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JEPPIAAR ENGINEERING COLLEGE
"When once you have tasted flight, you will forever walk the earth with your eyes turned skyward, for
there you have been, and there you will always long to return."
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PART A
1. Name four common engine classifications by cylinder arrangement
a) Inline engines
b) V type engines
c) Opposed or flat type engines
d) Radial type engines
2. What is the purpose of dynamic damper?
The purpose of the dynamic dampers is to relieve the whip and vibration
caused by the rotation of the crank shaft. They are suspended from or
installed in specified crank cheeks.
3. What should be done if there is no indication of oil pressure shortly after
starting the engine?
After starting the engine, check for oil pressure immediately. If oil pressure
does not register within the prescribed time (10-30 sec) shut down the
engine and identify the problem.
4. What is the function of the dimensional inspection during overhaul?
Dimensional inspection is employed to determine the degree of wear for
parts of the engine where moving surfaces are in contact with other
surfaces. If the wear between the surfaces exceeds the table of limits the
parts must be replaced or repaired.
5. What are the methods and purpose of the preliminary visual inspection?
Visual inspection is accomplished by direct examination and with the use of
magnifying glass. In both case a strong light should be used to reveal the
defects. Visual inspection reveals cracks, corrosion, nicks, scratches,
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galling, scoring and other disturbances. Parts that are damaged beyond
repair should be discarded and marked. So that they will not be reused.
6. How are aircraft piston engines classified?
Aircraft piston engines are classified by
a) Cylinder arrangement
b) Cooling method
c) Number of stroke per cycle
7. Write short notes on Master Articulated Rod
The master articulated rod assembly is used primarily for radial engines,
although some v type engines employed this type of rod assembly. It is
made of alloy steel forging, machined, polished to final dimensions and heat
treated to resist vibration and stresses. The master rod is similar to other
connecting rods except that it is constructed to provide for the attachment of
the articulated rods on the large end. Master rod bearings are of plain type
and consist of a split or a sleeve. The articulated rods are hinged to the
master rod flanges by means of knuckle pins.
8.
1.
2.
3.
4.
5.
6.
7.
8.
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9. What are the methods adopted for structural inspection of aero engine
parts? or State the methods followed in Non Destructive testing
Engine parts are structurally inspected by the following methods
1.
2.
3.
4.
5.
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22. Enumerate the precision measuring tools used in overhaul shop of a piston
engine.
1. Depth gauges
2. Dial gauges
3. Height gauges
4. Micrometers
5. Small-hole gauges
6. Surface plate
7. Telescope gauges
8. V blocks
23. Define Fretting.
The surface erosion caused by very slight movement between two surfaces
which are tightly pressed together.
24. Define E gap
In a magneto, the number of degrees of rotating between the neutral position
and the position where the contact points open is called the E-gap angle,
usually called E gap or Efficiency gap
25. What is meant by choke bored cylinder?
In some cylinder, the cylinder is bored with a slight taper. The end of the bore
nearest the head is made smaller than the skirt end to allow for the expansion
caused by the greater operating temperature near the head. Such a cylinder is
called chocked bore cylinder
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which melts at 200F and dissipate the heat through valve guide and
valve head to atmosphere.
PART B
1. Explain the inspection and maintenance of engine control carried
out in piston engines.
Engine controls such as throttle, mixture control, propeller, and cowl
flap controls need to be checked during 100hrs inspection.
CHECKS
1. Inspect push- pull controls for wear and smooth operation.
2. Operate the system slowly and watch for any strain on the rods and
tubing (may cause bending or twisting)
3. Examine each rod end i.e., threaded and observe whether the rod is
screwed into the socket body for enough to be seen through the
inspection hole.
4. Eliminate any play by making certain that all the connections are
tight.
5. Examine the guides to see if the rods bind too much on the guides,
but do not mistake any binding for spring back. Replace guides
that cause binding.
6. Adjust the length of screw end rods by screwing them into or out of
the control end. Re-tighten the locknuts.
7. If any rod is removed, label it to show its location on reassembly.
8. Replace any ball bearing rod ends that cause lost motion.
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COMPRESSION TESTING
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1. Define trouble shooting and explain the six step trouble shooting
procedure.
TROUBLE SHOOTING
Trouble shooting is the step by step procedure used to determine the
cause of a given fault and then select the best and quickest solution.
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SYSTEM RECOGNITION:
SYMTEM ELABORATION:
It is the next logical step, once a fault or malfunction has been detected. Test
equipment helps the technician to evaluate the performance of the engine and
its components. The technicians should use these aids to assess the effects of
the symptoms and to provide additional information to further define the
symptoms.
3.
When the technician has located all the symptoms of malfunction or fault it is
the third step to list the possible causes.
To aid this process, manufacturer manual list the probable cause for the
symptom and corrective action.
4.
Localizing the fault means, to determine which functional system of the engine
is creating problem. This trouble may be traced by trouble shooting charts.
5.
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6.
FAILURE ANALYSIS
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3. DEGREASING
a. All oil and grease should be removed from both interior and exterior of
the plug according to the approved degreasing method.(Either vapor
degreasing)
4. DRYING
a. After degreasing spark plugs should be dried inside and outside either
by compressed air or a drying oven.
5. CLEANING
a. Spark plug should be cleaned for lead and carbon deposits form on the
ceramic core, the electrodes, and inside of the spark plug shell by
abrasive blasting machine designed for cleaning spark plug.
b. Immediately after cleaning by the wet-blast method the plugs must be
oven dried to prevent rusting and to ensure satisfactory electrical test.
6. REGAPPING
a. The tools and methods used to set spark plug gaps will vary with shape,
type, and arrangement of electrodes.
b. The gap in any spark plug is measured by round wire gages.
c. To measure minimum and maximum widths for the gap, a spark plug gap
gage will have two wires.(0.011-0.015)
d. Smaller dimension gage must pass through and larger dimension gage
must be too large to pass through the gap.
e. If the gap is too large it is closed by means of a special gap setting tool.
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8. GASKET SERVICING
a. When spark plugs are installed either new or recondition gasket should
be used.
b. Used gaskets should be annealed by heating to a cherry red and
immediately quenched in light motor oil.
c. After quenching oil to be removed with a solvent.
d. Then immerse it in a solution of 50%water and 50% nitric acid to remove
oxides.
e. After the acid bath gasket should be rinsed in running water and air dried.
9. PLUG ROTATION
a. Excessive electrode erosion is caused by magneto constant polarity firing
and capacitance after firing.
b. To equalize this wear, keep the plugs in engine sets, placing them in the
tray identified by cylinder locations. After the plugs have been serviced,
rotate them as instructed.
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10. INSTALLATIONS
a. Before installing, proper type of the plug to be selected.
b. Long and short reach should not be interchanged.
c. Before installing plug and cylinder threads are to be cleaned
d. Anti seize compound to be applied on the threads
e. Install the plug along with gasket and tighten with hand
f. At last tighten them with wrench.
overhaul
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6. Name the auxiliary ignition devices and with the help of neat diagram
describe the operation of an induction vibrator
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INDUCTION VIBRATOR
The function of the induction of the induction vibrator is to supply low voltage
(pulsating direct current) for the magneto primary coil, which induces a
sufficiently high voltage in the secondary coil for starting.
OPERATION
When the starter switch is closed battery voltage is applied to the vibrator coil
through the vibrator contact points and through the retard
Contact points in the left magneto. As the coil is energized, the breaker points
open and interrupt the current flow, thus de energizing the coil, VC. Through
spring action the contact points close and again energizes the coil, causing the
points to open. Thus the contact points of the vibrator continue to make and
break contact many times per second, sending an interrupted current through
both the main and retard contact points of the magneto.
The vibrator sends an interrupted battery current through the primary winding
of the magneto coil. The magneto coil then acts as a battery ignition coil and
produces high tension impulses, which are distributed through the distributor
rotor, distributor block, and cables to the spark plug.
These high tension impulses are produced during the entire time that both sets
of magneto contact points are open. When the contact points are closed, spark
cannot be generated. Although the vibrator continues to send interrupted
current impulses through the magneto contact points, the interrupted current
will flow through the contact points to ground.
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The basic principles of the pressure injection carburetor can be explained that
mass air flow is utilized to regulate the pressure of fuel to a metering system
which in turn governs the fuel flow. The carburetor increases the fuel flow in
proportion to mass air flow and maintains a correct F/A ratio in accordance
with the throttle and mixture settings of the carburetor
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The main parts of a pressure injection carburetor system: 1. The throttle unit,
2. The regulator unit, 3. The fuel control unit.
When the carburetor is operating, the air flows the air flows through the
throttle unit. At the entrance to the air passage are impact tubes which develop
a pressure proportional to the velocity of the incoming air. This pressure is
applied to chamber A in the regulator unit. As the air flows through the
venturi, a reduced pressure is developed in accordance with the velocity of the
air flow. The reduced pressure is applied to chamber B in the regulator unit.
The high pressure in chamber A and the low pressure in chamber B will create
a differential pressure across the diaphragm between the two chambers. The
force of this pressure differential is called the Air Metering force, and as this
force increases it opens the poppet valve and allows fuel under pressure from
the fuel pump to flow into chamber D. This unmetered fuel exerts force on the
diaphragm between chamber D and chamber C and thus tends to close the
poppet valve. The fuel flows through one or more metering jets in the fuel
control unit and then to the discharge nozzle. Chamber C of the regulator unit
is connected to the output of the fuel control unit to provide metered fuel
pressure to act against the diaphragm between chamber C and D. Thus,
unmetered fuel pressure acts against the D side of the diaphragm, and metered
fuel pressure acts against the chamber C side. The fuel pressure differential
produces a force called the fuel metering force.
When the throttle opening is increased, the air flow through the carburetor is
increased and the pressure in the venturi is increased. So the pressure in
chamber B is lowered, the impact pressure to chamber is increased, and the
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C The chamber pressure is established approximately 5psi by the springloaded, diaphragm-operated main discharge nozzle valve. This valve prevents
leakage from the nozzle when the engine is not running.
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crack or discontinuity will create a flux leakage. A flux leakage occurs when
the lines of flux leave the surface of the material, resulting in a concentration
of magnetic strength at the discontinuity. Magnetic particles are applied to the
magnetized part and concentrate in the areas of flux leakage, giving a sign of
discontinuity.
After the parts have been inspected, they must be demagnetized. If this is not
done the parts will pick up and hold small steel particles, which can cause
serious damage in the engine during operation.
Liquid penetrant inspection
Engine parts made of aluminum alloys, magnesium alloys, bronze, or any other
metal which cannot be magnetized are inspected by means of a fluorescent
penetrant, a dyepenetrant, ultrasonic equipment, or eddy current equipment.
The parts are thoroughly cleaned and stripped of paint. The penetrant is
applied to the part and allowed to enter any surface discontinuities. The excess
penetrant is cleaned off, and then the part is given a coat of developer. The
developer draws out any penetrant that may have entered surface
discontinuities, making them visible either under white light in the case of
visible penetrant or black light in the case of fluorescent penetrant.
Eddy current inspection
Eddy current inspection is to discover defects inside metal parts. The eddy
current tester applies high frequency electromagnetic waves to the metal, and
these waves generate eddy currents inside the metal. If the metal is uniform in
its structure, the eddy current will flow in a uniform pattern and this will be
shown by the indicator. If a discontinuity exists, the effect of the eddy currents
will be changed and the indicator will produce a reading greater than normal
for the particular test.
Ultrasonic inspection
Ultrasonic inspection utilizes high frequency sound waves to reveal flaws in
metal parts. The element transmitting the waves is placed on the part, and a
DEPT. OF AERONAUTICAL ENGINEERING
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Radiography
X ray or radiographic inspection is to detect certain types of metal defects. The
x-ray is effective in detecting discontinuities inside casting, forging and welds.
A power full x-ray can penetrate metal or several inches and produce an image
which will reveal defects within the metal.
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cause
1. High cylinder
Head temperature
1.Octane rating of
fuel too low
4. Remove dirt
remedy
3. Starting at carburetor,
check fuel line back to
tank. Clear obstruction
4. Defective or stuck
mixture control
of mixture control
5. Pressure discharge
5. Replace it
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10. At what engine speed does the starter system disengage in a jet
engine?
The starter is coupled to the engine through a reduction gear and ratchet
mechanism or clutch, which automatically disengages after the engine
has reached a self-sustaining speed.
11. What is the purpose of compressor wash?
The purpose of compressor wash is to remove the baked-on salt, dirt, or
other types of contamination deposits. Because during engine operations
the deposits accumulate on engine compressor and turbine blades and
deteriorating the engine performance.
12. Describe the purpose of trend analysis.
Trend analysis involves the recording and analysis of gas-turbine engine
performance and certain mechanical parameters over a period of time.
The primary aim of trend analysis is to provide a means of detecting
significant changes in the performance parameters resulting from
changes in the mechanical condition of the engine.
13. What is hung start or false start?
If the engine fails to accelerate properly or does not reach the idle rpm
position, the starting attempt is called a false start or a hung start.
14. Enumerate the operational checks to ensure that a gas turbine engine
is in satisfactory operating condition.
To ensure that a gas turbine engine is in satisfactory operating condition,
engine and aircraft manufacturers specify certain operational checks to be
routinely performed. They are
1.
2.
3.
4.
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15. What is the purpose of bell mouth air inlet being used in test stand?
The operation of an engine on a test stand is usually accomplished
with a bell mouth air inlet. The purpose of this type of inlet is to
eliminate any loss of air pressure at the compressor inlet.
16. What is scheduled maintenance?
Scheduled maintenance includes the periodic recurring inspections that
must be carried out in accordance with the engine section of the aircraft
maintenance schedule. Usually calculated in aircraft flying hours.
17. What is the function of the exhaust nozzle?
The function of the exhaust nozzle is to control the velocity and
temperature of the exhaust gases. When a convergent nozzle is used, the
velocity of the gas is increased and the thrust is in line with the engine.
18. Enumerate the techniques required for Non routine inspections.
The techniques required for Non routine inspections are
a.
b.
c.
d.
e.
f.
Visual inspection
Inspection with lights
Use of magnifying glass
Applications of fluorescent or dyepenetrants
Use of bores cope or video scope
Use of radiography.
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20. What are the three major sections of a gas turbine engine?
A gas turbine engine has three major sections, an air compressor, a
combustion section, and a turbine section.
21. What is the purpose of turbine?
The purpose of the turbine is to extract kinetic energy from the high
velocity gases leaving the combustion section of the engine. The energy
is converted to shaft horse power for the purpose of driving the
compressor.
22. What is the function of the diffuser in gas turbine engine?
The function of the diffuser is to reduce the velocity of the air. As the
velocity of the air decreases, its static pressure increases. As the static
pressure increases, the ram pressure decreases. The diffuser is the point
of highest pressure within the engine.
23. Enumerate the instruments used for Non- routine inspection of gasturbine engine.
a. Borescope or video scope
b. Fiberscope
c. Electronic imaging
24. What action to be taken when an engine has been operated with no oil
pressure for more than two minutes?
When an engine has been operated with no oil pressure for more than two
minutes the engine must be removed for overhaul.
25. What is hot start?
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During the starting of a gas turbine engine, the EGT (exhaust gas
temperature) exceeds the prescribed safe limit, the engine is said to have
had a hot start.
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PERIODIC INSPECTIONS
Periodic inspections are required after a given number of operation hours,
flight cycles, or a combination of both. These inspections are classified as
routine, minor, or major. Scheduling of inspections is established by the
operator of the aircraft.
OVER SPEED INSPECTION
2. Explain over speed inspection for a typical high- bypass fan engine
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b. Inspect the core compressor with a borescope for blade and vane
damage.
c. Inspect the HPT with a borescope for blade damage.
8. If the core engine rotor has been operated above 108.5 percent, the
engine must be removed, disassembled, and inspected according to
instruction.
NON ROUTINE OPERATIONS
3. State and explain in detail about the instruments used during Non
routine inspections.
During the operation of the gas turbine engine, various events may occur
which cause the engine to require immediate special inspection to determine
whether the engine has been damaged and what corrective actions must be
taken. Among some of the events which require special inspections are
foreign object injection, bird ingestion, ice ingestion, over limit operation
(temperature and rpm), excessive G loads, and any other event that could
cause internal and external engine damage.
Instruments used for Non routine inspections
a. Borescope
b. Fiberscope
c. Electronic imaging
BORESCOPE
The borescope was used for examining the insides of cylinder bores on
reciprocating engine and is now extensively used on turbine engines. The
borescope is a rigid instrument that may be compared with a small
periscope. At the one end is an eye piece with one or more lenses attached
to the light carrying tube. At the end of the tube are a mirror, a lens, and
strong light.
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The tube is inserted through engine borescope ports located in the engine
case at points necessary to allow for examination of all critical areas inside
the engine. The ports are normally closed.
When the borescope inspections are to be performed, the technician should
identify the plugs which are removed to be sure that they are reinstalled in
the same ports.
FIBERSCOPE
A variation of the rigid borescope is the fiberscope. The flexible fiberscope
has a controllable bending section near the tip so that the observer can direct
the scope after it has been inserted into an engine inspection port. The
bending action allows the fiberscope to scan the area inside the engine once
inside the port. Many times it is necessary to inspect around the corners
inside the engine when no inspection entry port is available to allow a direct
line of sight.
ELECTRONIC IMAGING
A new imaging technique, Electronic imaging, is able to produce sharp,
true-color, magnified images that can be seen on a video monitor. One such
system is the video- probe 2000.
A video imaging system includes an inspection probe, a video processor, and
a video monitor for displaying the image. The system uses a tiny chargedcoupled device (CCD) sensor in the tip of the probe. The CCD sensor acts
like a miniature TV camera to transmit the image electronically to a video
monitor.
First light is transmitted to the inspection area, either by light emitting diodes
or by fiber optic light guides. A fixed focus lens in the tip of the probe
gathers reflected light from the area and directs it to the surface of the CCD
sensor. The signal then travels down the length of the probe through
amplifiers. The video processor receives the signal, digitizes it, assembles it,
and outputs it directly to a video monitor, video tape recorder.
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CONDITIONING MONITORING
4. Discuss about condition monitoring of the engine on ground and at altitude.
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also used to prime and leak checks the lubrication system when maintenance
has required replacement of system components.
PROCEDURE:
1. Ascertain that all conditions required prior to a normal start are met.
2. Position engine controls and switches as follows:
1. Ignition, OFF
2. Fuel shutoff lever, OFF
3. Throttle, Idle
4. Fuel Booster Pump, ON
3. Energize the starter and motor the engine as long as necessary to
check instruments for positive indications of engine rotation and oil
pressure.
4. De-energize the starter and make the following checks during coast
down:
(a)Listen for unusual noises. Check for roughness.
(b) Inspect the lubricating system lines, fittings and accessories
for leakage.
(c)Check the oil level in the oil tank.
WET MOTORING CHECK
It is necessary to check the operation of fuel system components after
removal and replacement or to perform a de preservation of the fuel
system.
PROCEDURE:
1. Position engine controls and switches as follows:
1. Ignition, OFF
2. Fuel shutoff lever, OFF
3. Throttle, Idle
4. Fuel Booster Pump, ON
2. Energize the starter.
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3. when core engine speed(N2) reaches 10 percent, move the fuel shutoff
lever to ON and check for oil pressure indication.
4. Continue motoring the engine until the fuel flow is 500-600 lb/h or for
a maximum of 60s. Observe the starter operating limits.
5. Move the fuel shutoff lever to OFF and continue motoring the engine
for at least 30 s to clear the fuel from the combustion chamber . check to
see that fuel flow drops to zero.
5. De-energize the starter and, during coast down, check for unusual
noises.
6. Inspect the fuel system lines, fittings and accessories for leakage.
7. Check the concentric fuel shroud for leakage. No leakage is
permitted.
8. Inspect the lubrication system for leakage.
9. Check the oil level in the oil tank.
IDLE CHECK
The idle check consists of checking for proper engine operation as
evidenced by leak free connections, normal operating noise, and correct
indications on engine related instruments. Engine drain lines must be
disconnected from drain cans to check for leakage.
PROCEDURE
1. Start the engine according to approved procedure.
2. Stabilize the engine at the ground idle.
3. Check fan speed (N1), Core engine speed (N2), Oil pressure, and
exhaust gas temperature (EGT) should be within the proper ranges
according to the ground idle speed chart and engine specifications.
4. Visually inspect fuel, lubrication, and pneumatic lines, fittings and
accessories for leakage.
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should be observed to see that EGT start decrease. If the EGT does
not decrease, an internal fire is indicated, and the engine should be dry
motored at once to blow out the fire.
After the engine is shut down, technician should listen for unusual
noises in the engine such as scraping, grinding, bumping and squealing.
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inspected according to manual. No cracks are permitted in the fan blades. Blade tips are
examined for curl, and the lightening holes are checked for cracks and deformation.
Inspection of the abradable material for damage due to rubbing of fan blade tips and
inspects the fan speed sensor head for damage due to blade contact.
CONNECTING RODS
8. What are the checks and inspections carried out on a connecting rod during
overhaul?
The inspection and repair of connecting rods include
1.
2.
3.
4.
Visual inspection
Checking of alignment
Re- bushing
Replacement of bearings
VISUAL INSPECTION
Visual inspection should be done with magnifying glass or bench microscope. A
rod which is bent or twisted should be rejected. Inspect all surfaces of the rod for cracks,
corrosion, pitting, galling or other damages. Evidence of any galling is sufficient reason
to reject the complete rod assembly.
CHECKING ALIGNMENT
Check bushings that have been replaced to determine if the bushing and rod bores
are square and parallel to each other. The alignment can be checked several ways. One
method which requires a push fit arbor, a surface plate, and two parallel blocks of equal
height.
To measure the squareness, or twist insert the arbors into the rod bores. Place the
parallel blocks on a surface plate. Place the ends of the arbors on the parallel blocks.
Check the clearance at the points where the arbors rest on the blocks, using a thickness
gauge. This clearance, divided by the separation of blocks in inches will give the twist per
inch of the length.
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4. Before inspecting the air intake or the exhaust system, make sure that there is no
possibility of the starter system being operated or the ignition system being
energized.
5. After any repair, adjustment, or component change, ensure that no loose items have
been left inside the air intake and exhaust system.
6. Observe fire safety precautions at all times when procedures involve the use of fuels
or similar combustibles.
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After rushing by the turbine, the hot gases continue to expand and blast out through
the exhaust nozzle with a high velocity, creating the force which propels a jet aircraft.
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The starter is light weight turbine air motor equipped with a rotating assembly, a
reduction gear system, a splined output shaft, a cut out switch mechanism, an over speed
switch scroll assembly and a gear housing.
The low pressure air introduced into the scroll through a 3 duct. From the scroll,
air passes through nozzles vanes to the outer rim of the turbine wheel. Since this is an
inward flow turbine design the air expands radially inward toward the centre of the wheel
and is then expelled through the exducer. The exhausted air passes through the screen
and out to the atmosphere. The expansion of air from a pressure about 35 psig to
atmospheric pressure imparts energy to the turbine wheel, causing it to reach a speed of
about 55,000 rpm. This low torque high speed is converted to a high torque low speed by
means of the 23.2: 1 reduction gearing.
COMBUSTION STARTERS
The two types of combustion starters are the gas turbine starters, and the cartridge
type starters.
A gas turbine starter is completely self-contained. It has its own fuel and ignition
system, its own starting system (usually electric or hydraulic) and a self contained oil
system. This type of starter provides a high power output for a low weight.
The starter consists of a small, compact gas turbine engine, having a turbine driven
centrifugal compressor, a reverse flow combustion system and a mechanically
independent free power turbine. The free power turbine connected to the main engine via
a two stage reduction gear, an automatic clutch and output shaft.
When the starting cycle is initiated the gas turbine starter is rotated by its own
starter motor until it reaches a self sustaining speed at which point the starting and ignition
systems automatically switch off. Then the acceleration continues up to a control speed of
60,000 rpm. When it is accelerating, the exhaust gas is being directed via nozzle guide
vanes, on to the free power turbine to drive the main engine. Once the main engine
reaches a self sustaining speed, a cut out switch operates and shut down the gas turbine
starter. As the starter runs down, the clutch automatically disengages from the output
shaft and the main engine accelerates up to idling rpm under its own power.
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