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 iS 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 trademark 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.

Effectivity: 915 i A Series
Edition 0/Rev. 0 Content
Page 1
December 01 2017
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
BRP-Rotax
MAINTENANCE MANUAL

Notes
Page 2
December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0
NOTES
BRP-Rotax
MAINTENANCE MANUAL

BRP-Rotax
MAINTENANCE MANUAL
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 Center.
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.
Effectivity: 915 i A Series
Edition 0/Rev. 0 INTRO
Page 1
December 01 2017

Notes
Page 2
December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0
NOTES
BRP-Rotax
MAINTENANCE MANUAL

BRP-Rotax
MAINTENANCE MANUAL
Chapter: LEP
LIST OF EFFECTIVE PAGES
chapter page date
Cover
page
INTRO 1 December 01 2017
2 December 01 2017
LEP 1 December 01 2017
2 December 01 2017
3 December 01 2017
4 December 01 2017
TOA 1 December 01 2017
2 December 01 2017
00-00-00 1 December 01 2017
2 December 01 2017
3 December 01 2017
4 December 01 2017
5December 01 2017
6 December 01 2017
7December 01 2017
8 December 01 2017
9 December 01 2017
10 December 01 2017
11 December 01 2017
12 December 01 2017
13 December 01 2017
14 December 01 2017
15 December 01 2017
16 December 01 2017
04-00-00 1 December 01 2017
2 December 01 2017
05-00-00 1 December 01 2017
2 December 01 2017
3 December 01 2017
chapter page date
4 December 01 2017
5December 01 2017
6 December 01 2017
7December 01 2017
8 December 01 2017
9 December 01 2017
10 December 01 2017
11 December 01 2017
12 December 01 2017
05-10-00 1 December 01 2017
2 December 01 2017
3 December 01 2017
4 December 01 2017
5December 01 2017
6 December 01 2017
05-20-00 1 December 01 2017
2 December 01 2017
3 December 01 2017
4 December 01 2017
5December 01 2017
6 December 01 2017
7December 01 2017
8 December 01 2017
9 December 01 2017
10 December 01 2017
11 December 01 2017
12 December 01 2017
13 December 01 2017
14 December 01 2017
05-50-00 1 December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0 LEP
Page 1
December 01 2017

BRP-Rotax
MAINTENANCE MANUAL
chapter page date
2 December 01 2017
3 December 01 2017
4 December 01 2017
5December 01 2017
6 December 01 2017
7December 01 2017
8 December 01 2017
9 December 01 2017
10 December 01 2017
11 December 01 2017
12 December 01 2017
13 December 01 2017
14 December 01 2017
15 December 01 2017
16 December 01 2017
17 December 01 2017
18 December 01 2017
19 December 01 2017
20 December 01 2017
21 December 01 2017
22 December 01 2017
23 December 01 2017
24 December 01 2017
25 December 01 2017
26 December 01 2017
27 December 01 2017
28 December 01 2017
29 December 01 2017
30 December 01 2017
31 December 01 2017
32 December 01 2017
33 December 01 2017
34 December 01 2017
chapter page date
12-00-00 1 December 01 2017
2 December 01 2017
12-10-00 1 December 01 2017
2 December 01 2017
3 December 01 2017
4 December 01 2017
5December 01 2017
6 December 01 2017
7December 01 2017
8 December 01 2017
9 December 01 2017
10 December 01 2017
12-20-00 1 December 01 2017
2 December 01 2017
3 December 01 2017
4 December 01 2017
5December 01 2017
6 December 01 2017
7December 01 2017
8 December 01 2017
9 December 01 2017
12-20-00 10 December 01 2017
11 December 01 2017
12 December 01 2017
13 December 01 2017
14 December 01 2017
15 December 01 2017
16 December 01 2017
17 December 01 2017
18 December 01 2017
19 December 01 2017
20 December 01 2017
21 December 01 2017
LEP
Page 2
December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0

BRP-Rotax
MAINTENANCE MANUAL
chapter page date
22 December 01 2017
23 December 01 2017
24 December 01 2017
25 December 01 2017
26 December 01 2017
27 December 01 2017
28 December 01 2017
29 December 01 2017
30 December 01 2017
31 December 01 2017
32 December 01 2017
33 December 01 2017
34 December 01 2017
35 December 01 2017
chapter page date
36 December 01 2017
37 December 01 2017
38 December 01 2017
39 December 01 2017
40 December 01 2017
41 December 01 2017
42 December 01 2017
43 December 01 2017
44 December 01 2017
45 December 01 2017
46 December 01 2017
Index
Rear page
Effectivity: 915 i A Series
Edition 0/Rev. 0 LEP
Page 3
December 01 2017

Notes
Page 4
December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0
NOTES
BRP-Rotax
MAINTENANCE MANUAL

BRP-Rotax
MAINTENANCE MANUAL
Chapter: TOA
TABLE OF AMENDMENTS
Approval*
The technical content of this document is approved under the authority of DOA ref.
EASA.21J.048
NNOOTTEE
THE APPROVAL IS GIVEN TO ALL CHAPTERS EXCEPT THE
AIRWORTHINESS LIMITATIONS SECTION 04-00-00 WHICH IS SUBJECT
TO SPECIFIC APPROVAL OF THE EASA.
no. chapter page date of
change
remark for
approval
date of
approval
from
authori-
ties
date of
inclusion
signature
0 INTRO 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*
Effectivity: 915 i A Series
Edition 0/Rev. 0 TOA
Page 1
December 01 2017

BRP-Rotax
MAINTENANCE MANUAL
Summary of amendments
Summary of the relevant amendments in this context, but without requirement on completeness.
no. chapter page date of
change
comment
TOA
Page 2
December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0

BRP-Rotax
MAINTENANCE MANUAL
Chapter: 00–00–00
GENERAL NOTE
TOPICS IN THIS CHAPTER
General....................................................................................................................................................2
Type description......................................................................................................................................3
Abbreviations and terms .........................................................................................................................4
Conversion table ...................................................................................................................................7
Safety notice ...........................................................................................................................................8
Safety information .................................................................................................................................9
Instruction........................................................................................................................................... 11
Maintenance Concept..........................................................................................................................12
Technical documentation......................................................................................................................13
Use for intended purpose .....................................................................................................................15
Effectivity: 915 i A Series
Edition 0/Rev. 0 00–00–00
Page 1
December 01 2017

BRP-Rotax
MAINTENANCE MANUAL
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
continues 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
Page 2
December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0

BRP-Rotax
MAINTENANCE MANUAL
TYPE DESCRIPTION
The type description consists of the following parts:
e. g. ROTAX 915 iSc 3 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 ASTM F2339.
Configuration 3Propeller shaft with flange for constant speed propeller
and drive for hydraulic governor for constant speed
propeller.
Additional
designation
AStandard version
Effectivity: 915 i A Series
Edition 0/Rev. 0 00–00–00
Page 3
December 01 2017

BRP-Rotax
MAINTENANCE MANUAL
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
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
DCDI Dual Capacitor Discharge Ignition
00–00–00
Page 4
December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0

BRP-Rotax
MAINTENANCE MANUAL
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
EN European Norm
ETFE Ethylene Tetrafluoroethylene
FAA Federal Aviation Administration
FAR Federal Aviation Regulations
hr. hours
HIC A Harness Interface Connector A
HIC B Harness Interface Connector B
IFR Instrument Flight Rules
INJ 1–8 Injector 1–8
IPC Illustrated Parts Catalog
ips inch per second
iRMT independent ROTAX Maintenance Training
ISA International Standard Atmosphere
kg Kilograms
KNOCK Knock sensor
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
Effectivity: 915 i A Series
Edition 0/Rev. 0 00–00–00
Page 5
December 01 2017

BRP-Rotax
MAINTENANCE MANUAL
NVFR Night Visual Flight Rules
OHM Overhaul Manual
OHV Over Head Valve
OM Operators Manual
OPS Oil Pressure Sensor
OTS Oil Temperature Sensor
PCV Pressure Control Valve
POA Production Organisation Approval
PTFE Polytetrafluoroethylene
PTO Power Take Off
Rev. Revision
ROTAX® is a trademark of BRP-Rotax GmbH & Co KG
RON Research Octane Number
RON 424 ROTAX® Norm 424
s.v. still valid (only Illustrated Parts Catalog)
S/N Serial Number
SAE Society of Automotive Engineers
SB Service Bulletin
SI Service Instruction
SI-PAC Service Instruction Parts and Accessories
SL Service Letter
SMD Surface Mounted Devices
TBO Time Between Overhaul
TC Type certificate
part no. Part number
TOA Table Of Amendment
TOC Table of content
TSN Time Since New
TSNP Time Since New Part
TSO Time Since Overhaul
V Volt
VFR Visual Flight Rules
LEP List of Effective Pages
00–00–00
Page 6
December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0

BRP-Rotax
MAINTENANCE MANUAL
MM Maintenance Manual
XXXX shows the serial component number
CONVERSION TABLE
Units of length: Units of power:
1 mm = 0.03937 in
1 in = 25.4 mm
1 ft = 12 in
= 0.3048 m
1 kW = 1.341 hp
1 hp = 0.7457 kW
1 kW = 1.3596 PS
1 PS = 0.7355 kW
Units of area: Units of temperature:
1 cm² = 0.155 sq. in (in²)
1 sq. in (in²) = 6.4516 cm²
K = °C – 273,15
°C = (°F – 32) / 1,8
°F = (°C x 1.8) +32
Units of volume: Units of velocity:
1 cm³ = 0.06102 cu in (in³)
1 cu in (in³) = 16.3871 cm³
1 dm³ = 1 l
1 dm³ = 0.21997 gal (UK)
1 gal (UK) = 4.5461 dm³
1 dm³ = 0.26417 gal (US)
1 gal (US) = 3.7854 dm³
1 m/s = 3.6 km/h
1 ft/min = 0.3048 m/min
= 0.00508 m/sec
1 m/s = 196.85 ft/min
1 kt = 1.852 km/h
1 km/h = 0.53996 kn
Units of mass: spec. fuel consumption:
1 kg = 2.2046 lbs.
1 lb. = 0.45359 kg
1 g/kWh = 0.001644 lb/hph
1 lb/hph = 608.277 g/kWh
Density: Units of torque:
1 g/cm³ = 0.016018 lb/ft³
1 lb/ft³ = 62.43 g/cm³
1 Nm = 0.737 ft lb
= 8.848 in lb
1 ft lb = 1.356 Nm
1 in lb = 0.113 Nm
Units of force: Cable cross-section: Conversion table-
Wire Gauge: AWG-mm²
1 N = 0.224809 lbf
1 lbf = 4.4482 N
AWG —> mm²
4 —> 21
6 —> 13
8 —> 8.4
10 —> 5.3
12 —> 3.3
14 —> 2.1
16 —> 1.3
18 —>0.8
20—> 0.52
Units of pressure:
1 Pa = 1 N/m²
1 bar = 100 000 Pa / 1000 hPa / 100 kPa
1 bar = 14.503 lbf/in² (psi)
1 in Hg = 33.8638 hPa
Effectivity: 915 i A Series
Edition 0/Rev. 0 00–00–00
Page 7
December 01 2017

BRP-Rotax
MAINTENANCE MANUAL
SAFETY NOTICE
Although reading such information does not eliminate any hazards, it promotes the under-
standing and application the information will promote correct use of the engine. Always
apply common workshop safety rules.
The information and descriptions of components and systems contained in this Manual
are correct at the time of publication. BRP-Rotax maintains a policy of continuous im-
provement of its products without imposing upon itself any obligation to retrofit products
previously manufactured.
Revisions BRP-Rotax reserves the right to remove, replace or discontinue any design, specification,
feature or other at any time, and without incurring obligation.
Measurement Specifications are given in the SI metric system with the imperial- and US customary
measurement system equivalents in parenthesis.
Symbols used This Manual uses the following symbols to emphasize particular information. This informa-
tion is important and must be observed.
mWARNING
Identifies an instruction which, if not followed, may cause serious injury or even
fatal injury.
mCAUTION
Identifies an instruction which, if not followed, may cause minor or moderate
injury.
ATTENTION
Identifies an instruction which, if not followed, may severely damage the engine
or could void any warranty.
NNOOTTEE
Indicates supplementary information which may be needed to fully complete or
understand an instruction.
ENVIRONMENTAL NOTE
Environmental notes give you tips on environmental protection.
A revision bar outside the page margin indicates a change to text or graphic.
00–00–00
Page 8
December 01 2017
Effectivity: 915 i A Series
Edition 0/Rev. 0