Rotax 915 i A SERIES User manual

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter: LEP
LIST OF EFFECTIVE PAGES
Each new edition to the Maintenance Manual will have a new List of Effective Pages.
Chapter Page Date
Title page
INTRO 1June 01 2019
2June 01 2019
LEP 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 01 2019
10 June 01 2019
TOA 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
00-00-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 01 2019
10 June 01 2019
Chapter Page Date
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
29 June 01 2019
30 June 01 2019
31 June 01 2019
32 June 01 2019
33 June 01 2019
34 June 01 2019
24-20-00 1 June 01 2019
2 April 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 1 LEP
Page 1
June 01 2019

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter Page Date
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
61-20-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
Chapter Page Date
7June 01 2019
8June 01 2019
9June 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
71-00-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
LEP
Page 2
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 1

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter Page Date
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
72-00-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
72-10-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
Chapter Page Date
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
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
47 June 01 2019
48 June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 1 LEP
Page 3
June 01 2019

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter Page Date
49 June 01 2019
50 June 01 2019
51 June 01 2019
52 June 01 2019
72-20-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
72-30-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 01 2019
10 June 01 2019
Chapter Page Date
11 June 01 2019
12 April 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
30 June 01 2019
31 June 01 2019
32 June 01 2019
33 June 01 2019
34 June 01 2019
35 June 01 2019
36 June 01 2019
37 June 01 2019
38 June 01 2019
72-30-10 1 June 01 2019
2June 01 2019
LEP
Page 4
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 1

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter Page Date
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
73-00-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
73-10-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
Chapter Page Date
7June 01 2019
8June 01 2019
9June 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
30 June 01 2019
31 June 01 2019
32 June 01 2019
33 June 01 2019
34 June 01 2019
35 June 01 2019
36 June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 1 LEP
Page 5
June 01 2019

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter Page Date
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
47 June 01 2019
48 June 01 2019
74-00-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
74-20-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 01 2019
10 June 01 2019
11 June 01 2019
12 June 01 2019
13 June 01 2019
14 June 01 2019
Chapter Page Date
15 June 01 2019
16 June 01 2019
75-00-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
LEP
Page 6
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 1

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter Page Date
29 June 01 2019
30 June 01 2019
76-00-00 1 June 01 2019
2June 01 2019
76-10-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
76-20-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
Chapter Page Date
9June 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
76-50-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
Effectivity: 915 i A Series
Edition 0/Rev. 1 LEP
Page 7
June 01 2019

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter Page Date
23 June 01 2019
24 June 01 2019
76-70-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
Chapter Page Date
29 June 01 2019
30 June 01 2019
31 June 01 2019
32 June 01 2019
33 June 01 2019
34 June 01 2019
78-00-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
78-10-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 01 2019
10 June 01 2019
11 June 01 2019
12 June 01 2019
78–20–00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
LEP
Page 8
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 1

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter Page Date
9June 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
79-00-00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
9June 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
Chapter Page Date
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
80–00–00 1 June 01 2019
2June 01 2019
3June 01 2019
4June 01 2019
5June 01 2019
6June 01 2019
7June 01 2019
8June 01 2019
Index
Rear page
Effectivity: 915 i A Series
Edition 0/Rev. 1 LEP
Page 9
June 01 2019

Page 10
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 0
INTENTIONALLY LEFT
BLANK
BRP-Rotax
MAINTENANCE MANUAL HEAVY

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Chapter: TOA
TABLE OF AMENDMENTS
Approval*
The technical content of this document is approved under the authority of DOA ref. EASA.21.J.048.
This document is part of the ICA for product [2019].
Current
no.
Chapter Page Date of change Remark for
approval
Date of
approval
from
authori-
ties
Date of
inclusion
Signature
0 INTRO all August 01 2018 DOA*
0 LEP all August 01 2018 DOA*
0 TOA all August 01 2018 DOA*
0 00-00-00 all August 01 2018 DOA*
0 24-20-00 all August 01 2018 DOA*
0 61-20-00 all August 01 2018 DOA*
0 71-00-00 all August 01 2018 DOA*
0 72-00-00 all August 01 2018 DOA*
0 72-10-00 all August 01 2018 DOA*
0 72-20-00 all August 01 2018 DOA*
0 72-30-00 all August 01 2018 DOA*
0 72-30-10 all August 01 2018 DOA*
0 73-00-00 all August 01 2018 DOA*
0 73-10-00 all August 01 2018 DOA*
0 74-00-00 all August 01 2018 DOA*
0 74-20-00 all August 01 2018 DOA*
0 75-00-00 all August 01 2018 DOA*
0 76-00-00 all August 01 2018 DOA*
0 76-10-00 all August 01 2018 DOA*
0 76-20-00 all August 01 2018 DOA*
0 76-50-00 all August 01 2018 DOA*
0 76-70-00 all August 01 2018 DOA*
Effectivity: 915 i A Series
Edition 0/Rev. 1 TOA
Page 1
June 01 2019

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Current
no.
Chapter Page Date of change Remark for
approval
Date of
approval
from
authori-
ties
Date of
inclusion
Signature
0 78-00-00 all August 01 2018 DOA*
0 78-10-00 all August 01 2018 DOA*
0 78-20-00 all August 01 2018 DOA*
0 79-00-00 all August 01 2018 DOA*
0 80-00-00 all August 01 2018 DOA*
Current
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*
1 TOA all June 01 2019 DOA*
1 00-00-00 3,8,15 June 01 2019 DOA*
1 71-00-00 6, 20 June 01 2019 DOA*
1 72-10-00 all June 01 2019 DOA*
1 72–30–10 6 June 01 2019 DOA*
1 73-10-00 46 June 01 2019 DOA*
1 76-20-00 8 June 01 2019 DOA*
1 78-20-00 16,18 June 01 2019 DOA*
1 79-00–00 all June 01 2019 DOA*
TOA
Page 2
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 1

BRP-Rotax
MAINTENANCE MANUAL HEAVY
Summary of amendments
Summary of the relevant amendments in this context, but without any claim to completeness.
Current
no.
Chapter Page Date of
change
Comment
1 00–00–00 3,4 June 01 2019 New configuration 2. New - wiring color codes
1 72–10–00 all June 01 2019 Change of text and figures. New - Configuration 2
1 78–20–00 16,18 June 01 2019 Change of text. New - Adjustment of the wastegate
Effectivity: 915 i A Series
Edition 0/Rev. 1 TOA
Page 3
June 01 2019

Page 4
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 0
INTENTIONALLY LEFT
BLANK
BRP-Rotax
MAINTENANCE MANUAL HEAVY

BRP-Rotax
MAINTENANCE MANUAL HEAVY
TYPE DESCRIPTION
The type description consists of the following parts:
e. g. ROTAX 915 iSc 2 A
type certification configuration additional designation
Designation
Designation Description
Type 915 4-cylinder horizontally opposed, turbocharged engine.
Certification iSc Certified to EASA CS-E (TC No.EASA.E.121)
iS Approved to according ASTM F2339.
Configuration 2 Propeller shaft with flange for fixed pitch propeller.
3Propeller shaft with flange for constant speed propeller and drive for
hydraulic governor for constant speed propeller.
Additional
designation
AStandard version
Options
Available options (optional equipment) for the engine type mentioned above:
external alternator governor exhaust system
for configuration 2 YES NO YES
for configuration 3 YES YES YES
NOTE
Conversion of the version 2 to version 3 and vice versa may be accomplished by
BRP-Rotax Authorized Distributors or their Service Center.
Effectivity: 915 i A Series
Edition 0/Rev. 1 00–00–00
Page 3
June 01 2019

BRP-Rotax
MAINTENANCE MANUAL HEAVY
ABBREVIATIONS AND TERMS
Abbreviations Description
* Reference to another section
@center of gravity
The drop symbol indicates use of sealing agents, adhesives or lubricants (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
00–00–00
Page 4
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 0

BRP-Rotax
MAINTENANCE MANUAL HEAVY
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 inter-
face for power supply
XXXX shows the serial component number
Effectivity: 915 i A Series
Edition 0/Rev. 0 00–00–00
Page 7
June 01 2019

BRP-Rotax
MAINTENANCE MANUAL HEAVY
WIRING COLOR CODES
Figure 1.2
00–00–00
Page 8
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 1

BRP-Rotax
MAINTENANCE MANUAL HEAVY
INSTRUCTION
Engines require instructions regarding their installation, application, use, operation, main-
tenance and repair.
Technical documentation and regulations are useful and necessary complementary ele-
ments for trainings, but can by no means substitute for theoretical and practical
instructions.
These instructions should cover explanation of the technical context, advice for operation,
maintenance, installation, use and operational safety of the engine.
Safety notice
In this technical Manual passages concerning safety are especially marked. Pass on
safety warnings to other users!
Accessories
This engine must only be operated with accessories supplied, recommended and re-
leased by BRP-Rotax. Modifications are only allowed after consent of the engine
manufacturer.
Spare parts
See Illustrated Parts Catalog, latest issue for the respective engine type.
ATTENTION
Only use GENUINE ROTAX® spare parts. Spare parts must meet the require-
ments defined by the engine manufacturer. This can only be guaranteed when us-
ing GENUINE-ROTAX®-spare parts and/or accessories. Spare parts are available
at ROTAX® Authorized Distributors and their independent Service Centers. Any
warranty by BRP-Rotax will become void if spare parts and/ or accessories other
than GENUINE-ROTAX®-spare parts and/or accessories are used (see latest War-
ranty Conditions).
See relevant Service Letter on www.FLYROTAX.com
Standard tools / Special tools
ATTENTION
Only use tools and appliances which are suitable for the relevant task according
to the latest Manuals.
State of delivery
mWARNING
Engine and gearbox are delivered in “dry“ conditions (without fuel, oil and
coolant).
Before putting the engine into operation it must be filled with oil and cooling liquid. Use
only oil and coolant as specified.
Effectivity: 915 i A Series
Edition 0/Rev. 1 00–00–00
Page 13
June 01 2019

BRP-Rotax
MAINTENANCE MANUAL HEAVY
See latest Operators Manual and Service Instruction SI-915 i-001 “Selec-
tion of suitable operating fluids“, current issue.
MAINTENANCE CONCEPT
General note
The maintenance functions detailed in this Manual are divided into two categories:
• Maintenance I (Line Maintenance)
• Maintenance II (Heavy Maintenance)
Repairs beyond the levels detailed in Manual I and Maintenance Manual II are not recom-
mended as maintenance functions and must be conducted by an authorized overhaul
facility.
Maintenance I (Line Maintenance)
Chapter 00,05 and 12
The scope of line maintenance consists of servicing and adjustment of engine compo-
nents (including part wear). All procedures in this Manual are to be considered line
maintenance.
NOTE
Where applicable, you will be referred to the Heavy Maintenance Manual for work
above and beyond line maintenance.
Maintenance II (Heavy Maintenance)
Separate Manual.
Maintenance Manual II details removal, installation and repair of components or parts nor-
mally considered beyond the scope of the "Line Maintenance".
NOTE
This Manual can only be used in combination with Maintenance Manual I (Line
Maintenance), as it builds upon it.
00–00–00
Page 14
June 01 2019
Effectivity: 915 i A Series
Edition 0/Rev. 0