AC65-12A Airframe & Powerplant MECHANICS POWERPLANT HANDBOOK ager s \; U.S. DEPARTMENT OF TRANSPORTATION XN ye FEDERAL AVIATION ADMINISTRATION Rs Stars OF"AIRFRAME AND POWERPLANT MECHANICS POWERPLANT HANDBOOK DEPARTMENT OF TRANSPORTATION FEDERAL AVIATION ADMINISTRATION Flight Standards Service First Edition 1977 First Revision 1976 one ‘Weshlogton. D.C 20802PREFACE ‘This advisory circular is printed for persons preparing for a mechanics cer tificate with a powerplant rating. It is intended to provide basic information on iples, fundamentals, and technical procedures in the areas relating to the power- plant rating. This is designed to serve as_a guide for students enrolled in a formal ‘course of instruction, as well as the individual who is studying on his own. ‘This volume is devoted to an explanation of the units which meke up each of the systems that bring fuel, air, and ignition together in an aircraft engine for com- ustion. It also contains ‘information on engine construction features, lubrication systems, exhaust systems, cooling systems, eylinder removal and replacement, com- pression checks, and valve adjustments Because there are so many different types of aircraft engines in use today, it is reasonable to expect minor diflerences to exist in like system components. To avoid undue repetition, the practice of using representative systems and units is carried ‘out throughout ‘the advisory circular. Subjectmetter treatment throughout the toxt is from a generalized point of view and its use can be supplemented by reference to manufacturer's manuals and other textbooks if more detail is desired. This advisory circular is not intended to replace, substitute for, or supersede oficial reg ulations or manufacturers instructions which should be consulted for final authori Grateful acknowledgement is extended to the manufacturers of engine, propellers, and powerplant accestorics for their cooperation in making material available for inclusion in this handbook. ‘This handbook contains material for which a copyright has been issued. Copy- right material is used by special permission of United Aircraft Corporation, Pratt aft Division, and may not be extracted or reproduced, without mn of the copyright owner. ‘The advancements in aeronautical technology dictate that this advisory circular be brought up-tovdate periodically. It has heen updated, errors have heen corrected, rnew material has been added, and some material has been rearranged to improve the useftlness of the handbook. "We would appreciate, however, having errors brought to our attention, as sell as suggestions for improving its usefulness. Your comments and suggestions will be retained in our files until such time asthe next revision is completed ‘Address all correspondence relating to this handbook to: Department of Transportation Federal Aviation Administration Flight Standards National Field Office P.O, Box 25082 Oklebore City, Oklahoma 73125 ‘The companion advisory circulars to AC (5-124 are the Airframe and Power. plant Mechanics General Handbook, AC 65-9A, and the Airframe and Powerplant ‘Mechanics Airframe Handbook, AC 65-154.CONTENTS 1 2 ‘Types of Reciprocating Engines ..... Seta 4 Reciprocating Engine Design and Construction. 2s. sece see 5 Crambhalts o.cscescesessesseseseseseeeeees reread Connecting Rods... 0..csccsceeseseeeeee ieee ag Pie tect ase ea ae eee 16 Piston Rings 16 Coinders Ww Cylinder Numbering 18 Firing Order as 1» Valves ee 20 Valve Operating Mechenism : 2 Bearings ..... = 2% Propeller Reduction Gearing 25 Propeller Shafi « 26 Resipreaing Engine Operating Pisin 26 Operating Cycles 28 FourSiroke Cycle 28 Reciprocating Engine Power and Eliciencies 30 Elfciencies 36 Turbine En 38 Air Entrance «2... 40 Accessory Section 41 Compressor Section « 2 Combustion Section 8 ‘Major Subassembl a ‘Turboprop Engines 6 Turboshaft Engines . 6 Turbofan Engines... eee a a Turbine Engine Opera 6 Thrus » 6 Gas Turbine Engine Performance or CHAPTER 2—INDUCTION AND EXHAUST SYSTEMS Reciprocating Engine Induction Systems « n Induction System Teing « 8 Internally Driven Superchargers 75 Externally Driven Superchargers - 0 Turbosupercharger System for Large Reciprocating Engines « 80 Turbocharger . ies eee oeCHAPTER 2—(Cont.) ‘Sea Level Boosted Turbocharger System ...... Tarbocempomd Syms for Fesprocting Engin. ae Turbojet Engine [let Duct Systems .....-seceeeescceceveeeey 90 Turboprop Compressor Inlets ... 4 Reciprocating Engine Exhaust Systems . 95 Reciprocating Engine Exhaust System Mi 98 Turbine Engine Exhaust Ducts... 101 Turboprop Exhaust System 102 Thrust Reversers 103 Engine Airdnlet Vortex Destroyer... 105 CHAPTER 3—ENGINE FUEL AND FUEL METERING SYSTEMS Fuel System Requirements 109 Basic Fuel System ....... no Fuel Metering Devices for Reciprocating Engines no Carburetion Principles a n3 Carburetor Systems us Carburetor Types « 16 Carburetor leing «2. 6 Float-Type Carburetors ut Pressure Injection Carburetors 12 Stromberg PS Series Carburetor . 134 Direct Fuel-Injection Systems peat 136 Carburetor Maintenance .....-+. Sete alae Fuel System Inspection and Maintenance ........+ 6 Water Injection System for Reciprocating Engines . ar Turbine Engine Fuel System—General Requirements .....2.+++. 149 Jet Fuel Controls ane eee geereae ea Coordinator 158 Fuel Control 153, Speed Sensitive Contral ..... 154 Fuel Manifold Drain Valve . at System Operation ......- 154 Hydromechanical Fuel Control 156 Fuel Control Description .. 156 Fuel Scheduling System : 163 Water Injection ReSet System . 167 Jet Fuel Control Maintenance ..- 167 Engine Fuel System Component 1 Fuel Quantity Indicating U 1m Water or Coolant Injection . m4 CHAPTER 4—ENGINE IGNITION AND ELECTRICAL SYSTEMS, Reciprocating Engine Ign 7 Battery Igeiti 7 Magneto Ignit ww Auxiliary Ignition Units 190 Spark Plugs 195 Reciprocat 196 Magneto Ign 197 Checking the Internal Timing of a Magneto 201CHAPTER 4—(Cont.) Timing High-Tension System Distributor Fingers Spark Plug Inspection and Maintenance ‘The Engine Analyzer ‘Turbine Engine Ignition Systems Ignition System Inspestion and Maintenance Remora Maintenance, end ration of Ipiton Sytem Components Powerplant Electrical Systems ....... Lacing and Tying Wire Bundles Cutting Wire and Cable .... Stripping Wire and Cable . Emergency Splicing Repairs Connecting Terminal Lugs to Terminal Blocks « Boning and Grounding oe Connectors Conduit : Electeical Equipment Installation CHAPTER 5.-ENGINE STARTING SYSTEMS General Reciprocating Engine Sterting Systems Starting System Using Combination Inertia Starter . Direct Cranking Electric Starting System for Large Reciprocating Engines «......+.+ Direct Cranking Electric Starting System for Small Aircraft . Gas Turbine Engine Starters Air Turbine Starters Fuel/ Air Combustion Turbine Starter ......++.+ CHAPTER 6—LUBRICATION AND COOLING SYSTEMS Principles of Engine Lubrica Requirements and Character Reciprocating Engine Lubrication Systems Internal Lubrication of Reciprocating Engines Lubrication System Maintenance Practices ‘Turbine Engine Lubrication Systems ‘Typical Dry Sump Lubrication System Engine Cooling Systems . Inspection of Cowling .. Engine Cylinder Cooling Fin Inspection ‘Turbine Engine Cooling - CHAPTER 7—PROPELLERS General Basie Propeller Principles » Propeller Operation .. ‘Types of Propellers . Classification of Propellers Propellers Used on Light Aircraft ..... Constant Speed Propellers .ssssssseserescsesessseserenenesenenes 23 230, 331CHAPTER 7.—(Cont.) Feathering -+++++0+++ + 385 Hamilton Standard Hydromatic Propellers Coir oa Hydraulic Governors «... ie au Propeller Synchronization .-....+s+..s++ 37 Propeller Ice Control Systems . 347 Propeller Inspection and Maintenance 349 Propeller Vibra Blade Tracking . Checking and Adjusting Propeller Propeller Balancing 352 Servicing Propellers ....... 358 Turboprop Propeller 354 Blade Cul ... 358 CHAPTER 8—ENGINE REMOVAL AND REPLACEMENT General - 350 Reasons for Removal of Reciprocating Engines . 359 Preparation of Reciprocating Engines for Installation . 361 361 QECA Buildup of Radial Engines ... Inspection and Replacement of Powerplant External Units and Systems 364 Prepating the Engine for Removal ... 365 Removing the Engine ...+.+scssusessersrseseaeses 368 Hoisting and Mounting the Engine for Installation 369 Preparation of Engine for Ground end Fight Teng 372 Propeller Check . saat 373 Checks and Adjustinens after Engine Ron-up and Operation . 374 Removal and ttlaton of 9 Oppend-ype Engine .a-vvnseesesss 304 Engine Installation... 375 Turbojet Powerplant Removal and Tns 375 Installation of Turbojet Engines 377 Rigging, Inspections, and Adjustments 378 Turboprop Powerplant Removal and Installation . 380 Helicopter Engine Removal and Installation 381 ging and Adjustment of Helicopter QECA + 382 Engine Mounts : 382 Preservation and Storage of Engines 386 Corrosion Preventive Treatment 387 Engine Shipping Containers .......... 388 Inspection of Stored Engines 390 Preservation and De-preservation of Gas Turbine Engines - 390 CHAPTER 9—ENGINE FIRE PROTECTION SYSTEMS General 7 391 Reciprocating Engine Fire Protection Systeme. 391 Fire Zones « oer 304 Fire Extinguishing Agents so. jec.cscccs-- 304 Tutbine Engine Fire Protection Systems 397 ‘Typical Molt-Engine Fire Protection System 399 Fire Detection System Maintenance Practices . 103 ire Extinguisher System Maintenance Practices 406 ‘Turbojet Aircraft Fire Protection System (Saberliner) 407