BRP Rotax 915 i A Series User manual

AIRCRAFT ENGINES
Maintenance Manual
ref. no.: MML-915 i A | part no.: 898863
(LINE MAINTENANCE) FOR ROTAX® ENGINE TYPE 915 i A SERIES
picture: ROTAX® 915 i A with options

Before starting any maintenance work, please read the Maintenance Manual completely as it
contains important safety relevant information. Failure to do so may result in personal
injuries including death. Consult the orginal equipment manufacturers handbook for
additional instructions!
These technical data and the information embodied therein are the property of BRP-Rotax
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.
Copyright 2017 © - all rights reserved.
ROTAX® is a trade mark of BRP-Rotax GmbH & Co KG. In the following document the short form
of BRP-Rotax GmbH & Co KG = BRP-Rotax is used.
Other product names in this documentation are used purely for ease of identification and may be
trademarks of the respective company or owner.
Translation into other languages might be performed in the course of language localization but
does not lie within ROTAX® scope of responsibility.
In any case the original text in English language and the metric units are authoritative.

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Rev. 1 Content
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June 01 2019
Table of Content
Chapter INTRO – GENERAL NOTE
Chapter LEP – LIST OF EFFECTIVE PAGES
Chapter TOA – TABLE OF AMENDMENTS
Chapter 00–00–00 – GENERAL NOTE
Chapter 04–00–00 – AIRWORTHINESS LIMITATIONS
Chapter 05–00–00 – MAINTENANCE
Chapter 05–10–00 – TIME LIMITS
Chapter 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
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Chapter: INTRO
GENERAL NOTE
Foreword Before carrying out maintenance work on the engine, read this Maintenance Manual
carefully.
If any passages of the Manual are not clearly understood or in case of any questions,
please contact your nearest ROTAX® Authorized Aircraft Engines Distributors or their
independent Service Centers.
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. The aim is the compatibility with the aircraft
manufacturers documentation, which means they must then adapt the documentation to
their standard.
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Rev. 1 INTRO
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Chapter: LEP
LIST OF EFFECTIVE PAGES
Each new revision to the Maintenance Manual Line will have a new List of Effective Pages.
chapter page date
Cover
page
INTRO 1 June 01 2019
2 June 01 2019
LEP 1 June 01 2019
2 June 01 2019
3 June 01 2019
4 June 01 2019
TOA 1 June 01 2019
2 June 01 2019
3 June 01 2019
4 June 01 2019
00-00-00 1 June 01 2019
2 June 01 2019
3 June 01 2019
4 June 01 2019
5June 01 2019
6 June 01 2019
7June 01 2019
8 June 01 2019
9 June 01 2019
10 June 01 2019
11 June 01 2019
12 June 01 2019
13 June 01 2019
14 June 01 2019
15 June 01 2019
16 June 01 2019
04-00-00 1 June 01 2019
chapter page date
2 June 01 2019
05-00-00 1 June 01 2019
2 June 01 2019
3 June 01 2019
4 June 01 2019
5June 01 2019
6 June 01 2019
7June 01 2019
8 June 01 2019
9 June 01 2019
10 June 01 2019
11 June 01 2019
12 June 01 2019
05-10-00 1 June 01 2019
2 June 01 2019
3 June 01 2019
4 June 01 2019
5June 01 2019
6 June 01 2019
05-20-00 1 June 01 2019
2 June 01 2019
3 June 01 2019
4 June 01 2019
5June 01 2019
6 June 01 2019
7June 01 2019
8 June 01 2019
9 June 01 2019
10 June 01 2019
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chapter page date
11 June 01 2019
12 June 01 2019
13 June 01 2019
14 June 01 2019
05-50-00 1 June 01 2019
2 June 01 2019
3 June 01 2019
4 June 01 2019
5June 01 2019
6 June 01 2019
7June 01 2019
8 June 01 2019
9 June 01 2019
10 June 01 2019
11 June 01 2019
12 June 01 2019
13 June 01 2019
14 June 01 2019
15 June 01 2019
16 June 01 2019
17 June 01 2019
18 June 01 2019
19 June 01 2019
20 June 01 2019
21 June 01 2019
22 June 01 2019
23 June 01 2019
24 June 01 2019
25 June 01 2019
26 June 01 2019
27 June 01 2019
28 June 01 2019
29 June 01 2019
chapter page date
30 June 01 2019
31 June 01 2019
32 June 01 2019
33 June 01 2019
34 June 01 2019
12-00-00 1 June 01 2019
2 June 01 2019
12-10-00 1 June 01 2019
2 June 01 2019
3 June 01 2019
4 June 01 2019
5June 01 2019
6 June 01 2019
7June 01 2019
8 June 01 2019
9 June 01 2019
10 June 01 2019
12-20-00 1 June 01 2019
2 June 01 2019
3 June 01 2019
4 June 01 2019
5June 01 2019
6 June 01 2019
7June 01 2019
8 June 01 2019
9 June 01 2019
12-20-00 10 June 01 2019
11 June 01 2019
12 June 01 2019
13 June 01 2019
14 June 01 2019
15 June 01 2019
16 June 01 2019
LEP
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chapter page date
17 June 01 2019
18 June 01 2019
19 June 01 2019
20 June 01 2019
21 June 01 2019
22 June 01 2019
23 June 01 2019
24 June 01 2019
25 June 01 2019
26 June 01 2019
27 June 01 2019
28 June 01 2019
29 June 01 2019
30 June 01 2019
31 June 01 2019
32 June 01 2019
chapter page date
33 June 01 2019
34 June 01 2019
35 June 01 2019
36 June 01 2019
37 June 01 2019
38 June 01 2019
39 June 01 2019
40 June 01 2019
41 June 01 2019
42 June 01 2019
43 June 01 2019
44 June 01 2019
45 June 01 2019
46 June 01 2019
Index
Rear page
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Chapter: TOA
TABLE OF AMENDMENTS
Approval*
The technical content of this document is approved under the authority of DOA ref. EASA.21J.048.
This document is part of the ICA for product [2019].
NOTE
THE APPROVAL IS GIVEN TO ALL CHAPTERS EXCEPT THE AIRWORTHINESS
LIMITATIONS SECTION 04-00-00 WHICH IS SUBJECT TO SPECIFIC APPROVAL OF THE
EASA.
Edition 0/Rev. 0 December 01 2017 Obsolete with Revision 1, which is a complete re-revision
Rev. 1 June 01 2019
Rev.
no.
chapter page date of
change
remark for
approval
date of
approval
from
authori-
ties
date of
inclusion
signature
0INTRO all Dec. 01 2017 DOA*
0 LEP all Dec. 01 2017 DOA*
0TOA all Dec. 01 2017 DOA*
0 00-00-00 all Dec. 01 2017 DOA*
0 04-00-00 all Dec. 01 2017 EASA approved
0 05-00-00 all Dec. 01 2017 DOA*
0 05-10-00 all Dec. 01 2017 DOA*
0 05-20-00 all Dec. 01 2017 DOA*
0 05-50-00 all Dec. 01 2017 DOA*
0 12-00-00 all Dec. 01 2017 DOA*
0 12-10-00 all Dec. 01 2017 DOA*
0 12-20-00 all Dec. 01 2017 DOA*
Rev.
no.
chapter page date of
change
remark for
approval
date of
approval
from
authori-
ties
date of
inclusion
signature
1 LEP all June 01 2019 DOA*
1TOA all June 01 2019 DOA*
1 00-00-00 7, 12, 14 June 01 2019 DOA*
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Rev.
no.
chapter page date of
change
remark for
approval
date of
approval
from
authori-
ties
date of
inclusion
signature
1 05-00-00 4,6 - 10 June 01 2019 DOA*
1 05-10-00 3 June 01 2019 DOA*
1 05-20-00 2, 6,
8–13
June 01 2019
June 01 2019
DOA*
DOA*
1 05-50-00 2,4,6,10,
13,
26,27,33
June 01 2019
June 01 2019
June 01 2019
DOA*
DOA*
DOA*
1 12-10-00 3 June 01 2019 DOA*
1 12-20-00 9,14,15,-
25,30,
31,35,41,
44–46
June 01 2019
June 01 2019
June 01 2019
June 01 2019
DOA*
DOA*
DOA*
DOA*
TOA
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Summary of amendments
Summary of the relevant amendments in this context, but without requirement on completeness.
Rev. no. chapter page date of change comment
1
1
1
1
1
1
1
1
00–00–00
00–00–00
05–20–00
05–20–00
05–50–00
05–50–00
12–20–00
12–20–00
7
14
2, 6
8–13
6
33
30, 31
44, 45
June 01 2019
June 01 2019
June 01 2019
June 01 2019
June 01 2019
June 01 2019
June 01 2019
June 01 2019
New: Wiring color code
change of text
change of table
change of table
Warning: change of text
change of text
change of text, new figure
New: Checking and cleaning plug screw
(turbo oil sump assy.)
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Chapter: 00–00–00
GENERAL NOTE
TOPICS IN THIS CHAPTER
General....................................................................................................................................................2
Abbreviations and terms .........................................................................................................................3
Wiring color codes.................................................................................................................................7
Conversion table ...................................................................................................................................8
Safety notice ...........................................................................................................................................9
Safety information ...............................................................................................................................10
Instruction...........................................................................................................................................12
Maintenance Concept..........................................................................................................................13
Technical documentation......................................................................................................................14
Use for intended purpose .....................................................................................................................16
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GENERAL
Purpose The purpose of this Manual is to provide aircraft manufacturers with technical require-
ments (e.g. interface descriptions and limitations) that must be adhered to when installing
this type of engine into an aircraft or certifying aircraft powered by this engine type. Fur-
thermore it should allow independent ROTAX® Maintenance Technicians (iRMT) to install
this engine into an airframe in compliance with the relevant installation and safety instruc-
tions provided by the engine manufacturer.
For detailed information related to aircraft and aircraft/engine installation, maintenance,
safety or flight operation, consult the documentation provided by the aircraft manufacturer
and/or its dealer.
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
Distributors
For ROTAX® Authorized Distributors for aircraft engines see latest Operators Manual or
the official website www.FLYROTAX.com.
Engine serial
number
When making inquiries or ordering parts, always indicate the engine serial number. Due to
continuous product improvement, engines of the same engine type might require different
support and spare parts.
The engine serial number is on top of the crankcase, behind the propeller gearbox.
Figure 1.1: Engine serial number
1Engine serial number
00–00–00
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ABBREVIATIONS AND TERMS
Abbreviations Description
* Reference to another section
@center of gravity
The drop symbol indicates use of sealing agents, adhesives or lubri-
cants (only in the Illustrated Parts Catalog).
°C Degrees Celsius (Centigrade)
°F Degrees Fahrenheit
rpm Revolutions per minute
A Ampere
AAPTS Ambient Air Pressure Temperature Sensor
AC alternating current
AD Airworthiness Directives
Ah Ampere hour
A/C Aircraft
AR as required
assy. assembly
ASB Alert Service Bulletin
ACG Austro Control GmbH
ACL Anti Collision Light
API American Petrol Institute
ASTM American Society for Testing and Materials
ATA Air Transport Association
AWG American Wire Gauge
CAN Controller Area Network
Coil 1–4 Ignition coils 1–4
CPS 1+2 Crankshaft Position Sensor 1+2
CSA Constant Speed Actuator
CTS Cooling Temperature Sensor
CW clockwise
CCW counter-clockwise
CGSB Canadian General Standards Board
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DCDI Dual Capacitor Discharge Ignition
DC direct current
DOA Design Organisation Approval
DOT Department of Transport
EASA European Aviation Safety Agency
IM Installation Manual
ECU Engine Control Unit
EGT Exhaust Gas Temperature
INTRO Introduction
EMS Engine Management System
EMS GND Engine system internal ground reference which is intended to be dis-
connected from aircraft common ground during flight
EMC Electromagnetic compatibility
EN European Standard
ETFE Ethylene Tetrafluoroethylene
FAA Federal Aviation Administration
FAR Federal Aviation Regulations
FOD Foreign object damage
Fuse box Power conditioning and distribution for the Engine Management
System
hr. hours
HIC A Harness Interface Connector A
HIC B Harness Interface Connector B
IAT Indicated Air Temperature
ICA Instructions for Continued Airworthiness
IFR Instrument Flight Rules
IFSD In-flight-shutdown
INJ 1–8 Injector 1–8
IPC Illustrated Parts Catalog
ips inch per second
iRMT independent ROTAX Maintenance Training
ISA International Standard Atmosphere
00–00–00
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kg Kilograms
KNOCK Knock sensor
Lane A System A of Engine Management System
Lane B System B of Engine Management System
LOPC Loss of power control
MAPS 1 & 2 Manifold Air Pressure Sensor 1 & 2
MATS 1 & 2 Manifold Air Temperature Sensor 1 & 2
MON Motor Octane Number
MAG Magneto Side
N Newton
n.a. not available
NDT Non Destructive Testing
Nm Newtonmeter
NVFR Night Visual Flight Rules
OAT Organic Acid (Additive) Technology
OHM Overhaul Manual
OHV Over Head Valve
OM Operators Manual
OPS Oil Pressure Sensor
OTS Oil Temperature Sensor
PCD Pitch Circle Diameters
PCV Pressure Control Valve
PMA Permanent magnet alternator
POA Production Organisation Approval
PS Power supply
PTFE Polytetrafluoroethylene (Teflon)
PTO Power Take Off
Rev. Revision
ROTAX® is a trademark of BRP-Rotax GmbH & Co KG
RON Research Octane Number
RON 424 ROTAX® Standard 424
s.v. still valid (only Illustrated Parts Catalog)
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S/N Serial Number
SAE Society of Automotive Engineers
SEP Single Engine Piston
SB Service Bulletin
SI Service Instruction
SI-PAC Service Instruction Parts and Accessories
SPST Single pole single throw
STP Shield twisted pair
SL Service Letter
SMD Surface Mounted Devices
TBO Time Between Overhaul
TC Type certificate
part no. part number
TOA Table Of Amendments
TOC Table of content
TPS Throttle Position Sensor
TSN Time Since New
TSNP Time Since New Part
TSO Time Since Overhaul
V Volt
VFR Visual Flight Rules
LEP List of Effective Pages
MM Maintenance Manual
MEP Multi Engine Piston
X3 Connector on Engine Management System wiring harness which
serves as an interface for power supply
XXXX shows the serial component number
00–00–00
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