Rotax 24-30-00 Original operating manual

08 February 2019 Current valid documentation see: 24-30-00
Initial Issue www.flyrotax.com Page 1 of 21
Copyright - BRP-Rotax GmbH & CO KG. All rights reserved.
d06515.fm
SI-PAC-001
SERVICE INSTRUCTION - PAC
External alternator for ROTAX®Engine Type 915 i (Series)
ATA System: 24-30-00 External alternator
1) Planning information
“PAC” Service Instruction Documents provide detailed information on non-certified ROTAX®
Aircraft Engine Parts and Accessories. Referenced parts and accessories are provided without
EASA certification or ASTM compliance. Certification / Compliance of referenced Parts and
Accessories must be completed by the aircraft OEM.
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
Refer to the latest issue of the relevant Illustrated Parts Catalog.
1.2) Concurrent ASB/SB/SI and SL
None.
1.3) Reason
An external alternator is not included in the scope of delivery for 915 i Series aircraft engines. An
external alternator set part no. 887259 is available which includes brackets for 915 i Series gear-
box mounting.
1.4) Subject
External alternator for ROTAX®Engine Type 915 i (Series).
1.5) Compliance
NONE - For Information Only.
1.6) Approval
None.
1.7) Labor time and credit
Estimated labor hours:
Engine installed in the aircraft - - - labor time will depend on airframe installation and therefore no
estimate is available from the engine manufacturer.
1.8) Mass data
Change of weight - - - see section 3.1).
Moment of inertia - - - to be calculated by aircraft manufacturer.
1.9) Electrical load data
See Chapter 3.
mWARNUNG
NOTICE
The external alternator is not a part of the Engine Type Design. The exter-
nal alternator has been tested and released by BRP-Rotax, but it is not
certified.
The correct function in conjunction with the entire system and the certifica-
tion of the external alternator is the responsibility of the aircraft manufactu-
rer and must be carried out jointly with the aircraft.

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SI-PAC-001
SERVICE INSTRUCTION - PAC
1.10) Software modifications
No change.
1.11) References
In addition to this technical information refer to current issue of
- Illustrated Parts Catalog (IPC)
- Maintenance Manual Line (MML)
- Maintenance Manual Heavy (MMH)
NOTE: The status of the Manuals can be determined by checking the table of amendments.
The 1st column of this table shows the revision status. Compare this number to that
listed on the ROTAX website:
www.FLYROTAX.com. Updates and current revisions can be downloaded for free.
1.12) Other Publications affected
None.
1.13) Interchangeability of parts
- Not affected

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SERVICE INSTRUCTION - PAC
08 February 2019 24-30-00
Initial Issue Page 3 of 21
Copyright - BRP-Rotax GmbH & CO KG. All rights reserved.
2) Material Information
2.1) Material- cost and availability
Price and availability will be provided on request by ROTAX®Authorized Distributors or their inde-
pendent Service Centers.
2.2) Company support information
- Any possible support by BRP-Rotax will be provided on request by ROTAX®Authorized Dis-
tributors or their independent Service Centers.
2.3) Material requirement and credit per engine
parts requirement:
NOTE: Refer to the latest issue of the relevant Illustrated Parts Catalog.
2.4) Material requirement and credit per spare part
None.
2.5) Rework of parts
None.
2.6) Special tooling/lubricants- /adhesives- /sealing compounds
None.
Fig.no. part no. Qty/
engine Description Application
1 887259 1 Alternator set 915 i Series

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SI-PAC-001
SERVICE INSTRUCTION - PAC
3) Accomplishment/Instructions
-ROTAX
®reserves the right to make any amendments to existing documents, which might
become necessary due to this standardization, at the time of next revision or issue.
NOTE: Before maintenance, review the entire documentation to make sure you have a com-
plete understanding of the procedure and requirements.
Accomplish-
ment
All measures must be implemented and confirmed by at least one of the following persons or
organizations:
-ROTAX
®- Airworthiness representatives
-ROTAX
®- Authorized Distributors or their independent Service Centers
- Persons approved by the respective Aviation Authority
- Persons with approved qualifications for the corresponding engine types. Only authorized per-
sons (iRMT, Level Heavy Maintenance) are entitled to carry out this work
NOTE: All work has to be performed in accordance with the relevant Maintenance Manual.
Safety notice
NOTE: Indicates supplementary information which may be needed to fully complete or under-
stand an instruction.
mWARNUNG
mWARNING
Identifies an instruction which, if not followed, may cause serious in-
jury or even fatal injury.
mWARNUNG
mCAUTION
Identifies an instruction which, if not followed, may cause minor or
moderate injury.
mWARNUNG
NOTICE
Identifies an instruction which, if not followed, may severely damage
the engine or could void any warranty.
ENVIRONMENTAL NOTE
Environmental notes give you tips on environmental protection.

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08 February 2019 24-30-00
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3.1) Installation - related information
Optional
extras
- External alternator (as option if the output of the integrated generator is inadequate).
3.1.1) Technical data
General note NOTE: The voltage regulator is integrated in the alternator.
Output Max. 550 W/DC at 6000 r.p.m. (complies ~ 4800 r.p.m. crankshaft speed).
Output voltage 14.2 V - 14.8 V.
Ambient temp. Ambient temperature range:
Weight Weight: 3.0 kg (6.61 lbs).
3.1.2) Connections
See Fig. 1.
Power supply
wires
Power supply wires to external alternator (1) have to be installed depending on the mounting posi-
tion and according to the regulations of the aircraft manufacturer.
Positive termi-
nal
Positive terminal (2):
M6 screw connection suitable for cable terminal according to DIN 46225 (tightening torque 4 Nm
(35 in. lb)).
Ground Via engine block.
Control wiring Control wiring (3): Via supplied standard plug (Sumitomo 6111-2568) and 6.3x0.8 Faston connec-
tors (female).
Fig. 1.
Min. Max.
-30 °C (-22 °F) +90 °C (194 °F)
IG
LB
Cyl. 1
Cyl. 3
Cyl. 2
Cyl. 4
1 External alternator
2 Positive terminal
3 Control wiring
1
03199

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SERVICE INSTRUCTION - PAC
3.1.3) Requirements for correct operation of the integrated rectifier regulator
Fuse The rectifier regulator must be protected by a slow blowing fuse or circuit breaker. Fuse or circuit
breaker rating must be determined by load, wire size and length.
Load distrubu-
tion
Due to slightly different output voltages of the regulators (alternator and regulator A/B of fuse box)
the power is drawn by the generator with the higher output voltage at low load.
Amperage See Fig. 2.
- Ambient temperature: 20 °C (68 °F)
- Voltage: constant 13.5 V
- Tolerance: max. ± 5 %
NOTE: The speed of the external alternator is 1.18 times the crankshaft speed or 3 times the
propeller speed.
Fig. 2
mWARNUNG
NOTICE
The current over engine speed graph was determined and is only effective
under the following conditions.
1/min. / rpm.
2000 3000 4000 5000 6000 7000 8000 n Generator
rpm. alternator
(A)
10
20
30
40
50
1000 1500 2000 2500 n Propeller
rpm. propeller
00547

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Wiring dia-
gram
Fig. 3. External alternator .
Fuse Box
Regulator board A Regulator board B ECU
123
Battery
Master switch Circuit breaker
(30 A)
AWG 12
AWG 12
Backup battery switch
(guarded switch) 24
31
Start power switch
(momentary)
1 2
3
4
AWG 12
AWG 12
AWG 12
A
AWG 04
AWG 12
X3
M
Start Relais
E-Starter
AWG 12
AWG 12
V
912 iS wiring harness
Airframe Ground
EMS ground
AWG 04 (21,1 mm²) AWG 12 (3,3 mm²) AWG 16 (1,50 mm²) AWG 18 (1,00 mm²) AWG 20 (0,75 mm²)
Optional (not required)
Circuit breaker
(30 A)
AWG 06
AWG 08
AWG 08
AWG 12
B
G
L
External
alternator
Circuit breaker has to
be provided by the
aircraft manufacturer
AWG 12
Indicator
lamp
Circuit
breaker (5 A)
Circuit breaker (Max.
850 W when using an
external alternator)
Circuit breaker
(50 A)
!lternatorFIELD
switch
08255
Bus bar (Airframe)
08255

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SI-PAC-001
SERVICE INSTRUCTION - PAC
3.2) Operation - related information
General The external alternator is a state-of-the-art, electromechanical three-phase generator (compact
generator) with small outer dimensions. It has the task of supplying the electric consumers with
energy and charging the starter battery with the least possible fuel consumption and low noise lev-
els during operation of the aircraft.
Drive Drive is provided by the engine by means of a V-belt.
External alter-
nator
Switch and warning lamp requirements
Switch The representation of components (such as switches, protection devices etc.) that are not
included in the scope of engine delivery is purely symbolic. It does not constitute a specification of
the version and shall therefore only be seen functionally.
The actual interpretation / selection of the corresponding regulations is the task of the aircraft
manufacturer.
Warning
lamps
Mechanical power consumption of the external alternator
Max. 1200 W
EXTERNAL ALTERNATOR
SWITCH Requirement Connector/slot
Switch type Single Pole, Single Throw (SPST) switch
Nominal voltage 28 VDC
Nominal current 5 A
Number of poles 1-pole
Designation on wiring harness Not connected to the wiring harness.
EXTERNAL ALTERNATOR
INDICATOR LAMP Requirement Connector/slot
Lamp colour In accordance with the regulations
Nominal voltage 12 V
Nominal current Maximum 300 mA
Designation on wiring harness Not connected to the wiring harness.

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SERVICE INSTRUCTION - PAC
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3.3) Maintenance (Line) - related information
3.3.1) Checking the V-belt tension
General note In the case of configurations with additional external alternator, inspect attachment and V-belt ten-
sion.
Checking the
V-belt tension
Inspect V-belt tension as per drawing below.
Fig. 4.
3.3.2) Adjust the V-belt tension
Belt tension To adjust the belt tension:
Fig. 5. .
Step Procedure
1 Loosen the hex. screw M10 (1) and the 2 Allen screw M8 (2 and (3).
2 Press the alternator upwards and tighten Allen screw (3).
3 Then tighten Hex. screw M10 (1) with tightening torque 40 NM (30 ft.lb) and Allen
screw M8 (2) with tightening torque 22 Nm (195 in.lb).
mWARNUNG
NOTICE
Deflection of the V-belt must not exceed 6 mm (1/4”) with al load of 50 N
(11 lb) at center.
1 Hex. screw M10
2 Allen screw M8
3 Allen screw M8
1
3
2
00353

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SI-PAC-001
SERVICE INSTRUCTION - PAC
3.4) Maintenance (Heavy) - related information
Safety
information
3.4.1) Preparation
- Loosen pulley tension
- Remove the propeller. See “Documentation of aircraft manufacturer”.
3.4.2) V-Belt pulley -removal
See Fig. 6.
Fig. 6.
3.4.3) Alternator - removal
See Fig. 7 to Fig. 10.
mWARNUNG
mWARNING
Danger of damage to engine!
There is a risk of short circuits and cable fires during work on the electric
system. All installation work on the electric system should be carried out
with the engine switched “OFF” and the battery (negative terminal) dis-
connected.
Ignition, main and Lane selector switches must be “OFF”.
Step Procedure
1 Loosen 8 Allen screws M5x16 with lock washers.
2 Remove pulley carries, V-belt pulley and V-belt.
1 Allen screw M5x16
2 Lock washer A5
3 Pulley carries
4 V-belt pulley
5 V-belt
Step Procedure
1 Loosen 2 hex. screws M8x20 along with lock washers and washers.
2 Remove the tension bar underneath the external alternator.

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Fig. 7.
Fig. 8.
Step Procedure
3 Loosen hex. screw M10x45 and remove the alternator and thrust washer.
Step Procedure
4 Loosen Allen screws M8x20 along with lock washers and remove the alternator
bracket.
1 Hex. screws M8x20
2 Lock washer A8
3 Washer 8.4
4 Tension bar
1 Hex. screws M10x45
2 Thrust washer 10.1/20/0.5
3 External alternator

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SERVICE INSTRUCTION - PAC
Fig. 9.
Fig. 10.
3.4.4) Fitting of the V-belt
See Fig. 11.
Step Procedure
5 Remove 2 Allen screws M6x50 along with lock washers and washers from the gear-
box housing and alternator support assy..
1 Alternator bracket assy.
2 Lock washer VHZ 8
3 Allen screw M8x20
1 Alternator support assy.
2 Lock washer A6
3 Allen screw M6x50
Step Procedure
1 Clean and inspect propeller flange.
2 Place V-belt pulley completely over propeller flange and insert the 9.5x675
V-belt loosely into the V-belt pulley.

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Fig. 11.
See .
Fig. 12 .
mWARNUNG
NOTICE
The two pulley carries must sit with the centring exactly on the inner side
of the propeller flange.
Step Procedure
2 Insert both pulley carriers with the centring towards the inner side of the propeller
flange,
3 Push the V-belt pulley onto the two pulley carries and tighten with 8 Allen screws
M5x16 and lock washers.
Tightening torque 6 Nm (53.09 in. lb).
1 V-belt pulley
2 V-belt 9.5x675
3 Propeller flange
1 Allen screws M5x16
2 Lock washer M5
3 Pulley carrier

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SERVICE INSTRUCTION - PAC
3.4.5) Installation of the alternator
See Fig. 13.
Fig. 13.
Fig. 14.
Step Procedure
1 Fix the alternator support finger-tight by means of 2 Allen screws M6x50 and lock
washers.
Step Procedure
2 Attach the alternator bracket finger-tight to the gearbox housing using the 2 Allen
screws M8x20 and lock washers VHZ 8.
1 Alternator support assy.
2 Lock washer A6
3 Allen screws M6x50
1 Alternator bracket assy.
2 Allen screws M8x20
3 Lock washers VHZ 8

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Fig. 15.
Fig. 16.
Step Procedure
3 Push the alternator into the lug of the alternato bracket and fix initially finger-tight with
hex. screws M10x45 and thrust washer 10.1/20/0.5.
Step Procedure
4 Tighten the pre-mounted Allen screws M6 and M8.
Tightening torque 10 Nm (89 in. lb).
5 Place the V-belt in the V-belt pulley of the alternator.
1 Alternator
2 Washer 10.1/20/0.5
3 Hex. screw M10x45
1 V-belt 9.5x675
2 Allen screw M8x20
3 Allen screws M6x50

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Fig. 17.
3.4.6) V-belt tension
See Chapter 3.3) Maintenance (Line) section 3.3.2) Adjust the V-belt tension.
Step Procedure
6 Attach the tension bar finger-tight to the alternator bracket using 2 hex. screws M8x20
with a lock washer and a washer.
Step Procedure
7 Adjust the pulley tension and tighten M10 and M8 hex. screws with safety wire.
Tightening torque M10: 40 Nm (354 in.lb).
Tightening torque M8: 22 Nm (194.7 in.lb).
1 Hex. screws M8x20
2 Lock washer A8
3 Washer 8.4
4 Tension bar

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3.5) Connecting the external alternator into the electric circuit
There are two options for connection of the external alternator:
OPTION A: Connection to main switch at battery. See Fig. 18.
Fig. 18
Step OPTION A - Procedure
1 Connect alternator terminal “B” to the main switch at the battery with a flexible multi-
strand wire with proper cross-section according to the requirements in the relevant
aircraft installation and a 50 A fuse.
2 Connect terminals “IG” and “L” into the circuit in accordance with the wiring diagram
(Fig. 3) using connectors and housing provided.
L
B
IG
L = Terminal “L”
IG = Terminal “IG”
B = Terminal “B”
00335

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OPTION B: Connection as replacement of generator B and rectifier regulator B.
See Fig. 19.
Fig. 19
See Fig. 20
Fig. 20
Step OPTION B - Procedure
1 Dis-connect the generator connector (1) from regulator B (2) by pressing on the plas-
tic tab and pulling the connectors apart.
Step OPTION B - Procedure
2 Insert DEUTSCH dummy plug (1) into open connector on rectifier regulator and
DEUTSCH dummy plug into the open Generator B connector (2).
3 Connect alternator terminal “B” to pin 2 (1) of the fusebox “X3” connector.
4 Ensure that ground stud (2) for regulator rectifier B is connected to airframe ground
with flexible multi-strand wire of min. 4 mm2cross section (12 AWG).
1 Connection socket
2 Controller connector
1 Connection socket
2 Controller connector
1 Pin 2
2 Ground stud
10126
10127

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Fig. 21
Step OPTION B - Procedure
5 Connect terminals “IG” and “L” into the circuit in accordance with the wiring diagram
(Fig. 3) using connectors and housing provided.
6 Using a multimeter (1), check for continuity between the ground connections regula-
tor A (2) and the ground connections regulator B (3). Continuity must NOT be present.
1 Multimeter
2 Rectifier regulator A
3 Rectifier regulator B
4 Ground connections regulator A
5 Ground connections regulator B

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Dynamic propeller balance
Dynamic propeller balancing is required after external alternator set installation. Max tolerated
imbalance is 0.5 gram (0.0011 lb) or industry standard of max. 0.05 IPS.
- Restore aircraft to original operating configuration.
- Connect negative terminal of aircraft battery.
3.6) Test run
Conduct test run. See Chapter 12-20-00 of the latest Maintenance Manual Line for the respective
engine type.
3.7) Summary
The execution of the Service Instruction - PAC must be confirmed in the logbook.
A revision bar outside of the page margin indicates a change to text or
graphic.
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.
3.8) Inquiries
Inquiries regarding this Service Instruction - PAC should be sent to the ROTAX®Authorized Dis-
tributor of your area.
A list of all ROTAX®Authorized Distributors or their independent Service Centers is provided on
www.flyrotax.com.
mWARNUNG
NOTICE
Engine vibrations can be caused by an improperly balanced propeller.
Operation without dynamic propeller balancing may cause engine dama-
ge.