Rotax 915 iS 3 A Installation Manual Download Page 19

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BRP-Rotax

INSTALLATION MANUAL

direct current

DOA

Design Organisation Approval

DOT

Department of Transport

EASA

European Aviation Safety Agency

Installation Manual

ECU

Engine Control Unit

EGT

Exhaust Gas Temperature

INTRO

Introduction

EMS

Engine Management System

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

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

Newton

n.a.

not available

NDT

Non Destructive Testing

Newtonmeter

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

00–00–00

Page 7

December 01 2017

Summary of Contents for 915 iS 3 A

Page 1: ...AIRCRAFT ENGINES ref no IM 915 i A part no 898871 INSTALLATION MANUAL FOR ROTAX ENGINE TYPE 915 i A SERIES picture ROTAX 915 iS with options ...

Page 2: ...f the Manufacturers can cause personal injury or property damage BRP Rotax GmbH Co KG disclaims any liability for any and all damage and or injuries including death resulting from the improper use of Installation Manual and non compliance with the installation requirements of the Manufacturer These technical data and the information embodied therein are the property of BRP Rotax GmbH CO KG Austria...

Page 3: ... 10 10 00 STORAGE AND INSTALLATION Chapter 24 00 00 ELECTRICAL POWER Chapter 61 00 00 PROPELLER DRIVE Chapter 72 00 00 ENGINE Chapter 72 60 00 AIR INTAKE SYSTEM Chapter 73 00 00 ENGINE FUEL AND CONTROL Chapter 75 00 00 COOLING SYSTEM Chapter 76 00 00 ENGINE CONTROLS Chapter 77 00 00 ENGINE INDICATING Chapter 78 00 00 EXHAUST SYSTEM Chapter 79 00 00 LUBRICATION SYSTEM Chapter 80 00 00 STARTING BRP ...

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

Page 5: ... ROTAX authorized distributor or their independent Service Center for ROTAX aircraft engines BRP Rotax GmbH Co KG hereinafter BRP Rotax wishes you much pleasure and satisfaction flying your aircraft powered by this ROTAX aircraft engine The structure of the manual follows whenever possible the structure of the ATA Air Transport Association standards The aim is the compatibility with the aircraft m...

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

Page 7: ...mber 01 2017 18 December 01 2017 10 10 00 1 December 01 2017 2 December 01 2017 3 December 01 2017 Chapter Page Date 4 December 01 2017 5 December 01 2017 6 December 01 2017 7 December 01 2017 8 December 01 2017 24 00 00 1 December 01 2017 2 December 01 2017 3 December 01 2017 4 December 01 2017 5 December 01 2017 6 December 01 2017 7 December 01 2017 8 December 01 2017 9 December 01 2017 10 Decem...

Page 8: ...December 01 2017 12 December 01 2017 75 00 00 1 December 01 2017 2 December 01 2017 Chapter Page Date 3 December 01 2017 4 December 01 2017 5 December 01 2017 6 December 01 2017 7 December 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 76 00 00 1 December 01 2017 2 December 01 2017 3 December 01 2017...

Page 9: ...01 2017 5 December 01 2017 6 December 01 2017 7 December 01 2017 8 December 01 2017 9 December 01 2017 Chapter Page Date 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 80 00 00 1 December 01 2017 2 December 01 2017 3 December 01 2017 4 December 01 2017 5 December 01 2017 6 December 01 2017 7 December 01 20...

Page 10: ...Notes Page 4 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 NOTES BRP Rotax INSTALLATION MANUAL ...

Page 11: ...ll December 01 2017 DOA 0 00 00 00 all December 01 2017 DOA 0 10 10 00 all December 01 2017 DOA 0 24 00 00 all December 01 2017 DOA 0 61 00 00 all December 01 2017 DOA 0 72 00 00 all December 01 2017 DOA 0 72 60 00 all December 01 2017 DOA 0 73 00 00 all December 01 2017 DOA 0 75 00 00 all December 01 2017 DOA 0 76 00 00 all December 01 2017 DOA 0 77 00 00 all December 01 2017 DOA 0 78 00 00 all D...

Page 12: ...L 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 TOA Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 13: ...Auxiliary equipment optional 5 Abbreviations and terms 6 Conversion table 9 Safety notice 10 Safety information 11 Instruction 13 Technical documentation 14 Approval of electric and electronic components Equipment Qualification according to RTCA DO 160 16 Effectivity 915 i A Series Edition 0 Rev 0 00 00 00 Page 1 December 01 2017 ...

Page 14: ...peration 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 F...

Page 15: ...cription 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 3 Propeller shaft with flange for constant speed propeller and drive for hydraulic governor for constant speed propeller Additional designation A Standard version Effectivity 915 i A Series Edition 0 Rev 0 00 00 00 Page 3 December 0...

Page 16: ...led cylinder heads Ram air cooled cylinders Dry sump forced lubrication Fully redundant electronic engine management system EMS for controlling fuel injec tion ignition etc Propeller drive via gearbox with integrated torsional vibration absorber and overload clutch Oiltank Electric starter 00 00 00 Page 4 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 17: ...sted for this engine are readily available at BRP Rotax Auxiliary equip ment certified The following auxiliary equipment has been developed and tested for this engine See relevant Illustrated Parts Catalog Auxiliary equip ment not certified The following auxiliary equipment has not been developed and tested for this engine See relevant Illustrated Parts Catalog Effectivity 915 i A Series Edition 0...

Page 18: ...ere 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 Temper...

Page 19: ...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 Mot...

Page 20: ...N 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 S...

Page 21: ...US 3 7854 dm 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 cm 0 016018 lb ft 1 lb ft 62 43 g cm 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 Conv...

Page 22: ...ns 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 m WARNING Identifies an instruction which if not followed may cause serious injury or even fatal injury m CAUTION Identifies an instruction wh...

Page 23: ...nufac turer assembler or owner user Due to the varying designs equipment and types of aircraft BRP Rotax grants no war ranty on the suitability of its engines use on any particular aircraft Further BRP Rotax grants no warranty on this engines suitability with any other part component or system which may be selected by the aircraft manufacturer assembler or user for aircraft application m WARNING N...

Page 24: ...se of propellers and their fastenings which exceed the specified values of moment of inertia and imbalance is not allowed and releases the engine manufacturer from any liability Improper engine installation use of unsuitable piping for fuel cooling and lubrication system and use of unsuitable wiring for electric and engine management system re leases the engine manufacturer from any liability 00 0...

Page 25: ... See Illustrated Parts Catalog latest issue ATTENTION Only use genuine ROTAX spare parts Spare parts must meet the requirements defined by the engine manufacturer This can only be guaranteed when using GENUINE ROTAX spare parts and or accessories see IPC Spare parts are available at ROTAX Authorized Distributors and their inde pendent Service Centers Any warranty by BRP Rotax will become void if o...

Page 26: ...ervice Bulletin Service Bulletin Service Instruction Service Letter Status The status of the Manuals can be determined by checking the table of amendments The first column of this table indicates the revision status which should be compared with the revision provided on the ROTAX Website www FLYROTAX com Amendments and current versions can be downloaded free of charge Replacement pages Furthermore...

Page 27: ...stem and are provided with a consecutive irrelevant number This number e g AE 5iS001 is of no significance for the content Some measurements are given in the drawings these are manufacturing dimensions and are subject to corresponding tolerances Installation drawings Installation drawings and a DMU model for virtual installation analysis are available from the ROTAX Authorized Distributors or thei...

Page 28: ...rational Shocks and Crash Safety Cat BD DO 160G Section 8 Vibration Cat S L DO 160G Section 9 Explosion Proofness Test not performed DO 160G Section 10 Water Proofness Cat S DO 160G Section 11 Fluids Susceptibility Cat F DO 160G Section 12 Sand and Dust Cat D DO 160G Section 13 Fungus Resistance Test not performed DO 160G Section 14 Salt Spray Cat S DO 160G Section 15 Magnetic Effect Cat A DO 160G...

Page 29: ... 160G Section 25 Electrostatic Discharge Cat A Component tem peratures limits System Limit Min Max ECU 40 C 40 F 80 C 176 F EGT Sensors electronic box 40 C 40 F 80 C 176 F Fusebox 40 C 40 F 80 C 176 F Effectivity 915 i A Series Edition 0 Rev 0 00 00 00 Page 17 December 01 2017 ...

Page 30: ...Notes Page 18 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 NOTES BRP Rotax INSTALLATION MANUAL ...

Page 31: ...UAL Chapter 10 10 00 STORAGE AND INSTALLATION TOPICS IN THIS CHAPTER Special tools 3 General 4 Engine storage 4 Unpacking the engine 4 Engine handling 7 Effectivity 915 i A Series Edition 0 Rev 0 10 10 00 Page 1 December 01 2017 ...

Page 32: ...BRP Rotax INSTALLATION MANUAL Figure 2 1 915 iS engine 10 10 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 33: ...BRP Rotax INSTALLATION MANUAL SPECIAL TOOLS Description Part number Engine lift set 876040 Effectivity 915 i A Series Edition 0 Rev 0 10 10 00 Page 3 December 01 2017 ...

Page 34: ...e engine is stored for a period longer than 12 months or it is not stored in the GENU INE ROTAX packing then maintenance tasks must be carried out every 3 months as per the currently valid Maintenance Manual Line UNPACKING THE ENGINE ATTENTION The attachment screws are only for transport and must not be used in the aircraft ATTENTION During engine installation take into account the total engine we...

Page 35: ...sport and engine installation They must be removed completely including sealing materials before the en gine is operated All openings are protected against ingress of contamination and dampness It is recom mended to leave the protective plugs in place until installation of the specific feed line The protective coverings can be found at following locations Pos Installation location Amount 1 Exhaust...

Page 36: ... fuel pressure regulator 3 Fuel rail inlet 4 Oil inlet outlet and oil return turbo 5 Coolant inlet outlet 6 Throttle body socket assy 7 Air intake socket on turbocharger 8 Wastegate 9 Propeller shaft 10 Cover governor flange 10 10 00 Page 6 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 37: ...e Attachment points The engine may only be lifted on the dedicated attachment points by using the GENUINE ROTAX engine lift set Make sure that lifting device does not bend the attachment lugs by relevant force distribution Figure 2 3 Attachment points Effectivity 915 i A Series Edition 0 Rev 0 10 10 00 Page 7 December 01 2017 ...

Page 38: ...Notes Page 8 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 NOTES BRP Rotax INSTALLATION MANUAL ...

Page 39: ...em limitations 3 Interface description 4 Interface overview 4 Electrical interfaces 4 Mechanical interfaces 9 Installation notes 10 Installation overview 10 Grounding cables 10 Battery 11 Control elements 12 Validation of installation 13 Effectivity 915 i A Series Edition 0 Rev 0 24 00 00 Page 1 December 01 2017 ...

Page 40: ...BRP Rotax INSTALLATION MANUAL Figure 3 1 Internal power supply 24 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 41: ...f electric and electronic components The Regulator temperature must be measured as shown within the following figure Figure 3 2 Regulator temperature measurement area 1 Rectifier regulator 2 Component temperature meas urement area Separation of EMS and Airframe circuit A connection between regulator plate A EMS ground and airframe ground should only be done during supply of the EMS System by an ex...

Page 42: ...x must be inserted into the X1 X2 and X3 Connector Fusebox side to enable a good connection between plug and socket and thus avoid un necessary vibrations and misalignment of connector pins Fusebox X1 X2 Connector The X1 and X2 ensure the power distribution to the EMS System Both plugs must be con nected with mating sockets on the engine wiring harness The connectors are not inter changeable and a...

Page 43: ... the EMS Terminal 3 can be used for supplying the Airframe with electrical en ergy after generator A has taken over powering the EMS Terminal Interface Parameter Min Max Nominal 1 Input voltage 9 V2 14 5 V 12 V Input load 230 W DC cont 290 W DC peak 2 Input voltage 9 V 14 5 V 12 V Input load 230 W DC cont 290 W DC peak 3 Output voltage 13 9 V 14 5 V 12 V Output capacity max 420 W DC at 20 68 F see...

Page 44: ...ions the output voltage can exceed the specified limits The following measurement is taken at an oil temperature of 135 C 275 F Figure 3 5 Characteristic curve of internal generators 24 00 00 Page 6 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 45: ...o DIN 46225 tightening torque 1 2 Nm The cable lugs need to be evenly spread onto the three available terminals Figure 3 6 Fusebox Regulator A 1 Regulator 2 Regulator plate B 3 Ground terminals ATTENTION A connection between regulator plate A and airframe ground should only be done during supply of the EMS System by an external power source e g during engine start Effectivity 915 i A Series Editio...

Page 46: ...e Airframe Ground The terminal is con ducted as a M6 screw connection suitable for cable lug according to DIN 46225 tightening torque 5 9 Nm Figure 3 7 Fusebox Regulator B 1 Regulator 2 Regulator plate B 3 Ground terminals 24 00 00 Page 8 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 47: ...BRP Rotax INSTALLATION MANUAL MECHANICAL INTERFACES Fusebox mount ing points Figure 3 8 Fusebox Connections and dimensions Effectivity 915 i A Series Edition 0 Rev 0 24 00 00 Page 9 December 01 2017 ...

Page 48: ...e is in the re sponsibility of the aircraft manufacturer The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual can be supervised by the pilot The execution of the installation must allow the op eration of the engine according to the Operators Manual INSTALLATION OVERVIEW Wiring diagram Figure 3 9 Wiring diagram GROUNDING CABLES The wiring of the groundi...

Page 49: ...he approval of the relevant aeronautical authority may be necessary For installation of lithium ion batteries refer e g to FAA AC No 20 184 The specification of the battery must ensure that during each operating state and also dur ing the transition between two operation states a sufficient supply of the avionics is guar anteed e g during engine start Depending on the applicable regulations avioni...

Page 50: ...ttery performance during the starting process e g ACL Anti Collision Light Navigation Light Avionic CONTROL ELEMENTS START POWER SWITCH Requirement Switch type Toggle SPST non lockable Nominal voltage 28 V DC Nominal current 20 A Number of poles 2 pole BATTERY BACKUP SWITCH Requirement Switch type Toggle but with mechanical interlock to prevent switch on during standard operation Nominal voltage 2...

Page 51: ...ing on the location where the engine should be used this measurement must be done at the lowest reachable temperature In case the measured voltages drop below 9 V especially during engine start the installation is insufficient In this case specification of the external power source the execution of the wiring as well as the total consumption of all electrical loads needs to be checked Separation o...

Page 52: ...t separation 1 Multimeter 2 Rectifier regulator A black connector 3 Rectifier regulator B grey connector In case of continuity the installation is not sufficient and the wiring concept needs to be revised 24 00 00 Page 14 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 53: ...VE TOPICS IN THIS CHAPTER System description 3 System limitations 3 Interface description 4 Interface overview 4 Mechanical interfaces 5 Hydraulic governor for constant speed propeller 7 Effectivity 915 i A Series Edition 0 Rev 0 61 00 00 Page 1 December 01 2017 ...

Page 54: ...BRP Rotax INSTALLATION MANUAL Figure 4 1 Propeller drive 61 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 55: ...2 3 559 lb ft2 7500 kg cm2 18 238 lb ft2 Out of balance Dynamic balancing of the propeller as specified by the propeller manufacturer must be carried out Propeller shaft System Limit Min Max Extension of the propeller shaft maximal 70 mm 2 75 in Hydraulic gover nor flange drive oil supply System Limit Min Max Power consumption of governor 600 W Operating pressure of governor 10 bar 145 psi peak pr...

Page 56: ...ce 1 Propeller shaft mechanical Interface 2 Governor flange hydraulic Interface N NO OT TE E The cover used for delivery needs to be removed before engine operation The cover may not be used in operational condition 61 00 00 Page 4 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 57: ...is not permitted Lk ø101 6 Lk ø80 Lk ø75 ø 1 3 0 1 8 ø 1 1 5 ø 1 2 9 7 5 ø 8 0 2 8 5 P ø47 0 05 Figure 4 3 Propeller shaft flange Interface Parameter Value Pitch circle diameter 75 mm 2 95 in 6x through holes 8 mm 0 31 in Pitch circle diameter 80 mm 3 15 in 6x through holes 11 5 mm 0 45 in Pitch circle diameter 101 6 mm 4 in 6x through holes 13mm 0 51 in Hub diameter 47 mm 1 85 in Gear transmissio...

Page 58: ...BRP Rotax INSTALLATION MANUAL Figure 4 4 Direction of rotation 61 00 00 Page 6 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 59: ...ANUAL HYDRAULIC GOVERNOR FOR CONSTANT SPEED PROPELLER Figure 4 5 Crankcase flange 1 Governor flange 2 Pressure oil line assy 3 Oil inlet 4 Oil outlet Effectivity 915 i A Series Edition 0 Rev 0 61 00 00 Page 7 December 01 2017 ...

Page 60: ...anufacturers instructions Technical Data Gear ratio from crankshaft to hydraulic governor is 1 842 i e the propeller governor runs at 0 54 times engine speed Mounting pad AND20010 Thread size M8 Thread length max 14 mm 0 55 in Toothing Internal spline 20 40 SMS 1834 NA 14x1 27x30x12 Power input max 600 W Operating pressure max 30 bar 435 psi 61 00 00 Page 8 December 01 2017 Effectivity 915 i A Ser...

Page 61: ...E TOPICS IN THIS CHAPTER System description 3 System limitations 6 Interface description 9 Interface overview 9 Mechanical interfaces 9 Installation notes 11 Engine suspension 11 Effectivity 915 i A Series Edition 0 Rev 0 72 00 00 Page 1 December 01 2017 ...

Page 62: ...BRP Rotax INSTALLATION MANUAL Figure 5 1 Engine 72 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 63: ...igure 5 2 Engine side view 1 Engine number 2 Propeller flange 3 Propeller gearbox 4 Connection for return line both sides mandatory 5 Connection for return line A Attachment points for engine transport Z Center of gravity Z P Reference coordinate system X Y Z Effectivity 915 i A Series Edition 0 Rev 0 72 00 00 Page 3 December 01 2017 ...

Page 64: ...ngine Front view 6 Oil filter 7 Oil pump 8 Exhaust flange 9 Muffler assy 10 Fuel line assy 11 Crankshaft locking screw position 12 Connection for Turbo oil line return 72 00 00 Page 4 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 65: ...ox 15 Dual ignition coils 16 Expansion tank assy 17 Fuel rail right left 18 POP OFF valve 19 Inter cooler 20 Connection for fuel feed line 21 Connection for fuel return line A Attachment points for engine transport Effectivity 915 i A Series Edition 0 Rev 0 72 00 00 Page 5 December 01 2017 ...

Page 66: ...erators Manual Installation position The oil system fuel system and the cooling system are unsuitable for upside down in verted installation of the engine System Limit Min Max Static roll angle ß 40 The oil level should be in the upper half between the 50 and the Max mark and should never fall below the Min mark For the oil level measuring procedure refer to the latest version of the respective op...

Page 67: ...n ɑ Bank or rotation F1 Gravity Attachment points For mounting the engine on the engine suspension R2 R3 L3 and L2 of attachment points must be used All used screws must not be touch engine components Effectivity 915 i A Series Edition 0 Rev 0 72 00 00 Page 7 December 01 2017 ...

Page 68: ...and vertical axis Propeller axis The y1 axis must be perpendicular to the longitudinal axis of the aircraft System Limit Min Max Permissible deviation from perpendicular α 10 10 72 00 00 Page 8 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 69: ...5 mm 4 13 in m WARNING Non compliance can result in serious injuries or death The aircraft or fuselage manufacturer must design the engine suspension so that it can safely carry the maximum occurring operational loads without exceeding the max al lowable forces and bending moments on the engine housing and attachment points Tighten all engine suspension screws as specified by the aircraft manufact...

Page 70: ...avity of engine The position information of the center of gravity does only consider the engine itself Parts without an specific installation position on relation to the reference coordinate system are not considered N NO OT TE E All distances are given in relation to the reference coordinate system P Axis Center of gravity X axis 376 mm 14 80 in Y axis 14 mm 0 55 in Z axis 112 mm 4 41 in Moments ...

Page 71: ... engine installation take into account the total engine weight and ensure careful handling The rubber mounts for neutralizing vibrations and other engine suspension components are not in the scope of delivery Those components must be designed selected and tested on vibration behavior during ground runs and flight testing at specified loads ATTENTION The engine suspension must be designed to preven...

Page 72: ...pension frame and the 4 stated attachment points R2 L2 R3 L3 Figure 5 9 Damping element engine suspension Standard aircraft industry damping elements e g Lord are suitable and need to be choosen according to the aircraft specific design requirements Check with the relevant equipment manufacturer The vibration and acoustic insulation factor depends on the airframe 72 00 00 Page 12 December 01 2017 ...

Page 73: ...APTER System description 3 System limitations 3 Interface description 5 Interface overview 5 Mechanical interfaces 6 Pneumatic interfaces 7 Electrical interfaces 8 Installation notes 9 Installation overview 9 Effectivity 915 i A Series Edition 0 Rev 0 72 60 00 Page 1 December 01 2017 ...

Page 74: ...BRP Rotax INSTALLATION MANUAL Figure 6 1 Air intake system 72 60 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 75: ...Engine Speed 5500 50 rpm Airflow 360 366 kg min 85 mbar Intake pressure loss Engine Speed 5800 50 rpm Airflow 384 396 kg min 90 mbar PCV ducting All pneumatic connections leading from and to the Pressure Control Valve PCV may not be changed Changes in length and diameter of the connections will have an significant ef fect on the wastegate control Depending on the installation heat protection must ...

Page 76: ...ition of the throttle valve is therefore full throttle Therefore never start the engine without connecting the throttle lever first m WARNING Non compliance can result in serious injuries or death The cable actuations being used must not be affected at all by vibrations emanating from the engine or the airframe 72 60 00 Page 4 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 77: ...iew and components 1 Turbocharger inlet pneumatic Interface 2 Overboost valve to throttle 3 Turbocharger 4 Intercooler 5 Overboost valve 6 Throttle body mechanical interface 7 Pressure control valve electrical interface 8 Wastegate boost pressure valve Effectivity 915 i A Series Edition 0 Rev 0 72 60 00 Page 5 December 01 2017 ...

Page 78: ...le travel 65 mm 2 56 in Actuating force 7 5 N 1 69 lb ft 20 N 4 5 lb ft Max permissible actuating force 20 N 4 5 lb ft Connection Set screw M6x12 mm Intercooler Figure 6 3 Intercooler Connection and dimensions To attach the intercooler within the airframe design four suitable fixation points are avail able and M6 screws must be used 72 60 00 Page 6 December 01 2017 Effectivity 915 i A Series Editi...

Page 79: ...nection on turbocharger Interface Parameter Min Max Slip on length 30 mm 1 18 in N NO OT TE E Use only filter elements which will not tend to restrict the flow when in contact with water Turbocharger to intercooler Connection on turbocharger Interface Parameter Min Max Slip on length 30 mm 1 18 in Figure 6 4 Connection on turbocharger Effectivity 915 i A Series Edition 0 Rev 0 72 60 00 Page 7 Dece...

Page 80: ... 5 Overboost valve Connection on throttle body Install the delivered hose scope of supply to the correct side of the overboost valve recheck if it fits ELECTRICAL INTERFACES PCV sockets The appropriate connectors on the wiring harness as well as the corresponding sockets on the PCV are color coded To avoid inappropriate behavior of the wastegate the correct linkage needs to be ensured 72 60 00 Pag...

Page 81: ...and interface description as well as the comprehension of the operating limits in every operational state is in the re sponsibility of the aircraft manufacturer The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual can be supervised by the pilot The execution of the installation must allow the op eration of the engine according to the Operators Manual I...

Page 82: ...Notes Page 10 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 NOTES BRP Rotax INSTALLATION MANUAL ...

Page 83: ...interfaces 5 Electrical interfaces 5 Mechanical interfaces 6 Installation notes 7 Installation overview 8 Fuel lines 9 Inlet line 9 Return line 9 Bypass line 9 Coarse filter 10 Water trap gascolator 10 Fine filter 10 Fuel pump 11 Fuel pressure sensor 11 Fuel pressure regulator 11 Fuel tank 11 Fuel shut off valve 12 Effectivity 915 i A Series Edition 0 Rev 0 73 00 00 Page 1 December 01 2017 ...

Page 84: ...BRP Rotax INSTALLATION MANUAL Figure 7 1 Fuel System 73 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 85: ...TION For a detailed System description refer to the latest issue of the Operators Manual SYSTEM LIMITATIONS Operating limits Refer to latest issue of the Operators Manual Effectivity 915 i A Series Edition 0 Rev 0 73 00 00 Page 3 December 01 2017 ...

Page 86: ...ace overview and components 1 Fuel rail 2 4 outlet line hydraulic Interface 2 Fuel rail 1 3 feed line hydraulic Interface 3 Fuel rail 4 Fuel hose assy 5 Injection valves 6 Fuel pump connectors electrical interface 7 Banjo bolt 73 00 00 Page 4 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 87: ...re efficiency according to ISO 19438 edition 11 2003 dirt particles 35 μm are not permissible ATTENTION Independent from the ambient conditions e g fuel pressure and temperature and independent from the used fuel the design of the fuel system must prevent from vapour lock conditions Vapour lock may result in engine stoppage Connection M14x1 5 or AN 6 9 16 18 UNF Fuel outlet Interface Parameter Min...

Page 88: ... optional Sensor adapter for connectivity di rectly on the fuel inlet of the fuel pressure regulator Interface Parameter Min Max Tightening torque 23 Nm 17 ft lb 27 Nm 20 ft lb Component mass adapter with sensor 80 g Connection M12 x 1 5 73 00 00 Page 6 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 89: ...the respective appli cable regulations the consideration of the system limitations and interface description as well as the comprehension of the operating limits in every operational state is in the re sponsibility of the aircraft manufacturer The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual can be supervised by the pilot The execution of the insta...

Page 90: ...L INSTALLATION OVERVIEW Figure 7 3 Fuel system 1 Fuel tank 2 Fuel pump 1 3 Fuel pump 2 4 Fine filter 5 Fuel pressure regulator 6 Coarse filter water trap 73 00 00 Page 8 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 91: ...RETURN LINE The return line should have a inner diameter of at least 7 5 mm 0 3 in AN 6 or 3 8 ATTENTION Fuel lines smaller than this diameter may have a significant impact on the proper func tionality of this engine Vapour locks in the return line should be efficiently vented out of the fuel system to the at mosphere Adequate fuel tank venting system design is imperative Large vent lines with mos...

Page 92: ...tank and the fuel pumps and should be of sufficient capacity to prevent complete blockage between maintenance intervals ATTENTION An installation without coarse filter may have an significant impact on the proper func tionality of this engine WATER TRAP GASCOLATOR A suitable water trap must be installed Certification according to the latest regulations such as FAR or EASA must be conducted by the ...

Page 93: ... searched in other sections filter clogged pulsation of lines kinks in the hoses etc of the fuel system FUEL TANK In case of supply problems of the fuel pump the fuel tank should be emptied and filled with AVGAS If the problem does not occur at the next test with AVGAS then this is a sign of formation of vapour locks when using MOGAS or auto fuel Following points may have a positive impact on the ...

Page 94: ... line Multi tank system without catch header tank FUEL SHUT OFF VALVE The fuel shut off valve position on the pressure side of the fuel system after the fuel pump module can have an unfavorable impact on the installation of the 915 i 73 00 00 Page 12 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 95: ...tations 3 Interface description 4 Interface overview 4 Hydraulic interfaces 5 Air Cooling interfaces 7 Installation notes 9 Installation overview 9 Water inlet elbow 9 Expansion tank 10 Coolant hoses 10 Coolant 11 Validation of installation 12 Effectivity 915 i A Series Edition 0 Rev 0 75 00 00 Page 1 December 01 2017 ...

Page 96: ...BRP Rotax INSTALLATION MANUAL Figure 8 1 Cooling System 75 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 97: ... overheat due loss of coolant The boiling point of the coolant is mainly influenced by the type of coolant mixture ration percentage water rate the system pressure opening pressure of radiator cap For permissable coolant types see SI 915i 001 latest issue System pressure System Limit Min Max Coolant system pressure 1 2 bar 18 psi Hose connecting expansion tank System Limit Min Max Withstand of hos...

Page 98: ...olant hose 2 Water pump housing 3 Expansion tank 4 Radiator cap 5 Expansion tank connection hy draulic Interface 6 Water inlet elbow hydraulic Interface 7 Water outlet hydraulic Interface 8 Coolant temperature sensor 9 Cooling air baffle 75 00 00 Page 4 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 99: ...ow at 5800 rpm 70 l h Slip on length 19 mm 0 75 in Figure 8 3 Water inlet elbow Connection Outer diameter 27 mm 1 07 in Water outlet Interface Parameter Min Max Cooling system pressure relative 1 6 bar 232 psi Cooling water temperature 20 C 4 F 130 C 266 F Cooling water flow at 5800 rpm 70 l h Connection Inner diameter 25 mm 0 98 in Effectivity 915 i A Series Edition 0 Rev 0 75 00 00 Page 5 Decemb...

Page 100: ...x INSTALLATION MANUAL Expansion tank connection Interface Parameter Min Max Slip on length 18 mm Figure 8 4 Expansion tank connection 75 00 00 Page 6 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 101: ...r fuselage manufacturer in select ing suitable cooling air ducts Specification Description Cooling capacity The cooling air baffle must be designed so that it transfers thermal energy of approx 6 kW 5 7 BTU s at take off performance Cross section of air baffle Cross section of the air baffle min 100 cm 15 50 in2 Material Glass fibre reinforced plastic or heat and fire resistant material Attachment...

Page 102: ...BRP Rotax INSTALLATION MANUAL Figure 8 6 Cooling air baffle for tractor 75 00 00 Page 8 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 103: ...perational state is in the re sponsibility of the aircraft manufacturer The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual can be supervised by the pilot The execution of the installation must allow the op eration of the engine according to the Operators Manual INSTALLATION OVERVIEW Figure 8 7 Cooling system schematic 1 Expansion tank 2 Pressure cap ...

Page 104: ...nufacturer should give the possibility to the pilots to check the coolant level in the expansion tank It is also necessary to inform the pilots about the daily inspection of the coolant level in the aircraft manufacturers Operators Manual To allow this inspection e g a flap or panel on the cowling or a warning instrument in the cockpit for low coolant level should be foreseen COOLANT HOSES N NO OT...

Page 105: ...Parameter Min Max Temperature resistance 125 C 257 F Pressure durability 5 bar 72 psi Inner diameter 25 mm 1 Bending radius 175 mm 6 89 in Figure 8 9 Aluminium tube 1 bead Hoses Hoses exposed to direct heat radiation from exhaust system must be suitably protected with e g heat resistant protection tubes The hose between the overflow bottle and the expansion tank should be as short as possible COOL...

Page 106: ...temperature is measured using a temperature sensor 1 which is installed on cylinder 4 ATTENTION It is possible to record a false measurement when measuring fluid temperatures If fluid volume is lost and sensor is not fully submerged in the liquid the indicat ing instrument could incorrectly display a lower temperature by measuring the air temperature instead of the coolant temperature Cylinder wal...

Page 107: ...eck the efficiency of the coolant radiator and its proper sealing between cowling and radiator Check the proper flow between expansion tank and overflow bottle Ensure that no ram is induced onto the overflow bottle vent line Check efficiency of air duct and proper air flow through the duct and around cylinders Consider cold winter and hot summer conditions in ground and flight testing Check proper...

Page 108: ...Notes Page 14 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 NOTES BRP Rotax INSTALLATION MANUAL ...

Page 109: ...escription 4 System limitations 4 Interface description 5 Interface overview 5 Electrical interfaces 5 Mechanical interfaces 10 Installation notes 12 Installation overview 12 LANE Select Switches 13 Fuel pump switches 14 Start button 14 Effectivity 915 i A Series Edition 0 Rev 0 76 00 00 Page 1 December 01 2017 ...

Page 110: ...BRP Rotax INSTALLATION MANUAL Figure 9 1 Engine management system EMS 76 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 111: ...ALLATION MANUAL SPECIAL TOOLS Description Part number Crimping pliers MOLEX 64016 0035 63811 4400 n a Disassembly tool MOLEX 63813 1500 n a Effectivity 915 i A Series Edition 0 Rev 0 76 00 00 Page 3 December 01 2017 ...

Page 112: ...ngine ground and the aircraft ground would be short circuited Component tem peratures limitation Limitation see Chapter 00 00 00 Approval of electric and electronic components Connections When connecting the wiring harness with the ECU take into account the labeling on the wiring harness and the ECU Although the connectors are mechanically coded i e wiring harness connector A1 can only be connecte...

Page 113: ... 5 Regulator A electrical Interface 6 ECU electrical mechanical Interface 7 AAPTS electrical mechanical Interface 8 Wiring harness 9 Starter relay connectors electri cal Interface 10 Fuel pump connectors electrical Interfaces 11 Wiring harness grounding ELECTRICAL INTERFACES Harness interface connector A The HIC A connector allows powering ECU Lane A and Fuel Pump A interfaces to Indica tion eleme...

Page 114: ...er source or by one of the internal generators A connection between Terminal 1 and Terminal 7 will power ECU Lane A A connection between Terminal 3 and Terminal 9 will power Fuel pump 1 Figure 9 4 HIC A connector Engine controls 76 00 00 Page 6 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 115: ...ent 10 A Harness Interface Connector B Figure 9 5 HIC B connector In case the EMS is powered by an external power source or by one of the internal generators A connection between Terminal 1 and Terminal 9 will power ECU Lane B A connection between Terminal 3 and Terminal 11 will power Fuel Pump 2 A connection between Terminal 4 and Terminal 12 will actuate the Starter Relay Effectivity 915 i A Ser...

Page 116: ...rent 10 A 12 SUPP_START_ SWITCH 4 CONN_STARTER_ REL_SW Nominal Voltage 12 V Nominal Current 5 A The HIC B connector allows powering ECU Lane B Interfaces to indication elements are described in Chapter 77 00 00 X1 X2 Connector See Chapter 24 00 00 section Interface Description Regulator A See Chapter 24 00 00 section 24 00 00 section Interface Description Starter Relay See Chapter 80 00 00 section...

Page 117: ...L Wiring harness grounding ATTENTION The grounding cable must be attached to airframe ground Fuel pump See Chapter 73 00 00 section Interface Description Effectivity 915 i A Series Edition 0 Rev 0 76 00 00 Page 9 December 01 2017 ...

Page 118: ...MANUAL MECHANICAL INTERFACES Engine Control Unit ECU Figure 9 7 ECU mounting points 1 Connector socket A1 2 Connector socket A2 3 Connector socket B 76 00 00 Page 10 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 119: ...aximal diameter of screw in the interior of the mounting hole 6 mm 0 24 in Only mount sensor with a washer Ø 10 mm 0 39 in or with an adequate screw head diameter The maximum permissible pressure at the mounting flange may not exceed 20 N m2 0 0029 psi Effectivity 915 i A Series Edition 0 Rev 0 76 00 00 Page 11 December 01 2017 ...

Page 120: ...tations and interface description as well as the comprehension of the operating limits in every operational state is in the re sponsibility of the aircraft manufacturer The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual can be supervised by the pilot The execution of the installation must allow the op eration of the engine according to the Operators ...

Page 121: ...t Button S6 LANE SELECT SWITCHES Lane Select Switch A S4 Interface Parameter Value Switch type Toggle normally open Nominal voltage 28 V Nominal current 7 5 A Number of poles 1 pole Lane Select Switch B S5 Interface Parameter Value Switch type Toggle normally open Nominal voltage 28 V Effectivity 915 i A Series Edition 0 Rev 0 76 00 00 Page 13 December 01 2017 ...

Page 122: ...inal current 10 A Number of poles 1 pole Fuel Pump Switch 2 S7 Interface Parameter Value Switch type Toggle normally open Nominal voltage 28 V Nominal current 10 A Number of poles 1 pole START BUTTON Start Button S6 Interface Parameter Value Switch type Button normally open non locking Nominal voltage 28 V Nominal current 5 A Number of poles 1 pole 76 00 00 Page 14 December 01 2017 Effectivity 915...

Page 123: ...HIS CHAPTER System description 3 System limitations 3 Interface description 4 Interface overview 4 Electrical interfaces 4 Installation notes 8 Installation overview 8 Warning lamps 10 CAN interfaces 10 Effectivity 915 i A Series Edition 0 Rev 0 77 00 00 Page 1 December 01 2017 ...

Page 124: ...BRP Rotax INSTALLATION MANUAL Figure 10 1 Engine indication 77 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 125: ... only be used in combination with a B U D S Aircraft USB to CAN converter and B U D S Aircraft Software It is not possible to use the Mainte nance CAN for other displaying or data logging purposes CAN wiring For the Display and the Maintenance CAN twisted cables 3 pins CAN_H CAN_L CAN_ GND must be used for the CAN connections to ensure a high electromagnetic compatibil ity in data transmission Eff...

Page 126: ...tic shielding of CAN Bus ELECTRICAL INTERFACES Harness Interface Connector A The HIC Connector A is equipped with a Maintenance CAN interface a Display CAN inter face and terminals which can be used to actuate a warning lamp indicating the current sta tus of the ECU Lane A Interfaces to control elements are described in Chapter 76 00 00 77 00 00 Page 4 December 01 2017 Effectivity 915 i A Series E...

Page 127: ...N_LOW_1_A 6 CAN_HIGH_1_A 10 CAN_GND_2_A Maintenance CAN Lane A 11 CAN_LOW_2_A 12 CAN_HIGH_2_A Connector HIC Connector A included in the engines scope of delivery The HIC Connectors must be mounted according to the procedure prescribed in Chapter 76 00 00 The Display CAN is based on the CAN Aerospace protocol For detailed interface descrip tion contact an authorized ROTAX Distributor or its indepen...

Page 128: ...rning Lamp Terminal Supply Terminal Ground Interface Parameter Mi n Max Nom inal 2 SUPP_WARN_ LAMP_B 10 WARN_LAMP_B Nominal voltage 12 V Nominal current 120 mA CAN Interfaces Terminal Specification 6 CAN_GND_1_B Display CAN Lane B 7 CAN_LOW_1_B 8 CAN_HIGH_1_B 14 CAN_GND_2_B Maintenance CAN Lane B 15 CAN_LOW_2_B 16 CAN_HIGH_2_B Terminal Supply Terminal Ground Interface Parameter Mi n Max Nom inal 2...

Page 129: ...The Display CAN is based on the CAN Aerospace protocol For detailed interface descrip tion contact an authorized ROTAX Distributor or its independent Service Center Electromagnetic shielding of CAN Bus The electromagnetic CAN Bus shielding lugs need to be connected with the Airframe Ground Connector Ring Terminal M6 Effectivity 915 i A Series Edition 0 Rev 0 77 00 00 Page 7 December 01 2017 ...

Page 130: ...tion as well as the comprehension of the operating limits in every operational state is in the re sponsibility of the aircraft manufacturer The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual can be supervised by the pilot The execution of the installation must allow the op eration of the engine according to the Operators Manual INSTALLATION OVERVIEW ...

Page 131: ...6 Harness Interface Connector B Schematic Part Function 8 Harness Interface Connector B 9 Warning Lamp B H2 10 Warning Lamp B LED H2 V2 11 Resistor 1 5 kΩ F8 12 Resistor 1 kΩ F9 13 Display CAN B 14 Maintenance CAN B Effectivity 915 i A Series Edition 0 Rev 0 77 00 00 Page 9 December 01 2017 ...

Page 132: ...ive of the final application The proof of consistency with the safety objective of the final application is the responsibility of the installer Maintenance CAN To be able to connect the Maintenance CAN A and B with the B U D S Aircraft USB to CAN converter the Maintenance CAN A and B should be connected with two separate Sub D DE9 9 pin sockets It is highly recommended to conduct those connectors ...

Page 133: ...er 78 00 00 EXHAUST SYSTEM TOPICS IN THIS CHAPTER System description 3 System limitations 3 Interface description 4 Interface overview 4 Mechanical interfaces 5 Effectivity 915 i A Series Edition 0 Rev 0 78 00 00 Page 1 December 01 2017 ...

Page 134: ...BRP Rotax INSTALLATION MANUAL Figure 11 1 Exhaust system 78 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 135: ...st may be done if following re quirements are met All exhaust parts added by the OEMs are decoupled weight and vibration from the ex haust provided Exhaust back pressure must not exceed following limits System Limit Min Max Exhaust back pressure ambient pressure 1000 mbar 155 mbar 180 mbar Exhaust back pressure ambient pressure 900 mbar 175 mbar 205 mbar Exhaust back pressure ambient pressure 800 ...

Page 136: ...ATION MANUAL INTERFACE DESCRIPTION INTERFACE OVERVIEW Figure 11 2 Exhaust interfaces 1 Exhaust tail pipe 2 Exhaust pipe 3 Exhaust manifold assy 78 00 00 Page 4 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 137: ... tail pipe position Interface Parameter Value Tail pipe bending position P1 x axis 491 mm 19 33 in y axis 396 mm 15 59 in z axis 208 mm 8 19 in Tail pipe diameter 54 mm 2 13 in Tail pipe material 1 4845 X8CrNi25 21 Effectivity 915 i A Series Edition 0 Rev 0 78 00 00 Page 5 December 01 2017 ...

Page 138: ...Notes Page 6 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 NOTES BRP Rotax INSTALLATION MANUAL ...

Page 139: ...ace description 5 Interface overview 5 Oil tank dimensions 5 Oil tank interfaces 7 Oil pump 8 Installation notes 11 Installation overview 11 Oil lines 11 Filling and ventilation of the oil system 13 Validation of installation 16 Crankcase pressure measurement 16 Effectivity 915 i A Series Edition 0 Rev 0 79 00 00 Page 1 December 01 2017 ...

Page 140: ...BRP Rotax INSTALLATION MANUAL Figure 12 1 Lubrication system 79 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 141: ...he lubrication system must be designed such that the permissible operating tempera tures and maximum values are not exceeded Pressure limits Following measurements must be exceeded when operating the engine at full throttle System Limit Min Max Crankcase pressure relative to ambient pres sure at full load 5800 rpm Oil temperature 90 C 194 F Ambient pressure 400 mbar Pressure loss in suction line 2...

Page 142: ...tank is located higher oil might trickle through bearing clearances into the crankcase during longer periods of engine stop If fitted too low it might damage the oil circuit Figure 12 2 Oil tank installation position The oil tank must be installed on a low vibration position and not on the engine directly The oil tank cover and the oil drain screw must be easily accessible 79 00 00 Page 4 December...

Page 143: ...nterface 2 Oil return outlet hydraulic interface 3 Oil return outlet turbocharger hy draulic interface 4 Oil tank in and outlets hydraulic interface 5 Oil filter hydraulic interface OIL TANK DIMENSIONS Oil tank The oil tank must be mounted by using appropriate clamps Effectivity 915 i A Series Edition 0 Rev 0 79 00 00 Page 5 December 01 2017 ...

Page 144: ...ION MANUAL Figure 12 4 Oil tank dimensions 1 Oil tank 2 Oil dipstick 3 Oil tank cover 4 Hex screw M12x2 5 Gasket ring C 12x18 6 Profile clamp 163 79 00 00 Page 6 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 145: ...k cover is also marked IN oil tank inlet OUT oil tank outlet ATTENTION Both oil tank inlets must be connected with the oil return outlets 2x Oil tank inlet Interface Parameter Value Screw socket 3 4 16 UNF Tightening torque 25 Nm 18 ft lb Oil tank outlet Interface Parameter Value Screw socket 3 4 16 UNF Tightening torque 25 Nm 18 ft lb Effectivity 915 i A Series Edition 0 Rev 0 79 00 00 Page 7 Dec...

Page 146: ... the exhaust Formation of smoke is possible Oil tank inlet tur bo charger Interface Parameter Value Screw socket 3 4 16 UNF Tightening torque 25 Nm 18 ft lb OIL PUMP Oil pump inlet The oil pump inlet must be connected directly with the oil tank outlet Interface Parameter Value Screw socket 3 4 16 UNF Tightening torque 25 Nm 18 ft lb Oil return outlet The oil return outlet must be connected directl...

Page 147: ...nnection for the oil return line according to the propeller configuration and oil system layout Interface Parameter Value Screw socket 3 4 16 UNF Tightening torque 25 Nm 18 ft lb Oil return outlet turbo charger The oil return outlet turbo charger must be connected directly with the oil tank inlet turbo charger Interface Parameter Value Screw socket M10 x 1 Tightening torque 15 Nm 133 in lb Effecti...

Page 148: ...BRP Rotax INSTALLATION MANUAL Figure 12 7 Oil return outlet turbo charger 79 00 00 Page 10 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 149: ...e operating limits in every operational state is in the re sponsibility of the aircraft manufacturer The aircraft manufacturer has to make sure that the operating limits given in the Operators Manual can be supervised by the pilot The execution of the installation must allow the op eration of the engine according to the Operators Manual INSTALLATION OVERVIEW Figure 12 8 Lubrication system overview...

Page 150: ...ing 2 Cowling N NO OT TE E Water is a by product of the combustion of fuel Most of this water will dissipate from the combustion chamber with the exhaust gases A small amount will reach the crankcase and must be disposed of through a venting line The venting line must be protected from any kind of ice formation for condensa tion by using e g isolation protection or a routing in a hose with hot air...

Page 151: ...lator so that the air line pressure is between 0 4 bar 5 8 psi and 1 bar 14 5 psi Do not exceed 1 bar 14 5 psi N NO OT TE E The oil tank cover is not pressure tight some air can escape 7 Turn the engine by hand in direction of normal rotation until the first pressure indication ap pears on the oil pressure gauge Normally this will take approx 20 turns Depending on in stallation it may take up to 6...

Page 152: ...ll lubrication system connections lines and clamps for leaks and tightness ENVIRONMENTAL NOTE Protect the environment Do not spill oil and pay attention for adequate disposal 79 00 00 Page 14 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 153: ...ANUAL Figure 12 10 Setup for venting the oil system 1 Suction line 2 Oil return line 3 Free end 4 Tank 5 Oil return line 6 Purging connection 7 Plug Effectivity 915 i A Series Edition 0 Rev 0 79 00 00 Page 15 December 01 2017 ...

Page 154: ...read for the crankshaft must be M8 3 Start the engine according the Operators Manual and read the crankcase pressure value at full throttle 4 Compare the read out value with the limitations for the crankcase pressure specified in the section System Limitations of this chapter If the readings exceed the pressure limits then the flow resistance in the oil return line from oil sump to oil line is too...

Page 155: ...APTER System description 3 System limitations 3 Interface description 4 Interface overview 4 Electrical interfaces 4 Installation notes 5 Installation overview 5 Wiring 5 Validation of installation 7 Effectivity 915 i A Series Edition 0 Rev 0 80 00 00 Page 1 December 01 2017 ...

Page 156: ...BRP Rotax INSTALLATION MANUAL Figure 13 1 Starting 80 00 00 Page 2 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 ...

Page 157: ...hermal durability Suitable for short starting periods only Activate starter for max 10 seconds without inter ruption followed by a cooling period of 2 minutes Aircraft ground The engine block must be connected to the aircraft using a properly sized line minimum the same cable cross section as starter supply for the purpose to cause the starter cur rent and to avoid static electricity between the e...

Page 158: ...nal must be conducted as M5 screw connection suitable for cable lug according to DIN 46225 Tightening torque Min 3 Nm 27 in lb Max 5 Nm 44 in lb Negative terminal The engine block must be connected to the airframe using a properly sized ground strap minimum the same cable cross section as the starter supply for carrying the starter cur rent and to avoid static electricity between the engine and th...

Page 159: ... operating limits given in the Operators Manual can be supervised by the pilot The execution of the installation must allow the op eration of the engine according to the Operators Manual INSTALLATION OVERVIEW Figure 13 3 Engine starting circuit 1 Starter relay 2 Wiring WIRING The engine block must be connected to the airframe using a properly sized ground strap for carrying the starter current and...

Page 160: ...0 0 109 0 8 5 I 9 27 9 I 29 5 45 918 0 071 70 0 109 0 9 I 9 5 29 5 I 31 2 48 469 0 075 70 0 109 0 9 5 I 10 31 2 I 32 8 51 02 0 079 70 0 109 0 The internal resistance of the battery and the resistance of the electrical system wires contact points relay contacts largely determine the performance of the starting system Therefore the total loop resistance RSmax may not exceed 0 015 Ω RSmax Ʃ R RiBatt ...

Page 161: ...t execution and compliance with all given system limitations and interface descriptions as well as with standards and norms given by authorities must be proven by the aircraft manufacturer Check starting Check of starting at cold weather condition Starter interface must be executed Effectivity 915 i A Series Edition 0 Rev 0 80 00 00 Page 7 December 01 2017 ...

Page 162: ...Notes Page 8 December 01 2017 Effectivity 915 i A Series Edition 0 Rev 0 NOTES BRP Rotax INSTALLATION MANUAL ...

Page 163: ...orage 4 Engine Unpacking 4 Exhaust tail pipe 5 Expansion tank 10 F Fine filter 10 Fuel interfaces 5 Fuel lines 9 Fuel pressure regulator 11 Fuel pressure sensor 11 Fuel pump 11 Fuel pump switch 14 Fuel shut off valve 12 Fuel system overview 8 Fuel tank 11 G Gascolator 10 General 2 Grounding cables 10 H Handling the engine 7 I Inlet line 9 Installation notes 10 7 11 Installation overview 10 9 12 8 ...

Page 164: ...ply 4 Start button 14 System description 3 4 System Description 3 System limitations 3 6 3 4 3 System Limitations 3 T Table of amendments 1 Technical documentation 14 Terms 6 Type description 3 V Validation of installation 13 12 16 7 W Warning lamp 10 Water inlet elbow 9 Water inlet Water outlet 5 Water trap 10 Wiring 5 BRP Rotax INSTALLATION MANUAL ...

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Page 166: ..._________________________________________ Type of aircraft __________________________________________________________ Aircraft registration no ROTAX authorized distributor WWW FLYROTAX COM www abm at and TM are trademarks of BRP Rotax GmbH Co KG 2017 BRP Rotax GmbH Co KG All rights reserved Okea istockphoto com ...

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