Sky Ranch
Engineering Manual
by John Schwaner
2st Edition
Table of Contents
- Introduction
- How your engine works
- Spark ignition engines
- Continental engine specifications
- Lycoming engine specifications
- Chapter 1. Fatigue Analysis
- Fatigue
- Stress and strain
- Stress flow
- Residual stress
- Compressive residual stress
- Tensile residual stress
- Stress relieving and annealing
- Contact fatigue
- Fretting fatigue
- Cracks and fractures
- Fatigue cracks
- Thermal fatigue fracture
- Unexpected sources of fatigue damage
- Field analysis of fatigue failure
- Torsional failures
- Chapter 2. Engine Inspection
- The one minute cylinder inspection
- Engine temperature indicators
- Oil starvation
- Prop strikes
- Stuck valves
- Lycoming O235-L2C oil control ring
- Compression test at cylinder installation
- Do nothing engine parts
- Lycoming nose seal leakage
- Crankshaft journal finish - how smooth?
- Read the bearings
- Exhaust valve breakage
- Ring leakage and oil color
- Analysis of engine contaminants
- Inspection of contaminated aircraft oil systems and oil coolers
- Crankcase fretting in Continental 520 series engines
- Flow porting and its effect on cylinder head cracks
- Lycoming crankcase through-studs
- Checking and adjusting dry tappet clearance
- Bearing failure analysis
- Misalignment
- Chapter 3. Engine Performance
- Engine operation
- Preflight
- Engine starting and idle
- Takeoff
- Climb
- Cruise
- Leaning
- Descent
- Taxi and shutdown
- How engine design influences carburetor ice
- Pilot instructions for ring seating ("break-in")
- Detonation and pre-ignition
- ignition properties and spark plug performance
- Full-rich fuel flow - cooling vs performance
- Lead distribution in the fuel
- Spark plug thermocouple temperatures
- Polishing and porting
- How hydraulic lifters affect valve timing
- Compression ratio
- Horsepower ratings
- Keeping the paint on an engine
- How to alodine
- Painting cylinder cooling fins
- All-weather spark plug leads
- Chapter 4. Cylinder Repairs
- The valve seat
- Dirt and seat width
- Refacing valves
- Valve guide alignment
- Continental angle-head rocker arm alignment
- Continental rocker shaft wear
- Continental intake guide seals
- Cylinder honing
- Cylinder choke and piston designs
- Chrome plate piston ring failures
- Do the rings rotate?
- Piston inspection
- Connecting rod line boring
- Color coding of cylinders (Lycoming and Continental)
- Chapter 5. Lubricants and Wear
- Functions of engine oil
- Properties of oil
- Stability of the polymer molecule
- Cylinder barrel wear - steel
- Cylinder barrel wear - chrome
- Intercooling effects on cylinder wear
- Greases
- Friction laws applied to hydrodynamic lubricated surfaces
- Friction laws applied to boundary lubrication
- Oil additive supplements
- Chapter 6. Hose Assemblies
- Age limit on hoses
- Condition limits of hoses
- Buna-N rubber and toluene
- Hose fitting flare angle
- Firesleeve those hoses
- The hose mandrel
- Classification of hose defects
- Preventing kinking in low-pressure engine breather hoses
- Chapter 7. Fasteners and Fastener Failures
- What is a bolt?
- Stress distribution within the bolt
- Stress distribution within the nut
- Stress distribution within the stud
- Equalizing stress distribution
- Paint and broken cylinder studs
- Torque accuracy
- Lycoming stretch-style connecting rod bolts
- Torque failure analysis
- Fatigue failure of bolts and studs
- Chapter 8. Calibration
- What is calibration?
- What needs to be calibrated?
- What does not need calibration?
- Calibration interval
- Calibration reports
- Chapter 9. Troubleshooting
- Alternator belt comes off (Continental)
- Blown or leaky nose seal
- Cannot reach critical altitude
- Can't get proper fuel flow at full throttle
- Cockput fuel flow differential on twins
- Decrease in EGT on all cylinders
- Decrease in EGT on one cylinder
- Engine won't idle unless boost pump is off
- Engine surges
- Engine kicks back on start
- Engine shudder
- Excessive RPM drop on left magneto
- Excessive RPM drop during mag check
- Failure to change propeller pitch or RPM
- Failure to feather
- Fuel dripping out of carburetor
- Fluctuating RPM
- Hard starting
- High oil pressure
- High oil temperature
- High manifold pressure at idle
- High EGT on one cylinder
- High indicated fuel flow
- High oil consumption
- High cylinder temperature
- Loss of power going to altitude
- Low fuel flow
- Low oil pressure
- Low power
- Oil in combustion chamber
- Oil out engine breather
- Oil turns black
- Poor idle cutoff
- Poor acceleration
- Poor mixture adjustment response
- Propeller surging
- Rough engine
- Rough idle
- Sluggish start
- Split manifold pressure in twins
- Static RPM too low
- Starter ring gear damaged (Lycoming)
- Throttle or mixture control hot
- Unstable manifold pressure gauge
- White smoke in exhaust
- EGT Troubleshooting Guide
- 75-100F EGT rise for one cylinder
- 75-100F EGT rise for all cylinders
- Increase in EGT after maintenance
- Decrease in EGT after maintenance
- Sudden loss of peak EGT
- Slow rise in EGT on one cylinder
- Decrease in EGT, increase in CHT
- Sudden maximum rise in CHT, decrease in EGT
- Fluctuating EGT
- RSA fuel injector functional description
- RSA fuel injector troubleshooting
- Marvel Schebler carburetor idle circuit
- Function of air bleed holes
- Lycoming turbocharger controllers
- A few thoughts on troubleshooting
- Chapter 10. Performance Limits
- Fits and limits
- Does it wear larger or smaller?
- What are new limits?
- Displacement
- Horsepower
- BMEP
- Propeller load curve
- Power curve construction
- Chapter 11. Forces, Vibrations and Balance
- Rotating balance - rotating motion
- Reciprocating balance - translational motion
- Reciprocating force analysis
- Torsional balance
- Balancing the oil film
- Torsional effects
- Connecting rod balance
- Vibration isolation
- Gyroscopic couples
- Summary
- Appendices
- Lycoming Engine Specifications
- Lycoming Connection Rods
- Glossary
- Index