Mandatory ALERT Service Bulletin: Inspection and Replacement of Oil Spray Nozzle for ROTAX® Engine Types 912 i, 915 i, and 916 i (Series) SB-912 i-016 / SB-915 i-016 SB-916 i-006

Rotax Replica Tool 976740 - STL File (Digital Download) by Omnav Aviation

https://nd02u5-1f.myshopify.com/products/rotax-replica-tool-976740-stl-file-digital-download?fbclid=IwZXh0bgNhZW0CMTEAAR2eSIxSwOyB0PlTVlNWPTb7gJoCt8CcOnSw7BP1kqYGmFD4dS_juT_XHno_aem_vMq6o0YT3h6_lYRB8ueb4A

This is an STL file for printing the tool, along with printing instructions.  It is for those that have access

to 3D printing to fabricate the tool themselves.

The files are compressed into a single ZIP file.

This information and the STL are the property of Omnav Aviation.  Purchase and download of the STL

grants the purchaser unlimited use of the STL for production of the tool for their use only.  The STL file,

any variants or derivations based on it, and the instructions are not to be shared with others who have

not purchased the rights to use it.

This is a high-quality 3D printed version of the hard-to-get-your-hands-on tool required to complete the

flow test prescribed in Rotax ASB-912 i-016 R1 / ASB-915 i-016 R1 / ASB-916 i-006 R1

 (revision of SB-912 i-016 / SB-915 i-016 / SB-916 i-006).

* Note, some images below show the old-style replica with the small hose barb exiting the rear of the tool. 

This version, like the original, requires a greater clearance between the rear of the iS engine and the firewall. 

 The current version sold here has been modified for a standard 1/4" hose barb exiting the side, eliminating

about 2" - 5" of required clearance for use.

** Also note, these are practically identical to the original Rotax tool with regard to external dimensions. 

There is an embedded o-ring in the orifice, with a thin layer of plastic on the top.  Please be mindful

with your careful use, to keep this orifice in good working order.  It is a good idea to lubricate the o-ring

 with a drop of engine oil before use.

*** To use this tool, you will need to build a testing device, complete with a pneumatic flow meter,

a pneumatic pressure regulator capable of controlling pressure to 300 mbar/4.35 psi, and a shut-off valve. 

 Be sure to regulate the pressure before opening the valve to this tool.  It has been tested to the test

 pressure (300 mbar/4.35 psi),

 but not for higher pressures.  Specifications and parts required for building the test rig can be

 found in the Rotax ASB/SB noted above.

Disclaimer and Limitation of Liability

Use at Your Own Risk: This tool is provided as-is and is intended for use as an engine testing tool.

The buyer assumes all risk and responsibility for the proper use and maintenance of this tool.

No Warranty: This product is sold without any express or implied warranties, including but not

 limited to the warranties of merchantability, fitness for a particular purpose, or non-infringement.

Limitation of Liability: Under no circumstances shall Omnav Aviation, LLC be liable for any direct,

indirect, incidental, special, or consequential damages arising from the use or inability to use this product,

even if Omnav Aviation, LLC has been advised of the possibility of such damages.

Indemnification: The buyer agrees to indemnify, defend, and hold harmless Omnav Aviation,

 LLC, its officers, directors, employees, and affiliates from any claims, liabilities, damages, and expenses

(including reasonable attorneys' fees) arising from the use of this product.

Intended Use: This product is designed for testing Rotax iS oil spray nozzle flow rate per

 Rotax ASB-912 i-016 R1 / ASB-915 i-016 R1 / ASB-916 i-006 R1. Any use of the product outside

 of its intended purpose is at the buyer's own risk and may void any applicable warranties or return policies.

Compliance with Laws: The buyer is responsible for ensuring that the use of this product complies

with all applicable laws, regulations, and safety standards.

May I ask fellow 915iS pilots this: have any of you been able to do this inspection with the engine installed on the aircraft?

I wonder whether there even are aircraft that have enough spare room between the engine and firewall, together with whatever auxiliary equipment might be installed there, to even access the generator and apply the flow meter kit.

Any idea how many are failing the test? I’m curious how wide spread the problem really is? Still need to test of course. 

I purchased the STL 3D print file posted by Rotax-Owner and sold by Omnav Aviation.  The file (model) looks well designed and the print instructions are well detailed. I would have designed it myself, but to do that you either start from scratch with your own design (with some measurements being difficult to obtain), or get your hands on a Rotax tool, which is not easy to borrow. The Omnav design is modeled from the original Rotax tool, and has been tested. I think that’s worth the $100.00.  

The seller recommends printing with one of the more advanced engineering materials or ABS, and says not to use standard PLA or similar materials. There are valid reasons for this. Also, you should know your slicing software well enough to make specific settings for a high quality print and be able to specify specific support types. Lastly, the model is designed so the O-Ring is embedded in the print so you need to be able to program a pause in the print cycle to place the O-Ring, then resume the print.  I use CURA, which handles this easily. You could also just watch the print at that stage and then just manually pause the print at the right time.

I’m about to print using Nylon Carbon Fiber filament in a heated build chamber. I will report back tomorrow on how it goes.  My only negative comment so far is that it would be nice if you could see the print instructions before purchasing the model.  That way folks could determine if they have the proper equipment and skill set to complete a working tool.  

I've ordered the pre-made replica tool from Omnav, and now I'm assembling the rest of what I'll need to do the inspection... Figure 2 on page 5 and the table on page 7 say I'll need Loctite 243 & engine oil (both of which I have) as well as Loctite 648 Green and Locking Paint. The former is available from Lockwood for $417, the latter for $87. It also says I'll need Loctite 7063, a cleaner/degreaser, which Lockwood doesn't sell, and isn't even listed on Henkel's US site (though it is on the UK site). Are there acceptable alternatives to these products?