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Page 1Open in PDF

d07234.fm ASB-915 i-021R1 / ASB-916 i-009R1 This ASB supersedes ASB-915 i-021 / ASB-916 i-009, initial issue, dated 18 November 2025

ALERT SERVICE BULLETIN Inspection of the propeller gearbox of ROTAX® 915 i and 916 i (Series) Aircraft Engines ATA System: 72-10-00 Propeller gear assy.

Description:

Mandatory: unsafe condition, therefore legally binding after publishing an (E)AD as referenced in EASA CM-21.A-J-001.

Obligatory: no unsafe condition, but BRP-Rotax demands to implement measures referred to in this document.

Recommended: no unsafe condition, BRP-Rotax assumes it is advisable to implement measures referred to in this document.

Optional: no unsafe condition, advancement but no need to implement measures referred to in this document.

MANDATORY OBLIGATORY RECOMMENDED OPTIONAL X

1) Planning information To obtain satisfactory results, procedures specified in this publication must be accomplished with accepted methods in accordance with prevailing legal regulations.

BRP-Rotax GmbH & Co KG cannot accept any responsibility for the quality of work performed in accomplishing the requirements of this publication.

1.1) Applicability Regardless of whether previous revisions have already been cleared, this revision of the Alert Service Bulletin must be observed.

All ROTAX® certified injected turbo engines of following types are affected if they have installed one of the propeller gearbox with S/N listed in the Chapter 4) Appendix:

This applies either when the propeller gearbox was:

- installed in the original delivery configuration (see columns 2 and 3 of the appendix), or

- subsequently installed during repair, maintenance, or any other gearbox replacement.

1.2) Concurrent ASB/SB/SI and SL In addition to this Alert Service Bulletin the following documents must be observed:

- SI-915 i-001 / 916 i-001, Selection of suitable operating fluids for ROTAX® Engine Types 916 i & 915 i (Series), current revision.

Engine type 915 iSc2 A 915 iSc3 A 915 iSc2 C24 915 iSc3 C24 916 iSc2 A 916 iSc3 A 916 iSc2 C24 916 iSc3 C24 916 iSc3 B

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ASB-915 i-021R1 / ASB-916 i-009R1

ALERT SERVICE BULLETIN

- in general all relevant Alert Service Bulletins (ASB), Service Bulletins (SB), Service Instructions (SI), Service Letters (SL), Service Instruction - Parts and Accessories (SI-PAC) with relevance to perform this maintenance, repair or overhaul task.

1.3) Reason Following a field-reported incident, a deviation in the assembly process of the propeller gearbox was identified. Specifically, the omission of the M40x1.5 collar nut can, in the worst case, result in the propeller shaft being pulled out of the housing during operation. This condition constitutes a potential unsafe situation that could lead to loss of propeller retention and possible in-flight engine failure.

1.3.1) Reason for revision

- Correction of table in section 1.1

- Correction of appendix header and the S/N of the affected gearboxes was added

1.4) Subject Inspection of the propeller gearbox of ROTAX® 915 i and 916 i (Series) Aircraft Engines.

1.5) Compliance

- On stored engines: prior to delivery.

- On uninstalled engines: before the initial installation.

- On installed engines: Carry out this inspection before next flight on the engines listed in section

1.1, according to the instructions in section 3, but at the latest after 1 year (from the date of the initial issue of this Alert Service Bulletin).

1.6) Approval The technical content of this document is approved under the authority of the DOA ref.

EASA.21J.048.

1.7) Labor time A labor credit will be provided for work performed by a technician with current applicable iRMT rating. To apply for labor credit, contact your ROTAX® Authorized Distributor or their independent Service Centers.

1.8) Mass data Change of weight - - - none Moment of inertia - - - unaffected

1.9) Electrical load data No change.

1.10) Software modifications No change.

m WARNUNGmWARNING Non-compliance with these instructions could result in engine damages, personal injuries or death.

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d07234.fm ASB-915 i-021R1 / ASB-916 i-009R1

1.11) References In addition to this technical information refer to current issue of

- in general Illustrated Parts Catalog (IPC) and in particular:

Chapters 61-20-00 and 72-10-00

- in general Operators Manual (OM)

- in general Installation Manual (IM)

- in general Maintenance Manual Line (MML)

- in general Maintenance Manual Heavy (MMH) and in particular:

Chapters 61-20-00 and 72-10-00 NOTE: The status of the Manuals can be determined by checking the table of amendments.

The 1st column of this table shows the revision status. Compare this number to the one listed on the ROTAX website:

www.flyrotax.com. Updates and current revisions can be downloaded for free.

1.12) Other Publications affected None.

1.13) Interchangeability of parts None.

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ASB-915 i-021R1 / ASB-916 i-009R1

ALERT SERVICE BULLETIN

2) Material Information

2.1) Material Price and availability will be provided on request by ROTAX® Authorized Distributors or their independent Service Centers.

2.2) Company support information Any possible support by BRP-Rotax will be provided on request by ROTAX® Authorized Distributors or their independent Service Centers.

2.3) Material requirement per engine Parts requirement for inspection:

Fig. 1 Parts requirement for inspection Fig.no. New part no. Qty/engine Description Application 1-1 825016 1 OIL FILTER PACKAGED Inspection 1-2 * AR ENGINE OIL XPS / AERO - SHELL SPORT PLUS 4 Oil level check 1-3 230150 5 SEALING RING A 10X14 Oil line assy.

* See SI-912 i-001,SI-912-016,SI-914-019,SI-915 i-001,SI-916 i-001 Selection of suitable operating fluids for Rotax Engine Type 916 i (Series), 915 i (Series), 912 i (Series), 912 and 914 (Series).

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d07234.fm ASB-915 i-021R1 / ASB-916 i-009R1

Parts requirement for gearbox replacement:

Fig. 2 Parts requirement for gearbox replacement Fig.no. New part no. Qty/engine Description Application 2-1 825016 1 OIL FILTER PACKAGED Inspection 2-2 950141 1 SEALING RING A 8X13 Lock pin bolt 2-3 845431 1 FRICTION WASHER VS30 Drive gear 2-4 832953 1 NEEDLE BEARING 40-52-20 Overload clutch 2-5 810310 1 OIL INLET FLANGE Torsion shaft 2-6 430175 1 O-RING 46X3 Governor flange 2-7 830415 2 O-RING 7X2 Governor flange 2-8 686810 (1) GEARBOX 2.54 - 3 916 iS (Series) Propeller gearbox replacement 916 i (Series) 2-8 686790 (1) GEARBOX 2.54 - 3 915 iS (Series) Propeller gearbox replacement 915 i (Series) 2-9 230150 5 SEALING RING A 10X14 Oil line assy.

2-10 841153 (1) HEX. SCREW - M12X20 V2 Torsion shaft 2-11 950380 1 O-RING -32X4 Governor flange 2-12 * AR ENGINE OIL XPS / AERO - SHELL SPORT PLUS 4 Oil level check * See SI-912 i-001,SI-912-016,SI-914-019,SI-915 i-001,SI-916 i-001 Selection of suitable operating fluids for Rotax Engine Type 916 i (Series), 915 i (Series), 912 i (Series), 912 and 914 (Series).

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ASB-915 i-021R1 / ASB-916 i-009R1

ALERT SERVICE BULLETIN

2.4) Material requirement per spare part None.

2.5) Rework of parts None.

2.6) Special tooling/lubricants- /adhesives- /sealing compounds Fig. 3 Special tools Fig. no. Description Qty/engine Part no. Application 3-1 Puller assy. 1 877660 Propeller gearbox 3-2 Locking pin 1 240880 Crankshaft 3-3 Extractor assy. 1 877615 Propeller shaft, Needle bearing 3-4 Press-in jig 1 276000 Needle bearing 3-5 Pull stud 1 276004 Needle bearing 3-6 Twist tool 1 276962 Overload clutch

- LOCTITE 7063 AR - Cleaning / degreasing

- LOCTITE 243 AR 897651 Oil inlet flange, Countersunk screw

- LOCTITE 603 AR 899789 Collar nut M40X1.5

- LOCTITE 648 AR 899788 Hex. nut M30X1.5

- LOCTITE 5910. AR 899791 Propeller gearbox m WARNUNGNOTICE If using these special tools observe the manufacturers specifications.

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d07234.fm ASB-915 i-021R1 / ASB-916 i-009R1

3) Accomplishment/Instructions ROTAX® reserves the right to make any amendments to existing documents, which might become necessary due to this standardization, at the time of next revision or issue.

NOTE: Before maintenance, review the entire documentation to make sure you have a com - plete understanding of the procedure and requirements.

Accomplishment All measures must be implemented and confirmed by at least one of the following persons or organizations:

- ROTAX® - Airworthiness representatives

- ROTAX® - Authorized Distributors or their independent Service Centers

- Persons approved by the respective Aviation Authorities

- Persons with approved qualifications for the corresponding engine types. Only authorized persons (iRMT, Level Heavy Maintenance) are entitled to carry out this work

- Persons with type-specific training NOTE: Indicates supplementary information which may be needed to fully complete or under - stand an instruction.

General Further material on general inspection, maintenance and repair can also be found in relevant Advisory Circular AC 43.13 from FAA.

Advisory Circular The Advisory Circular (AC) contains maintenance methods, techniques and practices.

Procedure

3.1) Illustrated Parts Catalog - related information All work has to be performed in accordance with the relevant ROTAX® Instructions for Continued Airworthiness (ICA) of the respective engine type.

Step Procedure 1 Check the criteria given on page 1, section 1.1, if the aircraft engine is affected by this SB.

2 Check the engine logbook and maintenance documentation, if this SB has already been ac - complished.

See current Illustrated Parts Catalog (IPC) for the respective engine type, Chapters 61-20-00 and 72-10-00.

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ASB-915 i-021R1 / ASB-916 i-009R1

ALERT SERVICE BULLETIN

3.2) Installation - related information

3.3) Operation - related information

3.4) Maintenance (Line) - related information

See current Installation Manual (IM) for the respective engine type.

See current Operators Manual (OM) for the respective engine type.

See current Maintenance Manual Line (MML) for the respective engine type.

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d07234.fm ASB-915 i-021R1 / ASB-916 i-009R1

3.5) Maintenance (Heavy) - related information

3.5.1) Inspection of the propeller gearbox Before the propeller gearbox is removed, the work described below must be carried out:

- General visual inspection, see current Maintenance Manual Line (MML) for the respective engine type, Chapter 05-20-00, Section Visual inspection.

- Remove the surrounding assemblies, see current airframe and propeller manufacturer’s instructions.

- If installed, remove the gearbox oil line assy, see current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 61-20-00, Section Removal.

- If installed, remove the external alternator, see current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 24-30-00, Section Removal.

See Fig. 4 Fig. 4 Step Procedure 1 Inspect the oil filter and magnetic plug. See current Maintenance Manual Line (MML) for the respective engine type, Chapter 12–20–00, Section - Inspection of the oil filter components.

NOTE: If contamination is found, contact your local ROTAX ® Authorized Distributors or their independent Service Centers.

If no contamination is present, proceed to step 2.

2 Remove the propeller gearbox.

See current Maintenance Manual Line (MML) for the respective engine type, Chapter 05-50-00, Section - Removal of the propeller gearbox.

3 Remove the overload clutch assy. (1) and damping clutch assy. (2).

See current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 72-10-00, Section - Disassembly of the propeller gearbox.

4 Inspect for the presence of Collar nut M40x1.5 LH (3).

NOTE: If collar nut is present, proceed to step 5.

If no collar nut is present, proceed to section 3.5.2.

1 Overload clutch assy.

2 Damping clutch assy.

3 Collar nut

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ASB-915 i-021R1 / ASB-916 i-009R1

ALERT SERVICE BULLETIN See Fig. 5 Fig. 5 Collar nut torque check See Fig. 6 Step Procedure 5 Install damper clutch (4) into the housing.

See current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 72-10-00, Section - Damper clutch installation.

NOTE: There is only one position to install the damper clutch. It is indexed through the splines of the propeller shaft (5).

Step Procedure 6 Install overload clutch (6) so, that the marks of torsion bar and carrier of the clutch are properly aligned (7).

See current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 72-10-00, Section - Overload clutch installation.

4 Damper clutch 5 Splines

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d07234.fm ASB-915 i-021R1 / ASB-916 i-009R1

Fig. 6 Overload clutch

- Install the gearbox oil line assy, see current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 61-20-00, Section Installation.

- If equipped, install the external alternator, see current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 24-30-00, Section Installation.

- Install the surrounding assemblies, see current airframe and propeller manufacturer’s instructions.

- Replenish operating fluids or check filling levels, see current Maintenance Manual Line (MML) for the respective engine type, Chapter 12-00-00.

- Purge the oil system, see current Installation Manual (IM) for the respective engine type, Chapter 79-00-00, section Purging the lubrication system.

- Make an entry in the engine logbook stating the execution of this Alert Service Bulletin and the operations performed.

- Restore aircraft to original operating configuration.

- Connect negative terminal of aircraft battery.

- Proceed to section 3.6 Step Procedure 7 Install the propeller gearbox.

See current Maintenance Manual Line (MML) for the respective engine type.

6 Overload clutch 7 Alignment marks

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ASB-915 i-021R1 / ASB-916 i-009R1

ALERT SERVICE BULLETIN

3.5.2) Replacement of propeller gearbox See Fig. 7 Fig. 7 See Fig. 8 Fig. 8 Step Procedure 1 Remove governor flange (1), O-rings 7x2 (2) and o-ring 32x4 (3) (configuration 3).

Remove oil inlet flange adapter (4) and o-rings 7x2 (2) (configuration 2).

See current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 61-20-00.

Step Procedure 2 Remove and replace the needle bearing (5), oil inlet flange (6) and o-ring 46x3 (7).

See current Maintenance Manual Heavy (MMH) for the respective engine type, Chapter 72-10-00.

1 Governor flange 2 O-ring 7x2 3 O-ring 32x4 4 Oil inlet flange adapter 5 Needle bearing 6 Oil inlet flange 7 O-ring 46X3

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