-

FlG. 7 8 tont.ei; iLre re.tof 5!sie: si eo o. r erq re feldv'e

'o'lrne/l

aa-=, ,
/ i fFOTT E
eosrron
I
, l\i TO MANIFOLO VALVE

,=\

,,
FUEL NJECTION PUMP ASSEMBLY

FLIEL PBESSUF E GAUGE

FlG.7-9 S.h.nt. d !'m ol Cot n!.i rLre e.tor 5!'5i' ilerdlre Corinerd,
rto the intakc Dorl. Thc orzle boct! contdns dilled cen
a "e the
Near the rop ol be nozzle body. radial holes
ral ssaee iLiih a counLerbore dL c.h .nd Th. lo\1er end errl-''leIi"'.bodr"
of tc no)zlc i' used for luel ir rniling ch.rmbcr bennc .,,'.'. ,' -r'n( lh(.. '. e'r' le r'r.
.,,e 1,. .r_r I " - ,ne.
',r'.e,,
..t'. ,g1,, \1,. r
rcmoiblc oLiilce ri,r calibrrrins e norrles screen fittccl orer thc no77le body The screen kceps dirt

150 chapter 7 Fuellnjection svstemt

r.d other foreign nrateial ou! of dre interior of the nozTle. a ateed tlur1ger nr a o.ificc. The thngeis molernenl
A press litted shieid is mounled o the orzle body dd vrries rlre anourt of fcl b)pssed through rhe relief lalve
exterds o!er rho g.aLcr pait of Lhc liltcr scrceD. lcvirg an !D.l drus compenstes fb the clloct of lower pressures at
otennrg ncar tho I'oLtor. Thi! pro!idc\ boLh icchaicl hjgh allltu.Le. A punlp ilhich incorportcs the aneroid vahe
protccLion ancl aD ir tlh Nith an abrupt chlngc in d;cc is shor i Fi! 7 I I
tion as an aid t() cl.ness. \ozzles rc calibratcLl r sc\.ftI
rxngcs, ar1d dll ozzlcs fumishc.l lirr oDc cnginc rc ol the
same nnge The 1nge i\ ider)lilied bl leter saflped on
e heriaeo! ot lhe nozzle bo.ly.

complete System
The conr!lere Cotinental fuel injeclion sysrc in\tallccto
a engine is shown ln I-ig.7 8. Ihis digranr \ho\s (he
fuel ir cotrol uit installed at the usul locaLio ol thc
.arburrlor. Lhc punrp ifxllcd on lhc accessory secio- the
luel rrifbkl lalve insLlled on rhe rop of dre ersnre. and
lhe nozzles instlled ir rhe cjlirders ar e irtake polts. The
r"P.... r ro..,uf,r r.(r .F
nd econorny of operali.,r. A diagnLn of the colp1ele lys
rern is show in Fig.7 9

lizes tuel pressure (esabllshed bl the englne lpl1r and the

felef ralre) and vafiable orifice (conrollc.l by duottlc
position) to mcter the corect volrnre .1 prcssorc of fucl
lbr ll to\lcr \crigs. Thc mirtrrc i\ corrollcd by dirst
ing the qantit) olfael rctumed to thc purp inlcr.
FlG. 7-11 FLre pLrrp icorport ! rhe nero d v ve.

lnstallatons f or Turbocharged Engines Adjustments

To pernl lhe Corrtirerltl lirel i|jec1on sysen 1.:) operate The idle speed adjustmnt lor rhc Contincnrl fucl nrjcc
r rhe hjgh nliludes encouered by turbocharsed egincs. tion sysiem ls rade $'ith a colrvenlional strnrg loacled
ihe fnel nozTles are nrodjfied b) incoToralig a droud that screw lFig 7 l2l on lhe hrottle leler ol lhe lirel con(.ol
. I .,- pJj,o rFJ (F..r. l.li unit. The {rew is lunred ro rhe ngh to increase and lo the
':r t|
iue at high rlliiude\ is not mfficienL lor ir tl) cDLcr lhc lelt to decrc$e the idle !Fed.
1..d\ and.rir \vith the fucl prjo! to rjccrioD. Rm air is l hc idle nrixturc adjustment (Fig. 7-12) consisls ofthe
:h...lorc afpljcd to the no/rlc shr)trds, *hich.lircct il to l)cknuL ! dre neterjng valve end of the ]inkage belween
ih. ozrle i! illLrrrared i Fig. the mcrcring \!lve and rhc throtle lever. Tightening the nu
_ ir blc.ds A
10.
shroudcd fucl
lo sh.)fe (he linkage trovidcs a ichcr mixte. and back
.\noiher modiiication required lbr high altitude ofera ing olT rhe nu leans ihe mixlure. Thc nixtLrc should bc
::n rs a altitud compensating valve i the iiel ftrmp. &1.1ulted slighllt richer rhnn besr poser, as is the case iridr
TnLs vahe ls operaed by an aerojd bellows $hlch nn)lcs ll s)\tcr;. lhjs i! checlied atier adjustneDt b) running lhe

IDLE SPEED AI]JUSTMENT

:lG. 7-10 Shro!ded flel nozz e FlG. 7 12 !d e speed nd m liLrr dirstnrent

continental contlnuourF ow nject on system 151
e|gire idle ard slowly movirg the nri\rrre control
L I Ispect nozzles tirr clcanness. with paiculr it.
tlrd r
rDrcLroFF. Idie sfccct \hould lcrcase slighly jult ti. o i screens nd oilices Use srandard ! m ll2.70
bcforc the e|gine begnrs to slop whe thc nunifold pres nnnl \p'k pltr-q nreD.h ldeep sockel to renrc\e thc ttz
iure ggc is used for the .hcck, {he XIAP sho!ld be \ee 1') -ler Do r rer r ' . clc,r rl . i .. r .r
de{se slighlh as rhe mixrurc h leaed with dre maul Ihe nozzles. llo nol rse wire or oher objecls 1o clean he
orifl.es To cle! thc ozzles. remore thc from the
engine and i.ner\e thelt] i fresh cl.anins solvent. Use
.omprcss.d air 10 df).
Pump Pressure for the lnecton System : tr.r(.1( rJrplr! ror.LrLe rtr..

trn vh'e. and clexn h. screen ln liesh cledning sh'eni.

Since thc llo\r' of .r liquict rhror-lh { gi\en orifice sill Reinslall. st,!. aDd chcck fbr leaks.
nrcrerse s the pressure inccases. ihe fucl presslrre delj! 6. Dud|g teriodic lubricalion. apply x drop ol elrgrre
ered bt Lhc engire'dri\en llrcl pulp nlur be correc if Lhe oil o ech erd of the air thrcle shaf! and at ech end of
flo throlrgh the melering unit rrd the tucl Dozzlei is o b. rhc likge belrleen th. ir lholle l]nd the luel meerjng
correct. Thc luel turt a.ljusrLnent is acc.trnplished as \ ahe. No other lubdc{lion is required.
dire.ted b\ thc ma| tri'cturcr tu sen ice raLrals or hu l lernrs 7. l the eleL Lhal a line lttig nr anr par ol te inicc
'Ihc luil punp prc\sLrre is odjsLoct aI brlr iclle \teed
iio !yst.r iusl be replaced, onl\ a luel-soluble lubdc!r
d iull-poirer rpm. ,\ pressure gdge Ls conf.cLccl 1o lhe (such a\ cngmc oil) should bc usecl or lhe filtiDg thrcads
ludl purp outlcl line or lhe nrctcri g rit iDle( line b) dlLrin8 iDstdlhti.in. Do not usc an) oher form of Llitcd
.rcds of n tee firling. The lechnicin can thcD nake the
lirel adirLsnrent in ccrirdance with lhe istrtcLiorrs fr the '|.t /.. ,J! J lr'a,r e.ret I cr '.,1
s!srem being te\Lcd. not ccc\sa.I Lo replace !hc cnLie set Each reflllcnrent
To illustfurc the tuel pressurc requremenrs lbr tlpical i./ lc hr . .n Ll e u,e , .c.1. - r ,..\ed
e]rgLl]e\, the lollo(1rg infornti.il is quoted liorn hc "
T(Icd\ie Coti.nk S.triL Bull.tin:
Operation
Egin. Nfoclel lO 3.16 A.B
l-or thc oDeralio ol a airc.lt englre equippcd \iLh lhe
6110 4rDr Co!jcDral fuel irjeclion slstenr, certain fcts n1Lr-\I be
plessLre I 9 psi
Pur! 'lE-: kPa remembcrcd b) Ihe iechnicin or pi1.'1:
Nozletressure 2.0 2.5lsi 13E 1l21kPr
L Whcr1 the engine is bcing stalte.L, it is easy Io flood
:700 rTr thc s)(erD if lhe riring ol the fain3 e!et\ is ot correcl.
Pumt pre\\!rc 19 2l psi l3l 1+5 kP \\her the mirture conlrol in any posjio oe dun lDLt
\0771. plcssure ll.5 1,1.0 psi 86 96.5 kPa cLroFF, when thc thrortle is ofen leren llighrlyl. and when
FLLeltlo$ 7it 8-5 lb/h ll 1'1gl/h rhe rlriliL! fn.l puip is ope'atin8. fucl sill be flowing
-15 I -lS5ks/h into the itxke polts ol lhe c)liders. Therctbre, he egine
should be stafied \ilh :r fu' secods llter the aLrilir"
Ergr|e Nfodcl cTslO 510 C fel pump s tumcd on.
2. The eglnc cnro be Salted wiLhoul the anriliary
liLel tunrt bccuse the egiie dri!. pu]p Nill not suppLy
Punrp plessLLre 5.5 6 5 fsi 3E '+5 kP xdcquaLc pressure until th. cnglre is runig.
liorzle tressure -r.5 -1.0 psi l'1-28 kPa l. The aurilixry fuel purnp should be rIed ofi during
2.100 Dor llight. It nul be leti on clurhg takeoff s a safet) reasure.
lrll ,1. For lakeoff. thc Lhrole should bc fll] advanced, and
Purrp trressurc 30 3-l tsi 128 kP
Nozzle prelrtre 16.5 t7.5p\i 1l'1 l2l kP the nixture conlrol \hould be se! a rr.r r Rrcrr.
Fel flos' 115-225 lb/h 36 :8 g!l/h 5. Fo criiing. rhc cngxre lpm should be set accordig
98 l0l ks/h Lo inslciron,! i
th. operaofs hndbook. The mixtrc
."..r1,1
codition. dcpcndilg o the judgment of the operrror. cate
lnspections lllusr bc c\crcised rot to le Lh. rr1ixtue oo much
6. Bclore redciLlg po$cr 1r descen. se thc mixlurc to
To \oid rrr djllichy r'llh drc fu.l irjection streln. ii is best po\cr. Oce the rffic pdrem is entered. thc nixture
$ell tu ferfor cerlir irrspcctions d chccks el'e conll mu\t bc se ro { L. Ri.r ard kep in this lo\itlor
LhouSh o opcrdtnrg discrefn.ics h\e been Dotcd The
nnlo rs jste.tioDs are recornrenclcdl l. lhc cnse i\ stopped by r]lolirg dre nirtlnc conttl
to irL,.riroFF tier he egine lras been idled for shor
1 Check dll Ilaching Urs lor tighlnc\\' Check all tiic. sliiches shoul.t bc rured off innlcdilelv alier
^ll
dro cgine is sopped.
2. Ch.ck ll t'uel lin.s for leks n.t 1or eliden.e oi
damxg., such rs ihnry bends. areed lubs. or chxflig
liorr meLrl Io mel contct. Troubleshooting
-1. Clhcck coitr.l conneclion!, l.!ers. and lj.klges
lhe
fir tighr aIaching fats. n)r raleiying. anLl lbr lost nn)lion Bennc ssurnhg l th. fucl coniroi system lr an ergie
is r fauh Nher rhe engic ie ro operxting properly. the
'152 chapter 7 Fue nject on systems
 TFOUBLESHOOTING CHART

Check miture colro ior proper pos t on,

auxiliary pump oN and opeat ng. feed valves
ope, fue filiers open, iank lue teve.
Pe,-. 1 o.t
". q . 6, oro I.r
r, :- !ase press!re Loosen one ne al z e f no fel f ow shws
w tlr melered fuel pressure o gaqe repacelhe
lle lfo d v]v.,"

Nozz e ir screens resir cled. Remove oz2 es and crean.

lmproper idle miriure adjustrnent. Readtusl as described udet Adjusinens page
125

ld e nrixture loo lea. Feadjust as desc bed uder dlrsersj pase

125.
Replc worn elernents of Inkage

Remove and c ean a I nozles.

Feslricted flow lo meier g valve
lnadequale f ow from pump.
[ xiue conlro]- eve intfrenc
Restr cied f ow beyod nreler ng va ve.
Restr cied reclrc!laiio. passage
Oheck nrixture cortrol sett 9.
lmproper pump pressurei rep acej or cal an
auihorized representaiive to adj!sl.
Check mixl!re control lor futltrave. Check for
c qged flel f ters
lvay be worn ile pump or siick ng retief va ve.
Fep ace the lue purnp assembly.
Check for possible conlact with cooling shroud
Check for reslricted nozzles or fuel man iold valv.
C ean or rep ace as requ r-"d.
n Rep ace pump assemb y.

:,:i!a1 g oace pressure Vapor systemi excess fue terpera lf ot c eared w th aux ary purpj check for
cogged ejeciorjet in ihe vapor separaior cover.
C ean onLy w th so ve.t no w res
Fue in gge ne, Leak at lage conec. Drain lhe qaqe e and repair the teak

Engine oetliq lue. Check rn xlure controlto be f! DLEcuraFF.

Check auxilarV pLmp t be oFF. C an nozzte
assemblies (screens)or rep ace
Fep ace manifo d vlve

:G. 7-13 tote.t iLre lectontro!besrootiq.hdrr

:::.iciar should mke strre that oher fctors are no
- i'lred A rongh running englne rna\ hrre ignim trob
::ii shlch shorld bc che.ked befole dismrrling rhe fuel
Thc troublcshooting chrt trov ded in Fl!. 7 I:l is
. " .l.rIr.ut'J I .r ,l he ...Jr.
:-.rgcd nr order of the apFoimrt. ese of cbeclrrg nd
-: necessaril) j the order of prcbabilir!.
Prncples of Operaton
ihe Bendix RSA fuel irjectio slsrcm i\ r continuous
( s)slcnr rD.l is based oL1he lamc princiirlcs as those ot
::e pessule lypc c{rburelors descnbcd tu Chp. 6. A picto
-al rief' ol lhc RSA injecior Lrnit is show nr Fig 7 1.1
Bendii fuel inJectiorl sysrcnr! are designcd ro n1eer fet in
direcl rati{) ro lhe voluc of xir beins consumed by tre
enginc {r a gilen il]rc. Thjs is accomplishcd bl sensing
lenturi suction ad impct r pressures in the iluote
bod). Ope.ig or closig rhc rhrrle !he rc\trhs in
change in the \clocily ofair passing acrcss he i prcr lubes
nd lhrough thc \enti. as ilhrratcd in FiS.7 15. When
lhe air velociLy mcrelses! t-he prc\sure a the in\ract tubes
.cm.tr reladycly corstaDt depcncling on dre inl.r drct con
figLtration ir lilterlocatio. etc. The pressLrre al the \erluli
throat decrca\es. This decrcrse creates a dilferential
',p.( r,r .,r.u \]i
surerent ofc !olume ofair conlume.1.
All il] a
reciprocarnrg cngine\ oterrc nn)sr efficieily
ler) {ro( ol djr fuel (A/F) kr fuel air (F/A)l
rang
rtnrs l'he Bedix jjcction slfem usos thc neaslrrenenL
olan vohre llo$ to gccrate n lorce $trich cn be used to
rer:ulre dre llo\r' ol lircl to rhe engie in p()porrion to lhe
amount of air behg coDsumed This i! .rcconrplished b)
Bend x RSA Fue llection Systenr '153
charnellg th. i.rp.lcl rd l,enrlLri (uctior pre!sures to Fuel is srLpfl ed to drc .ngne lrorn lhe ircrat't fuel s\ i
ofposile dithragnr. s shoi nr Fjg. 7 16. Tlic
si.1cs o1 em. Thjs systenr ustrallt includes boos |ump lo.red i.
differe.c b.Lqee these two prcssure! rhen bcco cs a elrlrer rhe {Ie r rk {n' rh.r tirel lle bel\'een the Lnk rd lh:
us.rble rbrce r\hich is eqnxl n) rhc area of rhe didthrgm efsiie lhe cngj.c drile| tuel turp rece \es ftcl lrom rhr
tines the trcsiule dierece arcraft !) \rcm (nrcluding lhe oo\t purf) nd suptli.\ thar
fuel .rl x rc!Lircl\ co sta pre\snre to thc lir.l intecto.
DLE SPEED scr\o inlcl. The egloe minufl.trr.r \pe.iiies lne lusl
ADJUSTMENT NLET-FUEL-PRESSURE pu p pirssLrre seiring fflicbl. 1o thc sfeciic liel inje.
Ior irNlallli,r. The fu.l inj.crors re clibrated a d t jnl.i
pressure. The lcLtig\ re checked o esurc Lhr mot.ieLt
luel llo ilill nor bc lftcted bl change! i mlcL lucl pie'
sure crsed b) nonnl o\ or.rFF opertio ol the boolr

The Be.tix lircl iniecion s)ltenr. if propcrl) asselnbled

ard caljbrtc.l. $illnreel all peirnnan.. lcquirernenls o\er
r, r.,I \r. -. rl | ..'c lr' e-r.
drc serro pressure regulabr.
Thc ciiest wa,\ e\flxin thc opcrliol ofthis reSulto
rn.l ils rehtioNhip lo the r nclen gje is t{r describe
f . rr, .1r. .r r '
'.. lrom r eNisc condition \1,here air \elocit\
We sart
OUfLET tlrough the lhrcItle bodf l\ gcncrnlng alr ilpact pressure
.rinus \cllri $crion pr$surc dillrcntial l a theoreti.!l
IOLE VALVE ..c li , rre. . rr lr
AD]LJSTNENT lorce ro lhe ri3ht, s I
shorr rr Fig. i7.
Iel , r'.,!r '..t.'-rr .'-Lr .r
MPACf AIP je. gefcr.\ x luel pressLrle "
differential luDmerered rinus
rtc.7 14 BedR5A rle.or Lrn i ineqf aoir.]s Diri,

illll lltli

FIG.7-15 AiowlhroLgh ihe ientrr lnrql ao,/t flc.7-16 n .t.nd letLrr sLr.torl
aantrals D,/. Eendr\ Cotp I

154 chapter 7 Fue lnjct on systems

 lilt

l
METERED UNIVlETERED MPACT
FUL FUEL

FlG. 7-17 Sefr'o presslre reqLr tor. /Eer!/j, Conrob D\t . Bendt, Cae.)

merere.l tuel prcsstrrel This pressure diftrerril atflied
r.ross a recond (fuel) .liaphrg.r, is !l\o creaiing force
rirh n value oi 2. rhis \,alLre ol I is exerlng lbrcc !o ihe
l:r'. as sho\ln in Fig. 7 17.
The tivo .,pposing forces (lucl {nd ir difteren(ilsi dr
:qual. nd re reJ+ tor serro vahe (which is concclc.{
i.r both diuphragnr br- stenr) is held at lixed losltioLr
iht dllos! schrre oljN eroLgh etercd irL.l ro lllair-
npJ\-b-....1 etl o ie'. p .r.r..l-rcJ..
:cNcr. rirfioN imnccliatel,! increses. This rc\ulrs h ar
rncrcso i !he tressure differertial across the air
Jiphrrgr to a theoletical lxlte of 3 The i nrc.li{te resutt
ii r movcrcn of rile requlnr lello vah e o rhc right. This
rnceased scr!o lahe otenrrg caules oh a decr.asc in
',,(.,r1. -, - -o:r ,c-.,..
;oel pressurc.tifferetial cross thc rain reteins icr.
\le, , r.-. .r , la .,e.r.l ...,-,,rcerc
.. ! !alue of 3 (equaling the air diaphr{gm lorce). the regu
.. n o. r^i,o..Jrle.d-o,,1 ..,. Le.J.. p.,,
:io which will mritain the balacc of pressure dill:rn
:iels (thal is. air ad fuel. each equalmg ll.
Fuel flow o thc cgine is incrcasd to suttorl dre higher
ro\lcr lc\el requested. The luel diaphragrn linle heing gen
'' I t ele e, " lonl idlr
:qual to he ajr dlaphragm force belrg ger)erarc.l by ihe
This seltrence ol otcrti.ns js marrrDrcd over all
..girncs ol foser opcr.lrio nd a1l po$er chngcs. l he
..sulalo seno !ah,e lcspo.ls ro charges ellctive ir
diathragm dillrential presiurc nlces ad rdjtrsts the tosi
tion of the scryo valle to rcgtrl1e uffnctcrcd to mercrcd
lucl tressnre differentil fir.ces accordingt,"-. Fuel itos
Ihrough he nretciing je l\ fuct o of it\ \ize and rhe
pressure diftre ial c rols he jer. l he selro ! .rl!c does no
neer luci. l o ) cotrrls the Fessurc dirteretirl across
The dle vxlle is conlecrc.l to ihe rhro[tc linkase. il
accurate r)etcrig of firel in Lhc idle mrrge. Figure 7 1E
slns rhe funcLion and oper.uio of he idte \alye Ir is
Jrtern,]l) adistrble xnd alloss rhe technicin ro tropell
luDe the fuel iiect to rhe errgnre instalarion fbr proper
idle nrixture. The idlc rixlure ls con.e.r \ther thc engine
ir :alns approxinarely 25 ro 50 rpm lioi iL! idte speed sct
ting as Lhc mitue cori1)l is placed in nn.f .LrrorF. \Iantrat
,
control ol the :dle lniilurc is ecessi) bccule ar e lcr!
o Jr I 11 rl .:, lr 1 -
'!.
nereing lorce is rol sulli.ieni to ccurirel) conr.ot rhe
On some engnre\ ccording to sp.cjfjc irfallLio
requireDlcDts. xn enrichmcnt.ier is adde.l irr tral]et $irh rhc
rain rnebrg te On hesc istllatlons. lhc sliding (rota-
ral\e ,l e,r .t r j- .. .
prcsct rhroltle posjtion. as sho$n m l,j8. 7-tS
This plrnl-
lel ll.w path tucrcases the F/A miiLLtre lrength to p)ride
l. "tucl cooling" ollhe engire rhc h gh power rge tn
sirplc teflDs. xrcrcascd fuel consu.rftion is rrdcd for
Bendix RSA Fue lnject on system 155
 ENRICHMENI JET

IDLE SPEED

DLE VALVE

TAKE OFF

DLE VALVE POS T ONS

FlG. 7-18 d e ! ve d mLr r rlur cct o (Erctql aanital5 Dtr . B.!.jix.otp.)

NOZZLE

ilil
M XTUFE CONTFOL +

g
DLE VALVE
+

f'

CENTER CONSTANT
BODY HEAD
SEAL SPRING METERED UNMETERED IMPACT
FUEL FUEL A F

FlG. 7--19 toft ed d e sor .r iEncqf Cofols D , Eendu Catp )

 Thc mDuai mixnLre corlrol. shown in Fig.7 l8 s a
.l:Jig !alvc cxn be trsed by e pilor to eltcli!clr- rcdncc
--: size of drc mcte rg jer. Wirh he serlo pl.essurc jgula
::. iuncti(ring to r{itain a ilif}rerrrirl p.essre cro\s Lhe
-:L.rig jcL in Urcporio o the volume of irflo{, Lhc
:1..r through the.let may be laried bf changing irs cllccri\c
.:ri. This gilcs thc pilot the optjo ofma uallt lernrg Lhe
-\rue lbr besl cruise lo\rer or best SlC. lr lso prc\ides
.: meas to shul olt lucl ilo\ 10 the egine at engine shut-
The constart had idle spring argmcnrs Lhc frrce of
.,, Jr' .., rl. iJ. r.": . . n pe !r.
j:irertial is LroI sullicicDt to oten the seNo valve. 'lhe
::: spring shoivn rrl Fig. I l9 ensures th{t the regulatol'
i:r o \alve ls o|en sufticielly to rllorl ftrcl bcig meered
:: ihe idle vatle to tlow oLt Io llre llos divider. As airflotr
'.. .I le.r.(I r.!',, be! ro
:: ihc richt iD rcsponse to increasing ai fessue diiltren-
rr. ft \lill confrcs\ the costant head idle sp.lng until its
.::rner and gui.lo contrct the diaphragm plate. Foln this
:::iI onr'd. i r.n\ of ait{]os'. luel llolv, or power. lhe
- r:tar hed idle sprjg assenbly is a solid nlelnbe mo\-
:: $nh the an cliarhrasm nd e)ies ro lrce ol ns o\,n.
..: .ofranr head strrilg is fuDished in various rrengths
: :rxt the oledraul echicin c properll c{librte rhe
::.io. for idle fuei flo\r and for lhc lrrn\ilio to seryo
-:.rlrt(, cotrclled fuel llos.
h most insallalions. the lrrnsilion lionr icllc ro scno
-:rlior conolied luel llow hs to bc supplcnrcDtcd with
: constanteffort spring, piclLred in Fig. 7 10. This string
r:i ii;sts the .rjr diphragn i moling lrnoothl) irom rhe
: ; ri.llo\! i.lle .ge to ihe higher-power rge of opcra
:G. 7..20 torii eiloi spt.9 lEnetqy Contrck Dit , Bendix Cotp
tiolr. It also comes in a selecdon ol frengths o be Lrilircd
b,v the oyerhaultech cia tbr prpcr calibmion ol rlre unir.
lL Jel .. reg 'JJr I\cp..
r,rred liom rhe air section by I ccntcr bod) seal assembly.
as shoqr ir Fig. I 20 L-eakage th.ough rhe cerer body
seal causes eincrel! rich operation nd Uoor cLtoff.
Leka:e of rw fucl out of dre irprcr tubes .ra) indicare
u..il-ie e" .(r..!.. | . ' . rl ..rt r.! rc. !!. I I
ar! olcrhaul shop. The seal canot be replaced jn e field.
Automatc Mixture Control
The AMC adjasts the F/A ratio to corpcDsare for lhe
decreased ir rlcsity as 1e aclt climbE to altirude.
7-21 shoBs lbc fu.ctio and operation of the AI,C
I:i-elLre
and cxpands on e descripti(D of the nunual mixture con-
tral {d idLe lahes. The mixtu.c control is shown in rhe
I :r \ rl rl.. rJ, \:,t P I tr of(r . J. L
' rJ i. -r .'L. e lr rhe ., r \ \'.u
thc two n)t.rting valve assenblics .t.e spring-loaded ogeth
er. back to back. $,ith an O ring !ea1 be\'ee rhem. Fuel
1lo$n thfough the rixrure corhl valve- d ough ihe idle
!al\c. and out to the regulalor scrlo valve. The inler
ainer is locted underneah he lucl inlel fiting ard
insalled sprig ed fir!!. so t]le opcn ed is mated ro the
ile flitllg. Il lhc \crccn is blocked by conraniDt r1er
l3l. ir et pes\ure w jll f(nce the material a$,ay tu).r dre r'jr
ting. cornpressing thc sfring !o allow fuel to brpas! the
screen if eccssary. This screen filte is replaced rt over
haul. There is no approled mehod of cleantug (his screen
CONSTANT EFFORT SPF]NG
CONSTANT HEAD SPBING
CENIEF BODY SEAL
)
Bendix RsA Fue lject on system 151
 When calculating e F/A ratio. both the fuel and the air through the veturi, produces the air nereig sigal previ-
m rnesured in pounds pcr hour. The fuel injector meters
fuel on a pound! ler-honr bas. relercDced to the lolume An engine punpsair on he basis of volume, not iveishr.
. | \.h.r.rt(, c.'rir.J J,e...ittp...r-! 'lli. oline r..re nileob .i, -,!i ,e ar\p': -(Ter,r

AIR FLOW

UNMETEFED

nrn
(lI ) METERED

"",.,.-rubl

ilq
rS

CONNECfED TO

flc. 7-21 AMf (En,"ryy Cantrolt DN., Bendi\.,otp )

158 chpter 7 Fuel tnjection systems

ihr is. 5.10 inr l)er conrflete li)trr stn)kc clcle (irlake. corn-
:rression. po$cii and c\hxu\L ior 11 siri cylirders).
Ih.rclir an IO 5.10 cngnrc ruDnrg t 2500 rpnl ilorld be
rn\unri3 (rnrting) rir r rtc of

'^',-'".1
)iirr

..: 'l l
r'0 r r r r r
trll
390 x 0.0165 = l0 lb/rin lli.6 kg/nrinl

l0lb/mn x 0 rtu = 1800lb/h 18l6 kg/hl

r: $ould be eqtrivlen t(, cNilc poser se lelel. An
.r raio of0 0N would rcsult nr r li]cl lloil rate of
18{10: (l.0ll = t.1.1lb/h 165 kg/hl

\i he aircraft climbs 1o rltitude. dt spccitic $eigh of

:. i.creases tio]n 0.0765 lb/ft: L1.22 kg/mrl until. t
:. 00 li. air \r,ei-hs onl)- ll0.112 lb/iLr 10.692 kg/nrrl. The
.. p, Ir..r 'rn t'.-lrl. '.r. -
: i:/mi ll I mr/Ninl, icsul(ing r irllow rate of
j9rl x 0.11.132 x 60 = l0l I lb/h 1.159 kg,4t

..; 10ll
lb/h l15t) kr/hl nflo$ will prcduce he sare FlG.7-22 B\) et type A/C irFgy Conttah Di, Eendit
-.:n;rerl-e signal lcross thc rcr1lud ha 1800 lb/h
r : k!/hl dirL al se,r lelel This rir neterlrg slgrral \l'ill
:.:trm he 1,1.1 lb/h 165 kg/hl lu.l lk!, whlch relulis xr is conloured Io perlo n he lrcion of ihe venruri. The
fncrion peormed rnd the prxrciple of operadon are eriact
l =Lr tt FA xr(l l) the same as for the eriterally noured unit. There are
l01t t\ro baiic diffe'encesi
..:hou ,r ANIC, it \oul.l bc nccc\\ry lor ihe pilor lll
:r ::rilll le thc ri\rtrc lnlll lo mainialn the 'r. 1. 1.. ., ) .\'...1
rxlher lha imfcl fre!{re.
:::rr:.r0.0E ljlA raLn).'lhc AN,ICI vorks irilependel,v ot
' \ '.(,.eele f.( :1t:(
r
--: :. arallel Niih, dre nual .rixlur:r conlrol b,\, frol,id fr..r., Lr. ",r'.1 rl ..'r"
:: : rr.ieble .rific. bc$.cn lhc two i presse sigxls r.ductio of thc {ir mctcring lrcc across thc ir diapirrgr
-:::i xncl \ucLionl lo r11o.lift the air nretering signal
cxaclly rs dcscribcd .rbole.
i: \\lC dsscmbl) cosisls ol a cololcd ccdlc tht
- .:J in nri out of a orilice by bclk)\s a\scntblv. Flow Divders
' . -:llo\s rcc(s (o changes ir air pressur. dnct Lcnrp'era-
: .:..asmg in lcngth as pressuF ltitude iDcrcascs..\t lllcrcr.ct lucl flo\ is dclivcrcd fiom the iiel injecto servo
i -: l:\ el. thc nccdlc iltosrtioned in rhe A\fC orjlicc so unil lhe eginc through slsten {'hich Lsuall} iclLiles
: .: nlice is ckrsed. or rearly closed. nr rllow thc inari- a floll divider d \er of discharge nozzls lone nozzle
- - :pacl pessure olr the rnfac tre\surc \icle ol the ir per cllinder). A lew engire rrrslallaiolls do not use a lloiv
cLiv er. O drese eLrgrnes. the lxel lloir is divided by either
:.r r;crcrsc.l allilude. he AN1C
he ircraft flies a srrgle lu-ilal lining (forr cylider engies) or a tee
': : sith the {ir tr.ssurc decrease ard ihe
:longales \\ich divides he liel flow innr t$o sefle talhs.
,:::: rnolerL ito its orifice. This creses the o1If-1ce The tio$' divider ilhsiraed in FS 7-21 consists of
:: ii L\e lee the inpa.t air d.d \ellLrri srcllor nd . e. le- e .r.'J 1'tr.1'a p .lL( 1l ..11,.
. :-r!ac ir o |leed irlo the !cturi suctiorl channel. loacled 1o the closcd posiriol r rhe ileele. This etteclilel]
' .:ices Ihe air IrleterinS forcc cross lhe air clc\cs Lhc path ol lt]ol tio\! licxn {he luel iecor serlo to
dre rozzles d ar he srne time olates exch noTzle from
: r:.dle i\ contned r) th.u ngrnless of nlitude or all the oihers at engxle drLLrdon. The t\ro irrnxr! func
:-:r,t ) dre corect air rclering signl is e\ablilbed ios of the flow.Livider are
, _i il dirphragm ) raintir a Flalelt confaL
. ..,<Ji .1 .i. | .rrJr"d( l. lb ensure eqtril .listribuLio ol mctcrcd luel lo the
--::r troduci.n yp. locl ijcc(,rs Ltse x bullcf-tlpe nozzles a indjust bovc i.llc
- .: urrted in Fig. I 12 $hich is mounted i. Lhc l. lir trovide isolatnr ol cacb nozzle fiom all lhe olh-
' :.: rhmle bodv. Thc c\lerior drameter .f thi\ uiL cis nn clc cn:rc shutdo!n

Bendlx RsA Fuel nject on system 159

FlG.7-23 Exte,al! ew oi fiow d !de..

'Ihe are! of the fuel discharge jer in the fuel nozzles js

sircd 1o acco.nnodt. Lhc m\lmum fuel flow rcquircd a!
rled horsepo\cr rvilhout cxc.edig thc rcsulated fu.l
Pressure rnge caprbili(] ol rhc scM) pnssur. rcgultor flG.7-25 FLre p.es5!re !ga ifow rd.tori
The rca oflhcicl ln Lhc nozzle i\ such lhat nrc(ered fuel
pressure t ihe nozzle is ncgligiblc r rhc low luel llow\
lioln thc jcc
reqLjred at andjust bo\e il:lle. Mcrre.l Jul
tor servo eners the tlo$ dilider and is chnneiccl ro a
Ii e luol rcstr icnr in one or
used a\ a ll(^vrcter rrdicIor.
rnore rozzles bcconre\ paially plLrgged. lhc t()trl e\i path
. . | .r " rrl h a,Jt,r1:, \ rl. l,er rr. , i for nretered lucl llo$ is rcdtrced The fuel injccror s.r!o
ol) s!llicicnt ro r)ve the floiv dlvider valve slighly $ ill .orlnue o dclilcr thc saie arornt ol torl 1low.
ope. eriposnrg (hc bouon of r V slo i ihe exit ro each
nozzle. s illufr cd u I
2.1. lhi! position prolides
Fig.
\ill incre.rse. giving mdi
Thcrefore. rhe nozzle pressurc
the ccurac) ol lul diriibuion eeded tin lnroot idle. ,\!
cLio .f fuel Uow increr\e o thc llonreler gage An
.\.r ,t . .fe lo\-J..r ,. i, rJ
the ergine i\ ccclc.r(cd. rnetered fuel !rclsl icrcases al
The c\ linder(s) havirs rcsdctcct o77les wiil be fl|nnrg
r'eil . J..i.l r,1..:,,hF.lp .Tl i .re..'l l.aD. nd rhe rcmnrling cllmders will be rich. lhe esult is
grdualll ovcs thc ilor! .li\ider valre ote {grinst lhe rough engine otertion accorpiclt b! r hiSh fuel-ilo\r
stling tressue unlil e arcr ol thc V sloL opcniDg to eich
o77le i! lrenter har the arer of the fuel refriclor r Lhe
Wher llrc mi\ture cont|ol is placed in curon, luel pres
orzlc. At thi! foinl, lesponslbililr tbr equrl dirrib!Lion 01'
e ilo\ di!idcr diofs !o zero. TLe \priDg i(trc.s lhe
lLtre o
rcr.r..t fuel flow is ssured b,v the ozzles Since nrerered
fioN dilider !1\c to drc (1o+D posfio ard nrcdiely
lucl prcssurc ( r/,le pressure) inc.eases jn diec propor-
interNpts e llo$ oJ fuel to encb nozzle. This brc{ks the
Iion ro nrcrcrc.l luel flo$'. ,r ! mple pres\ure gage crn be
plth ofcapillarr- ll{^!. r!hich ilould allo$ rrxnili)ld \u.!ion
nr colinne to d.\! itrcl rr ilrlbbles fiom one or more oz
7le lines as dre cngin. corst! don. Wlrhoul rhc llor
dj\ider, his dribblnig oI lucl nfo one or roe cllindeF
coul kccp the e:ie runrig for rirte or m.re.

Fuel Nozzles
Bcndi\ no/zles, illusirated ilr Fig I :6. rre furnished ivjrh
\c\cral djfferei pa11 nrnbers The trr n(nnrer generally
idcntilics the ,ipecific inslalltion rcquircrct for he
engine that is. onnally aspirted. $hich requ;rc\ rhe sim
ple nozzle sscnrbly $ith be air bleed screen cl shroud
pressed 1 |lcc, or configuratior ofthe shroLrd sscnbly to
lccept the superchargcr nirt.eslure signal to he nozzlc.
All nozzles Lrc ol thc ajr hleed t)pe illuslrared in Fig
7 27 Thls merns Lhlr I'rcl i\ discharged lnride rhe no//lc
bodt to chambcr which s verted ro eirher armolpheric
air pressLre or supcrchrrgcr xir pressuF liiecror rop .1ck
tre!!trrel. The ozzlc is rouDte.l ln the iiake !hc porl of
th. .\linder head. lt\ erll 1s ls) s c\tosed ro N,lAP. which
on a orrall! alpirted erlglre is rlsa!\ lcss tha alllos,
pheric prcssre This resuls in rir being dw in through
llic ir blcc.l ad mixed ith fuel dre lucl an chmber to
or^ il. u ' I 'i -r'.{ l, o ,.rl I. r,r,{r.
FlG.7-24 FLre io\.',,dvder fEne.ql, C.trcE Dr, B-.ndu rn e idle nd k)\r poer rxnges $here ]lr\P is lo\ef {nd
bleed-air Llc i\ lreatest. A pluseed ir bleecl i rhis
160 Chapter 7 Fue lnlect on syfers

d@0)o@E
FIG. 7-26 Bend x ile rczter iEneryt Canttols Dtr , B-"ndu Cap )
IN
FlG.7 27 S.henir:dgrmol -bedfue ozze
.nge alloss lheeit of the fuel reltri.rD Lo bc cxposed (o
nniibld suction. $nrich effeci!el) ierc$cs thc plcssLrre
J.re'r..| :.r . 'r.r- . r.'I
ael flow throush rhat norllo. Smce this rozzle is, in etlect.
.r.hrg lucl lrorn e orher nozzles (injector seo ouput
.l,r\ rlill .cau thc sarnc), rhis cylinder will run rich nd
ihc othcr cllinders $ill be coreifond;gly len. A ncL
lrrcsc in nctcrcd fircl tressure ll reslt {nd sho$ up
n. thc flo\meler as lo\ler-tuel-flow idicrtion. This
.oulltnsuh il rough idle $ilh a lo\,fuel flo\ mdication
rd a higlrer than norral rpln rise going rto cutoll. The
.ngine sill also h,rve lery poo. ctrloff, tcndiug to cotinue
jhugging tr selernl se.onds folloaing nlovencn ol rhe
:ni\1urc control t() ( L !orr
CIUTION lhc l'ollowug tcr i\ inrended olly
rielhootmg aid and shouid not b. coDstrred as a clibrarion
.heck of the nozzle ssenrblies. Should r queiiio adse
:;grdinS serviceabilit\ of r given Dozzl. ss.nblt. he
rjr mtrst be \ent lo ! .ertiiicd o!.rharl ard epai tacilit\'.
\'lo\t ozrlcs $hich are istalled rr c)ljnder head! arc
:librtccl likc. For crr]nple, ih elnctl! 12 p'ig
il.s kPl nnct pnssure. apphed flow should be 12 lb/h
'll.5l kghl plLrs or rni rs I per.er.
A corntrison check of luel tlo ftrim the orzles
:.1lled on nv !iven engire can be n.lc s iolloss:
TWO PIECE NOZZLE
F
SUPERCHAFGED
Renro\e no771es lior c.v-lindeheads nd econrecl lhem Io
their strtply lires Posit on equal-sjze containes lo crpNre
thc outptr of each o77le. Tur on he boost pump. and
opcn thc mj\ture cotml d dnoltle. When a good reler
'.e I.r ' r) L l 'r ,l-e"r . .cred :, er.h cor.r...er.
p
cbse the nri\ture control xd throfile and tum off the boof
pump. Align the contriners on flt sulfx.e. xnd conrpare
the levcl ol ltrcl ctturcd. as illustrltcd iD Fig. 7 28. A
,r\rbr.r rrrr,,f r....1
indicaes resliclion i lhe ozzle lirel rcstrictd. flow
.\ll currcnt t(xluctio Dozzl.s h!. two tiece configu
ntious. Thc lircl rcslriclor is a nage.{ iserL trhi.h .an eas
ily be reno\ed lirr cleaning. Alfu. it cnn bc casily Lost dur
r. \. r li .. \ 1 .. d,r r.'ycJ i, Fll " ..t.r r. J , .
ozzte assenlbll because he] are il.iw-ratched ssern-
blies. In older fro.1nctjon oz7les. the restrictor r's pressed
iDLo the norrle bod] D.l was not renn)vrble.
l'rior to jstlljg Dorlle ssembl,"-. alwals refer !. the
e!ie manufactuer's jstruction manual! for lhe proper
torquc !alucs ofno/rlcs and ljcs.
Overorque of the nut connecting the luel line to rhe
nozzle can fress dre inser deeper ino lhe body and close
off the !ir hleed on the older no77les. Oleforqne cnn crrck
lhc fl{ngc oll Lhc nrse on thc newer Lypcs. In cither c\c.
lhc nozrlc is dcrroyecl. O\erlorquc ol rhc norzlc ito the
cyliftler hcad distorLs the basc ol lhc Dorrlc and otsct\ ils
as a trou calib rio aDd spra] !tlem.
A L,: ir . :"re y;ood prJ.r'.e ,. 'JrJ
common configlLrarion of ,r full set of oe tyte of norzle.
''. Ir:"r c r, r''' rJfe n . or J.,en!..
eqtripted with the older tyte !hould crele no problem
Also. ${crc possiblc, incli\idl ro ti.,cc norllcs should
bc kcpt as naLchc assenrblies. IntcrDriring these parts rJ
nor cuse probLern: ho\',e!er, il or $heL1a proble occurs
as a resrh ol intel,niing. a new nozzle \r,ill proabl) be rhe
The letter A fourd sllr rped or ore flt oflhe rcnching
herxson js located I80'lronr rhe air-bleed hole in the noz
Bend x RsA Fuel njection system 161
 BODY ASSEITBLY
2.

CHECK NG FUEL NOZZLES

FrG. 7 28 Test o iLre rozz e olipJt ttr'ral Dr

' Ben'1i! Catp )
'anrcls

/le bod!. AlLe fil inJtllation lolaluir-!. the ni bleed h.\ This nrrk is locled 180" ftrn e xir bleecl lrole rDli
.no.l. r , oe \''r'r' or " 'r' l. o c

re,..,t,. r'".r'.e 'r '"lJl . Lrne |Dle.a I h'Ilbre'r'

'
.'o \ r' ' fo nLn r \ rrrruL! rsl Jftc \hrrrn'{n
util 5 \ i.bl( rr (r "l
encled tu cns;r.-continued s{risfactory opcratio
I.r rl r ... r1 r' o r' /"rli ' t e '
\ ^'6..tr r,r ,1r.. tll< i r\rJllJ
Fuel \iraiLrer contigrtrIion mv varl acco irg lr)
lnstallation of the lnection System I'r,'
'l'he lollo\\'rs infnntio. about installallon of tle RSA rum) \cFe i\ u\ed.
'' r. tn n,u'L irslllions I o. ilerible hosc is us'd
fncl in.cLio:!\ler ws prolide.l bv ih' EergI C'ntrols '1
and is gi!en here r\ ar fronr the itiocor ouLlel to lhe flo\\'divi.lcr' l-xler-nrodel
Diinio ol le Bentlir Corloraio
exrnple oihe dta suftlied Lo arrcli otert$\ nd nrai injecLbrs hric m ltcrMte tel orllet 180'liorn rhe \Ld -

8. A l,r r Ii.l]5-mnrl (outside di{ reier) sainl'ss'

I T|e iniect can bc l]lotnted on lhe i e! flrlge ol feel lubc is rorr.d lionr reficted fiLl g lnurked 'iAcll
re cnsrne s i|lahc ffxilolil lL .rnl ttiNdc llnl lcilitxLc\ on lhe flor! di\ider !o the fircwall A o. I loi! f'cssure
h{,\e is usuallv lsed f|orn lhe tireirll to thc gage ln all
ensineitu iriire combin,rtior lrsLlllion raking into l]rinimLnn
.ses. ihc ho\e lolulne shorld be held 1o a
coisiderattr thrr Lire throltle linkage rtrd thc m^n!al Jnix .(
rr .o lt-" (lr''e i L r I ' l
I \r -o.:\e I b r'Flor.r" r' rr'l r\ed. a no. .l lle\iLrle hose is connecied lo the luel fssure
th. irrecr becruse of possibl) high arbierl em trkeolT filling n the tielrrete g s)stcni
tlon 1o
r.,.trre. srthi the eflr re rJ!clle 10. The nozrlc lie length Nill .lepcrd on he egine's
ll,. I ... ; irsrlhlion nd lhe locIron ol the flos di\i'ler' Thc LlozTlc
1..ri.i with 3 Lrre,:lelcnrlied brackcl conligurtion: ho lies re for ed fron 0 0t5 Lo 0 090-in L:'159 Lo
evcr. 1 rnu\ b.-nountcd ith lbe Dozzle line fi{iJrgs iL1 a
I 18 nlrl ir1-qide.linelcr ilD) x; lf f-r'115 rnrl olG
sidc dlanleicr lODl srallcss-stecl tubin!,. $'jh \uitahle lii-
lJlor 'J ris\ tbr connecijo Lo th Lop of llie DZZle od Lo dre 1lo(
lOr r:r .. ' ro,l ' bel rr,r" l'rl di\:ider.'llrc lines re.l11rpect suil:Lble locations ro
',, ,-...,.,,r
o
'
,.,' l .r ',e . I ,FdL,.c lie \ibl.ltion

162 CL"pt", z ru"l njectlon Svstems

lroqbleshooting
The troublc\hooling charl jn Fig. 7 l9 ma) be used ro trou-
rl.ihoot the Bendix RSA fuel injectio s),sren h is irnpor-
::.r. hoever. Io keep in nrrd any nrodilicari{Ds of he
rnir\ drn ma\' chagc dre troubleshoolmg proccdtrres.
Operaton
- princitrl consideration i tlre ground operation ol a
:rgine equippcd with nn RSA licl mjection sysren is rlre
::lrlpcralre \!jthi. rhe engc ncelle. hr fligh ote.tlo,
ir: englne and rcelle rre adequtcl) cooled by the msh of
,:. rhr re\ulL\ botlr lionl dre rrn ollcct and tiolll the rol
, ir 01 rn ucd h) the prpellcr O the grounil, ho!re!,
::. there is liLLlc or no ram ellecl. nd thc \oiume of nir
:rl he protrellcr is ot ndequate lor cooling {t idlif:
..::ds dur g hol wclher.ondirions.
High tempeatues in the engine nacelle cruse ftrel
:forj7tjo ihI, ir turn,.tffecis the {,ry rl) cgie
::.fods in ils slarting, idljng. and shurdo$,r. Thc fcrson
::rring the engrLre slioul.l be ware of rhe ellecrs of high
::-p.rLurc\ rd shoLrld rdiust ihe operatlns procc.lures
.-r.din-el\.
In hor $.athcr. arler the enginc is shui do\.n. the high
:::::neaures i thc crgine ncelle caus. re fuel tn the noz
: i:ed lines 1o \dtorlze ard eicxpc Llnlugh rhe rozzles
_:: ihe n c mdninild For is r.rrr. lt is not necessrv
: irirrle he cgie if il is resrcd $ithin l0 to 30 rnin
'lllo. LT' ,!r... .,
r: lhe IDLE.rjr.r posirion: as {ur
s the engine fires.
'r
_:.nnr'ol is !Decl to he Rr.rr to\irio. The tirel
FL'LL
:::: lines qnickly filt aDd supplt fuel 1 rhe orzlcr before
-: :n!in. cr stof. lfan cngme hrs been \opped lin more
-- r{l nnr. lr i! likely drt rhc ltrel lafor in rhe rn{.ilold
-i liisipLcd and hat slr primin! ]llat be reeclcd to
l:,nng glound oterats. palriculrly in hot i!earhcr.
: :.. .tfoll slroul.l be made lo kccp the egine rrd a.cllc
:-:.:rarures s Io{ r\ tosslble. To do rhi\. keef grclrncl
::.riions al a rini.ranr. keef the er)gra'ryn rs high s
i.d..r ic v f.o. lp.i '. r.r'r ,c.
: :i!lne. ofeae rhe cgine at 1200 r.i 1500 rlr lor a fe\r
.iirj to disslpaie lesidual her. A hilher rani lso ids in
. :rS rhe luel ljnes by nlcreasiS luel plesrur n.l fldr.
:.J jdle speed ard rnirrtrre shoLrlil be adju\rcd Lo effecr
.. .'r.t I,..(..,t-egI.. t( ,r;
::-:.nr.ts for bolh cool d ot weather A corfarx
:. high idling Teed t700 tu 750 rpor) is besl lir hot
: :..3r. bLrI it ll1ool.1 not be so high that il nr*es the ir
:'ihcLrll lo ot.rte on the gloud.
.: iille mixru:i l(r hocwether opcrdLion should be iet
- '-.., ri.e|r,1.
: DLE flroFF. Thc richer settiig i.crcnsc\ frelsure ard
.i :,r dissrparc any vxtor wlich mr\ fo the strelr1.
r: ore:r hor.Sie js sroppc.t. it should be rLn ar
-:ri.il rpl lor Ltr nr nutes ro clniaLe ! much herr
::iibLe The mi\lu.. conlrol is en Inorocl slowlv io
. \\.'rr..r-rner
::. ii ture.l otl: U (hc cgine is quite rr. ir will like
: : r ghly lr selernl seconds beforc stoppmg bc.use
..j/ed fuel teedil]g om the lnel rozzles This is
: :\c thoLgh the ictlc cutoff ill conlplelelv fop rhe
: inel !o he llo$ dilidcr
The opcrtor is cautioncd rha greaL care mLlr be raken
in no\'tug the propeller on an ensire that hasjust bec \hut
down. Sorctinres ho spoLs ma! exir in oe or rlorc colrr
busion canrbers, and lucl vapor ca be ignied nd catrse
lhe enginc ro kick o!er. Ir is besr o aloid moling dre tro
peller unlil the englne has cooled fo s.lerAl njnures
Feld Adustments
-{s $ith th. tressue di\chrrge carbxrcr(n field adshiers
l the lircl iniecior systcm are sererllv lil1r1ted ro jdte
speed aDd jdle nixture. Thc procedure lor making Lhesc
xdjuslmcnl\ is outh|ed bclow: howelcr. the procedure
given ni tire irdare operaror's manual should be r ovcd
for a traficuhr tyle and noclclof.rircrll:
I l)edorr1r a rgero check
r accordarce $ith infruc
lios lfthe +m drcp ror each rnagcto i! saisirctdy. pro
cccd $ jrh lhe idlc rirtu.e.Ldjurnrct
l. Retlr.l lhe throttle to he rDLr posii on Il lhe jdle
specd i! DoI in lhe rcconmended rag., adjust he rpi wirh
thc idle lpeed clirsting screrr adtccn to ttre rhro[te ]erer
r.cc FiS 7 1.ll
l. \lhen he cDgine ]s idlxrg srisfxciorjty. stortv role
rle, . ( .. p ,. Trrlc|
oFF po\iri.. Clbser\c th. tachoreicr or \'1Ap ggc. If the
enrine l1].r increnses rlishLl] or IIAP clccr..tles, this indi
ctes drr the lrurc i\ (nr the rich siclc of be po$er. An
mnediatc decrese r rpnr or incresc i. NIAP i dicares
tha the idle nr xlure is o rhe lean lidc of be po$cr A
inclease ol25 ro 50 rlnr or a decrersc j. NfAp olI mHg
10.85 kPl should prollde a ii\ture nch cnorgh ro provictc
s{tisfctor} a.celerariolr u.1.r all conclilio! nnit tea
- tl- -ic. ror-r .1..,r r.
.1. Tf the idlc mjrturc is fi't corecr, tun lhc idlc .rdrs,
rneL (see Fig 7 1l) one or rwo otches irl rhc .ljrecrio
requjr.il lor correctjon nd recheck, rs explaxred prtvious-
ll. Mke rddiriona .rdju\trnen\. ii necessary. utir itre
iiturc is srirll,(:ro,r
t. B.'" er .. ... I t.. -,r i...
.,...00n .r ,r'-..,.,Jk ," ,,, 1....
aj. The mi\lrre i\ .ljLsrecl b) lenshe|i g Lhe lnkge
bctwee| the (hroule leler d idl. \,ulve ro errich the miri-
lurc ad by slnn(cing rhe lillkngc 10 tearr the nrixrure. The
ccnrer screi! l{s ri:ht hnd llredds or both end\. bul one
c.I h\ r Lro lll 1.1 thred rn rhe .rher trs a o. I0 32
Ihrcld. l-or easy rclerefce. coniidcr only lhe coarsc rhre.td
ed cd \hen rhis cnd of rhe ]]Irh is backed our ot its blo.k.
the mirtue is errichcd. l-ertrng is xcconrpli,ihed by \crcw
ing d)e corhe rhrecled crr.lofthe Lnk nrr{) the biock.
7 ll thc cenrer sclc\ bottors oLl i on. of ttre btocks
hetre s{tisfactot lixrure j! achic\cd. {n.rddirioal
ad.lLslmrnt nruf be nrdc. l-irsr. nc\ure lhe djsrcc
betlleen th. block-r. Thcn di..connect oc of rhe btocks
frcil ils lc\.r bl renx)\ing the lrk pm. Tum tre btock and
adjLslrcnt s.reil unril rhc xd.lusrirs $hccl is cerrered and
te dislancc ber\teen thc btocks is the srmc {s trel,icnstr
rcasured. Thcre is noir addiriorxl odjusrmenr ran8e, rd
lhc rclererce poinr is retnined.
8. \lake te linrl idle speed a.liuslmeni to obrain rhe
desircd idling nm $ith the thlortle clos.d
9. If the ieriig does nol rerni stble, .heck rhe i.llc
llrks. for loosenc!\ In rll cses. allow for rhe etlccr of
earhcr condiliols Thc |rev,rilLng \ind .xn ndd ro or
Bend x RsA Fuel njection System 163
 TROUALESHOOfING CHART

frd slrl r_o Techn qle Reler 10 aircraft i.lla.lurer s re..mmnded

strllng pro.edure
F ooded C ear en! ne by cak nq ,iih :lrroll e oen .d
m rlurc conrro Ln lco
fhrott e !a !e opened too lar Open thrtt e to a ps t n at appror nlerf
00 rPm
lsull c ent pr m (usu y accompaid l.rease amL.1 f pf q
by a b.kf rel

Folgh d e M tlre too r.h or 1oo ean Conl m w tlr mirllrc .olro A too rich
m x1!re wi be .ofe.led ana rcu!lress
decreased dur nq ean out llh e loo- ea.
x1!re wi be a!gravated ani rou!hness
dre ro !v a 25 ro 50 rpm
ilg:1'r".lr:1'"
P ucqed nzz e(s)1!sa y accompan ed clean nzzles
by h grr takeoff fue f ow red not
Sl !hl air eak nt dct on syslem Contirm b! temporar y p ugo no dra ine
throloh man lo d dra n check ra ve Repla.e check !a ves s .ecessary.
(Usa y ab e 10 adlusl il al d e
bul rouqh n 1000 lo r500 rp
ranse )
S rght a r eak r.lo ndct on syslen Fepair as necessar!
thro!gh loose ntake P Fes or
damaged O r nos iUsua ly ab e to
djust in tla d e bt roush n r000
to 1500 rpm raoe )
Lrge alr eak nto duclln system. Fepir s ecessary
severa cases or + t3.175 mml
p pe p qs dropp rig oui. (Uslary
!nable t throllle eng ne down below
8001o 900 rpm )
l.ler.a eak n njeclor (LJsua y Replce inlecto
unble to ean oul d e range l
Unab e 10 set and ma la n de Fepace inlector
Fue vapriz.q n iue nes or Coo eng ne as mlcri as pss b e before shlloll
d st buior lEncountered only uder Keep cow taps opn wlie. lar nq or wheo
h glr ab enl temperalre cond I os the eng ne s dl ng LJs fast d e to a d
or ror owinc pro o.Qed operal on a1 .oo inq
lovr derpmsl
Lo{ 1ako1f fle I ow. Slra ner p ulged. Remve strarner ad clean . su tb e so lent
Acelone or MEK s re.ommeded
nlector out 1 adluslmet. Fep ace jec1or.
Fu ty !age. ln a tw. eng .e .s1a lat on cr ss.ross tlre
sacs. Fp ce as necessafy. ln
sin! e-e.g ne cha.9e the !aqe
Stlcky f ow d v der va ve. CLean the flow d v der va !e

Hiqhfuelfovr nd.alor Pugod.ozze fhghfue Jow s Femoveandcea.

ead ng accompa ed by oss of power and
rouqhess.
Fa! 1! gage Cr sscross the qages ad rep ace f e.essary
jeclr o!1 of adlustment Rep ace jector.

Staggered m xture colroL f lakeorl s st sfaclory do not be 1oo Check r gO 9.

.oncerned bot slaqqered mixtu.e
conlro levers bec!se some
m salgnent s normalw tlr 1w n
--q :,..tci,
Poor clloff. mprper qq nO of alrcrafl inkage to Adils1
m xture conlro
Mirture-contro valve scred or nol El m nate cse ol scorln! lusla ly burr or d rt)
seat ng proper y. and lap mixture coniro v ve and p ug o
s!face D ate.
Vapr . .es Coo! enqine as much as poss b e befre shuloll
Keep cow I aps ope. when 1ax ng r when
tlie eno ne rs id q Use fast d e to a d
coo ng

Rouqh el] ne lurbo A r b eed hole(s) c ogged. C ea or rep ace nozu es

chargd) and poor.uloff.

FlG.7-29 Bed R5 lLe nle.io 1ro!b e;|oot q.hd

164 Chaptr 7 Fue lnjection syfems

reduce the propeller load and afTect the ensine rpm. During
the idle mixlure and rpm checks. ihe airplane should be

1. What s.ednt by "fue nlection"?

2. Lst the dvantages of fue nlection sytem
Inspection and Maintenance 3. What are the foLrr bs c un 1s of the Contientl
cont nuous-flow fuel njectron 5yslern?
when a e\r injecio unit is insalled, he irjecor inlet 4, How mny fuel contro Lrnits re ncuded n the
srainer should be removed and cleaned alier 25 h of opera' fuel conio ssembly? What are theyl
ion. I hererfter. dre llrnier should be cleaned t each 50-h 5. At wht ocatons on the eng ne are the fue dis-
charge nozzles n51 ed?
m an aircraft engine is equipped lvirh a fuel injeclor hal 6. Describe the constrL.rcton of a fue dis.hroe
includes an AXIC. the operaor should be alelr for sigrN of 1O-7e O rhp O o.'Uo
problems sith the u. Dir can build up on tbe needle and 7. What spec feture s requ red for the fue d r
cause rich operation nnd possible !icking of the needle. charge nozzles nsia ed on iurbochrqed eng e?
sith renLitrnt loss of rltitude comFnstio. lhe following 8. Expla n the opertion of the a tlt!de compensat
jnstmcti(rs arc givcn tir cleanig lhc nnit: ng v ve.
9. How woLrld yoLr djul the d e speed for the
L Carlulll renove lbc A\'IC uDit. Il rhc g$ket is claDr Continenta fLrel njeciion system?
agcd, rctlacc il wilh { cw gdskct with (hc altropriatc '10. Ho\/ wou d you check the dle mixiure for the
Bendix par nnnbcr. Continenla fuel nleciion systerllT
I Renove lhe f 2:1plug and imrncrse ihe unil in clcan i
11. What un s considered th-" heart of the Bendr
naphha o other pfroved peroleurn solfert. Invefl lhe RsA fue inlect on system.
irit so hal il will lill comtleel) $idr dre soh et. Eercise '12. Wht nreans re provided n the RsA syfem to
ilre AMC needle with x hardwood or plastic rod to faci]naie provlde for adequle fue f ow' at id ig eng ne speeds?
.leaing. Shrke he unit vigoroush ivhile allolving rhe sol' 13. Wht is the purpose of the AMC on the Bendx
\rt t.r .lrui. Repeat seleraL times to wash our all lraces of RSA fue inject on syste?
14. Describe the opert on of the AMIC on the RsA
3. Drain lhe uit. and allow the solvent to evaporate fue inlector
:t-rmplelely. Do no d'1 wilh conpessed air. 15. Descr be the opertion ofihe fow d v der
I Repiace the tlug. and i|srall the unj o the injector. 16. Wht factors deierm ne the s ze of the ca ibrated
Torque to 50 to 60 found inches (lb'i) 15.65 {l let n the lLre nozz e?
a.-8 Ne$'tor-meters (N.m)1. 17. What s eant when fue nozzle is c as5 f ed as
n r-bleed type?
The inieclor sho!ld be IubicatcLl in accorclance with thc 'f8. ln what postion rust the ow dvider vlve be
:,-pro!ed lubdcaion cha lbr Lhc paficular iL1sllltion. nstled on the RSA system?
1r clevis pins used in conncctio \rilh thc thotlc d thc 19. Why rusl hor zot y insta ed fuel nozz e5 be
:-:ual nirtue control should be clecked lbr lieedl)rn ol rnstled wth the ldentflcaton rark on the owersde?
.-hoo
-.r\ emet and lubrlcted if necessary.
Lubdcae the lhrotle shaft bushn)gs b"\'plcig a clrop of
20.
^1" """"por"d o
het dur ng ground operat on?
t....q

:.Sine oil on each end of the ilrotle shaft so hi the oil 21, What cuses a waTm eng ne to cot nle lo id e
::. $ork ito lhe bushings. for few seconds fter the m xture contro s p aced
Lse care in cle.Lning and oiling the ajr filter element. If
'..|F,F i reflJ eJ s rh e),e..r'e 'il . ,:r':r. r. 22. Lt the tems that re generaly cons dered ie d
i ne ofthe oil \\ill be draw inlo dre injecror rd $ill ser adjLrstab e on the RSA system.
: .rn lhe lenllLri. Thi,i can greatly affect lhe meleriDg cbnr 23. Descr be the proced!re ior check ng the id e m x
:i.:stics of ihe rjector. ture for an RSA fue lection system

Review Questions 165

 Reciprocating-Engne lgnition ffi
and Starting Systems ffi
.. r .i \ , -, ) ,. ..,r,. ... per.., e .. |U, .
'' r.,{'t. :,.,, ,,, ,."i tt"
'.rr,,! .w,1., , J,... nr-L . .,ge
Trr maintemnce. seNice, and rrobteshoorins of aicraft in the le.odN of rtre jgniriol coil rhjch is dtcred
b\:a
. ".. (.' rde.. r ,: , r , iL o, l, rr,r' .reo",er . i..e \.,,1,
'r. o rl . . r' . re\t .. . re r .i.( I hrier\ rgrrrr,s\\rerrs\hurr inFi! 8 I
..d rnaintence of ig, tion syfcms. strtes. nd ottrer
.l:ric delice\ rhnr arc, or nrav be. Nsocialed $ilh enqine\ Magneto lgnition
rrr I .i l, r ,,, ct- I.i I 4 rd rn:
. :, I ur rl. , o. .e. \laqnrro isnition ., ,.. u
''r. . e, ',. ..- -. ., r t-.
' 1,1 -le.li.J rl., ..dor.!,ca,,t.r..o., je I o lr.e' ., ' . <l"ine .pF. t . .' i i. J
. . -r1r "r I elr l1o. Je. , ,r J. - . Jr. ,
e -( ,J1Jr, ro,..,erJ . . J ..rp..J .o I.p.l
::\r )i1rnl1 El?'lctr axt Ete.rnniL\.
rhc .ragieto is r spectal tytc of atternriD:-crrcnt (ac)
gerlertor that ptuduces cleclic
tutsalion! of hjgh i,otLage
tnr purposes of iqnirior

lgniton Event n the Four-Stroke Cy<le

Dunng the first evet of rtr. trr slroke. fi\,e-event cvcle.
I',., rw .Lw ,\rJ . . e. r. .,o. .ro rF, l\e. r.. ,r ':1. ..J.. .r," ,.,!,.t... L,..rr-
r' .,.t , <.1 i, o , ,. ,t. ,de.. T, . . . re ,rJ
'' [c J ,. ,, n.t ."ri. ni.' . .e.,, ,.- .. -e ''.r,.,r 1",\..., t,t. ..o".1 ,,-.
'r.,r!
iiroke. rhe crakshlt conrinues to rorate ancl tte plston
'..\ ".. Jr,..r,t e..rtr L..t .i.rt \rr.\.,.F.
,. u' -t 1 .(. - op.. . .., \ir in rhJ Low- and High-Tension Magnetos
. i,d... dr e... i p,,r r, :r.,.... rti r. r.,,t .,.
A low-tension magneto rteii\crs cu .er at a tow vohrse
,i \Lr,-t .er.. p . J '. . r rl . I.11.. I. LL
. LA , \',. r',n. ,a(\p:,,. ., r_
,"en r,i eo ||.. . .., ,o .,u., i
,:,. ,',J:.,. '" _,. r. ...,,i
r.j\ure dri!es rhe pi\tol down,ard. Thjs cause! the ",
. 'l !.' roru|e q,,.e,, i.,te...J .t-.r, e..,
'5 | /'L 1,. t .. :t. I | .rJ-r, . e.l
r.D.'(. r,.le..'.. ri. .(r,,,r,..., fl"-^1.,,
.r".. . rte ri p..r I ".e ., . " .,", r,..., .l Tto
rrloe, btrt e) nnr be eviewed brjeftv in or.te. to nctcr
iind n.laft engre isrilnrn.
The clectric sparkjumps beiweo the etcctroctcs tpoinLs)
i. a sprk plrg insratted in rhe cylide hcd o conbrsLio
:harnbcr of the ergrre cytider. Te igDitior s!rer tir
'I . r.\.rr .1r o.t - . F"cn.: .1o. rJ .. L rp
ion of n .ron rnrl \ \, ,.,,, 1

Battery lgntion System

\ lew alro afi and nosr utomotrites xsc a
' ",kli.rr...'.J.)or
baerr isnitnn
.,.".'r," .,.,,".,, ., n.: T
rto as its sourcc of encrgr. I dre bxery jgnirro sy!em. FlG.8 1 8tiery qrion sysiem

167
curent mrst be transfoncd o hi::h rcn\io (high-\oh Symbols Used to Des<ribe Magnetos
age) cner by a transfbrrner at or near he spaik flug.
A high-tension nragnoto clcli\cl's a high voltgc n) e Nlag crG {re technicall!.lescribed by lctteF ard fisures
splrk tlug ad ha! both a t.nry rinding a.i I sc.ond T lr.i r,l. F rr.. .. .te. ...
'' ,:. \ .r"'1. rlr. .,., 1.. i-t.
' smc
ihe doubl. $indig accorplishes the '; purfose The '..
loiv vohase gccried iLr the primar! $inding nrdtrces n Erample I The DFI8R\ is a doublc lfe flrngc
high voltage cunc! ir re secondar) rvrrdirg whcn rhe mounred rgnero for usc o ar 18-c,-lin.ler eginc
prirnrt cjrcir is brole. d.siged lor ctockslse rotali., .1 nrxde b) Bcndix.

Exanrplo 2 Thc Sl l:lLU-7 is I sigle-rypc llange-

Rotating-Magnet and lnductor-Rotor nx)utcd n1aselo lr ule or1 14-c)ln]der erglre. dc\jgned
Magnetos lbr counlerclockwisc fatjon and r)rclc b) Bosch. sclcnih
I a rotatiry-magnet mrgnrto. rhe prnxrl rd secondary
\nrdi.Bs are (oL cl on the sarne iro corc. This core is I'r/. l,xch mrrutucru.er uses dash lolltNed b! tclLcA
Lrontc.1 beween two pol.s. or inductors. nhich cxtcnd o ' r' |. r. [e-.t,- .\ | ., I ,, ,.r,. ,r.
shoes o. clch side of hc rctrring mngnel Thc rotrig selies or particar rnodel. Thc leners F nd B nrc o tongel
nag|et ii usuliy nude $'ith fimr toles. which air nged uled tor ciyilj mngrreros bccuse nll it lhnge moulelt.
altemlel\ north lrnd south ir polrirf.
The indtrctor-rotor mngneto hrs sratiorLry cojl
lilnntuit) just s lhe marig mgnel yfe does. Thc dif
rence lics m the nrethod ol nrducing a magelic llui i
the core of hc coil. l he indrct l()tor nragnero has f r
lion{ry magne or mgnes. As the r)tor of ihe lagneto 'lhe magnelo cofsisrs olthrcc circuits: magnetir, primar.r.
Lurns. lhe Uux lio thc masnets is c jcd rhmugh rhe seg-
and sccondarJ c;rcuits. Thc) \ork iogelhcr rr produce rhc
rnets of the rotor o (hc pole lhoes and polcs. fjN in one
high ensio lpark ar the sprli tltrg. The ragctic cicliL
dircctio and he i thc odrer.
include! he pcnarenl mrgncL, coil core, trolc shoes. and
pol. lhoe ertc.sion\. The tnrr,- .lrcLir cosists of rhe
prjmlrry r'nrding olthe c.iil. rhc breiker poir\ or loDtacc.
Sngle- and Double-Type Magnetos
,J rle . Jr . .r,....r. l..e!o,c. ., !o-
'
TNo sigle-l\pc ma:reos it cononlr, used on tislor Lais the secodar\ Nindilgs. rhc disriburor od r)ror. ihe
type engines. Thc singlc-t]pe mgcto i! jur i:,hat ir\ igh tensiof ignitnD lead, ard lhc spark plLig Thcsc basic
rc implies-ooe n gneto. rnrgrelo ciiuLits arc illtrstrlted j Fig. 8 3
Thc double-tlpe mgncto is Senellly used or differen
rmclcls of releral t,lpes ol en3ines Wl)c r&le n[ rxdia]
engine\. it is ersentilly thc \ane as rhe rasncto.rade ir
iLr-linc cngi.es except that two comfestccl canr! nre
Order of
ernplo).d. The compesatcd cnrn is eaplicd ldrer in lhis
Dc!igntion S)mbol Nleanirs
The doublc tyte nagreto is esseriall) \ro nrgn.tos S Single 1"vpc
having ore rotarjg magner corrD o boh. lt co|lr\ ll Double r'pc
o ses ol brcaker !ois. and Lhc hiSh vohase is drrib
2 ts Brserountcd
rled eiher b) to distribuion nn.d eises'here on lhe
engire or bt disibarol! fornlins fn .f lhe rnagreo prot I Flange-mounlcd
er Sirce there xr.t$o sets ofbnrkerpoinri, anequrl nnr 1.6.7. Nunrbcr L)l
ber ot sprrkr will be prodrced b) c{ch coil ssernbly pcr dist,-ibuior i:leclroes
reroluilol olLhe mageto drne \l lt. I Clock$,i\c rotalion

dr'ive-shafl cnd
Flange- and Base-Mounted Magnetos
Co ntcrclockwise
A flalrg-mo nted magneto is Lt!.hed o the e|gxrc Lr,,- rolation ls \ ie\aed
re.' ^l .'", ',le a. L Ji,.r lr.r.rr fr-oJndri\'e'shrft end
holes xr rhe lhge are ror carlar: insead. the) arc \kf! L, Cicneral Electric
lha pemiL a sligh! adjuslncnr; bv rorrio, in ririrg dre
N Bendix
magnelo $ilh the egire.
The sirgle llpe m:neto ma! be either base-moLnlcd or
flaDge-loxnIcd. The dorble r!pc nrxgneio is l!rals U Dosch
C Dcho Rem), (Bosch
A base-mounted magneto is arLxched &r a noLrnring dcsign)
brcket on he engnr. b) rnears .iI cp scrc$s. which pass Edison-Splitclol{
through holes in thc bn.ket ard cntcr t{pfed holes i'r ihe
l'se of rhe magncto. FlG. 8-2 Mqneto .ode des qi o.
'168 chapter 8 Reclprocting,Enqine lsnit o nd start nq Systems
 SECONDARY W ND NG

EAKEF CONIACT PO NIS POLE SI]OE EXTENS ONS

SPAFK PLLJG

l_
T

FlG. 8-3 Bs1: m;qto . r.! ts

Magnetc Circuit
Ihe rrgneric cir.uit of Lhc r11g elo nla) be deiigned in
li1e1e|r a)r. O.c t!pc ol clesign ures roating tenanct
iir3fets lra\j.g t$o, ft. and even ei:hr mSnctic |ole\.
Th.ic ngners re r,ften mde of alnicr,, dn lloy o1 lu'
.rinur, !n, nickel. and cobal! that rctis nagnetism lor
rn rdcfie penod. The rngne6 rnxic ude fole pieces-
:hich complete ragnetic circuir Lhrgh coll co1e.
lnother ttpe ofmagneto (le!i:n mke\ use of slalionary
r.rnne|t lngnets and a !yltcr ol rotaling irlductori
:, hich cdnpleie rle Jnagnetic .ircit lhroush the coil coE
rt Ii\o ditteren fxdrs. thcrcby pro\'id1ng !i!o directios
:i]Jough the coil core l rhc agrelic flu\.
The flAt llpc ol dcsig is clleil t|e (falig nrrgnet
:rte. and Lhc sccod i\ clled dre hducl rotr tlpe. The
rrialiS nragnct Llpc is rnore Nidel) usc.l m drcruii Lgni
t
The lies of flur reFl oire anolher: thercf(nt. drct tcd
to spread ou in lhe nir\pnce Lretwee lhc polcs of hc mg
fer. as shon in Fig. 8 4. The] al$ ted to scck the pth o1'
least resistance belwee the foles ofthe m{gct. A larit
ed sofi jron brr fr.liclcs rD csicr parh lbr lhe lines ol flux
flo$ing berwcen the pole\ Ihn:Li doesr conseqnently. the
lines $ill clofd ll)gelher il such a br (sornerrnes clled a
keeperj is pur er the masret. The lires of llLrr hen
assLlne Ih loctiors ard directiors shoivn in lig. 8 5,
wbelt thev re colcenaied illihur dre bar Lll\iead of beinS
spread out rs re irslrace of Fig. E -1. This heavt con
cenadon ol lles of ilLt{ withi dre bar is de\cribed \ a
condirio otb sh densilr-.'

Principles of the Rotating-Magnet

Magneto
The horscshoe-shated pernanent.rdgncr \hown in Fig.
: -1 h\ r ragnelic tield thri i! lEtrcscnlcl b) nnny xrdi FIG- 8-4 Pernaeni rrqet nd f e d
i,lual palh\ ol in\,isible magetic flur. cotu].idy knosn
:i linc!".,1 flu)i. Ech of these lincs ol llu{ s1hin the
.rrgncL iLsclf e1e|ds liom the nonh folc of dre tnagel
l..l le e \ r- rlLrr r'. r'i ,o.'r. c(
:. Lhe roulh pole (rnrked irjth rh., l.tLcr S). drereby iblm
r: Ihe closed loop indicatcd in thc .lr\'irg. These ljnes of
:lgnelic llul are invisible. but thcir p.eselce caf be vcri
:'rjd b) placiig r sheet of ppcr olcr dle ma3nel x.1 sprin
.lins iroll filings on the papcr. The iror liljngs *il1 ar !ge
r:rselve\ jn definirc tosition\ alone the li.s ol llui
iilich compole rhc ragnctic {ield represenled bt thc solid FlG.8-5 Permfeni r!_et \41 llrx !5: q throgh r
:s conainin: r\!s.
MaqetoopeationalTheoy 159
 Th. direcri. laker bt lhc lin.s ol llar in the llmlaed lio dnri0g ihis rolenren, and this chge in llrx lmkagcs
sofi-iron Lrr placed | .r rnagelic fi.lJ is dctcrnrnred b! rhe ircluces ,r currelrr iD the coil of ivirc ,r rh. appa\tu it.:
' .o . ''' rn , as idicae.l b\ rhc movernei ol the -e.rtvarorncLer
Fo errrrrplc. r l:i3. 8+ and 8 5 thc ctrcLrn of flo$ is
tio th. north pole t the soulh t.nc. Thc dircctio. world Thc roltge rrduccd in Lhc coil of \;tu js frolorionl ro
be rc\.bcd if the oith folc rlcrc thc uptcr pole in the rh. nr if.hse t flu\ lr,t!g.-i. The llur lnrkges c bc
rllLrsrralions d rhe uth toie ilere dl loscr polc inceascct br- addjrg rnorc rurs in rhe coil ol wire o. br
ll dre perrnn.1 rSnel is n]ade
ot lnico. Pemtllo"-, .ntJ , l'-rdr;
or sore hadered ro.l. iL ca retair n l ge portlor ol rhc rlohes a 'elemcn! "!,,..' 'e
of iine nd cn b. increase{l b} r)y
nrSnetisnr indrced i il\hcn rt $s lrriSinxll) mirgrerired r: lFhur <
Since the lnmiaed iron bd is .ude of mgericall),'.'\oli ing dre speed lr1 llur.hrn3e. \her rD) i)f r.se methods
il{nr. I does rol rclail much ofdre magnetisr sher lnag 1r incrensing thc rte of chnse of llux linkrges js rriecl
.elic hnes of Lrr ta\\ tlnorgh it. Ihi! nake! lt possible to drig an erferincr. lhe grlvanometer nocdle deflecio
change he direction ol lhc lu.s olrlux b! urxrg the mag- i clicxtes the n]agniludc ol Lhc i.duced cnnenl.
et oler !o thar rhe ordr folc olrhc mgne iD Fig. 8 -1 ad 'ther.
"lrstis roi inducedifl
be a thdn?e tlitkug?!tuttltrt'dtalt.
S 5 is t the op. inred o1 lhc boftonr. of rhe picre ds. Yoltrge m thc ..i1 ot' \l,ie il Lhc holse
shoe lgnct is heid staiolrary. rega less of the fregLh of
the ragnet or the trrber ol tuns ol wire r he coil This
Curret Induced n a Coil principle i\ aptlicd to the nagrero b.cuse rhe lLnes ol llor
,\ hoNc\h)e mxenet ca be uscd to \hx! rhat a cunet can n'lt have Ingctic path lnoLrgh lhe .ojl i. lhe tirsl plcc
be gccrlc.I or iduced, in coil o1 {irc For.le.hnstra d ther l'? ,nr . / /tott"t of.irhct tht L?il ot rh?
on prllosc\. thc coil \hould be rxdc with Lw tNs of ,r.qrr to produce the change in llur llkges. A \olragc
he!) cotpcr ojrc ad come.red ro a glrrtnonreter, a the same prpojons could be n ooed in rhe coil ol wire
i.slrumelrt thar i.dicr.s nl iloN of cLrert b) lhe dcflc br holdirg e horseshoe rna$er rr(iorl\ end movig rhe
ir .n<e. . r'! .. l. ',,.r- , coil lhis $onld pr^i.le the relatire Dn)\rnrenr necessar\
The lines cf ilux ol rh. hoAeshoe raset pass rhrcugh. o poduce rhe chngc ol iltrx likages.
o lirk.' the turns .il llirc in the .oii $hen in the tosirion We ha\. treriously \trcct drat magnel(^ ca b. d vi.led
sho\n jlr Fi!. E-6 Whc on. ie ol tlur parse! though lnto two cl$ses: the ro(a(ing mrgne tlpe d thc j.dno
oc t!'rn ot coil. ir is cal cd o.e flu\ linkagc. lf ore li e rotor lyte. lhe !bo!c ciplD{rion of he luo rcthods ol
.f f ux paises lhro!gh li\. turns of a coil. five lhr likge\ changing Lhe flux l1lrkges ro i.duce votrg. should clxrity
rre troduced lf tt\. hrcs of fltr\ txss rhough five tLrms oI is earlici !ttement.
coil there xre 15 flL)i lit]kg.s, rn.1 so o.. $l | 'r ,-.(. .'.: rl ,: -.o
,.r.. r..l . .'. leJ..t. r'.rt .Jr 'l .pJ ..
x
Ir Fig I6A ifrhe horseshoe rnagDcL i. b()ught ros ard
the coil ti,r r.moLc tosirio to the fo\i(io \how j dre the nra!elic licld of lhe honeshoc or perale l mag.cr
.Lrairng. Ihe .u.rbcr of lines of Lr. shich rc lrrkj.g the freviusly described.
.oil. coLrrrlh n.r.lcs drng the rn.,rio ol thc mS.et.
l more tech|ical h.Srge, ihere is chgc nr llur li.k Lenz'Law
lses as rhe horresl)oc rrgnet moles to\lrrd rhe coil. nd
this lhanle nrduces \olrge in the coil oi 1\ire This voit Lcnz' ta$ can be staed in tci'rs of duced rohg. thus:
..:: ..1(. u i ..., ( .le. ...-.r 'Il_
Lo flo$,thtrmgh the circuit. .d dris'r is i.dicated br. the rk.4 iklLkotct, ahtu)s ape)1tt(t nl nrh Ll ljtdion a!
tlcllccti(r of the Sal!arrorneter ncc.ll.. o .tpot 1l tok! oi \ Lt..ir1
In Fig. 11 68 f ihe h.ir\cshoc rg.et is m)yed asay -Thc \dme bjng cn c statcd in sirpler lens: $rhen a
ti.inr lhe coil. rh. r'ltrx linkges oc.!r in thc opto\ir. dircc chrnge in llui ll.klges froduccs i !oltxge ilhich csrrblish
,.r1.'-.,,-.i.
.lrJ\ .'. I I e r .

chnge r flux linka:es $hich pro.iuced he currenr. Lc/'

law is \cr) irporta. to operatio. of he nar\ero. rs
extlxined lirrlhcr i this te11.
I. l-ig 8-6A. $h.n the nragnet is r)ye.l nrwrd rhe
c0il. the cuerl flow\ up the Leit,hard !irc. Lhrcu-lh the
gl\anomerer, nd clo$n thc righ hnd $nc. rj \ho* bl
||.... \l.r | '::' ., .

thc .trret flo!',s up dre rishr-hrd \rn... drn gh rhe gt

yx.o'neter. ard do\. the lelt-hard sir.. N shorn ir Fis.
8 68.

Left-Hand Rule
Thc tolritI ol a gcric iicid car be de(er incd s,hen
MOTION
e dircctjons of the cuner r.1 re xrdng 1r1 coil .tlc
kosD. If the $ie is grltccl sith the left hnd. aDd if the
alc.8 6 Lr.rll.Lr1ntr; mlret. ed. iirgcrs of the left had cr{c.I {nurd rhe coil in r. .lirec
'170 Chdpter 8 Recproct nq Engine qnltion and Startlng systems
rion ol (hc cuFjnl. thc thrmb will al$)s poinr nr the LIi.cc
rion ol lhe 1lux. or thc orrh cncl ol rhe lield. This is callcd
Ihe ltt-hand le.
lfrhe left-hnd rule is Lpplierl ro lhe crrelrt in Fig lj .
rhe fikl which rhe curcnt estrblislies opposes rhe t1'?dr
c,r chagc ol llux lirkagcs. Whilc rhc nagncl is being
moled Lrp i Fig. 8 6A. e usul lendency
tolrard the coil
is Io i,.rrr lhe flrri tlxough the con core rn the direclio
1ol1l righ o lefi ofe iliLstration, s sho$r b) the aro\v1.
However. s soon xs the fltrx stxr.; to icrcasc. a currcnt
besins to flow in the coil. lt establishes { ficld of difcctidr
iror lefr to righ!, and his field ottoses the increrse 01'
ugreic flur and lctualL) exen! a !ill mechicrl lorcc
d eDd! o push te naget awa) liom thc coil.
]n Fig. 8 68, hen dre mrgnet i! mo\ing awa,,'f)nr thc
FlG. 8-7 Fo!,p e rotai rq mqnet
.oil. the ctrnent flows up the ght hDd $,irc. thraugli lhe
S,lranorctcr, and lknv thc lcli h.td wire. ln ccoldance
\ith thc rarcn)clol thc lcft hnd flrle. the fiekl ot the coll
' 1(r\ \. ,! hi i. J .\e rJ: ., \ tr r 'J,e, i.
pi
nned L\!ar lio the coil. Lhe llu{ llnkages occur h lhe
opposie direcrion nd 1duce cLrren in he coil which
\ers up a nrgnetic lielcl lhr opposes he chnge, lllowjng
\. -i Lp..l.'/ .\ H"'e... r.cr.':(. .ou:
dec'eaie: theretbre. the lleld of dre coil ow helfs llre nr.i:
nriic field, aiding jt in irs effofi tu of,tos. lhc changc. A
!.rall mcchanilrl tull is actally cxcilcd on thc rgncl b]
ih. coil's Lcndrg 10 rc\ist lhc fior ol the ragel $)

Ifthe .ircuir olrhe coil is ofened, no clncnl cn t].,rl in

ih. sirc hccausc rhcrc is noL cnotrgh lollage to for{"e lhe FlG. 8-8 Affn.lmet o rot nq magnet, po e shoe3, d
.urct ac()s\ Lhc gt whcrc drc *ire r Lhe cn'cuit i! bro- .ore of the .o mqeto
1i.n o. discoDcctcd. To tump the gp rcqules ligh volt-
:-ge. nd is vould nlake iL necessry' to increase greriy ]n Fig. 8-9, rotice thrr the fatig . gnct has dnted
rlre rae of chnnge of Uu lnkages. $e hale ilready dis ftonr dre toslion it had i Fig. 8 S. The neurraltosirioD of
iuised be nehods ofincreasxrg the rure of change of f trx D\ trfting nragnet is thal position where onc ol thc polc
rkages. ln ihe rimple horseshoe magDe! d \inglc coil picces ;s .etered between the pole shoes in lhc rnagclo
housing. $ shown in lrig. 8 9. Whel the otaring gnet is
!ho$n in fig. 8 6. if lhe lize of hc !oil. thc 1i7c of thc
:rsnet. ad rhe rate of nrovement of thc raget wcrc i iL\ ncunl politior. tire lllles of tlnr do rol prss thiugh
::reased, lhe l)orver required to nle the agnet rafidl.-
thc coil core because dre) are short-circuiled by rhc pole
:nough to prduce the high nte of ch{ge ol llux lnrkgcs sliocs $hcn a t\ro pole nragnet moves irto the neulral
trould bc r) grcat lhrr Lhis.lcyicc would nol be prclicl position, lhc polcs ol Llrc r{gel xre tosiioned too r'ar tiom
fh.relorc. the b sic desisn ru\r be chnged to lrolide he the pole shoe! to ailo$ llLrr to flo\ lhrNgh the coil core.
mpact. cllicicnt rrrcc ol high rcntase ].equired tr igni Notjce especiall) lhat prlmary rd secondrr" winclmgs
:rg the luel air charge ir the egnre cr-linder.
rc, shown iD e coil core xr FiS. 8 8 ard 8-9. They are
onritted o make ir easier to urdend he Sllelic aclion
Having learned rhe ction without vxrdrrgs. the readcr $,ill
Rotating Magnet lind it er\jer to nndeNtond the lunctions of the \llrxl1ngs
c\fhined lter i this ext.
ii-qurc 8 7 \ho$s r ftru pole roldrg magnet. sin lar to
rre used in sone nlodels of Bendix aircrafi ragnetos.
.. '< o lr ^,,c, l3r 'c,.!r. .\le' i '
::rfalled in lhe rgneto- pass fronr its noith tole through
:.. xirs|ace nr i1s rtrLth pole. in a irncr simihr to lhc
. tLrelre 'Lr'rl . ll l .r'{r," '
.i,r.8 -1.
l Fir. 8 8. the pole shoes rd their ertensio! are mldc
:: $ft iron laminaions cst in rhe nrngneto housing. Thc
:rrl core is rlso nrrde of soft imn lamintioDs ad is
-unt.d on top olihe tole shoe cxlcnsurs. Thelole shoes
I
'_m
.r:1
nd Lhcir cxLcsjoDs ts. Logcrhor \!ilh dre coil core C,
a magnctic path similar to that made by the larnirated
irD br {kccpct slrcwn with the o inar\ horseshoe
i,o)
.::,qnet i Fig. 8 5. Wh.n thc agncl is in ihe trosition
-:\n nr Fig.8 8. thc mxgcric palhproduces a concenrrx'
:r ol ilux iD rho corc ollhc coil. FIG.8-9 Rotatq r!net neLri' postion
Maqneto Operationa rheory 171
 to Dro\,rdc conr c torgh hich lre high ten'!ion rhigi'
The.ur!e in lis 8 10 shows hor !h' flr\ ln rhe coil .nirqel cunent ea b calricti Lhe di(ribunr'
* c|^Dses \']re! lhe ingteL is lumed with no {nrL]1g\ Th_is .lcscriDlion oi Jltsreto coil does ot neccs_qily
nNe.t. Tii\ curlc l\ called Lhe static'flul curYc becxuse o l I
i. ."or.'-,t tlt. stlrio{r! or .orrlrl codnion of e cir .,r ..1 .
. ....., \, _.
rrr"t", is luired \irh no Finchrrg\ on the 'oil coil ssrnrbl,l is iliustred !r Fig S II
".ii'ii,L.
..r.. Ilr. 1lLLr ;i]l huikL up thrugh the coil corc il] Iirsl one
.11,.:.tio n.i ren Lhe olher. as idicte'l b) the cur\e'
I .. r\- J-| .'|.L hr4 e I r' J J Rrk. Asscmbh. The breaker alsembl) of a lnS
\\ n rl\' to. l$ r.fr.cl ; 1\ Ihc contrct breaker' consist! of
,,. .. .t ., "..
i"" tlt. fl,* is ssic' through tlle coil i o'grelr
iftaJion .,"'-'1 ''
,," ,i" i*]t.. t. c"ne the hlle the th' tl
".*" nu^. , , ,t '
rfrihr
'- of lres oi llr\ in hc corc 'r ' ' le\rr'l:Ir'r Ir i\
ol -l\ pe
ii,".,r," *"'" is bel$\ the horiTorlal line, Ihe x is
brekrr poini. r-
.,"."; J^" \ '
r,.",'''',-.'.cl''l.r
,.-, ."'' rc 'rrb' l
,1"-
'
rollo$t rtra.ies un rh. iLlf" ofthc br'aker caln is
,. :
i' ,",. 1,". js b]
xllachcd ftr the br.ker
p.' ll '
nr' Ler model\ of mlgnet|i halc

thc liiir i thc coil coc 1;11\ to /ero xnd this 'hown
,;", ,
rP "' e r.l rJ r " \' er
'\':
"., -,-. .t b! the wcxr occLuring
ullecic.l at Lhe tirol bcriJrgs:
.., ,,. ' r- rr i . b.'r i \
.,u., ^,.,. .r' lr"Lrh
o" ,'"-. . ' .'. ' l "P (l f -
tiol. )iore rhl thc atrNe i Fig 8 10 hs rlecp
;-r' ,, f, r ' ^ r' '"ro : shpe ! ll "
^ '1n."".L. \'''rl1 ' Ir ''9'' er'"
:, ,,
.,;. -r'.1r". 'l . ' ,., , ...' r' r' ( b1 '
rL"i. . '-,. '., ' .., . l l '
'p",f! r]clutr 'rt'i'ifer "t' "''
{ r ILbIIJI
Primary-Circuit ComPonents
(',il \!!enrbl! r I l ' r ,( L
r.
o''r I
,,.,., . i., ,e..,".," -prima.
a secondarv rhe pmmr) $1'l
"': "r.i"" - 'inding
;". .,"ri'ii .1, lew turns ol rsulated cop-
.-, , . ,1 "-'p"'"ti!elv
.. .-"' '
*.,.".r.",' . . r" 'e I d
'
ul Ito. to.;. Bakelitc. \'amished crnbri'' or
"'i " ""r.
lx\Iic. ccordirrq Lo lbc lLesigr reqtrnerets of lhe mnu'
,.' " ,-r '. 'J''' 't ' ., .'\.,eref.orI r., o LA]NAfED

r; c. .e, _
'ii * i u,' .
',',,.n.
.,,nnecLetl in lhe crrefll circuit'
eri!nlL be)od either end or lhe
l?"r ort c,,ilcor"
..ll \sembl! r thr Lhev can bc secl1.ed lc) hc polc soe PFL[AFY AND
b,," eid of thc trirnxr) $inding is usuall) SECONL'AFY \/INDINGS
"ii."'1",,'.
qrotrDlle.1 lo bc core nd the other is brough out t. a SEALED IN PL-CS C
'nd
i.;...r('.r".o'-!r' prlmarv coil
CI]TEF SHELL
l'll* L".ntl""r on L. .nrl This end of the flc.8-11 Mqeto 55nb !
l. " points! xnd pro
u, LL. n,"gn.t to ih' brckcr
.,i.i,,'il. .,r- -"" li " colnection Io the ignnioFslriLch
"u,,]'..t"
le&i. \ore carefrlll tha whe Lhe breaker foils re
.'.,-''o'jr'r'r"(rn r';
.",;' Lo'r'( '' r' ' lr''
'' " rotatioL)
ilo\r aLLemares with lbc of re ngnc
lhe
Ore cnd ol the \econltar\ \indurg is groundeLlinsidc
."ii ""i il* tr'.' ""t i' b;'ugbt Lo the outside ol the
'oil

FlG. 8-10 Sietl. f trl.L:'re

FlG.812 OrI fF TI 01 Lre.lE'srb
'172 Chpter 8 Recip.ocatig Englne lgnitlon and sta'tinq Svstems
 The brexker .or.t frinrs rr. cle.{ricll! cornecred
i.rxs nr. prinrr\ roil r) th{r Lhcre is ,r .onrplete .ir.tr
thr)u-sh thc coil whcl] {hc poids re clo\ed x.d the cn.uir
\ btr)ken $h rh. poinrs opcll. The n:ero i\ t nred rl
. "r ' . leo r 1...r : r.
flur thtrLgh rhc oil corc ir xl x ]\inur.,\l his tinr.
rh.r. i\ a .rinirnur ol fl! change.
Pdlnrt Capacitor. l)lLri-! tbe op.itidr ol {he mas-
n.ro. lolage rd cLrrrerrr re indr.cd in bo lhe frxnar)
d)d lhe secon.lary $rlldmlr\ ol rh. .ojl \1l)elr tlre breaker
toilr opel. lhere lendenc! rir th. piinrl clL1elrl
rc n.ros-\ rLe !orr1\. Thii renllts in buNiIg ol llc co|tict
forrs. d rhe rnle of rhe collxt\e oJ lhc licld is ledl'ced.
rr\ultir)S xrr wek \frk tl!r the !.conr). To ole c.re
lhis troblelrl. prinrarr capcir)r roclerser is connected
cross the brcLicr tolfts. Thc opelaliim oi lhe frinrar)
.ipr.it(n \ ill'trr..I in Fig.8 13. The ctx.i!.r .r- t. r
nor-ee .hxnrbcr lL) rbrnb th. !!dde| rjse of \ol:. i. thc
trirr\ coil $hcn th. brcLcr forrr\ be! n to opc. The
prirr! .xf.il{]r pr.renrs r.inS bel\ieen th. colrLct
. I .b
i.dr.cd i thc prir] coil bl dre .oll.rt.c of thc .l.ctro
nastrelic firld.r.rlished Lr) trinrary.urcnt. This lield
''cLrli he ns ofrhe frinrxl) $i.1lrg s il c]lp!ei. The
Inderltlfs fri.jfle (.onrrol) .lle!l lhe self-induc-
Nere no r,indings of lhe core. As rhe rorarig magre ofhe
nrSner ls t.ed. the flnl .creases l. one dlrectio and
r' \1 . fr . r:r"
the oftosie directi.. Ihe strtic flur .rNe is rhr n r\ "
,,rnal lin. u rh rlr. {r ,!. nn th. r1.\r lrxr ll ,r
$ h.n prjnrr\ d lec{r.lu] rralinss rc plxccd on {he
'Lt .. !, r. t..
Tli\ curenl oqs dLring he trrne lhai the breaker poits
re closed. fs \hosr in rhe grfh. The dirccri. ofrh. crr
rcft is \orh tht iL produccs r{gnclic lield, s du$n I
Fig 8 1.1. lhr ,tifrA rLe ch:Lrrge !r
lnelic llur tr
duced b) Ihe rolaing rignei Thi\ i\ i .rcloxlx.ce wjrh
Lenz lrv. rs e\tlxined freriosLl lhi\ .lL.r oi rhc pri
mrry .trr!.L llo\ fftrfuccs th. l!\ultrnt thr sh0r'n dre
.'p.\ . . .. c e.
';r'
oJiglnl dire.tiu ixbore the 7e li.c) util thc breker
poi.t\ otc Lo stop (h. llf$ ol prilrlar! c!rrenr.
Ln)edir.l) belorc dre reker foi|s ope. ihe res!'ltnt
ilnr high lo\e the zero lie while the sraric fh\ i\
belo rhe lme Thi! liru.rtion !.rue! x high sh.si jn'!cll lhc
rd:neti. cir.nit vr rht sh. thc br.k.r toiDLs opcn. there
is n crtr.m.l] rrpid chansc nr thc llLrr trm lish in one
dnecdon to high nr he opfo\ie drlectlor. The efict ofnris
rclion m\ he comfxr.d tr) r spj.g lhr is itr.Lchcd 1o ils
ii , ,..t I .rr. JTl .r.r\....rr .=

tancc of the primar) $inding. elLc llLrl rough rhe cr'e oi rhe magne .oi1 indu.er drc
The pr]llrr\ clfc ror j\ il\]s cornecled cros. dr. lrish \oltSe in the secon.ld\ \indj.g ol lhc.oi] thrl po
d!.cs th. V&k l(r igiti r.
toiri. bur l( shate.rnd l..Iion \r\ or: different T rrgn.ri). rLe nLrnrber ol degrees ol rolIio beiween
rngrero rt).Lels lr m\ 1.. trnnnl. j.t!rre. or ol ilme .Iher
dnpe lr nr.L) he Lo.te,l i. rhe coil housr|g. m tbe brerkei rhe Ierrl poiirion rd lhe t,:,siior \her. the !orcr
hou\ .g n ith Lh. brcxl.r poiul!. or orr of ol rh. .oil f.i.ts.pef is.xLleLl tb. E-g{p trgle. u\uall\ \hofcDeclto
Bri.i! sLlc.l. ic lLr.li(D i\ (o L,sof \elf fduc.d.ur.nl \imtl\ tr gap, or efticiencl gap. The nnL,hciurer ol rhe
lldrrg i dre tr l circuir mrgnelo delerljres 1lrr ench nodel ho$ rrn) de.qr.c\
lpJ.' Lre!ond the feutr.r f.\ili.n i fr)lc ol thc rotor ragr)eI
"?.r To., lor .aprcitar.e \ ll fernrit rcing alld bLrt- \hotrld b. 1(, obrai lb. \lrurge\l sprk at the irrrrnt of
ing.f the bFaker foints tins \ertcn. urpur liom lhe rcrkcr poiDr s.prlLo Tlis rgulrr dis cere fror
re.o|drl. 1l rhe cirta.nrtnce j\ t(r, hjgh. lle irisnrIch \.--.'tJrc
bcrqeeu rtre coil |d lhe.i|r.iror \ill rcduce thc \.ntges nr 1r''. dependr! o the ixke d nr.del! brt i roprc
Lt.\elopeil rril rciuh in reke..d .fok. :.t{ri\. L\pc.l lr ln)lc nrxgn.to. such rs lhe one dii
.usse hcie. rhe coft.t E !p is i 1 No ce tht rhe (rrt
EIemcDts of Nt:rgnto Opration. A rfdertxdi.g \ I.,. .r, i te
rc!olution s thci rc poles
nf iheoterllo r)lxt\ficl rgrelor1l!be enhxccdb] x
srud\ of rhc s$cil .lcrrricl elemels or f.rn. l\ol\e.l \vher rhe gner hr erched the t.\irjo $hcrc the
in rt\ opr1 .n. Th. .srfhi. reDreserition i l:ig. I 11 corcl loins are uhotrt t .t.n. x l!'s leg.ee\ tsl lhe
ilhr\trtes rhe str!nglbs r.d dir.ctiol\ of the ele.icl d
.utIrl fo\irion. th. irirr] currer)I is rlairainirg !he
oi.sinl li.ld j. thc.oil .ore $hLle e rget h.rs lre.lt
nrsneti. f.t(r\ i r. otcrring mgero 'lhe ft.t(n\ nxli
cted the gth u. \nrr firi. l)n,rli(t r q |r dtr '.r "r r.., r. .'., i"
nd j,"ldll n, e(rhli\h .r field thi.ugh rh. coil core ir\ the ofposile
.rl, r.nr1n lIr, rtrru \olrrrt:
Thc nalic-llr)i cLLrIe ii +o$n t thc top ol e grth i. \\ . tc.1.. .. wr.. ,rerl( .I ,r I r, L " i
s hrokei lhis ;.tenrFs thc flo$ o1 1lr. prirnar) cLrrenl
,'1,1..r" an.1 cir\e. r e\r.mcl\ rpid .hngc ln Lr1 hrkges l
lickl lflrrr IIrLr!h the core .l lh..oil l!.iLrld be il there
x c\.ccdin!lr sln)f rilr)e. rhe lield efablised b) he fri
riu.) .rftnl lills ro zerc xnd is replced b) llre f eld ol tlrc
optosire !lireclion efablished br dre ma:ner 'lhls proccss
CAPAC iCF>:
ii repllrsred h! the lnro\r \crticrl tofion ol Lh. resul-
tr.t ll!\ cuNc i. Fig I 1.1
The rcconry $indrS ol a rx3.eto c.lL con\i\G fi
n) Iurns .il tirre ire. ofie ore' L0 000. ifd o\ cr rhe
priJnry on lhe coil !ore. The larse trnrtrcr ol trrs in lbe
caNIA.af
PO NIS
,"r se..ndrl \indi.S rnd thc \.r! rfi chunge in llLr\
ogerh.r riri\e hiSh rllle .fchngc 01 llui lrlgcs. rl';r.
FlG. 8 13 Or:'1.o'1r rfr..r....r ir rrr |rnduces the hi.!h rohxge in thc,c.or)drrl rrd r!
Mqneto operat ona Theory 173
 90" r ao 360"

BEFORE NEUIRAL,
CLOS NG INTERVAL_

Po Nr cLosiNc= 45e

3
RES!] LTANf

SECON DARY VO- TAGF

a
PP]MA RY VOLAG'

+ 244 +
+ 200 +
+ 160 +
+ !20 +
+ 80 +
+ 40 +
o
-44ao
-
- 120
160
- 200
- 24A
-

FlG.8-14 C:p-. eperent:r.r.it.r.t... . n.,i-;t.l.1 5 rr\i: _lhlper..r

oi r!e.. r'r':r t r! se..drr .,.! i lper iterd'r arr..iori.

Th. e\nenreiy rapL ilLr\ chr.!. retre\ct\ rhe di\iip l x rx\irurn ri\ho(rirlh!. 1o\er trrl rlthe Srafh.
tion.l lhc.ner!\ rnroheil iir lh. \r.\\ lhi !\ided in dre -\ole lhltt s..on(]ulr roitle( ]00 tlnre( Srerter thn rlr
magci! ccLuI betore rhr c(rLt.t toint! ofened. The l]Lrr piirr) \o rrrres This is b..r!\. rh. \e.ordr coil hxi l
i the..il core \ful orrll] .hx.Se s repFrenred b) l.!L l0lr rile\ is urul\ sjding' s rhe trxrl .oil.
\\'hcn nrxlner i\ !f.rrt. $iLh x c,)Drdere tath 1r
renl prr'\.n1\ thj\ rhnse rn hls lr.h th. il!\.hn{e sec.ilr\ .ujj.nr. {r.h s ,1 strfk fhg or test !xf. the
'rl ie.ondr\ rollxg. ri\e\.lr h gh eLroLrsh {o.dr\. rhe.or
The lact(n\ jlluffted br lhe.rr\c! in Fi.q. ll [. jcl] rello jLrip lh. :xp \ I s|rk. The rrl!e, nd diic.ri.n'
erif r )trlrg nrxg.ri
rcsenlxti\c ofrh. cordlrLrtrrs rhl ot the ln.l]rs oL o]r.rt orr l il mitlneto co ected ur sfrrk
uhcn th. s.c.ntlxl cilcuit Ls ofcn (hl is. trh.n rhcr. ]\ p uS, l1 rorrxll) ot.r!ii: xi crli eLrsre re shorn j
llot r conrplere .irlu t fol dr. \c.xr\ uindng Unll.r li:t j 15. \\ h.n rSncto l\ of erred orr tcir strD $ irh
Ihis.on!lition. both \erodlv urd prirnxr) roitrgc! build ote. xir sfirk gp!. th. rrhe\ rrc ' (hoirr r| Fig I15.
174 chapter 8 Rec procat ng Eng ne gn tion and start n9 systems
These \'les !rould exist 1r eighl-pole mgelo in
\hich the angulr difance rhrough shich the breaker
oinls rre either open or closed is 2ll".
]n Fig. E-15. [here the lagnelo is operating noma]ly
lrn an aircral engrne. the pressrre l the c,rlnrder aftctr lhe
l;\el of secondar) \,oltge necessay Io case lhe curen to
iunrf ooss the stark phg gaf. ln rlris case. secondi'y erf
nray reach onll 5000 V before the sfrk plug fires, {..1
hen lhe !oltrge dinrinishes jn n oscillarig pruem. r\
iho\n r Lhc $aph. Thc iiLial oscilllionr re cluc ro the
sucldcn currcrt load placed o he coil vhen secoda cur
rent str1s to flo. l he increasing "quench" oscillatioDs e
caused b) rlrc cllect of turbulece and presruc o curnt
i1o\ring across the sfrrk tluS gap. The resulring llux
change is dec.easirg !L Lhjs trne. and all energy is dissipa.
ed iusl belir.c thc brcakcr poill close o begln rhe nexl
Distrihutor. The disrributor nd rror gcar rc sho$r
tu Fig. 8 16. Thc large .listributor gear lrhlch is diver) by

900 45" 90" i350

N )F \ ,L PE T ) o E N N T :s
)t E G N T/ H G I ! R

E: T
.L
f
{
j

vl )

a
:D :D C E

5l il 6

M L M

T I

5 S

IE
NT s
B

B
A'POLE MAGNETO RUNNING WIfH E-POLE MAGNETO RUNNING WITH
NORMAL CYLJDER PRESSURF TEST GAPS IN AIR.
oN ENGIN. [aruoseaeae)
FlG. 8-15 6rirph . represenr'tlof ol ilre - -..1r. and rrgnetlc l.tors mqneto olret n!
.. opo qo B"d opo"a
MagnetooperationlTheory'175
 coL
(aBouT t0 TLTFNS No r8 t4l9E)
H GI] VOLTAGE
OUTLETS TO
GN TION LEADS
CO L CORE

POLE SHOE

i]GH VOLTAGE ,AGNET

ELECTRODE

FlG.8 16 t!l! reto r ir L tc rcror !:r ' m.!-'lc

ro.n. !1,f1 qc

th. lriller gerr llcL.J o he dri!. \hali of th. rolaurg
nrger is rsello di\t1iblle he high lcniio| \.lttgc lhe
(llllire )t .rLinilcr Lcnirr \ of thc dislribrrr block. The
rario bet\\ e;n th.\c ge s is rltr!s such lhlrt 1h. dirribulor
lerr el..trode iruIorl ! dri\.n nI tr. nli,qrL' .tu,rt
j/r.ri !ir.. Thi( ralio ofh. gcrs errure! thc lrofer dislri
bntior f Lh. ligh'Iension corrcrll o lhe sprk plugs in
'r , L r.e . 1 ..-
l
3enetul. thc distribut{r' rotor. ol the 1r'pi.l xircrxlL
mgner i\ x d.rice hi itlstribuics dre hilh !ollrge cufent
of rhc .1iltribrlor llocl I his roLor rn1y bc ur rhe r'onn of a
frg.r. .]isk. dNr. or othcr rhpe. depenmg on be dcsign
ol rhe rna:.eo.rnu1.ILrrer. l
x.ldition. dre.lisuiblor
rotor ! !e[ .]'l mgnlos 1\' hx\c beer des:ncct ith
.ither one or t\\o dji(ibui1rl: ele.uodes. \\'hen Lhere re
t$ dislributing clc.trodes. lhe l.djns eleciYl| whl.1l
obtxrs hi:lr \ollgc lir,m lhe nrag..l!.oil sccodr!
nke5 jrs .o.ncctio \ilh lhe .oil \c.oLldary hro!gh he
sl)rll of he nrr. shere\ the tiling electrtrl. oblains a
lish ten\lon \ol(ge iror thc booder bl nrcx.s ol a colle!
ror rifg Nornled eilher on Llr. rllionaD .11\tribrilor block
or of th. io10 ilielf.
It nrusl bc .\plnired thrt th. diribun! tilh he rrxiling
firger xr. nd eLrdoled o. lilc rnodel lircrrli rSfes,
mfSner)\ r\c!l on okler rr.lirl crgies. lhc erl,r \rltcms
LrlillT.d luler ln3ren)s or high'Iensio. troofer.oils 1o
fFrie sron: strl.ltirg errgine s1drl up. an, rh. rrrll_
lng Liser of rhe .1isibulor f.orided d rerarde.l sprtk Io
tr.\cr1l lhe ensine iror kl.LJrr! b.li llrlir: r r h.k-
construction and other charaderstics of
Magnetos
l\ierir \ us.d iI dle !on\tru.tio ol mg..to confon.nLs
are \.1r.1.J trimrlll ior thir ett'elts in the control ol
lnrg.cti. 1r.es Sr'enSrh nd dnrnbiljl)qllh resfcct l.)
m..hdicrl slre!se\ xnd hctt re lso.orsidete.L. 1)iel.cttlc
rxterjrls LitlsLrlalorir rust be ble to pro\ide dcq!Ie
iiulatior Io (irh\rnn hish \ol!e\ under ril op.rling
CONDENSER
FlG. 8-17 H -..ler5o. fa!_eto p.nrr/ q.ion5trnem
The cnse of x mgn.Lo musi be.on(nLcl.d ol a L1o
rgnei. allol. (u.h rs ahnriitr.r rll.t. !o thal ri \ill
rot rflecr the nrig.cLic circLil. Ih. cs. \ulp.,rls .d f)
..1..t,
t.l) col el! lhe opci lnrg lli\ ol !h.
tllachmerrls lr con]t l.
maunelo Io ue\enr thc cntr|ce of (rr.r, oil, or orher con
(rninrnis. S.reen.cl \cnl\ pernrit \e.lilttiorl rd .ooLing
Sorne rxgeti)s rc pro\ided \ jtlr lr.cd a c.oli..lr ()
emole het 1)nr ir)side lhe.rc
As e\plded prel iousl), thc tole \hoe-q and rhc coil .(re
of rhe nrgDclo re corlsru.tcri {r1 hLmlLied !.ft iron. Soli
irlr hs high pcneabilir) bilir) to cn: rxSfetir li.cs
offorcer but sill rot rei mrgn.tisr)1. For Ibis rcnm. thc
nxgnetjsm in e pole \hoe' xnd coil core c! ch.ge
rxfjdL,-!. rcqlircd i the (Ucrxlion ollhe Sn.n)
'lhc role shoes ind ..jl .ole re larintc.l lilli iLrs
rion beseef the hilioLrs o iedrcc dr. elcl .f tddl
rrrents shi.h dc\clop s x.e.ult.1 {h rfidly.hngnrg
ngreic r'.e\ i. lh.le p 1! l,dd\ crncl]l! ierier. \!ilh
the proter chrnses ir rlla-eneli. l(tce rd !enerrlc hrrt
The ll1agnel. cmtlo\ed Lr mas.ctos e .o(irrr'nrl 'r'
\ err' h.rd aLlor\. nrcli rs lLrico or Pcmr]]\' l hes. h\c
pror,ed to be mu.h slrorger drn hxr.l.|cil \leel. Thc xlloys
are shlt.d to reet dre requir.rcrt! f lhe mS..Ll) :Lnd are
rlrgn.tjr.d b\ mens oi. \rrong elecirornagn.tic lleld 1l
th. d.sign ol rhe 3nelo ro.tuires dain-s nrgrel lhe
rgncl is roured orr .r.tc.l llirll trith s itbl. bedrrs
sL]lfr.es for rotxlioLr.
'lhe distdb!Ior of lhe rxg.clo .on\irs of r rti itile
ol a dlrrxble diclccrnc nleri.tl. u{Lllt ibnclred b! )l.l
Lng. Thc mrcrial nrt'be Fomri.r. Bkelile. or !n. 01 th
r)rc c..nr lLerm.isellirs tix'tici. lrl an,\'e\cnl. lhc rc1i,r
nrust bc rble o nirh(n.l ligh lelnfertues tDd hig| ele.
r'ic jtr.\scs. The hi-eh tensi.,r oLllNLl fnm rhc ilinriluio i\
fnicd drr.iugh x dirtriblr.ir clr| Lrr bloclis in $hicb thc
hjsh lensior lexd\ f(n the strk pluss dic ruourled. ln\i.lc
th. di\tribnlor.! or blocks re eleetr, .s \li.h lick ut
rn, hlqlrrefii. .um.t lrm tlre r.r .l..ltude. l re di\

176 chaptr 8 Reclpocating Ensie lgnltion and start ns svstems

nibut roror afd cap or bl.,cks r lsull) coted with a
high temperxtue ltax to frelent rnoifurc absorpLion and
rhe lo\sibiliry oihigh volrge lenkage
Magneto Speed
l -, d l r. r'.i r. ."
tio s!ltenr usi! a roratir1g-n1gel rrgnelo. No(icc lhc
c{r oD the end ofrhe nagnet shli. I is nol a corpensated
canrr Lhcrclor.. it ha\ as manl lobes a\ drere ale poles on
thc raget. four ir this case. The rumber of hi-sh-\,olage
jmfulscs produced per revolutlon of he magnei h equal.
drer.fore. to the nnrber of poles The nunrber of ctlinder
firings fer comflee rerolution of he engi.e is equnl to
o.e hlf Lhe tr.rber of engine cylinders. I herefore. the
rrio of e rrgelo sh!ft \tccd to lhrt ol thc cngic crnk
\trli is equal to lhe urbcr ol cr_lmdcr\ di\idc.l br- twicc
he urbe of poles oD rhe rotariDg niger. Tlris caD bc
ried as a iornuh in lhis rnancr:
No o1 crlindcrs _ nragneo shafl speed
I x no. ofpoles egine crkshali speed
For exmtl, il rhc uncompensted cr hrs li)ur
lsince there re tour poios on rhc magDcLl and il
hs ll.vlide( rhen
l2 cvlirder
I I toles =!=rl
82
l hcrcnr.. tbe gneto speed rs l! Iimes the engine crak-
RerneDbcr Lhat in four snoke cyclc.nBine, each
cylinder lnes oce lor ccir t\o turn\ 01 (hc crankshft.
Thereibre. se kno\l' thal l2 c}lll]dcr englne \\i11 lirc si\
tires tbr each levolutlon ol rhe crankshali. Also, a rage
io havxlg fol lobes on e crn will troduce four strks
for each ur of the cnr. In the rngeLo !cler discussion.
dre cnm is mounted on the erd ol rhc rrgneto shali. so $c
know lho rhe ragreo lrodLces lbur sparks lbr each revo-
Itrtjon olthe magneto shati. Then. o prodLrce the six sparks
nee.led ior cch rcloltrtjon of ihe crunkshar'. the mag.cto
,\ ninc c!lindcr rudial engine reqrirc\ 4.,, sparks per rcv
ol!Lion, rnd a iour foie nrlgnet prcduces I sprrk. per rc!o
llior. Thc .tio ol cngie steed Lo rngnclo spcecl nrusl
elefhe bc,l:,11. oi 8:9 'lhc cngnrc rcqurs :16 \rrrk\ lor
8 r. nd thc nragncto prcduccs 16 strks nr 9 r.
Polarty or Direction of Sparks
rJ.r e,. \,l .r .r . t... I, :::r
Ior. modified 1o nabl. jr to.lcliv.r Lh. high volrgc
re.lulred lirr ignilion puTosc\ l Fig. I 1,1. thc hjgh raLc
01 chrge of lltrx link.L-ne! reprcsented by th. xlmost lclti
cal porio ol thc rcsuhrt flx .une is r.\poDsible for the
high lolage \.\hich prochrccs the sccodr) sprk. Ftum thc
clrlles. clerl) dre rapicl {l!\ chnge is dor\rard. Ihe
upNard, lienatlng in declion t ech openig of ]e cor-
acs. Since the direcli.)n ol an induced curre Lleperds olr
dre directjo ol llur chge $lich produced it. rhe spalks
prodlced by the mgnelo are of lter atirg polarilihat is-
rhey junp one w.r ard lhen the othe.. s represented lr]'
dre secondary-lolLrsc currcDt cuNe l Fig. E-1.1, wh;ch is
fiNt rbove and lhen bclow the line. indicaing lLcmatnrg
pollrity
Dual-Magneto lgnition
ri.r' An arangernent n which two.ragnetos lile a the src or
.rpproxnnIel,! Ihe sa]re tir. rhugh two sets of \pafk
t.rJ. i. ( ,u ...,
tcm The trincitil adlanlges are llic lbllowi.g: (l) lf one
mrgneto or !n! pall ofone mgneto s)fcnl fuils b ofeme,
the olhcr magneto lvser will lLumsh igmlion urLil Lhc dis
abld s)\tci fctnnr! a-qain. 12) Tr1'o \park\. igjrig Lhc
F/^ miittrrc in each cylinder sil]rultreorsly t rwo dilLr
er1l pl.es. pro!idc quickcr d nrore corplete cornburion
rl. , r,er...1..r, ,. ,- rP r(!,:'e
increased. -{ll cenillctcd rccipro.tig erjne! mu!t be
equifleil \rilh dnal lgrition.
l)ual igmlion spak plugs ury bc scr to ljrc u he sa]ne
jst (\)nchrooizedl or r nightl) diflcrcDt time! (sa:
whe
Seredl. !lggered igDirio is used. the tso spaks
o.cur xl diflent lirnes. Thc stxrk tlug on the e\hausr side
ol the .f'linder lts fire! lir\t bccus. Lhe lolef fte of
lotres
btrrnrg of tlre erpanded and diluled F/,\ ri\Ltrre at this
rhc .ginc poinr iD rhc cylider n.Lkes j desirble to ha\e n advx.cc
1r lhe igiLur ti.rinS.
Magneto Sparking Order
Almost all pislon llpc airctuft.ngines oferaie on the trin-
cifle of rhe foLr-soke. fi!e clcnt c\'cle. For thi! renson.
Lh., trmber of spa*s reqried lor each co.rplctc revolutjon
oltlrc cnglne i! eqLallo orre-half lhe n'b.r olclljders in
lle cDgic. The nunrber of sparks tr.'duced bl ech rc!olr
lion of the rotalig magnet is eqlal (o thc nunrbcr of its
polcs. Therentre. rhe rario ofthe specd aI Irhich the r)ttig
nrgcL is drive to ihe speed of the csinc crkshaft j\
ahrlL)s o.c half thc trmher of cyllnder\ on the cDginc
divnled b) (he nurbcr ol folcs on dre rontins n]agnet. rs
The numhers on the {listributor blocl sho$ thc mgnto
spffking ordc., not the firing order of the engine. Thc
dirrribtrnrr bkrck fosiion marked I is connectcd r{) rlr. no.
I cylindcr. dre dillriburor lrlock posilioIr rked : i\ con
Dcctcd to the lecond cfl nder to be flred. lhe dis(riburor
block positio mrked 3 is colnected to lhe lhnd ctlinclcr
to bc lircd. {nclso o.
Some dislrib!1or blocks or housjgs .li not nurnlered
lr all high-Ieniio leads. ID thcsc .scs. dre lead \ocke lr
the ro i c]-lide is rnrked ancl thc other\ follow h order
accodjng o dieclion olroLlidr.
Coming-in Speed of Magneto
To produce sparks. ihe roradr1g ragct ru bc turned r or
abolc a \pecifie.l rl)ln rt which \peed he rate ofchrrge in
lh.\ linkagc\ is \trffici.ll) higlr to rnilLrce the requlred pfi-
mrt curfcl xnd rhc rc\trll3nt high relsron otpnt This
' ..J i \, ' ,., r1 (, nirq.i .p((d f ,le ' J!,.ro:
lanes lor dillcrct t\pcs of nr{gnetos but averages alotrl
l00Io 200 rtnr.
Mqneto operat oalTheory 177
 trd nr the sprk Plus ilr.ii. : .:
Magneto Safety GaP
llarelo\ ar. somctirl\ equipped \\rh sr{et} gap'.rI
ro
,, ,L,,..',-.' I\',.r ,..'cm.'..o. 'r lgniton Wiing System
t.. ,... ,,. e .:.o *r".-d. o.e
l"li t,..i.t ",'n r,,,r.,. $hile lhe groun'led electrode i\ The to\'-tensio \dring o hish lef';f'
. -'r',< .,.
r.,r. .h,..l. 1.. ""f 'u- .J,t ...r 1r
; - *'i rrrrr t:'" lhe encinc isJrjlioLl s\tlch. lls 'ircit !x'!e' ii:''
g1 iiiJ Ir;:
;: : " $Dll b1 nreans ol c.,ncctor P1u3. h'equ''lll] ol 'f:'i:r
"".,,, t" eleclrodcs of the \park plug\' lu dcsigi. rhlclr rutdnalicalll grouns rh' mgr(\
(hi
."",,o l*np_.t".n
. . l, I " 1'r\ rhi lui L dr{!nrr tc,l
. '. .,' 'r.. "i. ' ,.,"' re,.\', 'n. . e,'. Hir'h-ren.inrr rahlt
" I l'(
,ecirtlarr l nrtling orthc nageo ",".,n.-l ,', '
\heres lo$ Lensio crble hts a ol lage cru\i
'onduclor
xlel! nnall crt)ls secfrr
lccioD rd i$uleiio of comp
Blast Tubes Lh.. .. I JP'
of lirctult io cool the ng'ctos' .t, -"t 'a nr ' ' rr
Blxrl nLln's arc u\ed some
,." ,,,"red hc es1e s baffling which :Jd!,r... ,,1 .,r,: ot . ,rl '
l" i"'i u,", ro
ri r.\l[t LcclLr rer L t hrgt] (rlioi
(rblr
i"ll".tt,"t "lt alL dirccts iL onto thc rgneto hotring'
.1, , . . ' .
rhr\ idi.g ooljng cfie.r'
t-.ro\ . .: t i '' r ' ',.
o; cor,g: ncoprcre. or tlr\ric. shcth Ilist\il
ln seitral sizes. rc no\I conno bein:5 and I mm
"n
---irl"l
able
,"*-,,1irinq is irlrccd i! the JPecil condLiit
., .n -nJn,,, ' .. i" '. , r J
r,h.
si.. he nlaq.eto is a spccil lbrr ol high freqrL'11c) gen-
strLion while il ir i
':'",,' n ".,i * a ratllo tansritting
oscilla' lg11ition switch and the Primary circuit
rtt oicilltions l.e crlle'l uncontrolled
'",.'^ii,,,,
t..** ,". .o'er $idc ruge or fiequencies rhe ALI Lrnit\ 1 n ircralt i!riiion rlslcl 3rc controllecl
bl
ii"i x
'
os.ilhtions ol coLertitmal idio transmrfirng naron ae irnliion ."rr:n
. ' '6'.
..rr'' " :r" r't ' J' J
t*"t ,tf,t ."tt.oll" t."quencl. For this rcas{rn tlre igi .;'^,1' "' ' '
r, ,.sLeL mr;r t'c sh ttded ' (' ' '' '|.\
r'' 1' (r''
srii"ii',e ,, , l "r (r'' rr" r'' r i., .,-' l'
.-ii,, 'ir1"* '(:'lc
"r( 'r 'oIr
rr .,, . , , .'. .-. .,' |1', . n" I- i

sni1.h is closed \ten it i! lun1ed oll. because iti

rd isition eq\ripmenr' srounded at pu{ros' is
;ii:].;;;i. "ii'"0 to
ii"* i"i".*r'. *"4 p.-i;d Ior the pu?olc of elimintiDs to sorr-circun LLe brekcr loilts of lhe magncto dnd
pLelenL coll.rpse ol thc plir) circurt required lb1 ftudrLc
n\ iniericrence 'irh radio recepjon
li rlrF hiqh tension .bles and s\it'h \\'iring of the mag --
hey tctma\ iiu,n i,, cocced ro lbc
i.,;ti,- s'"iLor' .r]]e lcrlinl is
*,,, ;;. ";.hielded t'equccics o{ Ilre nasnel(i oscill- '. cc.ic circutt L1etcell the 3n't dr Llreaker
ir,...*",-rl -i.',ri c'
'oil r'r
'"1'i'
,;.,,'-"'" *i""r Te rec;iLing anterna oI1 ar anllanc ise
ol r r'. 1'i' r' "'i
;,,;; " '.t" r (.\ " ' .' , " " er "'"
",.. , " r': ''.,.,r. otlier tcrrinl is con'cted Io rhe acfL
'e' '<fJ' JJl '\ \e'' r ' ' r' r :J
ii,.i; l'"J.
.\i i Fig S lEA nr're rc Mo
,,' ,;ii ."' Jtc'ei re
(roi\eJ ro b' he'Lrn i the
ercund lnruclurel
,"
shoirn
,, ,, ,, '"., (J
,h"..,''l"g l**lernce ,.,.,.;.;. r'
""iii".
radio re.eiver ll1 thc ail?lae' oi .. p,' o , lr' r. " - ir
. ft) lrl(rtrr.].
ln lrig.8 1SA.lhe frimar! current \\'r11o bc ilrteruft
Design of the lgniton Shielding '."i"'.i'"ct( olcr' lilce there is srill 1lath
"
i" "i ,-**r1 ,r, "sctl illl isnion \ritch Since the
""--tl.
Il:,.,.e' to prc\et dilr *_-"tt'.rt."" it "noi lrotpcd rhcl] he loDlcr pornLs
",,,.",i
ir," ."'*.j.i'ns are fitred listl!
"'"i.li,,i e' 1r! \r' i,;;,. ,i'r.'"."" I'e o sudLlen collxfJe of tlre irrittlq coil
''* r;,'l,l nu Ll" in'luce'l rll thc se'ordrr) coil
,'. -r' . 'r...'.
-"..l --rp ", "oftle
;,,.r-.,. .''^'densatiolr rndPr" '" tr) lre th( ,Lrrk rl!s
\n' ,., : ""' J re
i..rre ru. u"nritatiu'r t,, rcrove 'o
the cono
.,,-;; ,.., qB. ' . .','
,;l" s".'"' i'.,"*l v ,l'. lrcig of rhe masneo within dre ".
.' ,,( JJ e L r'' :
shie_l.li! of hieh lesiolr lcds 1br the igrllion sr'ete
i.,"',..,,l.
'
";";, ,,: _.,. '
r" | -"
'.' :"r't rJl'r 'n:
.,.11., i,'
:,;.,^", ,; ..,'p '-" '^' c'r o 'pL r(J .',:,,,..."r, circni! '

eleclricall) conrec!'d to drc magnetu case effcct on the flilDrr!

This \herth is

fia Chapter 8 Reclprocatlng-Engine lgn tlon nd starting Svstems

 +--lt'

ZE-^
I=
(al

FlG. 8 18 fyp c qn t o iich c r.L t rA) C '.! t, .+ po5 t on (B) f rclil n or pos lo.

h lhe Borrr posidon.loih ugneos opeae. The Rrcrr and

,,or ". '(d o. e. Jr1 sri'.u, ) (r..
.lo!r,. le r . !re.o ro
Atier he insllon of an isnition switch or afrer dre
swilch cicuil hs been reqrrrd, the ofertjo| of the circtril
mus be tesred. This can be done \,,ih an ohmmeter or a
coniinriy ief ligh. Discoec lhe P-lead froln rbe ngnc
io- and connec ir 10 one remi.al of he telt trnir. ConccL
the orher tenninal of th. telt tri to gl(Nnd {t or nc thc
enSine. Whe be igition switch is turDcd to (,!i . drc Lcsl
light lhould bur or lhe ohnnreLer should idicaLc a com
plele circuit (liltle or no esisraDce). Whcn Lhc ignirion
\\itch i! turned !o o\. thc tcst light lhorld So ort or lhe
ohnnnctcr lhould \ho$ riinitc rcsistcc (!n ofcn circuir).
r $oking rith rhc ngncLo slstern, die lechniciaLr
niusL.rlwdls kecp iL1 nind tha the rnagneo will be "hot'
when ilre P-lead ls discone.ed or rvhe there is { break i
the circu1 lerdhg to lhe igniliur switch. ll lhc stlitch cir
.Lrr 'a. et:re.l.i ,L {rJr cr'r.tr r'.r'rFr -
nal of dre nngneio be connected to g)und or hdt thc sprk
plus leads be disconnecre.l.

FlG.I 19 q to. 5tder5y/t.hes lleleyre corner/

Mota6 lqn itan s))netn:)

\'1ay siglc cguc dircrft ignitior systems employ a when atremfting o \tat n cngrc. oltc lhc engirc slllrler
dual magneto s)lter in $hich tho leli nragneto supplies the \till
no rotae the crnnkshat't fasr enough to Foducc the
elecric spark for the tot pltrgs i cach cllrnder nd the required coling in !peed of !he magneo. In thcsc
righl nrasneto fires the bottom plugs. One igrition switch is istances. n source of erternal high tensioD cuct is
nonnalll used to contr)l both nignelos. required for ;gnilion turtoses. The vious .lc\iccs uscd tbr
|-.rr', |.,r.Jrlt.a . rl".i i'" this purposc rrc cxilcd ignition boostrs o auniliary igni-
oFF. r.r.r.r. Rrcrrr. nclr,orH. hr the oFF tosirio. bodr g
res rrc gr)uDclcd and thus re inoperative. Whc th. AD igDition boorer rnt be 1ihe lorl1l of a booster
swich i\ in thc Lrir tositior. only the left mag.elo opcr ,.'.r..1i.. rrc trrr-r cr. i

tesi in the tsr.H1 fosition, ol) dre ngh m.rgnelo oferate\. supplicd lior a balery. or r vibrator qhichsupplies iter

gnition Booste6 nd Auxiliay lgnit on Units 179

riuel dircc( currc.t fiorn 0 bter direcrlv to lhe trir!r) tlug uon\iss of shell. sfr;ng. d hub. The hub is prorld
ol lhe rgcto. Aother de!ice used 1.ir incresnrg lhe c.l $jh flJ$cights $trich.rblc the nsserbl] ro rcc.n
high-tesroL! rollgc o1 thc mS.eto for strt,Lrt is called n tlistr its furpoie Thesc rc illu\nred in Fig 8 20 hr \De
ranu{ls. the shell i! rclrrccl to {s the rr,, and rhc hub is

$ hcr he rlnpnlse .ouplig js j!1lLed on rhe dri\c shlt

lmpulse couplng
Whcn n rnolt e.gine is starreil. he ergine nrrs o\cr roo
slo\!l) 1o tcrit thc nrrsneto to operale. The irntulse cou
pling insrrlled on thc drjvc sh.tfi of a narero is desisne.l
1o gilc thc .rscnr nroment:Il] high fotntio|al steed and
to trcli.le a retarded spark lr fartrrg the ensine This
couplin: is lfriglike rechanicrl lirkge ber'eerr rc
c.:in. ind rrgne!. lhai lrhich ilinds Lr| turd lets go'
al tho fropci romcnt lil sfinjS dre rnaglelo shaii. dNs
suppllirg Lhe high \oltas. necessar) for igrlion The cou-
SI]ELL (BODY)
FlG. 8 20 Ccmponets c': : np! !! .!!p rs
ol thc ragneto. re shell ol lhe coutlrg mi,l berorared b\
e egr. ddve for a \ubsa|ril portion of I r s{rile the
rolaDg r{gn.t remxins sraliorar}. s shown in Fig. 8 :1.
while lhi! is raknrg thce, he itriLlg ir rhc couflin: is
being i:,onld Lrp Ar thc tlint here the ren.ro rusr fire-
dle i])eighrs rc r.l.!ed ) rhe actio ol rhe Llod) .o
acing e lriggcr ranrt. lhis rcdon causes rhe Jlyscighr\
lo roiae on rhc pi\ot foint and disergase liDr (hc jrop pi.
,]s shoqr in Fig S :1. This rllos rhe strg to rind
lirin: the rcitins rnxgnct 1 rtid rfariDn i| the ronlrl
.lircctio This. ol conrse cus.\ th. nragneto to produce
stiong sfadi a lhe sprk tlug. r\s soo. xr lhe engine begnrs
Lo run. the flvseilhls de hcl r thc release posiiion b)
.c.trifugxl rorle (see Fig. 8 231, rDLt he rgneto lircs in
iA noi.r.r d\,aced posilid. Durig ersre siar-Lp. thc
r.tdrd ltark is prodr.ed $h. th. mSneto riliior i\ hcld
bck b) the irtnlse c!tling Doinrg normal operarion. rh.
nrpulsc.outling \pring lrolcls thc !f.ro j the dr ci
spnrk position lf the !!r1r1g qcre to br.1li. rhe mrignero
troulcl .ontinue to rotae but \1ould b. in the retircL sprk
positloll. Th. \frk fLuls fire.L b! lhis pxrricullr nrgeto
rol.t tre lirug lte
Booster coil
\bo.rerr,il' .,.r1 , ,.. i. | ' i .t
prolld. d sho$:r of lparks lo he spark plug\ u.til the
ugnelo fit\ protey. The boosler c.iil is rsuall) .onnect

FLY\r'JEIGHT ATTACH ED TO

il
o
SPR NG ItI NDUF S-AFTS

FlG.8 21 rLi 5:.o,rp :. nir:r poston FlG.8-22 mLr se.cr! nq r:r:: rosi.
180 Chapter 8 Rec pro.atinq-Enqine qnltion and Startiq Systenrs
 lnoles toward the core. the contaci poinls and the pdnury
circuit xre opened. Tjs del.Anetizes the core and pernis
c spriDg to 8i close the contct points end cornplete
the cifcuit. The rnature vibrates brck and forth mpidly.
mking rDd brc{kig lhe primry .ircuii dr long as the \olr
-. r", ,. h r' I irJ r" Lr. l'" . .1'
The use ol boo\ter coils s described here is limitecl 1lr a
1e$, older rnclfl which re still oferting. Mor irroderr
icraf eJnflol the induction librator or an impnlse cotr
tling.

FlG.8-23 npllre.o!p nq n iorNr. pos t on
d to tlle farte ssilch. Whcn thc cgire has rared, lh.
booster coil and the strter arc Do loger required: there
lre. lhev cn be lurned offtogcthcr.
when lolrgc lionr bttery is applied to thc boosler
coil, illrsmted in Fig. E-1.1, magnetisr is clcvetupelt in e
corc until the mgnetic foce on the soft iron arnalure
mnled on lhe vibrlor overcornes dre st rg tcsnm and
attrcls the rnaturc toira.I tle core. \\hen lhc .maLirre
lnduction Vibrator
The lunctjon of the induciion vibrtor is to supply iDier-
Npted lor! roltxge (pulsrtig clircct cuIeDr) lor lhe tnrgre-
to trimrrl coil. which duces sufticiertly hlgh voltage in
lhe secondry lor slarting. A scherntic diagran of the cir
cuiL ft)ra irducrion librtor deslgned fbr use i light
irc.lL engine magneos is sho$n in Fig. 8 25 Oblervc
rhat $4ren the slarler s\litch is closed. batlery vollage is
rpplicd to lhc vibrator coil ihrough the vibraor contact
poinls d thoLgh the reard cortac toints rll dre left nag
elo. As the coll is enelgized. the br rker pois open and
irtemrp dre cuffenl llo$', thus deenergizing ilre coil. vC.
Through spring actio thc contact poits cbsc Dd grnr
ener3ize the coil. causing thc points tu opc. Thus thc con'
t.t points of the vibrtor coliuc to lak and brcak con-
tct rany tines per \ccorld. ieding an iffelfupted cuent
Lh)ugh boLh thc rai nnd relard conlaci tolrts of the lag-
The !ibrrnscds d nltcrutled btlerl cu]renL drough
tlic pmary wicling ol r]1e rcS'lar mgneto coit. The lng
neto coil then acts s a atery igniiion co I and produces
high'tensiol imtulses. q'hich are distuibuted rhrough llre
dislributo or. dlfributor block. and cables o the spark
piugs These high-tension irpulses ae poduced during lhe
elirc lin1c Lhat bolh sels ol rgne(o colacr points re
opc. Whc lhc coLacl poirns rc closcd. spLs cnnot be
gelrerated. Although the vibno corirues to send inter-
upted currerl im!Llses lhrough rhe lllagneio contact
poinrs. the iterrupied current will uow thnrugh the cotact
toiDls to g( rd. This is thc trth oi lcar r.sifncc lr lhe
A .i.cuiL lor n indction !ibrtor s nscd wilh a
..{ ...r" |(,r...,..r ., ct I-t.r.. r n.grroigr i-
Lion is sho\! nr Fig. E 26A. Thi\ circuil applies Io one

GN T]ON

MOVABLE

MAGNETO

FlG.
INTERNAL
GROLIND NG SIRIP

8-24 Bo.sier..i s.heml.

= r=-

FIG, 8-25 lndLrct on v btor c r.Lr t lo qn rcrlt errq e

lgnitlon Boosters and Aux liry lgnit on Units 181

 si.rihr.ircult \ \i1h echused \\')en the i!irilrll swilch is ill th. 1)\ ponon n: :::
erlje o.l\.
e,:,e sa,rerls cnrcd. lc.urent lrom rlre Lra(c') i'
trur 11'1 L1e

.r ,"lLie"q",e i4rltre The idLrcrir \illralor is ie;L throush lhe coil of a relrr- $bi.h is orll\ ole Th'
ergize.t "LLdr rhe .re circiL \thich erergize! lhe sur_
"',"r,e
irq \'olenoid rr is thu. ecrgized or r dLuing rhc ti le tht ttcrv cuire cruses tlrc rel) foi(\ lo close thus corn-
crLrsi-q Lhe \ibl
rlri engLfe' re *Ltg 'Lrte,L tlerirg lhe cLrctiL Io lh. \'ii'rllnr coil nil
CONDENSER
SOLENO D

--l
l3$-.""""*
CONDENSEF

i"-.=-:Jul
: {fi-l--.,
(B)
= -.-" - -

CONDENSER
N

r- -d
r _t_

CONDENSER

>'._--S--
1::::::

fO STAFTEB CONDENSER
SOLENO D
fs{-

A-ADVANCE

8-26 aon 'r- qf i. 5h!T er r tprk5 |!'t cr r b'ior c t iA Al ;!vI'es 'l! ' r-
FlG.
lli ',"-';" '"1 ,ii:i..',i',':"'po'o" '!
i ad''e br::Kr ront!p LDrletrc be'!e
::;;;:..; ii: !;;,'.; ;" !a5r to ;.,i8 oir: o. rr-"r./j'e'oinendr'l
182 chapter 8 Reciproct ng Engine gnitlon ancl 5trlig svstms
 \
-@,t'
FlG.8 27 Copone1sofhgh-tensof !ftosystenrlorlqhircltenqe:(l)mgeto
s'mby. (l)comb nat on nrrtch, d (4) v b|a lTeledJ,ne Cannn-".tal)
rZ) h.rnes5
tor nr prodocc a rpidl,\, irrlel'lupted current ltlLl!!ing dircct
curcnr). Thi\ car be seel l Fi:. 8
268. ln l:ig. 8 26C. Lhe
.nsie has rdfanced 1ar enough ro open drc rd\Dccd sct ol
breaker poins, bu the retrd conrct points aij rill closed.
prelentig llow of the itenuprecl curcnt through the pri-
ury nllr-qneto irjndnrg As thc cngic contlnnes to tun. ai
abol op cenier {l_C) enginc position. the relard co|Iact
poins open. as sho\lD in l'ig. 8 26D.
The lapidl) inreutred curet tn)ducc b] rhe viblato
i\ sent through the trirnarl !!indi.g of thc nagcto coil.
This ticti.n can be seen i Fig 8 26D. The paih rough
dre trimary rindjng i\ nos rhe easie\t ard onl,r'palh o
g()und. B) inducridr. higlr \,oltage is created in rhe sec
ondar] windrg ol Lhc mgelo coil. and his high roltage
troduccs high lcsio spdks hich ae deli'ered to tlre
ip{rk plugs thro!gh tlrc magncto disributur block elec
".. Irf r'.r r. rl. r e ' :. re.o coll . I.r,r'
Thi\ trocess is rcpeatecl erch tirne dre magneb contci
loiDts ale separted, because the intern$e.l curct oce
nore floivs rorgh the pdnrary of drc rn{gnelo coil. The
rclion contlnues unil the egre is firjg bccrse ofregxlar
nagneto sparks. and the ensre ltxtcr js released. As can
be seen in Flg. E-26B. he ignltio swiLch 1(] lhe right lR)
ragnetois closed dndrg siar'ing 1o prcrcnl liring of the
nshl mgneo. This is done to elinrnr{tc thc possibility of
e 3h n lcre o l r.,: r r. l\'
{ l:.1 \. e .ror\ u.per re ,orJ
cally whc lhe eginc igDilio s\rilch is lumed 1o the o\
positio and lhe slarler i\ cDgagccl The vibrator lilop! whc
rhe stacr i\ discDggccl, as seen in Fjg. 8 26E. rvhich is
the Doalcgme rtrni.g posilion.
Geheral Description
\ tlpic.rl igili.Jn sysem lr light aircraft engine consisrs
1.._ c :\r I. J.,,,.\:r ".r'..,i
contjnenta lqnition
m
nnd \Lartcr $viLch. nd a hamcss asscmbly Thc\c part! !rc
illufraLcd i Fig. 8 21. This jllusrrrio \h)w\ rhc compo
ncLs ol thc systcm ssociLcd ith thc ContiDcnlal igitior
series 5-200 magnel.,. Ho\ever, il is qirile limilr 1o orher
Coninental igniion slsiems. and lhe pircitles arc ihe
Magneto
Thc S 100 rag..ro is complctcly sclf conlincd uni(
corporaling a t\!o pole rolting rngct. coil unit con
Ialning the primary md secordart windings. a disibulor
assernblt. mair breaker poi s, relard breaker points. lwo-
. . a. . l a l 1 , .pr ol .. . .1u"" .
r1 o'
"be
tions. d olhcr coitocLs ncccssary lbr asscrly.
Tl'. r..,,ir ,I ' b:I\., J.
locaed aI lhe breakcr end rd thc othcr at c dri\c cncl. .\
t\ o-lobe cal]l is secued o the breake end of rhe lolaling
r.d- r(l I r 'r. ... rr.oe r..J! .e'o he r rJ.' ! . r.: <l
tums l! limes engine speed. rhus. six lparks re produ.e.1
through 720' of engine nf{tion lhil is, : r of the crnk
shaft. four cylinder maSnet{r. the (fxtng mSet tus
I {
at engine s|eed. thu! prcducing four sfarks throush I r oi
As me!ioned previou!1y, the dunl br.!kcr nragncto
ico{nnatcs r.ctard brcakcr. This brcakcr is actuarcd b}
tlic sdme cam as Lhe rnai brealcr ad is positioed so lhl
its colcls opc r predcicmrincd nurnber of degrccs fter
the main breaker co|acts oper. A baleqJ operated rtrl-
ig libralor used with thls rgreto provldes ret ed igri
lio lor rartig. regardless of engnre cranking speed. The
rcrardcd igDition i! in llrc fn of a sho\cr of starks
inslcad of a snrglc spdrk likc Llrt pro.tuccct by a imtulsc
coupling. Rcmcnbcr rhat the slow crnkiig s|cccl ol n
egine dxrig st ting makes i ecessall' Io reiard ignition
Io preven kickback. ,\1 ltafin: sfeed. if .rd\'.rnced igni
tior is supplied. the full rbrce of the-l conrbusrion sill be
deleloped before the piston reaches DC {top dead cen
rer) and ihe fisto will be d ren b{ck.low the cylinder.
thns rotatin: the crankshlt i reverse ol lhe ormxl direc
.,
H qh Tension Msneto syetem for L ght-A rcrfi Eng ne 183
 sinsle-brcker eielo (righI m!gnet.) is ro longe'
Operaton of the System groiLrrletl; therehrre. troLh l]rlgr\eto\ re fiiurg if the full
'lh. .Deration of thc S 2ll0 mqneto svstcrn cx be uder
stood studIig Fig. 8 28 hr this cncuil rhe ltdrllrrg
br_ ^,r 1.eJ l_b r..
uiraoi,rn iictucs oth a ribrator and a control relal' I
fl.," I. iunirion.rrch ' r., '. c^e
. ,, .ll..l , .Le . Jrd "r',' P ln-d t ' J \\ e rre
ih. ".rt",i..1"1 grounds the righl agncro durirs ihe .lr...r llJ r . r.l r'!" -r'' ' d
rirne thl thc ste stilch i\ tumcd on thus pe\enmg an o ,. "r. . 'l
p"o or''l P'- liLrrLor L2 lo both m{geto brexkcr foits rd rhe 1l,
"l lr.i L or .("1 .;' ccr
'lr ' '" 'rol ' ' r r, "(a . ' \"
"'. r.',..
i. uscrt rilth r sraarlarrl ignition s$itch T|e cleclrical oper' "n,nb',.' 'o' nr lhc diagr '
Lioi ol his srich .n be -qee ir Fig 8 lt ln the dia lie. Ihe! wiU nor be in the rositior iho$
rd\n'c lning posi
gi",;, ,ll ,h" *'i,.1* contncL loints ar lb'wlr in their whe; Lhe ensine rcx.hes it! ornrl
n,'L P 'o ""a , ", ,,,, '..,, DrIr r, e \'. '. b
\,n i...t-na J -r ,ro, r' I Irr " r"l I | , r" ,., r'h 'e,,J
.,..," , r.l I' cJ!' rrr'' ' oil 'l hrek.r. rrhich does no! open uii lhc \I.ulirrg r'rrd po\i_
.","-." II:.(-r -r-J. ,.. c,,. .'' lion ol the o cif. is rcchecl. $h'n lhe retrd breakc
'..*1.,
.',. . P.. o' R:. lR rel. \''r c R1 oes. he ribirr curcnl flos lhroLr3h the frnnry ol
,r1 I P c' r^ o rl ae ,oncro coil Tl. rhus lLt'.in.s high loltge '$ cxpltincd
iit'. uri"i t"lns-l,oced0rell' Barte) currenL flows oreiiouslr. Thrs rrnLage p(\ i.l.\ ihe rclard slark nece\\r)
i"" ,'r, -! contir ill ribrtor points Vl ad coij L2 lr ioniti;n util thc rqine \pccd fickr uf I]d dre stc'
rie th,u':h rhe retrd beakcr of Lhe lcll mtgre() ro s$iili ; relcase,l The .olbrjon srjch aul!Ilcrll)
qr,,"n, tro"e[ rh" .cta] comact R2. rd through the i returns n) LIS Bor trj.silion. thx! remorirg thc farling
'., t., The tlos ol cuet Lhrough coil L2 ribrtor and slairer sol.n.iid liom ihc circuit Astud] ofthe
e. nr.le ',i,r". c r.r.t i,...1 ',!
'. i,.-, \sir.h.Lisrnr will als n(r'thl he sltch circuiLs of
\ l.,.r,r-n. l.e'br ''r .'.<-I er'' d cl hoLh rrrg etos re ungroudedi therefore holh trgneos
bolh set\
cunrt rhns fro{luccclli crled to grcu|d Lhrough will be frn8.
ofbreakcr
-- roints in Lhe lefi magneto' coinllio \ lch trsed $ilh I rgr'ro svstcnr hs
The
il.' rri. ..o"l cs it;rtorrll ad\nc r'lrlrrg losi file n.sjliolr! nd i! act ured bv cither n s$itch 'r a ker"
tnn. ihc mtm"ngu*
brerkeL oens llow'ver. Lhe crLrer is siill 'lhe ilvc poslrlons arc: (l) o.F borh nrgneros 3rcurded
.riecl to !r,rud lhrough llrc retard brcker' {trich doej ntl noL operli|gl (l) R ri-QhL mxsnco oper'Iting lell
uiiuo.n uitit r..o,Linr ren1nl Posirit'lof Llre 'ngiJre is nto off: (31 leti nt8n.to ol)erldg rlghl 'ngel{l
jr'\ts
,"..1t.. Wrt." Lhe rcLarrfbreaker opers (!hc min breaker off: (ll Foflr-both m!ener(\ operrirg: tl (5) -
,r','.,' qo l r"Irl l r\ stutar soleDoiLl operaig ai.1 tibrxtor encrgiTc'l cxrLshg
,. ,,"' -1 rJrr' o P l"..:1 :la 'lL' a inLernitLcrt curen o llo{ tl1fou-qh dle rclrd breker or
'.,',""""-, co| 'l . 'e |i-l the leli nrxsreo $hjl. the right mgne() is gnrded to
; ., . '.iL.. ' I (.'' l- r' rr' rr '. re p o,-.:nr rd :.<.
, 'o \n.\ " . ,, ', ..' ''' ,, '.1 |'
.,", .', ^,.".-'. I rc pl : th;s posilior. \Vhen fr. siliLch is rclersecl it aul'imicall_!
"|^.,.| r''- pir oftr llosiri.m
" r..r.uc
.,.. l -'l rclers to lhe
. "..^. t, ..'-e .1 trilh flo$-
\ hr "- Lhe . r: I Fi!. 8 29. 1. ,"getnt .rre
'quitfcd
wh,: nr en!:ine fircs nd begnrs !o pick ut 'pced the ' o 'L- ' -r: I rj
(tacr stiLch i;released. thus d'eLrergizing rely coil Ll ne-: r,...'..t . ' f e

ad .'rLrse rore LpjJ colltse of rlre mgelic lield \hen

.,lt sLaner Letar Li. This ofc s the vibrator cir'uit and lhe
,"".t reakeL ii'.ult. tl'us iende ng th ioperlile The

orr for Ccnt entd q t on S 20C FlG. 8-29 q t o ls:rm ur rl' .omb i or :lrter qr t c
FlG. 8-28 arr.Lri o
r.gnetos!!t:r iTeledlne aantln"nial) swtch

184 chapter8 ReciprocatingEngnelgnitonandStartingsvstems

dre brenker poinls open cluring nomral oper.riron ,{ capci L Inlrall the tiriDg kit as shown in Fig. 8 -ll. ad tlacc
,r ., .J.,, ..,., t.: ,.r.. rotro- thc foiner in rhe rerc f(xition. Il rhe nrladure's ri]n
J' r,l: ?r l- r. L p .1,. .,. p rc.I nrg kit is ro a\ilblc a subsrirue ca bc fabricred b\
ret !ibrakn curret. J c.r" .e , ri. I (. .r re-

l. Connecl a !ritabl riring lighi acro\\ the nain

Continental lgton lnternal Magneto
Timing
As extlained rn the ger.l cliscu\\idr ol rnrgnen)s. every
magelo nntsl be inlernally tirnecl 10 producc a strk for
igDitio l a preclse instanl. Frrhc.noro. the nragnetu
breaker poinrs mus be rirncii ro opcn $hcD Lhc grcat.st
magnetlc liekl slress crisrs i thc iagnctic.ir.!it. This
point is called the E ga!, or cllicioDcy grp, r.d it is mei
.iured n degrees past lhe rellrl fosillon of lhe nrignet
lhc mdgncto didributor musl be lireLl Io deli\er the l)igh
r.sio curct to 1e poper on]e reninal of the didribu-
ror block. Thc iernl iming procedure lnies sornewhrl
lbr diflrnl 1\pes of nragneiosj however.lhe prircitles are
Ihe same 1r e\ crr. case.
Difribrro tinring j! u!ually acconplished while the
nagneto ls being asscmhlcd. fjgrLre 8 30 sho$s the rach-
ing of the chrnlrecl td)th on the distributor dile gea
\!ith the mrted tooth o Llrc drivcn gcar. In this illusra
rio. the mrgneo is being rssrnblcd lirr ighr hDd (clock
-lhe
sisel rnati(r. direcio of roraioll refers ro rhc dircc
rion iI which rhe ngnet shrti rottes. fcing lhc dri\c cnil.
\\'hcn drc teeh of he Seas are mLrcled ns sl w. rhc di;
r.ibutor will be i
rbe conc tosition lrilh rc\pcct nr thc
rf{tiDg lgnet and breaker poirns at ll lLncs. Thc large
ilistribuL(n ger {lso has a marked ooh. which cn bc
obreed through thc tinrjS wiJr.Low on top of e case to
indicae whe the dirribr(or is in po! iof for i-1ring the ro.
I cr'linder This nmd is noL sufficicndv rccure lbr timing
f r,r .r l' h". P. F.lto
iio of the distbuor rd tullig rnxgneL ftr iming !o he
Ihe folloirig feps nre trkc to chcck and ldjust lhe
iiming of the breike poiIs lor lh. S 200 mrgn). which
do.s Dot h!e tiDring mnrks i {he brerkcr conpart.rcDi:
bleaker points, ad Lrr the rcner in iis normrl dircctior
ofoaion l0' s irdicnted by lhe poinlDr. This is rhe E Sal
posirjolr. Thc rain breker poinrs should be adjusled ro
.1. i'm the rotIir raget untul the crn li)llower is
a
Lhc igh poirr.in lhe cam lohe. rd measxre thc clearance
bctween dle breaker points. Ihis clearalce n)usr I'c 0.01E 1
0.006 i 10.16 t 0.15 r1. If the breker-poinr clcrance i!
not $,ihi these li is, lhc toints nrust be adiuslccl for cor
recl sctLrng. lt q'ill ther bc nccess{rv to recheck ad rc
.]just lhe tjmig for breake opennrs. lf lhe breaker poinrs
cannol be adrultd to .pe a lhe corcc |re, the) should
On dual-breker magctos (hose h\nrg rct.fd break
ersl. dre rerd brcal.r is xdjusted lc) opcn I frcdeternlred
Dumber of degrecs lrcr the nrxin breakcr opcs, sibin +2
lo 0'. 'lhe amourt of rcrrd in desrees 1r {Dr picular
agclo js siamped or rl)e bouonr of he beakd co]pft
. . r rr ( rerJrL o. f. i, ., (..1.. i I ..
sy Io add drc degrees of nrlic{red in e breker
rcLxrcl
comprlmcL to rhe redirlg of c Liinrg pointeL $hen e
uir brekcr toinl! xre opening. For clirple. if the rnrir
breker toiA o|en s'hen he timmg lojLcr i.. a l0'ard
the required rctrd ls 30''. the 30'shotrld bc added o 10'
The oaliig Drgct should thus be tumcd utjl the iimins
indicatol rcds.t0'. The retnd breker ponfs sho d be
adttrsted ro open l rhis tiDe.
If 1 engre ir desiglecl Lr ignirion 20' BTC (before
tr)p c.nter) under normLl otcrdting condiions. rhc iclar.l
ignitidr lhoukL be set t lexf :0' laer than the nor.rl ;sni
lior. At drii tjme the pillo is close enough lo TDC rhat ir
is no likel\ 10 kick bck whcn iSnjtio occur!.

L Renlolc the timjg i\pecion plug fronl the rop 01

rhe mglreto. Tum lho rottlg m.r:net in it! norrnal direc-
rion of rotario trLil thc priied. chamfered loorh on the
Ji\lribulor Scd is apfro\inr{tel}'. i the cenrer of e tuspec-
rion $,indo$. Thc tun the nragnet back a feu degrees
'rl .,; lf, t i , HF., F r'r..ere..
rt .t .rri,r- rrr .t.^.rrul

TI/NG

TOOTH

TIM NG

''L

FIG. 8-30 Nlat.h nq mrk5 o ger lor .iir,DLrior : m .1 FlG. 8-31 :n to fd u5e of t m g :i t

Cont nenta lgnition H gh Tens on Mseto System for Ljght Aircaft Eng ne 185
Timing for Magneto with "Cast-in" gf po\iliono1 lh. rorxlirlg ]agne. Thls losiion i\ rdical-

Timing Marks ed when lhe rrk or the calrl is rl]igned (ith he mrrk al
Ihe lop ole breker housirr.
Soe modcls ol Lhc S-200 mgneto ad othcr Conlientl
ignidon.rgD.r(x such xs dre S-tlll0 hlrc linlirg marks
ca( in dre brckcr cornptmen. These . rk\ re ilhrlt- Engine Tirin9 Reference Marks
ed i lrig. 3 :l:. On each side of the brcker colnprtnert.
Itfost reciprocrling enginei ha'e tinirg refercnc mrks
iring mnrks nrdicle E gap tositio d vadous degrees Irullt ito the en:ine On n.ginc rhich hr! o Propeller
of rc(arcl breaker iring. Thc marlj on lhe leit hd si.tc. redncio 8ear. the tinring rdk {ill norl]]all} be on he
vic\cd fioLn te brerker .omfu tter. are l'.n cl)ck$isc
r)radrg magnelos. nd . rrl\ oir the rghl hlnd.i.lc r'e trofeiler flnge cdgc. xs shosn in Fig 8 33. The TC rrt
*rpcd o thc .dgc sill ligr $ith the crankcale sdit lie
l(r co urterclock( i!e nfrtrg mgr)etos The fatjon o l dre whcn th. no. I fi\ton is TDC Other llage marks indj
gnelo i\ delernined b) lic$jng lhe uglrto ioDr the .e degr..! BTC. Tiring nrar'lis. also disflaled o. dre
st{r1cr rrg gcar. u ligred $lth a sJrull hole lo.ted on
Thc poir in rhe .enter of drc E gF boss. sho\ dL E n] Lir. top lcc ol e rlrl,ler houling. N sh.w r FiS. 8 3.1.
Lhc dras'ig. idi.te\ thc crlcl E-gaf to\ition il lhe irrdi_
cator i! first sct io zero $ilh re maget l the reulral posi
1on. Thc wi.lth ol e boss on eitlrer rid. !l lhe poinl k the
a1loablc Lolcrrnce oi 1.1'. ln ddlrio to ese rnark!. 1h.
cnm hs an inderled liLre icross its.n.l 1r locatius rhe E

/\\0 TMNG

20\y2a
t0 :10
-r?./ 41 1^

N!.]BE R OF DEGREES FETARL]

FIG-8 32 Tnnqmls brelr.rflprtre.

flc. 8-34 Enq " t . 'lq r.G on s.rier r q

FlG.8-35 p"o " I o

FlG. 8-33 P'cpe :' I n.te t m ..r mrkt

186 chpter 8 Rec proctinq-En.rlne qnition and stat ng Systems

 O sonre engics. thcrc dc ctcgree urklngs on tbe pro
peller redction drilc gcar. r! slro{,r in Fig. E 35. To timc
thesc cDgincs. thc plug lro\'ided or lhe exterior of thc
reduction gcxr housmg rusl be i:rnoved to vies,lhe timiDg
lrlark!. On other cngincs. thc timirg marks .rre on c.Dk
shafl unge nd cn bc ricBed bl relnolig a plug fror
rbe crd.kcase. In e!er] care. Ihe engjne mnufacLtrreis
inslrucLioDs gi\e the location of brLil! in timig relelence
Sone older engines do not hile brill in ming marl<s.
'l e'.c po r ., f h(t'.. " '. I Lr'ee.. r(.1:.
l."rrJbjr :rr.)p ol o or'oo
Timing Lights
shich he ragneto points opcn. Se!eral ypes of timing
lighrs are in common nse to. ). In sone, $o lighs go oli
shen e point! ol)en: other lighLs work jusi the olfosjrc
nd light up $'e ihe poinrs oper. Slill oer tining lighrs
|tilize an audibte ligal. With rhe \ride lariet) of liming
devices in use tod\'. it i\ rcrv ittofant dt the techiciaD
be fmilir wirh rhe inrructions for dre typc bcnrg used.
lwo L)pcs of iimirg iighs re illustfuLcd Fig. 8 36.
Thje lres core oLr of the tot of thc ti ing-llghl box.
Thcre re also t$'o lights o the tioL iace ofthe unit and
a lwiLch to trn the uni on and olt To use lhe tiring light.
lhe cctcr lecl. mrked ground lexd," is connected o the
case of drc magneto being tered The oLhcf leads are con'
DecLcd lo lhe pilna[ leads of the brcaker-toinl assembly
ol lhe gneos being tired. Wilh lhe leads comecled nr
rhls ]tlaner. oe can casil) deterrnire whelher the poits
are open or cl(^cd bv lurning olr ihe swit.h aD.l obsor\.D]g
Before the rngncto is il1salled on dre egic, chcck hat
i hs lhc conecl direclio| olroaion. lhcn proceed r fbl-
Timing the Cotnental lgnition 5-200
Magneto to the Engine
l. Rrnore lhe illnhg ispecljon irlug lioln he op of
rhc nagDeLo. nd urLr he rnage!. in thc orml diection
FlG. 8-36 Tm nq !l--
coniinental gn tion
of )tation utjl he pni1ed chamfered tooth on the disirib
ut(n gcr is appmximtcly nr re cemer of the vindow, a!
!r Fig. 8 17. Thc rgDcto is no$,in the corcci E gap posi
tion firr firg the no. I cylindcr.
2. Tum llrc engine lo rhc no. I cllicter full dvace lir
mg tosirion (conrprcssio sttukc) wirh the rsc oi strirble
pislon-tosition indicrtor or a lirig disk nd TC indicalor.
3. hsiall the magreto on he e|gine- and ighen the
.roLnr n:bo r.r P,r . 'drc,:-re. i'p..,i.1
but loosely enough thxt it cr be rotiled.
4. Connect the timiDg ljghL to thc nagDcLO switch tcmri
rJl .. !rl.f . r"'l\- ! n,.\lo,
Wen a direc cuncnL (dc) coDriDuiLt light is usecl lor
checking breaker pon opcniDg tirc, thc pnir) lead lim
the coil shoukl bc clisconnecled iron1 lhe brcaker poinrs.
This will prclent ihe flow of cunn lol1l lhe baftery in dre
teste lhrough the pdnar) winding.
5. lf the tinig ligh is ou. roae he magreto houiig
in ihe diecion of its nagnet roaon a feN degree! beyond
the pojnt where rhe light come! on. Ihen slowly tu r thc
|d!,( ,1 le ofp^.r c di (.ri.r ' rr:r lF lr! rj . ^
our. Secure e magneto 1o the engine in his tosiion" by
ighenig he rnounllng bolts. Recheck lhe tinin: of he
breaker points by runiDg rhe engine i reverc nd thcn
rotatine il forward until thc Iight gocs out. Thc lighl shoukl
go out $cn the egnrc rcchci thc adrarcc l ing position
as sho$,n on the liming disk.
6. Rerole ihe riringlight colrnecon, and irstall the
swiLch wne (P lad) colnecdon Io lhe s$itch terminal of
WARNING l is osi irnpofanl lo nole thnt the magnet{)
is ir) lhe't$itch or' condition whenever lhe P ied wi! i\
disconnected. lt i! rhereforc ecelsarl to disconcct thc
spark plug wires whe tiirg lh. magcto to thc cgiel
otheNise, he engine.ould fire and causc intury to pcrso
lnstallation of High-Tension Harness
The high Lensior sptd tlug lealls arc iccLrred to the proper
ourlels in lhc ragnero by mears of dre ,ig-l.rrl/r llt
l1r nd a rubbe {,1rrrl or /,r;l 1d.1. The lhjeld
FlG. 8-37 Mgeto tim nq mr[5
H gh-Tens on Magneto Syfem for Light air.rft Eng ne 147
ig ol (hc cbl.\ i\ s.clrcd i (hc orrlcr ple bl nears of cable i5 illushalcd n Fjg. 8 19. In dris nrethod. the qircs
icrulc. \lee!e. rnd c.{rtlirg n!I The lelL-Lle ad sleeve are are cLri otl erer\ silh thc nAulxLion. fd ther the cable is
crinrped on he elrd of lhe shleldirg to lbmr felr1ranel hse ed iffo the groniet. A icral ticr.ing !cre$ is Lrsed
coutlrg il(tillg \rith nasher I holcl the cbles n pla... Thc \crcris pene
Thc high t.sio cable-\ rre iuseaed lhroxgh rlre ourler trate the errds oi lhe slr.rded .optci cxbl. n.l form
tldL. rnd il]lo (h. gromcr li.r Ihe irsulrion h\ been threxd\. Tbe sce$s rusl rol be llmcd t\r tight. or else
rripped boul] r l1l.l nnnl back f'onr the ed of th. thcl rill \trill
\rire The are $ire,i rre e\lended th(m:h lhc g1)rnrct ancl N{crhod, loi \c.trring jgnjrior lead\ m distribLtor caps
secLred br' slnrll bras! sash.r.3\ \ho\n i Fis. I lS ncl lirr llchiDg stark fltrg Lcnnilrl! are delcrihed rr1
Another tble .r.thoJ for sccuriDg cofper high-lerl\i.lr mirlernce Luuurls 1r specilic rgnctos. I. ll .ses.
foll.iw he Lnan!laclrcis ir(ructirnr.
Dr.,! er ,\.o, 1 ,91 c . i,,..i ...
lr2 hDl 112 1N SrRlP END OF lial tu |ole IhI e high-Ien\iol led\ rc in\rll.d i. th.
oulle plate l the order of egtue firillg. The orcter ol rlg
neto llrjng lor ditierenr inagrelos is -\lroun nr Fis.8 -10i
howe\er. the stnrk flus lead! mrr not be corlrected iD lhe
srm. frdei. Sice the firing order of a r)p crl ..i\-c)linder
oUn)\cLI .ginc is I ,1 5 I I 6. the nragneto oullets nNsl be
con.ccrcd to spark plug lcds \ \hown in Fig. 3 .11.
PL]SH fI]R1] i\]IULT PLE
LE 'ABLE
RUBEF GFOi\jMET
In Lhc fr{crir. ofconnc.ring the lerds for dual ma3neto
HO
s)SlcnL. th. rishr nrxger. firc! the tof spnrk irhgs olr the
ght hand \ide of the ensie nd lhe bolorn ipa* tlxgs l:,rl
'J "::,' rc
Lrecled 1o lirc thc tof sfrrk fltrg\ o the lett iide ofthe
ergine ar)d e Lloltor sprk plugs on thc rjght \ide of the
engrne ,\ circl]rl diagrrrn lor thi\ erg.mcnt i\ sho!!n in
PLACE WASHER OVER l- ig. 8 .12.

Maintenance of the Contnental lgniton

IryFAP \]IR E STFANDS ]N S-200 Mgneto
NOTCI]ES PROV IDED
1r ii reconmerded lhl S 20{) rnrgncLos bc in\p.ctcd xfter
rhe fil\r 15 h oloferr| rd e\er! 50 h thcrcltcr. A tlpj
cl f\pecii,rlt ad check are peirr'rned s fllow\:

I Renrore dre scre(s rhlch h.rld e brerker co\cr Dd

loo'e. the.oref iutijcjeftl! io allr renr.Nl oI the lc.l
thr !h cfrciror nnil retrrIL ied termrals lronr thc brck

CROSS SECTION V EW OF \q RE
STFANDS N F NAL POS T OI\

S4LN S4F ] 56 LN

FlG.8-38 4.r!.t rg l9lr :-p.ro. !5 i! the r.!1. FlG. 8-40 lglto f. r! o:der

CUT OFF CABLE SOUAF Y AND NSERT

FIB[LY INTO SOCKET OF CRO]T]ET Ntagnelo Oullel Spak-l'lug Lcad
l 1

l
l 5
l
NSEBT SCREIT\r THFOUGH l1\TASNER AND SECUBE NTO CABLE. 6
T GNTENING F RI']LY BUT NOT EXCESS VELY. '.1

FlG. 8-39 L.l5e o' r. e!.r! l :t.. i._.r .. rpe I gh-.!5 on FlG. 8 41 t\.:,reto oLrt e.r rtr ro :!p..1 q !prk Lr!-
eds'o. sr{! der e9 fe

188 Chapter 8 Reciproct ng-Eng ne lgnit on ancl Start ng Syrems

 :6
5i
3.- - 't4
L. ..2
o
FlG.8-42 Wir ng d aq'arn for a h gh ten5on md!eto syfer
on !x cylnder opposed eg e.
ers. The teed through capaciror and retard lcldswill rcmau
i the breaker cover when the cover is rrcvccl from thc
I F . ', b, 1,.r. ,... porr o-e.,,. i'r
$ear orbu ing Poi s *hiclr ha|e deep tns or ericessivel)
bumed areas shoulct be di\cxrded. Exnme the calrl fbllo\r-
er fclL fttr prlDcr lubicrion. Il lhc fh is dr), apply l$o or
thrcc clrops o1 approvcd lubrict. Blc,l otT any excess
oil. ClcD thc brckc. conrparrrncnt with a clen. &y clo.
3. Ch.ck thc dcprh ol thc sprig contrci in he slrich
and .etad ieninals. The spnrg de! tiom re outlel fnce
should no be lllore nn! in 112.7 nxnl.
L Visuall) check the breakers o see th{t th. canr fol
loer is securely riveied io irs spng. Check thc screw lht
holds the {sserbled brelker fxrts ogether ftr lightDess.
5. Check de cqrrcit(r nouting bracket ftr cracks or
toosenesl. lell1he c.rlacitor for a mLrrinrum capaciLancc ol
0 j0 micr)frad (Lr lr) with a suitable c{pacitor lcsrcr.
6. Rcmovc thc harncss outlcl llatc iror tlie ragneto.
d inspccL Lhc rubbcr gronncl rd dislnburor block. lf
isture is prcsc1. dr't rhc block u,ith a soti. dry, clear.
lint liee cloth. Do ro rse gasolire o any solven for clean
ing lhe block The rtverl ill rernove lhe rvax coang ad
coulcl cause eleclricl lekaje.
7. Reallerble Lll parrs cIeiLlll.
The fbregoing direcions:rrc indicaive ofdre check! nnd
inspecrion! hnt should be made. eslecially if thcrc i\ an)
sisn of magneto lroub1e. lf possible. use the maDtrfactu.cr's
rninualto make sule dra|ro poan! detail\ arc omiltcd.
The Continena] D 2000 and D 3000 magneo ignitioD sys
rens Nere designed 1(r provide dtrxl igitio fr a;rcrlL
engies wilh only one magnetu These syfcrs arc vil
able for four -six , ad eigh! cyljder engmes. A co plete
i\siem includes h dual r.geto, lhc harness assembl!, r
rraning !;brator lfor the I) 2:00 d D 3200 stsrer)rs), nd
a igniLi(lr swilch. The D 3000 mgneto is idelricl ro ihc
D-100{) scrics with the excepiion ol:r le\ structual
Magneto
The dual ragnelo cosisrs ol a single dr'eshali and otat-
ing macre tha supplies lhe rasncric flu\ for two electrj
. lt irdeten.l(n ,!n|r . ! r L,.l r. 1r r . r.. r
icludes pole shoes. primar) inding. secondr! wn nrg.
pnrry c{p.rcitor. breaker poins. and disribxtor. Figurc
E .+l is r pholograph of a D 3000 series nagneto sho$,irg
Lhc b:ock and bearing assembly. Thls system utllizes eilher
fatiDg !;brator or imPrLlse couplrg o provide dequaie
slartig igition.
Thc D 3000 scries m{geto equitted wilh x siarting
\,ibrIo. has lwo scprrLe brc.tkcr .{ms mounted on the
same shali. Th lowcr cr oferaLc\ the min breal(er poins
tr both magnelo circuits. while thc trf|cr car opcrale! the
leti magnelo rctarLl brcakcr d the t{chometer breaker.
The lachonctcr bre{ker prolides electric imtulses to ope-
ale the ol-tchorneler thxr rtiliTes such inrpulses lr
lylc
pm indictio. Ii Lhc ryldnc js eqlLipped wih ;ury other
,vpe of acho eler, thc lachonrctcr bir.er is o! used. The
rachoneie breaker is loctecl abo\e thc ight nraiD brcker.
nd he rerard breaker is role lhe lcli n nr brcaker. On
the D 3000 magneio ai emllols alr imtulsc corplrg, rhc
ufper can1 js inslled only if a rchomeler brekcr is
The prinlalt capciors e fed-hro|gh types Dd !r'e
mo nted in he magneo cover, $hich is tn ol rhe hamcss
r\sembly. When the hnrness is assembled to the mgneo.
lhc capcitrD leds xre xtached to rhe breaker{oint ibs
belre the corcr i\ instlllcd overrhe di\fibuor block.
yihrtor.
Staing Thc \tarting librtor operaies o1r
e srnic prcitlc s rhc iDduction viblator described earl1"
e1. Tso typcs ol \t{rtiDg yibr{td\ .Lre used $'ith D-2200
and D 3200 ignitio \ystcms. dependin:l o the type of
FlG.8-43 Cotenta qton D 3000rnqeto al-'leC),np
Cantnenrl l\,1arc5 lgnnron SJ,stens)
cont nentalDua Naqneto tqn tlon Systems 189
frrcr nd ilriiior s\ilches u-qed ir the strenr. One rtpc
ol st{1ing \ ibmor in.ludes n el) o grourd our e righL
..r i:r L ,:d'r.! L r= I
.{one. lhe rilht mlgneto ould ar advrnced sp{rk
prodLce
a.I rlri! would c,ruse the enlme o kick back. Wher) thc
gii o !\\'irci incorforales the slarter s$ilch. Ihe \tarl.r
\ibrlnn do.s not rcqrir. a rel! because lhe cornbialiol
!sit.h g()u.ils out thc right mcneto he the swirc is in
HarDess, As Lllentiored pnliorsl,-. thc hnrcss s\cm
blt n.lu.lei lhe ngncto co!cr. Exch nrcss is dc\igncd
fir| a pnLcLrliu nnke md nb.lel of egine. The Nsenrbly is
lll! shielded 1(r tre\elll clecrrorgncrrc .nrdrios thaL
The hrress sLieldlrg c.rsisrs 01 lirmcd copp.r ricl lhat is
trcfared $ilh a silicole bsc utcrixl. The hrmess is
dc\igned so dt rr) tat,( cln b. rflxccd iD ihe fielil
I e. '
The Slick serie\ msncror manufa.rued tor use with tirur
.rl.\.,1.. p...1.r",, .r. rF.r _rrop:-
tjo to the Colrirentl nugielo s)stcnrs trcviotrsl) dis-
cussed. The Slick:1j00 nd 6300 rnagco! rre improled
de\iSs oler eallie marmfaclrrcll nrodels. linlike lore
crlj.r models. lhey can be olerhruled nr thc licld accord-
rg to rhe lnnLfclueas lrslmclion\
The .1300 a|d 6100 ragnetos ha\e cor.ur franre nnd
rotor dss.nrblv. but the drslriburcr housiirg. block, ad ger

\ \*..ar f{
29

\r.J--l l(dlhR
SFlr
2a

21
q.- !9t \5J SJ
2T

21

-tg u! !!
! 1., I

rL
I l
l5

l9 t8

13 12 tr- l\' . r-- , 20

5e U iql
\,/
lqGt
t6
i" ,q5 - -/2 5 3 21
a.is; G
7
13 I
12
6

ll, Bering (lap 5.rcr

2. \r 12. tserig C| (lhnrl 22, Aji vent \idr Iknl
23. Scre!
. Itnp!lsc Colt lilr.s A$cnblr 1.1. Corcr l,jirir Kir Piir[.! 2:1. Hrsi'rg. Di\L,ih$,n
5. Oil Scrl 15. Conr!!r Poi'n KiI Seconl.q
26. Di\trinnr Block rt GerA-sdnbL)

9. Bc.'rg Kir
20. a.i
FIG. 8 44 Erp oded ,, e,r of 5 .i 4300 ler es mlneto. i5i/,:t Eie.o]
'190 chpter 8 Reciprocting Enq ne lqnit on ad Strting Systems
 {;3
,.. t,,1
','t.

"4/l

: c. 8 45 S .K 4:00 nd 6100 r.qeto5 51.1 F/"'r'l

t\!o rodels limflf bccus' rhe 4300 { 1l uDDo I

:: ::r bet\1ee Lhe
-U1 r B' | \crr '^
.r' J'|r'u''r"
'''l' """.,.,*.1
.. ' \" '
'- ;' Ie,e r( '-
r

' ,,i -t"iion *ttil the 25' mrrk o the starter rrg ged and
:::ro rc jllittt.cl i; Fig. 8-'ll Thc '1-100 d 6l(x) the holc in the rder bouslg li-Qn.
: Frr' \ _lr'
:: r.. rr n!.ttrel rn L l-'e lirninq pin I I l" \"( J rc' L - {
,',.,.o..'. n- ! lr"r "."1'
.. ,.te "e ,

showl in Fig. S -16. Tuin the tdor fposite the nrtion of

,rife nLaqrcl Thc rol(r d berg asser rlr'is ron_
. ..,'r,l' ,-" d1i!e and liarc. BcrLDg pelodiirg is .' r'' L'o (
i rh' ieed lor L, l
- :, r totdlng sprrng. Ihus eliriring $ilh' ing, an,1 irrrroe r/r r;rrrlrr3 |i/. Tigbtcn ilr' mountiLrs nus
:,,,.: iurn ,g ihe oth.r colocir\ conincd
I' . ,r'c er,Jrn,e arc higl tcLrsiorl coil drrt i!
( r ( l " r ' ' l '
" "e.l .pFJ r.t. LItl thc left mngnclo co de'ser lenniral l'
gri
.l' ,.-.e.r eC ,b 'a - i'-/ rt rl sroun.l
.,1-j".. r't,c conLuc ,taL.r is dcln'rt'cl b) a lwo-lobc ;ia \\titult tt!t ht i| rht oi, rt'\itilr n'nl rold
l\' s'rles to .1. Rotate e conrtlele ignelo ofllosite to
-: :ie erd of the rrror shti The c ioD ofnrc ma!.eto r; he.nginc rrounlig rtll thc timirg
: _LDL lel tu the shli
- :.'.1-" rctarded statk for engine slarting rhe liqhr indicteiLh the conLct brcker Points re iust opetr-
, ,- ri l0 xnd 6100 nltgnetos ernp]."- a imlulse cou-
'. - rr.tPoits

r.-.'.allatio and Timing Procedure for the

3 <k 4300/6300 series
:ing rs r1errnlle of hc t)cedurc ior. instlltllg
:::: Slick rxgcLos on Tcxlnll)cor ng eng'ne
. :'. :r Lo rhc magrero or aircrft n\aintcnancc nr u_
. ::formlrg ani lvpe of rageLo ref or narre-

, 'o p P :: ' l' lr''r

b..r. l-,. l ,l ot... '\elr' e
. - . Ihe norml dir'cion of roltio nliLdr' conl
.::rk; i\ renched The cor|fres\ior soke i\ Indi
- ill. Dre\sue iLlsi'lc hc clltlder $hich lerds
I Tml!p rlt eo n5 !'-::
. ,..'n, of Ln. sfark tiug hole' IIr this posiion FtG.8-46
'i1005re!
. :. ilrc no l cvlirleire closed' Tum de crak
s (k series 4300 nd 6300 Mgnetos 191
rg. Sc.ur. th. nri!. i. lhi\ po\it:lLr. Tull the
5. Turr or thc !$ilrh.f the tirifS l3hr. lunr the
c|xlshlt rcr] ! orl\ in the dire(ior of ro1]l1al mio|
o I c 1'9
.qcar lisf\ \r th rhe drill hole in ihe frrer honsiig. r
_.r,1 .:l rl rr..
lighl
' p.. ':
" crircs o \h.n thc poifs in the nrxlrieto ote.. Some
dnirg light\ gri o!1 \hcn th. points ote. 'the t\pe f t nl
ing lighl tou re si|g sl)rld b. dcL.rnrinc.l bcftrc Lhc
Iinrig trocedure ii Llegun. Ii th. lighr locs or cor. on.
turn dr. ra.r:ncto r lt\ .uniS flnse sls nd r.tc the
procedure trnlil the lighl come\ oi it l:' before 'l DC
Tighten dre r$o rou rrir: bolts.
6. Cofecr rhe lher fosirive ri e olthe iming lisht rc
rhe righr nrx!f.) ..fder\er ren 1, nd 1 lne th. nrrgfe
ro rr Lh. srmc rr.i $ lhc l.lir!.clo.
i ,\li.r Lrorh rgncLr\ hv. bccn tim.d. l.d!. th. ti.r
i, I ,...l ILIr:
1o lnc \!rc bfth.ugn.ro\ r.5ct t{) fir. tos.thcr Il thc
1irig is .orrcct. boLh Lrj.! lighl\ \ ill c(nn. .. siintrltr
Douslj- rhc lhc 15'urk o. rhc rig gc.[ x]ig\ trith Lhc
chill holc i thc stdrtc hou\i.g If rhf r.!ncL(x ic fot
tinled corecll). rcdjrsr thc nre.Lo Lnrg until Lroth
rnrgreros iire I lhe srrnc lirnc.1 1 15" Llclore TDC.
Secure iJrd turqLre he bohs Lrnrg drc conect torque ti,rn
lle milentce mtrual. relore the limrng lighl. llllil rake
nrre lhe igminrr $,ich is off.
whe| checkrrg lhe lilning. s.ribe or prr n rereLrce
, r... .!..' . lc -ie ... -
case beiore molrrg he Lngncto rcse rg e liln-
ifg, check rhe Lt de edier d^lier rneanue the ddace
rior th. origi.al in.rlled rk o the lcces\ory cse. Ii
thi\ Ll;r.nsio is Scarcr rhn if l.l.l8 nnl. rhc D.!.cto
mull bc rcrc\c.l ancl Lhc c.nrrr hrexk.r fojts nruf
nrspcctctl or rdjr't.ct: rclir to the mr!ntenr.rc nrnrl
Maintenance Pro<edures lor the Sli<k
4300 Seres
Thc tirllo\jg iDfonntion .on\isti of.\rnrltcs o1 itcm\
\.. :. r't.. ,.
AhLry\ icLr to th. maintenincc rlnual \rhc ferlirrring
Lhis rttc ol r\fccrio..
Aftcr 100 h ofotcalj. dnd.lcry 100 h ficNxrd. tbe
mgneb to..gin. timi.S lhonld be .hc.kccl. OLh.r it.r\
shonld lso bc checle.l: rcf.r o the mx;t.nrncc udl
l1 500 L inrcnl'. rhc colcr point x\\cnblles \horkl
be checked lirr brrnrrg or $err If rhe p.iinrs re nor discol'
orectnd ha\e Nhire. lrosl.! surlce roLrnd e edles. dre
toirs are li|cioing troirerh .1 rr be 1eLsed Apflr'
caln Srese strnn:ly lo erch lobe ol the !a if |eeded
If e poirls r L1l!c (icticring .\cc\\irc rcirg)
red. dre) should be ltiscrclcd.
AI dre 500-lr in\peclioD. il i\ neccs\rt Io check a|d
Iepl.e the crbol brush i rhe disriburor ger if rl i\ 11orn.
crcke.L. or chitped. The drfriuror Lilock ihould .o be
checke.L for cracks alr{]./or sisrls ol.i bo rxrkins
shonld Lre reIlaced il nece!sr).
hqpecl and pu drop ot SAE ro. l0 nodctcrgcr
machrne oil irr earh oihe beam! xr he dirribut(n blo.k
aLld beadlg belre reassernbL).
192 Chapter 8 Re.ipro.t n9 Ens ne gn
ig|ilion hsfccl lhe hjgh ieffiLrr lerd lior rbc .oil to nake \ure
it Lllcs ronrct sith he crbo bush o the disdbutor
gear sl li. Clex residLre fionl lhc high tension le.Ibel,Ie
reaiscrbl). rk fg c enoro -rcrxrch rhe {rlce ofrhe
\1 lhc 500 h mspeclior. !is!llt insirc.r rhe inpulse
couFhrg lhcll dnd htrb ir cricks. loore rilcrs. or rurded
flyweLglrs thl ] slip Juriig lxrching ut or rli. srop pnr.
lf r.! olihese .ondilio\ is c!ident the couphng sholrld bc
Pressurized Magnetos
\'Ian! rgn.trs thrt .terfie !r h !h llilutle! rre pressur
ized h) rcgullcd dir $uic. lmr th. ,rrcrrli en!Lne. The
jrt]lf g ol hish \olt{gc isid. thc disrribr)r. cnlled
li\drrr c occur. .!t.cill) \hcn rhc ir.rti i\ ofenr
ing i high aitilucs. Ar high rlliLrdc\ rhe ir is less dense.
rllos,ing lhe high Icr\ion sprk to irf t) gr.u.d nrore
easilt. To Ue1'enl lhjt. rir is purpcd j.to Llr. housing \ iih
n coirolied bleed ol rii criring Lir. rasneto r a1l iimes.
T
I':'\e'.-rco(r.-
s ) tr tr.,per \.DtnrS of hcat aDd other snie! todLrced bv
the r.in3 berlree ihe diilribnlor an rlfor in the r-!.eto.
\lo\t prcssLrjTed l:rgelos are gla) or drk bluc x.I ue
uscd o tubocharsed en!ines
\urne()us 1)pcs of hish !e.! n mngnetos h\'e bee
.'.,,'.1 ee. I
e(senial Io de\cibc ll rrp.\. The bsi. pifcifles are rhe
bc jxnre tor ll such rrgnctos. ud jr is o.lI eces\an o
delennine hor each is LcLl int.Nll! xnrl {r lhe ensire.
\ith good udcr\talLig ol rh. trincnes of operatior)
anil i irg. llc LcchDicix. .! unLallf xdlLrsi an) ]tlagneio
i,r salilc(or opcrdtior. jf th.rc is nv qtrestion cocerl-
ig p icnlar lrgrcl., d iL\ iNtlltion. the mrtrlc
lureis m.ttr.tls lbr he nagneto n ILe cginc should b
Reasolt5 for Developrent
Seleral lery sedous probleurs xll: cncotrnrcr.d j. rh. tm
dLrcrion ard dirdburio i,1 lle lrigh !oluS.. cclclt\ nred
1o fire ihe spark pllg! ol rr] i.crxli cn.rin.. Hlgh \oltage
eieclrici$ c,ruses co.rosi(n o1 rcLrls . deteri.rnl or ol
xriLrlatirg rltcrial\. El.cLiicit\ k) hs x rrked lellderc\
or frl to elcape liori thc rorte\ tro\ided for it b) dre desrgner oi
There arelu. frincryi cru\cs ol the lr'oublei encoLrlr-
lered ir
rhe nse ol Ligh'\lrg. iS.iri(i. !,-rr.nrs {t)
flasho\er. rzl xpacirnce. l3l Lnorslurc. n i1) high \olr
.1
Fla\ho\ er i! the lLrnpiS l dre high lohxge nr\ic di!
tribtrtrr \hn rrr rirpl.rne .r\cerds lo high hilctc. Thl.
oc.ur5 b.cxuse fre ! r i! le!\ dese at higlr .rlrirre\ nd
th.rcfr. hxs less dielectii.. or ifsuliang. rrerrglh.
tlo nd Starti ng Systems
 Clapacitance is (hc xhiliy of a coduclor o rore elec-
fUF
", ' .. , i I \. .r, -...tr., ,rr.
lAO NS HEAVY WIFE
L I l,
i ile high-tersr.ir lcns lior thc malneto to he sprk
rlugs cuscs lhc lcrls to srore x toio of the electric
Jrrge lniil thc loltgc is boilr ut n!fficieily to caLse the
.ful 1o iullu th. gf ol ! sfxrk tlus \\hen the spalk has BREAKER 13,OOO TUF
.rrrted nrl eslrblishr tth cn)ss th. gat, the eeryy
::,:,red i rhe ie,rds during Lh. risc o1 !ollrgc is dissitted i
i3rr:u the \rrk flug clcc(rodcs. Smcc tbis clischarge of NOTE: ALL VALUES OF WIRE TUBNS ARE
C VEN FOF COMPARISON PURPOSES
:r:r3v is l the rrm ofa r'elIulJ lo$ loltge an.l high ONLY & ARE NOT FEPFESENTAT VE
::neft. it bunrs the electrcdes and shofens rhe hl ol rhc OF ACTUAL SYSTEN PARTS.
. rk plu!.
\loture- r'here!er i1 ciisls. iDccs.s coDcluclivity. FlG.8-47 Loviens o iqnlion s\,nem
]hu;. ir nray prolide res arcl uDloresccn rc!(cs for thc
:!:3re of h;gh'loLtage elecicit!
High-loltage corona is lerm otten Lsed Io descrille a
:diLion oi frcss rcrcss an) insLlaior (dielectrlc) exposed hed no.rr rhc \tdrk flugs. This permirs the usc of sho
: high \olragc Whe the high !oLiaSe is lnlpressed high'lensio leads fronr he transforiner ro tlie sparli tltrgs.
.-:i\..D lhc condu.t(n of insulated lead and a) rnetlic lhLsreducig Lo large e\len! the opporrunitics 1r leakage
.:ii Dcu thc lcrd. x elecni.l slress is se! up in the innL of high tension rnent.
.:1.. R.pcrt..l tpli.rtio of rhis ltrcss to rhe insulaion An a.lrLrgc of e low tesion syfeln is rhat rhe fail
, :Ll .\ cnrorlly r\ult nr insulalion failure rre ol lhe trinrary or seconda[ of one rransloDrer wi]l
Lo\! tcsio ignition stsems are desifned so aI dre a lcl oly one stark plug. For erarplc. if thc primar]
::ih \ oltage necclsr) tu firc thc strk tluss is .oniied to indig is short.ircuited. o.e slark tlus will siop firing
,'.3rt srnall pollioll ol (hc ctirc circuit. Th. grealer tarl of bu! lhe engin. $ill coDrire to operae s'e11. Thc .lerd"
.: circulr ilnolles the usc ol lo\ volLrge: thereftre. the coii and spark phg t\ill Lrc dcrected when the rert rgcro
:rr lor!{ension ignition i\ rsed to describe quch r sy\ chcck js nade on gronnd run rf.

\'.n) ol 'rp be .. ,1rl "-r.r.rI

r::r,; ]n itre psi have bccD olcrcorc bl thc usc of D.w
:!rrlaing mterials lbr high rcnsio lcds. \'los egine
:.jrio syslelns oday r'e of thc high lcsion (ypc because
: :he high losr.tnd added $'eight of lor-Ie|sion syrers.
General Des(rpton
Operation of Low-Tensoh lgnton A low-tensior igition s)ster enrploved on somc olcle.
System rrpes of engines lbr lisht aircrft is the series 5-600 dcvcl
13 lo lensiol igrridor syslem consisrs ol (l) a lo\r ten oped by the Co|tinenLl Col]rorarioD. The rnodel numbc.s
.:ri magnelo, (l)
a carbo brush clistributor, nd (l) { are S6RN 60U fr lhe .lul brcak.r mag|eo ard S6RN 604
rrri-ormer for each iprk plug. Figure 8 -+7 sho$,s thc lor the single-breaker ragncto. These mgnetos are lso
.::rrip{l prrts of i sinrple loq-elsion s}siem. Because desigrcd lor left hd rotadon.
- r one \fxrk piug xppears in this dirgranl. rhe distribnror

Du.ing Lhc ol)ction of he lo( lension sfsem. snrges

' :l.ctrjcitv ajrr lererated in he rnagneo generaor coil. ELECTRICAL CONNECT]ONS
-: teak sur:e voltage ls L1e!e in excess of 350 V and
-. $l)'is ne{rer:00 V on rost installadons. This corn,
i:ri\.lt l^! loltge is ted throush ihe difributor to the
r--r! of the \Park phg lran\ftr.rcr.

Transformer Coil
e rr L,. J \'..1 lq e,r",,r
'! "f is. pulle{l oui of its case) o
coil "rclcs.opcd" (har
.r

-,,.
..:r it\ .lcsig. This .o I coosisis of a primary rd sec'
jr) \rnrding $ith
ciSorette" ofifanslner ion sheet HIGH.TENSION
- :i. center an.l dother cig.]lelte oftransfrmer iron shee ENT BE CASE S FILLED
AFTER ASSEMBLY W TH
-ounding Lhc fri.rry widxrs, $hich is on the ouisde A PLAST C NSULAT NG
:: i. \econclarl Nrdjg Lisu,rlly the translbrmer unit con COI\POUND WHICH ELIM
:\ [ro lro!1i)rm.rs. oe lbr ench spnrk p]ug in dre cllir NATESALLAFSPACES
"CIGANETTE'' OF TRANSFOFMR RON SHEEf
Th conplle institrmer assernbl) provide\ a compact.
::i\\eight unil .onlenie.t for ins|llaion
on the cylinder FlG.8-48 Trsiorer.o ior o\,!-rel^1o q uon svstenr

lowTer sior gr-io-(v'rpmro i91.airL"'c g^-s 193

 I

:a

/r'
FlG.8-49 Crnpof rt! oi Berr i S 60C c! .e5r q o.
;lnrm.'1.i!dlr. aorrret,
FlG. 8-50 [orpe5ted.m
T|e .n\rnelts ol tirc S 600 lo\ tcsjrrr \\srcr ire
sho$ll n) Fig 8 ,19. Thi' s!\tcnr l. dclig.cd nr rse on I 'l'his virrioD is cl.\jgn..1 lto lhe cam ro corrpen\rtc fo
sir-ct lxrder op|oscd cngi.c. Each i.lrllio .onsiss of l., . . , , ,et
'' JI'.r .- | lr'. rt be 'rs rnch \ 2.5' nrne or lesi thr.10" lr x nie
\ibrltd. h.r re\\ a\\e]l]L,lt. anslon]rcr.oils. high lcn\ui ct ll.ler rxdiil e|gnre.
lcrd\. x.d.jther r combirio| igririon-slller silch or x thc conlpensed cur Ir'\ at onc half ihe cralkshrti
sranddrd lgnitil)lr $itlh spccd bcc.rure ii proiluces spuk ior cach clljnder duri|g
Thi! s)stem is.Lesigred Io lererrle rr.1 dislribu(e los crch co.rt ete relolutior. Sr.e (hc cn.kshft nrlLst roare
\oltage .trnenl thrgh lo$'tension crbles to iyiul tltuugh two tns to ir1.e ll lhe lliston\. the .rnr cnn lurLr t
hi-,h \olt!:e rrxnsfo 'mer coils r11ourted oIr lhe cngic onl] oe half.llllrkshalr speed Thc .omteslted carn is
rrrnk.r\e. lhe l.N rollage ls sletped Lp Io high \ollxge ruorxll\ mouDted orr re srrre slxli lhlt dri\es rhe dis1ib-
b\ thc idi\ dr.rl rlr\iormer coils turd her codnrred ro nlor bccus. the disributor aiso r lun t onl! ore half
(he \pdk plug\ h! \hn engthr ofhi:h ten\ion cale. Borh
he lor urd high rc\i(r .bl.( rc shi.lled o frelent

Sol]]e r\rgcL(x reqrre jo\fecdon! 1 rcgular rt.rl\ 1o

Reasoh for Compensated Cam eriure lenicerbilir) Nlosr .rSieros sirollld be i.srcctcd
rfer ever! 100 h c,L ofcr(i(m or during the anul ii\pcc
In rrctirl cngine. be..rure ofihe orrrg of dre li rods Lio Some Irlagreros rcquirc a lxirly det,riled irspeclio
on rhc lla.g.\ of the nuster Fd. rlre t|a\el of rhe pifors xltcr 500 h of sel\'ice. lf corponcnrs are \orn or darnged.
conncclcd Lo thc ljnl n s i! not iform. \orlnall) ge th.l should be repla.ed. Celerall) no nLctunl repiri e
crpc.r thc tjst(nrs I a re'cJlider r.liri erlgine lr:j Fach llc ,r. '. ! r,l
TC.+0' lfart lh,rt i!. for erch.i0 ihe cr.u*sh.rit tLurls, '
_ll)C. sp.ifiralh descriecl rl1 rhe o\chaul nranual.
nothcr tin. r.rche! Sir.e he naser rod lips liol The nspecrion rd rnitcanc. of a migeto nre Lrol
sidc 1o
'id. l bil. it is.ir ed nL.d bl.rflihari. rhe
rhe
lik rodi lollos tt1 tllit)r.tl t)ath inslex.l ol (hc circnlr
dillicrlt. but the\ reqLue creful {ttctio t{r deil. Itr aLl}
case. lirllo$ Lhc i(ruciors gile in n atprl^e.L ina nte-
talh reqrlred tor rili,ri n)rcrenL For thi\ cxrm there lance nrnurl. A con1tlee inspectior ol !t r)sn.o geDer
is less thllL].10 ol crirkshrJi rr\.1 bcricc thc TDC posi aU n)clu.l.\ th. fo Los'irlgl
.or 'ror 'o '. r '11 I r' '
'lo brajn ilrihou t prcciscl) 15'- BTC. it i\ Dccc\sr)
io cornfelsale thc bickc . in thc nrgn.to b! tnN ding
I Romo!l of he rngn.to jn ccordxce wirh
ptr)led jstr.ucliorls The tcchDicia. nrusr nole har rhc
n seprrte c11r 1rcxch ctlj.dcroithe engme.
nrLgclo.ir.uit ls ljkel) I.i be in an 1)\ conditlon helr rl)e
P-lad i\ discon.ecred
Design of Co]npensated Cam I Rerno\i oflh. distributor blocl!. hich Lcn\jo tlae.
terjral block. or orher tn $lrich mr) hold rhc high re
\ c.imperslc crn iir r nnrc clli.i.r rxdil cngine i\
sho{1lm Fig. li 5(l Thc car lobc lor th. no. I c,-ludci js ' cer cle..er'rr '..r
rarked n jdr ctol.
x ct lhc djroction oi r(fri(r is \ho$n b) bl).
ar ano\\. A ccl!l in\pc.rio. ol rhc car sho\s \light dif lf'.. ' J. . ,.leor...-p.,r ..r
teteLrces org llic di\tn(cs Lr.($ccn thc \arious lobcs. bll an{l capciror ll lhc brcxkcr toint( ha\e a smooth ad
194 Chpter I Rec procatig Eng ne lgnjt on nd strting systems
 NORMAL PO NT IS SNIOOIH MINOR BFEGULARII ES WELL DEFINEO MOI]ND
AND FLAT SUFFACE HAS S]\4OOIH BOLLING I]ILLS EXTENDING NOTICEABLY
DULL GRAY SANDBLASTED" AND DALES W THOUT ANY AEOVE SUFROI]ND NG
DEEP PTS OR H GH PEAKS.
TH S SA NOFMAL CON
OIION OF PO]NT WEAF

(cl

FlG. 8-51 Conta.t o nl' (A) Norma \./e' (Bl Se,r.eb e .od t o (Ci Nonrer!.eb e

.r.rit apfernnce. as shon ir Fig. 8 5lA, thet e i b. Plug thc ;stNnren! fo\1er cord irro to\ler
.-od conditio. This rnens thal dre loinc are \ror| in and
.::rd lo e.rch other. hereb] proridlrg the ber posrible c See drat dre ef leds arc not shof.ircuited o.
:::nicrl c.r.tct !nd higher elciect of irerrra|ce.
'.1 :r irrsujaririe!. such as hose illsaed m Fig. 8 5lB. d. Movc te leiecior snirch lo sFr. rnd djus tire
.-, -ru-!hes! of poirf srrfces arc or hrrmful. ll rhe jnslruDrcnt forNro|er sefting wih he sEr knob.
- :rr seiJ deed pirs |d lound!. such ns in l-ig. e. TLln thc sclccn, ss'itc otl and conec e tcsr
: - :1r.\ (hould be retected. lerds io ie cp:rcior: onc lcrl to te.se afd one
_:ii.n oxide Dr,r,v occasioallt r' nr o the sufxce! leJa h. '.-r.d,e,, . '1 ' ,h. .,t".'o.
- i:._r breakers. This oride .rcs ns !t diclectric rd f. Set lhe isunlelr range for thc capcil{r being
:. : .u enl llos rhrouSh the close.l contdrls. A frst
: : i. :.nrcd! is to tkc r piccc ofstifl, clcan paper. such . a'r.l .
: -:r.!s crd. d pull il lhrough dre
closed contc ldncc bI rfrting the selectd s!ilch.
- . : : This rhould rernole the oriide: it' lt does not. rlre Do no hardlc lhc tcsLcr lcxd. e\cett $hen lhe selector
: - :. - rins shoLld e reflaced. sivirch is in ihe oFF positior The high \oltge ca cause a
. .:.ker polr]is should be checked for adeqLie
--:rn A op or t!!o of engre oil o the rll./,cll 5. Checking ol e nrrgeto shalt ad g.us for exces
, .- :.. ihe tol1 asserbll' $ill usualll resro'e the lubri si!e fll a|d brcklash ll lhcsc rc bc)ond \fe.ified lirirs,
-rre nrusr be taken thar o ojl gets on the breaker the nragnelo rrst be olerhaLlcd
. :r..ss oil nrusr be renroled. or else it my .ruse 6. P\nrinrtion of high-tensio! !irrs. \uch s the dis
' .n,hLirh{k (for. di\tribulor Itock. nnd tellnnlal block These
rributor
: : .:. tojnt sprig tcnsio can be checkecl br hookilg pafs lnr! be radc of FoDic, B{kelie. or nnother heat
.:ring icalc to Lhc nr!blc tonrt ad pplring \ui- -(.,Jr , ir .,.T ., :r' .",
. : .-J to opc thc potuls. Thc poinls shoLld not be '. rr
called dielectric pas b.cusc thct rust h\c high diele.
e.

| <o ,r . b..: . \e ir 1! . ic slergth to $ilhsta.| thc ignilion !oltige\. Defe.ts to

: .:r.d A $eak brcakcr poit \prirg $ill carre the
' : ilorl.'or lail lo close in lirne lL] bnild np ihe pri
i_ -: j ro lLrll slrength. This is nrof likel) ro occu at
r::.,:. The bFnker-poir a.e is !'lrecked for clen
, : :: ilre exceprion ofthe oiler lelt. nll fxrls \h.uld be
- : ::n An xtfrored soilerl my be sccl lo clcdn
:: a\. bur the solve1 nrust ot gct on tirc oilcr
: :.:rar cnpxcilor (codesel) shonld be tc\t.d \ilh
-r : :.rrdeser lester. This inirrunrent in.ludes rDges
: -r.! !rF. {1..1 ro i.6 !lJ. ad i 5 ro 1.0 $f,. lhe
:. - ::.e.red 10 n cornrodde lhe cqrcintr bcing tc\lcd
;,.: l rhe selectu xi1 rhc \11'I) (mjcrolafudl ftge
\lfl- . r. .. 1... c. ...p.. J!.
f.L .iL'.i' . .J T\ .r u .JT..'r!c
_: -r.Lfuctrcrjs insuucrio\ slro!ld be tollo$ed:
, :- :.\c \t.fs r.c gcnciall) laken:
):: ihai thc scl.cro slitch is ir the oFF posiiion.
look tor rre crcks. d.k lines lcarbon rr!ks) idicrrig
flasholer or le age, rl bunrilg. lr) crtr\ed b] lcrkagc
of high tension creL O\er tirne. a lhiD coLig oi clu\t
m! colle.t in rhe dirdbulor re. This clusl crn bsorb
enoush moisure fron the air io make i cordLrctile. so hat
Lhc high tcsi. crLren can use tle condLrcrive dLtsi as a
briltgc ro ground The currer $jtl ollen create bumed
farh rcferrcd to as a carbon track. Thi-c lrack beconrer
nu. conduci!e as the curcrr floq conlinues n.] erelllu-
{ll,- .t! s a shol ciruir The hol spli burns ihe insulat
rg.rateri!l xnd duir ard releses c$on. hich is conduc-
Li!c. ll carh)n lcks are lixl. tlref should be reinoved it
possible. Il Lhcr cannot bc ror)!cd. thc tart should be
Ieplced. All llc hish tcsioD pt\ shoul.l bc clcxDcd $rh
econmended solvol\ and thcn dricd dnd saicd \rith a
high-lerpelaturc !1ari
. T,o-o r.l , te. o I ,\r , /tl
Clolloslon problems car be aribnled I.i rL rumber of ditlr-
ent lciors lbr irstnce. $ae inlefiolr, operation in sah-
Maqeto Maitenan.e nd lnspectlon 195
ir e|\ircrmenr\ relte.lll) on frgn.\ ur hou\rfg\r. or The lgnelo -qhoulll be clerned rh{rro!ghlJ lrcl dj\a
rll ..u,. , : p p I

A nrgfer $ith r.log:..1 \cft flug or orilic. plug hul nrnnual. Tbe ugret \hould be hllled ctelirll) and
lp1.cssLrized n se\r \ i innx.o i\ rrinovhcic is shorld hxve soit-iron keeper or lhe troter \hrtc plccd
reiult ol elecnl. rrr fS l th. di\ribuLr! x.d subs{r.nl .rcr the toles ro prelerrr lois of magnetrsm Clare rur be
'. : jr r. Lr r t<cn rc ensure thnt he mlnei ir nol .lropted. jrl1ed. or
ritrjc \er\ hr luL trj rrc Lii.. j1crrl corto
acrr:1. srbjc.r.l to excess \,e hcr. ll of \'lrich crn c.rirse loss of
renrs. a.dsion or r.t.ri.rLion. il l.lt nrttfncJ. cn DrgDcti\r.
re\Lrli lf p.r rx!n.L(i f.rl!mn( qith r!'\LLlrl rrgh J 'pr ,., i p, ,l .,,...i'
coJnf:rfr|rerred rrry tr pdecri.ir) nd cor)!i|niencc ol hnn
Ch..lting.l int.ml tiDin! This b.r.comthshed as
N. dlrr:
elplaled ir rhe (iii.u\.i(, ol rgn.lo tiirriirg. BI rse ol
Ixnrl! lisht. t c.Lf h! {l.r.Lr f.Ll thl th. hreker froinls lnspecton
oteLr ar rhe F. Sp |o(iion lt'n..cs:r\.lh. ,inls c! be
. ..,' . .lr . f l The nagne rd Lnrgne shalt e rrsirecled ror phlsical
The ririn! f the .liir ibLrtr)r cx. !{ ll} be eterniled by danrrse an.l qear. The rfsnei sloLrkl ilren e rened ritlr i
forig thc tosjrio ol rrrL\ or the di\triLrror lear s tlr
re\fcct to nrdt.hig rr ks on lhe Jinfiblrrcr ne 3er. srr.n:th js ltdequ!e for operalion. Weak ml-enes can be
L). R.irrxlhLirlr ol lh. rnsneto \heir rlir is doe. the retured !. the nrnufa.tuer r renraSnel zxt on or cnf be
trc.edurc fr Lrg rhc mrgDclo ro llte ergine mu(t he f(il .r ,rFir 'r. -'r ": r' -l .r

The magnetomter is r delice lrcofpofailrg -qoli-iror

fil the poles ol lhe magel \her rhe
shoes desi:ned Io
mge! is.oecrly positioned n the shoe\. rhe i|dicrrr
sho\s the level of nrienetiin.
Thc ctrcjt(n (co.deser) forlhe trimary circu I is olten
replacct l mjor o\.rhxul tr) cnnr. . \rr operliorl
Il is lrn our ifre.r to des.ribe i detil th. olcrhrul ol n) liie. IIosc\cr. it js ot usll.- nccc\!ry to rcplace rica
catci(s jl a c.Lfacitdncc t.\t and l.al(age te!t reyeal saiis
be lon.L in rhe apprcprirte nrxnufxcrlrci\ mxll!xl. \\e do.
ho'evel. drscLrss dre geerlrl reqnureL\ ior o\crhul ol Thc cdfdcitce tesr i\ {..onrtlished b\' capacitr'
tlplcil nragnero (catcil{nc.) lester. is o\tlr.d treyiously. This devi.e
O\erhul of thc rrgn.to js gccrall) reconxneded applies crelull,- rcg1(ed rlrc.rrLjng ctr.rcnL to th.
rheD rhc cgnrc is o!crh{ulcJ. }hc oternig conditions capacitor. ard lhe resporse ol the cfcili i\ udicatc.L j
l ..r"..' et(r. '.!:r' r
inicrotrads o n indicIiLrs di]. A",/r ,rnd t
spced or \udder\ sloppageJ. nd atier .1 tears regrdles! of fht Ldtdtit te\ter. he.dust the i.lt.\e is i.t.tt d
ho$ l(rg lhe ixgrelo hs opelled since ihe l.rd olerhaul 'ts rhnh can be nuttn!s rt e\tn
lettt iiLrdt
or sice ils p!rclse. ltlgner., o!erhul irrvol\es at least Leakge. iftlicating fihre of e cticlccrric. shrtrLld be
l. I r! . .'.,1-..1. efed in accordrce $ilh rhe llrnnulxcttrrcr'\ r.connncnda
rcpir. r.placene|r. re:rssembl). nLld tesliig. Erch set ions. Usull,\ this Lrvohes pplicdon ol irecr crrcnt
r.'o(.. rp, ( r.. lnc of specified !ohase lo the capxcilor Nirh i millianelej
ren ole rlul nanual. Durifg olcrh l. rnn) n)agr)elo hook.d rp in series. The rmout of lelkxge is i.di.eted b\
pa1s re leplnced. Some conforeft! rc docrned lt)0 ter- i ., e
celrr replacemel trts. nd the! n st bc r.phced drrmg
t .i.\
olerh.rtrl. Although which p\ rre to bc r.plced ivill !ar) Tr i r I rL 'r 'l ' .,
.rl .':'.r" .,r .,.rr '.'i blies . Thi! $ill ..sure blt
rcplaccct t mrtor o\cihaul.
'ee'-
erl lis of itenr! lo be replaced nt olcrhrul: pcrlorncc n.l mriunr lilc. Wom point\ rn.1 $.r
clrl lolloqcIs, c\cD though rccodirioed..annor pr)!i.1e
Di\lribu(or bl0ck ard he durbiiitt nd perlor rc. 01 ctr sscDrblics. A ci.r
tolloser rorn be)ond cein liuritr sill rxlc it iinfo\sibl.
(loil Fcll rrips ard \1 rsher s ,u. t, re l e. l-- p
'
The brenker cam is iLrsirecred lor \!co n coD.liLx. I1
Oil,cdl Gxskcrs the qea. is be)ond stecilied lilir\. thc .nr rust b.
(irtrcr port r\\cmbl) C.rtlcr pir replaced. The cam snrce nrusl bc \mooth l.d li.. of fit!.
corrosion. and other \urlac. d.li'cl\.
The dilttibll'()tor is clcncd j n.|fmred \oh'ent
nd eral]lired lbr cracL!. carbon tra.ks. or othcr s :s .f
Recevn9 ad Cleanng filtrre.'lhe lrelrr used for clening rust bc ol r t.-p.
hich r ill or dmage lhe fiislr ol ihe rotor Li\!all) licr
\\h. r rrgcr. is rcc.ircct li, o\crLaLI. all peier rsl)e.tio. nd any other tro.eliifg sfecified l he n)u
jnnrnLio \uch \ rkc. lrpc. Llld \edal runber should lactlnrr. !h. rnor is colcd \ilh a hish-ernperate $ri ILr
bc rcordcd .n thc $ork orclcr Iir ;Lddiion. lhe serrile 'r irJ :.e.ri... .'r Ior ro,r'o tr..
r.rord of thc ragncto shoul.l bo DoLed. tucllrding dre tinre Shft bearings nnd disibutor be.rings are Llipecred nd
ofopctutio sincc iLs purahasc or snlce e lst overlraul. ir r .-er\-\-:l
196 chpter 8 Rec procaiing Eng ne lsnit on nd startlng systems
lorjes. Since hex inss xre rnnlly seled. it is re.ommended
rhrr neN belriSs be i.stxlLe.i rl r or ole|hu O\,edrl
mnrls \rnr.lirc\ t^'irlc iSlitrrjos ftr th. rccondj
Iionirs of sertled berrins\.
The coll of n ligh enslo! rn:neto icluLlcs borh a tri
Drr) nd sec,rdar) !\nrdrng. SoLne coils;n.Le rhe tri
mart .ipacjior r the coil. The coil should be tested for crr
rent lefkage bereen the pinrary d secondrr wj..1ings,
lbr contiNi\ of both $'indjngs. rtnd for icsisrxncc ol cch
rndlng. Re!i\lance lan be checkcd with an ohnncrcr or
rullinreter with trinrnry lead to Srcund li)r thc trrt.
d lgh-te|sio| conrac to ground rbr the secodry'.
Assembly
\licr ll !rlsre irrspected- teed. ard frocessed in c.or
dance wilh irsruclions. he nr.tsnet! is rerd\ ior \scDrbl).
The sequerce ol assenrhly frcedu.s is dcLcnincd b! the
Inke and Iype of ln.:neo
The plrciiral lctors in asserbl\ r. fropcr hadli.g 01
,l.l ,: , -^ I I :..{r.. r'.l'
f'
ol ,c ', '. .l. l i l- ,.r' r
iion\ rel.rri: ro $senrbl.v xnd tinring.
Testing Magnetos
Lpon cornpletion of .r seN ice j\l]e!tion or x. olcrhaul, a
1agnelo should be rested o a nragnelo test siand. TIis
slad inclLrdes \,ariable drire to FnniL opcrrtion of tle
nagneo l ant desjred speed. a rachonrctcr. { stark rack,
and sritble c.iols. A t\ficl magneto Lcsl \td is sho$r
in FiS.8 2.
'lh. lc\t srrDd is cqufpcd li)r bolh base rnounling d
flange nlounring. The\e nxrunting\ are rdjustnble to permit
accunle lignenl o1 rhe lesL frL ddle ro he mngeo
,hali. The re\t sland is rclcrsible. so he magneto ca be
rottcd to cilhcr dre ighl or the leti, dependig o rhe
requiremerl The operar nNr tke plticular care hai the
mcnero is rotrerl i. rhe.rir..r dire.rio
FIG a-52 A m.e1.1esi s1;nc
Aler ihe rnagnc(o is rnoulo on th. rxncl. th. hiSh len
sion leads are colrll.cred lrotrr th. di,tribuLrr l() rhe sprk
rJ(k.T,e |\,.\ 1,. :irL . - l
iied Io1 he prfiiculr mrguelo beirg tcncJ. Norc rb{t drc
gaf used tr he spald rck i-q urucir gretcl thxn thc gp oJ'
a sfark tlLrg becruse dre cuell rr r prtic!lnr !oilagc will
jtrnrp x ruch grertel dirance nr urlncsnrcd ii lha r
the .onrtre\sed r in .)linder.
Thc c.mln:t in sF,.d of rxlrneio is I lood idlcriiorl
ol lh. .igcur'\ pcri(nmancc \!iLh rhc \fdr !rrf sei r the
spccilicd disL{cc, thc magncto r'fm is slo\lI i.creased
$hcn rlrc coming i \tcc.{ i! ittied. there is r ltead! .lis
ch{.gc 01 spirkr t thc sfrli gts. The nr{gner) speed s
incrtscd Lo Lhc marimur \f.cllid rfm Lo t.\t hiSh !|eed
pcrinnracc. Strch tcsring i\ con.hct.d f(n ltccifred teri
ods 1o ensrr. raliblc pcrldmacc undci ofcaLi-e ofdj
It ihe connrg llt speed ol a rnagclo is tln) high. lh.n th.
mag|ei is ireak. dre inler,lrl lining is ror corrcct. thc
capacitor is defclile. or lhere i\ sore olher dei.l i thc
rnagreto. The magler can be tesred with r nugcL(ct.r
(Guss meterl! il $crk, it co bc rcchxrgc.l with a nr{gnct
chgerol propcrdcsign Thc cdtrcitor cn be restedsidr r
cafxcilor esler. s c{pli|cd trc!iou\l)
I)urin3 tefing ol r rnagreo o1r tesl stand. lhc nragcLr)
ru!1 not be oteraed ithoLt rhe high-rer\ior le \ cor
ncctcd nr the spnrk rack or \ithorl some olher nerns
\yhcrcby the hi-eh tension .nreft ca. flo io grorild. ]f the
cu enl cnot dilcharse lhroLLgh ornlnl pnths. tL. voltage
will build trf to x lerel whi.h nrxy bre k do$ e insnla-
tjon in the magneto coil and lllh the coil. The gp of the
sfark r{ck mNr nor be jncrcased 1o such.r siace tha the
spk cnot jump. bccdtrs. the hlsh !olrase currel ill
seek aothcr tth to gurrrd rD.l this \rill .lxmase the coil or
The \rne drngc nrI occu during opcrario of the
engine rr llight il \park plug lolcl shotrll huk .r jl high
resistnce should oc.ur nr r igjrjo lcad lor anv olhcr
Fun(tion
The spli trlLg is the part r,1 e ignilion slrcrn in shich
dre elechic erers ol e hlgh loltgc cfr.lri p1duccd bt
he rngleo. or other high-tesion delice. is co]rlefted to
dre heat energ\ requied to ignile he F/A InlxlLre ln dre
.ngje cyliders The !f.Lr plug prolides an x;r gap across
$,hi.h the high loltale of the ignilion slrenr troduces a
sfrrk 1o ignile the mirrue.
Construction
Ar aircraft spark tlug fLndrDertally coLrsirs ol llucc
major parts: (l) dre elec.odes. (2) he cemmic jnsulalor.
and lll the neral shell.
l;igure 8 53 sho\a! thc conflrjclion teatNes of a tlpicnl
{ircraft strk plng. Thc asscDrbl! shoil. in rhc cenrer of the
sparkflug is the iner cl.cr(xlc \scmbl.- consisting of the
Lcmrinrl coDtacr. strig. rcsjstd, brx\\ c.Lp lnd c.duct(\'
lciLhc. labcl.d nr thc illusr rion), Dd lhc Dickcl cl!d.ot
spark Pluss '197
 CERAIC INSULATOR

fERi\4INA L CONTACT

ELECIFODE

rlc.8 53 Shle ded sprk N uq lamplon 5prl P/ug Co) FlG. 8 54 5D;+ pllq \! th rr d rr e e.trods. /Chmpro

pcr electrode lho inrrLtor. slros. bel$ee th. ele.rrode

a\\crnbl) and tbc shell. is nide in t$o sections The rai
secLid erireds fi\n the lenlnal conlact to x poirn near dre
electode tif. lhe bdrel-insuLrting scction e\rcnds fio'n
ned e top of dre shieLding blrrel lrr eotrgh 1o o!erl.r!

The ou.r sccrion of he \park tlu: iLlurrred i tig

E-51 js a mchined seel \hcll The ihell is oiie tlate.l ro CTAMP Oll

eliminatc co.isio nd to jduce the tos\ibiljty oI thrcad

seizure. To tre\,er the escape of high prc\sure Sa\cs ftorrl
the .!lincr of lhe en!nrc throueh lhe sfrk plug a\\cnnrl,!.
it.inl pressLre lcrls. such s llrc .errer seal dD.l lhe
seLI. re used bct\eer dle oulcr slell .1 rh lsul-
-gla\\
!or n belween thc isulor and thc center elcctrode

The ihell ol Lhc rpa* fltrg ucl'rdes rh. ndio-shieldig

bxrel. ]n somc s|rk plugs. rhc sbell and \hieldtr! bml
are made in t\!o \ectio|s 3nd rrc scre\1ed r)gclLer. The tso
prs should e!er be dj\\sernbled b) (he e.hni.ian
becaLrse dnrirg ll1aruf,rcture 1hc conect trcssure is attlicd
ro Fol,ide x S$right seal. An) dirurba.cc ol dre \e!l rx)

The \hcll rnd the rdio shiel{ling blrrel corflctc Lhe

grotrd ciicuit lirr thc radio shieldig .rl the ignitio hr FlG. 8-s5 uns e ded sprk p Lr! icampn 5prt P/rq
ness. The lhell ii ext.nall) Ihreaded on oth en.l\ so dral t
.an b. ioined t. thc rdio shieldmg of he ignitior hanress
at lhc lop rd can bc sceired irrLo the cylindcr head ai lhe ,\noher inrproreme|l $'hjch lcds Io gret.r dcPcnd-
abilii) and l(ngcr lile is ihe use of iridiim-llo\ firnrg Lips
\:r-. tl.; ' .lJ,rt. Jl rJ" ,\ slark plug sith thir l-.''pe ofconstruclion ls illlLstLed i
"h I

Fig E 5.1.
co\rrucion to mccl lhe denr{nd\ ot' aircrlft cDgmes.
Resisto-t]pc sprk plugs are desigDcd to reduco the bnl Unshielded spark plugs arc srill usod ir a fe$ light ir
it]g and ercsio. ol .lecrodes in crlgies hrling shielded craft ergincs..\n lrshielde.l \tark plug is slro'! ;n Fig
harnesse!. The caprcitace b.lweer he high te|sion chlc 855
,. ( h.IJ:r' r' :.'r I or( 1...r ce.e-.:l Thc conslruction of sp'rrk pluss for ircrali engines is
qurtities \hich produce a corpratilelr high-ct]re.t .lis frdh.r ilhfrated in l-jg. 8 56. The lpark plug olr lhe lelt js
chrge at thc sp]t tlug elecltudes The .ncrgy is consi.tct the nrassile-elecode type. so narned becatrsc ol he size of
abll grenter thd i5 necessry Lo fire the F/A ntrrre rlr('e thc ccnrdr ird Sround cLccrrodes. Thi\ lfrk plrg is a re!i!
lre. it cxn bc rcduced by mcs of .t rc\i\tor i orilcr 1o n L\pe thai reduces .lccttode erosio \ickel seals are pft)
povide grcaLer spark tlug liie. vi.lccl betNeef the insula(or nd shell to clcilelv el;mi

198 chapter 8 Reciprocat nq-Enqine jgn rion and 5trtlnq Systems

nte gls lexkgo. Thc ccrncr clcctrodc cosists of a coppcr
coe i\i a nickel-lloy shcath. Thc insultor rip is trccsscd
to majtain the proper tempenturc Io trevenl lbuling and
led bLildp The thee groud ci.codes re ade .il
nlckel llo) and e desigrect 10 be cleaned witlr a llnee-
blade vibntor tml. Thc cetcr clcctrode is sealed aginsl
gas leakase by a
eal-glss binder.
lhe sfffk phLg on the dgh
Fig. 8 56;s
tyl]e. ft is similar i
conn]1lcion to lbe nrassive elecde
Ulug cxc.tt rin th. electr)des. The ceter cl.code is nde
of platN. !d thc two ground elecodc\ .c cormcrcd
of either platiDum or iridiun]. The use of platiunr and iridi
unr ensurcs marinrtrDr conduclillty and minimunr wear.
In Fig. I 57. n)ur lyticxl fornr! of electr)de construc
tion re illustrated: elecdes of the pro.cted cr,re nos.
trlo-prong fine-$ie, tso-prong ground. a d push,wire
'l he projected core osc sprk tlugs hale beer dcrcl
oped for use ln ergircs lhxr h{!e hxd troblems $i lcd
louling of plLgr. Whlle the prqc.re.l core nose does nor
nece!sarily prerenl the rccurulation of lead deposirs.
1,. Ii d(.:, r..:r.Joh. 'i '- J..fire I .e.ee
a re-wire lerd buildup.
Spark Plug Reach
Rcach is determred by lhc licr djstce tioln ihe shell
gasket se io lhe encl 01-lhc shell threads. comronly
referred to as he shell skifl. An e\rfle of spak !]ug
rerch is shoq'n xr Fig. 8 58. Thc reach or legrh required

II]ASSIVE E LECIFODE fYPE

FlG. 8 56 f,*lve e e.irode .nd I fe r/ re spark p uqs $GL Aubt)rn spark Plug Ca )

PFOJECTED CORE NOSE

FlG. 8-.'57 Typ. type5 of le.trodo r:onnr!.I ar laharnpian Spark Pluq Co )

spark Pluqs 199

 L No lerrer, E. or H. \o lctter. un\hictded: E-rhictd
ed;; in.2.1dredr H shielclc.l l: i.2{l rhrcad.
- \l.i .,o eJ!,...Jhe
'L.rl -u e

l8 lnnl. 1,. r reach. fa r srock hex.tgo

b lll nl. r,,;. nr rech. ,(-m rilte.L hexco
d l8 nrm. )l-in rc{ch.1 in rock etiagon
j r'i nr redeh. 1r,; jn slock he\agon
I -1.1nrm.
n1i !inrec l/i in stockhcragon
-14
' 18 nln\ i reach.I nr.rilled her.tgo
Ii
FIG. 8 58 Spk p Lrq re.h .1. Hea ratiDg range. Nnnrbcrs orn 26 rr) 50 rdicrte
coldcr 1o hol{esr beal range. Numbers ii.inr 76 to 9il ]dj
for a gi!en cngine is derernincd by rhe cllrrxle-head .rc stecil-ap!liction aviati.,n plugs.
5. C.Lp nd el.c(rode stvle. E two pros aritiol N-
desigl. The tiofcr plug rech \ill cslLre rhat rhe elec fbnr-pr)ng .rliaor)r P plntinulrl tirc lirei B
des a,e posiliir.d at the mor srilldctd.y dcpt in the rwo prlDg
combNrion chnn]Lrer to ignite the iuel. massire. tangenr o cenldr : R push 1l,ire 90' ro cener.

Classifcatioh of Shell Threads Heat Range of the Spark Plug

Shell threads ofs!rk pl'rgs are clas\ilicd {s l:1 or l8-nnn
dimeter. long rearh or slrt reach, drus:
Diamlr Long each Short rea.h
l.lntr l in 112.7 innll ;,:irL953nnl
l8 nlm l,r jn 110.6lnxnl !inLll.Trnnl
Terminal lhreds ir the rop ol the radio-shieldig sprk
plu:s re eirhcr r in l15.8rl mml 2.t thread or tl i
119.05 n)ml 20 lhread The lucr q?e is parricnlarlr- itrrr
ible tr high dkittrde fligh and for odrer siruai.ins wher.
fhshover sith rhc sleeve mighl bc trobler. E)iarplcs
ol shi.l.led leminal thrcrds de shoivr tu Fig. 8 59.
Thc desjg.rtion nurnbox for spak plugs indjcure he
charctcridics oi he flug. The Uhanpio Spark PlLrg
Clompan) utilize! ietels dd numbers o indicarc whether
the sltk plus .onta s I rsi\tor afd o idicatc thc barel
svie. mounting thread. rcdch. he\agon sizc. h.{t rrtinc
rnge. gap and clecllode stllc. The .leslgnarlo]rs arc xs nn
I \o .. r: < ll. R . .P : r<.r.or-
tlu:.
The het rang of a stark fhg is rhc |rlcjpat fncr(n gov-
erning ircrali perlilrance ucler yarious ser\icc condi-
tiors The tenn hc{t rnge rel* tu the clssilicsioi ot'
stafk plLg\ xccording to dreir ability to tfanslr heat fun
rhe trig end ofthe spark tltrg tu rhe cylinder head.
Spark pluss ha\e been classified as "hor. noru]. , nd
''cold." Ho$e!cr. lhese tenns ma! be rislcading becaxs
Lhc het ra gc v{ries though nry degrees of temperarurc
lll)m e\tremclv hot to errcmcl.- cold Thus rhe wod ,hcn ,
or col.l or'unral docs.ot necessadh tell dre \,hote
Snrce the tusulat.n is designed to be rhe horLcst ltn of
the spark ths. its t.rFfatLue c bc reLnied ro lhc preigni-
tjol r cl louling regions, rs ihoqr r Fig. 8 0. ftcigitjo
is likel) h) occur if surixce nreas i the comburioD cham-
ber exrecd crilical linia or f rhe st* p ug core ose tem-
peralrre cxceeds l610'lr 1888'Cl. Ilo$,e!er, fouljn!r or
.. ,,,;.. o n' ", lepo. I .e.-
"
i ,e r 'r, r'i.r.r't..' r" lr".o ' .' r, r.. r. ct:
ll00"F 1.127'Cl. lhus. sp{rk pltr:s nnsL operrte ber\!c.D
fLirlt well-detined tenrterature linrits. nd so ptugs nrust be
p. -(npphcd in larioLs h.t ranges to rn.cr dre equirercnts of
dillerct cngxres undcr .r valieil ol opcalirg condiri(rs.
Fronr the engrrecurg slxndpoinr. cach irdilirl!l ftug
r'r b. 1". -,e. o rr l.,,,ert,..,1t. .. :
nge This means rhr a gilen type ol spnrk ptug shoutd
oterare a\ hot as possiblc t iow speeds and lieht toadi Dd

.// ../p.,. cN r ////

SH]ELD NG
1750', a// 2N J)r.
1954.44' Cl
"ar/ ,,' ./
.r">-/
revc I ,a{t/ ,{t-'/
^+cX-re ",osl
SHIELDNG
^ llj",,o!t/ *,w'ilZ
WITI] "YgZ"+9)-
,,. ,'a}"
(B) ',.'/, / , / / , /, /
' 1371 00 cl< / / / /CAIAFOULIt)3'/ / /
FtG.8 s9 IDLE CFU SE CL MB TAKEOFF
[1 5 88 nrn], 24-Lhed 5tdndrd des q
1B)l,l n t19 05 mnl, ENG]NE POWEF
20 lhe.C \',,rether des:g ,'hrch n.o'portes r nproved
se to prelei etrt of mo 5t,re FlG.860 L" o o g po qp

200 chpter 8 Reciproctlng Egi tgnit on d srrting Systems

:i cool as possible under cruising and lakcoll rowcr. Plug
r:rfu,mxnce lherel'ore depends on tbe opctuLing Lcnipe.a
1re of he insulat(r nose. with the mor dcsirable terpen-
:ure rnge flling betwee 1000 nd 1250'F [5]8 ard
ri'cl.
Fundanlentallr. an eDgine which runs hoL re!uires rela-
:r\elt cold strk plug, shcrca! an cgnie $hich nlns cool
:.qnires rclxtilcl) hot spark plug. If :r hot stark pltrg is
:nltilled nr n cngiic $hich nmE hot. the spark plu-q tjf rli1l
.: ovcrherled nd cnse preigdio|. ti a cold spdrk plug js
:n\Lalled in n engire whlch luns cool. the lip of thc spark
,.lug e,ill collccL unblrned cr'b.,r. cusing fouling of thc
tlus
A di\cussio ofhot. norrnal. rnd cold plrg\ is technical
\ conrjcL.bu L we mu st erpl]nslze fhat ill. rc Dr h.ar nnle \
ii arrufr l\ak llugt td lot bt sub:itut.d d )tdtilr, d\
:t .on ra in auLottD^: prd.i.., bec{usc the seleclio| ol
r r. lJ's pl, -.:. - er -J | \. r.r r.r. le run
:rtcturers' ad the FAA appro\als govcming lhe use of a
rricular st.rk tltg r ay nrrilt cngine.
The princip.tlfactors govcming thc heat range ol alrcraft
ipk plug! are ( l) lhe diltancc bct\lcen the cotpe sleeve
.rround lhe isulard lnd th. in\ultor rr. (21 the lhernll
onductility oI thc isultiDg nut.rial. (i) dre rhernxl co
Jucrility of the eleclrode, (.1) ihe rate of hel lfxnsie.
bJLween the elecode ard ihe msLrltor. (5) the shate ol thc
i.\ulrtor tlp. (6) the dislance bet\yeen thc insulaL(tr Lif and
ihe shell, ard (l) he L\,pe of orside gskcr us.d. Hor acl
. l.tr!." . ..r, . r',r-,,'fi:a
Oer larure, ol spa* tlug consl ctio nr) rllct thc
-,ee.,(, h,ec rr.i,.r"
ri.,led a1e those of prxnary co! der!t()n. I all cses. tlre
Irchicj.rn !hould infltll thc r)fc ol sprk phg approved
ior thc tricular cDSinc being ser!iced. Spark pl gs
rppr)red for iD\tallatio i an egiLle are lisled in the
.gie Type C.rLilictc Drra Sheel Sorne ranLrfacrurers
u\e color code \ystcn or lhe cflirders to rdicate the
hcal rge ol.\prk phgs to be irslalled.
Servicing Aircraft Spark Plugs
Scheduled servicing Lrerl,als ore .all) dcrc ntued by
rhe irdilidual arcralt operalor. l hese inrcr\rls Nill vrry
accoding Io opernling condirio\,.ngine models. ard
\park plus lyles. The princip,rl dereriiniDg lactur in he
FlG.8 61 ao!ir!.io oi hot o.od 5p.rk pl!!s
rcmovl ad \crricing of stark plugs is dre $idth of le
sp.rrk gap thr is. thc di\tace hetrveen he elecnodes
qhclt Lhc spark i\ produccd. This sfxrk fhg grt widen!
with rse util lhc.li\tcc bccor.\ v) gret hit the stxrk
tlug usl be rtnxrved and eilhcr jglpfcd or r|lccd. Il
rhe spard tlug gap bccores 11 \idc a highcr sccondary
loltage nusl be delelotred bt the itnirion slsleni in order
tu cEoe a slark ai lie gxf. Tis highe \'ohage irill end o
lerk drr gh the insuirtio ofthe igitio \'iri9, elentual
l"- carsing lilule ofLhc high rcnsion l.rds.
Thc corrcct rpark tlug gaf lor a trticulr strk tlug
instllation i\
establishccl by thc mrnofcturcr. No spdrk
plug should be opertcd wilh 1gp grcaLcr lhr that spcci
licd i llrc rnrulacrurca\ instftclionq.
Servi.ing Procedure. Ir generrl. ircrafi Efark plugs
re serviced ir ihe fbllo$ing seqrence:
l Remoyal. Shielded terlllinal connectols are
r., (dbr l"o.er r!rl F. ' ',,u, rlF {ofer '.F
crowlot or open end wrcnch. Care n st be taken lo avoid
dal1lagins ihe e1bow. lelmial lleeve assenblies msl be
tLlled our ul a straighl 1ie o .rloid damgig eiher the
sleele or the barel lnlrlaror.
'lhe spark plug is lisened fronr dre cylinder bushing by
rLr. f l .i .l'o .l . r. .' .I i. rc."rr
rncnd.ilht a six poil $irnch bc usd becus it pro\ides
a greaer being sufce than a l2-poin $'r'ench. The sock'
el nrlsl be seled securel"r or e spark plug he:igon o
a!oicl possible clarl]age lhe isulor or co reco
e As each rpark plug 1s renoled.lI should be placed in a
ay wlh rurnbeed holes so dul dre englre c)linder fiom
which the sprk plug has been remoled can be identified.
'lhis is imprtat. he.ause the.ondilion of the spark plug
mi,\' indi.re inrpeiding friltrre of some p of the pi\to
or.yl;nder assenrblies.
lf o x hard surlacc. ccks m,-
spxrk plug is droppcd
occur in lhe ccranric in\uldtrcn which rc not af!rent on
visual e\nrinrio. A \ tratk plkq has been
toptd k ",hitt
b te e.rottetmret.lE tanfauzt
when ihe hreded forion of a spaR plrg bre.rks oiT i
the c)llnder, greal care lnust be exercised in the rcmo!al ol
the broken leciolr. Nornr.rllr' i w jll be c.c\\ary to rcmore
the cylinder fronr the enfine. Before an attcmpi is nidc to
rcmore lhe sectjon. liquid fenetrant shoul.t be {ppliccl
around the thred! rnd llowed to strcl itr xr lcxf l0 mir.
lf rhe bmke pnlt i! trpfcd lighrl! wjrh thc ed oi a plnch
ivhile the pecdnt i\ v(nkilg. lh. librti r will helt lhe
lictuid to cL.r Lhe spLce bel$een the hreads. The elec
troclcs ol lhc phrg should be ben oul of the wa) r'ith a pin
punch or silnilar tool lo perrni he inserjo of a scre\t
e\lraclor (Ea\!out). ,\ readll_\'icreasjns torce on he
scre\! e\rfact should be enongh to rerole dre broken
If this prcccss is oL slccesslL. the {he pIl
rLn be
r'cLt1oled b) cullit]g \\'ith a s
all metal sa. SrLch a saiv can
e rnade by cunrg a .rck!$ blade o x siTe \rhich c bc
insered inside he !tx( flus scctio. Tho \s lust be
caretillt naDitulnled tr) ctrt thrcc slol\ iside the section
Nithoul ctrtli3 deetly cnough to Ldrch lhe thiecis of he
cylinder. The bree sccrions oI lhc t can then be broken
out bI usinr i punch rnd .1 light hannner The blo$s should
bc djrected t(varcllhe ce|ter oflhe spark plue hole.
spark P uqs 201
 After the broke polLion of the ilark plug has bcc
rcto!ed. the hreads in rhc cylinder shoukl be checkc.l
crcfirll} lor danrrge Usullv thc Lhead! cxn be cleane.l b)
eans oi I drrcad chse. If thcrc js .Ltpreciable damge ro
the rhrcrds. n Heli Coil insert should be xrstalled. See
rstructio! in Chat. 10 on o!crh{ul pcices.
2. Peli'ninarJ inspection. Imnrediarell afler
renolal. rhc sp{rk plu]rs shoLld bc gire .reli \'isual
inspection. rd all trnseN ceable plugs \hould be discrr.led
Spark phgr with crackcd insLios. badly erodcl clec
lrodes. drmaged shcll\ or damaged rlrrexlts \hould be
3 Degresing. All oil nnd grease should bc rcmoved
liom both the inrcrior ad exierio of thc sprk plugs
accodirg to lhe degia'asing nre rod apprLrled tI at par
ticular ype ol strk pkg. hither laror degresirg or rhc
usc of solvenls. such !s Sloddar.l lven. ;s trsullt reconi-
rnfn---1.
.1. Drling. After they h\c bcen de:reled. lpark
plugs \hotrld bc dried. rside rnd out. to rennr\e all ces
ol $l!ent. Dry conlressed air cn bc used, or lhe spark
plugs cD bc put in,r dryjg o\,en.
5 Llleanig. Dnring opellio of an air.rri engje.
lnd nd carbon clcposits form on h ccraric core. the
electrodes, and the in\idc of the ifak plug thcil. These
lcposit! are Inost eadil) rcnNed b) an absile blasrug
machlc esFcialll designed lor cleanir spark plngs.
The trse of ar abrrsi\ c bl{st lfark flug cleaner is shosn
',.i-8h lr rl- r.co ..,e.r,,,:
!t ldall lhe propcr \ire rubber adaper i the clln
.r. {d tress the l ing cn.l oflhe \park plug lro rhc
b. Nlolc dr. contrcl lerer lo A!RA\r\i, B.rsr. af(l
slolrll $1)bble tbe sprl phg r d circular nrotion
for 3 Io 5 s. The $obbling-Ir)oli., agle \hould be
o glealer lhn 20 frolr lertical ro penir rhc hr!-
sjve rnalerirls tr) frely enter the liring ed of.ning
nrd to lcilitdtc .l.ring.
c. Conlinuc thc wobbl;ng Jrotio nd royc he
lerer 1o .\xr Bllsr ro rerno\e tbe xbrasive prticlcs
1rn the lir o hore
FlG.8 62 U;e oi b'5!e b rt rp k p !g ceer
2O2 chapter 8 Rec procalinq Enq ne tqnitton and Starting Systems
d. Rcrove rhe plug Dd erarnine jrs li.ing end It
cleaning is inc.,nplctc, r.fea he cleaing cycte fr
5 lo l0 s. lf clering is still icomtictc. check ihe
clencr od replace thc abrsive. For complere ser,
vice inlomration. relr to thc manufctur.er'\ serlice
Se\eral corpnics ofter s!rt flug clening machjes
lridithe abmsile suppofted in liqu . This is an excellet
cleaillg rethod, but thc operartr must rnake sure hai thc
abrali\e i\ of the aluminm oridc ilpe. Silic abralive
car contributc to late plug louling lnmeditcly atie
cleanirrg by the wet-blst ierho.l. the plugs shotrld be
oven-driecl to prelent uring aD.l to ensue I satisfactory
E\cessirc u!e ofthe abrasive blsr should be avoiclcd. to
pre!en oo Illuch welr of he eleclrcdcs nd insularors.
Strk plug threds arc cleaned by usmg a $,i.e ilheel $irh
sol] briltles. Threds which are sllghrly jcked may be
clcDcd by using a ch{sing die.
The coector sear r rhe tof ofrhe shicldig b el musr
be clcaned io provide a froter leatlng surhce for ihe g\
\. ,Jr., .r 1,..,1 ,,t ,(rlr l|or '' ... L re.e...l
lic erained garner paper or sandpapcr nray be sed ro
srnooth the seat. E1err p.Lt.r ;hord ror bc nsed becarse
rhe erctr conrtound conducts electrici! ncl md\, establish
o path for lckage of high loh{ge curen Aficr Lhe sea is
cleaeil. Ihe \hiclding a1Tel shoald be rhooughlr- blown
oul wilh an rir blalt.
6. Regapping,'lhe ools nd mcthods used ro seL spark
plng gats $ill !rv !!itl the shatc: lype, and araDgcmenl
Tbe gap in x) sfark plug ii casured b! round wiro
eage!. These gages a supplled i t$o sjzes for each gat.
1o mcantre boh the minirnun ard m\rum llidrlN ibr lhc
g!. For example. a sprk tlug gap ggc will have rvo
illrcs oe 0.0i1 in f0.279 mnrl in dinrcrcr xnd rhe ocr
mesu ng 0015 i f{).:l8l mml. wher thc stark flug gap
is being tclted. rhe \maller dirnesion grge musr plss
rough the:ap and rhc larger djmesion grgt .rust be oo
lage 1o ps\ throulh the gat. A gnge for checkng rhe gap
clexrance o1 sprrk pllg nd c corect meth.'d ol irxcF
tion are \ho$n ln Fig. I 6-1.
Il spark plug gp js too ].rrge.lr is clo\ed hy nreans ol
\pecial gap seting rt supplied bl rhe nantrf{urcr ad
uscl accordjng o thc manufactureis insrtrcrions. A gap-
sctling tool is show i Fig. 8 :r
Il the gp of a lbltr or two prons strk plug hs been
clolied beyond liruts. no clftnt shoukl be nrrdc ro ofen rhe
gt nd thc rlu! shoukl be discarded
FlG. 8-63 5prl p !g gap qaqe tchanpon spat Plug Co )
 rl.\i iLllG
o o- l.\-:l\':
.0ti El-:ll0D r-

lF lt| llils
r'Fl -\i\ TF lrll I

rftl E-OSl0ll G\llGE

FIG. 8-66 5p'k p q erosion qaqe lchanpian Spatk Pltg

FlG. 8-64 Cp-5ett nq toc ichan'ptoti Sprk Pluq aa )

FlG.8-67 1pe.trq i r ! ed iclprr 5pk P/rq Co)

plug js unilci trc\!ur.. lc\tnrg dc!ic.s hrlc bccn ilesigcd

b,- sprrk plug nanrlictucB to ptly thc corrcct frc\surc
and \ollage lo dic spr'k phg. Spark tlugs rc lcfcd u.icr
pressure to simulale operalhg cordilions to sonc calcnt. ,\
spark plug h:rt fire! stlsfacroil! nnder norllral arrroipher
ic condirios mar faiL nder pressure because of the
lceared lesistnce of the air gap Llrder lhese condilior\.
The iestmg d spa* trhrg ir a tressure lerer is drown in
Fig. 8 68. lnstrLrctions ir oternion re ircluded silh e

Sprk plug\ $,hich lail to lunctir)n propcrlt .luring th

FIG- 8-65 Sett q lhe qap o ne'!v e ee.irde spdrk prcs{u tcst shoulcl be L1kect in an olell lirr bou1.1 h rt
prg t,ahat.pioh 5pa* Plug ao ) 215'F fl0l'Cl This $ill dr_1 oul .rnt noirure with tlre
tl!g. Alier Lr has beer bked, the plus lhoukl be tefed
Single'electrode rnd l$o-prong s,irc elecr)de plugs .uc rg ! if 1I lails lndcr the secod ert. ii shonld be iecled
coffructed so tl]a lhe gap car be opened or c[)s.d $ill]oul or retuned to rhe nnnnlacturer
dange of cnckrrg dre ceranic insulan)r. A spccil lool lor E. Gasket sIvicing. One of e rost inportan essen
adjusurg lhe gap ofsuch a flug is show u Fig.8 65. tials ol spak plug xrrallaiion inl,olves rhe codition oflhe
Afrer strk pltrgs ha!. bcc corrccll\ Srtped. check for solid copper gasket trsed with dre sfnrk plu8.
erosio of rh. cl..t( .s. Thc Srgc sho$'n in Fig. it 66, When spark flugs re ibt{lled. either cr\ or reconcli
$hich is u\c.l \irh rssivc clccrrode plLgs, eliminrtes the tioned Sskets should be ased.
-que\swo.k by i.lctjlrmg strk
plgs ht require replace Llsed lfark plug glskls should be nn.rl.d b,"- bcig
nrcnr. Il lh. clccrrodc cnlo.s the cenier hole. oo much erc hctcd to .L che[] rcd and immcdiaelr" qLrcnched ir light
lion h\ takc plcc d rhc spark thg should be rcmoved l11olor oiL. Afier he quencbing. rhe oll should be reroled
lvilh a sol\enr and lbe giskei! imnrened in a $hLiion of
-. ln.pecron nd re\ring. ,, . r .J r f Ff r . 50 tercenr $,aer ncl 50 fer.ent nitrir dci.l to re.ro\.
a uscd strk thg ror sev1ce are irstection and lcslirg. orides. Alter lhc cid balh. lhe g\kels sho!ld be carel!lh
Vi\l irsteclion is dore wnh a nragnifr'iDg glass. r rilrsed in rurnirrg $aler nd rir-dried.
in Fig. 8-67. Good llghtlg nrus bc froliclcd. Tl)e Elen ouglr rcceplable reconditi.ireLl spark plLr: :as
'horn
lllolriLrg items are exarined: hreds,
clcctroclcs. shell keis ury be r!,rilabLe. il is reconxnefded lhar ne!! gskeri
hciago s. ceranc insLiltion, Lnd the conncclor sct. be insttled with nev or recofditione.L st,rrk plu:\ 'lhe
\r,r\ rl . . e,< e lo. -t \ r; ,:.1 . r. !... r'. - addiiional cosl lnroiled i! \o rxll ilrxt il.xnnor offst ilr.
lent to nonnal igniiion !olt!ge, t() th. splrk flug $hile lhe ad\,antase of neu,gasLer rclirhilitl

spark Plugs 203

 TESTEF S\] TCH SH ELDED BAFEL
BL]TTON CONTACOR
FlG. 8-58 P.erlre t!5i rq stfl !q ar.mpror ip.?.(
9. Plug rolfion. I--\.ess;re ele.trode erosro
. .r..,r:....,t.
alierliring Cosllt pohrirv o.cuN irith elen-rLrnbercd
!!linder nagleios Ore tlug lrcs rirlr folij!e tolnriy.
cau\ rg e\cessi\e !ronrd elecrrodc scu. \hil. tlre er!
flue f re! ne!rr\eh- cusins e\cc\sir. ccrcr c c.trode
$ear Cpa.irrnce alieirtug qcar is cru\c.1 b! the stored
energ! i. rhe iSnillor shieldc lccl unlo.lilg xJtcr nornrxl
'.q,-.e ' I lr, rr..(
sct\. plcinB thenr in lrnls iclenrilied b1 c)ljclcr loctjofs.
,\licr rhc plugi hx!e bee. ienLced. rot;rle 1l)ern,5 i icLc.l
in Fig. 8 69. Thi\ qill lore.t rlre pola.ir.! qer condiln.
and the capcitan.c $.o $lll be ce.1ed h] \rappLrlg
lons lead phgs 1lir}r short lodd fLug\
i0. Installaiion. Belr. j\rdl jng !f! l flLrg,,. the ech-
ni.ien nrtrr hr\e thc trotcr r]t. of fltr! for the ersrre.
T$o of the ror .riricl ld.l(,A rc the .d dr'. xnd ihe
rd . lhe elfeci of improfcr her irnge h\ bee
' r .lt . B \ , ;.'. 1
Iioll .1d cl.()naLi. nrav occLil: the phg i! oo cIcl. il
qillbcconrc l( ..1
ll log rcrch plug is i.ltxlled i ar ergille desige
lor a shorr rcch thg. \onre of rhe dneds ol he plug rill
ellen irlo rhc .orbusri. .hrnber. l th \ fo\iion. dle
reds nd rhc.d oltlre plug nu\ ecome orerhee.lnd
ILrs cruse frcignitio. lh ! \ill resuh in loss ot torer.
o\erhctj!. and possilrle dct(rrdtion. The thrclts $jll be
sLrbiec( to hi:h enpenlure corrcsion. ard hi\ \ill c{use
tbe plug lo \ti.k i tle cvlndcr The sticking endd.t rvill
be aggra!rrcd h\ the lrlrrtio o1 crrbon .rnd lead nsi.le
ai he elld oi th. tlug \\:he| dri\ condjioD eriss, dnag.
mat be cru\cd to the ctllrder rl)rcarls rnd ro ihe spar* irhg
t the line r)l rJovl
\. : le 1 .. '. e I e.r ,r.:. r .:' '. ,:
oul rll dre \tefs preliousll crplanred, their bert clll1s xre
in \in il drc) iil ro rrrtall rhc \tark irhrgs properl). The
tli!t \tct is tu inspecl dre sfark plug and dre c)lxrder bsh
m-g. Th. rhr.ds of ech shoul b. clcn aid free ol rr
agc A light .oxtlg of aptro!..1 anitt-. tonpotnd
shorld b. tf ied to the hread\ ol lhc sfrk tlu3. h shoul
rrol ho$$or. be ttlied to the lirsl t$o lhreds be..ruie e
mIerial ur] run do\. onro the ele.Iroclcs $hcn hor. thLs
sho circLrilir)s lir. clcctrodc! ofthe spart plug.
lhe ip plug is rhcn instxlled oledrer $i(h thc gsker
in the cllnder u\hing. It should be fossible ro \crc\ the
r|rk plug inlo rhc cr-lin.icr hrsh g bl hrd. Th. \prrk
p ug is tighlelerl bj nrc!s ol .1 deep,socker \rrech rvlh a
rs t.lltue h rdle I1 i\ \cr\'lnrfollanl rhrr rhe \pnrk |iug be
ti3hleed lo thc rolquc spc.ifed b,! e rnnn!iacrtrrcr. The
sul lorqtre lor 1S mnr \p{rk tlugs ls -160 ro.rl0 i..lh
f.+0 68 to .1r-.lo N.ml. d rhc t(trqtre for i.1-m111 plugs is
ll0 li) ll(l i.lb lll 1l ro -r1.9 Nl Olerighreumg r
sprk plug nry d,rnge lhe thre:Lds rn.l rke he spk
flLrS dilliculr to rerove oi. in e\lrcrc casc\. chanfe he
lap sellrg. O\.riShte|ing $ill rlso caus. dre stxrk flg ro
slick irr rhc c\lider. The igLnrion lcnd i\.one.ted to c
sfrk pllg b) Ler1i! rhe tenm|l slcc\e j. stfrieht linc
no the \hieldjns brel nd tLghei|g (hc tcnninl nu ro
rhc rf ol he shiclding b .1 The erri al \lec\c nr \t e
cl.n rd d.I rl nuulct not be touched b\ hlnrD h.r.di.
Th. entrr of lreign t(cr or moisture ifi.i lhe tcri.al
.on..cl(jr sell ca| rcuc th. istrl.rlion lalue ol th..on
neclor strch thrrl isnili{rr s\\t.r \o txles t hlgh !o!!cr cn
c.tusc lh\holer ol the isirilion.tr c1liolr] lhe ren)ial .r
$ell sui{.e to the !rcund \ sho\n r Fig. E-;0. This. in
lfln. co se the flug 1o tri!1ir..
The lernindl nri t the tof or the \park tlug shonid be
lightened as mrch a\ Pos\ible by lard ard lhc rurned
bout ore quIer turn $iLh Lh. wrench. A good. sirg liL i!
ll thrt is required Orerrighrcnjg 1!t! cause drinagc ro
lhc .lbo\r aid he hrcs
Alter o.orplete ser o1 \puk flugs has been rrs{rlle. it
is $i'. to u rhe er:ire rrd pcrlrm ! nrageto check to
\\css th. See[r] condiior l'1 lb. ig.jri. (\'\teJrl. A drp

FlG.8 69 Sprk p!q

2O4 chapter 8 Re.iprocat nq Engie lgnition and Start nq Systems
 gex'. lf lll cscs. rhe ger rxsement is \u.h rhr rherc i!
a high Sear r{io bcrwee thc \riuler x]lor rd the eginc.
That i\. dre srartcr motol tlLnN r nra\' (inc\ ihe lpnr 01 th.

Starter Motor
A l\picl d recl crulin! rotor is illuraed in l-i! 8 71.
|- . r.r i .. t( ...it-, e
lapble oi w thrandir)g !cr\ high nn)p.k-ee The $rrdig\
are insLrltcd (ih ltecixl he:t reliisL rr .n3]l1et. and attcr
dre,r r'e plced ilr the Il{ru.e. he erirc sserbt! is .{ou
''rl .:.' .,1....,r'rI 1.1..
om lhe rmlure coils r. sked irl tlxce jn rhe cournrut
Lor L,ar!r.l th.r soldered $irh lrigh-rnelri.g t.in solder.
An nrlllal!re.onsucted i rhis maLrer can q,ithsard

nrg
-.ir,
qirh the foLrr iicl pole-( held i flrce bl counerslrrk
I I r.'.. | , .. ,(
FlG.8 70 C:re.t! re i5ho!! iahapion 5patk Plg n)tor ol llis rtte s ree\ rotrd lle",ollclct coils musl be
$ound i1i(h c\] .opper wirc r. crrrl rhc high frrring

Thc cnd tiamcs rc olc.L\ nluIrinum rnd 1c rtt.rched ro

he cll anes br \crc\s rlnerllccl inr. ofe ed. 'the bu
lD e|91e rym Lrelod rhc stc.itied lirir \rill rcquire a
bengs rre sealed d ie pressed rlt r.!esses i]r rhe ed
check .)1 Lh. nrxgfer. l:Dirio .bles. mrd straik plu8s
tiaores A oil se.rl is plaed iLl he dri\c crd tric rr) pre
lerl cDg;ne oil lior.tcrirg dre nnfor.
Tl)c brtr,.h rscnblies xre ltr.hc.1 to he comnrurror
erld iir. i. bNsh holclcrs i. the
l-he brlshcs rre not hetd
particlir nrotor illLrrrrc.] Fig E 7t hui re arl!.hed
Ln
tilh screws ro i pilole.t brurh r . Thi, rm js tro\i,lc(L
\ith a coil lprins $hiclr bol.ls rhe brlsh liinrll asnrsL rhc
The dir..r t!pe ri1cr. hen eleclricxll.- .nersized pro
\ic5 in\trnt ard conri.uouj .rnking. Thi! rrafier tr)da lhe tielct lianre is \lorrc.l ur the connnutxt(n.erd lo tro
mctall! codslss ol rn elecric l1ro(o. rcdu.lior gers. Lnd \id. lccess ti) dre bushes nr,.ervice an.l replacemc.r. A
rn auLonrotrc ersagins/diseDgrgxrg mcchrisln. u'trich i!
cover Lrand closes the slor\ to ffotect rhc .roior tio dift
oprxL.d through n ad.ltrrrrie-or.L!c oyerlond reteasc
.lLrtch. Thc efsine i\ Lherere cranked dirc.tl\ b!. lhe The fo(iirc tcni.l erle.i\ drrculh {hc fi.ld tiarne tl
is ilxu]tLed olr1 lhc ire b] conrf.sitior1 sleere ind
l_r

The r)rfor torqre is x$ ed ihrongh rh rcducrio

:ears ro thc adjusrable lorqrc overload releu"c.lut.h.
l . '- ,.r. 1.. ti 1.,.r,. I SEALED
l.Joles e \tfterjin "'..
oL(qrd. !long ir\ alis. anlt .gases
r t. l" .r
:rSage.l. crnliin! st,ls.
\\her rhc.!ie rarrs to ljr.. the ltafier irronrticnll\
.r'r,,',1
:.:x!es uSair il .rnenl conrillucs to ener3iTe rhe olor.
.r. - e l .'
.Llcs Lhrcu3h he djrstrble-ro.qu. o\.ri.{1 Nlease chrrch.
rhich is a rulriple.Lisk clurch rnilcr ad.lufable \priS
fieisuie. \\'l.D the uii is ss.rbled. he clLrtch is scr lor a
.redetennirc lorque laluc. Thc.lisks i rhe clulch \lip ad
.bso the shocl .ru\ed b\ th. .g-eerenr oi rhc str.r.r
log\: Lhel lso slip lf rhe e|g|rc kicks brcl\.rln S rce lhc
gngcrenl .if thc ririer dog! ir rur(rnrti.. rhe sfier dis
.'ngrg.s $hen rhe.:ine speed ercc.cl! rhc st.Lrer speed.
Thc Dror prc\xlcr r\'fe o1 s(rrL.r u\..1 f.r ligh llcl SE,{LE D
l, -'- e .. .i'..r -..'!.
mcchanisn such \ ! Be|dir dr'e or rnn. orher neans of
Sgins ad dir'nggins the srmer g.r 1rn he engxre FIG. 8-71 D rect .rank q strrer mcror

Starteu for Reclpocaling A r.raft Eng ne, 2Os

sashers of sirilr nrarerial. The negari\c sjde ofthe poe
supll) con1cs Lhrough the field fine.
Overrunning Clutch
T. cr.!.,.e" dd .r-.!c. .'r .rt-.r' ,Fr, e.r,r..c.
csslly 1o cnrplo),' sotne lrte ol cgaging me.h!nis1.
Varlons llpes ol.rccha sms have been dcsigncd for li:h,
' eir . ., . , "f l r. , .:r e .
clutch.
A ttpjcal orcrrunDing clutch argerlreDr i\ show in
Fig. 8 72 Thc clutch .onlists of n inncr collari a scrics of
iollels. plungcrs d !|rings elclosed ir a sb.ll asscrblyi
and the sh11on which rbe a\sembl,v is rlounted. The hx.d
erred-steel rollers rc asscmled io lotches ir rhe shcll.
The norches taper isa s) thdt he rollers seize the collu
when the shell is tu ed nr such a direction that the
arc roled toqxrd the snull cd ol the not.hes. lhus.\rhe
Lhc shcll is tNned in one directi(r. thc collar ust
jt: howcycr. when the shell is runr.cl i thc optosire direc,
tio. thc collar can rerin slaliondy.
Complete Starter Asseribly
A snrer rsserbl\ c.rploying a ull] oporatcd s$itch
rd a shifi leler is sho\n i l-ig.8 7i. This ral(or dsscnl
bly rnakes usc ol a olerNnnirg clutch silrril. (o Lhat
described bole Dd il ircorprates a pdr ol gears $ thaL
drerc is ger..drctjon betileen he nx]lot nrtur. !d
.1.. ep: irTr ':.'r tJr.. ,p ..
in.rafklLr! torque t Lhc driye pinion.
'Ihe shiri leler is opcfutcd b) meni of a cable o \\j
contr)l firn the ! rplare cockpiL. The conrol ha! a reLrm
suing wirh strllicjeni tensior ro bris lhc lcler to ihe tLrlh
relersed fo\ilio tlhen he control is relc!\cd.
When thc control s operted ro sraf th..gie. he
lower cn o1 (he shlr' le\er thrLrrs gdist thc.lut.h ssem,
blv turd cauf's Llr. olerLnning-chlch dr i\c pinion ro mole
irlo re\h wirh rhc.fgie saller gear. If thc drile finion
ad faIer ged tccrh btrr rgaifft eac olher i\Lead ol
meshing, rhe meshing sp;ns nrside he chch sleele com
presles to spnngloa.l rhc drive pinion ngains rhe ft,tcr
gerr Then. as soorr s rhc rnnte begins to turn. engagc
ct rd cmnknlg lake plicc. in lhe un t llustrated. the
ovcrrunrxr-e ctutch.ld!e pinio i\ srtpoed on,r slub
'lJr |rr . \. (o|etr,or
no!ed ifo mesh, (he !1ub shaft cuses the dcmeshing
BUSH INCS
flc. 8 72 OvetrLrn'. . L,r.h
206 Chapter I Reciproctg Enqine lsnit on and Startinq Systems
ADJUSTING STUD
MOf Slr\rlTCH
I
BUSH
o\ elrunnirlr
\
ntlels
nm with
N
I
END
flc.8-73 5trte: fr'th ole Ln ! c Lrtch, r'r:! y oper.red
s\'rt.f. nd sh lt ere
spring inside lhc \lee!e to be corrpr.'\\ed The denc\hinS
\prjng pro.tuc.\ .lelneshing $'trene\cr rhe shiti le\,er i\
,r r. . reieased. Ali.r rhc ergire slarls. oycrtrning clurch acti(nl
ternris ihe tinion to o1err the clurch {nd gear duing rhc
brief per od h rhc tir;on emais in nresh Thus. higlr
steed is .r tranrnittcd Lo rhe cr,rnking rnoto.annare.
Starter Assembly with 90" Adapter Drive
Thc conrplere frrcr rliel1rblt. rdptcr. ad clurch rsscr
blv for a siri-cllnrdcr olposed e|ginc cr be seen ln rhe
erplodcd vie$ nr Fjs 8 7:1. The stfler is moured or
nghGaglc.|i!e adnp{er which is altiched to rhc rcar end
.f lhe crankclse. lhe iongLre ed of the farer shali rtes
direcrl] wil thc gllxrled eLrd of rhc wonn ihali. The wom
sharl (.13)l\ suptorted between a needlc bearrg (.1.1) ar ir\
lef end rcl a bll bearlll: (.111 rhich ;! etained ir rhc
daprer b) r sap ring. The ivorn (:lt)) is driver by rh.
\hifr through \\oodNff kel. The rlonn nheel (31) is
altxched b\'lbur bolt\ to llange on thc clurch drum 136)
\rhich bear\ o the \hft ger (l5l Tro clowels cenrer he
$heel o lhe dnxn ad lrasriL the dlilig rorquc. A hea!!
helicl spnrg (30) colers boLh thc xernall] groo\cd drulr1
rd similarll Broorecl drur mchined o rhc \hf g,-ar
jusl ahc{d oflhe cluich drunr. Tbe lfrjng is rctained on the
clulch drunr by an 1n turncd ollse! ar js rcar end which
rides in grcole aronnd thc drunr. jus head ol rhe fiange.
The nr Lumed otsel ol thc cltrich ltring is norchcd. .rnd the
.l ,.I r' d e, J,Jr.pp I : ir . ..r'ir _
scre{. The liont end of the spring lit! closely in a fccl
\lee!e. presse ilo the st! ter adaptcr When be srafier i\
cerfized, lriction beti!ee the clLtch strinS and thc
ld.Ltcr sleele rd bct\yce the sprirg and thc clulch drum,
\hich is turne.l b) thc nornr $,heel. rerds to sjnd up e
sprig on the cluL.h a.d shifr gear drln1s. lockig hern
log.ther so rht dre shrli ger nnaes ard ruN thc.rank
 )t\),
.{:; u
1liii:r
',o

:q- ,r(-''d'f/l"r
'-%f,,r#lli
'u4)i:<'"'
l 12. Lock washer 2rl. Gaskct 16.
2. 13. Plai washer (2) 25. Sleevc 17.
L I4. casket 26. Oil sexl -18.
15. Plaln nut (l) 27. Retaining rng 19.
5. 1. Lock washcr ll) 28. Spring rctainig
t7. Plain wlshc. (1) boll (l) :10. Sprine
6. t8. Cenertor drive 29. Tb washer 41.
7. Planr washcr (31 sheave 30. Clutch lpring 12.
8. 19. Coler bolt 31. Berring :13.
boll (l) 20. Lock wrsher 32. Bolt (r1) 11. Bcarine
21. Plai washcr 33. Lock asher :15.Plug r1)
t0. 22. Woodruf key 3:1. Sler wom whcel 46. Slud (2)
. PIi nL't (2) 23_ CoYer ls. Stder shalller 17.

FtG.8 74 Drectcrnkn95trterwthsping-typecutchnd90"drlve (feledyne Continental)

ihali. As soo n! the engine stas, Lhc shft gear is drivel Iightuess ln their nrorntings Loose ierminal \tuds can
iarer than lhe cltrtch spring D.l tcds to rrwi]rd lt. thus 'e.rlr r :]J.i,;:r,d irJe I. ol .rrrc..r.rnc-
r .i.1. J'. ,- rr . rl ,r ' re )r. -eJr .pir '
iee of thc strrcr drivc The generator drive t llel is IJJ1,gr-f J r,e'. .).r rp ,prp ri.r.r i.l
mounted o thc lcr'cd of e shaf genr and drive detennine the corect f{rt urber for the replccret prt.
ihrough a Woodrnfi ke!. so rh i al$'ays trn! rt shl:Lft Pr ntrbcrs r. sfccilicd i lhc manulacrurer's olerhul
grd speed. maual Dd rhc par t\ li\t fttr Lhc aircrft in!ol\cd.

Starler wth Bendx Drve

t rpical Prcsrolit rrcr m(ror, used on man) Lighl air
.raft engines ow in operarion. is shown in Fig. 8 75. Thc
lolo..is quite sinlla !o drose describ.d
PrestoliLc srarler
rr.yio'rsly An examinrtion ofFlg. 8-75 will show thr rhc
notor inclxdes lhe conle|tional parts 1r a series rfor Early Lyfe rdjal egines \!ere otie. eqnipped sith hand
n. end fiames (end heads). fiekl fia]lle, field coil1. Lr ahc\ incriir sta.tcr! or elcctrlc hand irerti,r starters. l hc\c
trnd brush plte assemblr. arl]rature, beaflngs. and assenrbl) n lc,, rere (i-e,r \e H . e (. ,cne
.es. This laicular rartcr hs e elecic srxer switch xsso.ixted with thejr rse because of ihe ecessiy of accel
rrcr relay) lr1ounlecl.Jr1 lhe tield tuame. emting the stxrler nd then enSrging it o the egine for the
The uintenance of the staner nronn illu(ratcd i Fig. fl. Il thc ccrgy \lorc.l i rhc llywh.cl wrs di\siprrcd
i 75 is the same as for anl, oher nrotor ol lhis lype. before lhe engie slrled. lhen it $as ncccssq, lo xccele.
lstectios lnclude an examinatio ofthc bruihes nd corr- ale again. The inerria strrLer sas lhcrcf'e nxne corpler in
-uLrLror. a check lr ihe pesence of oil or grease nrside the s)ster. coLrstrucio. ard operalion than r dilect-crrking
otor nd he presence of lead tafticlcs in nd lcar lhe elecldc stler. However. desigers rd rl]arulaclurers
rru\h llare assembly, and a est tbr the secudr] ol all clcc clertually devetoped {lirect-crnkirg strrer \ hich q ere
_i. ..nfe.riofs The rein teninrl str s ai c\anincd tbr convenien and el1cive in oferatlon.

Starters for Mdium and Laqe En.,ines 2O7

 r t4 6
t/ II illit\
E

tr/
\a- |
I
1 /t\
I

\i :d 1l / \
ll /l \
ii, !
::- lt l,: \ r
:)
3t F " ,ll rE,-
r'
\ \
\ l

\t\
^\
li
127
1. 7. Dri\e end b.jnq l.l. lh.ouah bolt
2. 8. Bend'\ drive 1,1. Thrust sshe,s
L ssenrltr' 5. Coneclor
9. Ilrsh plxlc
Iic 10. Ilnsh sprin-1: 16. Starter .clar"
5. aor
6. (l 12. Oil \el
flc.8 75 E:pod !-( oi Preno t nrtef

st ter opcte! rhe is is .lone. ihe \wirch i! detecri\e

ln lhis !c.rio. the u\Lrl tro!].\ f.und in t|e opera(nD ol
i_\'tic1. co!eni onal ft,l.rs jn\ralled o. airplarcs $ith
ncrfoctj.g e.:ines are discussed. Althougb ihe i fnr.
tios arc brord u rheir afplicrrio . tlrel co\cr fre sitLrlons
oallt eLr.or(crcd. The stud) 01 mnnudl\ nd hnnd-
books issued b) rnanuf{ctLuers nd rhL,re rcsposlhle fo
in\pe.tion aLld mircnnce is ,rl{als 1conncnclcd \o thxr
lho cquitnne cr be \cnjced in accordrcc sith it\ or,
tr ri.u ar desrln chrrcrcristlc\.
Failure of Starter Motor to Operate
Wh.n thc lrarrer suitch on . airplane is plced jn rh.
srarr tositio and thc \r0rer frils to opell]e. lhe r(rblc
. usu{ll\ be raced to one of rhe lolloq,rS: i1l clcctri.
toilcr source (l) rr'rcr conLrol !sirch_ (3) srartcr solc
roicl. l,1r clecric {'lrlrrg or 5) the ller moror it\clf A
ch..k r)ftiese itenrs $'ill LAl[tlly reverl dre ronble.
Thc cle.t|c polrer sourc. f(,. liShl airplane i\ rh. bar
ler\. Il thc strrer fnils 10 opcrrr. or if a.Li.k is herd. thc
batett ch:Lrg. ri) be lo' TIs cxn bc qujchl) .hecked b,r
telr ol hldroreter ,{ lll! chargcd buer} q ll grre a
rerilLrr! ol l.l7i to lioLr on the hlductcr s.ae. When
rhe blter! is lox. thc afier solenoicl! c ick or chrter
and rhe nar'rcr rtor s';ll lail to lum or $ili rur r'er, sloq-
iulh chrgrd brttery. l| na) clles the technician !rill
melell conn.cL r full\ charged brtcrl extern.rllf ir par: lel
rirh rhe latler) i fre airphre. When rhis j\ doDe. he
.\temal bIler\ nL\t hale dre sane \olrg. as thc b.frer)
of rhe ilqnarre nd the tejnrinls mlf c connc.ed tosl
ti!e !o fosire n.lDegtive o negari\..
il the brtter! oi rhc iitle is foLd ro L1e fllI chrrged.
thc fulr l1rI lie ill lhc co.lrd s$1tch Thls c Lrc che.ked
by co.neclins iurnpcr across the s$itch len|iDls. lf rhe
ad nn!r bc reflaced.
ll ihe slarr.r conlro1 swilch in the cocktit tpcrs io e
rn.rion]. {hc tiNble ma,v bc in the stafer solcnoid. Tle
soLeroid cn bc checked r rhc ranDer delcribc.l for he
\tater conrr1 \$lrch. In rhjs cnsc. I he\'] jumpe nrltst be
, e.lb(..' r l. .. .. 1. ..r,,. (r : p . I . r
of the solenoi.t i\ much greater rhdn iha i he coh.ot cjr
cuit. lf lhe slarl.r oferetes \r'he the JuDrper is conected
acrss the lain solcoic1 ternials. it i\ ! sign hr rhc $le
noi.lis defecile. Beftnc the soleroid i\ replced. ho\lc\er,
the ft.noid corrol cncrit rhould be rhoroughll checkcd
The cncuit beker or f'r!e in he colrol circuir my be
tai]nrg, or the q'idg may be defecli!c.
11 lhe toser source lylring conrn sslrch. and str].er
solenoid r rll fnctionmg thperl]'., thc L(ruble lies jn lhc
sra er nxrlor ln lhis ca\e. thc band coleri g the bru,ihes of
the notor should be renloled and rtre coditio of he
bNshes and connutad che.ked. If dre bNshes R badt!
\ '. t ..r.le. ir ..
rnxke slristclr\' .ot.t ivi the connut.ror. This troubte
can bc coxecled bt ittlcing e b she! ,rnd/or the brtr\h
\prings ns re,:tLrird. Tf the coxurat(n l! btack. dirr}. or
badly worn il lhould be cleaned wirh o. 000 sardpapcr or
lhc \ter shoLid bc rcro\ed rbl o\crhaul. UllLatty it is not
eccssrr) to o1,eharl a stuter berireen cDgine orealrts
Failure of Starter to Engage
ll thc arter molor rtrms bui does nor Lurn he engine whcn
onc aterfls 1o sLr1.t englre. c o\emning cturch. di\k
cluLch. or eggmg nrechanislr has 1iled. Thel ir is cces
sal) to rernore rhc sr{er ard corrccr the i|oubte. It the
farter j\ ensaged bI x Brnrlix-llpe r)rcchisnr in rnrich
the elgrgj: gear is mo!ed jnto ll1esh br ier\ of a hea\',!
spirl (hrcad on re scre$ shaft. rher cokl oil or !re,rse or
rierr..,".;l ..,t .-. ri ,;,.
:ear irol) reshig. \Vhelr ris o.curs. e Droblcm ca he
sohed br clelfirg tlre spirl shalt r.d applurg lighr oil for

208 chpter 8 Rec procrg Enq ne tgnirion and start nq Systems

 15- f the P- ead from the mgneto to the gnition
slvtch breaks or s disconected. wht effect w th s
hve o opert on of the syster?
1. At wht po nt n the four stroke cyce does the 16. Wht s the flrct o of irpu se couplng?
l_ iion elen1tke p ce7 17, Describe the purpo5e of an inducto vbrtor
2. Why s mqneio g tion 5!perior to battery gn' '18, Duf ng t m n9 of a mgeto to n eg ne, what
devce ry be Lrsd to deterr ne the exct oction ol
3. Now ray mgnetos be a ssfed? po nt open nq?
4. Exp n the d fJerence bet\,!ee lolu-tes on and 19. Wht prob erns ssocited !v th h gh-voltqte
_ gh-tens on ragnetos gnlt on sy5lers re reduced throuqh the use of low-
5. Name ihe three clrcu 1s of rdgneto tens on rgn iron syslem/
6. Describe lhe difference bet\ /een the pr mary and 20, Expl n the reson for the lse of compensted
jecondary \ riding ncoJ caITt.
7. lvhl s the advantqe of pivot ess breaker 21. Explin the purpose of sprk p ugs
ssemblyl 22. Wht re the mlor prts of a rperk p Lg7
8, p" f .o o L- ,, oo.'o 23. Wht s the p!rpose ol ihe res stor a spark
condenser n raqneto. p ug?
9. Def ne the term "E gp " 24. Def e "sprk p ug reach.'
'10. Exp in the events thi occur at E gap. 25. Wht s renl by the heat rnge of spark
11. De5.rbe the functon of the distrbLrtor rolor p u97
12. Wht re ihe dvantages of a dua rnagnelo 26. J t" t""p pooi poa p.q ooro
qn t on? 27. Wht s meai by the ter. "d rect type stter"?
13. Expl n the term "cor 9 in speed " 28. r\
" -p poor o, o g" gr'"
14. Exp the fLrnction of ignit on 5h e dlng d rect crnkio starter?

Revrew Questions 209

 Operation, Inspection, .r,*'
Maintenance,andTroubleshooting r

of Reciprocating Engines
crond sLrpf |er\oncl !rho are r lhe \iciDity of.ti.
cr:rlt thI e eing rr. !p eed to \!err pl,rpel e)e ard crr
r, 'i 't
crLrlio| xr thelr Jrncmct' bout (he rliD!: greal trnrb.r
Starting Recprocating Engines ol \'eq se ion. x..i.l.nr\ hr\c 11\olled peLsonneL in thc
The irLring ol dn cngnrc cu L,e elri\.lt snlple nlle . l1 lr ofe arin: ef :ine
.r lr.r. be rcr\ ..nr e)i nd.riri.l opcrrlLoL1. depend
r. T. r-l
,'''l|:. Ground Engine Fire
cnsur.\. Tllere
b\re\er. $i.1. \ialio]rs ln froc.dtric.
e. It ar egine firc o..ur' $hjlc rhc cngioe is behg slxrted.
!'..1 li)r marr re.L|rocli.g .ngt!. \o attcmpt sho ld line the fneL \hutolt lcr r tu dre oFr tos 1 o Conrjtre
be n1rde 10 us thc mcthxls presented herc for ctullt .rnnkifs or r.rorjng the egiLre unril hc l]rc h,L\ b'ecn
slrling a engine, l(ed. l$ dt rcter Io rhc tnr.cdurcs elpelled lllrnr thc cn:in.. I1 llx' llre perii\t\. curhotr dio\-
'
t..,,'l ide (CO ) c.L. b. ctischr-sf'l irLto rlre i.ler .lu.t \hile drc
ergife ls being .rnl.. Do rollischar:e CO. dir.cd.' mlo
rhe ei:ie erhrusl. b.cause il mr) drm.rse tbc cnginc. ll
Engne-Starting Precautons rh. ljrr..not bc erilgLrrslre,l. se.nre !ll 'ijtches nd
llthorgh lhe !1arrin: of i. ir.rii eDSle is iclti!el,\'
sirDle |rocedLue. Lre.rj trccauliors should bc trk.ir Ir' Il thc lirc i' on lhe:rclnd tr.d.r th. cngtue orerbord
ol'til lhe L,ef re.ult! ncl 1o nroid danras. thc rngrre .hanr. ltischrgc ll)e CO on the Str rdlh.r th.t oLr he
rDrl iLltLr) Jrer$.el ..ginc Tl)i\ lso r, rlue f the fire is t lho tilpifc nd lhe
,\ircrai \erice febonncl ihould cquire thc llloniLrS l!.1 i\ Llriplirg to lhe lroud .1brrug.
slet: h:]bit!:

1. Tr.r all trotcllers -r h,ru3h rhc igilio srirhs Startn9 Procedures

Ellgie-stnrtir! prc...1urc\ rill !rll for.Lilleret frl
I Ch.cl i+rlxnc or lest snnd \,h..is etre \,orling iuerering {le!ices Srarring fr{rce!tures fr flo:tt cxrhuicl(n..
Berr.lir iuel iJrjeciion. xnd Cor)rirenll cLrti.rlrtr. flo\
i \It.i n cngire rurr alrd h.inc lhe erline s lhrl irecliotr \!rers re dc\rib. Lor 1Lrili!1riT.rtion ttrt!\cs
do$n. pernnr n igirioll s(ilch rc\t L dele. a fau t."
onl,\ Sfecilic \ral1in-s tr{).clurcs re se lrh i. re o|cr
Ior's lnarll]. ll i! e\tr.rrlt ilnforn htl th. ofcrllor be
.1. Bsf.r. r,\ig proteller or .onncclL|g 1 e\eDal
Ihoroulhlf flrnrilir $itI lhe cockpL \\ir.h.\ rcl the
fo\rer so!r.. 1o n arrcrft. bc slr. lhal re x r.rllL ii eirliDe conrtrrls b.Iorc ttelntli|g to rnlr th. cngic. Figure
.hr).kcd. (he rg|Ln! \\rn.hcs xr. i lhe orr ro\ition. rhe i) I illusrrtcs th. \rrdrd krb \hxpes for Ih. cornLnoLr
t,.l ergi.e.otrols. nd ltpicl conr,l connrl. lor lighr
rd ll cqli|Lenl Lrd |ersonfcl rc cle of th. frot.ller ili engre lircfuii l irnp,rlnl lo rircrbcr. howeler.
r)t(,r. Ful1] diode\ i| ir.rail cleclric s\stenrs htc lha here rlxrd.or)ol k|b ,hrpei nr) n.t b. li,rnd
.u.c.l stcrs to e|gnge ( hen e\tcml fo$er $x" lptlic.l. on m ! lrLdcr irciail
resxrilless ol Lhc *\iI.h pollt o.
5 R.m.mb.r. lhen lrLi e r.nro\irg n e\tcnral
torlcr solr.e liom rr rjr.rlt. k.cp he equifrcnl rnd Startng Procedure for Float Carburetors
\.urscll cl.rIl he propell.i.riolor.
6. .U$\s srd.lear of rh. rolor nd tr)pcll.r blde L Sel lLe r\ter s$it.h 1o o\.
frh..\t .cirlll \!hef I.u lrc R1ng rhe ftrrf.ll.r. Bc far- L TLrLr or the boosl purqr if|eeded
rirlxrl) caLliolMror.1 $ xr erlgie\. 3. Open rbe th l. tpr,rr ntell ,' r I l.2l .rl.
r. The grourd .r ti\cm.nt ne the trof.ll.r shonld be +. ]f lhe en:in. i. cqLripped n,ih a cr,.\tdnt sNcd llo
li, tcllcr. rhe propell.r conrol shoLrld bc s.r in thc FLrl
 ol
-tr. THFOTTLE
F
rl
ri'e
.1 Turr on lhe luelboosr t]!rl]r $irch.
5. l\lole lhe mi\l! re colrol 10 r L rrL until th. liL.l
floN gge reads.l Io 6 gal'h l1:.11(Lr ll.r- L/hl: thcn
inrDrediaiel,r reLrrn lhe co|rll o rDLr.Lroll. I1 llt. ircr1r
doe! oI hale :r tirel flou,xrdi.or. pnI dre nrillure cor'ol

, l
t
'
r: '. 'l . .l
/'
,1 ailor\ frelto flo$ thtrNgh drc ro77le! i.n) rh. i.tle nri
F F,I ilold to pridc th..ngiDc.

-+u L_C
L]
6 Cldr lhc propcller
- Tr, , :l
r \... ,..ti .r" I

9 Rclcrsc thc igDiliorr !rril.h

10. Check lr oil pressure.

when ho or $rm eD3ine is beins nlned. ir i\ frobir

bly .or ecessal-r ro Idme rhe engi rer orheir ise. he prr\:e
dure is the sirne as liir co d e: fe *ri.

Contnental Continuous-Flow Fuel

lnecton Starting Pro<edures
l. Turn lhe igtriiol1sr,iches lo o\
2 Ote dre throle fproxr|lelt : nr 11.lr- crrl
L Set the proteller ffch le\ er liill tilrrd 1., iri r
.l Set the nr \trre elerrulLitr\xdt.njiFr_H.
5 Clexr nre fhte ler
6 luir rhe aLr\illar\ nrel JrLrrJr sirlrr'h nr rlre pRirrF
fosiro. Avid len\iJr! rhe nrllir't(rel JrL,rp sril!h i0
cirhcr rhc pR ! . or o\ f.\irio. nr rore rlrar o l;r' econds
unl.\s Lhc cnsm. is runDig.
7. Tr th. jgnition sljt.h to s lR rvhe the lrel flr
rechc\ I to,1 :tl/h Ll.5r t(, l -i 1.1 L/hl. Rcad th. iireL
pres\lrc ggc.) Il rhc cnglcs xr. irr. fir\t if rhe !ri-
(icr sqilch (o \ raRr. thc trun thc nuliliary purp s\ich to
FlG. 9-'l :q ! ..tri ..re, c . ,tnC c krob t,pes
ll. Rcl.a\c Lhc ig.ition .rich i s.o i\ thc e.!ine

9. TLrn off lhe ilnrjiiaq lel pnn| sll'iich llhen rhe

'q cngire ruJr! smoodnl. DIrinS rert ho s,earlrer. ilthere is
I l.r.
!iS. of !.rfor lr the fuel s\enr ridi.ied b).fluclxntjig
alexr the tru. fuel fl,r\) rith the en:ine rrnin:. tun rlre auriliaLl iiLe
I Trnr rhe l:njti. \rilch tr) thc \riRr posrtior. {On
nron nrJern rir.rxli. th \ r jll ! n) l|)w lhe urgletos o tnrf $ ilch o r\ trt I the \\ (ter i\ puf!:ed
l0 Che.k l'rn !n.il tre$ur.. fdi.iin \ithi -r0 s l.
noinrll $c.Lrher d 60 i .fld \crdrer lf no irxli!Lon
!. Rele5e rhc i! rion !n r.h tWhc thc ignition
apt.is. shnr offte ef! c f.l if\esrl:rre
'' '' t t . I I Di\con.ct lhc .\[rl fo$.r n)nr... il !.c.1.
lord..llo r rruin 1! 1h. BorLposili(r. TLri cii!rn $illdeer
.r:-i^ 1|. \rf.r.ir.rir nd l.\c th. urgrei,r\ n tlre r)\ l2 wrjn rp th. cnsin. tLt S0(l to l()il(l itnr.

l(1. Clieck l0r oiltirt\ur.. Starting Large Re<procatn9 Engnes

Bendx Fuel lnjecton Starting Pro(edure
lh..iitlS t)c.ilur. r en!if. cquitpcll$ith n RSA
ir.l if...t rr ,!\t.r h\ bc.f .1.\i:...1 1o xroitl 1lolrdxr!
Lh. c.Sin. fd t(, fro\i.1. fo\jri\. r.{rlls Thr oinl slets
ir rr)lf
'tt ic !\ L!)llo':
L ndequlte suppl) ofcxrbon dioxde grs rn rurrltle lr. e\Illl
I \.1j!.r r. rhioul.lo ,: iii rllSlnl)opel.
I. Tujir on ihr irr \rit.h
Lrgc rdil c:in.s isrrll.1 o tr. Da r. D( 1,.
Con.lcllrti(r. !n.l thci lrrgr ji.rlr \horl(1 he (llrre
ccordig 1{i lhc nrxrlclrLr.i s lf:tLtrr1i\ lhr \r.f\ i
sla.Iiug rre siinilr 1o tho\. Ls.!l j(ir Ljght rir.Lri.i:j.cs.
buI additiolll pr.cru{i(!s
should be plced {o rhe rer il f1hid l rlr..trgr
being lrxed. 1 cse the e rllfe )rckrle\ rd ti e lrLLnrs irl
rhe efsine xrducL.r syirem. Tlre lirlr !llrd nrlJrliih\e n
guisher boiles ilr older o innredirel) dir'ecl rhe !i lrlo
he engife i rdL,crrorr st fe.r. Ihe . rgife \on J be kepr

212 chpter 9 Operatlon, nspe.tlon, Maitennce, and Troubleshoot n9 of Rec procati9 En9 nes
 unring so tht the lire wili bc dra,n jrrto ihe cvlinde*
o rer r) " ,. \e e.ri ,", .te r.ie r'.l,oIr..r 'he L,..-o,.t. Je Leli,..
because te air Nshrrg ino tre .3ine caIi.s lhe tirc \aih rle .nr-. ,,, r . ",t .' -:,r r , -- ,c,r, ,.n I
ir and as the egine sras. thc tire camor coninuc to bu .e ."i , . ,.,, l,\. ; .-r o. ;, rte , po. r. , .,r.t .,,,t
in lhe ildrctio svrer. il. r Je.r,Ir,.,r.,i ^
Belre x\ attemfr to rrafl targe recjprocaring engine, B- , e 1. .-o,,. L.\lr .( r. .., rd !..,!.
l :, ,..l",rl J.",i.r( r,.t i"r . ... u.. -r..r..,r e..r.. .r.r ter repr^F,e
. li ,'r.r. -t . i. tituid tock. .,r.- ts... .n Neler rllo ar) irollion ot vour bodv o gct jn thc $.xv ot
Ihc loNer crlin.lers. Il the enginc srops suddeniy while rl'e 'up. er . | . 1,., r. . ..r L:t .
leir)g nfrted by hnd or niih he strner. o nas co]ectc.l b.i,,: r l"l
in r linycr cyli'rctcr. rn.l rhc oil rmsr be removed betbre rhe Stard close enoush ro thc tropeller lo be able ro sref
egine.an b ltaded. Thi( is be\r a.cornpt;shcd bv rernoy awal as it i\ lulled .lown. Scpfing rw) ,rfter crxnk1s is
ro|].",,',..1...r .1 erL..t . Ie-,. r, .,!:r ,. l Jl- .. Do r ..,rrl r - uu:.,n
lh|t thc engi c rfado be re\er.d to clear the oit. Aticr r ea.; . e.Ir. ' .',,r, l . Jton. rr o I
tli. oil is drahc.l from e *lidcr. dre spard ptrg ca be
...r Tl )
lrorvs dre bod) ofl balce a.l cout.l cluie volr to tall iiito
replcc.l nd lhc cngine \rarle.l. thc blades w|en he clrne surrs. tn sutnging ttrc prop
F,ir large recitrccai g c:irres, trinins is u!uattl ru ,
J . .ti,t L rt .t., ,^ o. r..c
.. ,f \o r.r. r.l ...rr(ornf"rt., Ir' Lr.ro"i ,. bl.J.
Jt|,.-.,., t.. ie .. .! ror edge. siDce kickbrck ry breati rher or .trrq, your h.i:ty
rire f
nr!.r to a spicler ldifriburing liLrjng) nfd c to e
rrf .]hrd.r! of rhe ngine. This applics ro x radiat engine,
clther \ir)slc or rrin rorr'. h) x nnre-cylrder radiat e-qjne,
,...' r .. e.. .,et ., ir,tr.
P' i, ,, D...,r r.f ir .,i.,i,n
rr r tlre tir(l b ,, Nter t,ur I r( rr r rcJ n
Largc recirrocrt ng cgines lnry have dircct cankjng
jlafier\ \ nilar 1o lhose lL\cd or] ljght,rircrllli cgines bu(
nrch jnore po$cL]. or rhcy ma} h\,e ierli salrers iD
Operating Requirements
\hirh the crrnl(ing eicrgy js sLocd xr a rpjdty rotarig Thc openrion of any ro(iprocarir! ersic rcqLires rhrl cer
ilrrlh.cl With the jncrrla r,rrlcr, the tlruhcct musr b .i,r,_",r, , l. .".. ...:r,n,.. .i...r., .0. .
ecrgize.l by eiecrri. Drotor or hnd cr!nked tntjt \',l'.lr r,. ....'.:.\.ib ..r.,rr...(r.
3rough energ) ir st(tred ro tn rhe cgtne tr sc!erol re\.o ,{rnong the (ondilions \hl.h rust he .hccked dur ! rtr
lurions Thc ensagc swirch i\ rher tum.d on io conec he ufer r nt . ,.r r' . rt . o'.,... 9
flrsheel rcdu.tir gc{rr! tu the crllnk\hdti hrotr!h ttre
J rr( r.. \ fl .. rrr' ..-r.lo. ,..' r.,. i. ee i. Egine :,il pressure
J ...-... .. :ll v . .t, I ,"F o iJ aJL,!. 2. OilrenDcrarure
lnerrill sl rL $ rc , lhe .rJer \ r !t ersrsLJ ",e .o i. C)linder hed empcrrDre tCHII
$r ,'l i -i IeI pi, ,. .-;,,,' ," ,. .1. Engie rpm
icfiliors$irt]h olr. th. engine shoukl farr !cr\"...
soo rtter ii 5. NIanilld rressue
is tated b! rhe rner. The throille is lhc; adjustd for 6. Dry in rn during switchir ro sigle mag.ero
profer i1 rr ut lpeed.
-. 1-, .t .r' t.f t .u..
Hand Cranking speed rcontrollble-pirchJ tropc er is u!c.i wtth rhc engi e
.' p.'.r,r. ' ,
I]and crankjn: of a srrrLcr eqnippod engine virh d toir bar
tci_l or delcti\e raflor. alrhough covenjenr..a,, e\pose
i r,.. ,.r. ' re:l'.d..or r... e..ol Oil Pressure and Temperature Check
L .r, 1, .r. r. .rd t. .eu.,-ro r.l No cngine shontd be opcr.aed ar hjgh pos,er selLj!s Lrrlcss
rr , i.r ,.J |tc . .t.,, t.-. ,r- r. I 't r. .'rJ r. it. : r.
1t1!. (rlh
.vetri..t1 p?tr,it ho Ll tlo rhe han.n l 1.. u 'er '..
' 'r r
or L i, .,r I, ,. . r,
iry. a Ll a ftltthl. pcrsr1 tllot.tlr! bt t 1. ..19r Had
crnnhing uirh drc cockpit uno.cupled has rc! t-- , t^.., ,.,a. rr.t !..r. r.,r.,.cr:rl
red in rany J!,d! '.",.,(..., .,i... i"!-, ,,1.
proterl) $anc.l up bcnne fu poiler oferatio i\ begun.
Il lhe rlrcrli hxs no \elf stafier. rhe engjne must be \le' ne-" . ..t.' ...rt.. .,...,.... ... ..
faflcd hy swingig the tropeLler. Thc perlo \\,o is turn- oi.. .FJ o .. ,...' rl . . ,l ,
1rg rlrc propellcr cnlis .t. Jiltt a , s)titch alJ, throte saiisfactorill. ll oll pt.:nn is i tticnt rrhi :0 s
'' tr. ..,. 1 ,. i-.neergi r.,irt liet nrlin]. rh("aoit. ru.ts h th ott1 u h. ,lt
\,.1 ".e ' .J J,.p. r< p, I .. -,e.tr..t .,ro
|
,''l ' ', .' liurtion l.clt. If rhe egine ls openred trithou oil tres
surc fbr.ruch fl)rc ra 30 \ darlage is tikctr- ro resulr.
'c t(o. .1 /. Tr ' r<.o \' .t,(r .., Pior to akeolf. he rcclproclig er:jDc lhorld be
ract ard Lhen tum on he nyirch. Never Lurn o dre s\/ilch given igniion check ard x tirI-po'rer esr. Thj\ js u\ul
and the ca1l coracr '' ly done while ihc ii4rtne is parke ttrlr o rhc end ol rhc
Whe you are swingiLrg rhc prop. a lw slte precau hkeoll nrrwav in r war|r up are. For the nrsneto ch.ck.
tions v,ill help o
rloid cci.lcnts. Whe you are touctrin{ rw... .^ l: J,.,,il ,(.,. - | ,

Ensine operat o. 213

rt rhc poi reconxende.l b! e nrnufaciNer. l'his is u\Lr'
rll,- lo 1500 to 800 rpi. alrhough il may bc ouisicle rh
rnge. To nrke rhc chcck, lhe igriion s$itch is lurred
fu the BorH poslion to thc LtFr magneto position and the
rchorreter i\ obier\ed li)r.p]]r drop. The lmounl of drop is
LJ. ' .. '1 ...r.1.. r 1 .1
r r^ .. .1., rr<e!L:.
lnoorhlt at drc lull-I..sl rprn The s\itch is then 1uflred r)
Lhe Rr.Hr magDelo posiio fot few scconds so the rfDl
drop c.rn b. noted. The engie \hould ro be llotr.cl
operaie f(tr rore han a fei! s.concts olr a siSl. nrrd.h
L'ecaLrse of to\.ible pluc loullng.
The permissible rpl drop dting the nxgnctt) te!(
\aries. ut it is usullv beiwecn 50 nd 125 rfm lr ll
.rses the ilsrrir.iors j the ofcratois mantrl should be
1llosed. Lsnall) the lpm .l()t vill be sore$htr lcss han
the nu\trnLm \fecifjel in rhe inetruction!
$hen IIre magct.' ar. checked on an rylarre ha\ig .l
codnGspeed or con ollale -piich tropcllcr. rI i\ esseliil
rhr the |rofeller b. r the lull HrcH Rpr (lo-Fchl posi
tioni olhen'ise. re indicaiion of ll)m ctrcp ma] nor he
check of Constant-speed Propeller Pit<h
The f()pcller is chected to cDsur. proper opentio o1 re
lltch c.mbol .rn the pLich chrngc rncchnism. The opea-
io ol ! controttable-pitch propller is che.kcd hl
indlcrion\ ol dre lachometer !nd rrrilold pres\ur. (NIAP)
gges ilhcn Lhe profeller go\crnor .onlrol is.r)\cct liolrl
orle lr(rsilior to ,rolher. Duing lhi! check. the propcller is
crclcrl so s (o (cnlre the cold oil tioln tbe trotcllcr hub
nd ro llitrr vanner oil (o cnter dre nub. To cycle the fn)
peller, the ol)eirt(r 1o!es the profell.r.(lnhol in he cock
tii.fidl) io rhc iull lt.cr'eaie Rr|'l posjtion. As lhe egic
rprrl begis r. \lo\r o$n. dre cotrol is noied bxck to drc
lull-1creasc Rplr posilic. Clcling of thc lropeller is doDc
durii lhe rn up $ilh dre engie sct pproximrlel\
1600 nr 11100 lpl U\ull) IIre eiSin. sPeed ls nor nllo$c.l
ro drot rorc thn 500 ryrm dlrrlng lhjs procedure. llccuse
each L)f. ol tropeller requircs ilIert trc.cdurc. the
npf liblc rrut'cturer'! istucrions shotrld b. llloed
Th. cngnre shoulll be gilcn bief full tower checl.
l'hi\ i\ ddr. b) slowly !d\an.ing he dnottl. to lhe lll'lr
\rrd tn)sition r{l obseNing lhe marlmum rpm oblined. lf
,. r.', l\'\1...r"..o..,..1 r1 ..e'.
snrnhl]. llre rhrlrle i\ slo$lt rel ded until Llre ergie hds
r.r'L rcd ro llre desired idlig spced.
$Jher lrlakig dre full po\er check, thc oferator nrr\t
rke nLfe thxt thc rirplane is .r to\itior sbjch iljll oI
ri. t l r rl'(
!.. D ie r..r' , I i i..
Io perso.1. nrrr' be cLsed Thc operator (hr'l rlr.
Ir1l:e $re tht th. br*cs rre o aLI thI he ele\rt con
Irol ij tulleLl bx.L. il th. eirplane hr\ .onlentionl landtrg
ger.
Power Settngs and Adjustments
J Iir! p..
mrst bc chnged iorn tire r) lime lr \riouq tltes ol
oferarion. The lrincipal torcr \elin:s arc ntr t.r//.
./nx r/!!s lliom marimum tr) rnLl mrml. 1lrr r, 3nd
214 Chapter 9 operation, nspection, [4a ntennce, and froubleshoot nq of Reclprocat ng Engines
The nrcthods lor chnging fo*er selltn:\ differ aclord
ing to thc t)pc oj .ngine. itte ol profeller. (hether thc
e.gin. i\ cqurft. uilh.r \Lrperchrler. rlte of. rtretion.
x.d oLhcr 1clors Tlrc ofernof! ma.uxl r jll gj!e rh. trop
.r froccdres lor trlicLrl rlrflan. engj.c corbirio.
Po lhc iollo$ng rrles generlly a|tly r nrosr airplaes
\''\
{rr de.res.. "Slo\l) nr dris case nrefi r1 lhc llnolLle
no\er.L om tuLll open io closed. or rbc rclcrsc. \hould
requ re 2 nr I \ irlhcr th he iiltion of \ccoDlt requirecl
lo-tanr" rhc Lhtutllc ir'r r.L ot len. icl*cd.
2. Redu.c thc polrer ieti-! n) th,i.li.rb \xluc r! soor
rs prrticrl li.r lrkcof lf tlre stecllie.l cli b po$er ls less
. r np .r
crn troduce ericeisi\e CH I d dcbnali.in This l( tnicu
lrl) ne illhe ai4rl.rne is .t.qrilrpeLl $nh CH I !a!e
3. Do rot reduce tot.! iulldcnly she lhe CHT is high
(aI or ner rhe red line on lbe !ser. The sucld.n roolig
hich occul! irhe toscr is rcLr..il shrrtl\ $,ill ofle
.use lhe c)linder he.rd ll) c.cl. \\heri )!u arc prepr 13
1o ler doq,. redLrce rie foser slo$l\ b) in.relllcrls to
nllos ltn ! S.adtrxl r.dn.t'.r ot lcnpernrre
I \\'hen yon rc o|.rrtig r. r{nne wirh c.nqtnt
spee.l proteller. l[\ j rrrrr ]1Al'\\th h,! r)r)rtlL
b.fote t.tu q frr $irh the froIcllcr conirol
lhe Con\.scl\. {lsls increale rlr. rtr s,irh lh. protellel
. .r.. r . \l l' '. lL ,:,,
t.o l{ Dd th. (hlle is xd\ arced. il is fossible to dc\e -
of er.esri\c c) lindcr Ire\\ure. $ ith th. corsequeces
.rtlxinccl prc\LoLrsl,\ The otert ol engine should
trcconr 1milir (lrh rhe h\lrnum( allosrble ior Lhc
ergnre d he| rake {r. thr Lhc egine is operated ith
nr rhese linis. Remenrtr.r tlil a corrrI'speed fr.feller
holds the engi.e fn to a !.rrli.ular ralue in ccotdrcc
iih iie tosit on .f th. tipcllcr corru]. Wher the thrfll
is rnored trialll thc tropcller blde angle increr\es lnd
\'\P,.(J.e r. , .'r L
..II..
on n .!einc .quLppcd .onsrx.t \pe.d tropelier:
"ith
' n. rea.c l,u$tr.
Lhe 4xn. dre rLljuit th. Llrolllc
b. To decrcalr po$r, rcduce IIre otlle. redrL.c drc
nm. and dler adjust Lh. ri\lLrre.
r' 5. D rr|S a plons..l gli. $Llh porer low thrrtlc
ncr closed p,rsltion) -.leu (hc crglne occ,t\ioxllr' ro prc
lenl spark plus f.rLig. Tlti\ is LloLle b,! rd!rncing the
hrole o nrcdir t{$er po\ii.n lor ! lir s.cods. Il
lhe engnre nr! inoorhll. dre l-.oFer mar bc !cltuced gilr.
r 6 Al$d!\ plcc the Lnrual rixtrre.onlrol i (he FIrLL
Frr tositior $h. rhc e|gire js ro be ot.rr(. l or enr
lrll f.rer. Thi! hclFs rrre\er oierhextig. Thc cngine
. r' I'
Iion onlf duriS ciuis., iir iLc.oldnce nilh tjr. inslructioDs
llr ihe oterntois rnurl. \\her toser is Edn.cJ nr lc(
down n.1 in pr.parLion lor lndins. the mi\turc cotr(rc]
shorll b. pldc.d i the rrr R( H fositioD SoLre irix're
ln Lhis crse ll)e niriure conll l\ flcelt r lhe RrlH pori
li. lr high foirer rd trL(colj.
i I1 thele is aI Nossibilir) ol ice torminS in dr. crbu
rctor $hile toirer ii redu.ccl lor ledolt preflru\ Lo
ldnrg. ir is neceisr\ 10 plxcc e .luret(r ht1 conlrl
in thc llrar .\ po\ition. This is r fr.cutionxr! mersure Range and Speed Charts
is .olnno prcLic. lir xll ..gin.\ m \hich crburetor
Thc chrLs pic.cL.d i FiS. 9 I ere e\eloped 1r lhe
8. Ar high rltilldc. xdtu\l Lhc rjrtrc conrro Lo a f.si opcrtidr Pitc PA ll 16(l ircftft lhe chafi r the
01 thc
tjrr lc.\ rjch th thxt tr\cd dL [^r r]Llrud.\. lhc dc\ltl oi lcli shcNs th. c11.ct\ ol poq.r s.ttings . rn3e !1nd ihe
ii r hi.sh ltitLrd!\ is lcss th xr l \cr ltitdeir therefde. chdf on th. ghL \lnr$. ho\ poser lerLifg\ (l rre l
rhc \rc \.lurc ol ir $ill or; l.ss orygcn. 11 lhc speetl (TASI r. r.lr!1. Fun th.sc chdt\ $c .n clil
crgc is s|crcirrg.d. thc nrcrcr. l(irudc \ill or bc .lelerrnine e proper por!er \elliirgs l ir\ lljght riLhin
ol prliculr conseq!ence !rlil lhe cpaciil oi the \rper- .. ..r !, o. re.1 e k .
chrger is erceeded Umll) Ihe N{AP Sage sill prolide f :' ,'lr. I r,
rurmilio| heiprrl lor prcper djurrnen ol the rnilure lf $e sish to mxke r fL ght ol !0(l ri ll
.118 +11 krl t
cortul: lLo\i,\cr. rr rcc!rt. ECT gge i5 c.iLrsidered lr \c
. iltitude of {i500 ll 981l0 ml. !.xn derernlLne rhe
cssentil 1r lclirrg thc r)rirl!rc lor cruise po\er t alti' flighr \.riues fo| r.Lriur \peed or mitrinum rrnge or
turle\ nor lh i].i$rr choo\c a conpronilc clling. Il $e \ilh ro nlLLie the fiigh
in h. !hor.!t po\siblc limc.75 pcr..nr fJ c cgirc
lowcr is rsc.l. Wiih rhis scltin.q,llt)0 rpDr nd lirll lhn
d.l. llt. TAS $ill bc bort 175 mlL ll81 l ki/hl 0 llf
tlighr sill lkc 5.L l h. rssu xrs !o lril ln oi h.d r!!trI
Ar this s(ling rLe irel co\untritr sill b. ll.ll sxl/lr
f71.11L'hlr therelore. rhe lligbr vili req ire 96.7 gal
l-ri6.{15 Ll oI lu.l. Il q c will to rl.. Ihi\ slc flight s ith
Cruise control i, thc rdiu\tmcDr ol crr!ire coulrols Io narirnrn\ ccono\). \r. mr) ot.rr(. rhc Nginc\ t 45 Lr.r
obtir rhc rosulc.lcsirl in rx.Sc. ccoom). or llighl tlme. cenl ol pf$cr silh lLrr uirtlrc .onLrl lc|c| r\ ld r\
| l ' .l |orr- .r: : o 'r . t r r f. ' -\ rr '
rrr l lotrer ;e(ings. ob\iousl) rmrrnrrlspee,l rrd ur ie TAS rill le bli,r 1lf rrtr :05 !,) k!L/h . J rlN lircl
xnul rge or ecolroml crrLrot be aftained $ilh rhe snre rcqtrircd for rhe if $ ll be borL1 77.r- Srl L}1.+ 13 L . ]|c
porer setiigs. ]i.r mrirum-djsrace fljght s o be nrxde. tinrc r..trircd for lhe fli3h s ill be abou I h.
i n desirable Io consene lel t olieraing ,rt n lo\l ltoser \e $ould seldor oterlc lire engine |1 the ellremes
\.riLrg BLr il r\inLrm speed js desired. it i\ ece!\xr] to .r . ,.., 1.. - - ., -.. . l. t.... ..
' I de. .. . r ,:. for .nLjre conduior! is 65 fer.er of irrer. for flighl r ar
crpbili(l xltLtude of 9500 i ll81la.rr nrl. rhis lronld frolide T.\S nf

ts. c

r;
:1
!d
It;
L

fTo
i
aa
5!3 *: tril
l=
i/l
:'/ -"

900 r000 lr0rl 1200 1300 r400 120 r30 r,0 r50 1e0 rr r30 r90
rr44Bl tr6osl lr7701 11931 t20s21 122531 .rs3l t2c9l t2251 12411 12571 127,1r t23sl 13051
AANGE N]ILES IK LOMETERSI fFL]E A A SPEED IIPH KIITH:
PA 23 -160,CF !1'T 3300181172330(61 PA 2: r60,6F. !r/T 3300181r72330KG
AL]X TANKS ]03 GAL 4O373LI

FlG. 9 2 Chrt5 ihoL! q r.qe .. ie-.d r r. tor_ to po,/r'er ;et n!

cruise conrro 215

:. i: ^ --t. 16 l+ km,hj li $e i!shed 10 ope.ate 5. lllAP seltings lllur be .ljLsed 1o niLxin trirr
.:.i: .nLrni.dll) o. $ith greaLer range. e woLrld proba lar poirer outpLr if the oui\l{le ir errperarurc i! xhor. (r
ri\ ui r poser seIig aboul55 percent ofmnrnunr. belo\ he srndar{l gire in the char.

Stoppg Procedure
Power Settings Usull) n ircrrri c.3ine has eooled strff;.ien] lor el
To se! lhe coftrols of cDgine for pIticular poNc out iLrmedilc slop bccdu\c ol thc lirn. rcqrir.d to mo\c the
frt. the I\,IAP and rym rc adjnstcd ccording 10 densil) rifdnrre into dre tarknrg !ea. ll is good prcrice. ho$c\cr.
alitude $4re the airylac is cquippcd wilh confrl'speed ro obseNe the CIHT gge Io see hi dle CHT i\ some$hat
prlrpellers. Figurc 9 I slnr \ Lhc \cuiDgs 1r e L)comirg r.J( 1,. t t,lbeo-. ot,q. l l-.r'.
O 120 B r)pposc{L cngic. Thi\ l.tblc i\ Ltjusled tor lhe rse equipted with n idle cuolT on the mi)ie corrrol. he
of lrelsurc .tlliLLLdc t \tnndrd Lcrpcrlture f, infead ol eigine should tre stopted bt
placrg the conirol ur lhe jDLE
densiry ltjrlrdc. ObscNc thc follor!ing fcts regarding the .r rrFr posiiior L rlediriely arier rhe elgire \lops- he
setings nr N4AP r..1ryr: igilion sitch mus be lurDed ofl 1f ihe airplane is
equipfed $rth cowl flaps. ihe flafs should be lett in rhe
1. Ar gi\n d a gile poser selli]rg. N{,\P InLst
rp r a opi,\ to\jtio ntil aft.r ilre cnglc has .o.le.l
b.: d.crcxsed \ llilrde increses. Th]! because dre I of Afi.r stoffing dre egi.e. chec( thrt all rritches i. dre
re n deceases and he densnl heretbre increases. lhus, cocktiL rre let to oFr.. This is especially irp.l.lit lor dre
a giren \olLrn)eol.rir at r cerlan fressrre $ill hve a igniLi( \!itchc\ and dre r\rcr btt.N ilch Check dral
srcalcl seishl as aliiude increases. and \1AP nru!! be ll $hcel chocks r instrlleLL. lnd rele$e the frki.g brake
redLrced Iomintain consa power ro prcy..t uncLtrc !tre!! on ihe brale slltelrl.
l. When the engine i! operled t higher rp]n. x loiler
}IAP is used o rnaiai the same power.
-i AI ccrtain lcvcl of xltitud.. NIAP cn o loscr bc
m{inticd bc.arsc of thc rcd ctior nr atrosphcric prcs
\urc. This i\ thc poit iD thc.harL \lnN as FT. mearirg Leaning the Mixture
full trot11e
4. Ar 55 pcrccnt o I r.rtcd powcr. Lhc fo \!er c be n]anr- Wi lhe rixre ln drc Frrr.r- Rr.r position, prcdctcmincd
laiDcd up to 15.000 ft [.1572 m] prcssrr altilude. All o!1- -,.-i i r.ed. lo L-^-olr.J , \r-re \er
pu of l5 percenr fo\aer can be nrxini.c.l oDl) up (o about lrl)g ot' FLrl Rrcrr is u5ed. Thi\ setlinr: cn{rcs rhe b.sl com
7l)(l(l i] I l:13.6 nrlfreisure alritudc. binrior ot fo\1'er rd cdr]nrg

120 hp 189.,18 k$l-

75d. raied
Prcls. Std. 81i hp [65.62 k$]-559 rated 10, hp [77.s5 kw]-6s--/ rated Appro\. fuel I gal/h
rlt. alt. Approx. rtl 7 sal/h 126.50 L/hl Approx. luel 8 galrh 130.28 L/hl l.31.07 Li hl
1000 ft te p,. rpln & man. prss. rpm & mn. prss. p'n & nran. press.
I.104.80 nll "F fcl 2100 2200 2300 2100 2200 2300 2.t00 2200 2300 2,100

SL 59 115.01 22.0 :1 .1 20.6 t9 8 )1.1 ll.6 tl.8 2t.I 25.2 2,1.i

l 5-5 112.81 2t.i 10.0 :0.1 11.l ll.l tl.5 :1 .8 15.6 ).1.9 24.0
2 -\2 ll r.ll 21.1 20.7 t0.l 19.i 21.8 :1.0 22.i :1.5 2,5.0 24.3 21.5
l 18 18 9l 21. r 20.5 l9. 19.1 2i.5 22.7 12.0 21.2 t-5.3 )1.6 23.8
I 15 L7.21 20.8 20.1 19.6 l E.9 .1 22.4 21.1 21.0 21. r' 11.0 )3.2
1r ti.01 20.5 I9.9 19.3 l E.6 21.8 t.1 2t.4 10.7 FT tl.7 2l.t)
lrJ lr ll 20.2 19.6 l9.t) l8.4 22.5 11 .8 212 20.5 FT 22.1
i4 ll. rl 19.3 18.8 l8.2 2).). 21.,5 20.9 2t2 FT
8 -: I | 0.561 19.5 19.0 18.5 l E.0 21.2 20.6
9 :7 | :.81 19.2 J.8 18.3 t7 .7 FT 20.1 19. ,-

10 2i t 5.01 I i.9 r 8.i t8 0 l/-.5 f,T l9.1

ll l9 | 7.21 1E.6 i 8.2 t7. iJ i7.3 FT
tl l6 l-8.91 18.3 17.9 ]].! tl0
13 ll l-11.r1 FT 11.6 1r.l 16.It
1,1 9 | 12.8J FT 17.0
1i 5 I 15.01 16.3

u,t rr rmtrrtrrei blrr !r!{x'! nbft., tr rci,i!nrft\ bluu nrir.rl

FlG.9 3 Po4er 5eit .! .h i for L!.cr nq l"looe O:20 8, 160 hp [] 19ll kvll, e-q e

216 Chapter 9 Operatjo, lnspect on, Maintenance, and Tro!b eshootlng of Reciprocat ng Engines
 As ar aircli clnnbs. dre air becomes less ilense On the
.iLL RlcH sel{ig. thc c{uret.r s fu!ing out about the
\rnre onrornl of fuel. bur rhcrc is less ir to mix \rith it $
dre mixlure gets richcr. IJ the xir.rxft.linrb* h gh enough.
dre F/,\ rtlo becones t(rr srrt for lrooth operatlon. Not
only wlll the enginc ru rotrghi),-. bul lrlso ireL irill be wrst-
ed. The punose ol the lircl mctcring dc\j.c js to eabljsh
rhe optinrrr flA ralio 1r ll opcratnrg condnioDs.
The t\ro bnsic t]pes of fel nelcring dc!iccs .tiscussc.l
xrc thc f[)t c Neror an{] iiel injection. The gelcrl trc,
..dorcs fttr leaning al lhe rnarrnfa.heas econnrended
.ruilc po\cr,re as lllorvs:
1. Irlo.rt tlpe carbueto
., E\'Jt I Ir. fc e.le1r o.' ma\imum
inrrer\e irr rpm : I IF- Ie forn ,
betorc ellgine roughcss o.curs. hgin. roughess i\
nol deonalior) irt crui\c po$cr. but is causcd becaule
lhe leanest c,llinder docs not firc.luc Lo a y.l\ le!
l\1,.,e 1,., ll ,or ,p ll. 1,,,
thar c)linder. " las this polnt rsults in t coolifg eilircl rarl by cxccss
I ',, I .(-o.- or.- 1.
unril engine roughness is encourrered. and rhc
crich slighti) urljl roughness is elurinted ad
cnginc runs snroothl!. There may be a ilight icrease
^l pe. I ,ur. ' , ,il | .Lr-r e rj .,, "e
pmpel) lea'rel r cruisc co.rtarcd n) full rich.
I Fxel urjecrio. tjccdus. ofthe !{rioN nrodel\ ofluel
i.."r ,.d. he trrJ..,:
handbook lir spccili. l.nin.s insNctions.
Ho\ever. s a brsjc rech.ique- al the rn&idrrf r
t.t:.hk'tklc cuise poret ltin i|, ilirh I nrnual nx1-
turc cotrol, lear itirlll b! r.ference to the {ircl flow tif
a\rihbler for the percentagc of cruise powcr. sithotr!
exccedin: the manulcnrrer's recomnrended lilniL\. Then,
lor n)r. frecise lenlrg. il n LGT rending is rvxjlable.
find pek EGT silhort exceecljng limits, and operLc
lhee.
lf the ECT d lircl fl(ny re |o a\'rilblc. the lean ro
jtrst bere engxre roLrghncss. or to n slighl aintccd loss.
The I-.GT melhod of ni\turc confo] elies olr themo
couple in he erih.ruf stck not lar lionr the exhanr \ahc
To \ee lhe effec ol mi\Nre conrol. rhe opemrr rIuI wtch
Lhc EGT gge as the ]njxllrrc is leane.l frcm rhe FLLL Rtrrr
positio. This is ilhrfmted lr Fig. 9 4 At tsLrL Rrcrr. a large
. anounr ol excess tueL ls unhurned. rlhich cools llre exhausr
,J.r:,Jr. ,r.i,J .-r '':1 ... .t. ,. r.ri^t.|,..
leaned. the aiount of ex.ess tirel is rcclucc,ct nd thc rcrr
pernlure clirnbs. Ar thc poinl here there is corplete bnm
ig of lhe F/,\ ri{ture. dre lak -.(iT i5 .drlizc.l LcaDmg
tir, rd lbe engic ncars .nd tiinr o1 1.,n nrislirc. Thc
ni\tlre is lhen said to be or the ler s c ol fcak EGT.
Pck EGT is he keJ Lo lh Bai l .rethod olr!riat!,.on|.
Of cour\e, e neler rcading for peL F.cT $ill rr)'
$ith the to\er selliLrg. alitxde, ousi.le i' lem|crt!rc.
ard $hethcr (tr ol the cylinder lnonfore.l is ttrctioni,rS
As lhe nrjxtule i\ leared tim rhc f|r I R rH poliiolr, the
dpeecl rlill i.rese alons trith rhc EGT !p trr a poiit

@@@@
FlG. 9 4 EGT.h.qet y! th m xt|]re e nq

Enq ne Opetrq Condrt o5 | /

p oriurreh 1(lll'F 155.5 Cl r. Lh. ri.h side of Ieak
EGT. This is rhe ni\mre setl ngl(n rium po$er. tl
leunr! ol rhe nri\iu e s c..ti.u.d lntil the leak EaiT js
i.chc. llri uirlfeed \ .Le.reNc rpprornrel) l rph
fl.l k ihl. Frel ecooJrt rnd dre xircrli rt]llge. holre!er.
\ill trc nrcrer\ed bl'aout l5 f.rcc.r.
Problems Caused by Spark Plug Lead
Foulng
\hn\ 'crLii ensines deij!cd to r)f.rte on 301E7'octae
r\!\ xr. Lrced Io Lrse 100L1 llo$ lcrdl \gs becuse of
rh. r..lu.rio ir dre r\,ailabiliry of 80/87 a\gs. Although
ib. cngnre' re rtpro\ed lo.peftt. oD l00LL algas. thi!
pr.rur ! 1l)e pi .hl. nr f
sp' k Dlg forling bec.tNe I 00LL
r\gr\.friin! foui tjrcs the TEL (Ieraeth)l l.ad) ol
S0/1i,i o.r0ne \gs Normll) 8ll/31 41,!!s IrN lcad co-
rer oI0,i ml/sxl +hcrrs l00LL as :.0 ml/gal. The
ersiie i rhiiir\ ro s.r\cngc rhe eitr led frrn Lh. cylin.ler
s !.etLr.l..i.rs.c1 $hil. olerriing on l00LL xrgr\. ,\s a
renrlr. led deto.it\ on Ih. \tark plLg\..using li)trlj.g of
sprl plls ]crtode\ Tlis sprk pl : iouli.s ca. cre
rlr! otcrxtifnl problems and crn i..rclsc lhe ned lirr
sprL phg clcu!1S.
nl _. Fr
9.lo.fe',. .'.- .. '.1r., '(
rci ril drrt oprilnm nri\!u. coLrol bc chosen ro prelent
cr.ess leil LrlrildLrp. Fir,. \ilr
propcr rirture colrol, ir
m\ nfr b. p.,ssible o lei the sfdrk plug pedorrnnce
.l.sircd. To !!pplel1]elrl ni)iure ..it)l ptucedrres. ruel
etnenr sch s TCP rricre\vl phoyh!(er cr be mixed
sL tlre tuel if the tnk .i ri\. (ir]r iLrel s it i..1i\
fen\ed lnJ rhe rnk lalP rednces sfark flug li)trltrg br'
Lnrki! rhc l.!.t l.\ coducrire nd lesi.or.\i\. ro the
ele.lfoll.\ lr l{) \olicDs the led deposits fomcd. which
.f h.lp in th. s.\.gmg oI led detosits fiun t]rc col1r'
lrtr!ri.n.hrnrb.r. TtP is gener.rLlI n.t u\od i rLrr
bl)chig.d .ngjcs or e|girer lhal do rot .\pclience Iead-
relltte.1piob].m!. T|erel.ire. iI is no n\ed $ d \landrd
Crrruin le.hrr."; ofground eginc.rfcrIio! can aid in
tic\.nrio ol sp1d flus fouling \hcn l00LL a\'-eas i\ usect
j. orsll1es desLgned f 80/Nl lgs LeI the en:ine idle as
jtllc s possible becn\e of thc rjch nirhrre used dtrtrg
l.llcr rfpll lhe foier lnroothlr'. ncl re\,er open drc th1c
hiUnl] dir rg |orrl tk.o1l\: rD the egie bout
l0l)0 ryLr rler ihtt i3 loqn lhc crgirle, and then morc
Lhr irrue ln r {r . Th.\c .cjusr a ri$ e\impl.s ol
reclrflqrc\ l(r r.du.iIg sprk phrS f.nli.g. The engine
,:,jrerard'. hin.lb()k sl)oLrkl lr'ts e.onsoltect lor stecif
i. l\ u.tin.!..ngre operioD.
Wnterizaton pro<edures
Cotd1ether oteirof ofr. xircrxli enlrre !ol\,es \tc
.irl treprli,rfs .d trerutio.\.ol]1lared t ormrl
!t\.o\il\ ol il cusc\ redLrced crakin.q Tlis doe; rol lncn thdL th. cngie qill jl!5e to rnll aiier
c!lr. alld rhe hi:h
ipeerLthrcconrfa)inghjghlod.or)rhenler selting our jn \uch n c\tr.nicll colJ en\ironmetrl
218 chapter 9 opert o, nspe.t on, Malntenance, nd Tro!bleshoot ng of Rec procating Eng nes
Olrc th. cngjc xccer\ories lLril becnse ol corleled
oil. Thi" is r.rr- clcr liour the ilcresed rlurnbel of.ril
coolcr lrilrci o rcci|r,rcl: egnles nr cold seiLther.
I i r. r r rr 'lc I
nd .\ljD!t.r \{lls. c{u\in! dre piron Io s.L'tirrd \core dre
c,- ludcrs.
Sorre crn rse $lnerizinf kit\ ro rifr.r I deired
engie operailg le|Uertrres nLl to trcr c.l oil coolcrs
and 1tor \enl llnes fmr frc.rjg. AlLclion 1o ll.lrils.
{Lch N iurig ut the .ngmc Lrci)rc l{k.o rd allolrrrg
the engje t. co.l dos prjor to shLilrir)g iI o. p\\ dirl-
ded! r reduccd nrarnl.nnce rnd eile|ded ersrne llte.
\\ifier opertion lhoul.l includc r cliecl ol the carbLercr
xir hel sysrenr nd th. dcgrce ol hel ie \nilble At lhe
sr!e tie.lhe e.gine idle r]rm and lni\we. r1th .Lrl,l qiILr
d,i1 .r,hrn,ror her rh.nld he.e.ked
,..r .. eo"e. ler '1".1. r..1..t..1 I -
1r cold $exdrer. Froze blerher I res hre .rcar.d .nr.i
r,us proble N Nlos ot' rhe Irxrer .f.o]busri.. gocs out ol
e eiha: bolleler- sone Nater entcr! rhc .rnk.s. rn
i-c vaporized \Vhen he lxpor cool!, it .o..in\\ in (lrc
brealher llne. inbleqrentl) lreezLS il clo!.d Sl).. rL trc
llighr cre i\ reconrnende.l o enfe har rhe hrerher s\a
- -
,
Draining sumps
Proper arnirg lrf be srp s lcrr1 nrfoLtxt duiig dr!:
preflighl check SLlliciefr luel shnld he drr'n ()il into
anrparet coniairer o see if the lirel is lree (,1 rrer nd
conaminns. This ii e\pecjrllr impollnnt during rhn:r'
in emteraiure. paicLrlrl! n.d fic7ig Ic.. \hl.h r)
rurn ro raler sher rbe tenrfertuc iisc\. 11\ be in the
tks rd filtcr do$n int(' thc crburctor or luel controllcr.
.nsirg e.gine frihre. $t.r c liccr. in linc! d lihcn.
.dsjg stoirfrge. A !nll rort 01 $!tcr. IlL(! lir.
cn fre!e f()per ojrcrtjon ol luel pu ps. \eleclor val!es.
lel
Anti-lcnE Addtves
Alrhough proper fuel srpling and troper di.iS ol lh.
sunlt lle essentil ir trelening jce fornrat n due t. fre.
saer in he luel. the) rill o elinri.nte the h/xrJ of jce
o o. .J!e .l ^ . .re
srspersio! or solulon mr) lrlr1 ice cl)!rl\. Sin.r $Lcr
in sr\pension or sollrdon is nol reno\ed bl th. strrf. thc
( ) ' I l.l ' Jl :
additi\e.. snch as isotrot)l rlohol or ECNIE (crtl.re
gl,-col m.ometh)l eLlrcrl. i rhc 11.1. BoIh adilires
ibub $atcr and lotrcr th. tieeri|g poinr ol he mirlL|e
\\ hc. .tlcohol or FC;NlE i\ u\cd. jn\tr ucrio\ 1r ttupcr use
nust tre carefully follorcJ.
Engine Preheating
I'rchcating e!3ie rorrsisi\ of f.r.its hctcd tir in rh.
egie xrei to heat th. .irgiDc. hbric{.t\. n.l acccssr,ric!.
I'rehexting i. require.l lin ost iicdll r.ciIro.(irg
engines she. out\r.le tcmfcrtluc\ arc +10'F i 1l:'Cl
\lrling $ ithour prchc{tiDg hs liequentl,! cxused engie 5. Fleriible ribration dampers lr poor conditio
d.rmxge. Sorc 1)pcs ol damge are scored ctliDders,
\.ulic.l pi\(ir skis. l)d bmken tiitor ring\. lhc applic . Engine controls lirr delecis. imtrofcr trrvcl. and
rioi oi hcdL Lr) onl) the cylin.ler tuea lails to cn\urc that thc
entire oil \r-src i\ clolrlel) heated. Ar tcml)erurcs o1' -. Line.. lro,e.. nd (l:,mp\ f ..,1 , 1

+10"1- | ll2'Cl Dd bcloe. preheting of the .omflctc concliti.. d looseness.

efgine. oil srptly lDk. rlcloil sysrenr is requirc.l. 8. Exhaust stacks foi cra.lt\. clclca. an in\pr.,pcr

9. Acccssories for nlitLrenl deicls if sec!riry of

Engine Peheatng Precautions
The lllowug:rcorrrlncndatios regxrd itur.tli pjhctrrg:
1. Prehclt thc rircrNli by st.irirg in r h.aLcd hang.lr,
2. Us. onlt hc(.rs lh( re i. Sood condition. rnd do
01 relnellhc hc(cr rrhiie ir is otertig.
l. Durnrg the hering pn)cess, do ot lea\e the aircnft
unttcn.. nd keep r ire errin.quj\hcr hndy.
.1 Do nor plare he dLrctifg nr Lhat it will bloil hol air
dirc.tl\ on (orLbunible pr( of thc aircrli. such s uphol
!icr). c!!5 efsine..\ers. or llc\itrle txel. oil, !.1
h\.1tur li( ] rLi\
10. All slslems lbr inploper lrstallatio.. poor rcn.r
,l .onilltid d:L.rs d irsecui rchmenr.
if ll. Co$ling tor cracks and defecs.
A.r!ntrlacrurcr's inspectio checkhf is shown in I'iS.
I Il show\ the items to bc ispcctc.l o.l lhc opcratiul
5.
iifervals lirr acconrplishing cx.h it.i. Nolc\ t lhc bollom
r Ierr.te. ror I r -lr .Irlc r'^ rJ.r r -orJrn
refeences io other !trblicrtio! ol thc rrtrNli(tr.cr l lhe
fbllosing tex, $'e di\ctr\\ Lhe nri. iterns or the checklist
ln Fig. 9 5 Propeller instccljo i! covered il Chap. 21,
nd ad.litjonal lnformatio on ispcctio! !rcsrm! ny be
found in an accomprning rclt in Lhis srric\. 4 ll nrr

opening and Cleanihg

lrAR,l:1. Affcdix D, beglns by stnting:
J:nSics !c rlcsigncll rd bnilt to fn)vidc iLrll years of
ie,\ice. l'oi rn cgrc ro remln in xiNo h] condltion, jr ''I rl1'-
ihonld be otertcd in ccor.lance $'iLh lhr ecomlnendn
' a. '
shxll. I'efore thrt irbpccrior. rcrrollr iir oltn lL ecessr\,
jo.\ ol thc r)nutrcnuer ffd c.trc.l ior with ioLrlr.I rnsfec isfection fldtcs. access doors. ad cowling. He sh.rl1 lbor
...et'.r. \'. ,ou. rr r'i,r' oushl\ cler. the aircrafi nnd a1irali cnsj.c.
b. ob\ened 1 the i.sf.ctio rnd nrirnenan.e ol an diF
.nfi cns . re e\fli.ed i the ll1o{irg sections. When operrnrg co$Ligs. the techni.ian slLul.l norc n)
A liral irstect o s nccdcd to delennie tbe curcnl accrnultior of oil or olher nnei:n rlt rl, trhirh !ur'tn'
fo dillon ol the efsinc nLl its (ornponenl!. l_he rcpair ol a sigr of lluid leakage or oter abo 1'nl condition aI
Jii.repancles rs reqLrired Lo brj.-q the engie back up to a' should be coffected.
{olh\ slandri]\. lir kecf th. rircrati rn aivorthr'coDlli An engile nd accessories $sh do\ shotrld trc clone
r.1..' pior o each 100 h inspe.tion to rerclc oil. grcsc, sli
be perlrLled t \ rlo!\ op.r(ins te^ls. Also. bclbre an consion. or other r.\i.1Lrc thrt righL coceal compoent
.nSine is \er\ic.d. cori\u11 lhe handbools nd manLtrls .Flr. r'r P rl , ' I .eJ'i
iued b) rhe nrrnul.lur.rs ol IIle eqtrif.r.nl 1r lhi tar rn aproll or coveralls. anil fce shi.ld o.
ruhbcr g1(^,.\.
:i.ulnr nrrlie. nr)d. . d tlpe ol egi. The lbllowing gogglcs. shold be Iken shen $orking with clcnjg
.."ull,rr..i{'
thxt will srtifctoill cconplish the work. lhese clerDig
Durio! rr i r\te.tjo.. cl).cklist nrost bc !scd ihl gents inclu.lc: (l) Sloddar.l sohen: (lr x urter bae xlh
.r.(ls rhe scote xrl deujl o{ FAtt,3. D. N4o!i Line cl.r.rgcnt.lcxner .onsislil! ol I pr.lerer. to I i
.rnulactnr.r\ hx\c dc\cloped recltli\ts thrt nreet or
^ppndiri f!rs stci. nd ll 1o llpasSloddrdlohent:r,r(l)r\ol
:\reed rh. \copc ird dcrxil of A|Fndi\ D. Accortins \cnr bsc erulsio clerner corpri\rng I |!rt clcincr ancl 3
FrR ll. AttcnLli\ D. cnch |erlon pcrlornring rn fnulor plts S{oddr sol!eIi.
.rr0 h n\t..tion rst il]stecr ..nrpon.irlt of the eginc
:i:rd.x.elle.ur.ut ! l0ll0$! WARNI\G Do nol u\e !r\oline or other highlt llln r
'r', .'rrJll -o |cl| l Jrrr- .

I Ergine se(1ion l( \isurl e\,rt.cc r)l c\(e\\i\t rios i scll \.rrihre \\'{r'k rres. nd en!nre tru rdc
':1. f|rel. o h\drlul c lcrks \ s cll \ sourccs ol such Lerk\ {luftc liL. Ii:b(ig r sler) equLfrenr is rxilahl..
I Sfuds nd nuls lol iriifro|er t{)Lqtig rr (ib\i a.rpi.ss.cl xir. uscJ lor cle.ing Sent ftli.xrtr). or .lr.\
r.ri defe.r\ ing. \lhulll bc resulrted nr rh. lor.st llxclicl ticinue.
-r Intcrnnl etgin lr.ylrnd.r.oirt)rc\\,,i irf,l li Llsc ol r .ri1l-brlsrle lib.! brush. r(hcr lhr x feel blLlslt. i\
:::.ralfr iclcr or lincign rrlter o \rrccr! r l(l \lrfrf (llj i.coifnreIded it cl..in! xsc!rrs do ll0 remole ercesi
riLrSs. lf rhcr. i' $ck clli!rer !onrtrc\sioLr. cLrc.l (h. grrrse l] SrLnr. durig W,-iog. Betirle cleanilrg rh.
r''l'1..,'.r.1. .rrgirie conrfrrkr]r. tlcc slrr ol lfe on the r:rn.t{l
+. EngiDc mounl jr.rck\. looscc\' t)r nornl. !cnts 1. fre!e rt rr- sol\ct lror)r .nterins the\e ur lr
-d loosene(! ofenrin. Ll) lrrouni Pl.c hrse fd rdcr {h cr)gill.lo crrfuh \r(c \irh rh-'
nspedion and Mintenance 219
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220
 .'!i1- orri ,. .,, co .pr. , h r.,.t ... .:,,e
, .l P 1,.1 n.t eJ.( I, cr^.1 .
- .!: \l. ,cpo..i ..r(.e.
salr Io bruih rruai rht have bccr spr!.d.
UTARNING Do ror \play sot\.r inro rhe tternatol. \ac-
rum purp. starL.r. or air lniales. Altow thc \ot!enr ro
er)jn or the engnr. for 5 to I0 n Ten nnsc the ensie
ri ^ 1.,.r(,,' J., \i .(..,..
age|ts lhoLid e1er bc teti on engrre compoets fi
extend.d period\. Failu. to erro\e ltrerr m.l} cru\c dam-
jelo. .o. r' .l .( pr. e.(.t
l. .. :o , r .. .,, i. l.r.er.
dl) lhc rgine anclacccss.ries. rs;ng clea dry c.)mtresse{l
a. Il Ltcrired. rhe ergric..irtrs m.rI be sashed \iith rhe
same sol!eni. Rcnrore rh. Iroecri!c tape U1!n the magne-
'''.,.1 D.r ,c.r .. !
'r
ccodacc $,idr lh. Lubcariof Cthit. Other Drrs .t
i FlG.9 6 O i t,"r..rtrrq tool
rn
c' !.r le. r t I i,r'i .. r
lln:lg gexr .Lnd the u.dersrlc ol rhe rircrxi NI{xr con] I e ,rulo | |
pounds used lor relorin: oit grelse nd strircc di tor i rr( nJl cnrl c dI J{r
ihcsc es arc ernulsif)ing Serr!. These comtoLds. . ...- , LJ .,: re.. . r, . r p.n
whc ri\c wjth pch.oleul \ottenl\. cnmtsif! the oil. cles of nerallic sharlings njght be du.i Thcle arc oftjrrlc
p ?- I 'i r..r' coJrs..tuece xn.l shr{Lld noL be cofused wjrb tarser rert
I r..i,- - -n'. , | 9 lr.. li.er,. Lr .,i,.o ,-.
', te
Ofe ng\ luch \ ri scoots should be co\ered prior ro
l .o ., lc,, (- I ri're. r . .
clcanirg. '- '", il]xnu.tl
mif e lhc .aLrse. The rnanur'ir(turcr's rnienrce
shotrld alsar.s be c.nsulrcd lr troper Ljcerrni.ulion of
rolal pa i.les lound l rhe engie oil llttrr \\hef th$c
Sevi<ing Oil Screens and Filters .l r'.. , .. lep-J11.,o.1,. -J
'..,
Nlost cnglres iorpoiate ar oit suior scrc.n irlrjch fitiers
At oil .h.rnges. oil smptei {re ofre rke and serrr
oil rs;t lea\,es the.il {r.it bcfore ir enr.rs the oilpres-
, I r', Tt. LI udy to hboratories ro bc natyed fo ver lrclrls. .\
.. i. :er.. tt. r. -. ..I .l coinflete discussron of .it rLlsis .af bc fonnd jn CLraf.
rl. . rl f. ,.. ,.,/.,r \ it.
-..r, . t. rc.,..\"r--.r;o
1 ,9.
r.at.a..d.c,.J.. r ol lnspecton of Oil System Lines
''lrr...^rr.,
" lrl 1: ..r l, .,T .-.r. r,.. Tl)c inspecrion ol thc ptumbins tbr d oit svsrenr ts siLitar
scr.c. the c.:ire should bc ernxncd f(n.inrenral ''danasc Io rhe inspccrio| Lrl a! orhcr ttLrnbinA. The hrbin!. hose.
\r rr' ,'. ir':.1 ..rr c.t ..J,rl . .trt.
rnd sfct! {ith s.rfer\ $ ire I rcr 'r. r., , i l. .dt !
\r"1, .r..' i .eo \' -(. l.r.:1
.hi.r .'....r.."..i '- I or . -. \,lr . :

tion oi thi\ scrcc. ll oil p!\sins throunh it i! nnder prcs r' . -r. f er "r fo eJ -r. ,rr rb rne - J n.r ..
su|e h is loc r.d i a holig on rhe accessrn! case ol the . r.,et r-. ,, .i ,.,;f-p..
cgire. -lhe ojl fres\trre screcn lholtd be terned rnd iistlladon. o1'errorqnirg. cressj'c rensiui. or orh.r c,:,rl-
iTeclcd t lch3e o rijartt irrpection Aiier rhe
each o dilxDs whi.h mr- leld ro lailure.
pre!sufe screen is re ro!.,1. )! a.ctrrutation of stuclgc
r.l'r. Compression Testing of Arcraft Engine
! t -lto$, oiL fher in\t|ed
\fosr mod.m ergjnes h.r\. Cylnders
o| (hc acces$ry casc be6recn rhe mngctos. This tilter can -\ r ."..r..r ,rrte! i t.. ^,pr... d.r.,-
be"t ,l-. | , .t.. ,i. l , .. ..{ li o, L . ,ro , ,,,nt,
'rl r1.... .-l ; , er .rr- Lr. te^ '."t--..tret..
n|, T. .n. i.rr .*,r( . -.,. .... t.'e
'r . ', I
Tlpes of Clompressior Testers. The r\o basjc rlpes
eleme.t tlpe is jr
horrsed a canjer thar j\ di!l]sserbl.d to oI cornpressionrercb cufl.eDrt,- in usc xre rhe dircct-con-
llow isfecrio ol thc fiter etcmenr. pre..i,r tc.lef LF dilterrntiit-pre..rrr.. te.rer.
Tl. pr .1 .,rr., .,.dl ',... ". Lt ."'." .. "r,le i .. .u. r.:.. e r-
\rrr ,!,
Lo.... 1., le i.i tr p..r,t I.r .nh thc dilftronrial,rrr. corprcjsiolr rcst;r
i.a v ollc
'rl .o i,.,.trr. ... Lr...,
usnrg x rhary lif ro cur through the ttrt\ ot rhe eten]er rcrli c)l.rs. h tli\ re ccL. i is suseesred !h e
.rt bolh ends. Then crelllly Lrri)t.l the pteared ctemer nd dire comtressior Dlerhod be !scd lirsr ,i,i e iinn,:r
lnspct on and Mitenance 221
 :1. lf a corlplct. \el ol corlpre\\rm re!es is alailble,
ift(all one iester in cach c)linder. Il ol) one tefer i\ bciDg
Lrsed. check eich crlnrder i. rur.
5. L'sing the cngine starter_ roltc the efgire t tcasr
,\.. 't c,(1 rir
erdi.g. bk,j Arr exrc rrl l]oer sonL"c should tre used. it
posslble bc.ule a lo$ brrLcr\ $.ili resulr i lo'r engjne
r t 1.
rning Ite ad loef readnlss Thjs \rjtl roticeabl) afrect
\ '.1a,r\ ot
6. Recheck a! c\linder shic \ho\rs an abnormxt
rcacting compared $idr ihe olhers. Any cllifder haling
(A)
ra.lig appolin]atclr l5 psi l1{J3..1 kPdl lo$er thn the
(B)
,.r .\", 1 oe rp. eo .c, -0 .:
7. Il ! comprelsidr teser is sus|ccrcd .,f b.ing defec
tlve. r'ephce jr (rth oc kow ro be accurre and recheck
f lG. 9-7 ao rrer o r tefers iAl D 1f e.e.: -p'rL e tetter he comtrs\iof ot the Iftcteltcrlrders.
F) D r!.t-..,r.prel5 of ies:er
Differentil.Prissure Conpresshn Check. Thc dif
substantlaed r1'irh (h. clillerentil treisrue mehod. This ferenhal-prtssure te*er rs designcct to check he coipres
\ie1ds r coss-referercd ro \alidte rhe rendxrgs obramed b! sion of ni-ftfi .ngines by nresudnS rhe lcakagc thFrgh
ech melhod rd reds to c.ntrc that the cyhliler is delcc the c)llrders that is cused by sorn or dnxLgcd comlo-
r. r..B . nents. The operario of rhe conrfressio reste is ba5cd on
cd. notc the loLlowi.! poirns: ihis princille: For y Silelr airlioq hrorgh a Uxcd o.iiice.
co.(n! pressLrc drot x.os\ that orifi.. wiLl lesuh. Thc
L whcn {hc spail tlug.. are rerned. id.ril! rhe c!lir- dirtrc.\ions of the rc\tlicr.r or lice xr dr. .lifferenti:Lt pres
.er' o r..1 '1.: ..i r. 't.S snre lesrcr \houkl be sizcd. A schenatic digr.r of the dit'
'; '
$ill elel rhe acturl oFratjng '.
corlirions cl aid in diar fererlial fressure efer is sho\rn in Fig. 9 8.
osirg probler\ i the cllinders Shc. dre regulred xn trc\sure is applied ro one s e oi
I Revie$ thc oper{ting d rnainenancc rccord\ of rhe e rc(rictor oir'jce wjth tc air !lve clo\ed. thcfe $jll be
ef!rDe. Record\ ol pre\ions cornpresrior lcsr\ r.\el tro no lelige or he other si.l. ofdre oilice n borh pressue
greisile wea ror)itio\ rnd help to erablish e necc\\rrl ra-les riil r.!d lhe salne. Uo\Le\er. irherr dir ir \alve is
mnntcrnce approch. otened )d lcakge through rhc ctlirder increser. rhe
3. Prccaui.s Jroxld be tkcn rc tr.\ent lhe accidenll .)linder pressu: gare \1ill recoid x pruorriorrll] l)er
sfirrg of the efgLre. Rernc)\c xll \trk pltrg leadi. rnd rcrdi9.
plce rnr !) rhrt the spar* plLgs clnnot fire. The lbllo$nrg p1r.el1r.es oLrthrc thc prjnciples rl1!ol1e.l
.Tr. di'c-,t . I m tefonnxrg dillereinl pressur corplessi.in rcsr !nd
must be k.tt clca and shonll:l be.hcckcd re:ularl) ror arc rtended tu (rll]p]enen he mnullcturcis irrruclion\
accrrac). Chcck equ4xnerr sirh Lhc ( toff rahe closed ft)r the pafiicnln. r.stcr beils uillzed:
and regultcd fressure nt 80 psi f552 kPl dre .]linder
tresure gage I]]u\( i.licte lio:: p-\i f55l I il.8 kPl 1. Pcrfonn llre cr,niprc\sio. test a\ soon a! possrble
and hold this readnrg ftn it le\t 5 s. arler ergii. shutd.r'n o ensurc thar rhe pisror igs. c)li.
5. ClonbLrslion chxnbcrs wirh li\e pislon rings rcn.l r(l der q alls. .d other engine parrs re sell lubricared.
\cal bette hirl lhose $ith tlree or fLrr. ilirh rhe resl( thr L Remo\c th. ror accessible sprrk plue tom exch
the differenrial-pressurc tcster does ror cor\isletl) shos
'l...rrf I r. : Widr rhc ir !.rl!e cl.ised. ppl,- an e1eul source of
.ler ajr, pprornel\ 100 io 120 psi l6sq o 8t7 kPl ro
.:r ..,.....e .ror -."' p j
ispcct drc compressior te\rcr rir watef of di1t. .1. lstall ar clpt.r in the spak plug bushig. and con
necr rhc conpres\i r tcsrer rc ihe clllnder.
Directcmprtssion Check. Thi! trpe ol conrfres, 5 .\.ljtrst rlre trei\urc r.gularor o obrnin a rcding oi
sion tes irdicxrcs the xctual prcssurc\ withi the c!lifder. 80 p\i f552 kl)!l on rhc pr.lnre egul or gas.. A hjs
A el r. .'i.r'.ee. I .. .{ , 'l.....r. tinc. lhe .)linder prss0e gge shorid rl\o r.gister 80 tsi
is djicLrh to delcrrine b) thls method. rhc o.! \ec) of f55l kPal.
redings lbr all cylinders is an indicatlon of orerall egine 6. Ttrm ihe crakshaft b) hnd xr thc direcrio ot' ro
co dition. Thc followirg guiclics for perforrrling a lion antil the piston ii the c)ln.ler benrg ch.ckedl ls conr
direct-coLnpression te.t xre sugge\rc: tug up o Lts compre\\io strcke. Slo\rh otcD ihc air \ ai\'..
ad pr.ssurize the ctlinder Lo afpr.\imntel) 20 psi ll-:8
l. \rnr ut the engine ro opcr{tig rnr|er
Thoroughl,! kPal. Cni., tse.rell in opc.ing rhe ai. \'ah. lince
e telt as s(rn as possible lier shutdd!.
.]ure. an{l do \ulliciet ai. tr.\sure irill hale builr up i re c)h dcr to
2. Reltlole he nosL rccessible sprk piug loDr cach cause it Io rotte the cr!kshali il the pi\ron i\ ror a TDC.
Conin!e roraring lhe erlgire agarf rhls pressure nnril
L Rotale ihe erEinc $ith be slarter to erpel anl ciccss the fislon rcchcs TDC. Reachirrs TDC is indlcared br a
oil or loole cabor ir d)e c!linders. llt slto! or suddcn de.reNe i lrce rcquired ro rurn he
222 Chapter 9 Operat on, inspectlon, Ma ntenance, nd Troub eshootinq of Re.iproct nq Engines
 li lir is lcakjg fro thc \alve!. dre techniclar $ill hear
rir clitilg ltunr thc cxhaust \tcks or cartureor inle. This
lcakagc D1y bc cdusccl by smll piece of cnon stuck
unc rcth thc !al\c. Gccldlly this problern cn be cor-
recled by plcing fiber clrili oD Lhe ock.r ann directlv
o\er lhe fxl\e renr nd lapprg thc dift sc\cral Linres with
a harnrne. .) dislodge an) toreig mrerirl or crrbon
bel|een the vahe face and seat. Nrn,r When you are cor-
recling i rhis manner. rolate the propeller so
low reading
tht lhc pisto will ot be t TDC. This \ill prelent the
..i 'j \ L p lf .ii,.,
=r'.
RotaLe th engie belirre rechecking Lhe cornpression io
rasct thc !l\cs in he lonLxl rrc.

Magneto lhspection
D rr. ,": ror .rrLJ rr.p:..or. r.. ne.orr pec.ron
noimrll) Llorre silh e n]agelo on lhc engide Sore(idr"-q
it is lecessrry lo ltnole dre nagrelo lr ispectio, such
as qLth rhe Slick series nagleto\ ibr the 500-h check or il
iufiher insteclion ard disssembl) re \!arraIed b) dis
crepancies. The lollo\',rng is an exaln!]e lis ot' nragneo
prts iht shoulrl be inspdcled durnrs 100h o a rLral
insFcioi (see F S., 91. ( lhe furhe.s rf rhe Llhrsnriof
r! r_lcr' r ,((r. rlr. rp<.l r
will rcqrirc th. r.molrl ol thc igitio hrmc!! .Lnd brclcr
contct Irldte frrn thc rageLo.

L Ispect Lhe dirribr tor blocl contcl \!rinu.\. ll bro-

ken or coircded. the) shor'ld bc rctl&cct.
2. lnste.t dr oil felr rarhe.. lt shold be saru.ared
silh oil. Ifit is !trr. check 1 $or! bushnlg Lllxicle s
FlG.9-8 !.hlmat. of typ. tl ltent ressLr.e.ompree needed \lrllr o. 30 oil.
3. lnspeci rire distibur'block til crcks or hured
areas. C'rlr,rr The wa\ coating on tle block lhouLd ot be
rrankshafi. lf dre rinkshaft js ()tatcd loo 1ar. back rp.rt
it 0.5 r d s1t o!er. to cli intc lhe elIecr of bnckhlh 4. Look lbr e:icess oil 1ll dre breaker colnpalll1lent. It
:n rhe \l!e operxting .rcchnnisur and o keep he | !1o. rua) rnean a bad oil seal or iL seaj bushriS a dre .hi!e end.
rnss seated on thc l.$cr inrg lds. 5. l-ook for fiayed in!trlaion or brcken wirc strnds in
7. Otef thc an \al\c conrplelel) Check tne rerulatc.l leads in bck ofthe mgneto. See th{t terin{ls re securD.
rr.s\rrc ad aus(. i1 necessry. to 80 psi [552 kPdl. Bc nrrc thc $ircs arc prperl) tosilioned.
S. Obscr\e the pressure indicxtio. oD thc c)lnder p1.es' 6. Irspecl dre cprclor r'lsnall,r. li possilrle. te! iirr
iure gagc. The diftrence eeen dri\ prc\sure and rlre leakage. capacilarce. and series resisance. lndiscrimitc
rrrssu.e shoirn b) lhe regrlrt(n prcssLrre gage js he rcplcemen of dre capaciror e.rch lilne the brcaker poits
mount ol lekage d oulh lhe cllind.r. A loss ir excess of are ferlaced incu\ af ur]e.es\ry exlEnse.
la percert ol irpLrt air prelsure i\ cause (.i sspeci the
.\lnalcr d beng defecd!ei hoevcr. rc.heck he 1.eadings
.iLcr otelaling he engine t] rt l.{( 3 min o allo for
..alLS oflhe rigs wilh oi1.
9. lf lerkgc is sLill occumng lltiel a recheck, 11ra) lre
,1.r.:..r'.
.e pisto rigs c, o\er lie. rno\e in thcir gnx\cs ltr
nre csc! thc pislon ig gaps can be.ome lign.ct. This
r ill cius. { ld! corrtr.srion check. Ihjs froblcm cx be
:llected bI sinrflr rullirg np the en:inc trnljl rhc.jng
:t\ becomc staggcrcd agin.
whcn lcdg. occ!rs. e echician cD dctcrnrine the
!ur.c o1 l}c trobler| bJ listenig. lfdre ai. is leaking fiom
:he ornkcasc brcther. Ihe rhe lexkige is fio] ronnd dre
. rro rings or a hole 1lr the pi\t(nr. ll spr)_hg oil into the
:r lnrlcr ard faling dre en-eine s.lcftl irns lmpove the
.idug on r compres-qion lest rechcck. then lhe problem
riobabl\ lics \rirh he tisto rings. Thi\ lrpe of test ls
FlG. 9-9 lilqneto rems to be spe.ied

lnspectlon and Maiteance 223

 i. (lrrrccl thc djuslrrer)t of he breakcr\ lo profer $ill sho$ lekage betr,,een led! ri \.i:
inremll rjr;ng ol the lgrelo. .r^.r Tl.e\.1. r J;(l(1li ,

I Ch..l rhe breker .rDr. lt shoulcl be cleI and
If thc i.rpulsc coLrplins is nccessiblc. it should be
l.s|.ct{l in rccordace \r'irh rhs tn)fcr ser!ice bullelin or
nrinLcnce mnLial
lnspecton and cleaning of Spark Plugs
,\- cch \t.Ik plug i\ rcrno\ct] liol the cylnatcr. e elec-
ltudc eril shotrld bc in\pccrcd tor posiible dcp\it\. These
deposir\ ftcn icllccr the irleml condition oi the cylirder.
Ihe oDerti.. ol thc llel slslem. ad !b. $r" h \r,hich be
eSin. i\ b.ing o|ered.
Vitrrll) Lr\tec e.r.h strrk plug lor he f.llo\ing
I Severeh drmged \hell or \hield threrds nickcd.
rlriplrcd. or cross lhreded
: Br{11) bttered or r.urde.1 shcll hexgofs
3 oul ot rnnd or drnds.d shielding bxnel
,1. (lhrfpcd. crcked. orbroken ceranric isulalor parls
. tJrdlf eroded elecodes sorn lo rptro{ilnalel,\,50
pcrlcnL 01 origrl sjze
Afref rhc -\park plLrs ha\ been invccrcd. rI should be
clencd xs rc' irc Alrer.leaning. it shorld be gpted and
' D. r rl t \'.
du.i cr be lbnnd rr Clhr!. E.
Harness Testing and lnspection
As rrroriru!l) me|iiored. hi-eh tesi. clc ior ircrati
isnilion slsems co\i!\ of fe\ \Lrinl\ ol slidess-steel
\!irc coleled n'rrh a hlck laler of n iDslnlig material
iuch as silicone llrber. O\er lhis i\ lr-er.if Slass fiber
ieilirere|r. and oler hc r.inldacmell another bick
lt er of i.s!lating nrxtcri1.
The lLlsulatlon .f the iS.irioD cable is desiged ro
f]rd !eT hiShr.ltrsc $ithou bleakiS doNn. O!cr line.
h,rire\,er, leak!:c ol i:njrio culrelrt (ill occu. E!e a nerl
cable lrill leli lorc$hrl. but lhis is o irp.r1x.t unlil lhe
likge icrelei s. r.h thal lhe spnrk t thc iparL elec-
1es is ekeneLl or rotpcd.
To ef.ure thil lh iclcclric srength ol igr)ilion
i'rlxrifn is ile.luae ad thxt e\ccs\i\e leakag.'is not
o.!ning. hrress lester called a mgohmmeter! or meg-
l{cr. i\ ured T!picl tenell! arc thc Continerrli HiSh
Tcn'i.!r Led Tester nd dre l\tcm Elecronics Cxble
\ l)rleis lerer i\ an elect . unil .lcsigned lo produce
dc \(rllxsei Lrt ILr 15.000 \ iltilh c.r bo pplied to indilid
rl l.cls rn n igrLrior hine\s. A t)picd Lrnn innt include
gges ro re$r rhe xtplicd lollgc Dd lekr3e cune1. a
!ollge con'ol. itut lexds. rrpuL lcds. nd requne.l con
rftt s\ irche' I hc.c unit\ rclrde inrlllctions 1or lroper
To e\r igfirion l.dd\. xll lerd! re dirconnected liolrr
he spalk plug!. nd rll l.ds bul lhe one b.irg tcrcd re
lrouded to rh. cn.!rc Wi{h Lhe leds groundcd. the lerer
o the stark plug terminil of tbe lead bei.! i:!.:i! Th.
groud lead is altnched !o the engine. The irir m:\ rl.o
be grorded 10 e.th thrcugh x wlter fife or orh.r nrrn.
Nlanutacreis islructio. drc f)lidcd tir rll hxin.\\
lc\tcr\ and should bc lollo\ccl. Since \uch uil ptu.luce\
lerl high loltgc. it i! csseluial hl rhe operarcr be mor
carefl when the uii is Nrned on.
The voltge ol he lener is djr\d nr the le\el giren in
the irstmcions, which js uslly 10.000 \. Nhcn thc con
ol sirich is ured on, thi! \okagc js .rfpljcd 1o c lcrd
beirg ese{]. Leakage siLl sho\ o thc ricrcnmcLcr and
should noi exceed 50 nri.roxri)er.s l!A).
As testing of lexds oDtinlcs. oc or c lc! sill
likely sho$ hi:h lexkigc bc(au!c ol lhc posillof ol llre rlii
ributor rfor in rhc nrlgneLo lf he roor tiS.t s l gne.l
$irh thc clccrroclc for thc lerd beirg lesled. rhe cLrrenl s,jll
Jurp the gap 1o llic rotor ard l]oi! ki lroud dnouSh the
mr:clo coil Whcn lhr\ occurs. rhe efgine .rkshfr
should bc rolatd lll chnge lhe iigrrefI .f
rhe .lisrihuor
roto $ tht thc lccl .n be relesled. L\ir! rf ohnrrere..
or cable lesle, chc(k ech leLd lix conti ritJ. ll..irinu-
it) does nor e\in. hr.kei fd nNr be ret a.ed.
the led ls
ll eressi!e ea(age ii several crhles. the
tlre esl shoNs
drsrributur hlock or enirl blo.k ls trobbl) dcfc.ti\'..
lhe block \hould thcrclorc bc thourghl! crnre.]. Il rhe
re!i !how\ rhlt the hdrne(r is faulrt, all lhe cables ihould be
When .lisrribtor block !ho\s trulesl rlr{)url ,,
ru\( lexkSe. it cD lnc1cs b!: Nllorcli t., gooLl nidjl,i hy
.leniDg nd sairg silh mr approlcd hlgh-IemterIure
\rxx. ll lekage tersisls. he block should be replxccd.
A corqrrrrd!ely lnrtle cble lerer i\ ilhted Flg.
9-10. This uril oterales lior either ll or ll \ .lc. lh.
irslrunerl is set for he corecl voltSe by nrcn\ of th.
selector s\l'itch. When the elter ii properlv !onecreli 10
iglrition cbles. the rldlcntor ligh ill rereal er.er!i\e
\illr
cable
FIG 9-10 An .n t. .tr e ih:r..rl tenp.

224 chapler 9 operation, nspecl on, Mlnterance, and Troub eshoot ng of Reciproct ng Eng nes
 During the insl)ecrion of n iSitior hnmess. ir is inpor i ..' I' l e 1r . :, Or ..,r. .r ,.," . pr." i. ,
rnr ro ote dre rcutin! of indiyi.ttrat sprrl plug cabtes rvith rrr' .,e. r|r .tu...,rep rctu L ,e. 1
'pe. r'.rri r. Jr .: ru , r.rl \ wrt. p\r J,r rrr. rng
old.'Ie .ff..a.rt-r .e\
,r w. .rl..,r:, . (roi ,. ,,. r.c.o.. .Jre"r t..r 1. .,.
.l !r.. 'i a- r,rei Lf.," ro.i.re,r
Foam-Tlpe Air t'itters. fonr-tlp air fitrers are
.1.t-.r.J JJ'l .. .( (, rlt .. u .r - I r.r.. H. .\e\.
. r. L rfp,, . " ...,.... ,"- . .". 'nr I l. r(
i.orn a tro\irion thcre it cr becoDc danagc.l by absion cleannr! procedLre ftr toaDr rype fitrers. Insecl. lhev re
Sharp bend! sh.'uld be a!;ide.t in i!irjon teds. ll a 'eI ..J -. Dr... rD.. i' er' l. . h , . e .. I r, ,
iabic is ber shapl) or rwisLcd. rhe jnlularlo is ulder Tndll(rion \\\tem Ductinr. ] .. .r
'''.:,.1 ..,r d,..1 .p,. w, .., I L
-,.rt,!,Fe, " r u. dr ..i ,- i. r J .r.pe.r,., t , .\r.r J r,.
' u rulre]rr rJn l"-ll lJ.( :r' r .' d ,. crr .. I . pe..r
rl ('r. 'o1.,. t .. o ( J._..I u. . ur b-o^ci .i,,
'Fu ...c.J -i.t.!,.... h.i.- r
lnspection and Mantenance of lnduction o! lr.,o.\''r. hi ,.e,ir.r<r..r
and rethcc the allcted d!cr or ducLl.
System Air Filters and Dudn9
Ihc inductn srrcm air filrcr remo\cs dj ad ab.asi\c
rricles lioln rhe a betolE ir eters thc c.fbLrct(r and/or l11spection of Engne Fuel Systems and
:n. srperclrargcr in1pcller.. whcn rtre an. fiker has not becn
Carburetors
'.o. l) rr,.' r. .. e. r
'l ihout a lilor. The nnxl coJnn)ll resLlts ofdirl orte.
Ifpossible, inspatirns \holrld be c c.t ouL ir accordancr
siticon with manufactureis or operatois rstrnd on! as ser fol'lh
:neins the ensine ac $orr pi\ton .irrgs and eiccslive ln ttropriate manulrts. It these rre not rvitrbtc tie nn
:t: groove wear. As rjg grcore $.ear progr.sses. lhc rins louin8 gencral pracLices ca he litowed:
''| ..,r'.l or.
iI is imferailc hat rhc lnduclion slster xir tihcr be L Remorc co$lrrg as ncr.essar! to qain c(crs (o rhe
1,-l.Ll r* o( lr o.et..rt i.r r. .De.red P',....
::r iducriol system $irhonl benrg filrered. dir,! air i,ill
.
c e,-,",. , .,i,o.
11! k. t, r\rLl drrrruL
:rer thc engine This src problcm erist anr$.hcrc i 2. l]\amine t] lncl llre connc.tiors rd firrii!s lir
. le '!iU
IJk.pF... - ,. e !e. L . . r..,t ;( . . ,,.. I '.o..ror
There aie se1etul d renr rypes ,:,t air t1hrs. xnd crch - ,. ,i r. o.r.i .l( r '.: t, : e ,-..r o.
-! its os' paltrcular seN'icing Irocedui:r\. J fel\. -opl i,crl. ; .(c p..t, h rq r.,,
.,J.,o,J.e,,,tr.(J. .rt , i. ,,,
DrJ l'aper Filters. The dry paper filrer rust be 'r, ., b JL.e .r ,. ,. I,ct., - r (
..rlJ..\, r... e.lrJt oti.n.,r trn: JfLl r i !n]r rlrepar.b]r- r!(.
- \' l- ..r. - rret. .. I, e..ri,t er, ed L Obs.Ne the col)liittolr ot rhe hoses. Ttrc oLler \trr"
'iel .l e r'o. rL,i e..r, litces sh.,uld be snroolh tirnl. d tiee of lrtisrcrs. butges.
:rJ shake otl th. loose dift bv rappiD! on a hard. it{t su- collrtsed bends. or decp cracks. Sna| bhsr.rs c! bc
::e Bc especially crelul no 1., crcrse or cic he sclinr nccefred. prorided thir there is llo fuet iet(ge when lhc
-J \\l r c e.r.i," f blister is pLcrl d ir;rh ! lin n{t \hcn rhe tiose js rc\ted
. '
!1. liqtrjd or sork it jn oil. nd n.\cf tr1, to blow olt di
,,.idr comfrussed ir. The filrcr honsnls.aD be.le,rred bv leI\l r-P
rlFl ! ,r I. r. ,.rrt\ ro.pi-
h
'
::q ir dry. r.insall and sel Lhc
. o \\ I.
fihe etem.nr.
' :.eJ. -ire. .'. I . li. '
fibric lv.r 'e r..Fnr.hl,
L Ccfutlt cra;nre rhe colrctition of rhe ho{s nd t!b
\\ire Nlclh \,Veutd Oil-TJp Air fitrer. Te wetted irrS at thc clmts or brackers u\c.l tr nr(rtjr!. Borh rh.
oil .rir ffltr shoLld b. irspecrcd dailv fbr di accumutarion -, '.r..'.r '. l: c.,. rt. ,.. te.' J r..r ..J JnI
.:r,i proFr oiling whc djrl ls tord, rhe titter should be looscess. A l.ose mounting u.i
. 1 | | |. 'it.<- .. r.(. .. r,n ..r . r...e- cause \l.ear
5 alheck rhe mcrrl let Ines for (.er. nicks. curs
. i,.r.r. oe | | (r .je ..,' c i.',..1". 1 5, ,.t ..r .,..\t,.,.c
Thor'lughlt w\h thc lilter in tchr)lell] sotyent. not etcnd de.ler rha l0 perceDr ol rhe \1 rhjckl)c\s an{l
\Ikc cerrain dra ll di s remoied fror the flhcr and ..e . ill ee, . L(,a r,,\ D" . -, e . .,o,:
..:I e li ter xnir is xr \cr ! iceabte condirior. It, after ctern_ aJ Ir.- ri..,, cl .\ Ir-.r. ,tr., Jerr rJe.p. !.,r I

::!. Lhc sulces of thc rir tiltcr !ho$ .rea ic w res thn 2(l percent ol tire nbirrg diamerer D.t re ot io he
::rough the rcrrainil1g llocking nrateriat. rhc fi]rer shoutd heel of a bcnd ae accepable. DcDrs car bc remolcd bv
_e repiced
Dry the ihcr at roonl rcmpernrurc. makjns cer Jr\i 1,.le r.!. rc,,bi ,^.r,.
:::n lI is thoroLrghll drt, bcfore proceeding sith rtre ncrr "J.,. Tubin! $hich i\ _r. ne;
steet cble no re;airabte must bc
. I l t -r , -,.i. it rcnl.c
: r :r l . r r - , ( . .l.llt ..e.. "rre,,,.r-ra t
l . , r 1
6. Rcnrove thc drar plugs in the cd.btrrcror nd sLnts
:.!s decrcale its clficiercy. \exl. lr)rcrse the tilrer i| hc . ,..t..r.t -,"-rr
-:.omcnded grde ol oil for 5 nrin. Afer rhc -
liher i\ lel'rrl rroD. .r,'..,r t...:'p.,. ...,,.
':no!ed lror drc oil. all y i ro drnr thororght).betbrc ers ilith rhc liugs where reqired.

lspect o and M ntennce 225

 r- Rcrnove all fel scr'ce|s aid lilLcrs o clen thern:rrd
1o chcck heif concliljon Collxtsccl \ceens. lnd tilters
\hjch do not pro\jlte tree fucl ilo{, 1ust bc replaced
llaln line iuel lcrc.n sumps and rk drnins sliould be
o|enc.l briefl,\'! prcllighl spections io renrnc wate and
8 ll he fuel slsten iDcluLlcs n eginc dri\en fu.l
furp. check rhc purnf iir scc'r1it,\. oil lcalu:e from dr.
rourlnlg. nd froper sifelr'ing ofrnountrg uts. bolts, or
sc.e$s. Ch.ck the eleclri. fuel boost punp lr dre opcla-
ri,,n n,1securil\ of bolh fel and elecnic conections The
hNshes of the pump non shoultl be rcplaced in accor-
drcc irlth thc schedule set ti)rh l lhe \cr!ice manurl
9 Check rhe cfbure(r tu] securill ol moLrnling. Iuel
lckrge, and troper !f.1"-ing. Check the g(l.r rr rl'e
niourring flange or bsc 10 deie nine if ere i\ poiribili
1) of dir leakage E\dnn\e tlre drolile shaft bcarings .rnd
he cotrol llrms ftrr the hrottlc xnd nixtu.c corlrol fo
excessi\e pla\. Rcmcnbel tirut.\cer-cile cl.rLr1ce thc
rh .rr. \har'r cin xll(\ ak l .ntcr re c burelor ird .n
lc,r Lhe irrure lu.ic!t ro the berings arrd mov
^ptl! ltih the scni.e iNtruclions or dr.
ing ionils i. r.cor.lance
atprL'!ed lntrric{Lion clr .
lnspecton and Maintenance of Fuel
lnjecton system
lhe roIre instecljo :Lnd rnaint.nnce of rn .ngire fuel
{rer rir rrclde\ ! fuel iniection s\rer arc sinilir !o
tirosc ol crbureo. ancl 1uel s,rstcns. The frincipal renr!
to notc arc rLshtness ad slelfi.g ol Ltut! xncl botts. leak
xgc from lines ncl hllrrgs, and lfoseness in corlrol lik
lcs FLrel striincrs shouLd b. cinored a.1clened a\ slrc.
ilied. \iifr lLrel -clai! t the lel o77lcs re romil nd
clo no reqrirc repair.
when ne\ nriector nDr is rstalle.l, the lnienr trlcl
stniner shouki be enro\ed dnd clexne.t rlter:5 h of opcra-
rl.n Thcrclicr. IIre (rirer should be clsmred ar erch 5011
lf n !ncrt en:i. js equipped ilirh iirel i.j.ctor thai
icludcs r A\lC. hc oferior should be aler r'or sigrls of
futrlcnr ilirh be unir. Dirt ca buikl up on thc nee.lle xc1
cinse ch operxtion nd possible \tickig oi re 'ee']le
i!ir resrlianr loss ol llhrde colpensation
Lubricaiior.l rhe iniecror should be.t.conrplished in
accorctnce $,rlh rc appoled lubrictiof chtL 1r lhe pr
l cuLdr inralltion. The cle\,is piN used ii .oneclio ith
thc (hror]e ad the lnaul miilLre conol should bc
checked t'{r frc.orn of nr.!nret d Iubricle.l, il nccc!
\'rl
Lubricrc lhe hrorlle shalt bushiJrgs b) placrng ltrop oi
englf. oil on eacb ed ol lhe hrcttl. \hrlt so dr{t thc oil
c $ork inlrl the btrshjng\.
Ll.e c(rc in clernin-s dnd oilig the i] ler el.nerrt ll
he e!enr.nr is replrced $hile ercessi!c oil is ciigig 1o il
sor. of Llie oil s, ll be dren no ihe inicctor and t!ill \e1_
rle o. rh. lcntui. Thi\ cnn grcdtl) ac rh. nrclerig chir
aceristics ol Lhe intector.
lnspe<ton ad Maintenance of Engne
Controls
Engire corol\. su.h s lhc throfile, mirture. fn)|ell.r, nd
co$l 1]p co.!l\. nee to be che.kcd drrnl! lhc .ourse of
226 chpter 9 operation, nspction, Ma ntenance,
100 h or a rLral if.f.cliorl The m\telllon oL these.or
Lrol\ shonld nche th. li)llou,irg siets:
1. hsfe.t ttrsh pull .orrol\ lor \rer n sLnoolhless
LOfe rte thc s!\lem slo(l\. nd {lch lbr n-ers of
a]ry on Lhc rorl! rril tLib fg thtr \ill .rlrse bending or
rrin
wiring.
I F\lrir. ..h nn1 ..d th.rl Ls lhiexde.l. tDd obsene
$hc(hcr rlre rcd is s.re$cd i o lhe \r.ler l.odJ fu eogh
Lo bc \eer hru!h th. rspec1on hole
,. Erninare nt pl\ b) ukg c.r in th all coe.
5 Errmine rh. Sr csroieeif the ul- bird too mrh
on lhe guide\. but io trol .rirke an] t]ldlng for rNdng
bck. Retixc. n) gliries thxt.!use bi.ding
o, I r.
Ihen jnro or o1 ol dre .orltr.l .n.1. Rerighlen he locknuts.
,- lf an) rod is renn.d. hbcl il 1o ;h( ils lortion on
t Replcc nr b,ill b.rritr-! .,ril e.ds tht ca qe lo\t
lnspecton and Maintena11ce of Exhaust
Systems
fhe imt.lrr.re ol trcper i.!pc.tici r n]intenrnce of
erhr't s\ren1s carnot be f!crclLph;iie{1 /l/.3 !r.r
k 11s.ti l. tu tns|n'fr(. o!nt IuIttt(.
ur, ., .t1tht,t ,t,)i.( posaniq
'tt:t.tL,t1llil'
Affroximrel) one hnll ol c\huf lyrenr fxilu.s ocrur
in h..ihu!( gs to ir hc{ crrh! sei. rd - Lr rcsLrh.
. nr monoride gx! r.b the cbi thr.ush th. aircr.rft
The e1husl \\\rcr) co1f!rnets r. subje.ted ro
\rr.ic temDeran e!. l.cl th rcsLrlturr! e\fnsion and con
trlelioD ful!.e sie.s.s \\hich olier lertd Lo trc].s nd
dl.rolt ior rcs!l(ir! fr.nr r frge.
' 'I . I
iDacquale.tfd inficquenl insfe.tions x d check\ 3nd tln'
lack of rjnc rd pte\cti\c l]linIerc. l-r.L\!ee
iLrste!tion(. EihaLrsI j)ltcms eleliorte h.rr !' .r r i
ergire .NrxLrg ternf ert'tcs. (ll \ itrari.. $hich .Lses
metnl ftigu. ort rei1! .f sLrcss c.rncennrti.D nd !!ear !r
loints or concciioi(. nd (-rl er!le bxcklirillg d
rnbLL red l!L.l ir the nrufilcr .v,g The\e ...dilions be!.xr
to rLe.ll.cl lhe llrr hour o1 engile opemtio xltdeterio
r.i. progresles hj\nLgh lire lile ipan of thc clhruil sls
IdictioLls ol .r{clcd or lerkin-{ erhnsl s) srenrs cn
oc.!r i| r] rer ol Lhe s) sem ho\\c\r. the flLo\ring tre
Lire ron proin.L f()blel rea\:
l. Erhansl lnrtnifold rnil fac( tu;gue 1ilLues rsuall!
oecur r $eld.d r c mp ioirns (l erxmirlc. erhLrsl fnk
flngc. slcl to rxifold ctossfipe.. .r nr,,ttl.r..ne.
riosl Thi is sh.s in Fig. 9 11.
l. Nuffler lilurc' |d hear e\chngcr 1ilures n$ally
occur of th. incr sll !uncc. E\mtlrs ot' ligue r..
are nro$. i Fis. 9 12. A frfcr in\pcclioLl c!1n be ..or
plished.nl) \hc the ourer h.xt -hiclil i! renr.\ed. This
;stecti(r shc{rl.] be dofe r' r.cor)nerded br rh. mrrr
qofD- oo.oE1o-e.

ND CAIED AYAFROW
FlG.9-1'l ExhLrr syrem n5pe.t on po ts
NSPECT FOF CFACKS N fHESE AREAS
FIG. 9 12 ly! c mllfier lt q!e re3
Precutions. I the instection ad servlce ol erihrust
.,.rm\, celin trecauLions lnusl be obserled. Faihrc to
:ipby dcquale crc j working wilh e),hur sl\terns can
-:iult in thcir.laragc and dctciofttion.
Corosion rcsistant crhausL slslem parts ur be prc-
::-red agai sr contact $ith zinc coaied {gahanized) tools
. any zic-coared meral pafs. Frthennore, lead pencils
-rr lrot be used o mak erihauf syseln t)as.,{1 high
::r,pe!re\. the rneal of e eust s]!!em $ill absorb
r-: zic or lead of the lead pencii. nd t;s will matedall)
.i:.ct he molecl stlxclure of the metal. tsecause oflhis.
r-: \oliened nelal ll1 likely be iubjec io he {levelotrlnelrt
:: .racks m lhe r kecl afeas
The exhust s,\,reln pas must be cleaned Nith care.
ii' is parlicula.lr' hue ofceanic coaled tar1s. The) nrus!
::i be cleaned \\'ih hanh alkline cleiners or b! sandblast
.:. Degersirg il,ith a suitable \olvent will usually suffice.
f. r.u. r,.'k( d.,o'e f:.r r'l'. ,. .ri
:: Jre unxfactrer shonld be follo\'d
le(: .,(r 'b\o.,('l-1 J.,. r 'tP.,:
J repair is rnosr citical. Alier the exh{ust stcks orriscr
-
are sec!ed to he cylir)de.s. nll other lalls shonid be
llled .^ . ,. r . r'u,. 1(r'pope
rlisnmer to pe\et e\ha!sl l.kgc. Nu!. bolts, d
clmp scress nrust be ightenccl to drc correct orque.
O\enor.tring will probably rcsult lnilurc.
Procdues. l he frocedures for performing cxhrust
syrenr ;rspecLios arc gi\cD in the 1anutacureis rnainte
ance man'rl lor e lircrft. In gener|. lhe requied
inspectjons are similar in type d scole for rost oircrft.
'l'he following seps are ypicl:
L Renove he engie co$ling r llicierl\ !o lee all
farls of the exhaust s)sem.
2. Erarnine all ferls for dacks, sr., loosrncss, .lcnts.
corrosioD. and any other aplarent deerioratior. Pa] !r'ric
rlxr arcnrion r. aLta.hjng flages Neidedjoiis. slif ioilts,
I'r tfF .\.r J,.. tir ,t JrJorJ.fre er.e\
3. Check alljoit\ for sigi of exharsr leakage.
Leakage cn causc hot spot\. in ddition to being hazaclous
I., passcngors and crc\!. With superchr3ed engines opert
irg 1 l)igh rlLiltrdcs. cxhatrll leak! ssume he nature of
blo$torchcs because ol the sea level pressures nrartricd
in the syster. Thcsc lcaks dc a firc naTard as well as bein-c
darnaging ro parts nd strucrures. tiyidence of lekage is a
lighl grav o. sooty spor rl rI slip joint or dt any oher
point where pipes are joired. LeakSe slots also relel
crcks in the syslem.
I \ (. : lo | \ .L n.td. ur. rl.d.,|-.'.r.t \,
'r
'e .lLl, .eor( .re,le.kel.\,r..,r\p'...' ....i
.', '
:r .n L.,Ln,.l...rerro,le,- o pe . terr ,e. ' i'P
suitable rubber fluS to lrovide se!]. Wi(h lh. \crum
y leel or wllh a
cleancr opcraLig. chc,rk lhc entire systenr
soap solrtion lo re\eal lerks. Afer the pressure ter.
emo\e lhe soap sucls \iLh w{t.[ dry the systerr cornlro-
nenls $ith corntrc\ sc.l ir .
J,.r pl.. ,,p.. ir -, rrrJ,r'-
'f en, I
rnal be necessary to disa\semble the sysem and check
idivmual componelli. Diss\crble the s)sten according
r. ter -. ir,,(.,g..r,tt. .. rr,F
all atta.hing fa]ts. lrch as clamps. br,rckels. bolls. uts, d
ar. Rcnyc thc shroucls from the nrtrffleH. Use rubber
phgs Io seal thc otentugs, ad pp y 2! fsi [l7 2:1-kPal a r
presr \lhilc the nrullldr js sul'rcrgcd in \\aer. Seal lhe
erhust sl.rcks aDcl pitcs. a.d 1.st in lhe sre nranner.
r.r- < p l'-ol P.lPr, , e ' lr" re.r,: '.
rarv. bul \\,hale!cr e manulaclurcr rcconrcnds sho!ld be
7. After all componeIs of lhe erhauf slre ha\c
bee examined d lblrnd sailrfctory. reassemble the sys-
tem on lhe engxre loosely ro llow lr dirsrnent ancl prt
er aligrent. Tighte| the fck rtlchmets (o lbc cyliNlcr
exhaus pols tisi. using a orque \\'r'ench. Bc surc thrr thc
lroper rype of hea-esisrnt rur is uied l]d thaL ew g{s
kels e inralled. Nerl. tighter ll other ioints d aLtach
rnents. naking sure a ll pafs ae in cofecr aligr1rnt.
8. After the exhaust slstern hxs been i.stalled- run the
p'!r-"1:er rlLrr"L ir- I f. '. n cJ'i r! -
tenirm. Shut dorvD the cngie and.erove the cowling.
I rspccr elch c{hausl port and ll ioin$ \hert conponenls
arc auachd Lo one alloLher. Look lor signs ol erhusr
I l.aks. suclr as r light stay or sooL! deposir I{ lerk is
f(iu,1 l,)$r rhe..ne.lior nd relis. it
nspection ad Mlntennce 227
 9. lf n e\hust s,rrem irclrdes ugrc.t(r\. inslect SHOCK IVIOL]NI ASSEMBLY
thc augr.Dtors in the same mnnner s tlie othcr compo
nen\. Leakr i th. rlnrenrors caLl caLr!e lies ancl .\cdpe
ol gx\c\ into the cocktir or cabir. The alignrncnr ot the
augmentor\ i\ prrticularll crir.al. The an lcruicr'.
\tcilictlios .u!t be iollo\led peciselj.
1{l O a s}\tcnr $hich rcludes i Lrbochrger, \pecjrl
3,rc-=;
insleclios ol thc turbine and comtessor asierbljes rnusl
be mde. hsp.ct lhc inreri(r of xll unit! r'or he buildup of
coke deposit\. These dcposiL\ ca. cuse rhe !\rsle aate lo
sIick. causirg ercessi!e boo\tl !he turbine. crrbo
Jco 1.r,... r r e.(.!
c\. sirh rcsulting .lccrc{\e in engine fower Whercler
coke buildup is luDd nr t it. renrore n in x..ordi|ce
$ith e rnanulacrurer's instructios.

Repairs. Erhansi syslem .o rpollelll\ $hich ha\c

beco.re bunred. cra.ked. il.nled. or !o \ronr lhar lekag.
occuh should nsullr be replced with es parts. 1 cerraiD
iDstn..s. crcks c be repaired b) heliarc (ire gs)
scldins \iLh thc proler ype of $elding rod. C:rre rLr-rt be
Lalc. ro lojd an\ repair (hich \rlll cause rongh ipor Lrr
frotrusion inside a e\h,:usr flpe or rultler. Alrl such are ENG NE MOUNT TO FIRE\]ALL ASSEI'BLY
$illcreate a h.t srt nd.ause e\,enul bum through.
Dens ca s.itnctimcs be |ero\ed. provided tha! he den
ls not cused r thi spot resoltig frur j1eml erosion FlG. 9 13 D,/'o. erg re o!i
and burlrirg. Dnts are.emo\ed br- tli.ing rlre e\h.ru\r
pite oler a suitble ndrcl rd rorliing ou the den wi

Aiier an) repair to corfo.ent oftbe e\hult sysleJn. a

lFsnrre test shlnrld bc nr.ie.
En9ne Mounts
F.ngine moLuis are rnell rnoti ol the Upe \l sinlijg
9 l--1. shich colec e engirc k) Lhc arLarc. Rnbbcr
!hock mo!nls isohle lhe engin. lrom th. mctdl egine
\1or rnode recitr.,calig cgic inttalltions nse
'noun!.
dJna-foca) egxre rounts. The -(locl nrdrn(\ on { .l}nr
i.cl cngle rourl point toqard the cener ofgralil! ofrhe
c.Sinc. a sho$ in Fig. I 13 The bonded ruber slrock
m.,uts rDd lrctl mounl are desigred to rcduce he trans-
mission .il.ngine rihrtion! o dre ajriiare. This prorides
sRrlhcr ircrrlt opertion .rnd reduces he possibih\' of
nrurtul liltrr. fnln !ibratrrn ltigue.
Cleaning rnd Inspection. AII meral pats of the shock
mounl assenblies nra) bc cl.a.cd in a suitabl. cl.ai.g
so]!eni. The mbbr !d\ isho.k .urnts) should bc $jpcd
clean $1lh a drt. clean clolh. Do nor clcan c rubb.r tl1j
\rilh ar) Ilpe of solvenl r\pecr thc rell lrfs ol rhc
rnounts lor ccks. conosioir. ilen. dislorrioll. d .\cc\
The rLbber 01 lhc d}l mic sho.k nr)unt uDit\ c$ deteri
orale silh age all het. In\tcct thc rubbcr tr.ls lor scpar
lio belween pnd md rnetl bcknrg. \$elltug ard crcling.
or ! lroounced set idislorlionl ol lhe parl. Replace all rrb-
ber p.rd\ dral !ho\r evidelce ol{larage.
T ,, . n r p(.
bolt toqre f.r (ecurig the e|grre lo the moun! ard lhe
nrout to the rixme. The engxre rouni bolls should be
chcck.d f(n p!t.r torque and an\'\ig! ofrotllior
Fire Wall Seals
Durilg n insp.crion of lhe aircrli the seling compound
d bushigs Lht f.nn seal! aloL, $irig .d conrrol
cbles hI pls\ through lhe fire \11 lhorld dl$uls be
js|ectel rd rcp{ircd. il needed. ,\ny rtpe of ofeirgs irr
llre lire qll are crn llo elhausr gscs nd fures r
enrer dre cabir {r..
lnspection, Mantenan<e, and Repar of
Superchrgers and Turbochargers
The sane prnrciples of insNeciotr. maiLcnln.c r.t rcpxjr
thr apph lo othcr sections of the poqerylnnt s)(cD affh
to ruter.hargei! d turhochrgers. \isrl Lrspccrion ofrll
risible prr\ shoul.l be terrirrnred d.rit) to ob\erve oil lcak\.
e\lau\t lenks. crack\ i Lhc r.rr ol hot seciolrs.' l(!i\c
or insecxre unils. and orher ux.ccptible cofdiioDs. \ole
thrt c\hust ducs. !\sle gles. orzlc b.res. tuires
ar. subjected to e\elt]el_\' hLgh temtcratcs: ^.d hus, $xcks
develof be.use oflhe co]rtlnnal erpan\ion ind.oncrion
ol thc nrrtltl it\ relperrnrre chrnges occur.
rl ..Jr .J. '. .,. I I i, o.,rrpo-
,.0......pt.
cstblished for peiodic in\pecrios. An insfection of a
comtlcrc \yfem lhold iclu{le the lblloeng. i iddirioi
to rrv olher inspcctiurs lpec fically required by the corpa
r1! s operalion lnurl or rhe nranufcluler's nallrtennce
I l\lounins ol ll uils.
I Oil leaks or.lripping liorn ,- uniL

22A Chapter 9 Opert o, lnspectlon, Maintenance, and Troubleshoot ng of Re. procatig Eng nes
 :1. Sccr.ilt ol oil ltues.
.1. Sccurily rrd co|.lllion ot'electri. \iring.
5. Cncks ducrng ad oher nret{l pars. iDcluing lhe
lurbjc D.lhousing.
6. Wd4ring ()l rnclal dncG.
"t rr lrl. u,pc. r're, r Ir' 'i r''r
. .1 , ., rnoe.,r.,ore -r J,. -.nJ , n c..
.tcnce o1 librati.,r UnusLral sounds a.l ppncirble vibln
Lio rcquie reroval and |eplxcemct ol thc 1r$ochrger lo
cocl he liuly c.ndiriur.
lipmper lubicatlon or le rsc oi rll incolrect lubricanr
cn cause serlous malfunction! und rhe lilurc of unlls.
B.cause ol dre high enpernturcs to \lhicL a tu$ine ivhccl
is crfosl, lIe loJhine shaft is lso \ubiect to high remfen
rurcs. This ca .atrse -.oking" ol c lubricnt. with { {rb
leqLrenr huildtrt of c n lcoke) a turbine shft scls nd
berlSs An |trccjble 1lrourI of cokjrg can cause fail-
nre of tine shdfL scls nd beadngs. l-eakig \hali sels
perltrjl hol crhausl gascs to reacli lhe shft bcrirrgs, $4rere
additional cokmg i\ likcl,- 1., occnr. Coki-! ol lhe bcanng,
is Likel) to lnnit thc rlrnr that lhe iurbie Dd comtress.ir
asle.rtrly cn lti. In lhls case. rhe lu rochargcr \till
rc.tuirc raDnvl drd replacemenl. Becausc 01 lhe problertls
cdsc by colLng in he rurbine ar.a, il is mor esselial
drt rhc prcper tytre of hbricant be cDrployed. The service
rlo r.rlr _rJr.rJ. \ ltr".:J , ,o n.,ror
AII overhaulig and le\tig ol \uperchargers and tLLr
bochrgers shoxld be acconfli!h.d ar cerified repa sla
tioDs. This is tlculad) xrlpofant bccause of he need to
bln(c rhc lurbire ard corpressor ssrbl)''. accuratell.
These rirs roare t speeds of up to 70,000 rIm: rhereforc
slighl L|balarce can canse selere vibl1Lrio ad ultirate
di\regmtiolr |d tilure.
With th. inrrcasig corpl..{ity of toda} s po!!er!lxrs.
nrintcnDco tcchnicians tue more dependenl on thelr xbili
1! to utilizc p!bli\hed technicl intrmrion i perforring
.uirrtcnircc. Trcubleshootln! skills arc ircrcasirly ncc.l-
cd br- tlt's lechnici]rs. Tmubleshooting is drc stcf b)'-
stcp proccclurc !{ 1o de(efnr .e the .xse of a 8;ven fanlt
d thc sclccl lhc bes nnd quickef s.lulion. \\rhen tfor
bleshooing. lhe techician must evrluate lhe frftninance
ol rhe en-eine b) cunpd ng dar o how ihe engifle should
operae with ho$ il js curretlt perll)rning. To rrou-
bleshool. ihe lechnician nccds lho.ough kDosledge o1 the
egine-s theory of olErati{D.
'lo pinpirt a lult. with(trLt wastig tic ard fforcy. is
\l ... r.,e. r rl ...,lcI.rr_.1.
nuking re p,oblenr lery difticulr o !soLte. Reloving ard
repla.ing comfonenls.n a ;al and crror basls car tre
r;ewed s lholeun' oublcsh.otnrg in in wonl fom1. To
be effective. oulrlcshooting 1nus bc a anaLr-\is of ihe
PJ b . r. l'le'.r".,r\r.r.r"
corccr Lhe prblerr. rllold be firnd llxoLrgh a logica and
s)rc.rtjc dtprorch.
A sir stcp troubleslLooling proccdlre is illusl.red in
Fig.9 l:1.

LSTNG

THE

EYES EYES EYES EYES EYES

KNOWLEDGE KNOWLEDGE KNOWLEDGE KNOWLEDGE

fHINK TH NK THINK
NOTES NOfES NOTES
EOU PMENT- EOU PMENT EAU]PMENT

TESTING TEST NG- TEST NG

DEV CES

FIG. 9-'14 5 x rep iro!bleshooi nq pro.ed!re

rroub eshoot n9 229

Symptom Recognton Falure Analyss
The prereqLri\itc\ l(r rrobleihool g arc to b. lanrilj \'ih Once the lauh cd be traced to r \pecir'i. crponent or
, I ,. l-. . .. _r.. conrl](nrents. an tt.nrtr rhoLld b. mde lo derc nie the
$Jren a engnrc i\ .ot operatins properl) Thcrcf(ne. s)lnp cus. of rhe tailure. Sub\trtuiig n.$ conpoelr i to rhe
o recog.iLio. the fjrs sep in ttuublcshooting s\stcr ilithour nal\zing rhe reascm lor the fajtLre ur] jusr
in\,olles haurg kD.sled-se of an] eL!ic codiLion drr is dragc the neir conipo.cnr. Sornerires .ra! colpo cLs
.ot noDri nd kro$ig 1. $ hrr erierlr rhe tLrh is rllectir! hal'e snnilr funcios.I rhi\ cr\e. ll Le comtoners ml
th. c! e \ Nribrnr.c. need o be retlted or retairc.l.
To determi. if there are urulritle l1raltirnctios. rhe
Symptom Elaboration tcchricin \hould colider the ellcr olthe compoe t rl
functiolr or ergiDc oferarion. ll lhe .or|oen is rhe prob
Svnrrrninr elaborali.in i-r IIc err [)fi..t] \tep, once I trh able cause of nll the ihnonl siniptd! nored r erlicr
or rrlfufct on hr5 beer .lcl.crcd. len equifment. built i slets. drerr iI c bc xssuned thar e cornfoenr is 1ult.
or e\rerl helJrs the techDjcjd to c\alunte rhe perfor- Usig lhe srep trc.edure. r'r liye x. e\drplc ,,1
si\
nrn.c of rh. ef!ine ard ir\ compo.nrs. The echicin lios lo troubleshool a frult .n i elgr. tlut \!ill ror m
driuld u5c th.\c ril( nr lrssess the ellLs ol th. \\.r$oms cosisrentlf x! idle specd\. Thc fiis fep i\ 5lnrttorn recos
d to pro\iLlc dditionl llijn.nion l.) lurLhcr dcfine the
:)rD|o s. Detcdins on the t)te ofengnre.lhc rcch.icin Enginc perfornace can be nrexsured lgi\t s.refal
shoLrkl sk $r..l rlre tullo\rrg lueirirrs lo holp ehbo sian.lard\. The presenr perlnnn.e f a fri.rlr egrDe
can le cort,ired lrith rrs past perfirrnulrce. prolided ade
qute records hle beer kcpt. Engine peomnce . atslr
l. \\'hrr .on1pocts of rhe eng e are not opcrati.g be contarc.l wih ht ol other englres illtll.d on ltre
srne ltpe ()1 rircraft Ty|e t.cftifi.re l)al Shc.rs d ihe
\'' .. 1 't .r. r '. cgine operalo/s mfual ca bc (onsulre.t lbr engine per
3 Is thi\ n j.t.rmiiren lalt or d contrlou prolernl lordnce irnrrirr
1. ]s r) .gi.c txrmeer s!.h s rcnrtcruln.e or fres, Once dre bnsic l. ulr hds been recognircl tltra! ttre engine
$ill otldle). he Derr \tcf is o elb.rLc r) rhe tLrh rcl
5. D.\ rhe m funclion occur onl\ rLler trecitic sei asccrln rhe ergic otcr3ling condiLio\ ar !'hi.tr rr is
exhihited. lhe 1llo\nrg ifomarior my be of l,atuc i
defiig rhis frobl.rll:
These rrc 1r c\.rl1rples of dre t)pes ol qu.\ti.! that
1 W\ an) roughness notcdl ll \o. !trcr $hr condi
aclion. lhe re.hnl.i slturl.l tN .ot to ovrlook ay inlr ions ol opcrdLir)n?
mti.lr S.metinre( the s llcf.lerail cn le d ihe irv tri I Ho$ 1.,g hr\e rhe engiic d stark ph-g! b.cn i.
rn!lnr ollh. frobler]r usel How long hs it heerr sircc rhc Ist ispecriontl
-1. \Vere Ih. r:njtlon s\cm lr!neto) otrftrionxl
List of Probable Faulty Functions chcck and poscr chcck normall
:l Did the pr.bleltl change $hcn the fLrel boo\r fnnrf
\hen h. t..hni. n has localc.l rll thc slnrttos of he
nrlt]'nctioll f! 1lt. th. drid dep ls ro l;sl. cirhcr netllI 5. when did e oublc fiAt xfperl
lr' p . 6. \\\ Lh. full-dottle terirmfce norIrrrl?
nro(r rfrLricrur.r'\ L.chricnl service rnanu.rl! lisL thc
'|Ilhle .ause lor r ccfain en!le s\mftom. along $i(h 'l'he exl \Lct is io lisl rhe pr.b.LLrle fnutrl fu crio..
(h rr:!eed corrc.rirc x.tio. This inrmlition is .ftcn Reter lo Fig. 9 15. Reasors ior lrLilure of he engc ro idle
c.f'lned in r tlolbl.shooriS.hxrl luch as that ir Fig.
t) l.
l. Propelle'lc\er sel to decrea\e ryr
Localzng the Fault :. llproperlt rdiulred.bLfet,rr or tuc] jDiectlor r),s

Arrled trilh r.orflere ie ot slrlrpns dnd rhcn.prcb.tble -1. Fonled spk plugs
c('\es. lhe lechnjcjr i( rerd) tor e ilth slcp. loclizi.g +. Ar lerk l! iIakc nrnilold
the irh. L.rli/in: ihe tauh is r rrertr ro dcL.rnrine
which lLlcrionl \\ltcn of rhe engirre is crurll\ creatin3 wjrh .onplete scr r)i s)nFor\ and probble carse\.
[ra] be lr.cd b,- using rhc nranu
the trolrleur. Th. ri)uble the rcchnician i5 r.xd,,- tu do rep .1 ol n.rblestroorins.
frrnleas oblcsho.rig .hafs rr cmtlo]iDg .onrpures L1.., r,re . e.r'.- lcr.e. l
! r" jn oc slstenr This cn be done s.metnDc, b\ clinrif;Lril!

lsoatg the Fault to a Component

lr l1rosl illltr.es. nssurne rhr thc Iorble ]ies irr on. ol
On.. th. mlfuncio is i$lxred t. one !)enl. addidorl thc folloning s!\lcnr!i
le\irg i\ don. ro i\olite Ih. fuult r. a \fe.ifir componer.
The lech.icirn or'len uses rc\t.qnifnr.ni t(i nreasure or 1. Ig tio]r s\ (cnl
iLldicte lh. ..r'.ri outputs lr !ariotr\ s\st. comfoners. :. Fuel reieri.,i \Ister
230 chpter 9 Opertio, lnspectlon, Md ntenance, d"d ro-ble.Loot 'r9 ot ee p o . S r-q --
 3. Indcon sysiem
4. Po\rer or mechanical s,,-stern
5. lnstnuent.tion systcr
Uilizing lhe nranf.rcrnel.s tr1)ubleshoolirg nanuals
rnd chafs o est and elinrifale drc laious slferns nkes
it possible to pjpoin! thc irduction slstem as the probler
Let's go oD to thc nexl sep nrowing lhe problem t{r
.|'\rr !.o".orcr.\.r.1 r'oec.^" rl-r,J'.ri { \'
Lc nleLls t ot]e cylirder intake pipe ha\ lucl \Lains and
a bd glskct. This i! rletennired to be dre causc ofthc lauh.
ard with a nc$ gskel. the elgire cn be ret{ircd a.i its
1 Lroublcshootlng sep 6 (tilure nalysis), Lhc Lcchni-
cirr sh.iuld determine rhe cuse of ihe gasker lailure arrd
$heiher other engjDe corponcts have been ailcled by he
Itlallunctio. l this case. thc cau\e ol the gasket failure
appeah to be honal aging.
lr :. r; rl-.t d. '....r1. ec r r. .. ' r.re
"-1.
that the cylinder wiLh lhc lcaknrg i rake pipe has been oper
iing ith a very cdn Drirurc. $hich could hale caLrsed
the c\lidcr Lo nm ho!. Drnage to other cylinders on rhe
cgna: is higlil unlikel!. but dmage could hare occunccl
iside dre leakrng cllinder. The leakjng cllinder should bc
thoroughly inspected lbr danrage thrt could ha\e rcsuhcd
Unr he iake leak.
In all rroubleshoon: ca!ei, the knowlcdge anct experl-
cn!:c ol rhe lechnlcin $ill be needed along wirh a gooci
I..,:rro'oJ.l .oo<{or', ..,e-fr''., r" l. '.
Troubleghootn9 Example5
Ensine operational rnalfucions c{n osuall} be rrced I.)
of tee bsic cusesr (l) igniLir lnallc-
:r. '' ,e - -,'lf,r. i",.:rLl .1j.1. retr'
rallunctions. Allhough in tncticc it ii necessary to consult
dre s|ecific lnannlacrurer'! maual. m th fbllowing texl,
eaclr ofthese ryl)e! of nralfunctjons is cliscussed ieparaielv.
Ignition Ntalfunctions. IgDiriorr roubles ray be
r . J. .1 \ ''' .r '. l.l.c e r'r';1r" r'
lo{ tesion \y\rcr- nnproter tlminS. stark pltgs which
drLj bumed or otber$,ise darnaged, poor insultioD o the
high !ollagc le ct\. short-circuied or farlill] gouncted
trrry o. s\itcl lP) leads. bLrrned break.r po.ns. or loose
Mksi g at high speeds N,lilfiring ol rhc cgnlc .rt high
ipeeds can be caused bI alnlt dll the foregoing defects in
\ r,urg degrees. lf the engie is opc ting ai high speeds
rd high loads. he maifold tres\ure. nd the cylinder
.ressure. will be high. As trc!xrudr explanred. more !o1r
rge is eeded 1 the sf{rk plug gap to fie t|e plug ilhen
.he tresstrre r the grt is inci{sccl. This means lhai at high
rn-qine lo.Ld! the ig tio lolLagc $ill build Lrp nore thaD a
lo eDgje loads. This highcr volrage $ill seek 10 reach
:rotrd thrrgh th. casic\t path. rd ilthere i! a tath e1jcr
ar follow than that t]fough rhc sprk plug gxp. the spdrk
.l g \!i11 not lnc and thc spark will junrp btrngh a brck in
:i. insulatior or frnlow a palh {'here damfncss has :duced
Il lhe airplne is operatils i hieh ltitudes. the high-
.olrage spark will be slill rore likel) to lcak oll lhe high-
lcnsir)n lcads instcad oi gomg throrgh !h,- 1lartr, !lug. The
loscr air prcssurc 1 high ltitudes fermits dre spark o
iurp gap rorc rcclily than at thc higher tresstrre near
A \leak bleaker toint strir)g will lso causc nrislirmg at
high speeds. Tlrii is becLuse rhe braker poiits do Dor cl)se
corpletel,v afer hey are olened bl lhe cr. Tbis condi-
tion is called floating poits hecnse ihe cam folloiver
aclully does ot nraiain cotact lrith the cam but floats
at rnnc poiDL Lrct\lccn thc car lobcs.
Engin.fails to statf Ll thc cDgnc will not st{rt. c
trouble cx tre x defective ignirion slrirch. Since aircraft
cgnrcs hvc dtrd igriition systcn!. it is rrc tht both \yv
tems lil at the sane tirne. Iloireler, in sone rnagnero
s$ilclie\. borh ngnetos could be grcunded tlrrougb shor
circnit inside tlre silch
ll eco I .(10eo prJ.. .( . r .r..r. lne <nJrne u I un<
rnagreto only and dre engine riil no sta, ir) to st l thc
engine on he oher nagco. If thc causc oi thc troubic is
i the lirsr rgnenr s)stern. the engife sill firc on rhe ther
The checking of magetos during the engie lesl will
usually relel rallucri.s i one nragneto.r rhe nthei
bcforc a complele failurc occur!. Thc dclecti!c mgnct!)
caD thc b. rcnucd nd rctairccl bc1rc \ciou! rrorbl.
DeJ.nr! \park pluss Dclcti!., spuk phrFs nro lsurl-
ly dete.ted duins dre mtgneto .heck If one sf flug
tuils, Lhc cnsuc rtm shov n eirelli!e clrop lvherr il is
'vill suppllig thc delecti!e
chcckcd on thc rgnelo
}rlug. The
bd phg ni) bc locared br- l]Le cold-cylirdcr chtk. TIns
is accomphshed as follows: Slart and run the engine for i
f nlinies on boih nusnetos. Perln a nrasnenr che.k.
and determine $hich magnero indicaes a high ryn1 drop.
Slop the erglre. rd let i cool nntll dre cylinder! can be
ro .hed " ||lor I or , n! \or \-rd. sr-n,he(,. re -=J n.
and operate on he rnageto for \rhjch the high em drop
was indicted. Run the engine for aboul I min rt 800 to
1000 rprn, {.1 Lhcn shul ir dow. ImnediIely feel lt
cthrders wilh yo!r hand. o nse cold-c,llin.ler refer ro
derernrille hich is he cold cylinder. This c)hnder \aill
hale he defecive stark plug. The tjnre nnd e{pcns.:
invohed rl rcnloling and retlacjng all he lpdk plrgs to
r'< P.rc...n le: rJeJ Prl rrr'r-
n.re (c cpr.orl orrrr.u..J rer ,he..
luel SJstem Troubles. l"ucl syltc.rs, .rbrrctds, iucl
purps. and fuel cotrol un;ts c{n ca$c a sidc vadcly ()1'
.ngine malfuctions. sonrc ol hich ra) bc i1licult Ln
nalyze. A thorotrgh udcNtading ol thc sysLcm and ils
conpoen!! i! eslentirl if the te.hicir hopcs to $lvc lhc
problem! of a pnrtjculxr \y\tem effectilel). Figure 9 l6
lists son1e of the nrcst comron f(le.rs cncotercd wiLh
fuel ryllems ad llLggcsts rcmcdic1.
figuc 9 16 docs or co\cr all s\rptors which r1laj-
clcvclop \ith lucl syrtems and cbureo^ because of lhe
man) difiiert designs involved. The technicin. i ea.h
case. should allze ihe t)pe of s)stem upon Nhich she or
he ls $'orklns ard becone tlniliar wilh dre operatiolr ollhc
r(, n ul J', r.ed ,r<l .Je , rJ ,
inrohe some uque poblerns Figure 9 ll lists problems
rroub eshootins 231
 TROUBLESHOOTING CHART_GENERAL ENGINE

EnO .e w I noi stan Engine Che.k fuel va ves Sevi.. lue lanks
crank ng Al c rcu I breakers
and sw lches n cofcl posil n.
c ear e.A e Fo olv corecl slart .Q
nduclion sysle eaks

Engine wi nol un al d inq Prope ler lever set lor DE.REsE Pace pope er everinHcfRPu
pos t on tor a! !round operat ons
rmproper y adjusled carbLr1o Readlusl sysl6m as requ red
or rue nje.t on syst.

a r eak in ntake manirold. Tglrt.lose connect on or ep a..

Eng e m sses al h Ah speqd-

Hyda!lc tppe1 worn or

Weak breaker spr q masneto

EnO.e runs 1oo ea at cru sino lmFroFer mnua le g Nanlal ean n accordance w th
check ar c ean fle slra ner
Carbre1or or fuer nject n

Engie runs rough at high speed Loos mounling bo ts or T 9hlen or rp ace mounlinCs
dmaoed oulpads.

Prp!f out of ba ance Feore .d epa r propeier

9iton system ma fn.t on lroub eshoot cn lLon syslnr ard

lmpropr y adlLsled ca!retr Adlusl sysiem as required

or tue - ject on syslem.
Clen r replce spark p ls
lmproper y adjs1ed f!e
DschrOe.ozzearvent
man fod feslrcled o

Dirty or worn hydrau c lters

Bufned r arped exhausl
valves. seals S.ored valve

E0 ne ru.s rch al c! s o power Fskict on af itake passage

Sprk p uqs .nt nlous y loul Piston r ngs worn r broken.
sprk p u!s have fng lreat .sta proper raf!e spark p uos

S gq sh eng.e operat o and low rmproper r O! ! l conlro s

Leak ng exhaust system to Coecl exh3ust system eaks

Fep ace turbochrrlr

lqnn on sysl a luncl o. T.obreshool o qn lion sysle nd
coffecl mar,u..t oi.
Carburelor or rLe inject on Troublslrool and.oec1
system ma funclion
Engine va ves Leak n!. P s1n
r nos worn or sl ck no

H qlr cylnder hed temperalure octane fai n! i lle to w Dr n lue and I wrth .ctre.t qrade
lmproper nailal lean n! LJse le. ng prcedure set forlh rh
Benl or loose cyrnder baffes nspect ior cond t on and cotre.
Din belween coo ino l.s.

FlG. 9-15 Geerleng ne troubesroot.g chri

232 Chapter 9 Operat on, lnspction, Maintenance, and Troubleshoot ng of Rec procating Eng nes

O pressure gaOe fluci!ates.
Engine w ll nol acceteale
Slow e.g e ccelerat on on a hot
Eg e w not siop at oLE
JMalfo d pressure overshoot
eng e accelerat on
Slow eng e acceierat on at
aif e ds ilh gro!nd elevatio
above 3500 ft 11066.80 ml.
When c rnb n9 to l2 000 1
13657.60 ml engin qu ts whei
FlG.9 15 ico1!ed)
Engrne slrls, ru.s bnefly, then slops,
Black smoke issues frn exhaust.
Red or orage llame al n ghr.
FlG. 9 16 F'Jel 5vstenr fo!bl-..hoor
TROUB!ESHOOTING CHART-cENERA! ENGTNE (Conr,red)
Exausl sysiem ieakaqe.
Excess ve carbon deposils in
comb!stin chamb',ers
Damaged sa s, gaskets, O r gs,
Excess ve y wo piston r ngs
Unretered fue pressure too
hi9lr,
T!rbochrger wasle !aie noi
Leak l t!rbocharger dlscharge
Man fa d valve not sealing
liglrt y.
o. Th.ott moved forward too
TROUBLESHOOTING CHART_F{JEL SYSTEIV TROUBLES
Fuelva ves lurned off.
Delective or siuck ixture conirot
Pressrre discharge-nozzl varve
d aphragm ruptured.
Primer sysler inoperative.
Fueltank venl c ogged.
Fue sirainer c ogged.
Water n ihe iue system.
Engine f!el p!mp ioperai ve or
Engine m xture seilig too rtch
Pimer syslenr eaki9.
At idli.g speed, ldle rnixture loo rich
Deieclive diaphragm pressure
no .hr1
Delerrine cause of ow o supp y
Fepa r or rep ace as .ecessary 10
Adj!st engine !el press!re accordins
f
Fete 1o l!bocharger ad coniro s
Repair or rep a.e as necessaiy
Len m xture ut acce erallo pi.ks
up. Then return cotrol lo FULL
Repa r or replace maf fo d va ve.
Open tholt e aboul ha i way. Lei
man fo d press!re peak, then
advance hrotlle 1o fu ope.
Lean rn xture w ih manu mixllre
conlol nti operar on is
Operale boosl pump when c mbin!
to h gh allit!des. Keep boost p!mp
o !nt danger l vapor is
Slarting al carb!reior, check fue ne
back to 1ak. C ear obsluct o.
Check carb!retor for operat on ol
Rep ace discharoe-no2z e va ve.
Repa r prlmer system.
Da n s!mp ad carburetor lloai
Rep ace eg ne-drve fle prmp
Coreci th fuet air mixl!re
Rep ace or rep r pr mer vatve,
Fesel carb!relor f oat lvet.
Replace pressure carbureror.
rroub eshootins 233
 TROUBLESHOOTING CHART-FUEL INJECTION

Enq ne wiil nol stat No iuel FLe -se ector valve n wronA Ps t on lue seec1or-valve hand e

Dirty meter g !n t screen.

lnrproper y riOged mixt!e Corecl riggins ol m xl!re

Eng ne acceleralion s poor. ldle mixt!e ncorcl. Adlusi iue a r conlro un t.

Eng e w Inol sta(. C ear enqie of excessve fue.
Fueli ow Oage shows fuelflow.
Loosen one line at fue man fo d
o?:lei f no fue shows,
replace tue man fold.

Festricted fue ozz e

lrpoper idle mixlLre. Adlusl fLe air conio !n i
Very high d e and lLrll throllle Relief valve stuck .lsd Repar or rep ace njeclor p!mp.
fue press!re present
Reslr cted fuel nozzle.

Low iue Fressure al hiah power Leaking lurbcharg-"r discharge Fepa r ieak ng is and f tlinOs.
Check va ve sluck ope. Repalr o replace injector pump,

Lw fuel ilow gage nd calion. Festricted flow lo metering c ea. iue filters and/r adjust
mixture conlrol for full trve.
rnadequate f ow from fuel pump

Fluclualing or etroneous fre Clear w th a!xi ay fuel pump.

fw gage ndicat on
Clogqed eteclor jel vap
A r flel f ow oaoe e. Repair leak and purge ine

H gh fuellrow gage i.dicat on A t iude compensalor stuck.

Festricled nozzl or f!e C ean or rep ace as requ red
Rec rc!lat on passage n pr.rmp

F!e dscharqing lnl engie FePa r or replace itector pump.

comPadment. Re ef valve
probab y nol operaling.

Check va ve sluck ope. Fepa ro replace injector pump.

Unmetered ful press!re. li high, nterna or f ces are Clea internal or iices injeclo.
p Lgged.
lf ow, rel ef valve stlck open. Bepair or rep ace injecior pump.

FlG.9-17 FLre nlecio troLrb e5hooi g.hrt

that m,! be cncountered wilh one prticula iuel idectnrn
Oil Ststem Problems. Oil s)sten t1ubles ae Lrsuallr-
relealed as leaks rbsccc ol oil tressure. ioir Dll pressure.
lluctuatirg oil pressLrc. high oil prelstrre. nd high oil cor,
sumFio. Te colreclion ol oil l.dks is conrllrti!elI iinr'
ple i thal jr ivohes laclng the leak to irs rtrtrc. !d the
maling te indicaied rtpair. I1 oil hs sprca.l olcr a lrge
rea of lhe engie. iI is so|retirncs nccc\suy to wash dre
.Dgine sidr soilent nd dre operale it for a shorL pcriod to
lind dre lerk.
A .heck i oil press.c whe af engine firf rare.l is
alwav\ srandard parl of rhc \taing procedne. If lhc oil
pressurc docs no! show $ithin abour l0 s, dre engire is shur
do$n. Lacl of oil tressue ca be causc.l b\, an) one ol the
llloiling condit()sr no oil h e nki no oil in rhe engine
oil purntr (thelelora, no prinre)t an air pocker in Lhe oil punrpl
an oil phg leli ouL ol a main oil passagei an inotcratile oil
pumpi ar ope prcssure relief lahei a plugged oil supply

234 chpr.r o op-'d io , -)pe.rio.r. \,4" rrerd1r.. and Troub eshoting of Reclprocatinq Enqies
lnrc: or a broker oil hrc. If ther. is no oil tressnle, fre lech-
nicia sln{ld fari qith thc osr likeiy clse nd hen check
each possibilitv j !urn uriil thc rroublc is locatcd
Low oil fres,iure cn be ca\cd bl laricL) of.liscrep
acics icluding he tollowing: oil trc\surc rcijcf \,rl!e
inrfrotcrl.,- xdjrisled. broke! oil rclicl lalyc string. sticking
trcssurc rcljef valve, plLS le1l oul ol aD oil pssgc, .{clic
rile gaskct irsidc the engine. wor oil tressure puin|. sorn
bearings ad/or bushigs. div oil strarer, ercessl\'e le|r
peraiure. \\r,r g gradc ol oil, and ledling o I dilutjon vatle.
The cause ot' lo\\' oil frc\\urc is ofte lnore difficuh to dis
coler lhn the cuscs of sonre other nil probLensi ho$erer.
slrnlic alr"sis of the problenr bt technicins ill
srlly let solatio. Oe of the firs! qestions technj-
1o
cians muf sk n whcdr.r rhc .odition dereloted rr,rdnal
lr. or sho\le.l u! suddcnlv. lhcy should rlso check ho$
nar_ houl\ of oleraion he eDg e hs had. Anothcr most
impoant .onsi.Leraion is e cLual lelel oI lhc oil prc\
sure. Tf it is exrremelv lo$. techniciars look ior a 'acu{c"
.ondjtio.. and if i! ls oly slighdt lo!v, the causc \\'ill prob
IIiSh oil prelsure car esuh ironr only a {s cus.\:
irtrcfcr sertiig of rhe relief \ahe. .r sricLing r!.1Jicl yahc,
.r ,-p.P. r ..e^ I .r'r. rf.r r.r
and r trlugged oil passge. l he cNe ca Nuxil,! Ire located
ea\ily ecetr a nc\lj- o\cihxtrled engje $here a relief
\alve passage rr) be blockcd. \otc tlrr Lhc oil treslLue
11lll be abnonrallr high r\h. { cold eSine i! first sraed
ard is not,!eI \rrc.l ut.
High oil consunltion is trsuxlh the re{rl1 of nelr or
leks. lf blue oll smokc is cnritted fnn the eng e brearher
d erhrus, rnor hkel) Lhe pisrdr.rg\ arc vorn. !o lhar
blo$bl occurs. l blo\bt. pre\sure built rt i thc
crrnkcsc c{usc1 dre oil sprt inside he crrkcsc ro b.
b .' \. Lr" ,l.l r<.'rlerne .. u..r
some engtuc\ bocause of bu ldt of sludge ill rhc br.drcr
Iube: is nla,r'. tre dctecte.l by erce\li\,e leakage tn the pro
peller shtt seI. Clcncs\ of the breirlher iube is xsLrall)
.hecked a lhe 100 h nrspecilon on egres rlrere is nral
be i pmble . Thc worn rings also illos oll to piss the tis-
ton lnd eter tlle combustio chdmbcr. ryhcre ir is bured
Thi\. ol.our!e. produces bhre smoke aI lhe eha\r.
Another c,ruse of high oil consxlnplion is n wor Drd\t.r
iod bearng in d radiaL engret llris pen ts loo nilch oil ro
bc sprar-.d fionr the beariog and inio tle cylinder orcs I1
thc s.ar.nger ftrnrf is defeclire, the oil !rill ot bc
iroyed frn the enp.rs pidl) as requiled. and this uill
also lctlo ciccssj!e oil cosulnptio.
Oterating a cgiDc {t hjglr toser setmgs ad high
ternperlures \rill inclease lhe oilcosu.rptior lfan nppar
etl1 normal ersiLle is usnig morc oil thdn it should. the
til.i.Lr!rd eq'e.ro.eo .f d ! ,tr ,. ..,r .r"l
r'light l-he pilor should observe he readmg olrheoil pres,
\urc gage frequentl) duing operalion If rhe gage should
begjD !o flucunte. Ihe llighl should be tcred as soolr
as poslible because ere n1al be a l ! oil \uppl].
Induction SJstem Problems. The clesigls of indtrc
tion system! for reciprccallg enghes \ry con\iderbiy
for differet a rcrali-and-engine cornbiralions. The sinl
ple\t rlircs of induclion syslems inchde an alr filter nr thc
t{ J --r .. ot J..brco.r l.,r '\.
ductiDg to the.arburetor. he calburetor. nd aD iD1dk.
ranifold or ilkc f\res ihar c') c llA nirirure ro thc
lahei. Others!stcrs include tu$ochrgcrr. superchargers.
alLcmrte air slstcnrs. and crbureor dcicig sysrerns. For a
puticulxr aircrfl cnsiDe combnrad.,. the rechnician
slbuld corsull the operxl(njs nd lllalriennco mxnuals fr
the jr.raf.lnducdol \),srcms re described in alh.L! 5.
Thcsc prcblems n1a) arise in a typicai inducrio \.-srem:
l Dity and/or.[mSed air ii]ter
2 worn. loore. or dmiged air ductug
l. l-oose or delcti!c xir remperanrre bulb
:1. Deri.tive ir hei rcr vl\.
5. Delicile hentc air !lve
ar. Loose carbrrelor nrouring
7. lleli.ive crblrctu ronLiDg gxsket
8. Lcking tackiigs or g\krts at jrrlc pipes
9. Leaking inrke nritold
Anv cnck or odrer opelirg thrt rllows jr !o ener an
itake mnilkl. in nrr.rllt rslirated engifes. \rill .usc
the F/A rixLurc Lo be ercessivcly lca rd nral cr!!e
englne dn.rgc dd dlersely rffccr cginc pcol]rance.
leaks in rhc jnlaLre nrfilld 01 x \up.rchnrged or ur
bochrged elgnrc will all!r lhe F/A trri\rLrre ro escale,
thus redtrcjng l,lAP rd cngie po\rer orLrput.
lLfectio of a 1r-piclindu(lion sysem ircludes rhe tul
lowins:
I Che.k tbe air lrlrcr lor onditiorl, clenncss, dnd
'...i. \' .(' . r' orf
2. alheck the ir ducig to Lhc crbuetor lbr wer clxm
age. crack\. nd \ecurit! ofmouDtig
3. Check the air heater lalyc rnd.lnctig l.r wer,
ctacks. alcl secu l-! of nouniing Che.k the tr:lve doo
benings for rcr and lubri.te according Lo i.(rrctions.
.r Ceck drc CAT brlh for securi}.
5. Check hc cdrujt rnoxftirg lor lcrurirv. Tighlen
bolts or ct scrcw!.
anr" loose
li.Check llre .r bul .l(n rounrrg gskl lor lo\,i ible air
lcrkSe Repiace lhe Srskct il ir ir damaged.
7. Chcck the itake pipes .rd/d mrnlrnld for condio
E. Check lhe inLlk. tipe lacking rxrs ft'tighress
Check the prckings or g!\k.rs for \hrirtaee or.lanrgc.
9. Clheck lhe ltcrnaLc air system t conditior
Backfiring. Backfirig occus \,hen rhe flanre from
be combusdon charbcr bum! back irlo the intke mani
lold rd ignies the F/r\ nirtLoe belore dre rnirtrrc ctcrs
Ihc cngje Jt otlen occurs dxrig saning of a cold eng e
becatr\c ofitoor (sloq) corbnsdon. Thc F/A mitue i the
cr]nrdr is ltill buning at the ri.ic ihc iake \,ahe otens.
ad thc flxnre brrns bck tlrroueh the intake vh'e. This
soncrres caules a fire in the iducrion sysrem.
Any defect in he carburetor or fueL corol svsrcr
hjch cuse! an e\cessively lern rixtLne can lead to back
fting. Il thc coDdirion ter\lrs aft.r D engine is $armed
up- ibllo\:, ].] systcmatic t|ocedue o locate thc crule
Anoher caulc of ba.kfjring is silckmg intake valve!.
This does nol uiu.rll) occur rvilh a nes or reccndy over
hauled engine. bul it is likcl) to be encourered $irlr an
older eDgie operaled ar high tenferaures. lf a rjckrs
-
,.... 1..,...'.
rroubleshoot nq 235
 5. What 5hou d be done if there s ro nd ction of
o pressu e 5hot y fter fart ng the engjnel
I!iLj rouhle\ olielr caus. brckti rg. IJ hish rensrol 6. the operion o an engife [/ith a constnt
r..; ,.. e1, speed prope le, ,,vht sequences shou d be fo lo\,ved
ro lir. our of ime, io th.u rc nr lrure m\ lirc i. cvtrnder chnging por.'er sett ngs?
' 'r-,, c., , F, tJ.. ....,, 7, What s nret by "crLtse coftrol"?
enginc i\ bcins stxled lbr rhc firs me rd brckfiri.s
per, 8, llow s rxrm!m rnqe obt ned n the oper
siss. e (cchnjc n shoLrkl chccli li)r ignitiorr (imng rn.L t on o: ircrft eng ne7
tbr prcper connccLlon of rlre \frk plus leads. l: itio out 9. Wher n engne s eq!pped wth a crbLrreto
ofile cll) lso car\e aiedirilg rlr.ush ihe e\hrr. . ,n oo o.. .a pooo a o.
hLrTT q do\ rn tl e ect ne'
-\ftei rg. Afieifilrg is rhc btrffirg ol F/r\ riiue 10. Why s the mxture leaed out on rec proct ng
in lhe crhxusr nr.rf fokl lrcr rhe rixiure has pdssed eng e7
lxongh dr. cihrtr\ \'rlve Ir is chx$erized by edpl(ire 11. \"/hr is ihe geneal procedre for en ng oLrt
slr'rrrls ucl lrgc nres trallirrg our$,rd lrorn dre eihatr\t the . xtL-rre on eqt ne equipped wjtl f oat-iype
strcks (brchigl. t nLallv e\ccssi\c lucl (rich mixnrrel j. arbLrretor?
the erhxtrst.ontiuucs to bum 1ler drc mi{tue leaves c 12. Wht opertig pocedures.| he p redLrce ed
. ir r. ll,( 1..'.. .\ tr'',.. iou ing o the sprk p uqs?
*ccs\j\cly rich rni1lur.. po.r i:nirion. nd inrprofer r1l1 13. ta,/ht is reani by prehetin9 f eng ne?
1g. Sifce there re (oif.Itivel! ter crusc\ ol atefiLirg 14. Wht sho! d be !5cd ro c e a a rcrfl ecric?
it i! usrl \ .i(v to coc.t 15. A oo o ho., b..-oe
"
the enq e \,hen n o screen is selrced?
.l

16. Ho\,\, is a o f ter nspected ,!hen it is.emoved

ror an eg ne cjLrr 9 nspcction?
17. Nme t,ro types of comp ession teles ut tzed
on rec proct ng efqifes
1. f a f re occurs during !irting of t re eng ne, 18. \'Vhen Lrs g d fferet l-pressure compresg o
\,/hat 5rcir d the opertor atol te5ier, whal perceflqe pre5su e oss s cons dered
2, \",rhi f re exi qLr 5lt ig gent is aom oniy used u.ceptb e?
on rec proctinq enq ne 1 ret 19. Wht re ihe procedures Jor !erv cing dy
3. V/he !trirn! an erlq ne \,r th f ot type .rbu ppe nduct on r f lte
retor, \/here ! ror.rld il.e m xtLrr- aontro beposltonedl 20. L s1 the s x steps ihiri lhou d be Lrtr zed n to!r-
4, V,,rhr rs n'ret y the ier' qurci ock"? b eshooirg n enqine

236 chpter 9 opert on, nspecrion, Ma ntennce, nd Troubleshooting of Recjprocatng Engtnes

 Reci procati ng-Eng i ne 4#%
Overhaul Practices ffi%#

I.lrircnrncc o1 xirlinrcs d po\lcrTlrs is one of the oterried so lhat it har nol bccn o\erterted or()veistresred.
:,\L c.ilicl srgrrenrs o1 l]ie lirdor irldusy. lndividuls Teo'.,r:r Ji ..'rr'r'r'. , ( d'.1
::.1n\iblc 1r the rinteuce or o|elnul of a ceifica haul lile unlil il is decided that a ljor ovedranl is
- 'r l. pJr. D..'r 1(r .' et.r.
.. rp..ol.r. .l e..n
required. e decision Lleng bascd th. pcrfoNancc .f
D
lhe engire. Or rln' o$ ) dc,.i.lc t., hr. a top ove.-
: . n. Thc\ nr st do lhir'e$,ok ir ".ler rJ.'r ,
snch a u'ay lha hen haul pcriornccl., thc cginc. \hich is thc.omdete rccon-
:.:t have completed a paricLrlar rcpair or olerhaul lob, ir ' rool or. !) i'J. . i. r. rJ.: 1.r.r',-
..\ cn st. This fall (or is enslne) Nill not fail."
The owne muSI realize rhal $hcc!cr thc ovcraui fcri
od for n engi,re is extended. olher laclors ry Lrccomc
irFntat. lhe valne of rhe iaft may be dcplcciatl
l-. .-.f rLr" .' F l..r-,c,.
crcturlly olerlrauled t nray be $o1r beyord repanUe
lir;ts. thtrs rcquirinn exiefsive replacemetrr of prts rd
j.r.onc crrcing e licld of aviaion maiterrance nrxy grcltly increasing the lrverhnl cor. lhe addiliorl c,ir
roc 'h. e:.r-o(1r.rl re.. l,r'.r.r. ray be Brearer than the m.unt snred b! elr.rdirg ltrc
(, .'.rleo,e:.1 l '.. ..".r 1lrajor oyerhaul periocl. The advice of I qu.rlilied engire
:'.thei qtres1ions. lhesc qtrcstios xre not dillicrlt, specilirl shoukl bc obrrcctbli! rho dcciliion i! made Lo
r:arse exFrien.e hs p|orided thc {D*!cA exerd the oled\Lrl lirnd.
\...err.r r,l.. .I Ip,,' rli' Tle.. ., r,Lb., -.' .l.',..,-BO r!' -n,n.:r.r
trndc.gocs \ rious chngc\ which rnakc a olcrnll ncces is deter icd lrgely bv he rnanne of is olerLio. Il rhc
.rl The rnoit in)pora.t ollhcsc chage\ Lr'e s lollowql operLor is cdr.ftrl an.l .ontinually obserles the rulcs liD
good cgine oteration. the life of the cngirc my be
L
Crilical .linresios in thc cngine re chrDscd s ..c..d.r.. r^ r..B,r . et!...f : I

..:uli ol {ear ard nresscs. lhus briDging bour clecrese l]lt clere ncc.l l(tr cngjc olerhaul in mLch less an dre
'e... . r"rt ror .

::rd ar increse in engine libraio|.

L l. (r.n r ,. rer J.,,(, LL r :(.:.n . (o o. e
Overhauled vs. Rebuilt Engine
!rbsances. ard abrasile subslaces. accumulate in he
Alr orerhald engh, accoiding to he F,\A. is one that
-r. The Ineal rlr cntic tarls of e engine may be crys- hs becn disasscmble.t, .leaed. lspecie.l. repajred rs nec,
:: rizrd as a resul of costal attlicior ol recurig cssut reaslembled. .rd resed accordirs ro tbc mntrfac
irrer'r ifructjos aDd specificrions. A rebuilt engine
: Oe or nore pam ma) acmall) lail. mtr\t al$ udergo all e srep\ cLscribed abole. ln addl-
tirD, the lalrs that are reused in lhe rebuil engie mxst
\pci.Dce with taticular mnke lrd model ol egine mcet the same limitr d tolcrnces specilied lbr new !rfs
:.::tlirhes the alerage ime this model may be olcrared by the ergine r{Dufaotrrer. The rebujh enginc nrlLs also
:rtrr extecttion of failure. be funconall! Icsrect dd must neet e rcqtrjremenrs of a
lh. recomlneniled overhaul time is delemried by rhc
. .i. er t...crrwaeot ro:1o..d.r f.r... .\ '.b r l . ,F ,. 'e. ro r"\. o I) .Irc. I.
::: is madc known !o e aircrart owners and lechnicis operaling hiso11, \hen it is reruned to serrice. lr can be
r -::gh scNice ftrbljcations. Opeaors of aicaft used in said drat the engine has bee granred zero time. ,{n aircrafr
: :-nccial {ir tranlpotalion must adhere o he olerhaul cgnre may be labeled as rcbuilt olr b! ihe maulactur.r
:-: .ecomcdation! of the rnanulcurer or ger aptroval
'. \\.' .le:rer. ele\ tr 'r' ',e. overhaul cgines 10 the speciflcaLion\ of a rebuil erglne:
iJ\erer. Llrc o$Der of a private ircratt has r$o other howe!cr. sjDce these sencies are not apfroled bl he man-
a. " . l( ir rJl eI!:.. r.. ulactur.. fo engie rebuilding rhe cngie lnus be Iabeled
-::::d olcrhaul tire. esfecially if he engine has reen as o!ehauled nd cxry the prclious opcrting time.

237
 Thc Ie rcmnrfhctrred s.nc lsed l r.gid 1o mrnulrcrucis.lcsjgn speciallns rncl lirturcs to be nsed
.gile anil cccsr)r) urairlenince. hrl is nol delled b\ Lhc for the o\crhrul ol thrir elrgies: howc\cl. it is no Lreces-
F,\A when rD cngilre or xccessor! is lbeled \ rcru sxry t(r h!\c.!cr) lool iisted in the orcrh!l )rrurl. Nlan)
fctlred. il is imfott 1o obain .lctiled descript;on ol' nxndxrd t{rls. such as wren.hes. Seu pullcrs. $o$. lifi
bc nrxrlef n.e t.rlirned. ins slin.!\. rcxnrers. elc.. can hc trscd nr place of similar
lools i!hich a) be avaihblc iom thc rranufacurer.
l.' .: : .rI .l.', ,' kel ,or r\c
Major Overhaul and Maior RePairs manl cngiLres of rhe sxnrc Llpc lor olerhaul. il is good
plr 1o gei Lnost (or ill) ol the lools deligne.l for Lho otcr
l h. process of tki.g parl, in\rectjDg. rpiriJrg. reNsonr
.i' . of.nginc Ano: the nx)ls and
hul ot' thr i,"'l)e eqnipment
r..,.. n'aior
needed tr englc o\crh.l'rl a1e e follo\ring:
t'!erhaul and \hould ot be confuscd with major rcpan\. A
major o\erhLrl lan Lr. perfrmed or lupcr\ised bI thc tol- Enqitl Shop Equipnrcnt
erpl!r nechnic and docs ot requirc FAA fon ll7 Arboi of selctulsirc!
n .ss thc engie is .quipted \1ith n nrrcgrl sul)erahtgcr hrgine lc
or hns a propelier.cduclion \yste.r wilh oer thtn s!!r-
Ch{in hoist
tlpc gers. Repir\ 1o sltuclltrl cngile lafs {r.h s seld Herling equipmenl
Clcaning.!ripmerl
ig. ll.rlirg. nct letallizing con\tiLLrle major rerils nd Lilinrg slins
Crankshali tlnead cap
nrat be xpurored orlt br x|proPiaell rt.d penos or
Ctunksh.llle'rerch Peneranijnspectioncquip
NlgncLic inspecdor eqrip rent
rel Test sand and propcllcr
Tilnig dlsk and TC indi
lvlxgnoto linirg ools calor or Time Rilc
Olcrhrul stnd equipnent
Pns lrys Timing iighis
To tro!ide lir. efticie1 o!crhrul operatlofs so lht engi. C)linder fixture\ or hold Vises
orerul can be icco plirh.ct I mintrtrr cos to lhe xir in: blocks
{ji oer.r, a ol'etl \hop nrusl be $ell orgrLrized Ihe
1r-pe oforgnizatior 1ltrgely .tcp.nds o the sircs ofegjes trngie Orerhaul Tools
Io e overhauled and lhe !ohl1rc llnrnlber ol engines 10 he alignmenL lgnition hanrcss tools
olerhaulc.l in r gn'e ilrer. Olcrhanl shof\ lnny be ellab Piston rifg corfrcssor
li\hed to handle cornparat\cll rt{ srnxll cngi es. or lhey Cylirder lrse wrer.h
ltlal' br lrge corp.rnics trhich olerhaul hundrcds of smll T,r! and clic tool\
dn hrse engines crch rcar Val!e spr ing .onlressor
R., ..' , r'l l ro' ll -"r. '
', ".. rle c r. o . - rl.'ell.. '{ .e .
Valve refacug equipr\reIrt
Vnlre sext grnrdmg cqLrip
I produciion lr. The bsic slets ol the olerhatl lrocess
Hand Toos
1. I(e.ei\ ing Lnspection Safet\ \1irc r )ls
l. I)is\\crnbly Scrc cxrrrcors
3 Visu iffpecio Spner rvreches
.1. Clcaning Dirgonl cuters
. Strucrural inspection Ditis of several sizes Shril irers
6. Dunensionnl instcctic1 Dillnrotor Srud pLrllers
7. Rcprf and retlce cnr EDd $ieches Torque wenches
8 Rcsserbl,\' Plier\

10. Engire lelting ad ll-ilr Prcision Ileasuring Tools

11. PreserrtioD and sorn3e l)ctlh gges Srnall'hole g.l:es
I)j!lSages Surlce plte
Each of thcsc rlepsir l1 be discrssed i delril. The Hcight gages Tcte-rc.,pe gges
lrocesse!
jn\ol\ed in each \tcf $ill also bc (ic\.rihed V blocks
Sone of thcs. processes requirc specialized eqtriprne|t that
t not be xrailrble Io lhe indiyi.tual Fo\e'plxnt lechnl Nondeslruclive Inspectirn and Testng Equiunent
ciaL1. lt is uf to to\!erplnt tecbiciar !o d.tcmine
tho \1agxil\
*hrc tunctions hc/she can fert'ornr rd rj.h .rust be senl Zyglo
otTio rffrotrialely raied reftir ralion. Eclclr cuenl

In dd.lilio! Io the tools nd cquipDenl listed xbo\c. it is

Tools and Equpment ljkclt thI the ergie $ill hr\e cerll tantrc! $hich
8.1r'e rtienrpt;ng Lo olerhaul a rircrxli engie. thc po$- rcquirc the mannlcLuer'! spccil lools. lt is bercf(nc ec
.rylallr raintenancc tecluici sould ake suc Lhrl xll es\ar! 1o obtrin these speci{l tools lr each diff.rcnt t}tc
rhe required r)ols rnd equiprent trc r!'ailblc Egirle of.Dgnic o\,eauled

238 Chapter l0 Rec procatnq Engine overhaul Pract ces

Manuf acturer's Overhaul Manual
E!cr)_ clginc o\cr'haul rnusL bc crrid out accordace
with thc irsrrctiurs gi\cn nr thc nr llcturer's o\'erhul
mrrrl. Thc olcrhxul manuxi fro!id.\ i lbrnralion on all
frocc.lurc\ ol r sfccidl nrtuc ancl on geleral trrocedures
f(r lbc.lisrsscrblr. clcins. ir*pectior!. r'epir. rnodillc
lioD. kasseDibl), lnd lcsrg ol engires. These procedu'es
mLrsi be fbllowed io ensue hat lhe engine is overhtried jD
a lnnner \rhich r1{ll provide dre required reljnbility.
The l]1anutrctrrer of m aircrli engine ha1 ll rhc inft)r
trrlim .ellilg lo dre constLctin and de!i:tn of engnrc
pis nd irs lrl{le nuicns tess ofrhe assenrbled engnrc
{nd its p.ts. Thc o\erhul rnrual p1epared by the rnaDu
frcrurcr is thcrctbc lhc mor lalkL source of if(nrxLiir
lbr a paricuiar lnake and nodel ofeginc.
Tlle techriciar mus be sure tht thc m.rnual aDd olhe
dra relered ro l'or overhaul ifo ation a.c the iost crr-
ret and apfly o the specific nrc.lcl unber, nrcluding lhe
dash number. olthe engie being olcrhulc.l.
Certification of Overhaul Station
To pr.,\'ide overhLl s>'rices for ce ificxted aircrrft
ensines, an overiuul rgency shoLld be nn I:AA ccilicared
repir slaion $ith ralinss coverirg lll lhe lypcs ofolcrhaul
'vork
lerlor ed. A ce iffcated epair station is defnrc.l
br Fedenl Aliaion Resulations $ (l facilry fot tu nnn
natu. tpit-, an alteiltion o.l dilru"L , P.\.ryldnts,
ptot)tll?^. Lt ulplio te!. holirg t1 \:dl rcPa-\rari,1
ut!iJitat. rilh npprcprnI. rutlis it\t hr the A-
ntinktntut.'CcrtifictioD bl Lhc FA,{ as a ceiiicated
repir slxtion fernrits the re|rir \talio ., perfr major
olerhl on all items lor which apptupriate ltr]rgs are he]d.
lhis ce ilicxlion lso tcnils tlre repir 9laiolr to approve
o\ crharlcd ilcnr\ for rctum Lo scrvice All agencies curlei
l\ pprolcd by thc FAA rrc listeLl i lhe Consolidaed
l-istigs oi FAA Ccilicd Rcpir Sr.'rs. Furrher details
reg{rdnrg drc ijsponsibilities nd priljleges of r .ertifi.rt
.d rcpair sttlon e gi\,en in P.rll l:15 of the Fe.{l
A\iati( Regnlations.
Shop safety and Preparation for Overhaul
ln rhe treparaion of an oleraul shop. ll rcrluirccl !uip-
ment must be on hard. A listig ol cquitn\err is givelr laer
:n rhis chatter. l the otrtioD of lhc \hop. il is inporant
.har adequxe sfety frx.ti..s b. cxcrciscd. Srtelt' rrvohes
:he de!iS !n.l mgemenr ol thc shotr. use of prpe lools
.:ird equi|ment. r1 obrervancc ol sl practices by over-
:rrul technicians ad heil helter!.'Io cstrrc tht ll reL-
.nable sale) precuiors rre ixken d thnt all cquipnrent
riees sal; reqtriEDrents. it is xd!isrblc to hirc prols'
::nrxl safet] egieer.luring the cfrblishrncnt nl orgni-
r:rlor .f the sk)|. lhe \!fet) enginccr \holld be sked Io
. t l'i'l rr''l' |I ll p .
: check for unsafc trcticcs and conclitjoib :Lnd lt) discolet
.rt equ prt whi.h hs b.comc rslc.
The f.llowing r some of the r.quirrrcnt\ 1r slely
.::rd eqif.ret in n overhrl shopr
I Thc a {ngcmcnt ofthe lhop sh.iukl be srch th{
c(\vding .locs not exist.
2 lvllcrils mcl tl1s ust he siored I protcr rrcks
I Wlkways sholcl bo paiftcd on the rloor and kept
lrco ol obsrrtrcLion\ at ll tinrcs excepl nhe necessar! Io
.1. Suitable engine overhrul slncls must bc pro!jded
for the types of engines o be overhalrled. The derigr of
e.gre lrand! ! ie\ wi the ype ot' engile.
5. Adequate work (uiof rd hech \pace shoLld be
6. All ma.hiner! n st be i:ood.epiii nd pnr\ ded
r!ilh pprved safetl gurds
7. Electri. equif.ret and toile .nrlets nrlt be.or-
rcctly idcljlicd fo. voltgc xd f.ser hLLlin! cfh lil\.
q.f.i,i. , e.rL. cd. .1. rr'' .,i'
possible Lo plug ln equipret odrc dra at dcslgned for
dre voltgc d t),pc ot'cnrcn( spplicd aL c ourlct.
9. Adequte lighiin! musl be pro!icled l! ll rras.
10. Clerning ares nrxst be adequall) \'e Lilld lo
.erno\e all dngeros lunres lroirr sol\errG. dcgrc:iig
agents, ad other volalile liqui.ls.
11. Properlr- designdd ersine hoidirs equitrcnt nrusl
be \'ailable for litiing erl:ines.
I2. Operators should i!e.r sallt shoes lo prerent i|lur!
lo their leet i cn\e he!\.y equipnrenl or |rl1s re drrpte{l
Il. Ofertors of lalhes. mch e ro.ls. drills. nL
Srinde$ must er safery Soggles.
(lFranr6 of clexniS equifnrenr musr n,er Irorec
1,1.
tive clothi9, nLbber glo\e!. .Ld f.Lce \hield\.
15. Thc floor ol thc lho lhould hn\c .i rurl,tce \hi!h
ctocs nor bcconrc sl4rpc,ry.
16. Gr.rsc, oil. d smrihr tcr ils dn,ul.l tr. r.nr.r cL{
ru,rrl', r,.l .rl rrrl . I
17. Propr t)pcs of lire exingLiishers sh.rLld be r\.ril
ble to shop tcrsonncl
18. Personnel should lltke carc to \r! clcar o! f cnginc
. i.':.L'a I,,i r.J....t
lion sw]ig or timing.
''' I er.r... .ot prre".or...!
hul shopi All arex\ st be kept free of slfd. ,1nsr. Sreie.
.lity tugs, ofcotr.rinnLs.
and orher tyfes
20. Cixsy or oily rag\ rust hc \tor.d if cl.{l\ .o!
cr.d mcl .rns.'lhc rag c{\ \houlL] b. .mtlic.l ft..liL.r
tr' .
21. Fl.rnrxble liquids nrusi be storcd in n xtfro\cd
lir.proof rc{ -lhc rppro!l is DonrLl) grx.1..1 b) th.
local lirc dcfrtmcnt.
21. Tho rrc \hcre cngrcs c r! shold L1e p\.d rld
kepl liee o1 ll .lcbis which could e picked !f L1) ir citr
reIs causc b) r frcpellcr orjel ke
Recevng lnspection
i, The pur?o\e ol lhe re(eiving inspcctio is ) rlclrr L r. th.
ge]lerl condili.'n of rhe ensine shen ir sr.cci\.(l.ti.
r n1!eLllor) ol the eglfe xnd ll is r.css.ri.\ r.1 \*'
citcd parls. orgrnize rhe engire reco Jr. xd trrfr. lhr
cr!re lr lhe rexl \tep in the oled nl I o.e\s
Re.eiv nq the Enq ne 239
lnspecton
lh. ,:.n.rl c.nd;riof of the enlre should be creJull,-
n',red of rh. rc..jving repo. lf he engire hrs ee i. a
..!nr fii. or odrer !itrxtion shere dmrge ry hr\c ccn
.luied lrch c.diion\ hare ro be recorrlcd. Thc .o5r ol'
\erhrnljng rn.n.!jne \h.h h!\ \uered dmage orhcr
Lhr f.nl wc \ill hc c.siderabl) grener drnn L al.
r nrnt crsesit is ot cconorjcrll) jlible to o\erhnrl
the ergiu. shoulcl b. mortcd.. n orer
.\t rh( |oi|r
hx0l slmd xrd clenccl crr.rrlly. T some cNe\ rhe di
r)-oil lrillLrre i\ "bnk.d o. t. th. .\tc.t that rr i\ nor
enlnelt rcnro!rble silh an ordini\ \)l!.t. t.strllr. ho
c\er. thc oil rld loole irt c bc rcn,\cd by nrc.s of a
pc1,,,lcurr \ol\c1 such ! nricr{l stirit\. kcrcscnc. or
orhe. p|ned Itri.lennr \ohel Sornc qrcillors stcIrl
. en rhe enslne. rhus renrolrrs oilf deto\is ad clcd
d it. \\rhe. srer .lering ir done. Ihe engtue shLrnld Lre
\,tshecl off \'lh plxln hol qIer lieNrrrd ro rerro\e ll
tr.Lccl ol rhc lklie seIn clennirg solLtion This is rec-
cs\N to fre\en the co rosior of aluLlnlrLnr aLrd Lrrgc
l\fcction rltcr .1.fing a) releal cracks in the
crakcnse or cllin.lcrs rtr other dnltge llriclr mrty hale
beer hiclder b\ dirr or oil. Daiitxgc found .t1 !b s poi.t ln
the olerhrLrl proce!-\ $ill incrcs. (hc ccurcv .f th. c.st
esinate ad al \x\e cngie d.\ntime f the prrs i
queslion have ILr be ordctd oi scL out fd refrir
Inventory
It rs essenrinl thal erer\ frr bc lc.ount.d rr. bccausc a
.. i I.,,r.
ilere rero\ed belore e errgil. x5 d.li\cjd (o lh. o\cr
h.rul fr.iln). The receivLng ins!ecri.11 r.fofl
mlde on r \tandrrdizeil forln. nd .Lrpr'ol this lo.n
\h.tr d he -liren o ihe owner
l.cLuded in rhe recei\irg irspeclioD rcport 5houlcl b. rhc
mke nrodel. rnd serial nnnber ol rhc cnsnrc rnd rhc scril
numbei\olrll it\ c.es$re.. ln ddlon. all par\- iuch as
c]ljnd.r blllc\..{trcLrg. br.ket!. etc.. shoukl be l!1ed \o
thrl thcrc sil bc no qtrelt on resrr.lir: ihe resfo.\ibilil]
1or thcsc pls lt.r th. orc rul has beef cortlercd
Organizaton of Engine Records
f-xren( \'e e.o ds musr be keft s ihe engine |rg
rioughdrco\.rhxtrLtnrcess Ilr s intoinrxrion w
trrl oL lhc fcrrnr1rcrriL\ lhLl ru\i bc kc|l b! rh. o\,cr
r: I r'| ,Ilr..r
L..ig pr o.c\sc.l.
Tbc I-AA T\t Ceitjli.xre l)rir Shee f]ll!i he re\iesed
to.\!rr thL rhc cns fc .orli{J|\ l rls t!pe ccrtification.
lrn c\rfL.. the lnir-!neros. .rLr1elor'. ltLel ILrnrf. tud
orh.r.onrto..nr recei\ed silh lhe engire nrr\r Lie llie
o.s !!ith $hi.h the enS ne \.rr oigiflll ce,rili.tred
Al$. .t.\ rf.l .iher ifftior ielIir1g r ihe e rsife
l rj!c 1. rire. e!ie rrLl.rcrrLrel\ i\.Lre .tcr rl
icr\icc bullctins rhrl leqLrirc lrerrrior\ or tn\
.1.f1! desi!erl lo irpro\e t| t,ejlorLjrjr.. rjr jcljrbilLl)
of rhe eftie l)rLii! rhc o\rrhr I ol r .n!i... L,!llerir\
240 chpter 10 Re.:ipro.atig Eng e Overhau Pracli(es
rnLrsl bc comflicd with. and n saienrent oi \ueh .onrtljlnce
lnur bc radc ;n the ovefraul reco . Thc fAA isiues
D;rcctiycs pefiainin! to {ircrft and
vhc.cle it appenrs that celta changcs \hould be
^irworthinss
engxres
made to con'cct djscr.facies or to inlpro\e the rciixbilii!
: . r( o ( i.,l. .l' \ r\ ",1 r,(..
l)irecliles perlaininr: '4,
to drc cngire rust be conpliecl $jrh,
xn.1 a strlemert of conplirncc should be entered (hc
Thc rofair (at or shoLrld mairrlain a corflcre record of
all retljr ofc.irjofs and insteciions periorcd o each
engilc or comto.e ovelhruled. This rcco shorld con
rl ! r
''
rrd clcry p{ ret1.}cement. The inspection rec()rd rhould
sho\ o clnncn\()ns of each parl rneaslrred rd all lirs nd
cleaftrces. Thc5c rcsurcmcnt! nre cornpared !!ilh the
raufcturer's Tbl ol I-in;ts tscc Fi:. 10-1) so tlrL
refairs mrd replaccrc:nt\ can bc rade 1o resore \!orr prl!
to the ieqLrired stcciiictios.
l he rspectio record rhrld \ln)w ihe rlpe\ of lnspcc
rjon prccedures emtloyed, \uch ts nagnelic trarliclc rcst
jng, liquid penetrat inspccrion. ultmsonic in\pecion. radi,
o-qraph), !1 rn) othcr nlprovcd pocess enlployed io
detenni.e the nsoihnic\s of thc .gine and is pa s Il
y of these rnspeclron-( arc pclfor]ed b\' x .ther ger.y.
thc ccfiljcale of thai agency ust be in.ltrde.l in ihe ovcr-
Disassernbl) of a ryfi. ircrali englre tollo\s scqrccc
lfe.ifed xr ihe o\c.htrl rut1 During drsasse bly the
op.rntor idelil_\ and mark all pars. This is oitcn
shoLLkl
shold bc done bf ttaching sr{ll nrctll or flefic trgs 10 ll tars
with \ofi sfe $ilc. The tlgs are st.Infed $l the \rorl(
ordcr number The o\orh{ul {nual lpecilies whlch ps
rus be replced in thcjr originl locaions. There parls
mt ire deniilied bv alluchrg additjoal tags to sho$ the
loclioDs. Nuts nd bolts rnay be smng on safetl rlire in
gout\ wlrich are jdenified for 1ocdon.
Cllindcrs. pisknrs, .o.necting rods. vrl!e lilicrs. rDd
olher ps requiring e\act localiolr shorld be cl.rly
ma*ed Io sh(! thcn loc.ttjons ilr tlre engire. For era rplc.
he pislo lior lh. o. I cylinder should be rliecl with
e lunlbcr I Thi\ nunrber is sr,rnrfed o| lop o1 thc hcd or
esse\ o. ihe botritrl siclc ol the fiston Conne.tirg rods ha\e
ll be.onre .urber\ \IrFed o the big ed. Crrer'ul mrklng rnd
i.lcflifcion of pafs qill csu. frof.r asselnblt ard $ill
r' piuidc for correct fiLs ird clcxtu.ccs \rhe leamrerenrs
lr r.r rre r.rde Orgnirt(D ol pr s . a suitable pafls
rrclt will keep rhc o\.rhnl pr)..ss orderl) .1 lill h.lp
tre\efi til nri\uts fJ l{\:.\.
When lhc (cclicix. hrs.rrelirll\ noled e. r.p rnd
crrierl or I 1c ofcrxLi.\ rs !i\ en. the eogiIe is cori\rlct.l)
lr,l'.
!eplrce
All Ir1\ sroLl lr. gL\rir t)lrlinriiru\ \ j\rl ifsp..1or
eirh.rr\ th.\ f,.,.,f,)\.(1 li,) r th.irgirc r jnrnr.1i.t.l\
 Chart

otd
& &

-;o0 all lMain Beings and

.0060L

A-D-G-J-S-T-Y-BD-BE AF Maln Bearings and Cranksha1

(Th n Wall Bearing .09
.00601

B-G-J-S_T-Y_AF Ma n Beanqs and Crankshart

(Tick wall Bearin9 - .@11!
o41L 0050L

D amierof Ma n Bear ng
Jo!ra on Cra.kshalt (E)

B,D-G-J-STYBDBE D ameler of Main Bear ng

JoLfna on Crankshait
(2-3l8 in. Maj) (El

T1-T3 AF D ameler of Me n Bering

Jo!nalon Qa.k6haft
(2-518 n. Ma ) (El

s8-s10 Dameler of Front Maln

Bearing Journal on Crank. 23159
shafl (2-318 . Main) 2.3760 (E)

Dameie of Front Main

Bea.ig Journal on Crank
shait (2-518 in. Maln) ZE1.5s (E)

FlG. 10-1 5np T: e f li t; iLy.orninq Tltron)

,: ih. complelo ot disarselblt. befre they are clered Chafing The qear cauled by t$o parts rnbbis bgether
i:jidue folLd in recelles nd odr.r {rcas ol thc cngjnc under light pressure rd wilhout lubricLiinr.
l ol r!( ot erJ.: r! . l: { Chippins The brenkrng aal of snull Fie!r!:s ol mcxrl
\ .r... .. .it ur r..o.., . ^.l(d \r d . 'Jr. .' r.' , from a pn ns .r re\ul of careless handling or exces
-:.1 $ith the se of n rx3nifring Blxs,. I e{ch casc
:::nS i-shl shotrld be u\ed nr id in rereling ll poisiblc Corrosion Elecrolyiic ard che]nical deconrposrrion of a
I'Lr ",r r.r ,. t- r:l r. ,i , nretal. olien cxse.L b,r ioinnrg of dlssl|ilar nrctalr I
': free'.J. rl . l::.r''.. )L lJlr co oicr
':. 'ho$r damgc to bc n)\r lik.ll Visu lrspecLion Nill is cuscd by.i\iurc i. combjatiur lvilh c|enrical
:-rll\ rcvcrl crks, corosio. ichs, scriches. gallrg. elerirent-\ in (he ir.
.:r;n.s. ad othcr dilturbrccs ol e Lrenl surfces. Palts Clack r\ seprdon of nrell or olhcr rarcridl. usudll\
--i are obrlorslt d ged beyond re|air shorld be dis
jJrd d
cused br farious fpcs ol frcss. ircludig lltiguc
rarked $ thI they will rot be reLsed. A record stesses resrhg tiorn refeIed lods.
I rll prl! Lhus di\crdcd \lrould be ade ir the ovelhaLrl Denl( I ro1B.,-l ...p, Lerr rL
:l r Thc tcrnining prts shurld be gouled or labeled as alll lound ir shee melal $here he metal rs deinned
::ttrcn(U s.r!iceblc or reFinble. o both the side s'h.-rc dre iorce r:,s npplied ad the
l-. aro .ne .'r . !e . o '
' . . , - r 'el offosie side nsrall,! caused lry the irnfac of a htud
:r be noied rLLrxrg lisual insirection mn,"' hc .lciin.cl
'
\ ft)l object xgrinsr ! rtrrfnce
Elongrlifi SLrcL.hjg or rcre!ing r lcnsth.
Flking Thc hrckrg a$a"- of \uface coating or naer
.\brasion A rcughened area whcrc nratcrial has bce .l r, I " .'l- .-, Fdl' " r 'J.i ,!. u.r
eroded b] foreign mnterial beiDg rubcd bclNccn .oatnrg or selere bding condilions
moljs !udaces. Irctling llre surface ems on cxnse.L b] ley slighl
Binelling ldeDtalions of a sulfacc cau\cd bl high .royemet het\\'een t\!o sudnces hich are tichltr
trce !ressing oe 1erirl agrin\L xDothcr. \ bll
Lr.arjg frcss.d wirh sufficic.t lrce rgisr a soiier Crlling Thc sderc erosio ol mcll \urfcc\ trc\\.d
,r: i-,1 ill.-r-:-B rill n'.L.., n1. ,i r- ilhll! logcther ard rno!ed oDc gisr Lhc oLhcr
Bu.ning Dnrrge to r parL.luc to cxcessive empernture. r-- . cJr b..o il..d c..o,. rri ,

Fjgurc I0 : sho$s d cin)ple of bnr|ing i cylin Couging The tearing air\' of l]letl b,v hrd obje.r
l.rl.. .r' ,Jr..1.',. -.j-r r.. bexrg rnoled across sotief,urface urder hr\\
Burr A rcgh or lharf cdgc ol nreul. usually the resuh lirrce. A piece of hard rnrleril caughl be\een rlL
ofraehnrc orking. dillilg. or cur|g. tno!ing sLunces can cLrse goLr:irrg.

v,su lnspect on 241

 FlG. 10 3 spl q cl a irer bodl f.e

Scoring Dcct scmrches or groves ciused b\, brrd lirrr

'i- oe
'r-'r!I- ..o..^r..{ tr ro
5ult.
Srr,'tche..l
desree ol .lefth a|d $id(h. caused b! he Iresenrc o1
iine tirr.igD taicles du.ing opemrjor or by.o.t(L
sith orher trrfs during hrdhrg.
Scufiing. Jr pickp lhc trarsfer ol mer.rt tuorn onc nF
t'acc kr mliDs \urf{ce $hen the 1!ro re rroycd
logcrhcr rnder lalt f.r.e irithout dcqtrare tub.i!i1

FlG. 10-2 8.rni ! rolr ,r. r. i.t .r 'rrl-4r .,e.d

All pxfs xre o be inve.ell li\ulty. The vjsual istec
tio ol r liw \.rde pafs is . follows.

Crankcase
(;rooring The lr.rrio. of a chncl $om ir. nlet;i
rs reid ol poor rlig.meLl of pfl\. Crakc\cs re rrstccred for crrcks. wanirg. rnngc ro
Grosth lllogIinn cxtrsed by erces\irc h.t rd.erl machin sudces, \orn hNhhgi d beafll1g borcs, lo.se
LjltrSal irce on rurbie eline con\nc\sor d Llr-
01 bert stud\- cono\ion drnage. rd oher condittons
whlch nr) lcd lo frilurc in serlice.
Indentti{)n l)e.t or dcprcssio i. iuiluce cu\c.1 bv
.erbl Studs
\iclr .\ shdrt sided de|ressior \ith I v shaped boton.
caused b) .rrcless han.lliiis ol r(xr s or tarts. SrLrds arc che.ked t,I bcdmg, looseness. r.1 ercsj.ln. A
O\idation Chcnr lal corbinig .l meai $ih nos thrcde.l pxrts re istccrc.l torrhred dm3e
|he c oi):... A lmxruD oridc rinrr tough. lrcl
I u p ' 1. .. r , , l e.o.p
rrP
co\er or prore.l trdedvln! lnelli rhus. ori.{ri. of
\rcl t!J]! is progr.\\j!c rd deslrxcli\ e.
Peenirg Depressior\ in rbe suce .,1 rnerrl cus.{l b!
srikmg ofrhe \urlnce by blurr objecs or nrreil\.
Pitting. or spalling Sinll..1eet c1rrie\ sirh -h{rl
edges: r\ be caus.d i. hxdened steel slrlces h!

Figurc ll) I \hors

r.'.i..
n c\nrfle ot splh)s oJ x llfter

Runout Ec.lr ciir or qobble of o .oriis px .

-..certriciry ol o bored hol$ or t\r. shfr diarnc
rers A lole or btr\h nS onr ol rlurre $irh I lhr sr
tce. Lrnr.rlll rc.L\ured $'irh I dj i.dicrtur Lnnirs
shted nJic(c rc full ilellecrio. r)l !h. indicrror ree
d e i o|e coDrflcte rel olulicm ol rhc tft or the irdi-
FlG. 10-4 5.or.q on a p s:on sk ri
242 .lp"' l0 '". o.o., 9F, 9 eo\e.-,t o".."\
Gears
\cce\sory gcrrs r. cxa.ric.l ior $cr. o\crhcatjS, \cor
i9. pi(ing. .1 dltcratjon of the t Jlh pr)filc. Ay .Ltfrc
iblc danragc is cusc nrr reje.tion ofthe p.
cam Surfaces
Thc \u {ccs of thc .{rs nrust be e\{rincd rlith a r{gi
i" .. J.. r'r. f .r lr. \,. b r. '.
.rri ,-., i,.. ......t..{,,rir J r.. .
ior rcjcctio oi lhc .m!hll. li.iarjtjon wilh a rnagri-
iiin-s glss revexls srall porcs in thc \urlrce. this also
'qujrc\ thrt thc shaf bc discrdc.l.
Valves
\ l\cs arc inspcctcd fr burig. crosion. srech. cncking.
.ro.ing. \rpng, n.l thirkncss ol thc hcad e.lge. Because
i rhe high lenpcrdtures 1o \hich exhaust vhes are
r\poscd. thcsc \l\e\ oltc ncdcl to be retlaced ever
:iough lhe intakc \lvcs rc \rill in ser\iceable condili.ir.
\ ahes are subjecLed to naDl Lhousnds ol recuning le'
.ion lods. bccusc rhct are otened b) cam actlor and
rjnied b] re 1lre spirgs. Thjs. of courle. tend! o slret.h
:h. \ahe\. ,tnd he eilecis of setchirs r. conrnron )
i.red in exhus \'alves Figue 10 5 sho$s how a val\e is
.imijreil for sfuerch ililh a !a1ve elch g{ge or connrur
Valve Tappets
''''' l r"F.l. lf -r '' i_ i r"
:r!. rnd orher d.rnrxge. Defecl !e r,t fels rust be retl.ed.
Hydr.rulic lifterr or !a!pet!.u di\r\scrblcd !nd
::rlpecled for s'er. lf ,rny aplreciable $ cxr i\ . otcd. d! c\ i
::nced bt a lealhered edge ofworked mctal t th. shoulclcr
r the lapl)et bod!. the entirc tippet ssembl\ nmst bc dis
::rded. The hyclrrulic tatpet cyli.{er d plugcr \\cnrbl}
.rusr be chckcd Lo \cc tht no burs or brdnrg eiist nd
:.rL tho bnll check !nl!e ii ot leaking. A leaklrg check
:l\c can be Lesred .ls lllows: Nl.rke sure iha lhe c,rliniler
]d phger ssembly are dry'. L1d hold e lifie c,vlinder
.Ji\rccn the thLrmb d nddle tinger rn a lerical tositjon
,iLh ollc h.ud. Then placc the tturger irl po\irion so drxl
:.: pluger iusl eers lhe hlier c)linde. When lhe plun3er
:rG. l0-5 p"
is deprcsscd .tLrickly wilh the l(lex inger. it lhoulcl itLum
1o approximately its original l)osiriolr. tf the plurgcr docs
nol rclurr bur remxins i a collnpsed fosition. lbc ball
check \l!c is not seLin! protey. Tlre cytrn{le shoukl bc
leclearect and thc chcckcd xglr ll the check !ah'e srill
.loes not \caL. thc trniL js dcfectile nnd dre enire c)linder
and plunger asleDrbly nrust bc cliscdcd.
Hydraulic cylinder nd pluscr prts cdnno( be inter
chinged fron one assenbly 1o anodrer. nd if a p 01 ny
r. asscnrly is deleclive. lhe er re rsselnblt is discalded. The
. cylrdcr and flunger (hydraulic uni) assenblies ca be
rtcrchngcd in lifer bodies, provided tnl he clerances
r. $,ithnr thc pprovcd limits
It i! recessry to clean lhe engre errernally befo|c disas
s.nrbly and lo clean i|e pds rller disrsiembly. Crrl crri
mof be .rken dudng the cleanlng ]rrccerss becur tlre
e-eine !m c:l]] be serio!slr argcrl bJ irrprotcr cler
rg or tfliclion ot' lhe \\rorg t)ue\ ol c]n.s to (rldn
cgjc, prs. l e!er) case. ol rhe
rhe person 1r charge
clemg trocesles should itrLdt
rnnulict!rcis
re erlgxre
recorncdatior\ rcg{rding the cleeninB procedure! ibr
ladous prL\ of the engiDe d .omtly sith the dire.iions
frolided b) Ihe lnanrlacltrer of he cLeaning gent or
Ir genr1, two t)pcs of cle3ning tue required r\en ir
engnie is o\crhdul.d: (l) .lcgrc{sing, for rcro!l of oil.
sof tlpes ol dirl. rn soll rrboD (shlgc): nd 12) .l.,rxr
onizing. or ihe renoval of hard carbon epo\jts. lhe
renrolal of grese d soft |res 01 rcsidlcs is rclrilcl)
sirde. bLrt hard cal'bon ileposits require lhe pplition fl'
mrher sevee lehods. lt is dnring h rvpe ofclening th
the grenle\l ca.e nNsl be exercised Lo a\oi.l d.nging the
Degreasing after Disassembly
Alicr thc cngNe h$ bcc dis$sembled, 11 oil ihould he
r l ..!c tle.1e...i,;.....,(r1t
cd. hccu\c thc ddilionrl cleaning processes are much
nut.llctirc xlLcr lhc slnlac. oil has bcc rcmovcd. fwo
ol thc t ncipdl mcthods ti! rc.rc\ing thc res;duxl luhricat
nrg oil rnd lrsc shdgc rc \!a\hing in { fcl.olcunr !)1!cr
alrd emtloyrnent ol !por degtersr.
.leJr "I p'oe, .'e,. .b.l".i,..ti
cial cleaning booth where he p ! re supporecl on a grill
ard spa)ed $ith a sohent gun usnrg rir lressure oI50 ro
l1l0 psi 13,15 o 690 kPrl. as illuatcd i Fig. 10 6. Thc
spy booth shonld have lcntilting sysl.r to crr! w.t!
Ihe !pors lcl] in llre \trrbundig air. id thc operatur
should \rer rdcqute frotectj!c cloLhing. A drai should
be localecl Lnclernearh the grill 1o collccL thc uscd clciDg
sohelrt. Dnring the clening trocess. pfliclar cati:r shorkl
be lake thal all crevice!, corers. and oil passages are
Vapor dcgrealing i! acconulished $ih equrpnen spe
cinLl) designed for his rype of c1eanin3. A vapor ile:leasef
consists of an enclosed booth in which a degresing solu
.i , . .Lr rl ...i. P.,F.l I' Jl
clean nq 243
 2 Dissimilar mtals slrorld nor bc tlced in he !oh-
i.r r. \|.-.e.,,.h l, ,,r,,r.
'r
c1r be coDrplctelv de*rc,1ed bv electrrl!tic a.tion if rhev
irc trlac. m {.ler.l! val slth sreel pas fr nxre than a
i. \'loniLo. i.nchion tinres carefilr. Alkhrc (clN
ic) soludors *ill audck alunrinur. ugrreslum. and somc
of the allo)s ernploye nr ircrar't cngies. S!long lkline
\olutions \1111 also reno\e thc Alodi.e.oatig that is
{ptlied o nranl ahl]linnltl prls ol cnginc\. The Alodie
coati.g is u!u!rll] pplied Io lhe intrior srices of
rrrkc\e, vahe colers. nccessolt sections. ancl othcr sur
licc\ that xre no lailable lbr cleaninc or trclment ftom
FlG. 10-6 5c!.nt d._q'cs rq
lho outside. Selere dannge cnn rc$h if parh are left in the
slipping rgent ro long.
lh. cngic prit\ arc \u\f..d.d
abo\c thc hot r)lutio. r.Ll .,J.r ( .,unr.1 .nan-9 e.r-.r'
thc hot !rpor issol\cs rhc oil d $li rasi!c 1o llic crtetrl
pas lrr solurions contining \onp. bcca se some of the
l '.. l^ |r. II.. rorre- ,.. soi| illll beconrc tr.glared i thc !rf.rce ofihe material
belos The \.rtor rllgrc\cr nroulct b. otcraled onlj by a even housh e r)rtc rl is sa\hed th.roughll rrier soak-
person thoronghlr laniljar'ith lhe eqnlpmelrl n lhe ing Then. dnflng crgmc opcui{m, the he wi I .u!e thd
mnLrfacilrreis in\rucdo]s reg dig iIs r\e. $rf rerdLe o.onrurindLc thc cngie oiL and cause se1e.e
fLraming. Thir $ill rc\ult in lo\s ol oi1 .rDd possible damage

Decrbozig . Sreel tarts {ht h!!: bc.xr ixshcd \rith sop and
ertershonldheconle{l\riLhtrrst inhibitingoil irredlr.-
Pltrts cont:Lminaed $ith hard carbor. bked-oLl oil. 1) lier the clenirg operion is conirlcled.
resxx\rs vanlishes. d paii are redt f decarllonizing 6. Cr. nru\t be erer.jsed i he handling of decr,
rfier lhe degreasins prce\\ h-q been comfileted. The mos boniTjng lnriffingr iolioll! tu prelerl c lnrcrirl fn
..,nmon nehods of dec,rrL,onizing are slrifping, gi blst- colcrjns the skin. be.use hese solulios \jl usua Ly
jf. and \ apr bl,rsln3 jrri.rio or burning. The oterator rh.uld
lirlrclrc $c{r soggle.. rubber:lo!es and froective clodl
stripping rg ulrilc qorkig $lth these soltrrions.

Thc \tnfpj.: froc.\! i! uled to re]nole paift .rfd rlriou; Blastn9 with Grit and Other Materals
re\jnor\ \!Dlshes $ich hare frme.l in he e.gine dulrr
its opcrtioD Sonrc riffi.g soluions re l$.ffe.i!e in ror rhe remor l (r1 h cnrbon 1D dre ifsides of ct]nr-
relnorin.s some of the harder carbo det.\its. A .umber of ders ,rd he Io!\ ol pi\lons, vrft grit blalting otler-r ore of
rolrtiors sritrblc lir \Lriflring hue been dereloped bI the mor sais1clorl prcccs\c\ The bl!ti! matedt 1gnll
nrnulicturcb oi ch.Dricl .lclnr rgent\. b cxch rrln .ons \l\ of !roLrd xhrul lhcl15. sror.I frui seeds, rnd
Iion rnr\r be usclcco jng to frot.r dii c.Lr)n\. o cl\c rhc oth.r orl]anic or plfic mieril!. Thc grit is lfplied hv a
egile prrls l1]r) be chrxg.. In ll ca'c" ihe persoD high pr.ssur. air gur in an erclosed boorl). s shown i.
reiponsible for clenirg and sl ttirg he pari\ Irrur be Fig. 10 7 Thc orcrdtois hads xnd nn\ ire ee|ded (o
rhororghly tarmlir xi lhe soludor used nd uf kLloq sleeres ad glo\cs s.rl.d no the mhine for full Foec-
whal eng ne pa11s 1r\ be cleaned saleh $Lth rt. tior rlhile e guD .{ thc frl! bei! cLexned .tre rmB
\ r...o1.. i,!po.. e e rre o lied. The lrork crn bc ob\crv.d rhr !h I slndou' rl1 lrolt
o .' . .l ,k ',ol
..r,. ..o.r' :
rhe solution for seletl hours o olerlight. The pa.rs le l pertonrirg griL blsting ii! dr. r.nro!l of had car
lhef renro\ed a.d slem clened rc rerole all !ll1.es ofrhe bo. f,:iDl. md ocr rci n s nse care to
ucs. drc opcrrtor
jrrittig $lur;o ind ll rn!erjal loosened by rhe \oirrio. i!oid cxu"i.g darage to highly polishc.l surlxces r.1 o
Alier \tenr clcxi:, thc trrls r. wshccl $ith.l.!r. hol '.1 :-:o o ..... I

. rr.. rr.,L ,... I 1.. blfc.l. lll rbe rmrll ofenLrgs ino {.llich gril rna! c.tcr
.lc.\. 1" ..,,c \ i .,r '
rn\l bc thgged Sone oterators do ror rse grit blstig
becuse rl)e closging ol oc oilt\(dgc c. crusc lilrrc ol o. trts ha\i.!.il p\\agei.
In geerxl. sandblasting is nol crnplo)cd r the cle.rning
Thc .lripting ig.nrs i.st conrmol) r\e,l xre ! lxline of ens ne pars er.ctt thc \l!c h.xil.. This is because
rcxuslici \olutio\i thc! .xn bc tr\ed.old. or Lh.) r\ b. sandbhrifg ulll er.ide dre etl r) ticll\ tht seriolLs
1..,. ...o1,. 1..i., t.. \' dxmxgc nrry be dore efore lhe oterlor is $!rc of it.
genlr carl be hzidou\ to lhc tdls bciDs clened ! $ell F!h.rmorc. sd reid; t. enrbed rsell i soll netrl\ d
rs to the person pebnrirg (he sliipttuS !rrer!lio|. the 1l- qill lxrcr Lrccorc r sourc. of rbrx!iof i'r rhe operating
loq ing precntioff shoLld be.ibserled ege. Udcr so.r. .ir.Lmstarces. such as preparatlor for
rellizirg ofc\lid.r\. thc oulside ofthe.\'1ider is c e-
I The perso| slrippg lhe ergi|e pl,s Nsl be cle1l ilrlly sandblnsred bcl(. xffli.dLjon of rhc meial spr).
ro lllor ihe infruciorrs of lhe rannlactLrer of the rrip S]recil Lrses ol sr)dl\ring rr,- bc .ifpro\cd t'or fajculnr
flng :eft aod rhe manufrcurer oIe engine. flr]\e\: ho\rc\er. this nI) be onc onlr- by r thor.u3hly
244 chapter 10 Reciprocat ng E9 ne overhul
 lea!e \.rntrhes o he txrls tr'hi.h \il ler.l ro \tie\\ rrr
cerrior\ rd ullinrrte lui]tre
Hrrd larbor i reh.!c.l l!onr fi\rm hcx.l\ r.d fr.r Llr.
irsid.-s of.Ih er h.rd. Lr\ \oft srir b[stin-! lhc c0brl
\1hjch ha: c.lle.eJ isid. th. fisr, hcr.l d in dr. iin.!
la|ds is the r.\ diffi.n l nr renr.\e. Alicr rhc tl.t hrs
heen s.llcd in the .l.cdbonilig r)lulion. thc.rbo carr
-"'1 .,
Lncs ccc\lxrJ to rse n soli s.rn|er. The o|emlor mLrsl be
(r.lirl l1ol 1o da rge rhe tisro 1r l:rd( or r, reml)re
.r mcrrl iioLD rhe srall mdii benree the rig lxd\ and
tLc bouoms o1 lhe rins -!,.res lhe glaTed surfx.\ on lhc
pislorr lll the fifi,f pl( r r.nld ror be r.nr.rcd

Tle proc.\!c' rn.l tro..!lurc\ lr stru.lrrLl r\N.tin t

egine Ul1i rx) !ar\ $re\!hrl lronr one orerhaul sho| to
rnorher. The functio oJ rlle silucturl inspection ir Lo
dereflnine the rru.tjnl inrcgril\ ol e.h par. DefectLle
pa|ts xre renr\e.1frll the 0:erhul Procers rl'ller hel arr
founcl. Thi\ \\.! lir\re .lrrd l\oret Dd esures hllr drc
tr s -goin-g bcl into thi ergine Lre tiee lnrnr |o1.]xll)
FLG. 10-7 A !r t-b n rr:r r.h r: /P!bol
ElgiLle p s re stNcnLll insF.teJ by s.nr. or rll ol
lhe lblloq rrg rneods
Liured otcr{tor nd lherl o1l1l lrilhi dr. linlit\ s|ecilied
r te pr)ccs! Alicr cngxre p\ h1e b.n .].red rrd L iesl rS
NLgretir pLjlicle
:fied. th.) \houllt b..ot s1h a fre\ri\xti\c oil lllle l. Li! ui penelrturt mjpecrrn
:.lring isf.cL( nd tirlhel trocesling. This i\ doe il j. Eddl.cuenI jLrspe.tjorl
_,
:\ .t Lhe rusr nnd conosii]n hilh irc lilcl) 1o occur. .1. Uhraionic ir!tection
In .lirion r rhe gril rnd.hcr narteliuls emtloted n, 5ltdiogrthI
-1:nlrg bl blist .s. r .e bulls. fldsric telles. bnked \ hcxL.
:rii glaij ber.L\ rre r\ed. I..hnicixn-r lLrsi be \ure to u\c
j |proled mrleril for th. blarillg i.ib dre\ ire pernnrn Magnetic Particle Testing
\\ herr llass beds are usclt. the addjo of slumiur Nlgelic pafijcle iesting i\ nondcsltrtlire i.1lro 1r
locI19 suriace and {lrsrifcc dj\c.ntiuilir. rcrxcl\ or
-.r.le to\r,le. adds tL) thc .lf.cti\ces\ Df rhe frcccs\ delct\) l. le mgncti. rnt.ril\ sucli 15 slccl. The tfris
r.rher ir is tr(ed xs cle0rnrg tr.'ccdnre or $ mill linr
''\lr]lteening.' Thc lize ol lhe:l(\ bcxd\ is ij|tortrt re nrg.tircd b] !\-\Drg :L slrcrg eleciric crnel th !u.qh
:r.r shoul{1b. ch.clectin lhe irsLrcridr\ ln the prtlculr
or rtuud lhc r ,\ electric cLrner i\ rls,x)\ xc.ompdi.cl
b) nrgnelic lietd The mr!eti. lin.s oi llui 1r'rel
lln'ough rhe prr $hen ii i\ nrrseti/.d. A crrcL or discon-
tinniti {ill crerle n flur lexile. A flux leL.tge oc.uri
Vapor Blasting eh.rc rhe ihe! ol llur lex\e rhe sudcc .1 th. nleri].
rcsrhirg Lr concenti)n ol usn.tjc sLrcnglh rl lLe dls-
\ por blastiDg i. crntlorcd lor stecil .1.ning jobs rd contirilt'. s shon'n in lig ll) S
..:...Drdirhc.l bl m.!ns ol spe.lll] de.igncrl .quilrlent NIgrelic pafiiclei r. ifflic.l Lo tlrc r!grlelire fL
: nrilcrirls Thc \:Lpor solurio \ u\cd eilh fine abr.t ..1.k... r-. I
: rLl \holC be npplieil rl] rn .n.lo\.d booh. The rafor ble s Sn of^.lis.onrinuir)
. .r rn.lis fplied trLrh jrh fr.\surc ii Surr. \lr-lner. tfti.1. L.rti.g is .lonc {ith specil equit
h. .c ol \lor blrsrLl! i\ liritcd t{, pns l]d arers of rerl. \Lrch rr\ th1 nrruLx.tur.d l.\ \1Slrtl1r\ Uor
:. \hjch qrll ro1 be dnrxqeLl bt x lrll .lrlou rt of
.rl
I"AGNET ZED
. nr rl\o ctlld.r\. :Llr i| flro( ft .x rhi.h i\
, bclins \tr]rc ol lonre Il!e ln ll cx5cs. 1he u]|u
rr.i\ i\tr!.1ir! rr! be lo1.\r..1

5crapng
.::r ! fe rr.tl l th. o\crlirul fr1!1. \i. \rl\.
. .. rlt\. futt! lini!.!. rr rlr'i\e.\h.!ldnrnht\!1l
I FlG. 10 8 r,.l! r.Li r!! .'1r .r, r.r i ti:. _:
structl r. lspe.t cr 245
portidr PrLs rcquiriDg msnclic inslertior lr1av be serr dre pr,t i rhc Drlgneizins coil. as illusrectin Fjg. l0 111
'. ,u.(.1 i,.p..i..'.,..{ rrf .rr . ln this casc lhc cueit is tassed thoLrgh rhe coil. and n,:,,
be pedrmed by peso| ilho is lhoroughl) rfjned in the through lhe pxrr irsclf. When .able car!nig curcn folrrl!
use of mrgrelic il1speclion eqLripm..t. a loop. the llux lnre\ sunotrnding the condLrcror ll p!:
\lagnetic taficie lesirg lechnicias n si he lrrined and through the loot in o. direction. This is sho$n in Fi:
e\periencecl to successlullr lrrd dnd rterpret di\!orru l0 \r .llcr ce.. ' 1..l
'trr'.f uharacterislcs
ities. The mjor elernens rhl ust bc und.r\roo.l ad the loop irill rake on thc nrdgnctic of Lh.
deteured b) the operar ale licld \ithin the looir.
Il ry be ne.essay to use a (entral conductor.:!
I Ihe dii.tion r which the tesi pall rnLrsr be magre- shorlr ln Fjg. l0 12. iftlre desired magnetization c{nDor h:
achleved by pa\sing currenr through he parl or bt plari.
2. Ho$ sro3 dre mgneric fiekl rusl be iI nr r coil.
:. Whil tll)e of.uren ro use Tl... .'"'1.'r. ...b-rJprrr
.1. Wht tlpe oftIti.les to use depeds on sc!.r{l la.tors. A! preliousl.v nentiond. rh:
5 Ireer.trtion ol disr.ntinuities tield stlrngrh urr bc grort cnorgh t(r cr$e a flux leakasi
t a! disconlinuilt. Howc\cr. thc ficld stre.Sth rur f:
T" r....i. lieJr.. .r. ' LJ.. ,,i. hc r) grent iha a frorg backgroud is crelted whi.h si
belng sough a n trprecirblc anglc. tr.fcrablt 90' Thc
directior of greiznllor is dcrcrmincd br thc ijcrion in Th. {mout of ragneiisrD is prolot1ioal Lo lhe rour:
nhich ihe cL'rer is f!\L|g drtuugli thc palt. ol cunet passed thmugh or roud hc prt. Thc te.hniL-1.:.
The directio of rlre mgnetic licllt $ill al$ys be per collrrols rbl! b' limidg the anperagc apflied. The gene,i.
pendlc l r Io .urrenl flo\l,. If dre disc(rLiiujl} is e\tecled rlc ior dcleminig hou' uch cunerr{ to use ir 1000 A F:l
r) Lrc xftro\imely longiludinI. e parr \houkl be ragn. I i f:.5a cnrl of cross-secliolrrl dirc(cr. This \\'orks s:
ti7ed.ir.ularll. s llltrstrred in F,g. L0-9 Cjcular mag- ir nost inall svnrret|ic objects lvilh diuctcr\ up to I 'r:
netizaiion is chi.!.cl bt t.r\rig the cuiret direcil.r lr. .o l'._. lr,...on..r
th({rgh lhc parl fa oredrel\ thc plt xnd bunrs ir xt the contact ends she:
Iflhe dircontillllit] is c\pccrcd ro ru cii!'.nlarl,,- or trans Lhe f,rl1 is cicnl ly mgnctizcd.
\cAcl) tlrorgh the pIt. thc fx|t rust bc masnctjrcil logi he pcrmeability 01 a lcroDragctic nraterilll lur b:
rudnrall). Longitudirl magnetizatir, is cco.rtlishcd b! .onsidered i delernining the cunen srengh. Pe.m
$rppins he!,- ggc irc &)und the p01. or b) pl.ig bilitr is the ese $ilh hnh a rgDctic field c,rn be ser u:
.r .r h.d ce.l..l.., .,.?'l
ind re(i( being magnetized. Soli !tcc,l\ helc hig| pem:
bjlit) rnd can be mrgneiized esi]t.
CFACK W]LL RFEGULAR CRACKS

/-/*1, {r
CURFENT SOLENOID
WILL SHOW
FlG. 10-11 Fed 'r nd ro!d so eoid .drry nq d re.t .!-
FlG.10 9 El'e.r r:rf.r.k or entr on r: c r.Lr ry mEn? eni, d ts d re.to
t 7F hr

FlG. 10-12 U!- ol .--tr codLrcior'or mqet zt on

FlG. l0-10 P;
246 chpter 10 Reciproct ns Enq neOverhau Pract ces
 The loctidr ofthe delccr will detenine ihe rype olcur
rent to be uscd. The msnetizatidr pro.ess can be rccorn
plished wih eicr ltenaring or rlircct curenr. Dircc c!r
relrt teds lo pcnetrre lhe elirt cros\ sectio ofrhe marcri
al. rkig iI nxrj desirable lor locLnrg subsudace flails.
Alternad|g curcnr has renclcncy ro flow alon! the rurlce
of the rateri]. Thi! is reted ro as rhc Jn /l'./. Pars pcrmeabllilt and high in magreric reteni !it! (rhey must
nrrgnelized irilh alternning cltrrel Drust bc limied !o
in\pc.tion for sultcc ctisconrjnuities
Go.crll). nagreric trricles,ue errher visible or lltro
rcsccn(. Tho \isible rgnclic pt]ictes are availble in !
\ari.ty of colors n.{ can be irplied.lry or rirh a Iiqtrid
\ehicle. The.l.1 p.trvd.r is conposed of gr)--itun parriclcs,
xnd the prticies nscd in a liquid lehicle are iron oxi.lc.
Both r teted wirh color figmeis.
Dr) pow.Leri re llpically rsed for very iocl inltrec
ions and hare fiolen snperior ro farLicics used rll a liquid
\ ehicle for ioiing substrrhcc di\contjtrities. Hos,ever.
rhe \1er netho offers ease ol applicdLion. trorides corn-
flete colerrgc. is nrore etlecivc lhan thc dry rnelhod in
deectig surlace cra.ks. and ofiels c\..llc.t !jsibilily and
lleiror-.r.r '.r ,e fJ , Fig. l0 1i The nagelic prllicles gradutll! setle 1l' {he
i\ tlpic{lly lor nrstection l'1 egiL1e parrs. Howeve,.
trsed
Ihe irctull tehnicin m{) use x.,! of the orlicr m.thods
d-,..Jrr ' . r.-t r oc.'r,o. p
Whcn fluid j,j used ir which the m,rgnetlc paicles [e
suspcDci. thc fluid is rptlicd to dre pnrt by mens 01
hid ozzlc. As the Uuid llows oler the px. ihe mrgcLic
parliclcs .lhere tu rl rrcx shere the mngreic li cs ol
rlul leave lh suilce of he n)cltl. Thcre are two nerhodr
for apfl]xrg (hc lhjd brih o a tr: lbc rcsidul nethod
nd the.onrruous rcrhod. ln the residual lnetlnrd. th. frr
is rrasnctiTed lirst ancl lhcn lhe th is ppliedt jn the con
liruols rchod. ihe pLrt i\ flooded lvith thc, barh arld then
rnagnerizc.l. The yte ol nrcdxrd used \|ill dcfend tagetr
or the .)pcr{tor nnd the pernr.biliry of the ratcrial.
The rc\idtrl lneihod is rhe less operaror detendenr
nethorli ho\rc\er. the nteri.tls bejns lested Inusr be low in
hol.l their mrqerism o.e ihe cLrrenr is.lisconljnued). The
coLiDuous nrethod rcquircs !reate operakr skill bu is thc
norc.tcsirxb e nrerlrl. Thc continuolrs method cn he
r'- ' . .t , r,r-t I.
,e:, p. . i'l ocpcerr
is prssing through or around rre plr Also, rrLLi.lc Drobili
, . cJ r' lc) ,he.ri'e .,. \
',. , ... i .:.ic.
lo, faficlcs ro orien hernselver t djsconrinit,cs.
The nagotic tulicle/liquid !ehicle rnri...r t.rrridc
concenlatlol. is citjcal. the patlcler are nr \e.l {ith thc
li.tuid lehicle accordjS tu x brlir sengrh chaft sr\rplidrlb)
Lhc manufac rer ol rhe t)ar1.le\ Thc srrcn:th of rhe barh
should be chcclc lrcqncntlt. The !,sr widely used
'I b.n'.-(re'l r .i. * r9 r
gradraed ASTN{''r tcxr !h.rped certrifuge rube, nr!r nL
bo tLonr of the xbe. \i herc rea.iing ma\ b.: takc n by nriliz-
i s llic r{rked gradations on the tuhe.
i. Th. (cchnicin mus e ied n.l ertencDcd t. mnke
J.r J. ,r rf I o'. ) rd- i
p.xlicle lnsfc1ion. Suface crck\. $hor inspeced under a
black light. ill show nt s sharp. brigh. yello$ sreen
"
Lrnes. Srbsurf.e defe*s are or s wcll defired. Fisu.c
I0 1.1illLr!ltcs.rrck indicalLons on.ofe.ri.3 s
l\lxny i licrtios hn!e no bearig o rhe strucl!ral
qtregrh or ser!icc usclirhrcs\ ofihe p1. There indicaions
my bc cnused bl r) phr\ic.rL aspect 01 rhc pxrt drar Dier-
rupG Lhc flu)i flo$ anlt nic.lled iteltnnt itjjcatiat$.
E\dplcs of iele\,ant iDLlicaljons nay occur ar shtr
edges oi x prul $'here thcrc js gEt crcenrrtion of llu\.
Toohng nriks that r.v h\ no stnLcural significnce (i1l
pro.luce lltr\ leakage. Intemal ke,,-r.rs ot splircs $illn{n
ifest thersclrcr ns susnrfac llas'!, as sho\:, in Fig.

FlG. 10-13 Checkrg o prtr.-.oce.ird.o| wr .e FIG. 10-14 arck d c:os'ew:d br nrllrer. or:.:
',ltr]e irbe l,4atlnalu Carp )
Structuralnspection 247
lll 15. ln.lc\t indications nrav xlso oc!ur whe the
\chicl. -ruDs
$xy" Iom rhc ffticl.! o th. hori/ontal
tngeDls or boltoi side ol a cylnrdcr. lcr\ig "drrnugc
lnr.\.' Indicdl(rrs \uch {s th.sc. shi.h dre not r.htccl to
nugDctic lc{kagc licl.ts. arc.lled,/?rltu,?.11.lri. Il lalsc
indicLios occur. rhc c)linder shotrld be (rtxteLl n.l the
barh rertplied Io nxrbilize lh prriclcs.
Afle lhe prts hLrle beel ispecred. rhe! rLrst be
dernagneized. lfhis is not dore. dre parls \1ill pick ut and
hokl snrll steel pal1icles. ich c caLrse \eious darnge
.1 Lerr'.J r.uf.r.,r r L/. rJ;re r. J r. ' r .',
ptished b! passins the parts slowl) lhrough a strrs nc
nagnetic tleld nd then nlolirg lhe palts sloirl! oLr ol lhe
field urril ihe,r are exferielclng zero nlngetic flu\, as
ilLstmted i. I-i! l0 llj.
'lhe .qnitment for de.raSnetiTing consi\ts of a coil
cDcrg'c bt ltcnriig (unnt. It rnr! bc lhc \arc coil in
{}rich Lhc tirt sas nugr)etirecl or scpale c{ril sed sole-
ly tor deragnerjz;ng. Some nrclrj.es lrrure r aulomrdc
ddngncrizjng c)cle ir $hid1 the prrr is hell i he .oil
fd Lhc a lield \lowlt decrls lo zero. Regrdless of the
t,!pe of eqripruen nsed- the cnrrelrt must nol be iuned oll
uDtll either dre pa is out ol the coil or rhe c,rcle is com-
FlG. 10 15 Gerrdshltsho,rnq reev.l dctos
.!s-Fd br t-r 5p e5
I Becrnic enltrlsific' js sed this i\ called a postenrulsilL-
I carioll proc.ss. lhe equifmet illusated in Fig. t0-17 is
MAGNET C
MAGNETIC
I
I 'r-he
FlG. 10 16 S or' / de./:nq c mqe:r ie d n prt dLr q
244 Chpter 10 Rec procatinq Enqie Overhul Prctlces
Alwa!s consult muulactu.cr mdLena.e rnual! for
rp.cifjc in\trucions perlaining lo magncti. taicle telling
ol rhcjr producis. Precandons mighr mcludc tluggrrg smaLl
oil pass{ges or calities lh.ri may collect and bc obltructcd
b)' mrgneti. paj1icles wiih \\,ood plLgs or hard grclc
f:]nnr .omflerion of he ugneic inspcclion, lhc cngie
trrls shoull be w.rihed in clean feroleLIrl soh'en and
dlied \fiih comprcsscd ir. lrhc parls (nruld then be coated
\rih a hrr lyer o1 conosrcn inhibitnrg oil.
Liqqd Penetrant lnspection
Eginc !r,is nade of alurnium .r1lo,!s. magesium alloys,
bnmze, or anv orher metnl ivhicn cannot be nagnerize aij
usually nstected by nreans of a fluorescefr penerra t. I
J.. pe,.r . .r .. ,..,.rfrc,r. ' eJJ) ' Ie!, -
r |. P. ,, r ri. liquid penetrnnt in\pcrrion ., I -
monly nsed includc crnkcasc hallcs cccssory.,asc\ oil
!tps. ard c)hr.ler heacls
hspectio ililh pcnctnnt should includc nre resring of
lhe pats- hc rabul io ol rhc nalurc d cxtcnt of thc dis-
cotinuitjes ibrnrl. lhc linrl dcci\io rcg ing rhc suit
abjlity of pa s tbr lulhcr scrvice The orrcmror lhould bu a
sfecialisl lvho has bee drcoughly lrired lo crxh{e (or
rcetll th. var;ous indi.tions.
Thcrc are mx! mantrlacte^ of liquid felretnl sli-
tcms ad sc\.ral rethods fronr which to choose. Deter
rni illg $hich s)\tcr .Lnd nclhod Lo ule depends o ihe
rerirls bcig rc\tcd- rlork capncily ol thc sho!, frcqucr
cr- ol u\c. n.l tyfc ofdjsconinuLtics !ou:ht. The classifica-
tio ol liquid Fnetmt insFction is set foh hy x nr lit.)
specitlcaliorl. l\,lIL I25l15. It is broken do$r b] ryte.
nelhoil, and level. T]fc (lassilicalio! trlicntc\ to ltr-pc oI
penear, vlsible ard/or li!orescot. Thc nrcthod \rccilics
the process rsed fb amlicalion of the narcrials. The sc.sj
ti!iy is ndicted b]' the lelel nuinber
Relardless of he llpc. cthod. or lcvc,l, rhc prnr.ipl.s
re re lalne. P is are thoronghl"v clecd xnd slr4rped of
|rint. lhe Fnetra js applied o rhe ta d llowed ro
cnrcr an\ strrfce djscoxruries. The excess perelrant is
cleanecl oli: an.t thcn th. pat js riven x coit of developer.
T|e developer drss our ) pcctrDt thar mdy lra\e
etered suce discortiiriries, making lhcrn !isiblc cilhc.
under \hile lisht h e crse of visiblc pcnctrt or blrck
light in dre case ofllrolescent pener rr.
l-i!tuid penelrant inspeclior cn be perbr ed slmply
wirh the use of aerosol cL1s This Lelhod can be lerl
etlclive, but it is lnLte.L to lo'l'olLrne ]rptlicari.ins ard is
rrpicxlll rsed for lo.rLiTed inll)ecions. Liquid penetrant
iurpeclirm iatcrials rc rvaildble nr bulk quanritjes ad can
be applied \!ith commctuial spral equitrenl or bl dip!ing
'trr r.T\. . ." I., eJheei. ,i"r
sior stslc usnrg orescent teerant nnd an enrulsifier.
ntn 1crrrcd by Magnaflur Corporalion. Thi\ s)lteln
woutd be !s. by r opcrst(n .lojng hiBh lolmc of liltuid
penelrnl il1rpe.lig.
\\ e nrust rcemphasize tha all tafs nruf be completelr_
clen A\,oirl usulg ay lyte ol git blasting Io clean pts.
lieening ilcljon ol ihe blastlng rnedlun ll1at close p
\rrface discolrrLnuLies. Remenber hat liquid peneirant
jspe.t on s,ill disclose o|ly defects open o ihe srface.
Should x pall eed to be gdt blasted. it nru* be erched to
FlG. 10-17 q d pr" ,-rl 1 p" - oJ (\4"qt
"1 to p.
opcn up surliLcc cliscontiuiLics belorc the inspeciion con'
After bein-q cleaned, the pa is placed iD tfie penelmn
rar. lt may stay in the penelran tiom l0 to 45 min depend
rg or rlc re of he p"n. rpe,rd , /' " Ji .
",i
:ought. and emperature. lhe penetnt ente$ { discontinu
i* by capillary action. the same force that cuses oil to rise
in a lmf wick o. sap to rise in trees.
fhc prrl is rcmoved frnr thc pcelrat vrt ad placed
on drain rack. The pu1 is give a prerinse with a water
lpray Io remole the bulk ol he pdnetrat and prerent
.cessive corlaminrtion ol the emulsilier.
The penelrant xsed tu this system is not wteLsoluble.
Before the residual penetrant can be removed fron1 the lur
D]FF1JSION OF EMULSIFIER INTO
FG. 10-18 Actlon of emlrsife in llquld
face of the par, the peneat must be emulsified. or made
water-soluble. The parl goes irto the ellulsifier val. The
emulsifier begrrN drusxrg ino the peleiant at the sulce
of the peDeani and works its way down to dre surface of
,,r .) dre part. as illusrated ir Fig. t0 lli.-llle dwell time ifl tlre
emulsifier is critical. If the rime is roo so{, penetrart will
be left on the sudace of the part and e brigt background
will disguise signs of discontinities. lf the dwell tne is
too loll, the diffusio will coDtiuc to thc botlom of thc
discontinuiry and all peneml will be washed away.
The pa is given a posirlse afie it is reriloved liom e
emulsifier. The emulsified penetrani is removed, leaving
peneat in the discotiuities. There is litlle danger'of
overinsig or washing away indications wih ris syslem
EMULS FIED PENEIBANT
PENETRANT IN DEFECf NOf EMULS FIED
Stuctural nspection 249
 iirlc (h. pen.rrn iil the djscortiLluitic\ i( .r $arer-\otu
ble.
Th p.rr ru\t be dry belinc jr goes olr ro rhc .lc\eloirilg
sru-re. Th. tr i\ irhcecl in d slnlll boorh oi rtrrel wlrcre
h,: ir i\ .ir.u .ed arolnd ir. Ihe pa dn)uld be cornptere
li Llr\ l;i he(1 rr\Lhs.
Th. dr\eloters ml bc set or dr\ DN .i.leloter is
Norde. $hi.h is dusted o to Lh. fl1. \\,el dc\cloteN lrle
unll) pplicd b\ rprayrrg or .lifpjS. l tri-q s\sr.r. rtre
r1 is dippe i.to dre deleloper l(rs enoLtlh ro ensur. rhl
rhe enrile pa hr\ been !-overed. Then lhe par roe\ br.lt
inro hc drlcr until the dercloter h$ dried ro iooth.
r hre 1i]rl.
hspeclion rusl be.lore in d drtreed boorh uDder !t
black llgh rm.e f uorescert pcncrrint irlrs !sed. Alr). rhe
frolrer de\cloprct jme musL b. obseNed. This ! he
' ,,.D .,i,r,e , |.r;.t .

\'elli)r Sreer indicarios 1r is up o rhc insfe.or o dc{cr

iire il the lrdicalio rcfrcsents a dclccl $hjch reqnirc\
Ihar rhe f be reicclccl. iflhe parr c bc rct.rircd. or jf rhe
rndrcatiof rs ol conscquece. Acc.prLble parrs;Lre
'1o cleine,
cleDc.l $ilh a suitblc alld go on ro dre e\ ph\c
ln 1lr nLte.tlon Eocess.

Ultrasonc lnspecton
Allhoush rl i\ not ertelsi!cly ured for oleinrul ol r.cjpro-
.tin! cngin.\, some maufrctuers s!ccil! ulrr.tso|jc
rnslecor nn sonre enginc trts Ultasonic inspcction FlG. 10-19 X rf eql pment.
!rilize\ hisir lr.quency soud wa!es ro rrcrl llrs,s in
meral pans. Tre elelent rr{lrifting rhe $\c\ is ptnced lf clis.ontinuilr cxist!. he effecr of dre edd\ cujinrs q iu
of rhe trrl. d d rcr'lected \yc is ecened nd rcsisrered be chrnged nd he lrdicor nill pn)du.e rerdinq grearer
o n oscillo\cop. tf rhere k a flas l the pufl. (he rcilec thln n.ir l tr e !i.ular rer
ed sdrr rill !o{'a "blL[ or thc os.illos.ope racc The lr"e ' , \-.rr.d l .p(..,or .. .

pLr\rli.. .f the blip iirdicire! rhe depth ofnre fhs. routj.el,r u!e!t lor egrne orcrhrul. Hosc\ci. ihe eddt cur
Liltrr)nic ispecd can be acconrpli\h.d radst.roril! rcnt testel caD be of $er !xhrc io n ieclrnician sho rr erfe,
) J ..r a I !\t!1(rcea r.c i.:.r ..e .! ricDced n]rd kno\'! nhal twcs nf tesls cd b. mxde effe.
rl rl|l ( e.o,-... r..\rp,. I
Ii\cl).
and be able n) lle4rcl ll obseed irdicdtions accurareh.

X-ray lnspe<ton
X-.aI or radrgraphic inspectior! rhoLrgh ot c.rflo]ed
on .r roudr. brsis lo mor cSine olerhrlls. is spe.ified I)imesional insrectio ls emplo\cd o {tereie he
ftor rime lo lne t{r deecr ccrtrin 1!pes of n.tl .lefects. d(e.. fu t." .,..r.i'e (ero ...-
ihe r-r,! i\ priculnrl) ef]ctl!e h detecring di\co.tinu- tces c ir conhct NiLh orher suric.\. lfrhe lrectween
itjes iside crstings. frgirlg\. .tfd e1.1s. A po\orll r r,r] sLces c\ceeds the !iounr ser loflh r the rruficturcr's
caf pelelrlc rral for leycrl nches rd produe an Table ol i-imiis. the tr must be lcflcerl or epn.d jn
irxge \'hich trill revei delcts \ithif the nretl. X rt .cordcc s ith apprcycd nrerhods.
' '- rt '. ! l' ^ lhe Tublc of l-jmrrs sho\n i FiS. l0 l,llstslhe na.re
On y qualilied t.r\.nel strolld LLemft ro peorm \ olrhe prl. thc selri.e1. or m.rlinrn1 1nLr. d rhe mn
ra).\rnrinrtior 01 plits oD.l rrueril\. Pilular atrenrj(r ulxcturel s cw fxrf nlrnunr xnd mnri.rrn timjt, The
rusr bc fnld lo sliry co|sidertnis ro vord inlurt'fior scr\ iceble lirit sets lirrth Lhe marimur unroun of wear
rctixtor Qualillcd r r\ technicirn\ are rained r.i obscNe llo\iable nd i\ the dircnsior rhar i$r be dhered ro b\
all rirf licable stt) pre.autiors. rle r.'e.le'.,,r . L,e,
nried rhar if part $hi.h ;s r irhni thc serlice.rbte tnrs is
Eddy-Current lnspection jstxlled i n ernic. itshotrl.L n.,{ $ear L pojrr that
icop.rdlzer \afu oferariur ol the errgir]o frior ro rhe nex
lddr curreuL rstccrion is also clf.cti!e i disco!erig
clict\ inside n)ctal trfts. The edd! crenr tefer apftjcs nd r\nLrr)\ rr. the roleccs to ilhich rhc ns wer.
high equency clccrro.ragnetic $a!es to the meat. ad ,r .r r'<.r. I :r( 'f,r''trt rr-,r:r
thr\. wrtles gererarc eddy cuner)ri inside ihe met]. lf lhc r .r I '! ,i I p r .. i,
nrcul ji unirrm r irs ltrucL[e. the cdd! crn.enis \lill l]LN Ho\.yer, n]arJ o\erhaLlirg ag.D.ies' use rc nc$ taft rol
i x uniirln p:rr(erD rd his n'ill be \ho$i bl he i|dicLr(r. ennccs o ensltrc a quallr! olerh0l

250 chapter 10 Rec procat ng Egjne overhu prctices

 The insteclor shoulcl ko thai trs are usuall,v matr all cleamnce bet$ee lhe parLnrg sufccs bcfde the rea
liclLred wi dimensions ir sirteerts of on inch in non surement is taken \ri a lelescopmg gdgc. The mnrlctrr
inerr c engies. This is i ccordance with r tnctice est$ er ma\' reqtrire rhal he rneasurcmcnt bc tks at r sF.ific
irlhed lrl SAE mart years ago. A corecdy dlnresjoned anglc fionr the tarting srtce or cenrerlilc ol the fn.
:rrl r1ill lherefore rneasure -V16 ir + 0.000 mirs a
rmou np to the oleralrce. The decirn1s for sixleeths of
rn inc]r are s follo\rs:

= 0.0625 )1, = 0.4315 )i' = 0.8125

= 0.1150 l, = 0.5000 ii. = 0.8750
= 0.1875 r:. = 0.5625 t'; = 0.91t5
= 0.2500 ',, = 0.6150 ,i = l.1l00ll
= 0.1125 'i1. = 0.6E75
'l'i" = 0.1500

Thc dimcnsions o{ shlti. crpirrs, mah bearLng jour

:rls. pistltrr pins..:rd slmjlirr pn! xre mca{trcd wilh a
.ur <( (.,1, e,.' J .\' I r ln r \. ' ! |
::r lhoLrld be equifted eirh x venrier scle $ th{l ncasure
.-:ns c:Ln be taken 1o lbe nerresl tcn Lhousrndth. A
.:i.ronleter ha\iDg a raichet sleevc o. sLc i\ reconrnend-
..j- ro ensure thar the measuDg prcssurc borwcen e an|il
.:,:t (tenr s il'omr for all nrexsur..rct\.
Ihe inside diaDreteb tID) of bu*ings, bearinss, and
t"n: ..cr,..||.l\ \ (ec^t n- -Jger
.',:ile' the gge ic in the openlng. ll is locked lll place to
::.rne lhe dimen\lon. The dimension of te elescopnrg FlG. 10-21 MesL en'ret wrir t:Lesccpircl qqe
:::. it thc nesurcd $irh .r rnicrorete. as shown in Fig.
ll an.l l0 22.
lh ID measurement ol soli1e bearjgs ad bering
: :... \!ch \ cnnkrhali alrd carnshali bearing bores jn the
:.. t: ,r.t..r eqrr.l
"..r9.o"-
::rernbly of e crankcnse and con.ccting rcds. BolG
::- tud\ Nst be instlled d tightcDcd down 1o rernove

:j: ':-20 r,.,le.5lrremeni o: .rrkp n vrth m.rometer rlc. 10 22 MelLrenrel of th d men5 o oi . t: es.op .!
q.qe \'rth m 0ometer r: per

Dimensiona lnspect on 251


FlG.'10-23 les! n-r!.i vrrh
Thesc dimens()ns ae cornpared wiLh ihe oulside diamerers
ol .'.rh.l,rrrr:ril 1.llLt..L,r\frn..J o cJ I.h
'.r, .,1 . ll e Jil'"re ,.e o. ruee I i,. ru o
the clearance, and ir lrlust be rvjnin the vatues sDecifle.t nr
rte tr"r. lrri .,F.g. n
I h.le . r .' rPte,coo ; :-!e. r
\'nal-holr gage . .eL CJ-. . .t r' . ne . re .
hll gage,. Ieb.l Id.r h .
',. J.t(J
-Jee i1.. nea I rL( tJte
and{pandc.l unril il llts rhe holc snugiy as showr in Fig.
'r') ,, .,1.,.-ero rl ,eJ.,?d , ,i.ron!r..
'o hote. E:ine
Io obtajn the dirensior ol the JnanufacLrcr.s
.,lre suppll plug gages or ,'go and no-go,'gages ro mea
surc the dilneslons ol ccrtam holes or openings. Thes
ed-. e r.1J . I Jr .or. ti c I ,. tr.
ClliDder baels re mcisured wjrh a cllinder bore
gage. r\ \ho$n h Fig. L0-24. This gge win sho\ the
wear. out of onndnels, and Lalcr. The clt n.ler borc js
nrexsurcd by sliding the gage liom lhe rop to the boll. of
the cllitirlcr in he difectior ot' lisron diru\L and a 90" n)
thjr diecLioD. I rhis Nay thc our of roundness caD be
lhecked ji)r the tull Iength ol rho barrei. Beibre rhc sairc js
!n hoeqqe
tl .ea , 1. .\rF.. :..i<t. rt.; ge r.e. I. r. .r I
with the bsic dimesio ol ttre bnc1. Devirions rion^ro rhc
b . rner i,.' ,c.l"r. ( reede,,,.r. ia.
positi!e or egative dircctior.
A\erage c)lider mea\!rcienis ca be used to xvoict
eriremcs thar ca occu whc singte mersure cxrrs are
rakell. Arerage measuemeLs rcqLire tlt severat riresrxe-
meris bc taker ad then a\etuge.l. Rrl to the manutactur-
ets nrnul for melsuremet locarios for erch cnsine
Connectjng rods rusr be measured ti)r bearirs rnd
r.l' r".l r, Lor. h tor .t!rLnr
gcDce of bcring $,ith bushingl The reqlrirements for a
cone.ring rcd io e use.l in Continenat O,170 ensine
. I rr l-. ' 1. tt r r!r.r.r :..r1.
rhmcnsions as weu a\ the (terances for rri\r rnd conler

Thc 6vist oi { colnecLjg rod is checked b! iD!a lng

FIG. '10-24 [lei|r.]!t !rth c! dp b.re.r p r, l-r ', ir ,nc.J..' D .nc.t. .r ht
BREAK SHABP EDGES.015 N X
OF 45". IF OF G NAL CI]AMFEF WAS
THESE AXES PEF NC! OF LENGTH COMPLETELY FEMOVED AY BOF NG
1\ IH I\E\ BISH Nc} OF FEAM NG Af REPLACEMENI

NUIB E F OI] NE] FODS

iTO BE IISfALLED ON IOPI 1!I TH NEW

I'/E GHTS OF 9OD5 iN AI.Y N6 LNE

'
FlC. 10-25 D eslona reqrrremenr! ior .ofe.1i! od

252 Chapter 1O Rciprocat ns,Enqjne Overhaut pract ces

 :rr of th. a$ors on tnrallel steel haN resting on a sur
:: platc Nlc{sureents are then txken with i thickess
.-:: r each snpporlnrg poilt tr) .lercnninc thc xn)ut ol
:-: Thi\ chcck is show in Fig. l0 26. Thc clcrrancc
-.:.:..n rhc \utport bltr d thc aitror m c smdll c.d of
r: :d i\ mcasurcd xd divided by th. Dumb.r of ichc\
::.:i.n lhc ccDtcr points of th. sutportiDg slccl bars. Thc
::i rrust no ercccd 0.0005 in 10.012 7 mml per inch ol
r:: polnt cererlines.
.:r]ce belween he srpt:)ort
je arbor in he large end of e connecting rod rny be
,:..red y mached V blocks rather than o sleel bars.
r -:mehlrd !!ill gile the desircd resulls.
, check convergence, he diffeence in distnnce
::.r:e the arbors is measured ai given dlstlrce o erch
:: i rlre conecrig-rod cer]ler. Tlri! is accomtlilhed try
:.rlhg a lrecisio rneasuring arln rvLth a tral! end o onc
:-: ol rhc a$or into the small cnd of thc colnccLig rod.
: Jijt{ncc ol thc mcsurig an liom Lh. cctor'hne o1
r: !d is norcd, nrl lhc mcasuing ar is adjrslcd so tht
: : 11 jusl louches the or !r thc big elld of the rcd. The
::u.ing rr is then nrc\ed Lo the oppo\ite end of the
-r'.. nd the dillcrccc in distancc is checked $,ith I
..... ".,-f .. ru" , ir ". r. 2- I rl. I .r,r .r. ,re
::::ked i iroits i ir1 17.62 clnl trcn the cenierlire of the
. -:..rrrJ ruJ lhe o.. o Jr .e lerkee ,e r.e].r " '!
, :,is LS 6 jn t15.21 cml. ThelEtore. if the dierence ill dis
- ... b:....1 , ,h, .. -. "r e,h .i L f,h. , r.... ,.
-.le^.\n000 r 006r r
the fisons ad rrg\ c\taDd with he high enpe. u.es o1'
\ er .t .o r"r-f.opi. LeJ
in\talled o the pirons in the froter groves tur nrspection
. .de.'(rJr . ll e . .rr . ..'r. . . . r''. 1r. ,rrc..
nrensuled q,ith a rhickress gge. as show in Fjg. t0 29.
The sfecilied ring cleaance is neccssrr b cnsure free
rolcnreDt of the rings in the ring grooles nd a li:rc flow
of .ilbl I
pistos and ctlndersanct irslallari(r of the atfroved yte
of pistor rnrgs in cDginc re crirical boculc ihe \\'e,tr
belreen pisto dnss ncl utper cllinclcr sall\ is usually
r"e.'.rrl"rrI. . i'. J _:'i
"rr.,,,rl.... i. u-
.".
'-
tenrion. Piron-ring tenslor is nreasured a a foi 90'' lii
dre :at Nhe dre rlD: ls complessed rc the nornal gap. Th
tcnsion isgive. i th. lableofl.rts I f.ufds. Srtlller
o rlve sf.ing rester. s slurn in
riDgs can .re nrexsured
Fig. 10 30 Lxrger rjngs must he nresxred on a luithlc
Thc depth gage is ured ro fro!ide n accLrlrlre indiL:rtirlr
ol Lhedistan.e henveen fixed srda.es. sLxt as distr!x,

:.:in liIit!.
The dimensios of smxll gaps. \u.h N the clearnces
:,=::iee |islon riig\ lnd rirg lands is mealured with a
:iickness gge. li.r g.rgc of the spccificd rhicknes! will
::::r dre gaf sirlut drc u\c of uduc iorce. il is cvidccc
::r rhe gair is a le:Ls s gre:rl as the gge dilersior
rrckness gages ar used to nesLre s e cleararccs. erd
lol.r .r'.'r 'i,e' o,.
A thickness g.rge is used Lr mesure ltn: ed gap and
jid. clcrces, raher nelr rings are instnlleil on tile pistor.
lhe end cleMnnce (gapl ls checked b] iseliing ihe rirs in
rhe sklft of the .ylinder arrd tnhins it ;n ith the head of a
pistoD. 1o csurc thdL the ring is squue wiLh rhe borc. lhe
nng rnusl be to\nioned r a toit irNicle lhe cyliclcr Lrdrcl FlG. 10-27 fhe.[ q trr ..).!ergefLe ol.offect fg rod
n.. e.l \
See Fig. l0 -28. Thi! grp nrlsl be fithil1 e loler-
'ured
.r (..'r r,l o l ,r .\ p r''j!.f
necessary to preverl scizurc .,1thc gs iLr the cylinder as

FlG.10-25 Cf.kig the iw5t ol .or.1! rod FlG. 10-28 [1e5!rr]et ol p sion r q _.rp

Dimes oal nspection 253

 l
I

FlG. 10-3'l f.le5urenet i! ih depth qaq

FlG. 10-29 Nlellr.mel .l D no rq 5 de . e.-nce

FlG. 10-32 ae.lq.r,3ha1a qnnentlrunoNt)

sioppage. such ar rht caused \hcn llre prpeller ol the ar

crft strikcs rhc grolD.l or r sol object. To pelfoln the
chcck $irh rhc cngie srill installed in tie aircraft. dre fro
tcllcr is IcDlr cd Lrd dial idicto' is inslled fi!rnl," o.
the iront of the e|gire. The fingei' (xctatiDg rntl oi thc
dial irdicror is plced so thirr t lEsrs o rhe snrrh flrl ol
Lhe rroleller shali lbnvard of he splies. Thc sh{li is rhcn
FlG. 10 30 Test q th. .or'rp-e;s of ol . ! !e :ipr r! rorared. An) eccerrricitt of dre shrft will be nldicaied o
e dial. lf. dLlifg rlre rout check. a crDkshdli is ibund
lror th( trling st.e ol i oll tnrf housir! to the ed Io be ben. \tlniShienig i\ not rccorrnended.
ol the gear. The use of a defth SS. i. shorll tr I'iit. l0 ll. Tbe cnrshaii of u opfo\e.t or in-line engine cn be
Di1 gase! oi jLlicdLoi\ rc rxrricrlarl! u\clul 1or checked for alignmcnL in the sanre manrer s hat described
checkxrg lhe nout or otrl oLounuess of (,tling pIts. lbr x crankshrl. Thc shdli is nrourled iLr the V blocks nt rhe
sLrch s cmnkshrt'ts Dd c{mshrlLs. Cnrkihxft !rnul or end bexrings. {nd rhe Nn(nrL is e.rsired i the center bea-
be|dllg is.h..li.d by mornrig lhc lhli o V blo.ks
tlce.L on ,i le\el \uilc. tllLe x.d rolIirl: lhe \htli $hile l. I,' .J r '. p., i,o'r . re
r.r !r ' lr ' , ^l
checked trl]er resi(nr wirh rhe use l,1 l,lve spdng
ir
shos,f i Irlg. ll :l:.
Thc crulshlI rLr.r \hould be conrtre\sion rc\tcr. such xs (hrr shur ir Fig. l0 -10 Thr
checkcd xt Lh. ccler rrlnr io!nlls while thc shft is suf Tdbl. ol Linrils spccilie! etrsion it given \l]ring hcight.
toeLl rt th. Lhnrsl Lrd rexr iounrls lr .hould also be Vrhc sprnrgs. oil tressrre relief vxl!e \frings. oil lil(cr
checke.l xt tlc propeller aLlge or .rl the lron protelLer L1)prs\ rtrirgs. rd oil cooler byt\\ \trjng\ r'e all no.
bexrin-g \cxr. Perorlsrible rtlllim rolerrnccs re eiler j th. mllt checked t olerhaul.
\ur..rcl
\ cinknrli llgrlei rlil luDour chcck should alwrrs p1s is critical. lt
o un.omnr Lo nrciude the qeighlng
b. f.!loled or n en:ine thxr ha\ u.dcrlofe n Llcn olconecring rnds and tislons iD thc dinensiorml inspectiDn.
254 Chapter 10 Reciproct nq Enqie overhau Pract ces
 LI !i'.rr".r'
:n rhis sccLiori hose!.r. cSine rnnuftclurers often fro
, ide spccial gages to bc rscd wib their prticular egincs
llrese g{gcs are descrihcd ir the m,rnulclLrrefs olerhlul
rnual tur lhe engic concerre.L 3.d shonld be u\cd
..ordi: to the lnsiNctios given.
\l '\.\r( l, ' .' rto
.Jr a\ilble. The dimcnsions are rea.l clirecllr" from a liq-
, : :lslal displ.Ly. Thcse instrumeDls cr be Ned alone. or
.":: ..tn be itefrccd with digilxl Pocessors or cornpnters
:::. and lower due|slonal 1nir\ can bc progrInrned
: : .h 'yqen. As thc prIS are nrc{surcd by drc openot.
::nea\urelnenis arc dulorlraticxll) culercd inio thc coln
: :: Thc corputer .{n provide thc oferato wi a !inr
: i ll dineson\ nd r]]dice Llre pa! tht r'e oui of
i::i>poiL in lhe olerhaul procels. unrepairable prts nd
. --.oncnr slrould hl\e been dis.rded. repai.able tars
,:.':d. ar.l !,rs rululirg no fuhor acio orgDized lbr
--j:.mblr'. on fI(s ck. lhc discrepac) lisr Id labels
. :.pirablc prLs ill seNc ts a Sujde for \\'ork o be
::.. llr largcr o!erhaul facililies. diflcrcnl pnrrs rncl
:::mblies arc rollcd to rexs oi lhe shop thxl do specific
.iresses aDd iopir\. For exn]Ple. ll !ylinder 'ork is
:r in one lcclion olihe rihof. crnkcase rctair anolhcr.
-.d crankshl'l D.l cmslrnfr work tr1 sill anolher' Smaller
'p'r'.. LlJr'L rcrl
-trr do spe.ilizcd $ork. such as relding anclgrinding
Refairs done on tlilLs rd ssemblics by overh{uling
.i:Dcie5 lnns be done in tccordancc widr lhe $xl]ufactr'
:: r insLructions or olhcr itulustry pmcticer tha hvc beerl
::1ed nd ccetted b) thc Lnanuflcturcr ardor thc F,\A
- r.! cdsc, the pnts nrust be retumed to airirohy co tli_
:rn hefoir lhet go bck nr lhe engine.
Cylinders
L. repair opcraLions requircd lor ctlidcr\ depend on the
' d, -lJ l.rr:':i' .Jo s euer Iu'
:- perfomcd aI ech overhaul. ard othcrs are pefonned
:lt if requicd to rcnore lhc c)linder to an aiNothy con-
Il n enginc i\ beirg orerholed tor rh. iist me, froba-
l) Ihe oDly operalioD! r.,.toired o rhc cylindeN will be
r:uin. insDecons xftcr clexdlg. rcscLing dre rdlves bl
ac] lapfrg. t.d bieaki3 drc glze on rhc clli
=nding
::i nalls b-v meas of c)lin.Ler hoDc.
\\'hcr cylindeh hrvc been olerhauletl selcral dmes thc
._t.r...bor. .r...t-. r t.,\e,,, ,". oI J ^ ..i "r
- or"-pJeJ.r ,.r"',
, rl\ e need to be leplaced. ad if the vrlve serts
guides sill
:.r\ e bccD sr.iund e iunrbcr.,t' ires. ir ma,\ be Dcccssary to
r:tlcc the sents. Rockcr shafi bosses \\'lri.h incorporatc
.rihings 1ust he rcbushed fron lirne io tirc to reaii lh.
,:nrcnsion specificd in dre T.rble olLitnis
cylihder Heads
::trcks ofien dc\elolir ctlidcr hends 1icr rnny hours lJ1
.:r\ice. lhesc clliLlde.s should be repldced. Howc!cr'
,o.".n"nr n." t(r wcl.lcracks m cenin xreas 01
the cylinctcr "tpror'"| mur bc guurtl oLIl cLrmt etcly
hcrl alracks
ad rh.D filled in b) \'eld;ng. Thc $ellt l]ralerial is ground
or mchilccllo mIch lhe coL(trtr ollhe !!rroundrg rc.
A sall n.iur of fjtting is not generally scrious
enough to rcder lhe c\lirrdcr uDsdLi\1cLort 1r use. but thc
cdg.! of!irs shoul.l bc sn\oohed by a s.rltcr. a b0r-
'ough
nishnrg tool. or r suiLblc lile.
[ins. lnspcclion of the c] lidci rty releal lhat rc
ol lre coolig lins hle bee dam{gc.l The fins on tlrc
crlirder hex.1 {rc rrde xs intcgtul trs of the .asl tl!
rnrnum-xllo), hcrd: therenre. thcy r. bIile ad ca\ily
cracked or brokeD. Broken hed ltrs should be filed sftmh
the brokcn cdgcs to elimxrare roughness 'ud llrp odgc!
It' i beconrc! nccess.r,,! ro .ut out r V roch o llop a head
fin crack, slolted drill bushirg ihat fits olcr tlic li r)
be nsed ith a )i" in 14 76 rxnl ll! driLL t. crl lhe notch.
The p* ol lhe norch acl the edges ol lhe cul should .1
rounlccl to reduce hc possibllrly of furthcr cracking. Thc
c,"'lmdcr is corslilererL hclord repalr if an er'cc\\i\ e nrrrfr
offi arca is Lrrolen offor dnaged.I.rnr r5c, thc ftr-
factuels ovcrh l man!l should be co\ullc lirr r.-
Srtld.. '. r.r '..l'r.
rtlched lo lhe c-vliler hea.l re usually s!.cl to !.!!:rc
conosion becausc ol hear xnd the ch.]nicll effects ol the
cxhausi gases. ft is oLtc ne.essxry to rcplace these studs.
Durlng inspectioDs. llre thre.Ls of thc sruds should be tre-
lully eramined, Dd il pprec blc eroslon i-( noted. rc
r' \ruds \houtd bc rcpltced. Srud rcplacenenl is dclmblal !L
(he secfon c.vcmrg crarkc.rse repair
Valvc Guides. ll irspe.tio rc\e.]ls drnt v{l\c g!nn\
are o!ersi7., o. drtnaged if ny \n!. er- nlusl bc rcplced.
Vh'e euides shold be reno\ cLl ccoftlirl: kr th. nrntrL|(.-
tuer's lnstructir)ns,rd the n1clhod usurll) reqtires dri\nlg
\1,iih a slecil piloted dril't or rs. 01 \'ahe:tridc prllcr'
Since the lalvc guide hs a flage on lhe outsidc .n.1. il is
necessary Lo ddve it firm thc insde ofnre .\ lder. Belore
iL is driver or prlled. the iner ed ol thc gnide \ouliL be
clcred of all hard cnrbon o pre\cnL scorilr! ol lh. guicle
hole. Sorne opera!(n\ icornrl1efd hcaLnrg e c\Lind.r hc.1
to aboLrl .150"F l2:12'Cl berire renn)lus rhd !lie rliLles
bccause ihis tend\ ro clprd rhe vl\c gulde hole rd PeL
ir casier rernov{l h ll ca\es th. lli er nlonld bc tr,rp-
erll srpfoed on r crlinder holding fi\ure \hilr \l\e
gides re beiS reno\,ed anil rcplrc
lf dri\. llt \ i\e
or
equif.rcnt is lro alailablc to lull
guide from msidc lle cylindcr. iL ro.!r r\) rlre
is possible
ouler end and linge of Lhe glide I,v rexn\ oL spo lreL
and then {Lri\r e guide !o Lhc irslde of rhc c\li .lcr Clre
r rs be takcn to avoid cLriing irlo the guide fln.!:c s.1
At'ter the !a1\c guides 3re rcro\ed. Ihe guidc holes
ruf be inTct.d 1r sco'ig. roughcss. a..l di{r.t.r' ll
he iole size is o( rlithiI speciticd lnrlrls, it \ ill b. nc.es_
sary to re{m or broch it Lo xn olersiTe dirncrrsion. Th
a.iual sizc ol lhe hole should be aptrolilrrlely 0.001 in
10.051 mnrl snraller rhdn lhe oulside dimcter ol he !ni.lc
10 bc isrlled The ltblc ol Limits for tlpical opfo\.d
egics cfnblishes linrit\ 01 0.001 to 0.110.15 i'r L0.llla 1,,
0.06.1 nnl inlerlerencc lTl ti. Vl\e .!:uiclc\ e nrx1. it
o\ersir.\ 01 0.005.0 Ul0. 0.01{). rnd 0.01{) i l0 ll-.
Repa r and ReP ceme.i 255
 I

0 25.1. 0.i0S, r.d

0.762 mnrl. Vahe guid.\ and vailc guide aftropriarc for te rnterlat ad size of the sear bei!
'" r. . .' -d .. . r,.' i , L-. ,1, :.. r()!nd. A colse-grit stone is u\cd ro lnake he iirial cuti.
Cuide holes which are (ithin ihe equjrc.t dirnensional rd fine,grir ltones. or fini$lg stones. a.e ured to snroort:
linrit! ad are not lcored or danrrged in rny wa! do not olL or polis re iel.
rcqjre repn. Tt is nerel] ncccssarv ro jn\rall ne$ !at!c T\e - lrd ,i .lr. . I p r (^ ...
guide! br divmg rvith a suirrl'le jnst ing tt. The gtride o Jreoo, o.. r ' rlr rgv -e. 1.t. e, '..
o rt.
mu\t be carelully liged $irh the hole bcfore drj!iDs. colleL or srone holder, d Lhc Nhote $lenlbll js pl,rcerl o.
val\e \eats must be regroud lr,, \'al\c suides are a grtudnrg ilheei dresle. The grirdig $4reet ls ctrcssed b\
replaccd rr elery case. 'n.r' le 'e.l ., 1- ... n. ,.i,- .r .,o t.
r.r,' d',.. _ u.. ( ! r . ..(. .
Vahe Sents, V.rl\e scats ca ustrally be repncd b) c.rect ansle, remo\nrg onl) enough utc l o t11rc thr
-1 L'il '.! .J i-reJ,. !Il'e..,'irre. wheei. Thc gr ding sr(re lnusl bc dressed ca.h rirne ir ir
,1vpicl rxlle set g
r.ler is sho$.r in Fig 10 33. As can inltalled on the coller .d ilhenc!cr i esii ro becore
be obscrlcd the illLrstriLiolr. e \lve sea gdnder con grooved !dng:ddnre.
sirs ol rn clcctrjc moror equitped Nith xn angie drile ro The motor must bc.crered rc(rrarety on the lvhcl
lernlil grinding of the \ert\ ! the a slc rt lrhjch rhc) re holder. lf drc rotor ls ofl cenrer, caftefjfI ol rhe srone
m\tlled r lhe ctlider. Tl)c grindxrg $hecl i! moulred on will rcsult and a routh grinct \il1 be rrodD:e Ir i!
.ollet eqLripp..l $it! a pilot whjch tits into he \al!.
'i . .1.<,.r-.Jt .l 'er\
guide lhe pilor holds rhe grn ing ilheel rr exnct ligD \ritl pcrrit lriDcliDg in\read .t rLbbjn:. This \f,eed" i\
,.r .rle r'lrrr':i afprrnntel) t1000 ro 10.0U0 rtDr Erccssive picssure on
The techmcin n sr choose rhc correcr gi.ding rvhecl ( not lood lechnique io tcr
rhe i\.heel can slow i! down Tt
(lsle. hardness, giit. and !izc). the srore angte 1ur b. Ihe $heel gril]d dt lo$ spced h! trultifg |resluro on te
. ,. .r,ler. !,: ..., .r.: , t.:.,, . .o'e \her .r .i'e , 'or;.,e.1r.. tt..r.r\.rrr
h.r!e a -10'set l th. irrtoke vahe '..
anlt a:15. \cat for ihe tressuc L'!ed o the slolre t ny rime shoutd be o lofc
craus \'al!e. lhe 30' ogle of h nke !ah,e ser fro- than thrr cxcrled b,- rhe r.elshL oftre ,rhror.
!idcs rnlpro!cd girs ilow chrracrerisrics. wherea\ r.15: Arothcr tracicc often followe.l i5 to cse off o the
glc lbr the eihrus \,rlvc \ear tto\rs t better seal cool foe e!er! secofd or {) (r let the.ootanl wsh aaav the
nrg. The hrdD.ss and sizc of ttre grindnrg wheet nrolr be n.r:,.,rJr., ..,r p
t,,.o ''..."...;.,t
]iccp rhe rone up ro its c ect lpccd. Stce it is a rrjriql
jdr 10 rcplcc a sear. rcmole r\ liltte rmtent as possihe
during gindlng lnspcct le job frequetl} ro ffr\cnr

t
COLLET

t-
.-'" Lrnnecessrl g ndirg.
It nr!\'tje neces\rl (1, ctjus he $idrh nd dianrelr ot
the \eatifg surlacc ,rlier rhc -lLr oL15. afgte h!\ becn

4q S
""'& *.-'-{
groud.'lhe $idrh of rhe \err is .liusrcd by using.r 15.
.r e., li.r, r..trdi,
ifcreasc Lhe irndc dixneter. The
! Ja -<)l ne ro
rd dianeter of rtrc
.:i fied b\ lh. nianlicr.er.
,t.Jrc,..,.
'!ldrii
t,.
\/ lf a \al\. seat hs been regruond so lnrntr- t nres rt the
v
GR ND NG STONES
entire face ol the l5'' no$,ig ilhccl rLsr be bn)usht jr{l
co, .l e.-. ,..o: ..ri.d r.,.qre.
FlG. 10-33 nve si qrnCe. dimcnsion. s ilhsraied i FiS. 10 15, rhe lhc seat is
be)ond llnits rnd nrnsr be r.pl!ed.
A \alve seal i. trtically
r.roved in .ne ot' wo wars
1r..,, .rl .i.,, p<.,,..:. c ire
for c ttrrpose. hiie he cllider is lrnLnt.d "..,ir
in a iirrurr

WI]EEL

VALVE SEA

FIG. 10-34 A qllr-"i oi p ot, 9r .d r! rhee , d !. d rq

FlG. 10 35 ClsF 'o rlp .emer of ! !e sear.

256 clpLr i0 ac o,ocT.o -i9 e o.+dL p d-t -o<

ihich holds i a the poper angle under the spindle of a
:-ll press. The dnll press is used to olare the counlerborc,
.u'i 'g Lre
'.l.e.eJr ro, i,
-.e. T\i. i tr"
:arn operalio and mnst be perlbrmed by an experienced

The second nethod does lro reqrire machining or a high

:1.1 of skill. The cylinder is placed in an olen and heated
:r 600 to 650'F [316 to 3,13'C]. A specil tool. show in
::,: l0 16, is iseed i1o the vllc sct d grasps the
!:ri lhe cold wrter used rs x coolanl shrinks lhe vahe
-.-:. clicljng Lhc inLc{crccc lil and allowing the reat o
re lifted out. Crc n !t bc takcD irr hadltug e hot cyliLr-
r= nd prcte.tire clodrig and equipnrcDt shoukl be \\or
: ,.revent brms fiom hot w{ter sptLtcting ofl thc cylinder
\r_rer the \ex1 is reolcd. thc inside dirneter of the
:.re ieal r.ccss rnast be nleasufed to deemine whLch
: -'6izc \ear 1o irstll. The recess rusr en be cut to the
::r:cr olcrsie lliLnension as specified in lhe l'nbl of
-,rr This is accomplished by mens of r vxlve recess FlG. l0 37 Relc g !,r-"
:-::r arailable tion1 he m.rnufacturer.
]h cllinder is rhen heated to 600 !o 650'1. 1116 to
::: Cl. nd lhe nei! \alve sea is drive itu the reccs! Truc the gridnrg whciil bt me,s of .L dia,nond tlpped
,::- the replacernen drili. The rnarufa.trrer's m{nual clres\ig tu)|. Tum on thc mchrrc, and drai\ the diamond
::::: e conlulled to ascefain the corcct tcnrpcraturc to bc acrocs the whccl. cuiiingju\t deef enough nr nx.- rd c!ef
i:: After repl{cement, the n.\! rahc seas alc ground o
r: rroper lce dnneDsion s previousl) e\planred. Deterne tc lace g1., o1 (hc, rrhc, bcing groud. and
sel the no!.rble head ot' he nachtuc to concspond to this
vah'e angle. Lsuall.!. \'rh'es are grcxnd Io drc srandard
valves angle! of 30 or 45'. Ho$e!er, in some iffances. n ier
fercnce li of0.5 or l.5o less dun the sLr dard glc nuy
:: ral\es .re refaced by neans of stndrd \!l!c rctc be ground on the vahe face.
: rr.lrine lhis oferation is illr\tratcd in Fig. 10 17. 'lhe inlerfernce fit. illustaed in Fig. 10 31. is usccl to
': :.iacnrg rachnrc (fatcs thc vahe while Llie $indhg obtj a more fosirive se.l hf mens of no{ qrulrd
i:-r ii roled bck !d loh ass he tace. surlco. ThcorcLilrll). thorc i!i a line conlact beween the
,:.e many mchine iobs. \alve grindi.g is mosy .r lalle rncl scat. Wiih dris line coitncl. aLi dre load iha he
--:::. of seltirs up dle mchhe The lollos,ing should be lalre excrs ginst rhc sc.rt is concetratcd in I lery small
:,-.:d or pedbrmed belbrc gdndrns ls besuD. a. thcreb) incresig the unLt load at tur) one sp.r. lhe
lntercnce lit is e\recilly benefic al .luing the first fe$'
hours o1 opcrrtioD loilo\ig n o\erhau1. The lositire seal
reduces the tossibilit} ol bumc.L \!l!c or set thal iek
ing !a1ve nighr produce. Alier rhc libL lcs houls of ruD
ning.lhese angles tend to be fou ded dowr a d lo becone

The intedreDce .tngle i! grNrd into the vahe. no dre

\c!t. IL is exsier to change the anele of lhe valve grirder
$'(trk hcad than !. changc rhe angte of a valve lear grinder
stoc. Do not usc an inrcrJrccc fit trlcss thc mntrflctur

=G. l0 36 Too far (A) emo! ;d (B) epl.ement of ! ve

FlG. 10 38 niefere.e 1t of ! !e r.iv !e sei

Repa r nd Replacemet 257


To grml \al\c, fir\;.stxll the r,ahe i rhe chlck. !
sholr rr Fig l0 39. d.] then xdjusl the chuck so l rhc
lahe lace ls pprorimtelv 2 u [5.08.n]l from the chnck
lf the lahe is chuckcd dn! Iarfher oLrt. here is danger of
eicessiye \obblc ad r fos!lbjlil) of grirding inro rhe
Checll lhe tltr\el ol lhc !al!e flce acFss rhe ltone. The
\he should cornplclcl) pdss the \t(De o. both sides ad
\.I ror lravel li enongh to griDd thc rc.r. 'Ihere i stops-
ai iliuslaed jn Fig. 10-.:l(1. o thc rnchr. rhjch can be
se. io col|ol dris irarel.
Wirh the valre ser corrcctl! in tlacc. tnr on the
rachine and diust thc grnxli.g fltri.l so thr it sflashes o
the vahe lce. The grinding llaicl i! a wter $ltrble oil thnl
i! coninuousl)_ rn onto tlre \lyc lac to pro\ i.lc cooling
a.d ro cany a$,! gdndilg\.
Back the !lve aw,:] fr.,m lhe grir ig wheel. Piace thc
grindrg wheel in fron ofthe !he. Slo$4) big e !al!c
to$ard the gdndirg wheel rutil a lir:h cllr ls nrde on Lhc
!al!c. I hc itensit! .f ihe Blrll js measured by soLrnd
l]rorc lhn )lhj.S cllc Sl,r$i,r'lllole lhe $heel back nd
lflli cross thc yrl!. face slthout ircrelirg dre cur. Usc
thc linl fcc oflhc irheel. btrt alys keep lhe $lieel o thc
\alle lace. \\hcn thc gr.1ing suu.d dirinishe\. rnole the
\nile \lighlly closer to thc ginding wheel xftroximaely
0.001 in 10.025 .1 lnlnl ech tirc, keefjng the gridrg
pressure Light. Hearl grtudlg \ill rc\rlL nr d rotrgh fiDish
unsultable lr proper lal!c scrling
FlG. 10 39 P)oper ist dioioi!dve .h!r.k
FlG. 0 40 nop Drevenis qr n g t r nenr
258 chpter 1O Re.iprocat ns Enqine Overhau Practices
l
Bck lhe !al!e x$a) fft)r lhe gri dis shce hen
grndins is complctc If j.sf.cllon slnrws rhxr .n! grid-
ing is Decellary. repcal lhc trocess descbcd abo!e.
Altcr Srjndlng. (h.cl rhc \lle margii to bc nrc rha
lhc \!l!e edge has ror L'ccn gi.trnd oo nr. A thin cdge is
callcd a fcathe edge nd cdn lead o preig irx)n. Such a
\l\. cdgc $ould brLrD rv) in short ril]le. and lhe c)lin
der \ould hye . be o\erhrulcd {gin. Figure 10 .11
slrows a !ah. $ ith ! oul rnrgnr id one $,idr a tacr
edSe.
Alier \,he\ nd sc.rrs re goL|d. tl)cl arc lappcd io
provide a gasright {nd lilttrid ighr leI. Ech y.rlve is
pl3ced in its trrtieul{r set. one t lirn.. dnd rhe valve
fxce is roltccl rglins its ser with rppr.,rc.l lxtfLng
corpound undl ther. i\ a pefec fi becc d1e vlve .d
sexr. All lapfirg conpoul.l i\ drc carelilly remo\ed ftom
both the seal and dre !xi\c. Thc !al\.s le ihe pleed in a
Dumbered o Lnkc e.l(!iD that he,1 ri1l be iralllcll in
'ack
L|ted \'"lve\ ir s bc nrstrcctcd ro cnsue h:Ll re ice
nd sclr of each !hre riLke pr ofc coDLact rccordins to r he
ljrjts sfeci ed nr thc or..h!Lul lllanurl. Flgure l0-+lA
i
EDGE
FlG. '10-41 E9 e ! ,/ei sho,r il .'i| nrq d
PFOPER VALVE FACE AND
(B)
LAPPED AFEA SHOWS SEA
D AMETEF TOO GREAT
FtG. 10 42 Corre.t iAr d n.or'-.1 1Br! !e lce conC i os
laoss thc lapped Lrea of a properlr- ground \alve. The io| chanbers will foul the sptuk plugs ad cause an accu
.:Dpcd are.r is mid$,1, ber\ree lhe edge of thc hed and nulation of .aon. Forlhese rcasons. creful considertion
.. bollom ot' the face. The area shold lile a iiosty gray musr be glven kr the refir id servicig of cylinder bar
:.pcracc. In Fig. 10 428. te l.Ltped arca is loo near ihe
:.lse ollhe lace rt the op. Cyllnd.r brcls thar halc bcc dcrcnniecl lo be stnc-
l_hc linrl slep ii Io check the naig surlaces fb leaks. turall) sound and irh dincn\jonl liriLs n1,- only need
:r jee il rhe! are sealirg properly. This nry be done by to be .lcglazc.l bclrc benrg retumed ro lelrice. Cyhrder
:ialling ihe \,ahe in the cylindcr, holcling the vlve by the bancls bccome leq smooth alie several hours of oi)era
i:.n 1\ith e flnSers, and pouring kemsene or solvent into .urJ':':. ,e elr. r '-..
'r. \ alle pod. While atpllins liDger pres\ure oD th. !lve necessary to allo\! thc rigs to conforj to thc cylindcr
:::m. check whetlrer Lhc kcrcsere is lekg palt thc vl!e walls. The s]nooth, or slzcd, cllnrdc i{lls Bill nor t(r
_ rhe.orrhr;{r.amhcr. Il is i ot- the vallc rcse duce he liiction ccdc.l 1r tis $c.ig'in rocels.
-- peraion is finished. If kcrosene is leaking pasl ltre Deglazing lhe c),-lindcr wlls is ccoultished wih the
r::. cotinue lhe lpping opcraliol uril the le{kgc is use of a deglxzig honc such as lhc one illusaied in Fig.
10-.13 'lhe deglaring hone is uned by a suitable drill
noor anil nn,led in ard oni ol ie ctlider 1 mte which
will producc a crossharched parern.,rs sho$,n iD ]iig.
Ro<ker Arms and Rocker-Arm shaft 10 4,1. This car also be done with no..100 wcl or dr,' !xnd-
Bushings pater lbllowd br- lhe xse of crocus cloth. lhis pRrcess will
.crovc snall lnoLris ot' co osion or s.orlg ar weil. The
' ::r._. \ h. ,^ ( r. , ",. i' e
drcnsi(rs ol lhc barel shoLrld be measured iter deglaT
r-: nlr retaih rcqtrir.d uc i:plcement .tnd relming of
igi if thc) are oI within limits. the burrel must b honecl
-: uihings. lhe\c o|cfutios re accompli,jhcd by Drers { Jx o o e..,/( O\...r-c iim.n,i" . ,
:: .:, iuilable a nn a.l rbor prss bv rvhi.h thc okl bush- usull) 0.010,0.0!5. or 0 020 in l(1.25,1,0.381, or
-:i re prcssed our and ner bushings are t.csscd in. Each 0.508 l]lml. defendig Lrn h$,much nctl rLrsr bc
r:.hi.g hole should be erianined rirr coDdnion before lhe
rerno\ed to produce x ninnr ncw surfacc on nll p! of
-:{ bushing ls pressed in. Sl)ecii attenLion mLst be paid !o the c)llrder wall lhc mnufncxurcr's olerhaLl mnual
. to\jtion ofthe oll hote in the bshmg io make sure th.t1 shorld be consultcd tL, ctcrDinc llLe requirenrers tr ,v
: ii aligned $llh the oil hole iD thc llcker rn. particuLar mak and rodc:l olcngitu. Nole 1rr rhe g.eref
Rocker shali shings in the.yliDder head must be
sear of a cyiinder harrcl o(cu* ncr lhe tof be.use of the
:flcecl i1 et are woln belond limits. ll he bushing is
high iemterrtures iD Lhis Icx drnrg opeatlon l:or lhis
.:1d in place wih o dowel pnr. dre pin mur be drjlled orr
reason. care nrusr bc rake ro neasure the c_rlinder bLncl nl
r:lre ie bxshi3 js rem)vcd. Reoval ot lhe bushing is !his drcr during ispeclion.
.:.ohtllshed \rith a drift or abo. The cr'li.lcr musL be \rr
rropey sufporLed $hile dre ocker shaft bushings are
,I.l.
to cosull the nanulicure s
'J.
olerhnl mnual
" toclctcrrilre
, "'r.,'
r:rnoved to prcvcnt.lamge.
Aftei dre r)ckcr shtt bushlng! hale becn :Ino!ed, each
-.uihnrg holc usl be checked ir sizc \!nh eilhe r tele-
:.oping gagc or a \peci1l plug -eage. II Lhc bshing hole
:inrcnsioD i\ bo\e he maxjnum limit, i( is uecessay ro
ii5tll an o\ersize buslring. When it has Lreer decided
;hich ovelsize brshing is requirccl. the hole is reame.l Lo
:r conect size for e bushnrg. Thc ne$ rocker shxft bush
irg is insilled itlr a irallarion difi or limilar t()ol in
..rordance $ith the nraulcturer's instruclions. ll- the
iushing is held in plce $irh .lo$,el pin. ;! $ill bc ncces-
-u) to drill a rew hole in the buslig lor the do\vel pin and
cn to lnstnll a pin of the concci size. Special rstructions
.:laiig to this oiretution rc provided bl thc nranulcnrer
ior he cngrcs in $,hich do{'el pxrs arc cmfloyed.
Aftcr rockcr shalt bushigs are jnstallcd i rhe cylinder
ad. it is nccessry lo check tlenr for diniesion nd ream
ihe) to sizc, il rcqnLrcd. The finnl crL shorid be made wih
'r 1..'r e prolrce. er\.r r.,r1J..

cylinder Barrels
The conilitio ol thc cylir{le barrel\. pistons. and plslon
rlng! is a r)st \iLal lcr ir] he perfom nce of recipro
carig engiDc. Il the dimelsions and surlice condiiios of
rhesc pr1s rc nol srlislctory. combustion gase! caD
;scl]e p{st thc piron dngs llrto the crankcase- and oil from
ilre cnkcrsc cn crie the combustion chanlbers Ihe
egmc lvill lose tower. and the cicess oll ln the combus FlG. 10-43 fy dpr deq z no hone

Repair and Rep acement 259

 by means of an elecldc nror nd is mo\ed in ltnd ou of
he cylinder at a unilon ratc $hilc beig roated. The
slones remole suce roughrcss and ;reSularities. thus
froducing a slllooh crisscross s!rfrcc \hich the tisron
rig! can wea in to a good wortirg surlncc. In some ca\es
j! i! recomnended at piston rings be latpcd ro cllinder
walls. A cyljnder honlns rnachine is showll m Fig 10 45.
Ilost nrinteance technicians are not expected to grirxl
cylinderbncls because this ca be done ros satisl.toril)
in a specially equilped shop set up ft)r this tyfe of \ork
Technicians lnusl be able Io inspeci lhc cylin.lcr batl xnd
detenline whal tlpe 01 ealnlenr is ecessry ro r.\rirt the
bael io salislc{L} oteraling conclitio Thcy rrst clrcck
he op, middle. and borlon ol lhe cr-lnalcr lr our ol:round
conditio as set forth in e Table ol Lini(!. While doin-g
tbjs dre,! should lso check rr ihe chok ofthe banel. pro
10-44 Croshtcired ptierr licLed thn! the banel is desjgned $,]th.hoke. A choked bar
FlG.
r. ,rrJl le.c edriLr .,1 \'r ' ,l"e,.,. '
. ! p '. r .'r .' .t r B :,, r.l.e ope..'.r .. ,( r

pcralure! el th tot of the .)linder. .hoke hore fRr-

\h.thcr thc cylidcr bncls dc nilrided (surlnce-hard- vicles a slfuighi borc duirg ngrc oler,rioD
encd) or chro.rium plated. Nitrided balcls usually shoukl Clhr.lcr\ i opettun for sereral hundred hours will
not be gtuurd 1(r or Ih 0.010 h [i].251 nlrnl olersize usually hle a stef. or ridge. \rom nerr the r| of the ba-
Llcc:rusc ol rhc clngcr ot grindng throngh
e hardened su- rel. This rnigc is fornr.d at thc poit lahere the tof ed! {f
lce U (orn belonrl acceprable lirnis. chroniun plated he op piston iing dots $cD lhc pistoD is at TDC Whclr a
bturels should be chemcalll slipped and replated to san cr-linde ls .egroud, the ridge is rercved by the gnnderi
hoireler, ifthe cllinder banel is \l'ihin liniLs rd ocs not
Crindn: rd cluoltrium plaing shorLld be accomtlished require grin{ling, dre idge should be lel{rled or strunhcd
by rn operator hose process has been xpproled b) the ou by hand ho|ing.Ilthe ridge is otrenr(trd,lheloppis
FAA. The.rdranage of clnomiLm platins is hat the cylnl ton ring $il1be damaged $her the engjne i! assembled nd
der banel $ ill sho$ \'ery hftle \1ear ber\reen overbaul! and
\ril1 usuall) ren,ri !er!iceible Fith sandrd dimcDsiors When the cylinde barrels of ar ersine ha\e been
1r sci.ral thousod hous of opertio. g()nd to !t llandard oversize or $'hen the barrels have leen
\vh/.1 ht trlitltlrt\ rf a t is| hr bte .htunLon chroiur tlalcd to siDdard slze, an olersize lrdlctor
plLne, ht tis(ri titts use tu the\r L.t-liitlts n lst ot b? rnust bc fro!ided o. exch cyli.der. OveJlsizig of alrcrii
th rrinn t)lee. The olerhrul technicim nusl delermlne cngnrc cylinders is limited because of the rellivel) thin
rrherlrer cylLnders ha|e Lleen chron]ium'pllledi il so, the cylindcr walls. The color xd locxtion of rhe indicato. r\
pDrol rig! I]usl bc unplre cst u or neel. The flaing be spcilicd try the nrrnufacturer
lcihlv erntloled to cl]loLrunr plte lhc cylindels can sup-
plf ihe froper pislor ri|gs to atch is ulique plaing
Skirt, FlanEe, ad Fs
If i. a pxiutrlar engife one or lllore cylindcrs rust bc Duing the handling of cyiindels, crc nnrl be ereirised Lo
ground 10 o\ersi7e. rben all the clLLders in thc .ngie a!oid damaging he skins. Appoled practice calls tor
should be given the lrme netne.t l he crxkshar_i. pio nn)unling he crlider on a ooilen cylinder block when iI
rrd, and pi\ton ssemhll rli1l be seriously out ol balance il is Do! being \l orked on. Ifc)-linder biocks are nol alailable.
orcr\jre tisL.s rre i!t{lled in lome cyljders while orhcrs the cr"hder ]l1ay be placed on its side olr a woodel rack 11
pushrod housings are attac|e.L. rhe cylifder mLrsr be plced
Clli.ler grifding is acconrplished by mcas ol high on rrs side in a monner lhat does no put sress or the hous-
qualir! prccisiLm gnxtin.r cquitrct. Thc cllnrler is li 1-
l) rnouled olr thc grirlding mchirc. nd the griding
$heel is adjused so I l1 $ill rake e requied cut from
he ctllnder qlt
to produce lhe corre.t dxnension. fhe
operntor oflhe grmdins nchi|e must ltlke sure o use the
colrec l]pe ol grirdlns $hee] !o thar rhe flish $'i1l be as
steciiied. Firish is specilied micronrches. !in, usually SfONES
liorn l0 to 30 [0 000 25.1 Io 0.000 ]61 nlnl. lf a surface is
groL'd to l0 !tin. lhe depth of he ginrljng scrache,i q'ill
ro exceed l0 l1]illlonhs ola rnch.
A cJlinde. honing machinc is used ro producc thc finl
fiiish ofthe cyl;nder \1alls. lhe hone uslxlly consists of
tiN high.tlit) reclangul stones nronnled oD firle.
\\hen the .) li.der is nxrrred o the nrrchie an.l thc hoc
j\ j.seed in be.flinder. the siones nrke.otacL $ith Llr
cylinder \all\ lorg rheir lull leDgth. The honc is routed FlG. 10-45 tv ndr hon q m.h re

260 Chapter 10 Rec procating Engine overhul Pr.tices

r.3r. Thc cylnxlcr must nor bc liliecl or canled by grsping
r: pushrod housfigs.
Il lhe cylinde is hrdled trroperly, here is no re.Non
:h\ thc skirl shonld become damaged. Usualll such drnl'
r: is caused by carclessly allowing lhe skirt to frike a
:jrd mctl obiecr. I1 sll ick or scrach should be
:rund on e skir. n cn be removed bt caretul sloning xnd
:lishig.
The cylinder mounting Ua:e must tre ci{rniccl lr
::cks. \.rrpage, damaged bolt holcs, an.t bendlrg.
'; arpage of c flange caD be ohcckcd b) nrounting he
:.lider on a speciall)' desiged sufacc tlale aDd using
rL.kness gge o deermine the nrounl of walp. ,{nother
:r n]o method is to piace a slraightedge crss thc tlange
:: locadons aborr 45' apn and !o .heck e gap Lrder lhe
.:ightedge eirh a thickess gage. A lcry snrll arnount of
. urp c be r.nro\.d by l.iptng Llre botlom ol the Uange
:r.he crlindcr sudacc platct othcrwise. ary pfreciable
::i.ct! requirc that thc c!lnrdcrbc discarded.
The c!lider lhDge should be gl1'en an especially care
:l exmjnLion jf n," ol lhe cylinder hold-do$ bolls or
::ij !rer. foud 1i) bc loosc al e lime ot' disarsembly A
r.)s. hold dosD nut or bolr $,illcrule exceptio|al srelses
1. ' 'tro!.. o re | . Jr.l I rr(. rJr .F
'Je
Stccl brrel iis \rhich have been bent c{n be rraighl
::.d wilh log-ose tlier or a sfecixl sloLLccl lool
i:iigned to1 the purpose.
Ir rai be necessary. in so]ne c.r\cs. lo inslall a re$
:j linder barel on he cylinder head. To do this. thc c]l-
::. is put in n oven rmd heaed to 600 to 650'F f3l o
:-:'Cl. The ho cylinder is the ph.ed i li\rurc $hich
:rlds the cylinder ose ond strys cold water on lhe iNide
ihe lider ltt the thrcadcd cnd. This shrlnks lhe brrel
r.d alli^vs it to b uscre$,ed 1r.,m 1he c,llinder hend. l he
r:\r b{rrcl is installcd br heating the cyljnder head and
:.:n tlferdig thc rc$ banel lto tle bead lhe cylinder
_:trd shrinks onlo lhe threaded en{l ollhe barel os it cools.
-les are drilled ir lhe neu cylinder fl.r:e. afd fial
.::.hinnrg i\ doe ll lhe barrel is inslalled in the head.
Rbarreling is usurlly done in cases where cyliDdcr
:::cniblies are ot alailnble. xd th.n ol) bJ eell-
::uipped shops or br he rlnufrtur.r.
P5tons
:rsic nuDulnctrtrtls reconxned thxt pisr(rs be rcplaced
:: \crhaul. Hfwcver, if the pisons xv. ot scc nruch
-trg Iime or nre fructurallf and dncnsturlly rccepc
,r1.. he) ma) be reused.
\ ert shallo scoing is not causc lr rejection nd ,!
:.1eft on the piston. o {ttenpt should be rnade io remove
i:ht scorig \ith sndppcr or crLicus cloh because ti!
::r\ chage the coftlrur of thc skir1.
Cankshafts
r: crankshaft of an engine is. witln)ur ctuestion. one ot' the
.:.rt ciical pas. The dime1xrn\ 01 lhe journals, ad the
r.:lace ind 1ignren of thc shal( nLrst be withi loler
::.es. or else the engine will vibrale ard may ultimtely
.:il lt js eily undeNtoo.{ lhat the cankshalt is snbjectcd
: e\tremcl) riSorcus lr'crtmcnl durlng lhe operltjon of thc
:iqine becaus. it \1 bcar lhe confant hanxnerine of thc
coneclig rcds rs the! rrsfcr the force of he pison
ihruf lo the conccring ro.ljoumals. The repair of the
crankshrti rxst therefbrc bc acconrpli\hed with great ca.e
and pecislon ifthe crankshali i\ 1o pcrlom reljbl\ for the
hundreds of hoxrr bet$een o\erhaLrl\.
Cankshaft main jounal! or crankpins loud o be o\il
(out of roud) u) be ground urdersize wirhi thc mau
fc1rer's linrils. Crxnkshalis thnt re grond undersize
nru\t be reitrided. Il oly snull lmotri of rouslxress js
noted. the iour]lrl surfaccs ry bc foljshcd lt is best ) 1o
this hile Lhe shLli is rdatecl slo\ly i lnrhc. A line dbr!
si\. clorh is hcl ganrsr rhc jounal or pnr Lr) rcns of a
spccil block rntil ll rcughncss is rcnrvcd. Th. jourals
and prns rnusr Lrc rcncasuird rrd die dinlesions recorded
tbr comparlson !rilh bealirg measxremen$ ar a later rime
to deernine beng clearances.
Sol1re manufaurcrs a ow lilniied sailhtenlU ol the
trol)eller llarge. lhis ray be done only on llnges tht
have not been n1lrided. Consul lhe Illrnufactwefs oler
hrul mnrl for insrructions concenr ng pro|eller flfge
srightenlnS.
\o arelnF shonld be lnade o stuishter crnLiralls thar
have an excessile rroun! of runou. Any bedirg ol Lhe
shfl will fmctnrc thc nitridcd {l.faces and lead to corn,
plctc frilurc of thc .rdksh{lt.
$h. r crnkshall is .csround. thc c\!t rdii 01 lhc
odginl jo'.nal ends be tr\er!d ro \oid thc possi
'usl
,.JrlL-. or, fr^fe, , I ..r. .ope .ret .
lefi in lhe
etal ar the radius loction, the ihafr is likel! to
develop cracks \r'hich ma,v lead ro failure ofdrejon al
Counterweights
The crashalis of mant englnes are dl|anicllr bl.rrced
by meas of counrerFeighrs and dyranic balances monnG
ed on eltensloN of the crank cheeks. Tlre size and rounc
irg ofthese coLr|Ier$ellhts and llrces llr surh lll the)
danp out lreduce) the orsiolrrl \ibrliojr shich occurs rs a
esul of he connecring rod tblusr. The pmper method l
rerno!inS xnd refh.ing the cotrteNeights dilTers annm!
\aiious tlpcs d nodcls ol engm.\! thercfore. thc oler
haul lechnician sholcl n)ke sure thl the excr trocedure
outlined nr rhe o\e aul LnrLr]. 1or e nlodel ofendre on
Nhich $ r,rk is beirs done. is tlloiled.
sludge chambers and ol Passages
Somc crakshalts rc n1nulcrlrc $11h hollo\ cnnkpjns
$hich sel!e s sludge removers. Drilled on passxres
Ihrongh lhe crrk cheeks cl1-i lhe oil fiorn insjde the m.ti
joLrrnls o the chambers in he crarkpins. The rludg.
chambers rnry be lbrttred bl leans ol stooi slaped tlLbe!
crlled sludge tubes, p1ssed iLlto lhe hollo$ crankpirs. The
iudgc lubcs ur be removed t orerhaul Lrd the rolt-car-
bon slL.:lgc clered fioln the sludge chanbers. Ne$ sludge
tubei lnst be treised back uno dre holloi:, crnkpin\. The
overhaul echnician must nrake cenin drt the r!be\ r.
reinstlled co e.rly t() a\oid corcring thc cncls of the oil
The fn)nt oteDrg ol lhc crankshlt n)y bc \crl.rl ( iill
n .ipansioD fltrg il the ergine ls eqLripted qrlh ir:.
fiLch pro|cllcr. This phg rust be rcmored ar o\erlr::r .:
clcr thc sludgc liorn rhe tlaLrse end ofe crnntrhr.
Rep r nd Rep acement 261
 The oil passages in rhe crankshafl should ha\e bccn
.leaned at the time tha e shaft was originlly cleac.l:
ho\!e!e. thc), should be checkccl .rgrin belbre ihe cank
shafi is dcclred ready ior eas\c:rnbly in 1fie engire. Sofr
coppcr \irc passeil throngh rhe prssa:es will verifi ihar
thet r. clcr ofdifi ard olher obsrctions.
Conne<ting-Rod Bushing Replacement
lI the piston p1lr cleaancc in dre connecting-od burhins is
eicesslve. il is ecessrr) Lo rcplre the bushing. Thrs is
rccomplished by pressjng out the old bushing nd pressig
in a ne\' burhing !1itlr n arbor press The neiv bushrg
should be hbncaled bcforc it i,, jDllal]ed and must be ter
tly parallel wi the borc into which it is pressed. Afer a
e$ pistorin b!shnrs is istalld in lhe conecing rcd. ir
i! lsually nccess J to ream or borc thc bushing to the cor-
cl size. This operation is paficlr'ly critical tre.ause the
ahgnmcr ol dle bnshrg must be hcld wirhin 0.0005 in
f{).012 7 mnl fer I in 125.1l}lnl. as prcliousl.- explalned.
T.e b I.lrr" . ,. - .) r,o e v r" .fi. ..,a' ifr ,e I
desisncd 1. rhi\ fupose. One such devic. is the hJdro-
burc '1.. ur r li- . . r lr r.. r.l 'c.,. ,..
rod is mounied on a fceflte, es shoilr. so thl il is c{rcy
pe4redicLrlr ro e iis of rhc cufter bar roatior. The bor
ig tool js then broughl inlo con!ct wi he inrer surlicc
01 rhe burhing while trnrig al a slow rate.,{ rnall cur is
t.tke wih a snrooth cullig Ll f as rany passes s nec
cssary to provide he desired dirension
Crankcases and Accessory Cases
Rcpin of crankcases and acccssory .ases are generall)
limiled lo .epla..rent ol studs and drssings and fixing of
snall nickr. or \cmtches. Crankcase hlvc\ are manufac-
red s nfuchcd tirs. lloth hahe\ osL bc rc|lnced if o|e
hx f is eiecLd Som. facjliies hale FAA approval tbr
r.,l ,_.(t t1"r ., ..k ",rri ,r:r-fJ..
bring beairs borcs bck \rlthjn lirnib.
FlG. 10-46 Hydobore Lr5ed or bor g conect q rod blsh
nss
262 chapter 10 Re( procating Engie Overhaut pract ces
Replacement of Studs
SIucls or dud bolt\ arc reial pis rhrcrded on erch eDd tha
ar'e uscd for the trchrenl ot' pas ro oe noer. Oc .nd
i! lroyided $iih eobe (NCi threncls and ihe oher rjrh
linc (NF) dveds. The coarse,hrecl.d ed is desisncd to
be tcrmnentl! scro\ed into a cjLin8 snch as (hc
crankcrse. and dre line lhrcr.led end has a rr nrsllled fbr
holding r rLrLachcd par.
Suds rhich lre danrged, bct, or trokel rusr be
reroved ard reticc.1 wi r ne\r srud\. Studs s,hich ar. Do
broken can bc r.nryed rith a stud renover or \rith
srall pipe wrcnch. The \ud sholJ be tumed slon'l! ro
,. ille r, . .iJ 8o... ..r I. n,,. rro D
gnfted by stld romo\er or lipe \11e.h re rcmo!|d b)
'I 1,. loe ,r....,- )e.'. ,d',.r ,-
scrn xtrctor, The scr.$ extr.or oxrr lia\c srraj:ht
spllnes or heli.rl flutcs Thc Eslour e\rrcLLrr hs helical
Unles s shoiv l]1Flg. 10 41.
Atler ud is renlLr'!.d. rhc coarse-helcd cnd should
e eranricd o determinc wherher rhe srud is rudrrl or
o\ersirc. Thi! is idiclcd br mxchifed or shnrpcd mark
=
ings on the coarse-tbrdcd or1. ldentilicrn) arkings re
sho$r in Fig. l0 +ll. The replcement siud drould be ore
r Lhc stud remored.
size larger
A botlomng l p of ihe salne \izc rs the irrerr)l rhr.ail!
should be used (o .1.n the threcled holc If rhe rhreads i
e:re .r 'i J. .I 'reo. .rd ^-. '. ,l
ovelsize.it lrill be neessarl, to rclp dre ho e wilh bor
Lonins ap ad j.\ta I a Hell-Chii nr\crl lirr a sind si/e
B.fore the c$ stud i; irrllcd. rhc coarse rhreads
shoul.l be coatecl rth c.rporid 5fccilicd b! rhe mnnu
facturcr. Th s compouri lubricares rrd fror.cr\ rhe ihreds
:rn.l my lso seal lhc thrllds !o prelenl the lekage of
lubdcarug olL tiom insidc dre eng e Thc srrLd sboutd be
inrrll.d wih,r stud drire rfd screfccl irrro Lhc cle h!
''1\. e
FlG. 10-47 A E;5rori nc sr: nht-l i-.d !.er e1r.i.r
 Opiional identification
marks on .oarse thread end
Typical

XXXXXX Srandard

XXXXXXPOO3 0.003
@ Red

XXXXXXPOO6 0 006
@ Blue

XXXXXXPOO9 0.009
@ Gn

XXXXXXPOOT 0 007
@ BlLre

XXXXXXPOl2 0.012 @ Gren

=. 1G-48 detiraion dt l.,r oversize rudt

Hl-coil lnserts {n engine, lrch coalig! shor'1d be exanied 3d restorcd

- Feli-Coil inset is hclici coil ol $ire haling a dia-
.:-:'ihaped c()ss sectio. When thls coil ls properly
-.r..ed in x thEaded hole, il ftulides a durable thead o
;-::: e irandard studs or scrcw!.
a threaded hoie has bccn danraged or oversized
-: "irn
:;rd accepted linrits, it can be r.pand by itrpprng and
.1 in3 x Heli Coil inse. The tap and insialling tools are
-: :ij b) thc nanulcturer of he Heli-Coil mses D.l
:-.: !: used ccoding Io instructions. T]le inses nre uscd
: :rl:rderi lo rpart tlug holes and sud holes and j oth.r
:--. n. slud holes and screw holes.
::llcoil iserts n]ay be remoled ad replxced if they
-:: -e !!orn o danaged. The special extructi.g nr)l prl
r-=: ) he manufaclurer mLst be used rr remoral. Hcli
I :r r:j:ns and iools are illuslraied i lrjg. l0 -19.
teatment of lnterior Engine Surfaces
-:: Lenor sufaces of sol1le egine craDkcases, accessory
.
-,-. :nd sitilar parts are pro\ided with prrccli!e coac
:i.::liminate corosion dnmage. During lhc orerhul of
if neccs\ary. Oe comnoly cmploled coLiS ls Alodinc,
ad iL js csily re\tored by tullo$ing rhe maufrcter's
istructios. Thc r.ltorlion prccc!\ nrvohcs clcDDg the
barc luminun rhoroughl) $irh ppro\cd, nolsrcsy
sol\ct d then applling tbe corrcclive solulior s
iDstrcLed. The v)ltrlio! is rlloNed Lo rnrin lbr a lw min
uLes until thc.lesircd colo. is obLxined. The re is lhen
Nashed thorughlr and dried In all crses. he rrnutcur-
er's overhaul itstruciors should be lollo$ed lbr erch l]lake
and model of engine.
Recommended and Mandatory
Replacement Parts
Nlar- parts arc rcjccted bec.ruse ol dclecrs ad xear foirnd
dun g Le nrspection lhase of the overhaul, and ohers nre
lagged 1s serliceable onl,v alier rcpirs are nrxde. l\ln!
factre$ have designated leleril pas as re.ormedcd or
manda(n! replcereL iLems rt o!erhdul rcgrctldss of
!heir condirion. N4arf{ctLtrcrs gcncrll! grcc tht these
pa! sbould be replaccd al ovcrhauli

Pislon rmgs

N{in ancl.ocl bearings! allbushings

Connccting rod bolts and nuts
All hoses, g{skeLs, scls. coLLer pis. circlits, lock
fllles, nd r.tairrg r rgs

All seiccable rnd new engine pans shtn'ld be orsan7.d

on trrts ack prior lo reasserbly. These parts llcludi
:lG. 10-49 Heliao rsefts nd took. those Iht replace pts found no longer ser\icea1..

Ressemb y 263
 ,.,d.r\,(1.. .r
a....e. A.t p. I Th.ir Lr\c i\ ipc.itied tr!.ihc r ur,ct!r.,.
rrP.. u,r J. 2. Thc nrs \,iU o t)lt lnsrlc rh. end. shou.l r:,
, l ,. < . I r l : . rJl r. .c t. l ,, r, o
prls ar'e install.d o lh. errgie. j. 'lhcre is lea\r .ne 1i| lhrer{t p(nrdins be\ofii i:
T smal er oyerhlut shop\. the rornt rcsserbt) process
.,,..,u.t ,J-.. ,J.;e .1. Coller pi or ]ock\rirc trole5
ii lhc boh.r srud h.r:
'rJrr.'r. ,l- I ,.r beer rouldcd so the) ritt f ot crr rhc tiber of tjre n.
\ -r.-. (:.... ...,t -i. The ellcci\cness ol rtre scli:tockinr: fctur hs h.:r
o,ie-'ite t- u,,r...,pt ., ,\e. ., .,,. ,.
reasscnrblj nd rocked $irh riscc|atreous harNrre su.h
I
l. |-
lts bolr\. nrt!. lrrd\, s,asi.rs rd lock wshers Nh\r fcit
Engine arc.'\!oric\ ihould be ttLchcd n) rhc.fqine h!
. .r'Jtle h.' 1 1.. the r\ires ol rs liLrnishe.l $irh the engnc 0,, urai
I -J'rr .r. .Jo ..i -. .. .... , ,,, ..,
''I l.. e p..ro.e. .,.. 1,."-.,,," r' L, ' I Lt I "., "
,
I he echni.ia should be tarjjlirr $iil \elerl .ceDnal le he\ie- \u.h \ srarters xnd
.'.\f.! sen.rroi\
e 1..( :,, e..r. .. \ Of lrrn) ensie\. ttre r"tinler bat} e5. rocker bo! co\
ter' o1 these pr.rcicc\ \riU bc relie{ed belr. e dc\clre en drile aers drd t.]s. a[d tcessol anLj sl)cr.hruger
the reassenrhh fn)!-ess.
holsjngs lLr. tar.cd irh flbcr ifserr iockLrrs (ich a.c
.' dr" ,r p . -5nt
Use of Safety Wre . '. ,5 .1r., . ,.ttet
\equentlf lr:is. is locking chrecei\ic.
Dur S lh. fural isembl,- ol rn cDeine d
nrlr llt(rr rtre !ftisr eginc\ require sore sfcrirlh
ol ccessories. iL i\ oie; nece*ai, 1o sfetv-wire Io.k den!.rt.ul! to
wircl drilled head botts, crp rcLe*i. ti]isrc;head !.rels.
.r1.....r..-.r..,r
caslc furs. .d or isen.rs. The \rire scd tr hi\ D. t"
degrees of t qhtcning or lo.kmg bitit) $.hich slrrrill1e\
Doe.. ,1. D o .ire.. I reqLnes I strong.r. specill) her rrelcd rnareri1. a
fied bl the mrnLrfacrurer. hcil-
re1 r\s scct or1. or n spci.rl to.kin! mfls: t.
Th tLrcipal reqlirenret ror tocksjre jlra Lation i! lo t)tu\ide
arplc bear;ng mer under rhe ur ro re!.c ull tor;ir! i,
(ee lhrt the tensio ol the \1ife
tenrjs ro tjgt[.n the bo]r. fur. soilcr Dlerl\: a|d Lo pr.e\ cfr 1oo\cnjng ()I snrs rher;uti
r rl ,,.d..11ei..,.,
,ie". ie..er , ri(p .o, ,1.. .'.c.., .
b.lr Lcd or rl!t to e](en a ]htcnin etl(et
\'e,,ot ..e\ . Washers
'/\'.r(,.".. "".t.r,.(., .,;, orhe.
".',
hrnd or rirlr a rc.ixi salerv-lne toot. The tenJLh ot rhi Flt $rsheb iA\ r. ured trnder
9t;t)t
''.r. t.a:.a "j' -.. t, , ,,.' ...' L; ot , . . { t._ hc\tcoxl nrjr\
ort r-
he q ire is (hcn lsced rhroush thc Det hole. ard rhe i:,o " '' P a(lr
erd\ rre agai riristcd together. Thc \.ies arc trisrd richt
, t. e. \'l
" .,r:rhe .lnragcd shool.l be discarded. 'a
{iier the job is rorfiee.1. c{cess qir. j! clr off lo
l.-,, ,t..b Lock $.!her\ tnn) be use j. sourc rres btrr onlr \t
'e er \..1 ,, . a e, I t. .. I-r.r . I
\. ' ,,.,. I r. .. . ,t. . e
. . .
. .
.

s1'rs xre sh.,$ in Fig. 10-50.

I \ .,. r '
r.r'.er. ..t ..,1r to., ^.. | |
Self-Lockng Nuts becuse ol rhe drge rtiich occ,[s ech trrne Lte n ,

\e-^ r,ei r,., ue.t b lo..-,-.l..t. ,., .... .t ..e ,..

trl ,\ ir! corJrrLLr.\ .' , r -r rnk rlre! ren o\e t

Torque Values
:JD ) I'r.. re r .l
{J
-il- u
e
.ri1
( ).r r r. or.rr
..... ..t ,... ,,,.
s th torquc a rtted ro rj!trl. ;t\

'l
and b
d Required t(JrqLe values for irtoui nrr\ rd botr\l
''I 'ie'
ra1rcnncc.inLrls.

I
\ T.. .i,.,..,-.,
''-. .i. i. , ' ptti(.. ,. , . " .

,[r'l '' .. 1 .< . e. , i'(h-pund.

FlG. 10 50 Em! !i o.kr'! r !l

t' rpuun.l-inche\ .,, i tr,...r ..r.r,r'.
States lor smll to mcditrn bots mr nos. For b]]. I
.' . i. i'
os nore co\'enrct lo crtlov foot-pounds (f.:
264 (rp.e 0 o".oo"-.or19 ro.e,r", D.".!,"s
' r-:.c lb.r'). l the meic s!ser. he nl)rrton-mctcr
. i.d xs nrexsure of n}que. One foLrt rnnd is
:i \.n1
,. \honn on the srei.h in totrnd inche\ is eq l
-- ..ptlicd j. pounds a he hand. rultitlj.d b,-
:- l inchc\ ilegh) frorl the cefter of rhe h.dlc
.::: ol thc turDing ris ovcr thc nut. Thi\ i\ ills
.:i 10 51 Il lhc tdrtu. lrcDch is uscd $ilh
. i]\ ur Fig l0 52. Ihc lergth ot the .latter
: - :r! llrd ad the rotl rorqL compLrred
rLn! lirrrnula is u\ed ibr lir.ling lhe torque
.::::rg r, Ih:L( *ill gi\e r \tecilied moul of
:. .' I Io {he llrc.r:
.,
]j1
7,,
+l
L ctrlc fuilurc ln rll .r..!cmbl] oper.riioDs. thc echlcinr
'- 1..
= : :ruc 10 L1e pPli!'d to ii\r!'ner
= :.ylh i{ f\lcunc1
= ::iglh i,l rrqu. $Icr)th
: be rtplied to lhe laslener 4, crr be rol'rd
.:rlllre. s thle ol roques To xnlve al dre
: : r r.tt rS or r.JinS / , di!idc the len3rh of
dre ej(Ien\ion,1 L') Lhc lcngth ofthe torque \rrerlch . nd I
!o the quolieDl. nd di\ c rhc r.\olt in the to.que to be
rfflied to e iarcner I Nhc. 7 is ser or rexd on he
turq e (ench. e prpel rouDL ol r(nqre $jll be xfpl e.L
1l rhe ioque wrench i\ use ith oll\ct d.lafler. rhe
i\ or the leDgttr of rhe arfrer bur dre inn.c rcasurcd
bct\rccn two lies fefpendilir to the rii ol e $Fch
handlc. oDc pd\\i.g thrush the )trt oxl !t\li of the
qrench ar) dre orh.r prssig lhrough thc cc.t.i .f lhe tr!
or boll being lrned. Tl)js is illtr\!rc,l i. Fig l0 5:.
Ericessi\e 01lsc(\ nroulcl bc !oidc!t. A..rtri anro!nt ol
eor ma\ be inlroducetl -\ {hc xnglc icrc\cs \rn lhough
ihe crecl1n!!i i\ !\(d.
nrge ol boh or nut i\. licdl. !d icor
The orque
recl \rlue oi lorque alplied duing assembh $ill ofren
rr\t co!uk drc orltn. !ltrc chirls supplied b1 the lnr-
!\!.
Prelubrication of Parts
N,l!1uficturea! recorr)LeldlirrN lor pelubi!.tlion ol
trl.r! frior to r(senrbh nrnr he oblerrcd tu \oid prclL-
tur. filure .f engine fxrls I'jrofe. lubricatlt:ln 01 part! t
r\s.rbl) i;ll frotc.t thc fr|t( dtrri.f rhc iirst lc(
n(nncnG ol ofcr|ttion. bciore .gine oll lur cirlulllte L0
te. Nfnul{crurcrs li\L Lh. prelubricllnt! o be u\ed in
o\c rulrx.!ls or th.ir reNice publifntif!
eilhcr thcir

Assembly
f.ll.r x (equen.e .e.onl
Thc dsscrbl! of xf .ngi.e nru!1
:::.rr.i_r oj tor!!c
,. d o ,. t , 1., ,. L .: l
bted Sir).c Ih. core ol r cngin. i\ rh. crrli\hr11.
rbl r I

EFFECTIVE LENGfN,WFENCN

Connectirg Rods. Ne!\' con]recll!rS rod berrirS

is.rt\ \lr.uld e snafFd iJrlo rhe rods ltnd rod crps drr.
rn wilh c L.gs oi rhc inscrs fjttc.l into rhc cutdrs l]ro
lillccl Ech bcding i\ lubricxrcd \iLh rpFo\cd oil. Tlicn
the rcd ad cap rc jstll.d on Lhc cr.lnlipnrs c.ordng Io
the rumberi furpcJ on thc (is i .ps Thc rrurlic-
turcr's o!eihrul innunl stccilics +hcllc l]rc ioJ rLicl !ap
runrben lLce dos of up.
:: : :--.,.1 -r.h rtr .]pt. Since diller.nt r DllictLrreA 01 .gies do not neces
!rilt ilesigne eDgrre .\ljrxler rurnlrers fronl he sarne
:: . : -=\GTH, WRENCH IA] TN OFFSET AOAPER end of the egine. the o\edrxnl lech rin musr nrle .ure
-. _' --. (L2 & A2) lo hen fdxlli3 |rr! rcoll]in! t(,
use the conec order
.yliil.r lor c\nrtl.. l.lcorlS .ngln.. hr\. Lh.
nnrber.
.y indcb fumbered i\irh no. L beirg ihc right fruDt crl;
der. hereas rhe nu l .)l;nrler of ( onrinefrxl erine. s the
!'. .,,c lr tur ler .c(.r,..
lhe .onecti3 ul. rre in\txlled \ illr fe\ h.lt(. \Nh
- cr\. nul!. il conosion r.\rstdnt cottcr pL t$hc. u.cd).
and cch ur is tighlerecl sith r {ritle (orque rrerrch Io
e brqre recilicd. -\ nul muf rrot be backed ff r af
ellod o obli]r a ceriain orqne l:rhle brlr \horlkl ahilt r
pproach lhe corect lrlLre irh le being rjghlened Ilrhe.r
Ierpin hole carol be rlilreLl \!ith he r'i rhef rhe nLrr h!.
_ . ..rF.1,-r.lk.l .1e. beer orqLred proferlt. i l1lal e re.es\ar! ro lLrbnli ri:

Rea$emb y 265
-Lr+