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Rotax 898851, Operator'S Manual

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7) System Description

Topics in this chapter

7.1 General specification ............................................................................. 2

7.1.1 Basic specification ................................................................................ 2
7.1.2 Technical data ...................................................................................... 2
7.1.3 Engine components............................................................................... 3
7.1.4 Cylinder arrangement ............................................................................ 4
7.1.5 Direction of rotation ............................................................................... 4

7.2 Cooling system ..................................................................................... 5

7.3 Fuel system .......................................................................................... 6

7.4 Lubrication system ................................................................................ 7

7.5 Electric system...................................................................................... 9

7.5.1 Engine Management System................................................................. 10
7.5.2 Ignition control.................................................................................... 11
7.5.3 Fuel injection control............................................................................ 12
7.5.4 Communication interfaces .................................................................... 12

7.6 Air intake system and Boost pressure

control ............................................................................................... 13

7.7 Exhaust system................................................................................... 16

Introduction

This chapter of the Operator Manual contains information about
the general engine specification as well as a description of
cooling system, fuel system, lubrication system, electric system
and the propeller gearbox.
The system description refers only to the engine and not to a
specific application in a particular aircraft. The aircraft
manufacturers Operators Manual is therefore definitive in terms
of the operation of the engine, as it contains all the aircraft
specific instructions.

The design shown in this chapter does not represent a
specified execution but should support the understanding of the
system.

Effectivity: 915 i A Series
Edition 0 / Rev. 0

BRP-Rotax

Page 7-1

December 01 2017

Summary of Contents for 898851

Page 1: ...AIRCRAFT ENGINES ref no OM 915 i A part no 898851 OPERATORS MANUAL FOR ROTAX ENGINE TYPE 915 i A SERIES picture ROTAX 915 iS with options...

Page 2: ...hird 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 ROTA...

Page 3: ...ter LEP LIST OF EFFECTIVE PAGES Chapter TOA Table of amendments Chapter 1 General note Chapter 2 Operating instructions Chapter 3 Standard operation Chapter 4 Abnormal operation Chapter 5 Performance...

Page 4: ...Page Notes 2 December 01 2017 BRP Rotax Effectivity 915 i A Series Edition 0 Rev 0 NOTES...

Page 5: ...formation about safe operation of the engine together with descriptions of the systems technical data operating media and the operational limits of the engine The specified information and procedures...

Page 6: ...Page Notes 2 December 01 2017 BRP Rotax Effectivity 915 i A Series Edition 0 Rev 0 NOTES...

Page 7: ...Dec 01 2017 5 Dec 01 2017 6 Dec 01 2017 7 Dec 01 2017 8 Dec 01 2017 Chapter Page Date 3 1 Dec 01 2017 2 Dec 01 2017 3 Dec 01 2017 4 Dec 01 2017 5 Dec 01 2017 6 Dec 01 2017 7 Dec 01 2017 8 Dec 01 2017...

Page 8: ...017 9 Dec 01 2017 10 Dec 01 2017 11 Dec 01 2017 12 Dec 01 2017 Chapter Page Date 13 Dec 01 2017 14 Dec 01 2017 15 Dec 01 2017 16 Dec 01 2017 8 1 Dec 01 2017 2 Dec 01 2017 3 Dec 01 2017 4 Dec 01 2017 9...

Page 9: ...048 cur rent no chapter page date of change remark for appro val date of appro val from authori ties date of inclu sion signa ture 0 INTRO all Dec 01 2017 DOA 0 LEP all Dec 01 2017 DOA 0 TOA all Dec 0...

Page 10: ...s Summary of the relevant amendments in this context but without any claim to completeness current no chap ter page date of change comments Page TOA 2 December 01 2017 BRP Rotax Effectivity 915 i A Se...

Page 11: ...is chapter 1 1 General 2 1 2 Abbreviations and terms 3 1 3 Safety 7 1 4 Safety information 9 1 5 Technical documentation 12 1 6 Type description 14 Effectivity 915 i A Series Edition 0 Rev 0 BRP Rotax...

Page 12: ...s information to the end customer in an ap propriate way e g within the aircraft specific Operators Manual For detailed information related to aircraft and aircraft engine in stallation maintenance sa...

Page 13: ...lutions 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...

Page 14: ...deral 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 Ill...

Page 15: ...TFE 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 Catalo...

Page 16: ...nce Overhaul V Volt VFR Visual Flight Rules LEP List of Effective Pages MM Maintenance Manual XXXX shows the serial component number Page 1 6 December 01 2017 BRP Rotax Effectivity 915 i A Series Edit...

Page 17: ...remove replace or discontinue any design specification feature or other at any time and with out incurring obligation Measurement Specifications are given in the SI metric system with the imperi al a...

Page 18: ...Environmental notes give you tips on environmental protection A revision bar outside the page margin indicates a change to text or graphic Page 1 8 December 01 2017 BRP Rotax Effectivity 915 i A Seri...

Page 19: ...rcraft manufacturer assem bler and owner user Due to the varying designs equipment and types of aircraft BRP Rotax grants no warranty on the suitability of its en gine s use on any particular aircraft...

Page 20: ...ion is not included in the ROTAX engine package Verification to the latest regulations such as FAR or EASA has to be conducted by the aircraft manufacturer Engine log book Keep an engine log book and...

Page 21: ...for several minutes before turning off the engine Vacuum pump This engine may be equipped with a vacuum pump The safety warning accompanying the vacuum pump must be giv en to the owner operator of th...

Page 22: ...tatus of Manuals can be determined by checking the table of amendments The first column of this table indicates the revi sion status which should be compared with the revision pro vided on the ROTAX W...

Page 23: ...2017 TYPICAL indicates a general view which may not represent ex act details NOTE The Illustrations in this Manual are stored in a graphic data base system and are provided with a consecutive irrelev...

Page 24: ...4 cylinder horizontally opposed turbo charged engine Certifica tion iSc Certified to EASA CS E TC No EASA E 121 iS Approved to ASTM F2339 Configura tion 3 Propeller shaft with flange for constant spe...

Page 25: ...icants 7 Introduction The operating limits for certified engines are also given in the type certificate for the relevant engine type This chapter of the Operators Manual contains the operating limits...

Page 26: ...t system See latest Installation Manual ISA Condition International Standard Atmosphere Engine speed Parameter Min Max Engine speed at idle 1800 rpm Engine speed 5800 rpm max 5 minutes Performance The...

Page 27: ...ne operation at zero gravity and in negative g condition Parameter Min Max Acceleration 0 5 g max 5 seconds Static roll angle The dry sump lubrication system warrants lubrication in every flight situa...

Page 28: ...operation 50 C 120 F 130 C 266 F ATTENTION Operating the engine below 90 to 110 C 194 to 230 F may lead to formation of condensation water in the lubrication sys tem To evaporate possibly accumulated...

Page 29: ...lit at 3 Liter hour Fuel consumption 500 C 932 F Ambient temperature Parameter Min Max Ambient temperature at ground idle start procedure and warm up 20 C 4 F 50 C 120 F Ambient temperature at normal...

Page 30: ...s documentation Mixture ATTENTION Obey the operating media manufacturer s instructions 2 3 Operating media Fuel ATTENTION Obey the latest edition of Service Instruction SI 915 i 001 for the selection...

Page 31: ...the selection of suitable lubricants refer to the additional in formation in the Service Information SI 915 i 001 latest edition Oil consumption Max 0 06 l h 0 13 liq pt h Oil specification Use only...

Page 32: ...iations than single grade oils They are suitable for use throughout the seasons ensure rapid lubrication of all engine components at cold start and get less fluid at higher temperatures Table of lubr...

Page 33: ...erating and maintenance instructions The following description of procedures depends on the respective type of installation in the aircraft and shall therefore only be seen functionally NOTE The contr...

Page 34: ...ntenance Manual is necessary Do not release the engine in to service before rectification Coolant level ATTENTION Operating media must be observed Inappropriate coolant quantity can lead to serious en...

Page 35: ...Effectivity 915 i A Series Edition 0 Rev 0 BRP Rotax Page 3 3 December 01 2017 Figure 1 Expansion tank 1 Radiator cap 2 Expansion tank coolant Figure 2 Overflow bottle 1 Overflow bottle 2 Coolant...

Page 36: ...mpression 2 Verify free movement of throttle valve and the complete range 3 Inspect for damages leakage and general condition of exhaust system and turbocharger 4 Visual inspection for mechanical and...

Page 37: ...red to when refilling oil Step Procedure 1 NOTE Propeller shouldn t be turned excessively reverse the normal direction of engine rotation Remove bayonet cap from the oil tank turn the propeller slowly...

Page 38: ...nt Do not harm the environment by spilling oil Dispose of oil in an envi ronmentally friendly manner 3 3 Engine start m WARNING Non compliance can result in serious injuries or death Do not start the...

Page 39: ...airframe ground and EMS ground will activate Start Power The temporary power supply must be maintained during steps 4 5 6 Example Symbolic Start Power Switch HOLD 5 Check if Warning In dicators illum...

Page 40: ...e drop between Terminal 2 and Termi nal 8 permanent or oscillating is detected perform Lane and Ignition Check See abnormal operation if the voltage drop still persists HIC B If a 12 V voltage drop be...

Page 41: ...oltage drop between Terminal 2 and Termi nal 8 permanent or oscillating is detected shut OFF engine and perform troubleshooting HIC B If a 12 V voltage drop between Terminal 2 and Termi nal 10 permane...

Page 42: ...is detected shut OFF engine and perform troubleshooting Display CAN A B Check and ensure compliance with opera tional limits Example Symbolic Warning Lamp A Check Warning Lamp B Check Pilot Display Ch...

Page 43: ...cillating is detected shut OFF engine and perform troubleshooting HIC B If a 12 V voltage drop between Terminal 2 and Termi nal 10 permanent or oscillat ing is detected shut OFF engine and perform tro...

Page 44: ...compliance with opera tional limits Example Symbolic Warning Lamp A Check Warning Lamp B Check Pilot Display Check 2 Set Throttle Valve as required Set linearized throttle position so that engine spee...

Page 45: ...olic Lane select Switch B OFF 8 Observe engine speed Display CAN A B Check en gine speed Example Symbolic Pilot Display Check ATTENTION Engine speed may not drop increase more than 250 rpm If the fuel...

Page 46: ...ng Lane and Ignition check some sensor values are not displayed de pending on the activation of the Lanes Following sensor values are not available if Lane A is turned OFF and Lane B is activated Cool...

Page 47: ...l 10 permanent or oscillat ing is detected shut OFF engine and perform troubleshooting Display CAN A B Check and ensure compliance with opera tional limits Example Symbolic Warning Lamp A Check Warnin...

Page 48: ...le Symbolic Warning Lamp A Check 8 Deactivate ECU Lane B HIC B Disconnect Terminal 1 and Terminal 9 to turn OFF ECU Lane B Example Symbolic Lane Select Switch B OFF 9 Wait 15 seconds Example Symbolic...

Page 49: ...00 rpm and continue with Fuel pump check Example Symbolic Set Throttle Fuel pump check It must be ensured that both fuel pumps are working and no loss of power or irregular running by deactivation of...

Page 50: ...fied Step Step Description Procedure 5 Activate Fuel pump 1 HIC A Disconnect Terminal 3 and Terminal 9 to deactivate Fuel pump 1 Example Symbolic Fuel pump 1 OFF 6 Deactivate Fuel pump 2 HIC A Disconn...

Page 51: ...is detected shut OFF engine and perform troubleshooting HIC B If a 12 V voltage drop between Terminal 2 and Termi nal 10 permanent or oscillat ing is detected shut OFF engine and perform troubleshooti...

Page 52: ...ng of the fuel pumps is only allowed in emergency situations Step Step Description Procedure 5 Deactivate Fuel pumps HIC A Disconnect Terminal 3 and terminal 9 to turn OFF Fuel pump 1 HIC B Disconnect...

Page 53: ...ands 5 4 1 3 Engine on fire or fire in the engine compartment 5 4 2 Failures during engine start 6 4 2 1 Engine does not start 6 4 3 Re Start during flight 6 4 4 The sprag clutch fails to decouple fro...

Page 54: ...uct checks as per maintenance Manual Line Chapter 05 50 00 before the next flight Only qualified staff authorized by the Aviation Authorities trained on this particular engine is allowed to carry out...

Page 55: ...missible Land the aircraft Oscillating 0 12 V Oscillating 0 12 V Flight not permissible Land the aircraft Oscillating 0 12 V 12 V Flight not permissible Land the aircraft 12 V 0 V Flight not permissib...

Page 56: ...ng the EMS the airframe will not be supplied with electrical power by an internal generator This failure condition will be detected by the EMS Therefore see section Failures detected by the EMS for ap...

Page 57: ...n the engine compartment ATTENTION Carry out emergency procedures as prescribed in the flight man ual of the engine manufacturer Aircraft Manufacturer is responsible for defining a procedure for this...

Page 58: ...flight by windmilling but the speed is not sufficient to start the engine the electric starter can be used It is not required to wait until the propeller stand still 4 4 The sprag clutch fails to dec...

Page 59: ...and carry out precautionary landing Exceeding fuel pressure If the pressure is too high switch the AUX pump OFF If this has no effect then limited flight operation with reduced power is possible If th...

Page 60: ...Page Notes 8 December 01 2017 BRP Rotax Effectivity 915 i A Series Edition 0 Rev 0 NOTES...

Page 61: ...mance and Fuel consumption Topics in this chapter 5 1 Performance data and fuel consumption 2 5 2 Explanation of the parameters 2 Effectivity 915 i A Series Edition 0 Rev 0 BRP Rotax Page 5 1 December...

Page 62: ...nd throttle position ECU_throttle_lin Critical Altitude The engine was designed for a critical altitude up to 15000 ft 5 2 Explanation of the parameters Parameters Explantaion Case Number No Unit Sequ...

Page 63: ...elivered power will be up to 1 4 kW higher than the stated power in the engine deck Therefore power loss due to the use of AVGAS is taken into account Fuel Flow kg h Fuel flow at given ambient engine...

Page 64: ...Page Notes 4 December 01 2017 BRP Rotax Effectivity 915 i A Series Edition 0 Rev 0 NOTES...

Page 65: ...troduction This chapter of the Operator Manual contains information about the general engine specification as well as a description of cooling system fuel system lubrication system electric system and...

Page 66: ...controlling fuel injection ignition etc Propeller drive via gearbox with integrated mechanical shock absorber and overload clutch Oil tank Electric starter Turbocharged Electronic pneumatic control of...

Page 67: ...tax Page 7 3 December 01 2017 7 1 3 Engine components Figure 1 Engine components 1 Propeller gearbox 2 ECU 3 Fusebox 4 Intercooler 5 Airbox 6 Wiring harness 7 Turbocharger 8 Air baffle 9 Electric star...

Page 68: ...n of rotation Direction of rota tion on propeller shaft Direction of rotation on propeller shaft counter clockwise viewed from the front Figure 3 Normal direction of propeller rotation engine Page 7 4...

Page 69: ...top of the engine allows for coolant expansion Expansion tank From the expansion tank the coolant is sucked back to the water pump In common installations the coolant passes a radi ator in between Ad...

Page 70: ...fuel rails The fuel pres sure regulator 6 ensures that the pressure differential between the fuel injectors and the intake manifold remains constant This allows injecting same quantity of fuel indepe...

Page 71: ...ing on the engine installation trough the oil cooler to the points of lubrication in the engine and the turbo charger The escaping oil emerging from the points of lubrication accu mulates on the botto...

Page 72: ...er oil sump 9 Oil cooler Oil temperature sensor The oil temperature sensor for reading of the oil temperature is located on the crankcase on the mag side of the engine Oil pressure sensor The oil pres...

Page 73: ...ber 01 2017 7 5 Electric system This System is responsible for supplying the Engine Manage ment System EMS and the Airframe with electrical power It consists of the Fusebox with Regulators and the Int...

Page 74: ...l electric supply system changes to fail safe mode where Generator 2 again is in charge to supply the EMS In fail safe mode Genera tor 2 is not able to charge external power sources or supply the airf...

Page 75: ...me measurement values and send the same output signals Non redundant sensors e g oil pressure sensors are connected to one Lane only and serve for the expanded monitoring of the en gine functionality...

Page 76: ...s a maintenance and a display interface CAN bus While the maintenance interface is required to work with the BUDS Aircraft Diagnostic Software to perform vari ous diagnostic and maintenance activities...

Page 77: ...BRP Rotax Page 7 13 December 01 2017 7 6 Air intake system and Boost pressure control Figure 10 Air intake system 1 Airfilter connection 2 Air intake hose 3 Turbo charger 4 Intercooler 5 Pop OFF valv...

Page 78: ...exhaust gases have to pass the turbine The waste gate is powered by the boost pressure from the com pressor Pneumatic valves actuated by the ECU control the amount of the boost pressure necessary to a...

Page 79: ...the air filter Boost Pressure Sensor BPS The boost pressure sensor for reading of the boost pressure is located right before the throttle near the overboost valve Manifold Air Pres sure Sensor MAP Th...

Page 80: ...ther in the exhaust manifold From there the exhaust gas pass the turbine side of the turbo charger depending on the waste gate position From there the exhaust gases leave the engine thru the muffler E...

Page 81: ...Only qualified staff authorized by the Aviation Authorities trained on this particular engine is allowed to carry out maintenance and repair work NOTE Other useful information for service and airworth...

Page 82: ...of 5 min engine oil temperature between 50 to 70 C 122 to 160 F 2 Shut off engine 3 Allow the engine to cool down 4 Change oil 5 Remove the top spark plugs and spray all openings with corrosion inhibi...

Page 83: ...e back to operation If preservation including oil change took place within a year of storage oil renewal will not be necessary For longer storage periods repeat preservation annually Step Procedure 1...

Page 84: ...Page Notes 4 December 01 2017 BRP Rotax Effectivity 915 i A Series Edition 0 Rev 0 NOTES...

Page 85: ...be filled out and sent to the responsible ROTAX authorized aircraft engines distributor or their independent Service Center NOTE The form is also available from the official ROTAX AIRCRAFT ENGINES We...

Page 86: ...9 1 Form Figure 1 Form Page 9 2 December 01 2017 BRP Rotax Effectivity 915 i A Series Edition 0 Rev 0...

Page 87: ...espective collecting point or hand it over to an approved disposal company Fuel Dispose of fuel at the respective collecting point or hand it over to an approved disposal company m WARNING Flammable m...

Page 88: ...AX aircraft engines F O B to ROTAX Authorized Distributors or their independent Service Centers Chemical agents cleaner LOCTITE etc Please observe the safety and disposal instructions of the manufactu...

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Page 129: ...41 0 1191 229 05 1961 3000 1 013 0 94 1 0 33 03534968 9 82 0 9932 275 25 1962 3000 0 908 6 94 1 2999 31 19436206 9 42 1 0004 269 35 1963 3000 0 812 12 94 1 5997 28 03657184 8 72 0 9028 263 45 1964 30...

Page 130: ...256 45 2088 3000 0 485 23 100 18999 11 5040662 5 14 0 3613 252 25 2089 3000 0 446 27 100 21001 9 147381902 4 54 0 2676 248 05 2090 3000 0 410 31 100 22999 7 42253785 4 08 0 1887 244 05 2091 3000 1 01...

Page 131: ...70 0 7538 271 85 2135 3000 0 644 9 84 5 11998 17 99397121 6 01 0 6583 265 95 2136 3000 0 572 15 84 5 15000 15 52009519 5 34 0 5652 260 05 2137 3000 0 527 19 84 5 17001 13 90922387 4 91 0 5058 255 95...

Page 132: ...05 35 2262 3000 0 908 24 98 8 2999 29 99303619 9 21 0 8921 299 45 2263 3000 0 812 18 98 8 5997 27 24419316 8 71 0 8950 293 55 2264 3000 0 724 12 98 8 8999 24 87737409 7 93 0 8429 287 55 2265 3000 0 64...

Page 133: ...232 267 05 2309 3000 0 446 12 72 21001 7 085177577 4 07 0 3882 263 05 2310 3000 0 410 16 72 22999 6 376930134 3 97 0 3584 259 15 2311 3000 1 013 30 56 5 0 14 98185886 6 01 0 6241 304 75 2312 3000 0 90...

Page 134: ...7077 296 15 2436 3000 0 572 15 97 4 15000 17 07495027 5 06 0 6327 290 15 2437 3000 0 527 11 97 4 17001 13 69810858 4 37 0 5752 286 15 2438 3000 0 485 7 97 4 18999 10 53964712 3 78 0 5160 282 15 2439...

Page 135: ...6 318667534 3 91 0 3867 277 95 2470 3000 0 410 1 72 22999 5 583626302 3 81 0 3576 274 05 2471 3000 1 013 45 56 5 0 14 73000322 6 02 0 6225 319 55 2472 3000 0 908 39 56 5 2999 12 82960742 5 30 0 5881...

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Page 137: ...Management System 10 Engine not responding on throttle position commands 5 Engine preservation and storage 2 Engine run up 11 Engine shut off 19 Engine start 6 Exceedance of operational limits 6 Expl...

Page 138: ...017 BRP Rotax Effectivity 915 i A Series Edition 0 Rev 0 S Safety notice 7 9 Sprag clutch Starter 6 T Table of amendments 1 Technical data 2 Technical documentation 12 Terms 3 Turbocharger Exhaust sys...

Page 139: ......

Page 140: ...________________________________________ Type of aircraft __________________________________________________________ Aircraft registration no ROTAX authorized distributor WWW FLYROTAX COM www abm at a...

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