Front Matter

Aviation Maintenance Technician Handbook–Powerplant 2023 U.S. Department of Transportation Federal Aviation Administration

Flight Standards Service

Preface

The Aviation Maintenance Technician Handbook–Powerplant (FAA-H-8083-32B) is one of a series of three handbooks for persons preparing for certification as a powerplant mechanic. It is intended that this handbook provide the basic information on principles, fundamentals, and technical procedures in the subject matter areas relating to the powerplant rating. It is designed to aid students enrolled in a formal course of instruction, as well as the individual who is studying on his or her own. Since the knowledge requirements for the airframe and powerplant ratings closely parallel each other in some subject areas, the chapters which discuss fire protection systems and electrical systems contain some material which is also duplicated in the Aviation Maintenance Technician Handbook–Airframe (FAA-H-8083-31B).

This handbook contains an explanation of the units that make up each of the systems that bring fuel, air, and ignition together in an aircraft engine for combustion. It also contains information on engine construction features, lubrication systems, exhaust systems, cooling systems, cylinder removal and replacement, compression checks, and valve adjustments. Because there are so many different types of aircraft in use today, it is reasonable to expect that differences exist in airframe components and systems. To avoid undue repetition, the practice of using representative systems and units is carried out throughout the handbook. Subject matter treatment is from a generalized point of view and should be supplemented by reference to manufacturer's manuals or other textbooks if more detail is desired. This handbook is not intended to replace, substitute for, or supersede official regulations or the manufacturer’s instructions. Occasionally the word “must” or similar language is used where the desired action is deemed critical. The use of such language is not intended to add to, interpret, or relieve a duty imposed by Title 14 of the Code of Federal Regulations (14 CFR).

The subject of Human Factors is contained in the Aviation Maintenance Technician Handbook—General (FAA-H-8083-30) (as revised).

This handbook is available for download, in PDF format, from www.faa.gov.

This handbook is published by the United States Department of Transportation, Federal Aviation Administration, Airman Testing Standards Branch, AFS-630, P.O. Box 25082, Oklahoma City, OK 73125.

Comments regarding this publication should be emailed to AFS630comments@faa.gov.

Acknowledgments

The Aviation Maintenance Technician Handbook–Powerplant (FAA-H-8083-32B) was produced by the Federal Aviation Administration (FAA). The FAA wishes to acknowledge the following contributors:

Mr. Tom Wild for images used throughout this handbook

Free Images Live (www.freeimageslive.co.uk) for image used in Chapter 1

Mr. Stephen Sweet (www.stephensweet.com) for image used in Chapter 1

Mr. Omar Filipovic (www.glasair-owners.com) for image used in Chapter 1

Mr. Warren Lane (Atomic Metalsmith, Inc.) for image used in Chapter 1

Pratt & Whitney for images used in Chapters 2, 3, 6, 7, and 8 Teledyne Continental Motors (www.genuinecontinental.aero) for images used in Chapters 2, 3, and 11 Aircraft Tool Supply Company (www.aircraft-tool.com) for images used in Chapter 4 Chief Aircraft (www.chiefaircraft.com) for images used in Chapter 4 DeltaHawk Engines, Inc. (www.deltahawkengines.com) for image used in Chapter 6 Mr. Felix Gottwald for image used in Chapter 7

Mr. Stephen Christopher (www.schristo.com) for images used in Chapter 8

Mr. Yunjin Lee for images used in Chapter 9 Mr. Marco Leerentveld (www.flightillusion.com ) for image used in Chapter 10 Aeromax Aviation, LLC (www.aeromaxaviation.com) for images used in Chapter 11 Avid Aircraft (www.avidflyeraircraft.com) for image used in Chapter 11 Flight and Safety Design (www.eco1aircraft.com) for image used in Chapter 11 Great Plains Aircraft Supply Co., Inc. (www.greatplainsas.com) for image used in Chapter 11 Lycoming Engines (www.lycoming.textron.com) for image used in Chapter 11 Revmaster LLC Aviation (revmasteraviation.com) for images used in Chapter 11 Rotech Research Canada, Ltd. (www.rotec.com) for images used in Chapter 11 Additional appreciation is extended to Mr. Gary E. Hoyle, Dean of Students, Pittsburgh Institute of Aeronautics; Mr. Tom Wild, Purdue University; Dr. Ronald Sterkenburg, Associate Professor of the Department of Aviation Technology, Purdue University; for their technical support and input.

• Table of Contents
• Chapter 1
• Aircraft Engines

General Requirements ................................................................................................................................. 1-1

Power & Weight .....................................................................................................................................1-2

Fuel Economy ........................................................................................................................................1-2

Durability & Reliability ............................................................................................................................1-2

Operating Flexibility ...............................................................................................................................1-3

Compactness .........................................................................................................................................1-3

Powerplant Selection .............................................................................................................................1-3

Types of Engines .......................................................................................................................................... 1-3

Inline Engines ........................................................................................................................................1-3

Opposed or O-Type Engines .................................................................................................................1-4

V-Type Engines......................................................................................................................................1-4

Radial Engines.......................................................................................................................................1-4

Reciprocating Engines ................................................................................................................................ 1-5

Design & Construction ...........................................................................................................................1-5

Crankcase Section.................................................................................................................................1-5

Accessory Section .................................................................................................................................1-7

Accessory Gear Trains ..........................................................................................................................1-7

Crankshafts .................................................................................................................................................. 1-7

Crankshaft Balance ..............................................................................................................................1-8

Dynamic Dampers ................................................................................................................................1-8

Connecting Rods .......................................................................................................................................... 1-9

Master-and-Articulated Rod Assembly ..................................................................................................1-9

Knuckle Pins ........................................................................................................................................1-10

Plain-Type Connecting Rods ............................................................................................................... 1-11

Fork-and-Blade Rod Assembly ............................................................................................................ 1-11

Pistons ........................................................................................................................................................1-11

Piston Construction..............................................................................................................................1-12

Piston Pin.............................................................................................................................................1-13

Piston Rings ............................................................................................................................................... 1-13

Piston Ring Construction ....................................................................................................................1-13

Compression Ring ...............................................................................................................................1-13

Oil Control Rings..................................................................................................................................1-13

Oil Scraper Ring ..................................................................................................................................1-13

Cylinders .................................................................................................................................................... 1-14

Cylinder Heads ....................................................................................................................................1-14

Cylinder Barrels ...................................................................................................................................1-15

Cylinder Numbering .............................................................................................................................1-15

Firing Order ................................................................................................................................................ 1-16

Single-Row Radial Engines .................................................................................................................1-16

Double-Row Radial Engines ................................................................................................................1-16

Valves ......................................................................................................................................................... 1-16

Valve Construction ...............................................................................................................................1-17

Valve Operating Mechanism ...................................................................................................................... 1-18

Cam Rings ...........................................................................................................................................1-18

Camshaft .............................................................................................................................................1-20

Tappet Assembly..................................................................................................................................1-20

Solid Lifters/Tappets ............................................................................................................................1-20

Hydraulic Valve Tappets/Lifters ............................................................................................................1-20

Push Rod .............................................................................................................................................1-21

Rocker Arms ........................................................................................................................................1-21

Valve Springs .......................................................................................................................................1-21

Bearings ..................................................................................................................................................... 1-22

Plain Bearings......................................................................................................................................1-22

Ball Bearings........................................................................................................................................1-22

Roller Bearings ....................................................................................................................................1-22

Propeller Reduction Gearing ...................................................................................................................... 1-23

Propeller Shafts .......................................................................................................................................... 1-23

Reciprocating Engine Operating Principles ................................................................................................ 1-25

Operating Cycles ........................................................................................................................................ 1-25

Four-Stroke Cycle ................................................................................................................................1-25

Intake Stroke ...................................................................................................................................1-26

Compression Stroke .......................................................................................................................1-27

Power Stroke ..................................................................................................................................1-27

Exhaust Stroke................................................................................................................................1-27

Two-Stroke Cycle.................................................................................................................................1-27

Rotary Cycle ........................................................................................................................................1-27

Diesel Cycle .........................................................................................................................................1-27

Reciprocating Engine Power & Efficiencies ............................................................................................... 1-27

Work ....................................................................................................................................................1-27

Horsepower .........................................................................................................................................1-28

Piston Displacement ............................................................................................................................1-28

Area of a Circle ....................................................................................................................................1-28

Compression Ratio ..............................................................................................................................1-29

Indicated Horsepower ..........................................................................................................................1-30

Brake Horsepower ...............................................................................................................................1-31

Friction Horsepower.............................................................................................................................1-32

Friction & Brake Mean Effective Pressures .........................................................................................1-33

Thrust Horsepower ..............................................................................................................................1-33

Efficiencies ................................................................................................................................................. 1-33

Thermal Efficiency ...............................................................................................................................1-33

Mechanical Efficiency ..........................................................................................................................1-35

Volumetric Efficiency ............................................................................................................................1-35

Propulsive Efficiency ............................................................................................................................1-36

Gas Turbine Engines ................................................................................................................................. 1-36

Types & Construction...........................................................................................................................1-36

Air Entrance ............................................................................................................................................... 1-37

Accessory Section ...................................................................................................................................... 1-38

Compressor Section ................................................................................................................................... 1-38

Compressor Types ...............................................................................................................................1-38

Centrifugal-Flow Compressors .......................................................................................................1-38

Axial-Flow Compressor ...................................................................................................................1-40

Diffuser ....................................................................................................................................................... 1-43

Combustion Section ................................................................................................................................... 1-43

Turbine Section ....................................................................................................................................1-46

Exhaust Section ...................................................................................................................................1-51

Gas Turbine Engine Bearings & Seals ....................................................................................................... 1-52

Turboprop Engines ..................................................................................................................................... 1-54

Turboshaft Engines .................................................................................................................................... 1-55

Turbofan Engines ....................................................................................................................................... 1-55

Turbine Engine Operating Principles.......................................................................................................... 1-56

Thrust ......................................................................................................................................................... 1-58

Gas Turbine Engine Performance .............................................................................................................. 1-59

Ram Recovery .....................................................................................................................................1-60

• Chapter 2
• Engine Fuel & Fuel Metering Systems

Fuel System Requirements .......................................................................................................................... 2-1

Vapor Lock .............................................................................................................................................2-1

Basic Fuel System ....................................................................................................................................... 2-2

Fuel Metering Devices for Reciprocating Engines ....................................................................................... 2-2

Air-Fuel Mixtures....................................................................................................................................2-3

Carburetion Principles .................................................................................................................................. 2-5

Venturi Principles ...................................................................................................................................2-5

Application of Venturi Principle to Carburetor ........................................................................................2-5

Metering & Discharge of Fuel ................................................................................................................2-6

Carburetor Systems ..................................................................................................................................... 2-7

Carburetor Types.......................................................................................................................................... 2-8

Carburetor Icing ........................................................................................................................................... 2-8

Float-Type Carburetors ................................................................................................................................ 2-9

Float Chamber Mechanism System.....................................................................................................2-10

Main Metering System .........................................................................................................................2-10

Idling System .......................................................................................................................................2-12

Mixture Control System .......................................................................................................................2-12

Accelerating System ............................................................................................................................2-13

Economizer System .............................................................................................................................2-13

Pressure Injection Carburetors .................................................................................................................. 2-14

Typical Injection Carburetor .................................................................................................................2-15

Throttle Body .......................................................................................................................................2-15

Regulator Unit ......................................................................................................................................2-15

Fuel Control Unit ..................................................................................................................................2-17

Automatic Mixture Control (AMC) .............................................................................................................. 2-18

Stromberg PS Carburetor .......................................................................................................................... 2-19

Accelerating Pump...............................................................................................................................2-21

Manual Mixture Control........................................................................................................................2-21

Fuel-Injection Systems ............................................................................................................................... 2-21

Bendix/Precision Fuel-Injection System ..............................................................................................2-21

Fuel Injector .........................................................................................................................................2-21

Airflow Section .....................................................................................................................................2-21

Regulator Section ................................................................................................................................2-22

Fuel Metering Section ..........................................................................................................................2-23

Flow Divider .........................................................................................................................................2-23

Fuel Discharge Nozzles .......................................................................................................................2-24

Continental/TCM Fuel-Injection System ..............................................................................................2-24

Fuel-Injection Pump .............................................................................................................................2-25

Air-Fuel Control Unit ............................................................................................................................2-25

Fuel Control Assembly .........................................................................................................................2-26

Fuel Manifold Valve .............................................................................................................................2-26

Fuel Discharge Nozzle.........................................................................................................................2-27

Carburetor Maintenance ............................................................................................................................ 2-27

Carburetor Removal ............................................................................................................................2-27

Installation of Carburetor .....................................................................................................................2-29

Rigging Carburetor Controls ................................................................................................................2-29

Adjusting Idle Mixtures.........................................................................................................................2-29

Idle Speed Adjustment .........................................................................................................................2-30

Fuel System Inspection & Maintenance ..................................................................................................... 2-31

Complete System ................................................................................................................................2-31

Fuel Tanks ...........................................................................................................................................2-32

Lines & Fittings ....................................................................................................................................2-32

Selector Valves ....................................................................................................................................2-32

Pumps..................................................................................................................................................2-32

Main Line Strainers ..............................................................................................................................2-32

Fuel Quantity Gauges ..........................................................................................................................2-32

Fuel Pressure Gauge...........................................................................................................................2-32

Pressure Warning Signal .....................................................................................................................2-32

Water Injection Systems for Reciprocating Engines ............................................................................2-33

Turbine Engine Fuel System—General Requirements .............................................................................. 2-33

Turbine Fuel Controls ..........................................................................................................................2-33

Hydromechanical Fuel Control ............................................................................................................2-34

Hydromechanical/Electronic Fuel Control............................................................................................2-34

FADEC Fuel Control Systems .............................................................................................................2-36

FADEC for an Auxiliary Power Unit......................................................................................................2-36

FADEC Fuel Control Propulsion Engine ..............................................................................................2-36

Fuel System Operation ........................................................................................................................2-40

Water Injection System .............................................................................................................................. 2-40

Fuel Control Maintenance .......................................................................................................................... 2-40

Engine Fuel System Components .............................................................................................................. 2-41

Main Fuel Pumps (Engine Driven) .......................................................................................................2-41

Fuel Heater ..........................................................................................................................................2-42

Fuel Filters ...........................................................................................................................................2-42

Fuel Spray Nozzles & Fuel Manifolds ..................................................................................................2-43

Simplex Fuel Nozzle ............................................................................................................................2-44

Duplex Fuel Nozzle..............................................................................................................................2-44

Airblast Nozzles ...................................................................................................................................2-44

Flow Divider .........................................................................................................................................2-45

Fuel Pressurizing & Dump Valves .......................................................................................................2-45

Combustion Drain Valves ....................................................................................................................2-46

Fuel Quantity Indicating Units .................................................................................................................... 2-46

• Chapter 3
• Induction & Exhaust Systems

Reciprocating Engine Induction Systems ..................................................................................................... 3-1

Basic Carburetor Induction System .......................................................................................................3-1

Induction System Icing ......................................................................................................................3-3

Induction System Filtering.................................................................................................................3-4

Induction System Inspection & Maintenance ....................................................................................3-4

Extinguishing Engine Fires ..............................................................................................................3-4

Induction System Troubleshooting ....................................................................................................3-5

Supercharged Induction Systems ..........................................................................................................3-5

Internally Driven Superchargers .......................................................................................................3-6

Turbosuperchargers .........................................................................................................................3-7

Normalizer Turbocharger ..................................................................................................................3-9

Ground-Boosted Turbosupercharger System ...................................................................................3-9

A Typical Turbosupercharger System .............................................................................................3-10

Turbocharger Controllers & System Descriptions ...........................................................................3-14

Variable Absolute Pressure Controller (VAPC) ..............................................................................3-14

Sloped Controller ............................................................................................................................3-15

Absolute Pressure Controller .........................................................................................................3-15

Turbocharger System Troubleshooting ...........................................................................................3-15

Turbine Engine Inlet Systems .................................................................................................................... 3-16

Divided-Entrance Duct .........................................................................................................................3-17

Variable-Geometry Duct ......................................................................................................................3-17

Compressor Inlet Screens ...................................................................................................................3-18

Bellmouth Compressor Inlets...............................................................................................................3-19

Turboprop & Turboshaft Compressor Inlets .........................................................................................3-19

Turbofan Engine Inlet Sections ............................................................................................................3-19

Reciprocating Engine Exhaust Systems .................................................................................................... 3-21

Radial Engine Exhaust Collector Ring System ....................................................................................3-22

Manifold & Augmentor Exhaust Assembly ...........................................................................................3-22

Reciprocating Engine Exhaust System Maintenance Practices ..........................................................3-22

Exhaust System Inspection .................................................................................................................3-22

Muffler & Heat Exchanger Failures ......................................................................................................3-23

Exhaust Manifold & Stack Failures ......................................................................................................3-24

Internal Muffler Failures .......................................................................................................................3-24

Exhaust Systems with Turbocharger .......................................................................................................... 3-24

Augmentor Exhaust System ................................................................................................................3-24

Exhaust System Repairs .....................................................................................................................3-24

Turbine Engine Exhaust Nozzles .........................................................................................................3-25

Convergent Exhaust Nozzle ................................................................................................................3-26

Convergent-Divergent Exhaust Nozzle................................................................................................3-26

Thrust Reversers ........................................................................................................................................ 3-27

Afterburning/Thrust Augmentation ............................................................................................................ 3-27

Thrust Vectoring ........................................................................................................................................ 3-29

Engine Noise Suppression ......................................................................................................................... 3-29

Turbine Engine Emissions.......................................................................................................................... 3-31

• Chapter 4
• Engine Ignition & Electrical Systems

Reciprocating Engine Ignition Systems ........................................................................................................ 4-1

Magneto-Ignition System Operating Principles ............................................................................................ 4-1

High-Tension Magneto System Theory of Operation .............................................................................4-2

Magnetic Circuit ................................................................................................................................4-2

Primary Electrical Circuit ...................................................................................................................4-3

Secondary Electrical Circuit ..............................................................................................................4-6

Magneto & Distributor Venting ...............................................................................................................4-7

Ignition Harness .....................................................................................................................................4-7

Ignition Switches ....................................................................................................................................4-8

Single & Dual High-Tension System Magnetos ...................................................................................4-10

Magneto Mounting Systems ................................................................................................................4-10

High- & Low-Tension Magneto Systems ......................................................................................... 4-11

Types of DC Generators ............................................................................................................................ 4-12

Series Wound DC Generators .............................................................................................................4-12

Parallel (Shunt) Wound DC Generators..........................................................................................4-12

Compound Wound DC Generators .................................................................................................4-13

Generator Ratings ...............................................................................................................................4-13

DC Generator Maintenance .................................................................................................................4-13

FADEC System Description ....................................................................................................................... 4-14

Low-Voltage Harness...........................................................................................................................4-14

Electronic Control Unit (ECU) ..............................................................................................................4-15

PowerLink Ignition System ..................................................................................................................4-16

Engine Indicating & Crew Alerting System (EICAS) ............................................................................4-16

Auxiliary Ignition Units ................................................................................................................................ 4-17

Booster Coil .........................................................................................................................................4-18

Impulse Coupling .................................................................................................................................4-19

High-Tension Retard Breaker Vibrator .................................................................................................4-21

Low-Tension Retard Breaker Vibrator ..................................................................................................4-23

Spark Plugs ................................................................................................................................................ 4-24

Reciprocating Engine Ignition System Maintenance & Inspection.......................................................4-26

Magneto-Ignition Timing Devices ............................................................................................................... 4-26

Built-In Engine Timing Reference Marks .............................................................................................4-26

Timing Discs ........................................................................................................................................4-27

Piston Position Indicators ....................................................................................................................4-27

Timing Lights........................................................................................................................................4-28

Checking the Internal Timing of a Magneto ................................................................................................ 4-29

High-Tension Magneto E-Gap Setting (Bench Timing) ........................................................................4-29

Timing the High-tension Magneto to the Engine ..................................................................................4-30

Performing Ignition System Checks.....................................................................................................4-31

Ignition Switch Check ..........................................................................................................................4-31

Maintenance & Inspection of Ignition Leads ........................................................................................4-31

Replacement of Ignition Harness.........................................................................................................4-33

Checking Ignition Induction Vibrator Systems .....................................................................................4-33

Spark Plug Inspection & Maintenance ....................................................................................................... 4-33

Carbon Fouling of Spark Plugs ............................................................................................................4-33

Oil Fouling of Spark Plugs ...................................................................................................................4-34

Lead Fouling of Spark Plugs................................................................................................................4-34

Graphite Fouling of Spark Plugs ..........................................................................................................4-35

Gap Erosion of Spark Plugs ................................................................................................................4-35

Spark Plug Removal ............................................................................................................................4-35

Spark Plug Reconditioning Service .....................................................................................................4-36

Inspection Prior to Installation..............................................................................................................4-37

Spark Plug Installation .........................................................................................................................4-38

Spark Plug Lead Installation ................................................................................................................4-38

Breaker Point Inspection......................................................................................................................4-39

Dielectric Inspection.............................................................................................................................4-41

Ignition Harness Maintenance .............................................................................................................4-41

High-Tension Ignition Harness Faults ..................................................................................................4-41

Harness Testing ...................................................................................................................................4-42

Turbine Engine Ignition Systems................................................................................................................ 4-43

Capacitor Discharge Exciter Unit .........................................................................................................4-44

Igniter Plugs .........................................................................................................................................4-45

Turbine Ignition System Inspection & Maintenance ................................................................................... 4-45

Inspection ............................................................................................................................................4-45

Check System Operation .....................................................................................................................4-46

Repair ..................................................................................................................................................4-46

Removal, Maintenance, & Installation of Ignition System Components ..................................................... 4-46

Ignition System Leads .........................................................................................................................4-46

Igniter Plugs .........................................................................................................................................4-47

Powerplant Electrical Systems ................................................................................................................... 4-47

Wire Size .............................................................................................................................................4-48

Factors Affecting the Selection of Wire Size ........................................................................................4-48

Factors Affecting Selection of Conductor Material ...............................................................................4-50

Voltage Drop in Aircraft Wire & Cable ..................................................................................................4-50

Conductor Insulation ............................................................................................................................4-52

Identifying Wire & Cable ......................................................................................................................4-53

Electrical Wiring Installation .................................................................................................................4-54

Wire Groups & Bundles .......................................................................................................................4-54

Twisting Wires......................................................................................................................................4-54

Spliced Connections in Wire Bundles ..................................................................................................4-54

Slack in Wiring Bundles .......................................................................................................................4-54

Bend Radii ...........................................................................................................................................4-55

Routing & Installation ...........................................................................................................................4-55

Protection Against Chafing ..................................................................................................................4-56

Protection Against High Temperature ..................................................................................................4-56

Protection Against Solvents & Fluids ...................................................................................................4-56

Protection of Wires in Wheel Well Area ...............................................................................................4-57

Routing Precautions ............................................................................................................................4-57

Installation of Cable Clamps ................................................................................................................4-57

Lacing & Tying Wire Bundles ..................................................................................................................... 4-58

Single-Cord Lacing ..............................................................................................................................4-58

Double-Cord Lacing .............................................................................................................................4-59

Lacing Branch-Offs ..............................................................................................................................4-59

Tying ....................................................................................................................................................4-59

Cutting Wire & Cable .................................................................................................................................. 4-60

Stripping Wire & Cable ............................................................................................................................... 4-61

Solderless Terminals & Splices ............................................................................................................4-61

Copper Wire Terminals ........................................................................................................................4-62

Crimping Tools .....................................................................................................................................4-62

Aluminum Wire Terminals ....................................................................................................................4-63

Splicing Copper Wires Using Preinsulated Wires ................................................................................4-63

Emergency Splicing Repairs ...................................................................................................................... 4-63

Splicing with Solder & Potting Compound ...........................................................................................4-63

Connecting Terminal Lugs to Terminal Blocks............................................................................................ 4-64

Bonding & Grounding ................................................................................................................................. 4-65

General Bonding & Grounding Procedures .........................................................................................4-65

Connectors ................................................................................................................................................. 4-67

Types of Connectors ............................................................................................................................4-67

Connector Identification .......................................................................................................................4-68

Installation of Connectors ....................................................................................................................4-69

Conduit ....................................................................................................................................................... 4-69

Electrical Equipment Installation ................................................................................................................ 4-70

Electrical Load Limits ...........................................................................................................................4-70

Controlling or Monitoring the Electrical Load .......................................................................................4-70

Circuit Protection Devices....................................................................................................................4-70

Switches .............................................................................................................................................4-71

Relays ..................................................................................................................................................4-71

• Chapter 5
• Engine Starting Systems

Introduction .................................................................................................................................................. 5-1

Reciprocating Engine Starting Systems ....................................................................................................... 5-1

Inertia Starters .......................................................................................................................................5-1

Direct Cranking Electric Starter .............................................................................................................5-2

Direct Cranking Electric Starting System for Large Reciprocating Engines......................................5-3

Direct Cranking Electric Starting System for Small Aircraft...............................................................5-6

Reciprocating Engine Starting System Maintenance Practices .............................................................5-6

Troubleshooting Small Aircraft Starting Systems ...................................................................................5-7

Gas Turbine Engine Starters ........................................................................................................................ 5-8

Electric Starting Systems & Starter Generator Starting System ................................................................ 5-10

Troubleshooting a Starter Generator Starting System .........................................................................5-12

Air Turbine Starters .................................................................................................................................... 5-12

Air Turbine Starter Troubleshooting Guide ..........................................................................................5-16

• Chapter 6
• Lubrication & Cooling Systems

Principles of Engine Lubrication ................................................................................................................... 6-1

Types of Friction ...................................................................................................................................6-1

Functions of Engine Oil..........................................................................................................................6-1

Requirements & Characteristics of Reciprocating Engine Lubricants .......................................................... 6-2

Viscosity .................................................................................................................................................6-2

Viscosity Index .......................................................................................................................................6-2

Flash Point & Fire Point .........................................................................................................................6-3

Cloud Point & Pour Point .......................................................................................................................6-3

Specific Gravity ......................................................................................................................................6-3

Reciprocating Engine Lubrication Systems .................................................................................................. 6-4

Combination Splash & Pressure Lubrication .........................................................................................6-4

Lubrication System Requirements .........................................................................................................6-4

Dry Sump Oil Systems...........................................................................................................................6-4

Oil Tanks ................................................................................................................................................6-4

Oil Pump ................................................................................................................................................6-6

Oil Filters................................................................................................................................................6-7

Oil Pressure Regulating Valve ...............................................................................................................6-7

Oil Pressure Gauge ...............................................................................................................................6-8

Oil Temperature Indicator ......................................................................................................................6-9

Oil Cooler ...............................................................................................................................................6-9

Oil Cooler Flow Control Valve ................................................................................................................6-9

Surge Protection Valves ......................................................................................................................6-10

Airflow Controls....................................................................................................................................6-10

Dry Sump Lubrication System Operation ............................................................................................ 6-11

Wet-Sump Lubrication System Operation ...........................................................................................6-13

Lubrication System Maintenance Practices .............................................................................................. 6-13

Oil Tank ................................................................................................................................................6-13

Oil Cooler .............................................................................................................................................6-14

Oil Temperature Bulbs .........................................................................................................................6-15

Pressure & Scavenge Oil Screens ......................................................................................................6-15

Oil Pressure Relief Valve .....................................................................................................................6-16

Recommendations for Changing Oil .......................................................................................................... 6-17

Draining Oil ..........................................................................................................................................6-17

Oil & Filter Change & Screen Cleaning ..............................................................................................6-17

Oil Filter Removal Canister Type Housing ...........................................................................................6-17

Oil Filter/Screen Content Inspection ...................................................................................................6-17

Assembly of & Installation of Oil Filters ...............................................................................................6-18

Troubleshooting Oil Systems ...............................................................................................................6-18

Requirements for Turbine Engine Lubricants ............................................................................................. 6-18

Turbine Oil Health & Safety Precautions ............................................................................................6-19

Spectrometric Oil Analysis Program ....................................................................................................6-20

Typical Wear Metals & Additives ..........................................................................................................6-20

Turbine Engine Lubrication Systems.......................................................................................................... 6-20

Turbine Lubrication System Components .................................................................................................. 6-21

Oil Tank ................................................................................................................................................6-21

Oil Pump ..............................................................................................................................................6-22

Turbine Oil Filters.................................................................................................................................6-23

Oil Pressure Regulating Valve .............................................................................................................6-24

Oil Pressure Relief Valve .....................................................................................................................6-24

Oil Jets .................................................................................................................................................6-25

Lubrication System Instrumentation ....................................................................................................6-25

Lubrication System Breather Systems (Vents) ....................................................................................6-25

Lubrication System Check Valve .........................................................................................................6-26

Lubrication System Thermostatic Bypass Valves ................................................................................6-27

Air-Oil Coolers .....................................................................................................................................6-27

Fuel-Oil Coolers ..................................................................................................................................6-27

Deoiler .................................................................................................................................................6-28

Magnetic Chip Detectors .....................................................................................................................6-28

Typical Dry-Sump Pressure Regulated Turbine Lubrication System ........................................................ 6-28

Pressure System ........................................................................................................................................ 6-28

Scavenge System ................................................................................................................................6-28

Breather Pressurizing System .............................................................................................................6-29

Typical Dry-Sump Variable Pressure Lubrication System .......................................................................... 6-29

Pressure Subsystem............................................................................................................................6-29

Scavenger Subsystem .........................................................................................................................6-30

Breather Subsystem ............................................................................................................................6-30

Turbine Engine Wet-Sump Lubrication System ......................................................................................... 6-30

Turbine Engine Oil System Maintenance ................................................................................................... 6-31

Engine Cooling Systems ............................................................................................................................ 6-32

Reciprocating Engine Cooling Systems...............................................................................................6-32

Reciprocating Engine Cooling System Maintenance ...........................................................................6-34

Maintenance of Engine Cowling ..........................................................................................................6-34

Engine Cylinder Cooling Fin Inspection ...............................................................................................6-36

Cylinder Baffle & Deflector System Inspection ....................................................................................6-36

Cylinder Temperature Indicating Systems ...........................................................................................6-37

Exhaust Gas Temperature Indicating Systems ....................................................................................6-38

Turbine Engine Cooling .............................................................................................................................. 6-38

Accessory Zone Cooling ......................................................................................................................6-38

Turbine Engine Insulation Blankets .....................................................................................................6-40

• Chapter 7
• Propellers

General ........................................................................................................................................................ 7-1

Basic Propeller Principles ............................................................................................................................ 7-1

Propeller Aerodynamic Process ................................................................................................................... 7-2

Aerodynamic Factors .............................................................................................................................7-4

Propeller Controls & Instruments ...........................................................................................................7-5

Propeller Location ........................................................................................................................................ 7-5

Tractor Propeller ....................................................................................................................................7-5

Pusher Propellers ..................................................................................................................................7-6

Types of Propellers ...................................................................................................................................... 7-6

Fixed-Pitch Propeller .............................................................................................................................7-6

Test Club Propeller ................................................................................................................................7-6

Ground-Adjustable Propeller .................................................................................................................7-6

Controllable-Pitch Propeller ...................................................................................................................7-6

Constant-Speed Propellers....................................................................................................................7-7

Feathering Propellers ............................................................................................................................7-8

Reverse-Pitch Propellers .......................................................................................................................7-8

Propeller Governor ....................................................................................................................................... 7-8

Governor Mechanism ............................................................................................................................7-9

Underspeed Condition ...........................................................................................................................7-9

Overspeed Condition ........................................................................................................................... 7-11

On-Speed Condition ............................................................................................................................ 7-11

Governor System Operation ................................................................................................................ 7-11

Propellers Used on General Aviation Aircraft ............................................................................................. 7-12

Fixed-Pitch Wooden Propellers ...........................................................................................................7-12

Metal Fixed-Pitch Propellers ................................................................................................................7-13

Constant-Speed Propellers ........................................................................................................................ 7-14

Hartzell Constant-Speed, Nonfeathering .............................................................................................7-14

Constant-Speed Feathering Propeller .................................................................................................7-15

Unfeathering ........................................................................................................................................7-16

Propeller Auxiliary Systems ........................................................................................................................ 7-17

Ice Control Systems ............................................................................................................................7-17

Anti-Icing Systems ..........................................................................................................................7-17

Deicing Systems .............................................................................................................................7-18

Propeller Synchronization & Synchrophasing......................................................................................7-19

Autofeathering System ........................................................................................................................7-20

Propeller Inspection & Maintenance .......................................................................................................... 7-20

Wood Propeller Inspection ...................................................................................................................7-21

Metal Propeller Inspection ...................................................................................................................7-21

Aluminum Propeller Inspection ............................................................................................................7-21

Composite Propeller Inspection ...........................................................................................................7-21

Propeller Vibration ...................................................................................................................................... 7-22

Blade Tracking .....................................................................................................................................7-22

Checking & Adjusting Propeller Blade Angles .....................................................................................7-23

Universal Propeller Protractor..............................................................................................................7-23

Propeller Balancing .................................................................................................................................... 7-24

Static Balancing ...................................................................................................................................7-24

Dynamic Balancing ..............................................................................................................................7-25

Balancing Procedure ...........................................................................................................................7-25

Propeller Removal & Installation ................................................................................................................ 7-26

Removal ..............................................................................................................................................7-26

Installation............................................................................................................................................7-27

Servicing Propellers ................................................................................................................................... 7-27

Cleaning Propeller Blades ...................................................................................................................7-27

Charging the Propeller Air Dome .........................................................................................................7-27

Propeller Lubrication ............................................................................................................................7-27

Propeller Overhaul ..................................................................................................................................... 7-29

The Hub ...............................................................................................................................................7-29

Prop Reassembly ................................................................................................................................7-29

Troubleshooting Propellers ....................................................................................................................... 7-30

Hunting & Surging................................................................................................................................7-30

Engine Speed Varies with Flight Attitude (Airspeed) ...........................................................................7-30

Failure to Feather or Feathers Slowly .................................................................................................7-30

Turboprop Engines & Propeller Control Systems....................................................................................... 7-30

Reduction Gear Assembly ...................................................................................................................7-31

Turbo-Propeller Assembly....................................................................................................................7-31

Pratt & Whitney PT6 Hartzell Propeller System ......................................................................................... 7-31

Hamilton Standard Hydromatic Propellers ................................................................................................. 7-34

Principles of Operation ........................................................................................................................7-36

Feathering Operation ...........................................................................................................................7-37

Unfeathering Operation .......................................................................................................................7-38

Setting the Propeller Governor ............................................................................................................7-40

• Chapter 8
• Engine Removal & Replacement

Introduction .................................................................................................................................................. 8-1

Reasons for Removal of Reciprocating Engines .......................................................................................... 8-1

Engine or Component Lifespan Exceeded ............................................................................................8-1

Engine Sudden Stoppage or Propeller Strike ........................................................................................8-1

Sudden Reduction in Speed ..................................................................................................................8-1

Metal Particles in the Oil ........................................................................................................................8-2

Spectrometric Oil Analysis Engine Inspection Program.........................................................................8-2

Turbine Engine Condition Monitoring Programs ....................................................................................8-2

Engine Operational Problems ................................................................................................................8-2

General Procedures for Engine Removal & Installation ............................................................................... 8-3

Preparation of Engines for Installation ...................................................................................................8-3

QECA Buildup Method for Changing of Engines ...................................................................................8-3

Depreservation of an Engine .................................................................................................................8-4

Inspection & Depreservation of Accessories .........................................................................................8-5

Inspection & Replacement of Powerplant External Units & Systems ........................................................... 8-5

Preparing the Engine for Removal ............................................................................................................... 8-6

Draining the Engine ...............................................................................................................................8-6

Electrical Disconnects............................................................................................................................8-6

Disconnection of Engine Controls..........................................................................................................8-7

Disconnection of Lines...........................................................................................................................8-8

Other Disconnections ............................................................................................................................8-8

Removing the Engine ................................................................................................................................... 8-8

Hoisting the Engine................................................................................................................................8-9

Hoisting & Mounting the Engine for Installation ........................................................................................... 8-9

Connections & Adjustments .................................................................................................................8-10

Preparation of Engine for Ground & Flight Testing ..................................................................................... 8-12

Pre-Oiling .............................................................................................................................................8-12

Fuel System Bleeding ..........................................................................................................................8-13

Propeller Check .......................................................................................................................................... 8-13

Checks & Adjustments After Engine Runup & Operation ........................................................................... 8-13

Rigging, Inspections, & Adjustments .......................................................................................................... 8-13

Rigging Power Controls .......................................................................................................................8-14

Adjusting the Fuel Control ...................................................................................................................8-14

Turboprop Powerplant Removal & Installation ........................................................................................... 8-15

Reciprocating Helicopter Engine & QECA ................................................................................................. 8-15

Removal of Helicopter QECA ..............................................................................................................8-16

Installation, Rigging, & Adjustment of Helicopter QECA ......................................................................8-16

Testing the Engine Installation .............................................................................................................8-16

Engine Mounts .......................................................................................................................................... 8-16

Mounts for Reciprocating Engines .......................................................................................................8-16

Mounts for Turbofan Engines...............................................................................................................8-17

Turbine Vibration Isolation Engine Mounts ..........................................................................................8-17

Preservation & Storage of Engines ............................................................................................................ 8-18

Corrosion-Preventive Materials ...........................................................................................................8-18

Corrosion-Preventive Compounds.......................................................................................................8-18

Dehydrating Agents .............................................................................................................................8-18

Engine Preservation & Return to Service ................................................................................................... 8-19

Engine Shipping Containers ....................................................................................................................... 8-21

Inspection of Stored Engines ..................................................................................................................... 8-21

Preservation & Depreservation of Gas Turbine Engines ............................................................................ 8-22

• Chapter 9
• Engine Fire Protection Systems

Introduction .................................................................................................................................................. 9-1

Components ..........................................................................................................................................9-1

Engine Fire Detection Systems .............................................................................................................9-2

Thermal Switch System ....................................................................................................................9-2

Thermocouple Systems ....................................................................................................................9-2

Optical Fire Detection Systems.........................................................................................................9-3

Pneumatic Thermal Fire Detection ...................................................................................................9-3

Continuous-Loop Detector Systems .................................................................................................9-3

Fire Zones .............................................................................................................................................9-7

Engine Fire Extinguishing System ............................................................................................................... 9-7

Fire Extinguishing Agents ......................................................................................................................9-7

Turbine Engine Ground Fire Protection .................................................................................................9-8

Containers ............................................................................................................................................9-8

Discharge Valves ...................................................................................................................................9-8

Pressure Indication ................................................................................................................................9-8

Two-Way Check Valve ...........................................................................................................................9-9

Discharge Indicators ..............................................................................................................................9-9

Thermal Discharge Indicator (Red Disc) ...........................................................................................9-9

Yellow Disc Discharge Indicator ........................................................................................................9-9

Fire Switch .............................................................................................................................................9-9

Warning Systems .................................................................................................................................9-10

Fire Detection System Maintenance ......................................................................................................... 9-10

Fire Detection System Troubleshooting ......................................................................................................9-11

Fire Extinguisher System Maintenance Practices ...................................................................................... 9-12

Boeing 777 Aircraft Fire Detection & Extinguishing System ....................................................................... 9-13

Overheat Detection ..............................................................................................................................9-13

Fire Detection ......................................................................................................................................9-13

Nacelle Temperature Recording ..........................................................................................................9-13

Continuous Fault Monitoring ................................................................................................................9-13

Single/Dual Loop Operation.................................................................................................................9-14

System Test .........................................................................................................................................9-14

Boeing 777 Fire Extinguisher System..................................................................................................9-14

Fire Extinguisher Containers...........................................................................................................9-14

Squib....................................................................................................................................................9-16

Engine Fire Switches ...........................................................................................................................9-16

Engine Fire Operation..........................................................................................................................9-17

APU Fire Detection & Extinguishing System .............................................................................................. 9-17

APU Fire Warning ................................................................................................................................9-18

Fire Bottle Discharge ...........................................................................................................................9-18

• Chapter 10
• Engine Maintenance & Operation

Reciprocating Engine Overhaul ................................................................................................................. 10-1

Top Overhaul .......................................................................................................................................10-1

Major Overhaul & Major Repairs .........................................................................................................10-1

General Overhaul Procedures ................................................................................................................... 10-1

Receiving Inspection .................................................................................................................................. 10-2

Disassembly ............................................................................................................................................... 10-2

Inspection Process ..................................................................................................................................... 10-2

Visual Inspection ........................................................................................................................................ 10-3

Cylinder Head ......................................................................................................................................10-4

Piston, Valve Train, & Piston Pin ........................................................................................................10-5

Crankshaft & Connecting Rods ...........................................................................................................10-5

Cleaning ..................................................................................................................................................... 10-5

Degreasing ..........................................................................................................................................10-5

Removing Hard Carbon .......................................................................................................................10-5

Structural Inspection .................................................................................................................................. 10-6

Dye Penetrant Inspection ....................................................................................................................10-6

Eddy Current Inspection ......................................................................................................................10-7

Ultrasonic Inspection ...........................................................................................................................10-7

Pulse-Echo......................................................................................................................................10-7

Through Transmission ....................................................................................................................10-7

Resonance ......................................................................................................................................10-7

Magnetic Particle Inspection ................................................................................................................10-7

X-ray ....................................................................................................................................................10-7

Dimensional Inspection .............................................................................................................................. 10-7

Cylinder Barrel .....................................................................................................................................10-7

Rocker Arms & Shafts..........................................................................................................................10-8

Crankshaft ...........................................................................................................................................10-9

Checking Alignment .............................................................................................................................10-9

Repair & Replacement.......................................................................................................................10-10

Cylinder Assembly Reconditioning .................................................................................................... 10-11

Piston & Piston Pins .......................................................................................................................... 10-11

Valves & Valve Springs ...................................................................................................................... 10-11

Refacing Valve Seats .........................................................................................................................10-13

Valve Reconditioning .........................................................................................................................10-14

Valve Lapping & Leak Testing ............................................................................................................10-17

Piston Repairs ...................................................................................................................................10-17

Cylinder Grinding & Honing ...............................................................................................................10-17

Reassembly ............................................................................................................................................. 10-19

Installation & Testing ................................................................................................................................ 10-19

Testing Reciprocating Engines ..........................................................................................................10-19

Test Cell Requirements......................................................................................................................10-20

Engine Instruments ............................................................................................................................10-20

Carburetor Air Temperature (CAT) Indicator ......................................................................................10-21

Fuel Pressure Indicator......................................................................................................................10-21

Oil Pressure Indicator ........................................................................................................................10-22

Oil Temperature Indicator ..................................................................................................................10-22

Fuel-Flow Meter .................................................................................................................................10-22

Manifold Pressure Indicator ...............................................................................................................10-23

Tachometer Indicator .........................................................................................................................10-23

Cylinder Head Temperature Indicator ................................................................................................10-23

Torquemeter.......................................................................................................................................10-24

Warning Systems ...............................................................................................................................10-24

Reciprocating Engine Operation .............................................................................................................. 10-24

Engine Instruments ............................................................................................................................10-24

Engine Starting ..................................................................................................................................10-25

Pre-Oiling ...........................................................................................................................................10-25

Hydraulic Lock ...................................................................................................................................10-25

Engine Warm-Up ...............................................................................................................................10-25

Ground Check....................................................................................................................................10-26

Fuel Pressure & Oil Pressure Check .................................................................................................10-27

Propeller Pitch Check ........................................................................................................................10-27

Power Check ....................................................................................................................................10-27

Idle Speed & Idle Mixture Checks......................................................................................................10-28

Engine Stopping ................................................................................................................................10-28

Basic Engine Operating Principles ........................................................................................................... 10-29

Combustion Process..........................................................................................................................10-29

Detonation .........................................................................................................................................10-29

Pre-Ignition ........................................................................................................................................10-30

Backfiring ...........................................................................................................................................10-30

Afterfiring ...........................................................................................................................................10-31

Factors Affecting Engine Operation.......................................................................................................... 10-31

Compression......................................................................................................................................10-31

Fuel Metering .....................................................................................................................................10-31

Idle Mixture ........................................................................................................................................10-33

Induction Manifold..............................................................................................................................10-33

Operational Effect of Valve Clearance ...............................................................................................10-33

Engine Troubleshooting ........................................................................................................................... 10-35

Valve Blow-By ....................................................................................................................................10-39

Cylinder Compression Tests..................................................................................................................... 10-39

Differential Pressure Tester................................................................................................................10-39

Cylinder Replacement .......................................................................................................................10-41

Cylinder Removal ..................................................................................................................................... 10-41

Cylinder Installation .................................................................................................................................. 10-42

Cold Cylinder Check ................................................................................................................................ 10-43

Turbine Engine Maintenance ................................................................................................................... 10-44

Compressor Section ..........................................................................................................................10-45

Inspection & Cleaning ........................................................................................................................10-45

Causes of Blade Damage ..................................................................................................................10-45

Blending & Replacement ...................................................................................................................10-47

Combustion Section Inspection ................................................................................................................ 10-47

Marking Materials for Combustion Section Parts...............................................................................10-49

Inspection & Repair of Combustion Chambers .................................................................................10-49

Fuel Nozzle & Support Assemblies....................................................................................................10-50

Turbine Disc Inspection .....................................................................................................................10-50

Turbine Blade Inspection ...................................................................................................................10-50

Turbine Blade Replacement Procedure .............................................................................................10-51

Turbine Nozzle Inlet Guide Vane Inspection ......................................................................................10-52

Clearances.........................................................................................................................................10-52

Exhaust Section .................................................................................................................................10-54

Engine Ratings ......................................................................................................................................... 10-54

Turbine Engine Instruments ..................................................................................................................... 10-54

Engine Pressure Ratio Indicator ........................................................................................................10-54

Torquemeter (Turboprop Engines) .....................................................................................................10-55

Tachometer .......................................................................................................................................10-55

Exhaust Gas Temperature Indicator (EGT) .......................................................................................10-55

Fuel-Flow Indicator ............................................................................................................................10-55

Engine Oil Pressure Indicator ............................................................................................................10-55

Engine Oil Temperature Indicator ......................................................................................................10-55

Turbine Engine Operation ........................................................................................................................ 10-57

Ground Operation Engine Fire...........................................................................................................10-57

Engine Checks...................................................................................................................................10-57

Checking Takeoff Thrust ....................................................................................................................10-57

Ambient Conditions............................................................................................................................10-58

Engine Shutdown ..................................................................................................................................... 10-58

Troubleshooting Turbine Engines............................................................................................................. 10-59

Turboprop Operation ................................................................................................................................ 10-59

Troubleshooting Procedures for Turboprop Engines .........................................................................10-59

Turbine Engine Calibration & Testing ....................................................................................................... 10-59

Turbine Engine Analyzer Uses...........................................................................................................10-59

Analyzer Safety Precautions .............................................................................................................10-61

Continuity Check of Aircraft EGT Circuit ............................................................................................10-63

Functional Check of Aircraft EGT Circuit ...........................................................................................10-63

EGT Indicator Check .........................................................................................................................10-64

Resistance & Insulation Check ..........................................................................................................10-64

Tachometer Check .............................................................................................................................10-64

Troubleshooting EGT System .................................................................................................................. 10-64

One or More Inoperative Thermocouples in Engine Parallel Harness ...............................................10-64

Engine Thermocouples Out of Calibration .........................................................................................10-64

EGT Circuit Error ...............................................................................................................................10-65

Resistance of Circuit Out of Tolerance ..............................................................................................10-65

Shorts to Ground/Shorts Between Leads ..........................................................................................10-65

Troubleshooting Aircraft Tachometer System ........................................................................................... 10-65

• Chapter 11
• Light-Sport Aircraft Engines

Engine General Requirements ....................................................................................................................11-1

Personnel Authorized to Perform Inspection & Maintenance on Light-Sport Engines ................................11-2

Authorized Personnel That Meet FAA Regulations .............................................................................. 11-3

Types of Light-Sport & Experimental Engines .............................................................................................11-3

Light-Sport Aircraft Engines ................................................................................................................. 11-3

Two-Cycle, Two Cylinder Rotax Engine .............................................................................................. 11-3

Rotax 447 UL Single Capacitor Discharge Ignition (SCDI) & Rotax 503 UL Dual Capacitor Discharge Ignition (DCDI) .................................................................................................................................... 11-3

Rotax 582 UL DCDI ....................................................................................................................... 11-4

Description of Systems for Two-Stroke Engines .................................................................................. 11-4

Cooling System of Rotax 447 UL SCDI & Rotax 503 UL DCDI ...................................................... 11-4

Cooling System of the Rotax 582 UL DCDI ................................................................................... 11-4

Lubrication Systems ............................................................................................................................ 11-4

Oil Injection Lubrication of Rotax 503 UL DCDE & 582 UL DCDI .................................................. 11-4

Electric System .................................................................................................................................... 11-5

Fuel System ......................................................................................................................................... 11-5

Fuel-Oil Mixing Procedure .............................................................................................................. 11-5

Opposed Light-Sport, Experimental, & Certificated Engines .....................................................................11-5

Rotax 912/914 .................................................................................................................................... 11-5

Description of Systems ........................................................................................................................ 11-6

Cooling System ............................................................................................................................... 11-6

Fuel System .................................................................................................................................... 11-6

Lubrication System ......................................................................................................................... 11-7

Electric System ............................................................................................................................... 11-8

Turbocharger & Control System ..................................................................................................... 11-8

HKS 700T Engine ................................................................................................................................ 11-9

Jabiru Light-Sport Engines ................................................................................................................ 11-10

Jabiru 2200 Aircraft Engine ........................................................................................................... 11-11

Aeromax Aviation 100 (IFB) Aircraft Engine.................................................................................. 11-11

Direct Drive VW Engines ...........................................................................................................................11-12

Revmaster R-2300 Engine ............................................................................................................... 11-12

Great Plains Aircraft Volkswagen (VW)Conversions ......................................................................... 11-14

Teledyne Continental 0-200 Engine ................................................................................................... 11-15

Lycoming 0-233 Series Light-Sport Aircraft Engine ........................................................................... 11-15

General Maintenance Practices on Light-Sport Rotax Engines ...............................................................11-16

Maintenance Schedule Procedures & Maintenance Checklist ..................................................................11-16

Carburetor Synchronization ............................................................................................................... 11-17

Pneumatic Synchronization ............................................................................................................... 11-18

Idle Speed Adjustment ....................................................................................................................... 11-19

Optimizing Engine Running ............................................................................................................... 11-19

Checking the Carburetor Actuation .................................................................................................... 11-19

Lubrication System ....................................................................................................................................11-19

Oil Level Check.................................................................................................................................. 11-19

Oil Change ......................................................................................................................................... 11-20

Cleaning the Oil Tank ......................................................................................................................... 11-20

Inspecting the Magnetic Plug............................................................................................................. 11-21

Checking the Propeller Gearbox........................................................................................................ 11-21

Checking the Friction Torque in Free Rotation .................................................................................. 11-21

Daily Maintenance Checks ................................................................................................................ 11-21

Pre-flight Checks .......................................................................................................................................11-22

Troubleshooting & Abnormal Operation ....................................................................................................11-22

Troubleshooting ................................................................................................................................. 11-23

Engine Keeps Running With Ignition OFF .................................................................................... 11-23

Knocking Under Load ................................................................................................................... 11-23

Abnormal Operation........................................................................................................................... 11-23

Exceeding the Maximum Admissible Engine Speed ..................................................................... 11-23

Exceeding Maximum Admissible Cylinder Head Temperature ..................................................... 11-23

Exceeding Maximum Admissible Exhaust Gas Temperature........................................................ 11-23

Engine Preservation ..................................................................................................................................11-23

General Maintenance Practices for the Light-Sport Jabiru Engines .........................................................11-23

Engine & Engine Compartment Inspection ........................................................................................ 11-23

Lubrication System ............................................................................................................................ 11-24

Carburetor Adjustment & Checks ...................................................................................................... 11-24

Spark Plugs ....................................................................................................................................... 11-24

Exhaust System ................................................................................................................................. 11-24

Head Bolts ......................................................................................................................................... 11-24

Tachometer & Sender ........................................................................................................................ 11-25

Engine Inspection Charts ..........................................................................................................................11-25

Glossary ....................................................................................................................................................... G-1

Index ............................................................................................................................................................... I-1