ROTAX 915iS

Maintenance
Manual
 1. General
1.1 Introduction

Correct inspections and maintenance is the base of a reliable and safe flying experience.
This chapter recommends procedure for correct ground handling and servicing of RISEN. It
also determines inspection and maintenance requirements to be followed; it is wise to
adequate inspections and maintenance to climatic and flying conditions.

WARNING:
The airplane operator is also obligated to read carefully the Operators Manual for the installed
Rotax Engine Type and the Operator’s Manual for – Electrical Adjustable Aircraft Propeller
Idrovario, actual valid revision and all avionic manuals.

NOTE:
This handbook contains supplementary data supplied by the aircraft manufacturer. Porto
Aviation Group SA is not responsible for the consequences of improper use of RISEN aircraft,
not respecting the instructions reported in this manual.
Operating the aircraft is at your own risk.

The Maintenance Manual contains all the handling and maintenance information for
appropriate, safe and efficient use of Risen aircraft. It is mandatory to study this manual, at
its full length, prior to using the aircraft. The manual must always be on board of the plane,
together with operating instructions concerning engine, propeller, ballistic rescue system
and other systems installed.

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 1.2 Warnings, Cautions and Notes
The following definitions apply:

WARNING The non-observation of this procedure leads to an immediate or important

degradation in flight safety.

CAUTION The non-observation of this procedure leads to a minor or to a long-term

degradation in flight safety.

NOTE Any special item not directly related to safety but which is important or unusual.

V= Visual, you can perform the task autonomously.

C= Cleaning, you can perform the task autonomously.
L= Lubricate, you can do autonomously.
R= Replace regardless the part conditions. Simple task by yourself; by authorized staff otherwise.
A=check up by Authorized and specialized staff.
Oh=Overhaul.

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 2. Scheduled Maintenance
Before First 100 200 500 1.000
50h 10.000h
flying 5h h h h h
PROPELLER (READ PROP MANUAL) A Oh
Spinner surface integrity V
Spinner attachment screws V
Propeller bushings R
Propeller hub assembly R
Propeller pitch V A
Propeller balance V A
Propeller surface V
ENGINE (READ ENGINE MANUAL*) A A
Engine cowling screws V V V
Engine mount structure V V A
Engine silent blocks and rubber V A R
Air filters C A
Spark Plugs CHECK ENGINE MANUAL
Electrical links V V A
Joints and connectors V V A
Gascolator V C C A
Hoses V V A
Hoses thermal protection cover V V A R
Exhaust muffler V V A A
Exhaust holding springs V V A R
Exhaust mount structure V V A
Throttle control lever/wire V V A R
Propeller control lever/wire V V A R
FUSELAGE A Oh
External surface V
Wing connection points V A
Landing gear attachment points V V A
Hinges V V A-L L A-L
Control hatches and panels V V A
Ruddervator connection points V V A
WING A Oh
Surface and structural integrity V A A Oh
Ailerons free play V A
Flap system V
Bearings V
Fuselage/wing joints V V A
Sealing tape/Mylar tape V V V
Lights V
Fuel vent/drain holes C A
Fuel tank cap integrity V

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 Before First 100 200 500 1.000
50h 10.000h
flying 5h h h h h
RUDDERVATOR A Oh
Surface and structural integrity V A A Oh
Control surface free play V A
Joints to fuselage V A
Attachment bolts V A
Bearings V
Links to control rods V V
Sealing tape/Mylar tape V V V
PROBES A Oh
Pitot tube V V V
Static ports V V V
Instrument-lining connection V
Lining and hoses integrity V A A A R
Pitot tube connection V
Static port connection V V V
Instrument setting V V
LANDING GEAR Oh
Tires V V EVERY 5 YEARS or WHEN NECESSARY
Wheel rim/Axis V A
Landing gear attachment point A
Brakes disk V A
Brake fluid V A
Brake fluid line V A A
Bearings V
Fairings/landing gear doors V
Retractable leverage V A
Actuators A
CABIN A Oh
Panel V
Instruments V CHECK EVERY YEAR
Levers/controls V V A
Seatbelts V A
Seats integrity V A
Riveting/screws V A
Rescue system handle V L* A
Links between wing/fuselage V A
Spar pins/bolts V A
Control rods links V A
Fuses V
Baggage compartment integrity V A
Canopy V
Canopy actuators V V A

(* Silicon oil spray on activation handle)

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 Before First 50h 100 200 500 1.000 10.000
flying 5h h h h h h
CONTROLS R
Control column V L
Control column links V A+L
Rudder pedals V L
Rudder pedals connections V A+L
Control column rods A
Rudder pedals rods A
Ruddervator mechanical mixer A+L
Bolts/screws A+L
Hinges V
Trim V
Trim connection V
Trim lever
Flap handle V
Flap symmetrical actuation V
Rescue system handle V
Landing gear handle V
Throttle V
Bearings under seats V A+L
Autopilot unit links/connections V A
FUEL SYSTEM Oh EVERY 5 YEARS or 1000h Oh
Leaks V A
Water presence in the linings V
Water in the fuel tanks V
Dirt in gascolator filter V
Wing fuel caps V
Fuel tanks O-rings R EVERY 5 YEARS or 500h
Fuel valves V
Fuel vents V
ELECTRICAL SYSTEM A R
Batteries V V A
Battery connections/links V A
Instrument panel connections V V
Lights links V V
Fuses V V
OIL AND WATER LINES A Oh
Leaks V V V
Oil and cooling fluids level V V
Hoses attachment points
Radiators and heat exchangers V V
Radiators pressure caps V V V
*REFER TO ROTAX 915iS series MAINTENANCE MANUAL FOR COMPLETE INFORMATION

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Oil and fuel pressure limitations

Refer to Rotax 915iS Operators Manual.

3. Primary and secondary structures

The primary structures that carry flight and ground loads consist of the fuselage shell, the
wing, tail unit and landing gear. These parts of the plane must be checked: no holes,
fractures, delamination or anomalies shall be present. Any failure to the primary structure
would compromise structural integrity and flight safety.
Secondary structures consist of pilot and passenger seats, cockpit and luggage compartment
bulkheads, landing gear fairings and control panel structure which, in case of failure, would
affect the operation of the aircraft but not lead to its loss.

4. Engine

REFER TO ROTAX 915iS series MAINTENANCE MANUAL FOR COMPLETE INFORMATION.

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 5. Recovery System
(It is mandatory to read the recovery system operational manual!)

Line to chute canopy

Ballistic Parachute
harnesses are
shown here.

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 WARNING:
Maximum deployment speed is 320 km /h (175 kt)!

The aircraft is equipped with a rescue system, precisely a ballistic parachute. The system is
produced by Stratos 07 s.r.o. and is a model MAGNUM 601, suitable for high speed and aircraft up
to 759 kg.

Minimum altitude operation highly depends on the attitude and position of the aircraft with
respect to the ground when the device is deployed. The recommendation is to operate as quickly
as possible and when possible above 200 m.
Example: In general, survivability is greater after deployment in a straight or slightly banked
attitude rather than in an inverted flying condition. This is true especially at very low altitude.

The parachute is not simply released in the free stream, but it is pushed up to 15 m circa to and
then opened completely, this operation is to reduce loads on attaching points. The time interval
between activation, deployment and full opening of the canopy is around 3 seconds, depending on
atmospheric conditions, flight speed and attitude.

Before Take-Off, remember to remove the safety locking pin in the cockpit. Taking out the pin will
allow pulling the handle in case of emergency. Upon landing is mandatory to insert back the safety
locking pin in order to avoid inadvertent deployments.

In the eventuality of system deployment, it is mandatory to replace it. If it has not been used, but
a hard landing has been performed or there is the suspect for any damage, it is recommended to
contact the manufacturer.

Check all visible parts of the rescue device before every flight. Look for corrosion near the
activation handle located in the cockpit. The parachute harnesses and fuselage attaching points
should be in good conditions.
Front harness passes externally along the right side of the fuselage; the aft harnesses pass on the
top rear surface of the fuselage. If any part along the right side or top rear surface of the fuselage
is damaged, it may have compromised the integrity of the system. Call the manufacturer or an
approved maintenance centre.

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 6. SAFETY HARNESSES

Safety harnesses produced by Schroth, they have 3 attaching points to the fuselage and one quick
release safety buckle.

7. PITOT-STATIC LINE

The Pitot-static probe is attached on the bottom of the right wing. The pressure lines run through
the wing up to the fuselage and sensors casing and instrument panel.

WARNING:
When washing and cleaning the surfaces of the aircraft, absolutely avoid water entering the
static port and the pitot tube. If any water or foreign matter obstructs the pressure lines,
contact the manufacturer or any approved maintenance organisation before flying again.

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 8. PRIMARY AND SECONDARY CONTROL SURFACES

8.1 Tolerances and adjustments for primary controls

Check for correct movement of primary control surfaces, namely ailerons and ruddervators.
Aileron movement range must be free of play and be able to move in the +16,5° (upward)
and -12,9° (downward).
Ruddervator, rudder movement ±10,5°.
Ruddervator, elevator movement +19° (upward) and -12 (downward).

Acceptable tolerances imply no more than ±1° of deviation from original values and
difference between the corresponding symmetrical surfaces.
If any check measurement is not corresponding with the given values do not take-off and
contact an authorized service centre.

8.2Flaps

Flap system operated through dedicated control system. There are four positions, 0°, TO,
LND (Landing) and FULL, from 0° to 37,5°.
Flaps are actuated with three electro-mechanics actuators through the use of the switch on
the control panel. For proper use, see operation manual.

It is important to keep the flap rails and the flap system always operative and efficient. To do
so it is highly recommended checking and greasing the rails of the system before every first
flight of the day or whenever mud or dirt may have come in contact with the mechanism.
Greasing the flap rails it’s an easy task; the product used should be a white lubricant paste
F.U. graded, easy to purchase and non-toxic. It is better to use gloves, but bare-hands won’t
be dangerous either.
When renewing the grease film on the rails, it is necessary to extract the flaps to full
position, clean out the old remaining grease film by using degreasing products and when the
degreasing agent has been whipped or evaporated, it is possible to proceed and apply a new
thin layer of grease with the finger, sliding through the rail contour.
It is important to grease all parts that move with respect to each other and to not exaggerate
with the amount of product, as it may collect dirty and dust.

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 Checking and greasing Fowler flaps system

9. Fuel System
Approved fuels are:
 Min. RON 95 EN 228 Super (Unleaded Automotive Gasoline RON 95)
 EN 228 Super Plus (Unleaded Automotive Gasoline RON 98)
 AVGAS 100 LL (not recommended)

CAUTION:
Due to higher lead content in AVGAS, the wear of the valve seats, depositing in
combustion chamber and lead sediments in the lubrication system will increase.
Therefore, use AVGAS only if you encounter problems with vapour lock or if the other fuel
types are not available.

Fuel system is installed as per Rotax 915iS installation manual.

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 10. Landing Gear
10.1 Landing gear wheels

The main landing gear is fitted with 11x4.00-5 8PLY Aero Classic TL tires.
These are inflated at 58 psi (4 bar).
Nose landing gear is fitted with 3.00-4'' 4PLY Veloce TL tire. This is inflated at 36 psi (2,48
bar)

10.2 Wheel braking system

Brakes are manufactured by Beringer.

10.2.1 Air in the Hydraulic Brake system

If braking action appears to be reduced and applying full brakes is not effective, it may be
necessary to remove air bubbles in the braking system. Venting the hydraulic system is
possible by unscrewing the caps of the reservoirs of fluid, present behind the rudder pedals
and removing the inner seal cap.
Move backwards the rudder pedal that has no fluid reservoir until it lays resting on the
cockpit floor. Push and pull the brake lever a few times, this should be enough to let the air
bubbles move into the reservoir and then out of the system. When there is no more
presence of air in the lines, it is possible to put back the seal cap in position and screw the
main cap, too. In case it is necessary, repeat the procedure for the other portion of the
breaking system, on the other pilot seat.

WARNING:
In case of difficulties or air bubbles not venting, consult the manufacturer or an authorised
maintenance centre.

Other causes of insufficient braking action may be caused by nuts incorrectly tightened not
allowing the brake shims to press effectively. It may be necessary to consult a professional
maintenance centre or the manufacturer.

10.2.2 Hydraulic brakes system

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 11. ENGINE LUBRICATION SYSTEM

(Picture from Rotax operational manual)

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 12. ENGINE COOLING SYSTEM

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 13. Electric Schemes
a. Fuselage/Panel general appliances electric scheme

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 b. Landing gear electric scheme

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 c. Engine electric scheme

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 14.Labels and placement

The following labels are placed in the cockpit and external surface

Label placed in the dashboard panel in front of the pilots.

Label placed close to the ballistic parachute lever.

The rescue system shall be activated following the procedures in
section 3.16 Emergency recovery system. The handle is placed
between the head rests.

Labels placed on the dashboard panel.

Where the symbols are related to fuses of (in order from left to right, top bottom):

Strobo light Fuel pump 1 Instruments

Navigation system Turbo control unit Primary Flight Display 1
Landing gear Fuel pump 2 Autopilot
Battery master Propeller Primary Flight Display 2
Avionics master Canopy Transponder
Fuel pump Trim Communications
Auto pilot Light
Canopy Televel

Anti-skid in Line Fan On/Off

Regulator fuses

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14.1 Other labels (generic)

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 15.MOVING THE AIRCRAFT AND OTHER GROUND OPERATIONS

15.1 Moving the aircraft

During ground operations when the aircraft must be moved on the apron without its own
power, it can be pulled from the propeller root, just close to the propeller spinner. Before
touching the propeller check the magnetos are switched OFF.
Alternatively, the aircraft can be pushed holding down the aft part of the fuselage, in front of
the tail unit, so that the front landing gear is cleared from the ground and turning the aircraft
on the main landing gear provides more freedom of movement for an easier ground
handling.

The airplane can be pushed are behind the cockpit on the fuselage at a height corresponding
to the lower canopy line or on the area where pilot and passenger usually lean in order to
access the aircraft. Do not push other parts of the leading edge of the wing!
Do not push or pull from the trailing edge of the wings or tail units!

WARNING:
Do not push on the leading edge of tail unit!
Do not push or pull from the trailing edge of the wing or tail unit!

15.1.1 Ground handling and parking

Towing forward.
The airplane can be easily manoeuvred by hand, by pulling on the propeller at its root, just
close to the propeller spinner.
Turning and Moving backward.
1. Push down the aft section of the fuselage, near the tail, to lift the nose wheel
2. Using this technique the airplane can be easily turned.
3. The aircraft can be pushed backward by pushing on the propeller at its root or on the wing
leading edge.
4. Do not push on the trailing edge.

CAUTION:
Do not push on control surfaces.
Do not push or lift on the spinner.

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15.1.2 Lifting the aircraft
If it is necessary to lift the aircraft in order to make repairs to the main or front landing gear,
it is possible to sustain the aircraft with sawhorses placed under the fuselage beneath the
cockpit area. Be careful to provide a stable support when doing so. Ground transport, with
wing detached can only be performed by authorized maintenance centres with the use of an
approved trailer with spar-housing attachment points.

15.2 Draining and refuelling

The gascolator is attached to the firewall. To drain the fuel system, open the drain valve on
the gascolator and activate Fuel Pumps. Fuel should be collected in a canister to prevent
ground pollution. To close the valve, switch OFF Fuel Pumps and turn in opposite direction.
Do not use force or special tools.

The aircraft has wing tanks. Refuelling can be done by pouring fuel through the reservoir
openings on top of the wings.

16. CLEANING AND CARE

16.1 External surfaces and canopy

It’s recommended to clean the surface of the aircraft after every flight. Use water only and a
soft cotton or microfiber cloth. Special care is needed when cleaning the canopy. Use lots of
water to loosen and rinse away bugs. Only use soft cloth to prevent scratches. If cleaned
regularly, there is no need for special cleaning products. Always contact your dealer for
advice when using special cleaning products.

WARNING:
When washing and cleaning the surfaces of the aircraft, absolutely avoid water entering the
static port and the pitot tube. If any water or foreign matter obstructs the pressure lines,
contact the manufacturer or any approved maintenance organisation before flying again.

WARNING:
Do not use solvent, thinner (acetone), trichloroethylene, carbon tetrachloride and similar
hydrocarbon chlorides.

16.2 Interior

Do not use water for cleaning the interior. Use car interior cleaning products. Follow
cleaning instructions of glass cockpit hardware manufacturer for cleaning avionics.

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