AERO ENGINE MAINTENANCE AND REPAIR

Jayaprakash.P
Aeronautical Engineering: Assistant professor

Dhanalakshmi Srinivasan College Of Engineering And Technology

Mamallapuram, Chennai, India 603104

Aug 12, 2020

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 The aircraft power plant

 The airplane engine and propeller, often

referred to as the aircraft power plant, work in
combination engine and propeller to produce
thrust. The power plant propels the airplane
and drives the various systems that support
the operation of an airplane

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Engine

Internal Combustion Engine:

 is an engine which combustion process and power developed inside in the engine

External Combustion Engine:

 is an engine which combustion process and power
developed in different engine

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Reciprocating Engine

 Most small airplanes are designed with reciprocating engines. The

name is derived from the back-and-forth, or reciprocating,
movement of the pistons. It is this motion that produces the
mechanical energy needed to accomplish work. Two common
means of classifying reciprocating engines are

 By cylinder arrangement with respect to the crankshaft— radial, in-

line, v-type or opposed.

 By the method of cooling—liquid or air-cooled.

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INLINE ENGINES
In-line engines have a comparatively small frontal area, but
their power-to-weight ratios are relatively low. In addition,
the rearmost cylinders of an aircooled, in-line engine
receive very little cooling air, so these engines are normally
limited to four or six cylinders.
 The cylinders of an in-line engine are arranged in a
single row parallel to the crankshaft
 The cylinders are either upright above the crankshaft or
inverted, that is, below the crankshaft
 The in-line engine utilizes one crankshaft.
 Even number of cylinders in order to provide a proper
balance of firing impulses.

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RADIAL ENGINE
 Radial engines were widely used during World War II, and many are
still in service today. With these engines, a row or rows of cylinders
are arranged in a circular pattern around the crankcase. The main
advantage of a radial engine is the favorable power-to-weight ratio
 A single-row radial engine has an odd number of cylinders
extending radially from the centerline of the crankshaft
 The number of cylinders usually ranges from five to nine.
 A double-row radial engine resembles two single-row radial
engines combined on a single crankshaft,

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V-TYPES ENGINES
V-type engines provide more horsepower than in-line
engines and still retain a small frontal area. Further
improvements in engine design led to the development of
the horizontally-opposed engine.
 V-type engine has the cylinders arranged on the
crankcase in two rows (or banks), forming the letter V
 Angle between the banks of 90, 60, or 45°.
 The frontal area is only slightly greater than that of the in-
line type; therefore, the engine cowling can be
streamlined to reduce drag

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OPPOSED FLAT ENGINES

Opposed-type engines are the most popular
reciprocating engines used on small airplanes. Opposed-
type engines have high power-to-weight ratios because
they have a comparatively small, lightweight crankcase.
In addition, the compact cylinder arrangement reduces
the engine’s frontal area and allows a streamlined
installation that minimizes aerodynamic drag.
 These engines are the most efficient, dependable, and
economical types available for light aircraft.
 The opposed-type engine is usually mounted with the
cylinders horizontal and the crankshaft horizontal;

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 Reciprocating Engine

 The main parts of a reciprocating engine are:

 Cylinders
 Crankcase
 Housing
 The intake/exhaust valves spark plugs, and
pistons are located in the cylinders. The
crankshaft and connecting rods are located in the
crankcase. The magnetos are normally located on
the engine accessory housing.

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 Reciprocating Engine

Reciprocating engine use four stroke cycle

 Intake
 Compression
 Power
 Exhaust

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The Crankcase: of an engine is the housing that

encloses the various mechanisms
The function
 It must support itself
 It contains the bearings in which the crankshaft
revolves
 It provides a tight enclosure for the lubricating oil,
 It supports various internal and external mechanisms
of the power plant
 It provides mountings for attachment to the airplane
 It provides support for the attachment of the
cylinders, and
 By reason of its strength and rigidity, it prevents the
misalignment of the crankshaft and its bearings.
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The Bearings:
are designed to produce minimum friction and
maximum wear resistance.
Characteristics:
 It must be made of a material that is strong enough
to withstand the pressure
 The parts must be held in position within very close
tolerances to provide quiet and efficient operation
and at the same time permit freedom of motion.
Types of Bearings:
 Plain Bearings
 Roller Bearings or antifriction Bearings
 Ball Bearings.

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Crankshaft:
 Transforms the reciprocating motion of the piston
and connecting rod to rotary motion for turning the
propeller
The parts of the crankshaft are
(1)The main journal,
(2) The crankpin,
(3) The crank cheek or crank arm, and
(4) The counterweights and dampers. Figure shows
the nomenclature of a typical crankshaft.

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Connecting rod:
 The connecting rod is the link which transmits forces between the piston and the
crankshaft of an engine
 Connecting rods must be lightweight to reduce the inertial forces
 Types of connecting-rod assemblies:
(1) The plain type
(2) The fork-and-blade
(3) The master and articulated type

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Piston:
It transmits the force of the burning and expanding gases in the cylinder through the
connecting rod to the engine crankshaft.

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Cylinders:
 The cylinder of an internal-combustion engine converts the
chemical heat energy of the fuel to mechanical energy and
transmits it through pistons and connecting rods to the rotating
crankshaft.
 The cylinder assembly used for present-day engines usually
includes the following components: (1) cylinder barrel with an
integral skirt, (2) cylinder head, (3) valve guides, (4) valve rocker-
arm supports, (5) valve seats, (6) spark plug bushings, and (7)
cooling fins

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Carburetor systems:
Carburetor is a device to blends air and fuel for an internal combustion engine.

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Carburetor systems:
Carburetor is a device to blends air and fuel for an internal combustion engine.

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Carburetor systems:

 In the operation of the float-type carburetor system, the outside air first flows through
an air filter, usually located at an air intake in the front part of the engine cowling. This
filtered air flows into the carburetor and through a venturi, a narrow throat in the
carburetor.

 When the air flows through the venturi, a lowpressure area is created, which forces the
fuel to flow through a main fuel jet located at the throat. The fuel then flows into the
airstream, where it is mixed with the flowing air.

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Carburetor systems:

 The fuel/air mixture is then drawn through the intake manifold and into the combustion
chambers, where it is ignited. The “float-type carburetor” acquires its name from a
float, which rests on fuel within the float chamber. A needle attached to the float opens
and closes an opening at the bottom of the carburetor bowl.
 This meters the correct amount of fuel into the carburetor, depending upon the
position of the float, which is controlled by the level of fuel in the float chamber. When
the level of the fuel forces the float to rise, the needle valve closes the fuel opening and
shuts off the fuel flow to the carburetor. The needle valve opens again when the engine
requires additional fuel.
 The flow of the fuel/air mixture to the combustion chambers is regulated by the
throttle valve, which is controlled by the throttle in the cockpit.

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Mixture Control

 To maintain the correct fuel/air mixture, you must lean the mixture using the mixture
control. Leaning the mixture decreases fuel flow, which compensates for the decreased
air density at high altitude.
 Carburetors are normally calibrated at sea-level pressure, where the correct fuel-to-air
mixture ratio is established with the mixture control set in the FULL RICH position.
However, as altitude increases, the density of air entering the carburetor decreases,
while the density of the fuel remains the same.

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Fuel Injection System

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Fuel Injection System

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Fuel systems:
The gravity-feed system utilizes the force of gravity to transfer the fuel from the tanks to
the engine - for example, on high-wing airplanes where the fuel tanks are installed in the
wings.

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Fuel systems:
Airplanes with fuel pump systems have two fuel pumps. The main pump system is engine
driven, and an electrically driven auxiliary pump is provided for use in engine starting and
in the event the engine pump fails. The auxiliary pump, also known as a boost pump,
provides added reliability to the fuel system. The electrically driven auxiliary pump is
controlled by a switch in the cockpit.

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Fuel Tanks:
Normally located inside the wings of an airplane, have a filler opening on top of the wing
through which they can be filled. Fuel tanks also include an overflow drain that may stand
alone or be collocated with the fuel tank vent. This allows fuel to expand with increases in
temperature without damage to the tank itself. If the tanks have been filled on a hot day, it
is not unusual to see fuel coming from the overflow drain.

Fuel Drain:
Fuel samples should be drained and checked visually for water and contaminants. Water in
the sump is hazardous because in cold weather the water can freeze and block fuel lines.
In warm weather, it can flow into the carburetor and stop the engine. If water is present in
the sump, it is likely there is more water in the fuel tanks, and you should continue to drain
them until there is no evidence of water

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Ignition system
 The ignition system provides the spark that ignites the fuel/air mixture in the cylinders
and is made up of magnetos, spark plugs, high-tension leads, and the ignition switch.
 Most standard certificated airplanes incorporate a dual ignition system with two
individual magnetos, separate sets of wires, and spark plugs to increase reliability of the
ignition system.
Ignition systems can also be sub classified
Single magneto-ignition
Dual magneto-ignition systems

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Ignition system
 The ignition system provides the spark that ignites the fuel/air mixture in the cylinders
and is made up of magnetos, spark plugs, high-tension leads, and the ignition switch.
 Most standard certificated airplanes incorporate a dual ignition system with two
individual magnetos, separate sets of wires, and spark plugs to increase reliability of the
ignition system.
Ignition systems can also be sub classified
Single magneto-ignition
Dual magneto-ignition systems
 The operation of the magneto is controlled in the cockpit by the ignition switch. The
switch has five positions:
 OFF
 R—Right
 L—Left
 BOTH
 START
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Ignition System:

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Ignition System:

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Fuel systems:
The fuel system is designed to provide an uninterrupted flow of clean fuel from the fuel
tanks to the engine. The fuel must be available to the engine under all conditions of engine
power, altitude, attitude, and during all approved flight maneuvers. Two common
classifications apply to fuel systems in small airplanes - gravity-feed and fuelpump systems.
The gravity-feed system utilizes the force of gravity to transfer the fuel from the
tanks to the engine - for example, on high-wing airplanes where the fuel tanks are
installed in the wings.
Airplanes with fuel pump systems have two fuel pumps. The main pump system is
engine driven, and an electrically driven auxiliary pump is provided for use in
engine starting and in the event the engine pump fails. The auxiliary pump, also
known as a boost pump, provides added reliability to the fuel system. The
electrically driven auxiliary pump is controlled by a switch in the cockpit.

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Spark Plug:
 The function of the spark plug in an ignition system is to conduct a short impulse of
high-voltage current through the wall of the combustion chamber
 Spark plugs operate at extreme temperatures, electrical pressures, and very high
cylinder pressures
 The three main components
 The electrode,
 Insulator, and
 Outer shell.

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Spark Plug:

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 Lubrication

Classification of Lubrication:
Animal Lubricants: tallow oil, lard oil and porpoise oil
 Highly stable at normal temperatures, used to lubricate firearms, other light machinery
Vegetable Lubricants: castor oil, olive oil, and cottonseed oil
 Chemically unstable at high temperatures.
Mineral Lubricants:
Solid Lubricants: Soapstone, Graphite
 fairly satisfactory in a finely powdered
Semisolid Lubricants: Grease
 it is not suitable for circulating or continuous-operation lubrication systems.
Fluid Lubricants (Oils)
 Chemically stable at moderately high temperatures, perform well at low temperatures,
Synthetic Lubricants:
 Do not evaporate or break down easily and do not produce coke or other deposits at
high temperature

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Wet Sump Lubrication

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Dry Sump Lubrication

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Induction System:

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Cooling System:

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Cooling System:

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Exhaust System:

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Exhaust System:

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 Inspection

 Checks for general cleanliness of the edges and for sighs of any oil leakage
 Examine the crankcase carefully for cracks especially around cylinder pods as far as
possible
 Check exhaust manifold for security and blown joints
 Check exhaust muffler for security condition and sign of gas leakage.
 Check baffles fins for condition and security.
 Inspect cylinders fins for cracks and other damages.
 Inspect magnetos for security and attachments
 Check H.T Leads and L.T Leads for condition, security and proper conditions
 Check Throttle, mixture, carburetor heat controls for full and free movement
 Check Pitch controls and cowl flaps for full and free movements, lubricate, if necessary
 Check for general condition and security of induction air filter.

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Cowling and Cowl Flaps:

 Inspects for cracks, dents, other damages, and security of cowl fasteners
 Check cowl flaps foe condition, security, and operation
 Check cowl flap controls for freedom of movement through full travel.
Alternate Induction air system: Check for obstruction , operations, and security
Induction system: Check security of clamps tubes and ducting Inspect for evidence of
leakage
Induction Air filter: Remove and Clean. Inspect for damage and services.
Engine: Inspect for evidence of oil and fuel leaks. Wash engine and check for security of
accessories
Hoses, Metal Lines and Fittings: Inspect for signs of oil and fuel leaks. Check for abrations
chafing, security, proper routing, and support and for evidence of deterioration.
Engine baffles and seals: check condition and security of attachment.
Exhaust System: Inspect for cracks and security. Special check in area of heat exchanger.
Engine oil: Drain oil sump and oil cooler. Check for metal particles or foreign particles in
filter, on sump drain plug and on engine suction screen
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Replace filter and refill the recommended grade aviation oil

Oil Cooler: Check for obstruction leaks and security of attachment
Bendix driver starter assembly Clean and lubricate starter drive assembly

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 100 Hrs Inspection for Power Plant

Induction Airbox, Valves, Doors, and Controls – Remove air filter and inspect the hinges,
doors, seals, and attaching parts for wear and security. Check for operation
Fuel Line: (Stainless steel tube assembly) and support clamp inspection and installation.
Crankcase, oil sump, and accessory section: Inspect for cracks and evidence of oil leakage.
Check bolts and nuts for looseness and re-torque as necessary. Check crankcase breather
lines for obstruction, security, and general condition.
Engine cylinders, Rocker Box convers, and Pushrod Housings: Check for fin damage
cracks, oil leakage, security of attachment, and general condition.
Cylinder Compression: Complete a differential compression test. If there is weak cylinder
compression
Engine Driven Fuel Pump: Check for evidence of leakage, security of attachment, and
general condition.
Fuel Injection System: Check system for security and condition. Clean fuel inlet screen,
check and clean injection nozzles and screen(if evidence of contamination is found), and
lubrication air throttle shaft.

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Idle and Mixing Adjustment – Check idle speed and idle mixture (lean rise) adjust if
necessary
Magnetos: Examine the external condition and for correct installation
Examine the condition of the electrical leads
Complete a check of the engine timing(external timings)
Ignition Harness and Insulators: Check for proper routing, deterioration, and condition of
terminals
Spark Plugs: Remove, clean, analyze, test, gap and rotate top plugs to bottom and bottom
plugs to top
Ignition Switch and Harness: Inspect for damage condition and security

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