Rotax 915 i A SERIES Manuals

Manuals and User Guides for Rotax 915 i A SERIES. We have 8 Rotax 915 i A SERIES manuals available for free PDF download: Maintenance Manual, Operator's Manual, Service Instruction, Service Instructions Manual

Rotax 915 i A SERIES Maintenance Manual (523 pages)

Brand: Rotax | Category: Engine | Size: 33.53 MB

Chapter: 00-00-00 General Note

21
- Table of Contents
  21
- General
  22
- Type Description
  23
- Abbreviations and Terms
  24
  - Conversion Table
    28
- Safety Notice
  29
  - Safety Information
    30
  - Instruction
    32
  - Maintenance Concept
    33
  - Technical Documentation
    34
  - Use for Intended Purpose
    36
- Inspection of Parts and Report of Findings
  37
- Classification of Parts for Maintenance/Repair
  39
- Maintenance
  42
  - Fastener Information
    43
  - LOCTITE Application Procedure
    44
- Lubricant
  49
- Tools
  53
Chapter: 24-20-00 Internal Generator

55
- Special Tools
  57
- Service Products
  58
- System Description
  60
  - EMS Power Supply
    60
  - Drive
    60
  - Safety Instruction
    60
  - Maintenance
    60
  - General Information - Removal
    60
  - Before the Internal Generator Is Removed
    60
- Removal
  61
- Inspection
  67
- Wear Limits
  69
- Assembly
  70
- Installation
  74
Chapter: 61-20-00 Governor

79
- Special Tools
  81
- Service Products
  82
- System Description
  84
  - Safety Instruction
    84
  - Maintenance
    84
- Removal
  85
- Inspection
  88
  - Governor Drive Check
    88
  - Finishing Work
    89
- Wear Limits
  90
- Installation
  91
Chapter: 71-00-00 Power Plant

95
- Special Tools
  97
- Installation Checklist
  98
- General Note
  100
  - Engine Preservation
    100
  - Return to Service
    100
  - Treating Rust and Surface Damage
    101
- System Description
  102
  - Description of Design
    102
- Technical Data
  103
  - Operating Limits
    103
  - Operating Fluids/Capacities
    103
  - Weights
    103
  - Engine/Components, General
    103
- Serial and Part no
  105
  - Serial Number
    105
  - Part no
    105
- Engine Components, Engine Views, Cylinder Designation and Definition of Main Axes
  106
- Maintenance
  111
- Power Plant
  112
- Installation
  117
- Engine Suspension Frame
  119
  - Removal of the Engine Suspension Frame
    119
- Inspection
  121
  - Engine Suspension Frame Check
    121
- Installation
  122
  - Installation of the Engine Suspension Frame
    122
  - Finishing Work
    122
Chapter: 72-10-00 Propeller Gearbox

127
- Special Tools
  129
- Service Products
  131
- System Description
  134
  - Safety Instructions
    134
  - Connections for Display Systems
    134
  - Maintenance
    134
- Removal
  135
  - Torsion Shaft- Removal
    135
- Disassembly
  136
- Inspection
  143
  - Propeller Gearbox Single Parts Check
    143
  - Gear Cover Assy. Check
    143
  - Propeller Shaft - Check
    144
  - Overload Clutch - Check
    145
  - Damper Clutch - Check
    146
  - Torsion Bar - Check
    147
  - Checking the Splines
    148
  - Gear Set Check (Gears)
    148
  - Pitting, General Information
    149
  - Slight Pitting
    150
  - Destructive Pitting
    151
  - Flake Pitting (Large-Area Flank Fractures)
    151
- Wear Limits
  153
- Assembly
  158
- Installation
  168
  - Needle Bearing - Installation
    168
Chapter: 72-20-00 Engine Block

171
- Special Tools
  172
- Service Products
  173
- General Note
  175
  - Safety Instructions
    175
  - Maintenance
    175
- Sprag Clutch
  176
  - Sprag Clutch - Removal
    176
  - Removal of the Sprag Clutch Housing
    176
- Disassembly
  178
  - Disassembling the Sprag Clutch Housing
    178
- Inspection
  179
  - Sprag Clutch Housing Single Parts Check
    179
  - Sprag Clutch Housing Check
    179
  - Sprag Clutch Check
    180
  - Free Wheel Gear Check
    180
  - Starter Intermediate Gear Check
    180
- Assembly
  181
  - Assembly of the Sprag Clutch Housing
    181
- Installation
  182
  - Installation of the Sprag Clutch Housing
    182
  - Measuring the Axial Clearance of the Free Wheel Gear
    183
- Wear Limits
  184
- Finishing Work
  185
Chapter: 72-30-00 Cylinder Head

187
- Special Tools
  190
- Service Products
  191
- System Description
  193
  - Safety Instruction
    193
  - Maintenance
    193
- Cylinder Head
  194
  - Cylinder Head - Removal
    194
  - Removal of Surrounding Assemblies
    194
  - Cylinder Head - Removal
    196
- Disassembly
  198
  - Disassembling the Cylinder Head
    198
  - Rocker Arm - Removal
    198
  - Valve - Removal
    198
  - Coolant Elbow Inlet - Removal
    199
  - Removal of the Oil Return Tube
    199
  - Coolant Elbow Outlet - Removal
    199
- Inspection
  201
  - Cylinder Head Single Parts Check
    201
  - Cylinder Head Studs Check
    201
  - Cylinder Head Assy. - Inspection
    201
- Hardness Test Method
  203
  - Valve Guide Check
    203
  - Valve Check
    204
  - Valve Seats Check
    204
  - Valve Spring Check
    205
  - Washer Check
    205
  - Rocker Arm Check and Rocker Arm Shaft Check
    206
  - Rocker Arm Bushing
    207
  - Push Rods
    207
- Wear Limits
  208
- Assembly
  213
  - Cylinder Head - Assembly
    213
  - Oil Return Tube Installation
    213
  - Installation of the Coolant Elbow Inlet
    213
  - Coolant Elbow Outlet - Assembly
    213
  - Coolant Elbow - Installation
    214
  - Valve Installation
    214
  - Rocker Arm - Installation
    216
- Installation
  217
  - Cylinder Head Installation
    219
- Cylinder Head (Single) Repaired Per Engine Side
  219
Chapter: 72-30-10 Displacement Parts

225
- Special Tools
  227
- Service Products
  228
- System Description
  229
  - Safety Instruction
    229
  - Maintenance
    229
- Removal
  230
  - Cylinder and Piston - Removal
    230
  - Removal of the Hydraulic Valve Tappet
    231
- Inspection
  232
  - Displacement Parts - Inspection
    232
  - Piston - Inspection
    232
  - Piston Rings - Inspection
    233
  - Piston Pin - Inspection
    234
  - Cylinder - Inspection
    234
  - Hydraulic Valve Tappet - Inspection
    235
- Wear Limits
  236
- Installation
  241
  - Cylinder and Piston - Installation
    241
  - Installation of the Hydraulic Valve Tappet
    241
  - Piston - Installation
    242
  - Cylinder Installation
    244
  - Finishing Work
    245
Chapter: 73-00-00 Fuel System

247
- System Description
  249
  - Ecu
    249
  - Fuel Filter
    249
  - Safety Instruction
    249
- Connections for Display Systems
  250
  - Pressure Sensor
    250
  - Temperature Sensor
    250
Chapter: 73-10-00 Fuel System and Distribution

251
- Special Tools
  256
- Service Products
  257
- System Description
  260
  - Fuel Pump Module
    260
  - Fuel Distribution
    260
  - Safety Instruction
    261
  - Maintenance
    261
- Disassembly
  262
  - Pressure Control Valve Hoses - Removal
    262
  - Fuel Line Assy. - Removal
    262
  - Pop off Valve - Removal
    264
  - Fuel Pump Assy. - Removal
    265
  - Fuel Pump Assy. Single Parts - Disassembly
    267
  - Fuel Pressure Regulator Assy. - Removal
    267
  - Fuel Pressure Regulator - Disassembly
    268
  - Fuel Rail - Removal
    269
  - (2/4) and (1/3) Fuel Rail - Disassembly
    272
  - Intake Manifold - Removal
    272
  - Double Ignition Coil - Removal
    272
  - 1/3 Intake Manifold - Removal
    273
  - Pressure and Temperature Sensor - Disconnection
    274
  - Airbox - Removal
    274
  - Throttle Body Assy. - Removal
    275
- Inspection
  277
  - Pop off Valve - Check
    277
  - Fuel Distribution Single Parts - Check
    277
  - Fuel Line Assy. - Inspection
    277
  - Fuel Pressure Regulator Assy. - Inspection
    277
  - Pressure Regulator Housing - Inspection
    278
  - Fuel Rail - Inspection
    278
  - Intake Manifold - Inspection
    279
  - Airbox - Inspection
    280
  - Throttle Body - Inspection
    281
  - Fuel Pump Assy. Single Parts - Check
    282
  - Fuel Pump - Inspection
    282
  - Line and Hose - Inspection
    282
  - Air Filter - Inspection
    283
- Assembly
  284
  - Fuel Pressure Regulator - Assembly
    284
  - Airbox - Assembly
    284
- Installation of (2/4) and (1/3) Fuel Rails
  286
- Fuel Pressure Regulator Assy. - Installation
  288
- Fuel Pump Assy. Single Parts - Assembly
  290
- Fuel Pump Assy. - Assembly
  291
- Throttle Body Assy. - Installation
  292
- Airbox - Installation
  293
- Fuel Line Assy. - Installation
  294
- Pop off Valve - Installation
  296
- Pressure Control Valve Hoses - Installation
  297
- Finishing Work
  298

Rotax 915 i A SERIES Maintenance Manual (160 pages)

Brand: Rotax | Category: Engine | Size: 20.64 MB

Chapter: 00-00-00 General Note

13
- List of Effective Pages
  7
- Table of Amendments
  11
- Table of Contents
  13
- General
  14
- Type Description
  15
- Abbreviations and Terms
  16
  - Conversion Table
    19
- Safety Notice
  20
  - Safety Information
    21
  - Instruction
    23
  - Maintenance Concept
    24
  - Technical Documentation
    25
  - Use for Intended Purpose
    27
Chapter: 05-00-00 Maintenance

31
- General Note
  32
- Authorized Personnel
  33
- Procedure Notes
  34
- Trouble Shooting
  36
- Consumable Materials
  37
- Acceptable Methods, Techniques and Practice
  41
Chapter: 05-10-00 Time Limits

43
- Definition of Terms
  44
  - Operating Hours
    44
  - Terminology
    44
  - Time Limit
    45
  - Life Cycle
    45
  - General Overhaul (TBO)
    45
  - Purging the Oil System
    45
- Time Limit
  46
  - Time Limit for Parts
    47
  - Time Limit for the Coolant
    48
  - Annual Inspection
    48
Brp-Rotax Chapter: 05-20-00 Scheduled Maintenance Checks

49
Chapter: 05-50-00 Unscheduled Maintenance Checks

63
- Engine Check after Propeller Strike Incidents
  64
- Examination after Engine Failure
  76
Chapter: 12-10-00 Replenishing Operating Fluids

99
- Servicing Points on the Engine
  100
- Fluid Capacities
  101
- Cooling System
  102
  - Coolant Check/Replenish
    102
- Lubrication System
  105
  - Oil Level Check/Replenish
    105
Chapter: 12-20-00 Scheduled Maintenance

109
- Engine Cleaning
  111
- Visual Inspection
  112
  - Checking the Engine Suspension
    112
  - Corrosion
    113
- Leakage Check
  114
- Checking the Compression
  116
- Engine Management ECU
  119
  - Checking ECU
    119
  - Read out the ECU Data Memory
    119
- Locking/Loosen of the Crankshaft
  121
- Test Run of Engine
  123
- Cooling System
  125
  - Checking the Cooling System
    126
  - Replacing the Coolant
    126
  - Flushing the Cooling System
    128
  - Expansion Tank, Radiator Cap
    129
- Fuel System
  130
  - Leak Tests
    131
  - Checking the Fuel Lines
    131
  - Checking the Fuel Pressure Regulator
    131
  - Fuel Injectors
    132
  - Fuel Rail
    132
- Lubrication
  133
  - Oil Change
    135
  - Oil Filter Removing
    136
  - Inspecting of the Oil Filter Components
    138
  - Installing New Oil Filter
    140
  - Cleaning the Oil Tank
    141
  - Purging the Oil System
    143
  - Flushing the Oil Circuit
    143
- Inspecting the Magnetic Plug
  145
  - Installation of the Magnetic Plug
    146
- Electric System
  147
  - Check of Wiring
    148
  - Replacement of Spark Plugs
    149
  - Remove the Spark Plugs
    149
  - Inspection of Spark Plugs
    149
  - Installation of Spark Plug
    150
  - Fuse Unit (FUSE BOX)
    151
- Turbocharger
  152
  - Propeller Gearbox
    153

Rotax 915 i A SERIES Operator's Manual (141 pages)

Brand: Rotax | Category: Engine | Size: 11.35 MB

Table of Content
3
Purpose of the Manual
12
Engine Serial Number
12
Abbreviations and Terms
13
Safety
17
Type Description
24
Operating Instructions
25
Operating Limits
26
Engine Speed
26
Performance
26
Operating Media-Coolant
30
Operating Media-Fuel
30
Operating Media-Lubricants
31
Oil Viscosity
32
Table of Lubrication
32
Standard Operation
33
Daily Checks
34
Coolant Level
34
Check of Mechanical/Electronic Components
36
Pre-Flight Checks
37
Engine Start
38
After Engine Start
42
Warming up Period
42
Engine Run-Up
43
Ground Test
43
Lane and Ignition Check
44
Wastegate and PCV Check
47
Fuel Pump Check
49
Engine Shut-Off
51
Abnormal Operation
53
Engine Failures in Flight
55
EMS Health Status
55
Failure of Internal Generators
56
Engine Not Responding on Throttle Position Commands
57
Engine on Fire or Fire in the Engine Compartment
57
Emergency Engine Shut-Off
57
Loss of Display CAN Information
57
Failures During Engine Start
58
Engine Does Not Start
58
Re-Start During Flight
58
The Sprag Clutch Fails to Decouple from the Starter
58
Fuel Pressure Outside Range
59
Performance and Fuel Consumption
61
Performance Data and Fuel Consumption
62
Explanation of the Parameters
62
System Description
65
General Specification
66
Engine Components
67
Product View
67
Cylinder Arrangement
68
Direction of Rotation
68
Cooling System
69
Coolant Flow
69
Expansion Tank
69
Coolant Temperature Measuring
69
Fuel System
70
Fuel Flow
70
Lubrication System
71
Oil Flow
71
Turbocharger
71
Electric System
73
Internal Power Supply
73
Engine Management System
74
Ignition Control
75
Fuel Injection Control
76
Communication Interfaces
76
B.U.D.S Software
76
Air Intake System and Boost Pressure Control
77
Air Flow
78
Boost Pressure Control
78
Ambient Air Pressure and Temperature Sensors (AAPTS)
78
Exhaust System
80
Preservation and Storage
81
Engine Preservation and Storage
82
Engine Back to Operation
83
Proper Disposal
87
Performance Data and Fuel Consumption Model
89
Index
137

Rotax 915 i A SERIES Maintenance Manual (120 pages)

Brand: Rotax | Category: Engine | Size: 10.29 MB

Table of Contents
35
TOPICS in this CHAPTER Special Tools
35
Service Products
37
System Description
40
- Safety Instructions
  40
- Connections for Display Systems
  40
- Maintenance
  40
Removal
41
- Gearbox Oil Line Assy - Removal
  41
- Torsion Shaft- Removal
  42
Disassembly
44
Inspection
53
- Propeller Gearbox Single Parts Check
  53
- Gear Cover Assy. Check
  53
- Propeller Shaft - Check
  54
- Overload Clutch - Check
  55
- Damper Clutch - Check
  56
- Torsion Bar - Check
  57
- Checking the Splines
  58
- Gear Set Check (Gears)
  58
- Pitting, General Information
  59
- Slight Pitting
  60
- Destructive Pitting
  61
- Flake Pitting (Large-Area Flank Fractures)
  61
Wear Limits
63
Assembly
68
Installation
80
- Blinding Shim - Installation
  80
- Oil Inlet Flange- Installation
  80

Rotax 915 i A SERIES Service Instruction (23 pages)

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Rotax 915 i A SERIES Service Instructions Manual (18 pages)

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Rotax 915 i A SERIES Service Instruction (15 pages)

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Rotax 915 i A SERIES Service Instruction (13 pages)

Brand: Rotax | Category: Engine | Size: 0.07 MB

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Rotax 915 i A SERIES Manuals

Table of Contents

Chapter: 00-00-00 General Note

Chapter: 24-20-00 Internal Generator

Chapter: 61-20-00 Governor

Chapter: 71-00-00 Power Plant

Chapter: 72-10-00 Propeller Gearbox

Chapter: 72-20-00 Engine Block

Chapter: 72-30-00 Cylinder Head

Chapter: 72-30-10 Displacement Parts

Chapter: 73-00-00 Fuel System

Chapter: 73-10-00 Fuel System and Distribution

Table of Contents

Chapter: 00-00-00 General Note

Chapter: 05-00-00 Maintenance

Chapter: 05-10-00 Time Limits

Brp-Rotax Chapter: 05-20-00 Scheduled Maintenance Checks

Chapter: 05-50-00 Unscheduled Maintenance Checks

Chapter: 12-10-00 Replenishing Operating Fluids

Chapter: 12-20-00 Scheduled Maintenance

Table of Contents

Table of Contents

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