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Total Training Support's Integrated Training System. We are sure you will need no other reference material to pass your EASA Part-66 exam in this Module.
These notes have been written by instructors of EASA Part-66 courses, specifically for practitioners of varying experience within the aircraft maintenance industry, and especially those who are self-studying to pass the EASA Part-66 exams.
They are specifically designed to meet the EASA Part-66 syllabus and to answer the questions being asked by the UK CAA in their examinations.
The EASA Part-66 syllabus for each sub-section is printed at the beginning of each of the chapters in these course notes and is used as the “Learning Objectives”.
We suggest that you take each chapter in-turn, read the text of the chapter a couple of times, if only to familiarise yourself with the location of the information contained within. Then, using your club66pro.co.uk membership, attempt the questions within the respective sub-section, and continually refer back to these notes to read-up on the underpinning knowledge required to answer the respective question, and any similar question that you may encounter on your real Part-66 examination. Studying this way, with the help of the question practice and their explanations, you will be able to master the subject piece-by-piece, and become proficient in the subject matter, as well as proficient in answering the CAA style EASA part-66 multiple choice questions.
The course notes are written to suit Licence category 'B1' but also covers Licence category 'A'.
602 pages (in 2 volumes)
CONTENTS
VOLUME 1
Module 16.1 Fundamentals
Development of Power
The Otto Engine
- The 4-Stroke Cycle
- Valve Timing
- Ignition Timing
- Valve Operation
- Pre-Ignition
Two-Stroke Engine
Diesel Engines
- 2-Stroke Diesel
- 4-Stroke Diesel
Linear Measurements
Compression Ratio
Efficiencies
- Mechanical Efficiency
- Thermal Efficiency
- Volumetric Efficiency
Arrangement of Cylinders
Arrangement of Valves
Arrangement of Camshaft
Glossary of Piston Engine Terms
Module 16.2 Engine Performance
What is Power?
- General
- Horsepower Definitions
- Horsepower Conversions
Measurement of Power
- Definitions
- Power Measuring Machines
Factors Affecting Power
- Temperature and Density of Air
- Humidity
- Fuel Mixture
- Detanation
- Compression
- Fuel Metering
- Idle Mixture
- The Induction Manifold
- Operational Effect of Valve Clearance
- Ignition System
- Propeller Governor
- Overlapping Phases of Engine Operation
- Engine Power Troubleshooting
Module 16.3 Engine Construction
Constructional Arrangement
- Internal Arrangements
- Engine Type Classification
- Engine Cylinder Numbering
- External Component Arrangements
Crankcases
- In-line Engines
- Radial Engines
Crankshaft
- Nomenclature
- Journals
- Crank Pins
- Crank Cheeks or Arms
- Crankshaft Balancing
- Crankshaft Arrangements
Camshafts
Connecting Rods
- Function
- The Plain Connecting Rod
- The Fork and Blade Connecting Rod
- The Master and Articulated Rod
Cylinders
- General Arrangement
- Cylinder Heads
- Cylinder Barrels
Pistons
- General Assembly and Types
- Piston Rings
Valves Mechanisms
- Valves
- Valve Gear
Propeller Reduction Gearboxes
- Parallel Spur Gears
- Epicyclic Reduction Gears
- Compound Spur Epicyclic
- Gear Train / Epicyclic
Power Take-Off Provision
Module 16.4 Engine Fuel Systems
Carburettors
Intake Icing
Carburettor Icing
Fuel
- Fuel Grade
- Air/Fuel Ratio
- Mixture
The Float Chamber Carburettor
- Construction
- Operation
- Throttle Valve and Maine Jet
- Slow Running, Idle and Cut Off
- Pressure Balance Duct (PBD)
- The Diffuser
- The Air Bleed
- Control of Mixture Ratios
- Automatic Mixture Control
- Economy
- Power and Enrichment Jet
- Acceleration
- The Whole System
Fuel Injection Systems
Construction and Operating Principles
- The Throttle Body
- The Regulator
- Operation
- The Metering Section
- The Discharge Nozzle
- Mass Airflow
A Typical Pressure Injection Carburettor
- Fuel Control Unit (FCU)
- Manual Mixture Control
- Auto Lean
- Auto Rich
- Power
- Idle
- The Regulator
- The Throttle Body
Alternative Metering Systems
Bendix RSA Injection System
- Airflow Section
- Regulator Section
- The Flow Divizer
- Injection Nozzles
- Automatic Mixture Control (AMC)
Teledyne Continental Injection System
- General Layout
- The Fuel Pump Assembly
- The Fuel/Air Control Unit
- Manifold Fuel Valve
- The Injection Discharge Nozzle
- Supercharged and Turbocharged Engines
Full Authority Digital Engine Control (FADEC)
Introduction
Advantages
- Computer controlled
- Ignition
- Fuel Injection
- Vapour lock
- Fuel savings
Typical FADEC Layout
- ECU Architecture
- Fail Safe Control
- Maine Interfaces and Limits
Module 16.5 Starting and Ignition Systems
High Tension (HT) Ignition Systems
- The Primary or Low Tension (LT) Circuit
- The Secondary or High Tension (HT) Circuit
- Ignition Harness
- Operation of the Combined Circuits
Magnetos
- Magneto Operation
- Ignition Switches
- The Contract Breaker (CB)
- The Distributor
- Magneto Venting
- Magneto Speeds
- The Four Pole Magnet
- The Dual Magneto
- The Rotating Armature Magneto
- Magneto Mounting and Drives
Ignition Leads (HT)
- Construction
- Testing
Spark Plugs
- Construction
- Inspection and Servicing of Sparking Plugs
- Storage
- Plug Fitting
- Ground Checking
Auxiliary Ignition Systems
- Impulse Starters
- Booster Coils
Ignition Timing
- General
- Engine Speed
- Manifold Pressure
- Mixture Strength
- Automatic Timing Control
- Magneto Timing (Bendix)
- The "E" (Efficiency) Gap
- Timing Magneto to Engine
Starters
- Types of Starter
- Manual Cranking Inertia Starter
- Electrical Inertia Starters
- Combination Inertia Starters
- Direct Cranking Starters
- Solenoid or Pre-engaged
- Electric Starter Circuit
- Bendix Drive
- Starter Relay
- Bonding/Earthing Straps
- Troubleshooting and Maintenance
Module 16.6 Induction, Exhaust and Cooling Systems
Engine Exhaust Systems
Cylinder Cooling
- Air Cooled Engines
- Liquid Cooled Engines
Induction System
- The Air Intake
- Filters
- The Induction Manifold
VOLUME 2
Module 16.7 Supercharging / Turbocharging
Introduction
Aspirated Engines
Supercharged Engines
- The Impeller and Diffuser
- The Two Speed Supercharger
- The Two Stage Supercharger
The Supercharger
- The Roots Supercharger
- The Vane Supercharger
- The Centrifugal Supercharger
- Boost and Manifold Air Pressure
- System Layout
- Power From Supercharging
- Supercharger Control
- Manifold Pressure Control
- Variable Datum Control
- Boost Reversal
- Supercharger Drives
- The Centrifugal Friction Clutch
The Turbocharger
- The Waste Gate
- The Waste Gate Actuator
- The Absolute Pressure Controller
- The Variable Pressure Controller
- The Dual Unit Control System
- The Density Controller
- The Differential Pressure Controller
- The Triple Unit Control System
Module 16.8 Lubricants and Fuel
Lubrication
Types of Lubrication
- Boundary Lubrication
- Hydrodynamic Lubrication
- Elastrohydrodynamic Lubrication
Oil Viscosity
- Determining the Oil Viscosity
- The Effect of Temperature
Selection and Properties of Oil
- Society of Automotive Engineeers (SAE)
- Monograde Oil
- Multigrade Oil
- Straightgrade Oil
- Extreme Pressure Additive (Oil Extreme Pressure - OEP)
- Ashless Dispersant Additives
- Detergent Additives
- Use of Automotive Engine Oil
Condition Monitoring
- Spectrographic oil Analysis Programme
Engine Oil Use
- Protective Coating
- Moisture Formation
- Acids
- Location
- Oil and Filter Change
Fuel
General
Grade, Octane and Lead
- Calorific Value
- Volatility
- Anti-Knock Properties
Avgas
- Avgas 100
- Avgas 100LL
- Avgas 82 UL
- Avgas Density
- Some History of Avgas
- Identification
Mogas
- General
- Adverse Effects
- Testing for Alcohol in Mogas
Diesel
- General
- Bio Diesel
- Cold Weather
Aviation Fuel - Qualities and Requirements
- Anti-Knock Rating
- Volatility
- Vapour Lock
- Oil Dilution
- Corrosion
- Performance Number
- Mogas
Module 16.9 Lubricants Systems
Lubrication
- Film Lubrication
- Boundary Lubrication
Other Oil Functions
- Cooling
- Sealing
- Cleaning
Wet Sump System
- Crankcase Sump
- Oil Pump
- Pressure Relief Valve
- Oil Filter
- Oil Circuit
- Pressure Sensing
- Example: Lycoming Wet Sump System
Dry Sump System
Oil Tank
- Engine Driven Pumps
Anti-Drain Valve
Oil Temperature Sensing
Oil Cooling
- Oil Cooler
- By Pass Flow
- Non-Cooling Flow
- Cooling Flow
Oil Filtration and Filter Assemblies
Oil Dilution Systems
- Precautions When Oil Diluting
- Period of Effectiveness
Pressure Control
- Pressure Relief Valve
- Pressure Regulator
Lubrication Supply - Oil Distribution
Crankshaft Sealing
Oil Indications
- Low Oil Pressure
- High Oil Consumption
- High Oil Temperature
Module 16.10 Engine Indication Systems
Engine Indication Layout
Engine Speed (RPM)
- Mechanical Tachometers
- Mechanical Indicators
- Electrical Tachometers
- Tacho Generators
- Indicators
- Maintenance Practices
Synchroscope
Pressure Measurement
- Piston Type Gauges
- Direct Reading Gauges
- Bourdon Tube Instrument
- Capsule Instrument
- Transmitting Pressure Gauges
- Electrical Transmitters
Manifold Pressure and Boost Pressure Gauges
- Construction and Action
- Fuel Trap
- Testing Boost Gauges
- Oil Pressure
Measurement of Temperature
- Bimetallic Strip
- Resistance Bulbs
- Resistance Thermometers
- Wheatstone Bridge Temperature Sensor
- DC Ratiometer
- Thermocouple Sensors
- Piston Engine Ground Running Temperatures
- Engine Cylinder Head Temperature (CHT)
- Exhaust Gas Temperature
- Oil and Carburettor Temperature
Fuel Pressure and Flow
- Fuel Pressure Indicator
- Fuel Plowmeter
- Vane Type Fuel Flowmeter
- Synchronous Fuel Flowmeter (Motor driven)
- The Motorless Integrated Fuel Flow Transmitter
- The Synchronous Integrated Fuel Flowmeter
- Maintenance Practices
Module 16.11 Powerplant Installation
Engine Mounts
Engine Controls
- Throttle Control
- Propeller Controls
- Mixture Control
- Carburettor Heat
Control Systems
- General Requirements
- Push Pull Control Rods
- Bowden Controls
- Teleflex Controls
Engine Removal and Replacement
- General
- Reasons for Removal of Reciprocating Engines
- Preparation of Reciprocating Engines for Installation
- QECA Build-up of Radial Engines
- Draining the Engine
- Electrical Disconnects
- Disconnection of Engine Controls
- Disconnection of Lines
- Other Disconnections
- Hoisting the Engine
Engine Installation
- Hoisting and Mounting the Engine for Installation
- Connections and Adjustments
Preparation of Engine for Ground and Flight Testing
- Pre-oiling
- Fuel System Bleeding
- Propeller Check
Check and Adjustments after Engine Run-Up and Operation
Removal and Installation of an Opposed-Type Engine
Typical Removal and Installation Procedure
- Engine Removal
- Engine Installation
Module 16.12 Engine Monitoring and Ground Operation
Ground Running
- Ground Running Check
- Ground Running Precautions
- Pre-Start Checks
- Engine Shut Down
Overhaul Periods
- Private Category Aircraft
- Public Transport and Aerial Work Category Aircraft
- Engine Inspection Procedures for Extension to Overhaul Life
- Crop Spraying Aircraft
- Extension to Overhaul Periods
- Overhaul Periods (Light Aircraft)
Engine Overhaul
- Top Overhaul
- Major Overhaul
General Overhaul Procedures
- Disassembly
- Inspection
- Repair and Replacement
Cylinder Assembly Reconditioning
- Cylinder Head
- Cylinder Barrel
- Valves and Valve Springs
- Rocker Arms and Shafts
- Piston and Piston Pin
- Re-facing Valve Seats
- Valve Reconditioning
- Valve Lapping and Leak Testing
- Piston Repairs
Crankshaft Inspection
- Sludge Chambers
Connecting Rods
- Visual Inspection
- Checking Alignment
Block Testing of Reciprocating Engines
- Block Test Purpose
- Block-Test Requirements
- Mobile Stand Testing of Reciprocating Engines
- Block Test Instruments
- Carburettor Air Temperature Indicator
- Fuel Pressure Indicator
- Fuel Flowmeter
- Manifold Pressure Indicator
- Oil Temperature Indicator
- Oil Pressure Indicator
- Tachometer Indicator
- Cylinder Head Temperature Indicator
- Torquemeter
- Oil-Weighing System
- Metering Differential Manometer
- General Instrumentation
Reciprocating Engine Operation
- General
- Engine Instruments
- Engine Staring
- Engine Warm-Up
- Ground Check
- Propeller Pitch Check
- Power Check
- Ignition System Operational Check
- Cruise Mixture Check
- Idle Speed and Idle Mixture Cheecks
- Two-Speed Supercharder Check
- Acceleration and Deceleration Checks
- Engine Stopping
- Basic Engine Operating Principles
- Backfiring
- After-Firing
Cylinder Maintenance
- Hydraulic Lock
- Valve Blow-by
- Cylinder Compression Tests
- Direct Compression Tester
- Differential Pressure Tester
- Cylinder Replacement
- Cylinder Removal
- Cylinder Installation
- Valve and Valve Mechanism
- Valve Clearance
- Valve Spring Replacement
- Cold Cylinder Check
Module 16.13 Engine Storage and Preservation
Engine for Removal
Inhibiting
- Corrosion-Preventive Materials
- Corrosion-Preventive Compounds
- Dehydrating Agents
- Corrosion-Preventive Treatment
Packing and Sealing
- Recors
- Fuel System Inhibiting
- Blacks
- Engine Shipping Containers
Inspection of Stored Engines
Removal from Storage
- De-preservation of an Engine
- Inspection and De-preservation of Accessories
- Inspection and Replacement of Powerplant External Units and Systems
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