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Rotax 915 i A Series Service Instruction

Rotax 915 i A Series Service Instruction

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SI-915 i-007R1
Introduction of a new turbocharger assy. with new ECU soft-
ware and exhaust requirements for ROTAX
915 i A (Series)
ATA System: 78-20-00 Turbocharger
1) Planning information
To obtain satisfactory results, procedures specified in this publication must be accomplished with
accepted methods in accordance with prevailing legal regulations.
BRP-Rotax GmbH & Co KG cannot accept any responsibility for the quality of work performed in
accomplishing the requirements of this publication.
1.1) Applicability
All versions of ROTAX
NOTE:
1.2) Concurrent ASB/SB/SI and SL
In addition to this Service Instruction the following Service Instructions must be observed and
complied with:
-
SB-915 i A-004/SI-912 i -018 - "List of approved Engine Control Unit (ECU) software and hard-
ware configurations for ROTAX® Engine Type 912 i and 915 i (Series)", current issue
-
SI-915 i-002, "B.U.D.S. Aircraft Installation Instruction", current issue
1.3) Reason
In the course of further development and standardization, a new turbocharger assy. has been
introduced.
1.4) Subject
Introduction of a new turbocharger assy. with new ECU software and exhaust requirements for
ROTAX® Engine Type 915 i A (Series).
1.5) Compliance
NONE - For Information Only.
1.6) Approval
The technical content of this document is approved under the authority of the DOA ref.
EASA.21J.048.
18 November 2020
Revision 1
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
This SI revises SI-915 i-007 Initial Issue dated 7 July 2020
engine types:
®
Engine type
915 iS A
915 iSc A
On engines with equal or higher S/N than those listed above, new style turbocharger,
exhaust bracket, muffler and latest version of ECU software have already been fitted
in serial production.
Current valid documentation see:
www.flyrotax.com
SERVICE INSTRUCTION
Serial number
from S/N 9132575
from S/N 9127353
Engine Type
®
Page 1 of 23
78-20-00

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Summary of Contents for Rotax 915 i A Series

  • Page 1 To obtain satisfactory results, procedures specified in this publication must be accomplished with accepted methods in accordance with prevailing legal regulations. BRP-Rotax GmbH & Co KG cannot accept any responsibility for the quality of work performed in accomplishing the requirements of this publication.
  • Page 2 1.13) Interchangeability of parts Old and new parts are NOT interchangeable as they have different fixation positions for the turbo- charger assy. 18 November 2020 78-20-00 Revision 1 Page 2 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 3 SI-915 i-007R1 SERVICE INSTRUCTION 2) Material Information 2.1) Material Price and availability will be provided on request by ROTAX Authorized Distributors or their inde- ® pendent Service Centers. 2.2) Company support information None. 2.3) Material requirement per engine New part...
  • Page 4 SI-915 i-007R1 SERVICE INSTRUCTION 2.6) Special tooling/lubricants- /adhesives- /sealing compounds Price and availability will be supplied on request by ROTAX Authorized Distributors or their inde- ® pendent Service Centers: Qty/ Part Description engine number B.U.D.S. set Level 3 - Maintenance...
  • Page 5 See current Installation Manual (IM) for the respective engine type. Connection turbocharger bracket with engine suspension frame requires NOTICE WARNUNG a Metric or UNF fixed connection. 18 November 2020 78-20-00 Revision 1 Page 5 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 6 Lubricate the wastegate lever. 12-20-00 Inspection of the GENUINE ROTAX ® haust system included in the standard de- 05-20-00 livery. 18 November 2020 78-20-00 Revision 1 Page 6 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 7 Procedure Remove M8 hex. nuts and washers from turbocharger flange. Remove M8x30 screws to disconnect turbocharger from exhaust manifold assy. 18 November 2020 78-20-00 Revision 1 Page 7 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 8 Loosen the engine suspension frame / muffler bracket bolt (not supplied with the en- gine). 18 November 2020 78-20-00 Revision 1 Page 8 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 9 Support the complete unit of muffler - turbocharger - bracket, remove the tension clamp and take off the complete unit. 1 Turbocharger 2 Muffler 3 Turbocharger bracket Fig. 6 18 November 2020 78-20-00 Revision 1 Page 9 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 10 Step Procedure Remove hex. nuts with washers from the turbocharger studs. 1 Hex. nuts M8 2 Washers 8.4 Fig. 8 18 November 2020 78-20-00 Revision 1 Page 10 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 11 Clean all parts carefully Record the readings in the Appendix General visual inspection. See Maintenance Manual Line (MML) for the engine type 915 i A Series Chapter 12-20-00 NOTE: The turbocharger is handled as a complete unit, i.e. no spare parts are available from BRP-Rotax.
  • Page 12 It is not allowed to repair any of the threads inside of the turbine housing NOTICE WARNUNG with thread inserts. 1 Threaded hole 2 Gap Fig. 11 18 November 2020 78-20-00 Revision 1 Page 12 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 13 Check the wastegate lever for free movement. If it does not move freely, lubricate the axle of the wastegate with LOCTITE ANTI SEIZE 8151. Fig. 13 18 November 2020 78-20-00 Revision 1 Page 13 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 14 Fig. 14 18 November 2020 78-20-00 Revision 1 Page 14 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 15 Tighten the bracket to the turbocharger using 3 hex. screws M8x16 with 1x washer 8.4 and 2x washers B 8.4 (bigger outer diameter). Tightening torque 25 Nm (18 ft. lb.). 18 November 2020 78-20-00 Revision 1 Page 15 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 16 2 Allen screw M10x50 3 Lock washer 4 Washer 5 Distance sleeve 6 Connection turbocharger bracket with engine suspension frame Fig. 17 18 November 2020 78-20-00 Revision 1 Page 16 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 17 Tightening torque 25 Nm (18 ft. lb). 1 Allen screw M8x30 2 Washer 8.4 3 Hex. nut M8 Fig. 19 18 November 2020 78-20-00 Revision 1 Page 17 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 18 1 Turbo pressure oil line 2 Suction oil line 3 Wastegate regulator 4 Hose (wastegate regulator) 5 Cable clamp Fig. 20 18 November 2020 78-20-00 Revision 1 Page 18 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 19 Aircraft can also be started through the start menu entry (e.g. Start – All Programs - B.U.D.S. - run B.U.D.S.). 18 November 2020 78-20-00 Revision 1 Page 19 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 20 Check if both Lane Health Indicators (top left corner) turn green. If they are gray check connections and power supply and/or restart B.U.D.S. Aircraft. Change to “ECU configuration” tab. 18 November 2020 78-20-00 Revision 1 Page 20 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
  • Page 21 Verify if the installed ECU software version is up to date. If the software is not up to date continue with chapter 3.6.3. See also SI-915 i-004 - List of approved Engine Control Unit (ECU) software and hardware configurations for ROTAX® Engine Type 915 i (Series). 18 November 2020...
  • Page 22 3.6.3) Update of ECU software If there is a newer ECU software for the relevant engine configuration available perform software loading according to SB-915 i-002 - Software Update for Engine Control Unit (ECU) on ROTAX® Engine Type 915 i (Series).
  • Page 23: Wear Limits

    Exploded views are not technical drawings and are for reference only. For specific detail, refer to the current documents of the respective engine type. 18 November 2020 78-20-00 Revision 1 Page 23 of 23 Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.

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