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Running on Condition

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10 months 4 weeks ago #19850 by rspall
Running on Condition was created by rspall
Folk,

As per usual, looking to benefit from your invaluable experience...

My Rotax 912ULS will be celebrating its 12 birthday next year - not sure which month, but the Serial # is 5648209 with gearbox #35138 - in case anyone can get me more detailed information ?

Anyway, it has 190 hours on the engine, and along with the aircraft, it spent 3 years in storage 2014, 2015, 2016. It flew 12 hours last year and so far 15 hours this year. Except for storage years, it has had yearly oil changes, although its coolant was changed for first time this year! All fuel hoses were changed last year, and coolant hoses were changed this year. Finally, I am planning on overhauling the carburetors this winter.

Other than that, there has been no other maintenance forward of the firewall. The carburetors were balanced last year and rechecked again this year. It has always run on Unleaded, non ethanol MOGAS. The spark plugs and air filter were changed this year. I did a leak down test before I put away for winter last year and got 79/80 for every cylinder, along with 160 - 165 direct compression on each cylinder. Finally the last oil filter change saw no debris in the cut open filter, and the the magnetic plug had very minor debris.

So...

A local Rotax mechanic (and certified Canadian Aircraft mechanic) who checks over the aircraft every year says that Rotax 912's are 'bullet proof', and provided they are looked after correctly, they easily go well beyond 12 years TBO!

I am hoping to run the engine 'on condition' during its teenage years, and hopefully it will not be as troubling as most teenagers!. It is installed in a Canadian Advanced Ultralight aircraft, and therefore has no formal TBO requirements. However, safety is important, so does anyone have any advice on changes to maintenance schedule, or additional engine procedures that I should follow once it has gone past its 12 year TBO? I want straight talk, even if that means folk recommending not running on condition and replacing with a new engine - I have been told that is cheaper than an overhaul!

For example, should I start doing laboratory oil analysis on every oil change, etc?

Any suggestions / advice appreciated.

Roger

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10 months 4 weeks ago #19855 by alananpat
Replied by alananpat on topic Running on Condition
Hi Roger,

I'm in almost the same situation as you. I am doing my 11th annual now. With 12 years and 834hrs, I asked the tech center at Lockwood about what will go wrong after 12 years in service and was told it will be seals. I have already had to replace the coolant fitting orings on top of the heads so I can agree on that part. All the rubber is always replaced on a 5 year schedule. I'm going to run on condition until the engine is no longer serviceable and replace with new as I believe the cases must be replaced for my 2006 model engine during overhaul.

Let's see what the other Roger says.

Alan

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10 months 4 weeks ago #19856 by Roger Lee
Replied by Roger Lee on topic Running on Condition
This can be one of those topics where one side wants the TBO followed and the other side likes the on condition side.

I like the on condition side provided that owners have been doing their preventive maint. over the life of the engine. I have many friends that are doing on condition.

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell

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10 months 3 weeks ago #19868 by rspall
Replied by rspall on topic Running on Condition
Alan,

I am in same position with case needing replacement. So I will simply follow all preventative maintenance schedules and keep a close eye on cylinder pressures, leaks, rubber, and for metallic debris in oil filter changes (and magnetic plug).

Hopefully I can get another 10 years :-)

Roger

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7 months 2 weeks ago #20762 by xcropduster
Replied by xcropduster on topic Running on Condition
At what serial number was the crank case material changed in 2006?

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7 months 2 weeks ago #20763 by Roger Lee
Replied by Roger Lee on topic Running on Condition

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell

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7 months 2 weeks ago #20766 by xcropduster
Replied by xcropduster on topic Running on Condition
Thanks Roger.
After reading SB-912-057UL I am still confused as to the status of engine SN 5646671. Section 1.1 seems to indicate that the crankcase change occurred at SN 6,775.790 for a 912ULS but section 3.4.1 would indicate a crankcase change at 5,646.559.
Can you help me better understand this SB.
Thanks,
Jim

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7 months 2 weeks ago - 7 months 2 weeks ago #20768 by Roger Lee
Replied by Roger Lee on topic Running on Condition
You're good to go by just 112 engines. You qualify for the extension. You will need to replace the oil pressure plug screw and spring and then make sure all this gets documented in the logbook.

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell
Last edit: 7 months 2 weeks ago by Roger Lee.
The following user(s) said Thank You: xcropduster

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7 months 2 weeks ago #20778 by xcropduster
Replied by xcropduster on topic Running on Condition
Thanks Roger for your invaluable expertise.

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5 months 2 weeks ago #21462 by Marcpa
Replied by Marcpa on topic Running on Condition
I have same problem. My engine number 56.51.060
According to sb I can have extension to 2000 hours if I change oilplug and ALSO do a gearbox check.
Not clear to me is if the 12 years tbo will then also go up till 15 years.
Any info on this is very welcome as I just bought the plane and it will be 12 years old next year.
Thanks

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5 months 2 weeks ago #21464 by Roger Lee
Replied by Roger Lee on topic Running on Condition
TBO Hours and years in service both increase.

Roger Lee
LSRM-A & Rotax Instructor & Rotax IRC
Tucson, AZ Ryan Airfield (KRYN)
520-574-1080 Home (TRY HOME FIRST)
520-349-7056 Cell

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5 months 2 weeks ago #21466 by Marcpa
Replied by Marcpa on topic Running on Condition
Thanks that is a relieve. Can you give me any info on gearbox inspection as the eengineer I talked with said he needed to open the gearbox and change the gears. This is not what I read it looks to me only an inspection and messuring from the outside after taking the gearbox from the engine?

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5 months 2 weeks ago #21468 by RobSeaton
Replied by RobSeaton on topic Running on Condition
only change the gears if they are worn out. As detailed in the heavy maint manual.
The following user(s) said Thank You: Marcpa

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4 months 6 days ago #21894 by 914RB
Replied by 914RB on topic Running on Condition
I guess from what I have read that I will just wear my 914UL out before I have to worry about some of this. The engine is in an Autogyro Cavalon and I have put 645 hrs. on it in just a little over 2 years and thankfully I have experienced very few problems. I make sure the oil and filter are changed between 30 and 50 hrs. and always send a sample to the lab for analysis and the only thing I see in their report is high lead content if I happen to be away from my base airport and need to use Avgas. So far so good and I hope it stays that way. We are in the excavation business and all our equipment fluids are sent out for testing so I do the same with the Cavalon.

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