How To Maintain Rotax Engines - 100HR Inspection

[Music] come back to module prep Mike here guys so one of the videos that's been heavily requested is aircraft maintenance and today I happen to be here at the right time where several of the slings here at this link pilot Academy is going through their annual you see one of the things you'll learn early on is that maintenance is one of the most important aspects of aircraft ownership because again if you're not checking you all your engine making sure things are good you know then you're messing with your own safety so you got to be on top of it and for a lot of us especially someone like me I know I'm not the most organized person in the world and things can slip through the cracks so you need to be on top of this you need to be organized about it speaking of being organized today's video is brought to you by co flight Coll flight is an amazing platform that allows you to log in all of your records you can create no squawk codes for your aircraft it notifies you whenever you have something to do or maintenance do for your airplane and that way you don't have to worry about anything add new owners and members or even create a digital copy of your logbook you can log in your flight time log in the engine time for the aircraft and so on and so forth all of these features are available at the tip of your finger when you download the cold flight app you'll be able to have access and do all of these things with a mobile app make sure you check out cold flight today you can use the referral link to get 90 days free that's right if you use the referral code module grip you have 90 days absolutely free to vet this platform the website is called flight comm so I want you to talk to me as a no aircraft owner or somebody who runs maybe huh advice - yeah like what what does maintenance Intel what would I be looking forward to in terms of my maintenance yeah okay Mike you know it's one thing to build the aeroplane you've got an engine which comes from the manufacturer that's been tested and run so your new unit is perfect it comes it's not gonna have any leaks it's not gonna have any problems because it's actually has been test run at the factory you then install that on your beautiful they were playing that you built and the big trick there is your installation installation must be done perfectly because you can take a perfectly manufactured and test run engine and you can put that onto your sling and if you don't do the installation perfectly and very diligently you can introduce all sorts of problems so first of all and we'll cover that perhaps at another time that installation when we do the or build but if your installation is done and it's done your 40 hours of phase one flight testing and there's no problem and you sort out any small problems that might have come up you should have a very reliable aeroplane a reliable engine and the next most important thing is maintenance now maintenance on the Rotax engines they are good for tbo of two thousand hours the nine eleven five will hopefully soon be there and that means that your engine should with good maintenance reach two thousand hours without a problem ninety-nine point nine if not a hundred percent of our engines actually reach two thousand hours and it's quite sad because we're going to take this perfect engine and replace it so essentially you've got two services that you're gonna be involved with one is a 50 hour oil change and the other is a hundred hour service and a 50 hour oil change we very basically will drain the oil and we remove the oil filter and we've cut open the oil filter to see if there's any particular matter in there that might be a bearing or something starting to break down and we'll take out a magnetic plug out of the gearbox which all the oil that passes through the engine and the gearbox actually go past the magnetic plug and if there's any chip setting broken off or gear or any other parts well actually get stuck to that magnetic plug so as I say in the in the oil change basically the oil is the blood of your engine and you want to make sure that that's changed and reason me often if you're using low lead you would normally change oil every 25 hours because the lead deposits if using Mogis like we do every 50 hours you would do an oil drain which is very straightforward you drain out there and then you would remove your oil filter which is there you take that open off you cut it open we've got a special cutter you cut it open you take the paper out and you look at the filter side and see if you've got any particular matter there that might be indicating a problem that having been passed you take a magnetic plug here which is actually that's the magnetic plug now that there has a channel behind it where all the oil gets processed through the engine through the gearbox and all the oil passes past that magnetic plug and if there's any chips or anything off gears or anything that'll get picked up on on that and you'll have early warning of any possible problems that's a basic oil change then every hundred hour we do the same oil change we do inspection of everything on the engine and every 200 hours we will change spark plugs but even on every 100 hour we'll remove the spark plugs and we put in what's called a compression check where we put in compressed air the differential pressure differential pressure check which is comprehensive going into the cylinder we measure the pressure that we put in and we have a small little valve that it goes through a small jet and we measure how much of that air pressure we putting in gets lit up it can leak out again we're looking for early indication of any potential problems it can leak out through three places either through an exhaust valve an intake valve or around past the cylinder and in fact if it's really bad it might leak on your cylinder cylinder head sealed so if you get below a certain differential pressure checked there you would need then to open up and have a look and see you can hear if it's an exhaust valve by listening and the exhaust intake valve by listing the carburetor and if you listen to the oil it'll be and you yet air blowing through in the oil you hear the air blowing past the Pistons into the crankcase I mean there's quite a long list of things you go through on the 100r and that's why we use a checklist and we go but I'm just going to talk you basically through it from the nose of the airplane we've checked we'll take a remove the spinner you'll check on these propellers which is just a ground adjustable propeller you'll check the top all the torque on the bolts you'll look at the clamping system that holds the blades you look for cracks and that the talks are correct and you'll move through you'll check your torque ratings on your propeller extension so this is this is working hard you want to make sure there's never any anything going wrong here any cracks or anything you could be quite detrimental to the enjoyment of your day and you look through for leaks for seals you look through basically you look at the condition of each system so what the way I like to do it is take the oil system for example you'll start yeah once you've done all your your-your-your checks Daniel oil change you would start yeah the system basically works this is a reservoir it's a remote reservoir for the oil and you'll follow your line that goes with where it comes out of the the oil reservoir it follows along and again the good way to do any maintenance is systemic checks so we start through they follow that through you've got no leaks nothing loose here it gets then pulled through the oil cooler and up along this side follows up along here through you'll notice I keep my finger on it to check the system into the oil pump so the oil pump is actually sucking the oil on a vacuum system from their remote reservoir through the whole system so if you had a leak yet the oil wouldn't squirt out it would actually suck air in then from this point the oil pump pressurizes it through the crankcase through the big end bearings back into the crankcase and also through the end of the crankshaft into the gearbox and then from the gearbox it runs through back into the crankcase and then blowww bypass your Pistons actually blows the oil from this year like I say we follow the system from the bottom of the crankcase through this pipe back into the reservoir so you see there with my finger we walk the whole system through and that way you can check the whole system rather than just looking at stuff you actually follow systems then I would look at the yep then we have a look at the fuel system now on this is the carbureted version we look where the fuel system the few actually comes through the firewall from the fuel tanks on that part it goes down through the electrical observer pump back up and we're looking all the time for leaks for chafing of pipes and things through up here through this line into the fuel pump from the fuel pump that gets pumped back to the carburetors on the way to the carburetors it's got a t PCI with the valve for any fuel it's not being used by harbors at pump set back to the returned in the fuel tanks that way it keeps the fuel system cool this is a fuel flow monitor that's the impeller that gets driven by the fuel flow and that's what gives you your gallons per hour it goes in through to the carburetors that's a pressure read up to the to the instruments and that goes to the jus carburetors by having a look at it like it through the system I've looked very clearly see no leaks I've looked for any chafing good this is a very nice installation by the way it's done very neatly nicely laid out I really like it then you would look at your electrical system again starting yeah you've got two wires they run back to your ignition switches those would close the circuit to ground to switch the engine off so you don't want any of them rubbing rubbing through the ground so you would check those wires you check your CDI ignition which feeds into your high tension coils which sit underneath and then just look at wires things like this again yeah you're looking and aeroplanes got nearly 2,000 hours on very nicely installation done and you want to look and see if anything is wearing through for example if a wire like I was sitting on there two thousand dollars of vibration it's going to vibrate through so you look at things like that there other things to look at with Hightower's you've actually got a spring balance you put onto these spark plug caps and you pull it it needs a certain amount of pressure if it comes off you've got to replace them so the seasoned mechanic will be able to put it like that and know that it's that it's good to go we basically we've been on the fire wall now 500 for the engine things I haven't mentioned yet these cracks very important to look for cracks although that sling manufacturing standards are very high we don't find cracks ever in any structural parts but you look mechanical things can fail but as to this you know I've looked at thousands of hours of flying of of slings not once ever found any structural part crack because they well-designed well manufactured well quality controlled and they over design so it is we've got no no small cracks inning developing from fatigue but you always look for them so that basically it takes us to the fire wall from the spinner to the fire wall things that I haven't mentioned obviously like cracking propellers and they're there's a lot to look at but that all comes with your list that you get to do your inspection right airframe is another whole thing I like to do this is a thing definitely personal if you're doing personal maintenance I like to wash the airplane before I start the maintenance because when you do that you're finding cracks loose covers dents dings leaks it's a good ways to start off by washing the airplane and cleaning it it's also nicer to work on things you look at down underneath the wing here you've got some covers that you remove there there's actually removed cover that's great that that's open its have a look inside there if you look in here there's a bell crank and when you move the control surfaces you can actually see you can see how that works you're looking again for any possible cracks you're looking for seized rows joints we spray a certain spray on those so that they don't corrode and you check that they always got play on them and that they no cracks on any of these brakes of things again fling is very well designed and manufactured we never find any cracks on that even on the high arch we've never found a crack on any of that and it's quite nice that this is left open so if you just have a look in there you can basically get to see all the workings and it's the the slings designed with the with the push rod system you can see the the silver push rods down there moving so it's a very nice system to be able to check and it's not like aircraft that I've got pulleys and pull pulleys and cables and things it's it's an easy system to check and keep safe and keep well maintained you check behavior on it yes so again we've got a checklist we go through you would you know there there's two kinds of maintenance is the personal maintenance when you you the Builder and you're the pilot and it's your personal overplayed because as squawks develop or something goes wrong the instrument Eugene you get it fixed but then you'll get something like an airplane like this in the school where there might be a small and grounder will squawk that develops and it carries on flying and the that gets listed on a job card when it comes into the into the workshop and the guys will switch on the instruments go through everything will check everything will check the ELT will check that the ELT is in fact working and that it's battery is full in knotek's with the various expiry date and so will check all the instruments check the ELT will check the switches for example on the dashboard noise coming loose check all labeling check the brakes check the throttle check the action of everything so yep again we've got that long list that we go through and if you go through that you're gonna basically check everything if you do the work yourself if you get a repairman's certificate and which you can do because you built the aeroplane you would be able to do your maintenance for let's run through basically the worst scenario an annual or a hundred hour service spark plugs you need eight spark plugs three bucks 50 each you need eight of them you need three quarts of oil you need an oil filter which is twenty bucks and really that is all that you do on a service and you're going to go through in two thousand dollars you're gonna go through 20 of those services so the cost of running these engines is really good because there is nothing else to do very seldom is anything if you have serviced well and you haven't abused your airplane you warmed up in the morning you're not going to spend much more than that on anything you might get unlucky get a radiator leaked or something but even that hardly ever my airplanes go through and we work them hard here goes through 2,000 hours without any major components being replaced both on the airframe and the engine [Music]

Channel: MojoGrip

Views: 39,766

Keywords: aircraft maintenance, airplane maintenance, rotax, engine, aircraft, aircraft engines, airplane, rotax 912, rotax 915, rotax 914, mogas, oil change, airplane oil change

Id: ybKrg5yHvFM

Length: 17min 27sec (1047 seconds)

Published: Thu Oct 17 2019