Chapter 1 Aircraft Engines

Aircraft require thrust to produce enough speed for the wings to provide lift or enough thrust to overcome the weight of the aircraft for vertical takeoff. For an aircraft to remain in level flight, thrust must be provided that is equal to and in the opposite direction of the aircraft drag. This thrust, or propulsive force, is provided by a suitable type of aircraft heat engine.

Chapter 2 Engine Fuel and Fuel Metering Systems

The engine fuel system must supply fuel to the engine’s fuel metering device under all conditions of ground and air operation. It must function properly at constantly changing altitudes and in any climate.

Chapter 3 Induction and Exhaust Systems

The basic induction system of an aircraft reciprocating engine consists of an air scoop used to collect the inlet air and ducting that transfers the air to the inlet filter. The air filter is generally housed in the carburetor heat box or other housing close by that is attached to the carburetor or fuel injection controller. The engine used in light aircraft is usually equipped with either a carburetor or a fuel-injection system. After air passes through the fuel metering device, an intake manifold with long curved pipes or passages is used to send the fuel/air mixture to the cylinders.

Chapter 4 Engine Ignition and Electrical Systems

The basic requirements for reciprocating engine ignition systems are similar, regardless of the type of engine. All ignition systems must deliver a high-tension spark across the electrodes of each spark plug in each cylinder of the engine in the correct firing order. At a predetermined number of degrees ahead of the top dead center position of the piston, as measured by crankshaft travel in degrees of rotation, the spark occurs in the cylinder. The potential output voltage of the system must be adequate to arc the gap in the spark plug electrodes under all operating conditions. The spark plug is threaded into the cylinder head with the electrodes exposed to the combustion area of the engine’s cylinder.

Chapter 5 Engine Starting Systems

Most aircraft engines, reciprocating or turbine, require help during the starting process. Hence, this device is termed the starter. A starter is an electromechanical mechanism capable of developing large amounts of mechanical energy that can be applied to an engine, causing it to rotate. Reciprocating engines need only to be turned through at a relatively slow speed until the engine starts and turns on its own. Once the reciprocating engine has fired and started, the starter is disengaged and has no further function until the next start. In the case of a turbine engine, the starter must turn the engine up to a speed that provides enough airflow through the engine for fuel to be ignited. Then, the starter must continue to help the engine accelerate to a self-sustaining speed. Turbine engine starters have a critical role in starting of the engine.

Chapter 6 Lubrication and Cooling Systems

The primary purpose of a lubricant is to reduce friction between moving parts. Because liquid lubricants or oils can be circulated readily, they are used universally in aircraft engines. In theory, fluid lubrication is based on the actual separation of the surfaces so that no metal-to-metal contact occurs. As long as the oil film remains unbroken, metallic friction is replaced by the internal fluid friction of the lubricant. Under ideal conditions, friction and wear are held to a minimum. Oil is generally pumped throughout the engine to all areas that require lubrication. Overcoming the friction of the moving parts of the engine consumes energy and creates unwanted heat. The reduction of friction during engine operation increases the overall potential power output. Engines are subjected to several types of friction.

Chapter 7 Propellers

The propeller, the unit that must absorb the power output of the engine, has passed through many stages of development. Although most propellers are two-bladed, great increases in power output have resulted in the development of fourand six-bladed propellers of large diameters. However, all propeller-driven aircraft are limited by the revolutions per minute (rpm) at which propellers can be turned.

There are several forces acting on the propeller as it turns; a major one is centrifugal force. This force at high rpm tends to pull the blades out of the hub, so blade weight is very important to the design of a propeller. Excessive blade tip speed (rotating the propeller too fast) may result not only in poor blade efficiency, but also in fluttering and vibration. Since the propeller speed is limited, the aircraft speed of a propeller driven aircraft is also limited—to approximately 400 miles per hour (mph). As aircraft speeds increased, turbofan engines were used for higher speed aircraft. Propeller-driven aircraft have several advantages and are widely used for applications in turboprops and reciprocating engine installations. Takeoff and landing can be shorter and less expensive. New blade materials and manufacturing techniques have increased the efficiency of propellers. Many smaller aircraft will continue to use propellers well into the future.

Chapter 8 Engine Removal and Replacement

Procedures for removing or installing an aircraft engine usually vary widely with the type of aircraft and the type of engine. Thus, no single list of instructions can be provided as a guideline for all engines. Because of the many types of engine and aircraft installations and the large number of design variations within each type or category, representative examples have been selected to illustrate the most typical installation procedures for reciprocating, turboprop, and turbofan engines. There are some common tasks that must be accomplished when replacing an aircraft engine. Most engines require disconnecting and reconnecting electrical, hydraulic, fuel supply, intake and exhaust air path components, engine controls, and engine mounting connections to the airframe.

Chapter 9 Engine Fire Protection Systems

Because fire is one of the most dangerous threats to an aircraft, the potential fire zones of all multiengine aircraft currently produced are protected by a fixed fire protection system. A “fire zone” is an area or region of an aircraft designated by the manufacturer to require fire detection and/or fire extinguishing equipment and a high degree of inherent fire resistance. The term “fixed” describes a permanently installed system in contrast to any type of portable fire extinguishing equipment, such as a hand-held fire extinguisher

Chapter 10 Engine Maintenance and Operation

Both maintenance and complete engine overhauls are performed normally at specified intervals. This interval is usually governed by the number of hours the powerplant has been in operation. The actual overhaul period for a specific engine is generally determined by the manufacturer’s recommendations. Each engine manufacturer sets a total time in service when the engine should be removed from service and overhauled. Depending upon how the engine is used in service, the overhaul time can be mandatory. The overhaul time is listed in hours and is referred to as time before overhaul (TBO). For example, if an engine had a life of 2,000 hours and had operated 500 hours, it would have a TBO of 1,500 hours. Tests and experience have shown that operation beyond this period of time could result in certain parts being worn beyond their safe limits. For an overhauled engine to be as airworthy as a new one, worn parts, as well as damaged parts, must be detected and replaced during overhaul. The only way to detect all unairworthy parts is to perform a thorough and complete overhaul process while the engine is disassembled. The major purpose of overhaul is to inspect, repair, and replace worn engine parts.

Chapter 11 Light-Sport Aircraft Engines

Engines used for light-sport aircraft and other types of aircraft, such as some experimental aircraft, ultralight aircraft, and powered parachutes, must be very light for the power they develop. Each aircraft requires thrust to provide enough forward speed for the wings to provide lift to overcome the weight of the aircraft. An aircraft that meets the requirements of the light-sport categories must meet the following requirements.