Rotax 912 i series Operating instructions

03 July 2019 Current valid documentation see: 76-10-00
Initial Issue www.flyrotax.com Page 1 of 18
Copyright - BRP-Rotax GmbH & Co KG. All rights reserved.
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SI-912 i-024
SI-915 i-006
SERVICE INSTRUCTION
Introduction of a new connector for regulator B for ROTAX®
Engine Type 912 i, 915 i A and 915 i B (Series)
ATA System: 76-10-00 Fuse Box
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® engine types:
NOTE: On engines with S/N higher than the ranges listed above, new style connector has
already been fitted in serial production.
NOTE: On engines with S/N lower than the ranges listed above, the regulator B or stator assy.
connections can be modified for exchange or repair of the relevant component. The
modifications on the rectifier regulator B can be performed at a maintenance, repair or
operation (MRO) event as per section 3.
NOTE: It is NOT mandatory to retrofit engines with old style regulator B and stator connector.
1.2) Concurrent ASB/SB/SI and SL
In addition to this Service Instruction the following Service Bulletin/Service Instruction must be
observed and complied with:
Service Bulletin-SB-912 i-006, title “Exchange of stator assy.“, current issue.
Service Instruction-SI-912 i-004, title “Replacement of regulator A and regulator B“, current issue.
1.3) Reason
In the course of further development and standardization, a new connector for rectifier regulator B
has been introduced. The new connector allows higher current draw.
1.4) Subject
Introduction of a new connector for regulator B for ROTAX® Engine Type 912 i, 915 i A and
915 i B (Series).
1.5) Compliance
NONE - For Information Only.
1.6) Approval
The technical content of this document is approved under the authority of DOA ref.
EASA.21J.048.
Engine type Serial number
912 i Series optional
915 iSc A from S/N 9127323
915 iS A from S/N 9132300
915 iSc B from S/N 9122524

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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 - - - none.
Moment of inertia - - - unaffected.
1.9) Electrical load data
No change.
1.10) Software modifications
No change.
1.11) References
In addition to this technical information refer to current issue of
- Illustrated Parts Catalog (IPC)
- Installation Manual (IM)
- 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 the one
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
All parts are interchangeable with relevant modifications.

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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 and credit per engine
Parts requirement for connector gasket replacement:
* Please contact your aircraft manufacturer for further support on material and instructions for pos-
sible further aircraft related modifications.
2.4) Material requirement and credit per spare part
None.
2.5) Rework of parts
None.
Fig.no. New p/n Qty/
engine Description Application
951981 1 Connector bracket*
481510 1 Connector set stator Lane B
consist of:
864590 1 Connector housing Amphenol®
864595 1 Connector housing Amphenol®
864600 4 Faston connector housing Amphenol®
864605 4 Contact pin male Amphenol®
864610 2 Sealing plug

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SI-912 i-024
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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:
* or equivalent
Milspec no. Description Qty/
engine
Part
no. Application
M22520/1-01 Adjustable crimp tool
(DMC®AF8 or equivalent)* 1n.a.
M22520/1-05 Adjustable positioner
(DMC®UH2-5 or equivalent)* 1n.a.
-Extraction tool
(DMC®QXRT08 or equivalent)* 1n.a.
mWARNUNG
NOTICE
If using these special tools observe the manufacturers specifications.

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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
®- Authorized Distributors or their independent Service Centers
- 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.
NOTE: Indicates supplementary information which may be needed to fully complete or under-
stand an instruction.
3.1) Installation - related information
3.2) Maintenance (Line) - related information
3.3) Maintenance (Heavy) - related
For the modification of old style connector the following assembly steps do apply:
Pay attention to the specifications of the latest version of the Installation Manual (IM)
for the respective engine type.
See relevant Maintenance Manual (Line) for the respective engine type and its period-
ical maintenance information.
Points of inspection
Interval
Operating hours Chapter
reference
100 h 200 h
Visual inspection of the wiring harness,
connectors and brackets for secure fit,
damage and signs of wear.
x 12-20-00 section 15.1
Pay attention to the specifications of the latest version of the Maintenance Manual
Heavy (MMH) Chapter 76-10-00 section Fuse box installation for the respective engine
type.

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SI-912 i-024
SI-915 i-006
SERVICE INSTRUCTION
3.3.1) Replacement of male connector (regulator side)
In order to preserve maximum wire length, remove the wires with crimped male pins from regula-
tor B connector housing (gray).
Fig. 1
Fig. 2
Step Procedure
1Label each of the 3 yellow wires with its location within the connector. The rear of the
connector housing (1) is marked with numbers.
2 Gently pry the rectangular rubber seal (2) from the rear of the connector.
Step Procedure
3 Using fine-nosed pliers, pull the retaining wedge (5) from the connector housing.
1 Connector housing
2 Rubber seal
3 Retaining sleeve
4 Sealing ring
5 Retaining wedge

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Fig. 3
Attach Amphenol® male connector to regulator B
The following instructions depict the use of DMC® adjustable crimp tools. These tools or equiva-
lent are required to correctly attach connecting pins.
Step Procedure
4Remove pins from connector housing by releasing plastic retaining tabs (6) and pull-
ing wires from behind.
5 Cut off each wire at crimped pins (7) with a standard cutter.
6Ensure that wires are still clearly numbered and pull rectangular rubber seal from the
wires.
mWARNUNG
mWARNING
Failure to use correct crimping tool(s) may lead to engine damage, person-
al injury or death.
Step Procedure
1
Carefully strip off approximately 10 mm (0.39 in.) of insulation from each of the three
yellow wires.
NOTE: Use a quality wire-stripping tool set to 12 AWG (3.31 mm2) to avoid dam-
aging wire strands.
2 Set the crimp tool’s wire size to 12 AWG (3.31 mm2) (8).
3Stripped wires must seat fully into crimp pin and have approximately 1 mm (0.039 in.)
insulation gap (9).
6 Retaining tabs
7 Cut off pins

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SI-912 i-024
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Fig. 4
Fig. 5
Step Procedure
4
Place the connector pin into crimp tool with crimp-barrel facing outwards. Adjust po-
sitioner until crimp-barrel protrudes approximately 1 to 2 mm (0.039 in. to 0.08 in.)
from the tool face (10).
5
Place stripped wire fully into crimp-barrel and hold in place while crimp tool is com-
pressed by hand until fully closed.
NOTE: Crimp tool incorporates a ratcheting mechanism that requires the crimp
tool to be fully closed before releasing.
Step Procedure
6
Remove the wire and crimped connector pin from crimp tool and inspect for correct
crimping.
NOTE: Wire strands must be visible in witness hole (11) and crimps must be
between the witness hole and the end of the crimp-barrel (12).
8 12 AWG (3.31 mm2)
9 1 mm (0.039 in.)
10 Tool face 1 - 2 mm
(0.039 in to 0.08 in.)

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Fig. 6
Assembly of the connector housing Amphenol® part no. 864595
Place numbered wires in the following alphabetical positions:
Fig. 7
Step Procedure
1 Place rear connector screw cap over wires (13).
2
Push connector pins and wires through round rubber seal (14).
NOTE: New connector positions are marked A through D (15), whereas wires
were marked 1 through 4 from old connector positions.
Wire Connector position
1A
2B
3C
Step Procedure
3 Slide plastic sleeve (16) into the back of connector housing, aligning the keyway (17).
11 Witness hole
12 Crimp-barrel
13 Screw cap
14 Rubber seal
15 Position letter
16 Sleeve
17 Key

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Fig. 8
Fig. 9
Step Procedure
4
Push each wire into connector until its pin snaps securely in place.
NOTE: Correctly secured pin (18) will travel further into connector and lock in
place. Removal requires using extractor tool.
Step Procedure
5With all connector pins secured, push the rubber seal into the plastic ring and screw
on connector cap (20).
6 Place plastic sealing plug into empty position in rear seal (21).
18 Secured pin
19 Un-secured pin
20 Connector cap
21 Sealing plug

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3.3.2) Replacement of female connector (Stator side)
In order to preserve maximum wire length, remove the wires with crimped female pins from Stator
B connector housing (gray).
Fig. 10
Fig. 11
Step Procedure
1Label each of the 3 yellow wires with its location within the connector. The rear of the
connector housing is marked with numbers (1).
2 Gently pry the rectangular rubber seal (2) from the rear of the connector.
Step Procedure
3 Using fine-nosed pliers, pull the retaining wedge (3) from the connector housing.
4Remove pins from connector housing by releasing plastic retaining tabs (4) and pull-
ing wires from behind.
Step Procedure
5 Cut each wire at crimped pins (5).
6Ensure that wires are still clearly numbered and pull rectangular rubber seal (6) from
the wires.
1 Connector housing
with numbers
2 Rubber seal
3 Retaining wedge
4 Retaining tab

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SI-912 i-024
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SERVICE INSTRUCTION
Fig. 12
Attach Amphenol® female connector to Stator B
The following instructions depict the use of DMC® adjustable crimp tools. These tools or equiva-
lent are required to correctly attach connecting pins.
Fig. 13
mWARNUNG
mWARNING
Failure to use correct crimping tool(s) may lead to engine damage, person-
al injury or death.
Step Procedure
1
Carefully strip back approximately 10 mm (0.390 in.) of insulation from each of the
three yellow wires (7).
NOTE: Use a quality wire-stripping tool set to 12 AWG (0.0 mm2) to avoid dam-
aging wire strands.
2 Set the crimp tool’s wire size to 12 AWG (0.0 mm2) (8).
3Stripped wires must seat fully into crimp pin and have approximately 1 mm (0.039 in.)
gap to insulation (9).
5 Cut off pins
6 Rubber seal
7 10 mm (0.390 in.)
8 12 AWG
9 1 mm (0.039 in.)

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Fig. 14
Fig. 15
Step Procedure
4Place the connector pin into crimp tool with crimp-barrel facing outwards. Adjust po-
sitioner until crimp-barrel is flush with the tool (10).
5
Place stripped wire fully into crimp-barrel and hold in place while crimp tool is com-
pressed by hand until fully closed.
NOTE: Crimp tool incorporates a ratcheting mechansim that requires the crimp
tool to be fully closed before releasing.
Step Procedure
6
Remove the wire and crimped connector pin from crimp tool and inspect for correct
crimping.
NOTE: Wire strands must be visible in withness hole (11) and crimps must be
between the witness hole and the end of the crimp-barrel (12).
10 Flush
11 Witness hole
12 Crimps

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SI-912 i-024
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SERVICE INSTRUCTION
Assembly of the connector housing Amphenol® part no. 864590
Place numbered wires in the following alphabetical positions:
Fig. 16
Step Procedure
1 Place rear connector screw cap over wires (13).
2
Push connector pins and wires through round rubber seal (14).
NOTE: New connector positions are marked A through D (15), whereas the gray
housing was marked 1 through 4.
Wire Connector position
1A
2B
3C
Step Procedure
3 Place plastic sleeve over wires with key slot (16) towards connector.
Step Procedure
4
Push each wire into connector until its pin snaps securely in place.
NOTE: Correctly secured pins will travel further into connector (18) and lock in
place. Removal requires using extractor tool.
13 Screw cap
14 Rubber seal
15 Position letters
16 Key slot

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Fig. 17
Fig. 18
Step Procedure
5With all connector pins secured, place the plastic ring into the connector housing,
while aligning the keyway.
6 Push the rubber seal into the plastic ring and screw on connector cap (20).
7 Place plastic sealing plug into empty position in rear seal (21).
17 Example for secured pin
18 Example for un-secured pin
19 Cap
20 Plug

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SI-912 i-024
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3.3.3) Installation of optional support bracket
See Fig. 18 and Fig. 19.
Fig. 19
Step Procedure
1Remove M6 lock nut (1) and washer (2). Remove connector bracket assy. (3) from
the fuse-box connector side of regulator B.
2 Place bracket (4) over attachment stud so that bend faces away from the fuse-box.
3 Attach with M6 washer and new M6 lock nut. Tightening torque 10 Nm (89 in.lb).
Step Procedure
4Remove nut and O-ring from Rectifier B connector.
NOTE: O-ring is not necessary in this application and may be discarded.
5 Place connector through connector bracket (4).
6 Attach with connector nut (5). Tightening torque 10 Nm (89 in.lb).
1 Lock nut M6
2 Washer 6.4
3 Connector bracket assy.
4 Connector bracket part no. 951981

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Fig. 20
- Restore aircraft to original operating configuration
- Connect negative terminal of aircraft battery
3.4) Test run
3.5) Summary
These instructions (section 3) have to be followed in accordance with the deadlines specified in
section 1.5.
The execution of the Service Instruction 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.
3.6) Inquiries
Inquiries regarding this Service Instruction should be sent to the ROTAX®Authorized Distributor
of your area.
A list of all ROTAX®Authorized Distributors or their independent Service Centers is provided on
www.flyrotax.com.
4 Connector bracket
5 Connector nut
Conduct test run. See Chapter 12-20-00 of the latest Maintenance Manual Line for the
respective engine type.

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4) Appendix
The following drawings should convey additional information:
Fig. 21
:
Fig. 22
NOTE: The illustrations in this document show the typical construction. They may not rep-
resent full detail or the exact shape of the parts which have the same or similar
function.
Exploded views are not technical drawings and are for reference only. For specific
detail, refer to the current documents of the respective engine type.
1
1 Connector set stator Lane B
2 Connector bracket
2