recip 2 test 1

Why is proper cleaning required for an engine overhaul

Proper measurement

Visual inspections

Testing an engine after overhaul

Can be completed on an aircraft provided: engine cowls are installed; each cylinder is equipped with a temperature sensor; flight prop can be used if engine temperature is carefully monitored

Must have a means of reading oil pressure and temperature

Must have an accurate method of weighing fuel for fuel flow, or measuring fuel flow

Engine overhaul map – identify the correct order of events for the overhaul shop process

1. Receive engine

2. Perform a preliminary inspection

3. Disassemble, clean, & inspect the engine

4. Repair parts and acquire the need material

5. Assemble the engine

6. Package and ship the engine

Engine overhaul map – Receiving process – what is included in the receiving process

Review technical information and history

Pre-screen maintenance and overhaul requirements

Provide an estimate

Provide work scope showing predetermined repair and mods

Create a work order number

Store engine until overhaul begins

Engine overhaul map – Pre-test – what is included in the pre-test

Inspect for damage fins, components and missing items

Record P/N & S/N

If customer has completed the run up and compression test, request a copy

Engine overhaul map – Disassembly, cleaning and inspection – what is included in this process

Remove the cylinders

Split the crankcase

Clean and degrease components

Inspect for corrosion, wear, and damage

Ensure component wear are within limits

Engine overhaul map – Inspection – what is included in the inspection

Unserviceable component are repaired or replaced

Ad’s, SL, & SB’s are complied with

Modifications are incorporated

New seals, rings, gaskets are gathered

Engine overhaul map – Assembly – what is included in the assembly

New components are recorded with P/Ns and location

Original components are installed in their original location

All components are locked and torqued

Engine overhaul map – testing – what is included in the testing

Cylinder and assembly check sheet are reviewed

Engine installed into test unit

Test run completed and engine parameters recorded

Engine overhaul map – Shipping – what is included in shipping

Logbooks and documents are up dated

Engine log – engine overhaul entry, modifications, and/or AD’s are completed

Engine overhaul and inspections forms are completed

Transport Canada Form 1 completed

All fuel & oil drained from the engine

The engine is prepared for long or short term storage

Airframe logbook is completed

Engine storage, which of the following are consider short term storage

15 days

30 days

45 days

60 days

75 days

90 days

Transport Canada Form 1 – Which statements are correct

Box 11, Status/Work – Only the following words can be entered – Overhauled, Repaired, Inspected/tested and Modified

Elementary work – which statements are correct

Includes only the task identified in CARs Standard 625, Appendix A

Is not subject to a maintenance release

Must be record in the appropriate technical logbook

Must be trained and completed the task (at least once), both under the supervision of an AME

Maintenance definitions – includes

The overhaul, repair, and modification of an aeronautical product

The inspection of an aeronautical product

The removal and installation of an aeronautical product

Servicing of an aeronautical product – which statement is correct

Includes cleaning

Includes lubricating

Include replenishing fluids

Re-manufactured – which statements are correct

The component is overhauled to new standards

This is no official meaning for an engine overhaul

Top overhaul – which statements are correct

Includes the removal of cylinders

Includes pistons, valves, seats, cylinders

Cleaning aircraft engine components – which statements are correct

Use manufacturer’s approved cleaning solvents

Decarbonizing can cause galvanic corrosion, if soaked too long

Which method can be used to inspect an aircraft crankcase

Visual

Liquid penetrant

When inspecting gears, what do you look for

Cracks

Chipped or damage teeth

Pitting

Excessive wear

Deep scratches or scoring

When inspecting the crankshaft for internal cracks, which method is the current best method

Magnetic partial

When inspecting the connecting rod, you notice it has an excessive twist. What is the best practice

Replace it with a serviceable unit

When inspecting a piston, when should you discard it

When there is a crack

When the piston pin hole is scored

When the weight difference is not with in the manufacturer’s limits

When inspecting a cylinder, you notice a damaged fin. Which statement is correct

The EMM will provide limits on the damage a fin can have

When inspecting a cylinder, you notice light scoring, pitting, and corrosion. Which statement is correct

Light damage can be corrected by honing the cylinder

Minor damage may be removed when the rings seat

When inspecting the valve mechanism, which statement is correct

Role the push rod on a smooth surface to ensure it is straight

Measure the valve in three locations to determine if they are stretched

Valve can be refaced, if there is enough material

When grinding a valve, there is a limit for the Minimum Margin Thickness

When receiving an engine, you notice the spark plug areas (or the cylinder base) of each cylinder are

painted different colours. Which statements are correct

Continental engines do not have a green or a yellow marking

Lycoming and Pratt & Whitney engine have a green and yellow marking

Two silver strips indicate the cylinder is Nickel-Carbide (Lycoming, Continental and P &W)

The cylinder was chrome plated

Valve seats – which statements are correct

Grinding valve seats, you use three grades of stones

Use a dial gauge to check valve seat run out

Lapping creates a smooth valve seat surface

Crank case – which statements are correct

To measure the crankshaft and camshaft journal clearance you can use inside and outside gauges

The crank case halves are sealed with a silk thread

Logbook – which logbook(s) are blue

Airframe

Journey

Technical records – which statements are correct

A non-AME can transcribe (transfer) technical records from a Journey log to an engine log

Entries can be made in any colour provided it is in a permanent manner

Particulars of any maintenance performed is entered into the logbooks

The entry must include total air time and where applicable the number of operational or landing cycles

Entries into the technical logs must be made as soon as practical after the maintenance, but no later than thirty days

An engine overhaul shop must make an entry into what log book(s) after an overhaul

Engine, In addition fill out Form 1

An AME installing an overhauled engine into an aircraft must make an entry into what log book(s) after the task

Airframe

Journey

Engine

Propeller

Modification and installation

How does good housekeeping ensure efficient use of time

Tools & equipment are returned to their proper location

Tools & equipment are cleaned after use

Tools & equipment that are U/S are reported and tagged

Tools & equipment are maintained and serviced regularly

Shop and flight line safety is important because

Eliminates FOD

Reduces tripping hazards

Ensures there are signs to identify dangerous equipment and conditions

Safety lanes are marked and kept clear

When working on a piston engine

Always assume the magnetos are HOT or live

Always check the magneto switch to ensure it is in the OFF position

Be aware the propeller is an invisible danger

Rotating components (drive shafts, flywheels, rotors, etc.)

Be aware that items may get tangled into these components

Be aware that these components may cause material to be thrown out

Never remove safety guards

Ignition and Magneto safety

One must be aware of the six P’s

The starting vibrator can be operated up to 20 seconds without overheating

The ignition coil can boost magneto volatage from 200 to 30,000 volts

Fuel and Fume – dangers of inhaling gas

Can cause dizziness

Can cause cancer

Can cause damage to the nervous system

Can cause respiratory problems

Can cause rashes, irritations, and/or burns

Misfueling – which statements are correct

Is when the wrong grade or type of fuel is added to the aircraft

May require fuel tank draining

May lead to an engine overhaul and/or replacement

May lead to poor engine performance

Turbine engines can use 100 LL

Tagout or Lockout – which statements are correct

Prevents unexpected energizing of equipment

All ways tagout or tagout the energy source

Some energy source is potential energy