Rotax 915 i A SERIES Maintenance Manual
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Rotax 915 i A SERIES Maintenance Manual

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See also: Maintenance Manual , Operator's Manual
AIRCRAFT ENGINES
MAINTENANCE MANUAL
(LINE MAINTENANCE) FOR ROTAX® ENGINE TYPE 915 i A SERIES
ref. no.: MML-915 i A | part no.: 898863
picture: ROTAX® 915 iS with options

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  • Page 1 AIRCRAFT ENGINES MAINTENANCE MANUAL (LINE MAINTENANCE) FOR ROTAX® ENGINE TYPE 915 i A SERIES ref. no.: MML-915 i A | part no.: 898863 picture: ROTAX® 915 iS with options...
  • Page 2 GmbH & CO KG, Austria, acc, BGBI 1984 no. 448, and shall not, without prior written permission of BRP-Rotax GmbH & Co KG, be disclosed in whole or in part to third parties. This legend shall be included on any reproduction of these data, in whole or in part. The Manual must remain with the engine/aircraft in case of sale.
  • Page 3 05–20–00 – SCHEDULED MAINTENANCE CHECKS Chapter 05–50–00 – UNSCHEDULED MAINTENANCE CHECKS Chapter 12–00–00 – MAINTENANCE OF THE SYSTEMS Chapter 12–10–00 – REPLENISHING OPERATING FLUIDS Chapter 12–20–00 – SCHEDULED MAINTENANCE Effectivity: 915 i A Series Content Edition 0/Rev. 0 Page 1 December 01 2017...
  • Page 4 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2 December 01 2017...
  • Page 5 ROTAX® authorized Aircraft Engines Distributors or their independent Service Center. BRP-Rotax wishes you much pleasure and satisfaction flying your aircraft powered by this ROTAX®-aircraft engine. The structure of the Manual follows whenever it is possible the structure of the ATA (Air Transport Association) standards.
  • Page 6 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2 December 01 2017...

  • Page 7: List Of Effective Pages

    December 01 2017 December 01 2017 December 01 2017 December 01 2017 05-00-00 December 01 2017 December 01 2017 December 01 2017 05-50-00 December 01 2017 December 01 2017 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 1 December 01 2017...
  • Page 8 December 01 2017 December 01 2017 December 01 2017 December 01 2017 December 01 2017 December 01 2017 December 01 2017 December 01 2017 December 01 2017 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2 December 01 2017...
  • Page 9 December 01 2017 December 01 2017 December 01 2017 December 01 2017 December 01 2017 December 01 2017 Index December 01 2017 Rear page December 01 2017 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 3 December 01 2017...
  • Page 10 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 4 December 01 2017...

  • Page 11: Table Of Amendments

    Dec. 01 2017 DOA* 05-20-00 Dec. 01 2017 DOA* 05-50-00 Dec. 01 2017 DOA* 12-00-00 Dec. 01 2017 DOA* 12-10-00 Dec. 01 2017 DOA* 12-20-00 Dec. 01 2017 DOA* Effectivity: 915 i A Series Edition 0/Rev. 0 Page 1 December 01 2017...
  • Page 12 BRP-Rotax MAINTENANCE MANUAL Summary of amendments Summary of the relevant amendments in this context, but without requirement on completeness. page chapter date of comment change Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2 December 01 2017...

  • Page 13: Table Of Contents

    Type description............................3 Abbreviations and terms .........................4 Conversion table ...........................7 Safety notice ............................8 Safety information ..........................9 Instruction............................11 Maintenance Concept..........................12 Technical documentation........................13 Use for intended purpose ........................15 Effectivity: 915 i A Series 00–00–00 Edition 0/Rev. 0 Page 1 December 01 2017...

  • Page 14: General

    For additional information on engines, its maintenance or parts, you can also contact your nearest ROTAX® authorized Aircraft Engine Distributor or their independent Service Center. ROTAX For ROTAX® Authorized Distributors for aircraft engines see latest Operators Manual or Distributors the official website www.FLYROTAX.com. Engine serial When making inquiries or ordering parts, always indicate the engine serial number.

  • Page 15: Type Description

    Approved to ASTM F2339. Configuration Propeller shaft with flange for constant speed propeller and drive for hydraulic governor for constant speed propeller. Additional Standard version designation Effectivity: 915 i A Series 00–00–00 Edition 0/Rev. 0 Page 3 December 01 2017...

  • Page 16: Abbreviations And Terms

    Ignition coils 1–4 CPS 1+2 Crankshaft Position Sensor 1+2 Constant Speed Actuator Cooling Temperature Sensor clockwise counter-clockwise CGSB Canadian General Standards Board DCDI Dual Capacitor Discharge Ignition 00–00–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 4 December 01 2017...
  • Page 17 MAPS 1+2 Manifold Air Pressure Sensor 1+2 MATS 1+2 Manifold Air Temperature Sensor 1+2 Motor Octane Number Magneto Side Newton n.a. not available Non Destructive Testing Newtonmeter Effectivity: 915 i A Series 00–00–00 Edition 0/Rev. 0 Page 5 December 01 2017...
  • Page 18 Production Organisation Approval PTFE Polytetrafluoroethylene Power Take Off Rev. Revision ROTAX® is a trademark of BRP-Rotax GmbH & Co KG Research Octane Number RON 424 ROTAX® Norm 424 s.v. still valid (only Illustrated Parts Catalog) Serial Number Society of Automotive Engineers...

  • Page 19: Conversion Table

    1 bar = 100 000 Pa / 1000 hPa / 100 kPa 14 —> 2.1 1 bar = 14.503 lbf/in² (psi) 16 —> 1.3 1 in Hg = 33.8638 hPa 18 —>0.8 20—> 0.52 Effectivity: 915 i A Series 00–00–00 Edition 0/Rev. 0 Page 7 December 01 2017...

  • Page 20: Safety Notice

    The information and descriptions of components and systems contained in this Manual are correct at the time of publication. BRP-Rotax maintains a policy of continuous im- provement of its products without imposing upon itself any obligation to retrofit products previously manufactured.

  • Page 21: Safety Information

    • Due to the varying designs, equipment and types of aircraft, BRP-Rotax grants no war- ranty on the suitability of its engines use on any particular aircraft. Further, BRP-Rotax...
  • Page 22 • Improper engine installation, use of unsuitable piping for fuel, cooling and lubrication system and use of unsuitable wiring for electric and engine management system re- leases the engine manufacturer from any liability 00–00–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 10 December 01 2017...

  • Page 23: Instruction

    Spare parts must meet the requirements defined by the engine manufacturer.This can only be guaranteed when using GENUINE-ROTAX®-spare parts and/or accessories (see IPC). Spare parts are available at ROTAX® Authorized Distributors and their inde- pendent Service Centers. Any warranty by BRP-Rotax will become void if other spare parts and or accessories than GENUINE-ROTAX®-spare parts and/or accessories are...

  • Page 24: Maintenance Concept

    N N O O T T E E This Manual can only be used in combination with Maintenance Manual I (Line Maintenance), as it builds up on it. 00–00–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 12 December 01 2017...

  • Page 25: Technical Documentation

    BRP-Rotax MAINTENANCE MANUAL TECHNICAL DOCUMENTATION These documents form the instructions ensuring continued airworthiness of ROTAX® air- craft engines. The information contained herein is based on data and experience that are considered ap- plicable for authorized mechanics (iRMT, see Maintenance Manual Line) under normal conditions for engine removal and installation.
  • Page 26 Installation drawings and a DMU-model for (virtual) installation analysis are available from drawings the ROTAX® Authorized Distributors or their independent Service Centers on special re- quest and relevant non disclosure and copyright regulations. The illustrations in this Manual shows a possible installation variant included non certified parts.

  • Page 27: Use For Intended Purpose

    Flying components can cause serious injuries. Never run an engine without propeller. The engine ROTAX® 915 iSc is intended for use in certified aircraft. In case of doubt the regulations of the national authorities or the respective sportive federations have to be observed.
  • Page 28 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 16 December 01 2017...
  • Page 29 This chapter 04-00-00 provides information about “Airworthiness Limitations“. Airworthiness — NONE Limitations For the ROTAX® engine type 915 i A Series the airworthiness limitations are not applicable. N N O O T T E E Regarding engine operating limitations see the relevant chapter “Limits of Operation“...
  • Page 30 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2 December 01 2017...
  • Page 31 The information given in the Maintenance Manual is based on data and experience which are considered to be applicable for a skilled aviation mechanic (iRMT) under normal working conditions. Effectivity: 915 i A Series 05–00–00 Edition 0/Rev. 0 Page 1...

  • Page 32: General Note

    We particularly emphasize that parts and accessories not supplied as genuine BRP-Rotax accessories parts are not verified for suitability by BRP-Rotax and thus are not authorized for use. In- stallation and/or use of such products may possibly change or negatively influence the constructive characteristics of the engine.

  • Page 33: Authorized Personnel

    2 year period. Valid time ROTAX® iRMT specialty ratings are valid for a 2 year period after initial instruction. Recur- rent training is required after 2 years to maintain a current status. In order to be eligible for the renewal program training, the technician must be able to show and declare that they have been working on ROTAX®...

  • Page 34: Procedure Notes

    Always allow engine to cool down to ambient temperature before starting work. At maintenance of cooling, lubricating and fuel system take care without fail that no con- tamination, metal chips, foreign material and/or dirt enters the system. 05–00–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 4 December 01 2017...
  • Page 35 Re-assembly Before re-assembly check components for missing parts. Only use adhesives, lubricants, cleaning agents and solvents indicated in the maintenance instructions. Failure to comply may result in damage. Effectivity: 915 i A Series 05–00–00 Edition 0/Rev. 0 Page 5 December 01 2017...

  • Page 36: Trouble Shooting

    Possible problems are listed in the Operators Manual. At the same time, a brief description of the necessary remedial action is given. See chapter 4 in the Operators Manual for engine type 915 i A Series. 05–00–00 Effectivity: 915 i A Series Edition 0/Rev.

  • Page 37: Consumable Materials

    CONSUMABLE MATERIALS General note ATTENTION Use only the specified or technically equivalent materials from BRP-Rotax for all maintenance work. When handling chemicals, comply with all the customary reg- ulations and specifications of the producer, including the expiry date and instruc- tions of use.
  • Page 38 899789 LOCTITE 603 green 10 ml (0.003 gal oil tolerant retainer retaining compound (US)) Figure 2.1: Consumable materials 05–00–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 8 December 01 2017...
  • Page 39 (CASTROL ZA 30 or OMV-SOFT SOL). When using solvents, observe the safety regula- tions for persons and environment regarding use and proper disposal. Effectivity: 915 i A Series 05–00–00 Edition 0/Rev. 0 Page 9 December 01 2017...
  • Page 40 These deposits are then involved in a chemical reaction (especially of the sulfur and lead content of AVGAS) with the valve material. This effect may cause hot-gas corrosion on the affected parts. 05–00–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 10 December 01 2017...

  • Page 41: Acceptable Methods, Techniques And Practice

    N N O O T T E E When fitting lock washers, the curved-up ends (1) must point towards the screw head or nut. Figure 2.2: Lock washer Effectivity: 915 i A Series 05–00–00 Edition 0/Rev. 0 Page 11 December 01 2017...
  • Page 42 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 12 December 01 2017...
  • Page 43 Time limit for the coolant ........................6 Annual inspection ..........................6 Introduction The following checks are required at the times specified. This preventative maintenance is to help avoid and/or detect possible engine issues. Effectivity: 915 i A Series 05–10–00 Edition 0/Rev. 0 Page 1 December 01 2017...

  • Page 44: Definition Of Terms

    • In aviation there are different measurement methods used as an acceptable means to record operating time elapsed. • BRP-Rotax does not mandate a specific method to record time elapsed as a basis for maintenance and overhaul intervals. • BRP-Rotax therefore relies on common practice and defers to the aircraft original equip- ment manufacturer and/or local regulations.

  • Page 45: Time Limit

    Purging of the oil system is extremely important for operation and service life of the engine and therefore the procedure must be followed meticulously. See latest Installation Manual Chapter 79-00-00 section Purging the lubrication system. Effectivity: 915 i A Series 05–10–00 Edition 0/Rev. 0...

  • Page 46: Time Limit

    N N O O T T E E The maximum possible storage period of the engine is limited to 24 months. If this period is exceeded, the engine must be sent to an ROTAX® authorized overhaul fa- cility for inspection.

  • Page 47: Time Limit For Parts

    Time limit The following components and systems must be replaced every 5 years: • All rubber hoses of the cooling system (except GENUINE ROTAX® silicon hoses), which need to be checked by "on-condition" maintenance according to the instructions of continued airworthiness.

  • Page 48: Time Limit For The Coolant

    A 100 hr. inspection is to be carried out periodically after every 100 hours of operation or every 12 months,, whichever comes first. Chapter 05-20-00 section Scheduled maintenance checks. 05–10–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 6 December 01 2017...
  • Page 49 It is the responsibility of the owner and/or user to make sure that the aircraft mechanic required performing the work on the engine has access to the previous Inspection Protocols and any other required documents. Effectivity: 915 i A Series 05–20–00 Edition 0/Rev. 0 Page 1...

  • Page 50: Scheduled Maintenance Checks

    • The checks performed at the 25 hr. inspection are the same as for the 100 hr. inspec- tion. This applies both to newly delivered engines and to overhauled engines. 05–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2...

  • Page 51: Unscheduled Maintenance Checks

    2 hr. of operation Risk of fracture, wear. • Of the exhaust unit (where nec- Smooth engine running. Exhaust essary, replaced application of LOCTITE Anti-Seize) Effectivity: 915 i A Series 05–20–00 Edition 0/Rev. 0 Page 3 December 01 2017...

  • Page 52: Visual Inspection

    Surface damage, secure seating, locking wire, securing paint and other visually evident damage. Filter and Filters and screens must be inspected for contamination and potential blockages, cleaned Screens and replaced as required. 05–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 4 December 01 2017...

  • Page 53: Maintenance Schedule Procedures (Maintenance Check List)

    Replacement of Replacement of equipment (e.g. fuel pump, governor..) and execution of SB (LTA) must equipment be entered in the engine log book, stating S/N, TSN and date. Effectivity: 915 i A Series 05–20–00 Edition 0/Rev. 0 Page 5 December 01 2017...

  • Page 54: Check List/Maintenance Schedule

    Engine S/N TSN (time since new) TSO (time since overhaul) ECU S/N FUSE BOX Used operating fluids: Coolant • mixture ratio Fuel • type • viscosity 05–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 6 December 01 2017...
  • Page 55 50 hr. 25 hr. 100 hr. 200 hr. 600 hr. (circle on) leaded fuel more than 30% of operation Next check due at: (TSN__________) (engine hr.) Effectivity: 915 i A Series 05–20–00 Edition 0/Rev. 0 Page 7 December 01 2017...

  • Page 56: Maintenance Schedule

    If the points 1-4 are correct of the check list then to continue with the maintenance schedule. If one of the points 1-4 is not fulfilled, the engine must be checked and repaired in accordance with the BRP-Rotax instructions for continued airworthiness. Interval Operating hours...
  • Page 57 Sealing lip (wear, cracks, missing material): Inspecting of Findings: the oil filter ______________________________- components ______ Spring of bypass valve (small): 12–20–00 Findings: Inspecting of ______________________________- the oil filter ______ components Effectivity: 915 i A Series 05–20–00 Edition 0/Rev. 0 Page 9 December 01 2017...
  • Page 58 Check the airbox (GENUINE ROTAX® part) incl. throttle body actuation. In- spect sensors for tight fit, damage from heat, damage and signs of wear. 05–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 10 December 01 2017...
  • Page 59 Inspect the fuel system on the engine Fuel system side for leaks. Inspect the fuel system for damages. 9) Engine management 12–20–00 Check the ECU and its mountings. Checking Effectivity: 915 i A Series 05–20–00 Edition 0/Rev. 0 Page 11 December 01 2017...
  • Page 60 Check slipping torque of all 3 overload See Heavy clutches Maintenance Chap. 72–10–00 Check wear on the intermediate shaft See Heavy Maintenance Chap. 72–10–00 Change torsion shaft See Heavy Maintenance Chap. 72–10–00 05–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 12 December 01 2017...
  • Page 61 Check at______hr. (TSN___, TSO___) was carried out according to recommendations of the engine manu- facturer and was recorded in the Engine Log book. Location, Date_______________________ Inspector___________________________ Aircraft mechanic_____________________ Certificate No.______________________ Effectivity: 915 i A Series 05–20–00 Edition 0/Rev. 0 Page 13 December 01 2017...
  • Page 62 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 14 December 01 2017...
  • Page 63 After each special check/repair work, an engine test run and a leakage check must be carried out. ATTENTION Observe without fail all the specified instructions. Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 1...

  • Page 64: Engine Check After Propeller Strike Incidents

    Step Procedure Loosen M12x20 hex. screw with sealing ring. N N O O T T E E Do not remove the hex. screw completely. 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2 December 01 2017...
  • Page 65 Loosen two Hex/Torx-flange screw M8x45 and ten Sk/Torx-flange screws M6x40 from the gear cover diagonally from each other. The gear cover is held in place with two dowel pins. Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 3...
  • Page 66 WARNING Non-compliance can result in serious injuries or death! Overload clutch, torsion shaft and propeller shaft are plugged only and can drop down. 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 4 December 01 2017...
  • Page 67 BRP-Rotax MAINTENANCE MANUAL Figure 5.3 Puller part no. 877660 Handle Gear cover Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 5 December 01 2017...

  • Page 68: Removal Of The Drive Gear

    Remove the drive gear and the friction washer from the crankshaft. N N O O T T E E If necessary, carefully lever off the drive gear with 2 screwdrivers. 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 6 December 01 2017...
  • Page 69 BRP-Rotax MAINTENANCE MANUAL Figure 5.5: A1 Drive gear Crankshaft Friction washer Hex. nut M30x1.5 Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 7 December 01 2017...

  • Page 70: Installation Of Propeller Gearbox

    • Visual inspection of the crankshaft on the power take off side. Figure 5.6 Crankshaft (power take off side) Drive gear Friction washer VS-30 Hex. nut Procedure Step Push the drive gear onto the crankshaft. 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 8 December 01 2017...
  • Page 71 Chapter 72-10-00 section Wear limits. (CS24) N N O O T T E E If there is slight vertical run-out, replace the nut and repeat the measurement. Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 9 December 01 2017...
  • Page 72 If excessive installation force is used, the bearing or vacuum pump gear can be damaged. Step Procedure Check the overload clutch for correctly installation. Observe the mark. 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 10 December 01 2017...
  • Page 73 M6: 10 Nm (89 in.lb.) Tightening torque M8: 25 Nm (18 ft.lb.) Observe (Pos 7 Screw diagram): Secure the Sk/Torx-flange screw M6x40 with LOCTITE 243 . Tightening torque 20 Nm (15 ft.lb). Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 11...
  • Page 74 Inspect the run-out. See also Chapter 72-10-00 section Wear limits. (GB18) Secure Hex. screw M12 x 20 with LOCTITE 243. Tightening torque 20 Nm (15 ft. lb.). 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 12 December 01 2017...
  • Page 75 BRP-Rotax MAINTENANCE MANUAL Figure 5.12 Hex. screw M12 x 20 Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 13 December 01 2017...

  • Page 76: Examination After Engine Failure

    Oil pump defect Camshaft bearings/Conrod bearings rather consequential damage wear (low oil pressure) 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 14 December 01 2017...

  • Page 77: Returning Engine To Service After Submerging In Water

    The engine must be marked clearly “Engine submerged in water“. Define if it was fresh water or salt water. An engine which has been submerged in water must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. See current Maintenance Manual of the respective engine type. Inspection •...

  • Page 78: Inspection In Extreme Climatic Conditions

    Flying in areas with extreme climatic conditions or in extreme altitudes requires adjust- ment of the cooling system. To do this, it is necessary to contact the aircraft manufacturer and an authorized ROTAX® aircraft engines distributor. DIMINISHED FUNCTIONAL CAPABILITY OF EMS...

  • Page 79: Returning Engine To Service After Influence By Fire

    RETURNING ENGINE TO SERVICE AFTER INFLUENCE BY FIRE General note An engine after influence by fire must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. Inspection • Inspect all systems for correct functioning. N N O O T T E E Prior to the detailed inspection, all parts should be cleaned and inspected for weld penetration or melted materials.
  • Page 80 Step Procedure The whole engine must be inspected, repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. Check that the push-rods are straight. Inspect the crankshaft for out-of-roundness and torsion. See Chapter 72- 00-00 of the latest Heavy Maintenance Manual.

  • Page 81: Exceeding Of Max. Coolant Temperature

    Temperature exceeded briefly Table 1: Temperature exceeded briefly Step Procedure The whole cooling system must be inspected, repaired or overhauled in ac- cordance with the BRP-Rotax instructions for continued airworthiness. Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 19...

  • Page 82: Non Compliance With The Coolant Specification

    Step Procedure The whole cooling system must be inspected, repaired or overhauled in ac- cordance with the BRP-Rotax instructions for continued airworthiness. Inspect all further systems for correct functioning. Carry out detailed inspection of the affected engine components. Check compression by carrying out a differential compression check.
  • Page 83 Non compliance with the coolant specification Step Procedure Re-install the radiator cap. N N O O T T E E Run engine for a minute and replenish as required. Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 21 December 01 2017...

  • Page 84: Exceeding The Max. Permissible Oil Temperature

    Table 3: Excess temperature up to max. 160 °C (320 °F) max. 15 min. Step Procedure The whole oil system must be inspected, repaired or overhauled in accord- ance with the BRP-Rotax instructions for continued airworthiness. 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0...

  • Page 85: Oil Pressure Below Minimum Value

    Step Procedure The whole oil system must be inspected, repaired or overhauled in accord- ance with the BRP-Rotax instructions for continued airworthiness. Inspect all further systems for correct functioning. Carry out detailed inspection of the affected engine components. The whole oil system (oil cooler, oil lines) must be inspected.
  • Page 86 Inspect crankcase pressure (See Installation Manual, latest issue.). If no cause for the low oil pressure is found after the above checks, carry out an oil change. 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 24 December 01 2017...
  • Page 87 Step Procedure If after the previous checks and oil change the oil pressure is still too low, repair or overhaul the engine in accordance with the BRP-Rotax instruc- tions for continued airworthiness. Inspect all systems for correct functioning. Carry out detailed inspection of the affected engine components.

  • Page 88: Oil Specification Not Respected

    Remove the lowest positioned banjo screw (1) (banjo bolt, plug screw or screw socket) and drain the remaining oil from the crankcase. Screw in banjo bolt or plug screw. Tightening torque see Installation Manual 915 i A Series. Replace oil filter. Drain oil completely from oil cooler.
  • Page 89 Remove the lowest positioned banjo screw (banjo bolt, plug screw or screw socket) and drain the remaining oil from the crankcase. Screw in banjo bolt or plug screw. Tightening torque see Installation Manual 915 i A Series. Replace oil filter.

  • Page 90: Spark Plug Not In Accordance With Specification

    General note If by error any of the spark plugs were installed which are not according to specification of the engine manufacturer and/or not genuine ROTAX® parts, the following verification will be necessary. Spark plug not in accordance with specification...

  • Page 91: Smooth Performance Of The Engine

    The torque must be max. 150 Nm (111 ft.lb). If the maximum torque is exceeded, perform the following inspections: • Carry out detailed inspection of the affected gearbox components • Carry out detailed inspection of crank drive Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 29...

  • Page 92: Sudden Drop In Boost Pressure And Speed

    See chapter 76–00–00 of the Heavy Maintenance Manual. Check oil consumption. Oil level check. See Chapter 12–20–00 section Oil level check. 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 30 December 01 2017...

  • Page 93: Sudden Increase In Boost Pressure And Speed

    The engine must not be taken into operation before having corrected the cause of deficiency. ATTENTION If the permissible operating limits are exceeded or values fall below the minimum, the corresponding checks must be also be carried out. Effectivity: 915 i A Series 05–50–00 Edition 0/Rev. 0 Page 31 December 01 2017...

  • Page 94: Lightning Strike

    Detailed findings will need to be obtained for affected components. Always replace com- ponents if visible signs of damage are evident or if you are in any doubt. Direct lightning Send the engine without delay to an authorized ROTAX® overhaul facility for inspection. strike 05–50–00 Effectivity: 915 i A Series Edition 0/Rev.

  • Page 95: Reporting

    In case of any relevant occurrences that may involve malfunction of the engine, the form on the next page should be filled out and sent to the responsible ROTAX® Authorized Aircraft engines distributor or their independ- ent Service Center.
  • Page 96 BRP-Rotax MAINTENANCE MANUAL Figure 5.18: Form 05–50–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 34 December 01 2017...
  • Page 97 For reasons of clarity, only headlines and keywords are listed in the Maintenance Schedule. Please refer to the following pages for further explanation if needed. As far as possible, the content has been arranged according to system. Effectivity: 915 i A Series 12–00–00 Edition 0/Rev. 0...
  • Page 98 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2 December 01 2017...
  • Page 99 The engine should always be in a horizontal position before checking the fill levels. ENVIRONMENTAL NOTE All operating materials and cleaning products endanger the environment by improper disposal. Dispose of the operating materials in an environmentally sound way! Effectivity: 915 i A Series 12–10–00 Edition 0/Rev. 0 Page 1 December 01 2017...

  • Page 100: Servicing Points On The Engine

    BRP-Rotax MAINTENANCE MANUAL SERVICING POINTS ON THE ENGINE Overview Figure 6.1 Expansion tank Radiator cap Oil filter Oil tank Oil dipstick 12–10–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2 December 01 2017...

  • Page 101: Fluid Capacities

    3.0 l (0.8 US gal.). N N O O T T E E BRP-Rotax can give an approx value on the fill capacity depending on aircraft de- sign and positions of radiators and tanks. The volume may difference from this value.

  • Page 102: Cooling System

    For accomplishment the following special tool is required.: Figure 6.2: Special tool Part number Description part no. n.a Densimeter (1) part no. n.a Glycol tester (2) 12–10–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 4 December 01 2017...
  • Page 103 N N O O T T E E The radiator cap must be tightened until the stop lug is contacted. Figure 6.3: Coolant check/replenish TYPICAL Radiator cap Expansion tank Effectivity: 915 i A Series 12–10–00 Edition 0/Rev. 0 Page 5 December 01 2017...
  • Page 104 (engine oil temperature between 50 to 70 °C (122 - 160 °F). Switch the engine OFF. Allow the engine to cool down. Check for leaks. Check the coolant level and top up with coolant as required. 12–10–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 6 December 01 2017...

  • Page 105: Lubrication System

    (over servicing), oil will es- cape via the venting passage. Difference between “max.“ and “min“. - mark = 0.45 l (0.95 liq.pt). Effectivity: 915 i A Series 12–10–00 Edition 0/Rev. 0...
  • Page 106 Check oil level - Marks on the oil dipstick. Fit the oil dipstick and tighten the oil tank cover (1) by hand. Figure 6.4: Oil level check/Replenish Oil dipstick Oil tank cover 12–10–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 8 December 01 2017...
  • Page 107 (engine oil temperature between 50 to 70 °C (122 - 160 °F). Switch the engine OFF. Allow the engine to cool down. Check for leaks. Effectivity: 915 i A Series 12–10–00 Edition 0/Rev. 0 Page 9 December 01 2017...
  • Page 108 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 10 December 01 2017...
  • Page 109 Check of wiring............................40 Replacement of spark plugs .........................41 Remove the spark plugs ........................41 Inspection of spark plugs........................41 Installation of spark plug ........................42 Fuse unit (FUSE BOX).........................43 Turbocharger............................44 Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 1 December 01 2017...
  • Page 110 This chapter relates in particular to the maintenance work mentioned in the Maintenance Schedule for the various engine systems and covers the work in more detail. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 2 December 01 2017...

  • Page 111: Engine Cleaning

    After each cleaning procedure, dry all electrical components such as cleaning • Ignition unit • Spark plug connector • Clamp connections etc. by use of compressed air to prevent leakage current. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 3 December 01 2017...

  • Page 112: Visual Inspection

    (black ring), there may be loose attachments. 3. Inspect engine isolating mounts including for heat damage, wear and cracks. 4. Inspect engine suspension frame. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 4 December 01 2017...

  • Page 113: Corrosion

    For more detailed information about different types of corrosion and corresponding methods for dealing with corrosion refer to the FAA Advisory Circular AC 43.13. See chapter “AC 43.13-1B Maintenance and Repair“. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0...

  • Page 114: Leakage Check

    Avoid overstretching the fixing elements. Always comply with the specified torque! Complete a detailed visual inspection. When checking steel fuel lines (1), pay attention to the connection areas (2). Look for leaks and cracks. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 6 December 01 2017...
  • Page 115 MAINTENANCE MANUAL Figure 7.1: Connections and fuel lines Fuel rail 2/4 outlet line Fuel rail 1/3 feed line Fuel hose assy. Fuel rail Fuel injector Pressure regulator Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 7 December 01 2017...

  • Page 116: Checking The Compression

    General note m WARNING Risk of electric shock! Ignition “OFF” and system grounded! Figure 7.2: Checking the compression. TYPICAL Adaptor Manometer/Test gauges set Orifice jet Compressor 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 8 December 01 2017...
  • Page 117 Step Procedure Remove the valve cover according to the latest Maintenance Manual Heavy. Turn the crankshaft into the position, so that the intake valve is closed. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 9 December 01 2017...
  • Page 118 Following troubleshooting reasons might be applicable but are not exclusively limited to: • Excessive cylinder wall and/or piston ring wear • Broken piston rings • Burned valves • Piston damage 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 10 December 01 2017...

  • Page 119: Engine Management Ecu

    Inspect the ECU wiring for wear, chafing and other damage, and make sure that the connectors are securely attached. READ OUT THE ECU DATA MEMORY Instruction For read out the ECU data memory proceed as follows: Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 11 December 01 2017...
  • Page 120 N N O O T T E E Connect and disconnect the B.U.D.S. USB-to-CAN Converter only if ECU is OFF. Non-compliance leads to entries in the error / event memory of the ECU. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 12 December 01 2017...

  • Page 121: Locking/Loosen Of The Crankshaft

    Screw the thread bolt (2) into the crankcase. While doing so, move the crankshaft to and fro slightly with the ring spanner until the locking screw engages in the recess of the crankshaft, and tighten to 10 Nm (89 in.lb). Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0...
  • Page 122 Remove the thread bolt (2) and refit crankshaft plug screw M8x20 (1) along with a new sealing ring with a torque of 15 Nm (133 in.lb). 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 14 December 01 2017...

  • Page 123: Test Run Of Engine

    After full-load run, conduct a short cooling run to prevent formation of va- pour lock in cylinder heads. This is necessary to prevent steam locks in the cooling and fuel system after shut-down. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0...
  • Page 124 If the oil filter has been replaced, re-tighten by hand after the trial run on a cold engine. Check of leaks Inspect the engine for oil, fuel or coolant leaks and repair as necessary. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 16 December 01 2017...

  • Page 125: Cooling System

    BRP-Rotax MAINTENANCE MANUAL COOLING SYSTEM Figure 7.7: Overview Water pump Coolant hoses Expansion tank Radiator cap with gasket Coolant temperature sensor Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 17 December 01 2017...

  • Page 126: Checking The Cooling System

    Protect the environment! Do not harm the environment by spilling coolant. Dispose coolant in an environmentally friendly manner. Instruction To replace the coolant the following steps are necessary: 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 18 December 01 2017...
  • Page 127 See chapter 12-10-00 section Coolant check/replenish. Fit radiator cap. N N O O T T E E Run the engine briefly and replenish with clean coolant as required. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 19...

  • Page 128: Flushing The Cooling System

    Step Procedure Fit radiator cap. N N O O T T E E Run the engine for a minute and replenish coolant as required. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 20 December 01 2017...

  • Page 129: Expansion Tank, Radiator Cap

    The radiator cap must be tightened fully on the expansion tank. Expansion tank Inspect sealing surface (7) and tube connection (8) of the expansion tank. Carry out visual inspection of tank for damage and scuffing marks. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 21...

  • Page 130: Fuel System

    MAINTENANCE MANUAL FUEL SYSTEM Figure 7.10: Overview Fuel rail 2/4 outline line Fuel rail 1/3 feed line Fuel hose assy. Fuel rail Fuel injector Pressure regulator 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 22 December 01 2017...

  • Page 131: Leak Tests

    Step Procedure Check the fuel pressure regulator (1) for damages and inspect the general condition. Perform a leak test. Inspect all connections (2) for secure attachment. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 23 December 01 2017...

  • Page 132: Fuel Injectors

    BRP-Rotax MAINTENANCE MANUAL Figure 7.11: Fuel pressure regulator Fuel pressure regulator Connections FUEL INJECTORS General note Check for leaks. FUEL RAIL General note Check for leaks. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 24 December 01 2017...

  • Page 133: Lubrication

    Overview Figure 7.12 Plug screw Oil pump Oil filter Oil tank Venting tube Oil temperature sensor Oil pressure sensor Turbo charger with dry sump Oil radiator Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 25 December 01 2017...
  • Page 134 • Replacement of the oil filter and the oil change should be effected quickly and without interruption to prevent a draining of the oil system and the hydraulic tappets. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 26...

  • Page 135: Oil Change

    ENVIRONMENTAL NOTE Protect the environment. Do not harm the environment by spilling oil. Dispose of oil in an environmentally friendly manner. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 27 December 01 2017...

  • Page 136: Oil Filter Removing

    ATTENTION To ensure correct functioning of the oil circuit and the forced flow lubrication, use ORIGINAL-ROTAX®- oil filter only. Only these filters will ensure correct pres- sure in the by-pass valve. At every oil change, unscrew the oil filter and cut open using special tool taking care not to produce chips.
  • Page 137 To remove the oil filter the following steps are necessary: Step Procedure Remove used oil filter with oil filter wrench. Clean the contact surface of the oil pump housing with a clean cloth. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 29 December 01 2017...

  • Page 138: Inspecting Of The Oil Filter Components

    Unclear findings In the case of unclear findings: Step Procedure Flush the oil circuit. Fit a new oil filter. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 30 December 01 2017...
  • Page 139 See chapter 12–20–00 section: Flushing the oil circuit. Proper judgement re- quires years of experience in repair of piston engines. Figure 7.14: Oil filter Filter housing Filter cover Gasket ring Anti-drain membrane Spring Filter matt Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 31 December 01 2017...

  • Page 140: Installing New Oil Filter

    Inspection of the used oil filter. Chapter 12-20-00 section Inspection of the filter insert. Figure 7.15: Install oil filter Oil pump housing Contact surface Gasket Oil filter 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 32 December 01 2017...

  • Page 141: Cleaning The Oil Tank

    Fit hex. double ignition screw M12x12 with a new gasket ring. Tighten to 25 Nm (18 ft.lb). Safety wire. Reassemble the oil tank by following the same steps in reverse order. Purge the oil system. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 33 December 01 2017...
  • Page 142 MAINTENANCE MANUAL Figure 7.16: Oil tank Profile clamp Hex. screw M12x12 Oil tank cover assy. UNF O-ring Baffle insert Partition Gasket ring 12x18 Oil tank Safety wire 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 34 December 01 2017...

  • Page 143: Purging The Oil System

    Filling Fill the oil tank with approx. 3 l (0.8 gal (US)) of engine oil. Procedure The following steps have to be carried out after refilling: Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 35 December 01 2017...
  • Page 144 Reconnect negative terminal of aircraft battery. Chapter 12–20–00 section Purging of the oil system. Equipment ATTENTION Equipment is to be inspected in accordance with the Maintenance Manual of the aircraft manufacturer. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 36 December 01 2017...

  • Page 145: Inspecting The Magnetic Plug

    Steel chips in If there are larger accumulations of metal chips on the magnetic plug, the engine must be larger numbers repaired or overhauled in accordance with the BRP-Rotax instructions for continued airworthiness. Unclear findings In the case of unclear findings:...

  • Page 146: Installation Of The Magnetic Plug

    Install the magnetic plug. Tightening torque 25 Nm (18 ft lb.) Secure with safety wire. Inspect all system for correct function. Detailed inspection of affected engine components. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 38 December 01 2017...

  • Page 147: Electric System

    BRP-Rotax MAINTENANCE MANUAL ELECTRIC SYSTEM Figure 7.18: Overview Double ignition Spark plug connectors Ignition cable FUSE BOX Plug connectors Crankshaft position sensor Stator assy. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 39 December 01 2017...

  • Page 148: Check Of Wiring

    Inspect all 8 ignition cables to spark plug connector for corrosion or damage and tight fit and replace if necessary. Fuse unit: Check fuse plugs/relays and replace if necessary. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 40 December 01 2017...

  • Page 149: Replacement Of Spark Plugs

    Possibly indicates one or more of the following: • mixture to rich • insufficient air intake (clogged air filter) • engine operating temperature too low Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 41 December 01 2017...

  • Page 150: Installation Of Spark Plug

    Head area Cleaning m WARNING Eyes and skin irritation! Rinse off with water in the case of contact with eyes or skin. May be harmful if swallowed. 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 42 December 01 2017...

  • Page 151: Fuse Unit (Fuse Box)

    Apply small amount of heat conduction compound to spark plug thread and tighten spark plug to 16 Nm (142 in. lb) on the cold engine. FUSE UNIT (FUSE BOX) General note Check plug connections and fuse plugs. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 43 December 01 2017...

  • Page 152: Turbocharger

    Check the waste gate lever for free movement. If it does not move freely, lubricate the axle of the waste gate with LOCTITE ANTI SEIZE 15378. Figure 7.20: Turbocharger 12–20–00 Effectivity: 915 i A Series Edition 0/Rev. 0 Page 44 December 01 2017...

  • Page 153: Propeller Gearbox

    Propeller gearbox Governor flange CHECKING THE PROPELLER GEARBOX General note For checking of the propeller gearbox see Maintenance Manual Heavy for Engine Type 915 i A Series.. Effectivity: 915 i A Series 12–20–00 Edition 0/Rev. 0 Page 45 December 01 2017...
  • Page 154 BRP-Rotax MAINTENANCE MANUAL NOTES Notes Effectivity: 915 i A Series Edition 0/Rev. 0 Page 46 December 01 2017...
  • Page 155 Exceeding the max. permissible oil temperature ..22 Maintenance Schedule ..........8 Expansion tank ...........21 Maintenance schedule procedures ......5 Extreme climatic conditions........16 Non compliance — coolant specification ....20 Effectivity: 915 i A Series Index Edition 0/Rev. 0 Page 1 December 01 2017...
  • Page 156 Replacement of spark plugs.........41 Unscheduled maintenance checks ..... 3, 1 Replacing the coolant ..........18 Use for intended purpose........15 Replenishing operating fluids .........1 Reporting ............33 Visual inspection ...........4 Safety ..............8 Effectivity: 915 i A Series Index Edition 0/Rev. 0 Page 2 December 01 2017...
  • Page 160 AIRCRAFT ENGINES __________________________________________________________ Engine serial no. __________________________________________________________ Type of aircraft __________________________________________________________ Aircraft registration no. ROTAX® authorized distributor WWW.FLYROTAX.COM ® and TM are trademarks of BRP-Rotax GmbH & Co KG. © 2017 BRP-Rotax GmbH & Co KG. All rights reserved...

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