NOTES...

Page 121: ...n of rotation of the prop flange counter clockwise looking towards face of flange attachment of propeller on prop shaft flange P C D 75 mm 2 95 6 bolt holes of 8 mm 32 in dia P C D 80 mm 3 15 6 bolt h...

Page 122: ...on a vibration analysis of the whole system engine suspension propeller etc should be done If there are no limits found in the technical literature a max of 0 1 IPS inches per second at 5000 rpm can b...

Page 123: ...tion on the crankcase see Fig 81 and 82 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 Pay att...

Page 124: ...page 124 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04060 INSTALLATION MANUAL BRP Rotax Fig 82 08328...

Page 125: ...case see Fig 83 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 dr...

Page 126: ...page 126 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04060 INSTALLATION MANUAL BRP Rotax 26 97 26 97 22 2 3 8 5 3 0 1 8 A A A 1 Fig 83 08179...

Page 127: ...irect 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 loca...

Page 128: ...on the oil pump flange connection of sensor 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 temper...

Page 129: ...ording to the installationsituation e g shortenedorextended Forextension an appropriate commercially available cable can be used A resistance cable or similar is not necessary wire gauge stranded wire...

Page 130: ...or 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 Avias...

Page 131: ...on length on all joints Secure hose by suitable screw clamps or crimp connection WARNING Protective covering to be utilized for transport and at engine installation only If connection for pressure rea...

Page 132: ...MANUAL BRP Powertrain 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...

Page 133: ...perators 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 nomin...

Page 134: ...page 134 May 01 2007 Effectivity 912 Series Edition 1 Rev 0 d04060 INSTALLATION MANUAL BRP Rotax NOTES...

Page 135: ......

Page 136: ...ngine serial no Flugzeugtype Type of aircraft Flugzeugkennzeichen Aircraft registration no ROTAX Vertriebspartner ROTAX authorized distributor and TM are trademarks of BRP Powertrain GmbH Co KG 2009 B...

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