Rotax 912 line maintenance check list

• Document No.

• Client , aircraft or reference

• Booked in on

  Date
• Location
  Address

• Service performed by

• Personnel

Aircraft details

• Aircraft make

• model & serial nr

• total time

• propeller make

• model & sn

Engine details

• engine model 912-

• serial nr

• Time since new

• Time since overhaul

Used operating fluids

• coolant make % mixing ratio

• oil

• fuel type (a gas/ mogas) & octane rating

• NB: this schedule must be done in conjunction with the Rotax 912, line maintenance manual edition 3/ rev0 September 01/2012

• UNLESS OTHERWISE INDICATED, ALL CHECKS ARE @ EVERY 100 Hours

1. Visual inspection of the motor

• General visual inspection of the engine for damage or abnormalities. Check cooling air ducts and cooling fins of the cylinder for obstructions, cracks, wear and good condition. Take note of changes caused by temperature influences

  Safe

  At Risk

  N/A

• Visual inspection of the temperature sensors and the oil pressure sensor. Inspect for tight fit and good conductivity

  Safe

  At Risk

  N/A

• Inspect all coolant hoses for damage, leakage, hardening, porosity, security of connections and attachments. Verify routing is free of kinks and restrictions

  Safe

  At Risk

  N/A

• Carry out visual inspection of leakage bore at the base of of wat pump for signs of leakage

  Safe

  At Risk

  N/A

• Inspect the expansion tank for damage and abnormalities.<br> Check coolant level, replenish as needed. <br>Inspect radiator cap<br>Inspect protection rubber on ezpasion tank base for correct fit

  Safe

  At Risk

  N/A

• Inspect overflow bottle for damage and abnormalities. Check coolant level, replenish as needed. Inspect line from expansion tank to overflow bottle for damages, leakage and clear passage. Inspect venting bore in cap of overflow bottle for clear passage

  Safe

  At Risk

  N/A

• Inspect all oil lines for damage, leakage, hardening, porosity, security of connections and attachments. Verify routing is free of kinks and restrictions

  Safe

  At Risk

  N/A

• Inspect all fuel lines for damage, leakage, hardening, porosity, security of connections and attachments. Verify routing is free of kinks and restrictions. In case of steel lines, also check for cracks and/ or scuff marks

  Safe

  At Risk

  N/A

• Inspect wiring and its connections for secure fit, damage and signs of wear

  Safe

  At Risk

  N/A

2. Magnetic plug

• Check the magnetic plug at every oil change

  Safe

  At Risk

  N/A

• Take photo of magnetic plug

  Media

3. Compression check

• Record test pressure (psi) -

• Pressure cylinder 1 -

• pressure cylinder 2 -

• pressure cylinder 3 -

• pressure cylinder 4 -

4. Checking the engine suspension

• Inspect engine suspension and fasteners for secure fit, including damage from heat, deformation, cracks

  Safe

  At Risk

  N/A

5. Checking the air intake system

• inspect suspension and fasteners for secure fit, including damage from heat, deformarion, cracks

  Safe

  At Risk

  N/A

• Check the air box incl. airflap actuation. Inspect sensors for tight fit, damage from heat, damage and signs of wear

  Safe

  At Risk

  N/A

6. Engine external parts

• Inspect screws and nuts of all external parts for tight fit. inspect safety wiring, replace as necessary

  Safe

  At Risk

  N/A

7. Engine cleaning

• Clean engine

  Yes

  No

  N/A

8. Checking air filter

• Check air filter

  Safe

  At Risk

  N/A

9. Checking the carburetor

• checking the idle speed

  Yes

  No

  N/A

• 200 Hr Checking the ventilation of the float chambers. Any trouble with the float chamber ventilation impairs engine and carburetor function and must therefore be avoided. <br>Check that the passage of the ventilation lines is free and no kinks

  Safe

  At Risk

  N/A

• Check for free movement of the carberutor actuation (throttle lever and starting carburetor)<br>Check the bowden cable allows the full travel of the throttel lever from stop to stop

  Safe

  At Risk

  N/A

• 200 Hr Removal/ assembly of the two carburetors for car inspection

  Safe

  At Risk

  N/A

• Check carburetor synchronization. Mechanical or pneumatic.

  Safe

  At Risk

  N/A

• Annual. Inspect the float chamber ass for contamination and corrosion

  Safe

  At Risk

  N/A

10. Inspecting carburetor socket and drip tray. 200 Hr

• Inspect the carburetor sockets for damage and abnormalities, checking for cracks, wear and good condition.<br>Take note of changes caused by temperature influence.<br>see SB-914-019-latest edition

  Safe

  At Risk

  N/A

11. Spark plug connectors. 200Hr

• Check that resistance spark plug connectors fit tightly on the spark plug<br>Minimum pull-off force is 30Nm (7lb)

  Safe

  At Risk

  N/A

11. Spark plugs

• Remove all spark plugs, check the heat range designation, clean, check electrode gap and adjust if needed. Replace as required

  cleaned

  replaced

  N/A

• 200 Hr. - Replace spark plugs.

  yes

  no

• 100 Hr. Replace spark plugs if use of leaded fuel is more than 30%

13. Flushing the cooling system

• Flushing the cooling system where conventional coolants are used

  Yes

  No

  N/A

14. Checking the propeller gearbox

• Check the friction torque in free rotation gearboxes with overload clutch. Actual friction torque NM -

• Gearbox with overload clutch. inspect overload clutch if more than 30% unleaded fuel is used. 600 Hr

  Yes

  No

  N/A

• check the gearbox (with overload clutch) 1000Hr

  Yes

  No

  N/A

• Check gearbox (without overload clutch) 600Hr

  Yes

  No

  N/A

15. Oil change

• Drain oil from tank

  Yes

  No

  N/A

• Check oil tank and clean if contaminated .Refill tank with approx 3 litres of oil.

  Yes

  No

  N/A

• Remove old filter from engine and install new oil filter (1)

  Yes

  No

  N/A

• Cut old filter without producing any metal chips and inspect filter mat (1)

  yes

  no

• Findings

• (1) 50 Hr if operation with more than 30% leaded fuel (avgas)

16. Oil level check

• Verify oil level, replenish as needed.

  Yes

  No

  N/A

17. Checking v-belt tension

• on configurations with auxiliary generator, check the attachment and v-belt tension

  Safe

  At Risk

  N/A

18. Smoothe performance of the engine

• Inspection of smooth performance of the engine. For all engines with crankcase up to SN 27811 inclusive.

  Safe

  At Risk

  N/A

• Torque in Nm:

• NOTE: At engines with new crankcase S/N 06.0010 or even higher only inspect in case of suspected slugishness

19. Engine test run

• Record ignition check rpm

• Speed drop without ignition circuit A(off)

• speed drop without ignition circuit B(off)

• A/B differencedifference

19. Engine test run Observe the safety instructions

• Observe the safety instructions !

• Start the engine and run to operating temperature. Limits see Operators manual 912 series

• Engine check rpm?

• Speed drop without ignition circuit:

• A (off), rpm?

• B (off), rpm?

• A / B (difference)

• Hit the preheating and note the speed drop, rpm?

• Preheating off, engine idle running, note idle speed, rpm?

• After engine test run retighten oil filter by hand (cold engine)

• Check for leaks

General note

• All Service Instructions and Service Bulletins are complied with

  Yes

  No

  N/A

• List all Si and Sb effectedReturning engine to service

• Photo record of any defects

  Media

• Returning engine to service

• Record hours engine was serviced

• Date service was completed

  Date

• Service/ inspection was carried out iaw manufacturers specifications and due to the service / inspection the engine is concidered:

  Fit for service

  unfit for service

• Signature responsible person

  Sign