JET ENGINE THEORY AND DESIGN
THE ATHODYD (RAMJET)
THE PULSEJET ENGINE
GAS TURBINE ENGINE
Figure 1-10.-Effects on airflow through an engine.
NEWTON'S LAWS OF MOTION
JET ENGINE TYPES AND DESIGNATIONS SYSTEMS
ENGINE DESIGNATION SYSTEMS
MANUFACTURER SYMBOLS
Manufacturer's Symbols
Model Indicator
JET TURBINE ENGINE MAJOR ASSEMBLIES
Centrifugal-Flow Compressors
Figure 1-16.-Impeller with inducer vanes as separate pieces.
Figure 1-18.-The cascade effect.
Figure 1-20.-Fir-tree root-type rotor blades.
Figure 1-21 .-Drum-type compressor rotor.
COMBUSTION SECTION
Figure 1-25.-Cars-type combustion liner.
Annular or Basket Type
Figure 1-27.-Double-annular combustion chambers.
Figure 1-28.-Can-annular combustion chamber components and arrangement.
Figure 1-30.-Stator element of the turbine assembly.
Figure 1-32.-Turbine nozzle vane assembly. (A) With loose fitting vanes; (B) with welded vanes.
Figure 1-33 .-Impulse and reaction blades.
Figure 1-37.-Shrouded turbine blades.
Figure 1-39.-Turbine casing assembly.
Figure 1-41.-Exhaust system insulation blanket.
Figure 1-43.-Exhaust system shroud.
Figure 1-44.-Segment-type nozzle assembly.
ACCESSORY SECTION
AFTERBURNER SECTION
AFTERBURNER SECTION - Continued
TOOLS AND HARDWARE
TOOL CONTROL PROGRAM (TCP)
COMMON HAND TOOLS
HINGED HANDLE
Figure 2-3 .-Screwdriver adapter.
ADJUSTABLE WRENCHES
VISE GRIP PLIERS
DIAGONAL PLIERS.
Figure 2-10.-Safety-wire pliers.
TORQUE WRENCHES
MICROMETERS
Figure 2-14.-Common types of micrometers.
Figure 2-16.-Correct and incorrect grip lengths.
Figure 2-18.-Non-self-locking nuts.
Installation of Nuts and Bolts
Special Washers
SAFETY METHODS
Figure 2-24.-Safety wiring methods.
Cotter Pins
AVIATION SUPPORT EQUIPMENT
Figure 3-1.-Equipment indicator code.
TYPES OF SUPPORT EQUIPMENT
Figure 3.3.-NC-2A mobile electric power plant (MEPP).
Figure 3-5.-NC-10C mobile electric power plant (MEPP).
MOBILE AIR-CONDITIONERS
Figure 3-8.-A/M32C-17 mobile air-conditioning unit.
Figure 3-9.-A/M32C-17 operating control panel.
Figure 3-10.-A/M32C-17 control functions and ranges.
GAS TURBINE COMPRESSORS (GTCs)
NCPP-105 Compressor
HYDRAULIC POWER SUPPLIES/HYDRAULIC TEST STAND
NONPOWERED SUPPORT EQUIPMENT
Figure 3-16.-B-4A maintenance platform.
Other Maintenance Platforms
Figure 3-19.-4000A engine removal/installation trailer.
Aero Bomb Hoists
Figure 3-21.-Aero bomb hoist.
SE TRAINING AND LICENSING PROGRAM
JET AIRCRAFT FUEL AND FUEL SYSTEMS
Figure 4-1.-Vaporization of aviation fuels at atmospheric pressure
Flash Point and Fire Point
TYPES OF JET FUEL
Figure 4-2.--Enlargement of small particles and comparison to human hair.
Figure 4-3 - Sample of JP-5 showing common visual contamination (air bubbles not contaminants 0 shown here for information).
Sampling Procedures
Table 4.1 - Visual Contamination Table
Table 4.1 - Visual Contamination Table - Continued
FUEL TANK CONSTRUCTION
Figure 4-5.-Self-sealing fuel cell (standard construction).
Bladder-Type Fuel Cells
Figure 4-7.-External fuel tank (with cutway view).
Figure 4-8.-Ejector pumps. (A) Dual seat; (B) single seat; (C) wing transfer.
External Fuel Transfer
Fuel Level Control Valves
Figure 4-11.-Fuel level control valve.
FUEL LINES AND FITTINGS.
Fitting With O-Ring Seal
ENGINE FUEL SYSTEM
Figure 4-16.-Fuel control (JFC 25-3).
FUEL CONTROL (JFC 25-3) OPERATION
FUEL VALVES
Figure 4-18.-Solenoid-operated drip (dump) valve.
Fuel Spray Nozzles and Fuel Manifolds
FUEL SELECTORS
Figure 4-24.-Aircraft fuel filter (microfilter).
ENGINE-DRIVEN PUMPS
Figure 4-26.-Cutaway view of a dual-element gear-type pump.
Figure 4-27.-Variable-stroke fuel pump.
Figure 4-28.-Engine-driven, rotary-vane type of pump.
Fuel Dye to Locate Leaks
Preparation for Fuel Cell Maintenance
Depuddling
FUEL CELL REMOVAL AND INSTALLATION
Handling Procedures
FUEL SYSTEM PART MAINTENANCE
Fuel Lines and Fittings
Fuel Part Removal/Installation
RIGGING AND ADJUSTING
RIGGING AND ADJUSTING - Continued
JET AIRCRAFT ENGINE LUBRICATION SYSTEMS
FUNCTIONS OF JET ENGINE OILS
Table 5-1.-Classification of Lubricating Oils
TYPES OF LUBRICATION SYSTEMS
Table 5-2.-Common Military Lubricants and Their Uses
Figure 5-2 - Dry-sump oil system
Dry-sump System
OIL SYSTEM COMPONENTS
Figure 5-5.-Representative oil tank.
Figure 5-6.-Cutaway view of gear-type oil pump.
GEROTOR OIL PUMP
THERMOSTATIC BYPASS VALVES.
MICRONIC-TYPE FILTER
Figure 5-12.-Air-oil type of oil cooler.
Figure 5-13.-Fuel-oil heat-exchanger type of cooler.
Figure 5-14.-Engine oil system schematic.
Engine Chip Detector
Figure 5-15.-Seal packing information.
REMOVAL AND REPLACEMENT OF OIL FILTERS
Table 5-3.-Oil Pressure Troubleshooting Chart
METAL PARTICLE IDENTIFICATION
Identification of Wear Metals
Figure 5-18.-Dip tube oil sampling.
DRAIN SAMPLING
Figure 5-20.-Oil Analysis Request (DD Form 2026).
Table 5-4.-NOAP Lab Recommendations
NOAP Forms and Logbook Entries
ENGINE AND AIRFRAME RELATED SYSTEMS
Origin of Contaminants
HYDRAULIC SYSTEM MAINTENANCE
Figure 6-2.--B1eed-air and vane control system.
Variable-Area Exhaust Nozzles
BASIC ELECTRICITY
Figure 6-5.-Typical sealed ignition exciter box.
Figure 6-6.-Functional schematic diagram of a capacitor discharge ignition system.
Figure 6-7.-Jet engine electronic ignition system.
ENGINE IGNITION EXCITER.
Figure 6-8.-Air turbine starting system.
Electrical Starters
BLEED-AIR SYSTEMS (ENGINE)
Figure 6-11. - Bleed-air system.
Anti-icing System
Figure 6-13.-Inlet guide vane anti-icing system.
Figure 6-14. - Environmental Control System
Airframe Deicing and Anti-icing Systems
Figure 6-16.-Deicing system.
Figure 6-17.-Ice protection system.
Figure 6-18.-Typical onboard auxiliary power unit (APU).
HELICOPTERS AND TURBOSHAFT POWER PLANTS
FACTORS AFFECTING HELICOPTER FLIGHT
Figure 7-2.-Symmetry of lift.
FACTORS AFFECTING ROTOR BLADE LIFT
Figure 7-4. Typical flight control system.
FLIGHT CONTROL SYSTEM
Figure 7-5. Types of naval helicopters.
THE T58-GE-10 TURBOSHAFT ENGINE
Figure 7-6. t58-GE-10 turboshaft gas turbine engine (cutaway view)
Figure 7-7. T700-GE-401 turboshaft gas turbine engine (cutaway view)
Figure 7-8.-Inlet particle separator (IPS) airflow.
Figure 7-9.-Engine control quadrant.
Figure 7-10.-SH-3 power transmission system.
Figure 7-11.-SH-60 power transmission system.
Figure 7-12.-SH-3 main gearbox.
INTERMEDIATE GEARBOX
MAIN DRIVE SHAFT
TAIL DRIVE SHAFT
MAIN TRANSMISSION INSTALLATION
Figure 7-17.-Rotary wing head assemblies; (A) Self-lubricating head; (B) Grease-lubricated head.
MAIN ROTOR BLADES
Figure 7-19.-Blade pressure indicator (BIM).
ROTOR SYSTEM MAINTENANCE
Figure 7-22.-Electronic tracking.
ELECTRONIC TRACKING
TURBOPROP ENGINES AND PROPELLERS
Figure 8-1.-Four types of turboprop aircraft.
Figure 8-2.-Turboprop engine major assemblies.
TURBOPROP SAFETY SYSTEMS
Figure 8-5.-Reduction gear and torquemeter assemblies.
Figure 8-6.-Control schematic.
Figure 8-7.-Coordinator quadrant markings.
Fuel Control
BASIC PROPELLER PARTS
PROPELLER MODEL DESIGNATION
Figure 8-12.-Natural forces acting upon propeller blades.
PROPELLER SYSTEM ASSEMBLIES
Figure 8-13.-Propeller system.
PITCHLOCK REGULATOR ASSEMBLY.
Figure 8-14.-Variable pitch aircraft propeller.
Figure 8-15.-Propeller control assembly.
VALVE HOUSING ASSEMBLY
Figure 8-16.-Propeller blade damage rework limits.
Figure 8-17.-Propeller rework guide.
Propeller Cleaning
Figure 8-19.-Propeller removal.
Feathering Check
Figure 8-21.-Valve housing assembly (adjustments).
Preliminary Balance
EXTERNAL LEAKAGE TEST
INTERNAL FLOW AND LEAKAGE TEST
GENERAL ENGINE TROUBLESHOOTING
Table 9-1.-Oil Pressure Troubleshooting Chart
Compressor Section
TROUBLESHOOTING PROCEDURES
USE OF DIAGRAMS, DRAWINGS, AND CHARTS IN TROUBLESHOOTING
Samples of Various Troubleshooting Charts
Aeronautical Mechanical Symbols
Fuel control schematic.
Pictorial diagram of a fuel distributor.
Turbofan, cutaway view.
Fluid line color codes and symbols.
Fluid line identification group (A) using tape and decals; (B) using metal tags; (C) using paint.
GENERAL RULES FOR ELECTRICAL TEST METERS
Standard multimeter.
Digital multimeter.
Continuity test.
High-voltage insulation tester.
Figure 9-14.-Rigid borescope.
Figure 9-16.-Engine inspection ports.
Borescope view of thermocouple and turbine blades.
Examples Of Serviceability Limits
WATER WASHING
POWER PLANT INSPECTION, REPAIR, AND TESTING
SECOND-DEGREE REPAIR
Vapor Decreasing
Abrasive Blasting
COMPRESSOR SECTION REPAIRS
Compressor Failures
Blade Maintenance Terms
Repairable limits and examples of maximum repair.
Compressor blade repair.
Combustion Chamber Liners
Combustion chamber liner limits.
Combustion chamber support limits.
Combustion chamber inner and outer duct.
Examples of unacceptable sulfidation of turbine blades and vanes.
Stress rupture cracks.
Turbine Blade Replacement
Turbine rotor blade removal and replacement.
EXHAUST SECTION INSPECTION
JET ENGINE TEST CELLS
Variable Height Stand Assembly
Control board.
Exhaust Augmenter Assembly and Exhaust Gas Cooling System Assembly
Fuel System Monitoring Assembly
Portable universal engine runup test system.
Turboprop engine test system.
Portable engine runup test system.
Engine test and runup system.
Engine runup test log sheet.
ENGINE TEST LOG SHEETS
GLOSSARY
GLOSSARY - Continued
GLOSSARY - Continued
GLOSSARY - Continued
GLOSSARY - Continued
GLOSSARY - Continued
THE ATHODYD (RAMJET)
THE PULSEJET ENGINE
GAS TURBINE ENGINE
Figure 1-10.-Effects on airflow through an engine.
NEWTON'S LAWS OF MOTION
JET ENGINE TYPES AND DESIGNATIONS SYSTEMS
ENGINE DESIGNATION SYSTEMS
MANUFACTURER SYMBOLS
Manufacturer's Symbols
Model Indicator
JET TURBINE ENGINE MAJOR ASSEMBLIES
Centrifugal-Flow Compressors
Figure 1-16.-Impeller with inducer vanes as separate pieces.
Figure 1-18.-The cascade effect.
Figure 1-20.-Fir-tree root-type rotor blades.
Figure 1-21 .-Drum-type compressor rotor.
COMBUSTION SECTION
Figure 1-25.-Cars-type combustion liner.
Annular or Basket Type
Figure 1-27.-Double-annular combustion chambers.
Figure 1-28.-Can-annular combustion chamber components and arrangement.
Figure 1-30.-Stator element of the turbine assembly.
Figure 1-32.-Turbine nozzle vane assembly. (A) With loose fitting vanes; (B) with welded vanes.
Figure 1-33 .-Impulse and reaction blades.
Figure 1-37.-Shrouded turbine blades.
Figure 1-39.-Turbine casing assembly.
Figure 1-41.-Exhaust system insulation blanket.
Figure 1-43.-Exhaust system shroud.
Figure 1-44.-Segment-type nozzle assembly.
ACCESSORY SECTION
AFTERBURNER SECTION
AFTERBURNER SECTION - Continued
TOOLS AND HARDWARE
TOOL CONTROL PROGRAM (TCP)
COMMON HAND TOOLS
HINGED HANDLE
Figure 2-3 .-Screwdriver adapter.
ADJUSTABLE WRENCHES
VISE GRIP PLIERS
DIAGONAL PLIERS.
Figure 2-10.-Safety-wire pliers.
TORQUE WRENCHES
MICROMETERS
Figure 2-14.-Common types of micrometers.
Figure 2-16.-Correct and incorrect grip lengths.
Figure 2-18.-Non-self-locking nuts.
Installation of Nuts and Bolts
Special Washers
SAFETY METHODS
Figure 2-24.-Safety wiring methods.
Cotter Pins
AVIATION SUPPORT EQUIPMENT
Figure 3-1.-Equipment indicator code.
TYPES OF SUPPORT EQUIPMENT
Figure 3.3.-NC-2A mobile electric power plant (MEPP).
Figure 3-5.-NC-10C mobile electric power plant (MEPP).
MOBILE AIR-CONDITIONERS
Figure 3-8.-A/M32C-17 mobile air-conditioning unit.
Figure 3-9.-A/M32C-17 operating control panel.
Figure 3-10.-A/M32C-17 control functions and ranges.
GAS TURBINE COMPRESSORS (GTCs)
NCPP-105 Compressor
HYDRAULIC POWER SUPPLIES/HYDRAULIC TEST STAND
NONPOWERED SUPPORT EQUIPMENT
Figure 3-16.-B-4A maintenance platform.
Other Maintenance Platforms
Figure 3-19.-4000A engine removal/installation trailer.
Aero Bomb Hoists
Figure 3-21.-Aero bomb hoist.
SE TRAINING AND LICENSING PROGRAM
JET AIRCRAFT FUEL AND FUEL SYSTEMS
Figure 4-1.-Vaporization of aviation fuels at atmospheric pressure
Flash Point and Fire Point
TYPES OF JET FUEL
Figure 4-2.--Enlargement of small particles and comparison to human hair.
Figure 4-3 - Sample of JP-5 showing common visual contamination (air bubbles not contaminants 0 shown here for information).
Sampling Procedures
Table 4.1 - Visual Contamination Table
Table 4.1 - Visual Contamination Table - Continued
FUEL TANK CONSTRUCTION
Figure 4-5.-Self-sealing fuel cell (standard construction).
Bladder-Type Fuel Cells
Figure 4-7.-External fuel tank (with cutway view).
Figure 4-8.-Ejector pumps. (A) Dual seat; (B) single seat; (C) wing transfer.
External Fuel Transfer
Fuel Level Control Valves
Figure 4-11.-Fuel level control valve.
FUEL LINES AND FITTINGS.
Fitting With O-Ring Seal
ENGINE FUEL SYSTEM
Figure 4-16.-Fuel control (JFC 25-3).
FUEL CONTROL (JFC 25-3) OPERATION
FUEL VALVES
Figure 4-18.-Solenoid-operated drip (dump) valve.
Fuel Spray Nozzles and Fuel Manifolds
FUEL SELECTORS
Figure 4-24.-Aircraft fuel filter (microfilter).
ENGINE-DRIVEN PUMPS
Figure 4-26.-Cutaway view of a dual-element gear-type pump.
Figure 4-27.-Variable-stroke fuel pump.
Figure 4-28.-Engine-driven, rotary-vane type of pump.
Fuel Dye to Locate Leaks
Preparation for Fuel Cell Maintenance
Depuddling
FUEL CELL REMOVAL AND INSTALLATION
Handling Procedures
FUEL SYSTEM PART MAINTENANCE
Fuel Lines and Fittings
Fuel Part Removal/Installation
RIGGING AND ADJUSTING
RIGGING AND ADJUSTING - Continued
JET AIRCRAFT ENGINE LUBRICATION SYSTEMS
FUNCTIONS OF JET ENGINE OILS
Table 5-1.-Classification of Lubricating Oils
TYPES OF LUBRICATION SYSTEMS
Table 5-2.-Common Military Lubricants and Their Uses
Figure 5-2 - Dry-sump oil system
Dry-sump System
OIL SYSTEM COMPONENTS
Figure 5-5.-Representative oil tank.
Figure 5-6.-Cutaway view of gear-type oil pump.
GEROTOR OIL PUMP
THERMOSTATIC BYPASS VALVES.
MICRONIC-TYPE FILTER
Figure 5-12.-Air-oil type of oil cooler.
Figure 5-13.-Fuel-oil heat-exchanger type of cooler.
Figure 5-14.-Engine oil system schematic.
Engine Chip Detector
Figure 5-15.-Seal packing information.
REMOVAL AND REPLACEMENT OF OIL FILTERS
Table 5-3.-Oil Pressure Troubleshooting Chart
METAL PARTICLE IDENTIFICATION
Identification of Wear Metals
Figure 5-18.-Dip tube oil sampling.
DRAIN SAMPLING
Figure 5-20.-Oil Analysis Request (DD Form 2026).
Table 5-4.-NOAP Lab Recommendations
NOAP Forms and Logbook Entries
ENGINE AND AIRFRAME RELATED SYSTEMS
Origin of Contaminants
HYDRAULIC SYSTEM MAINTENANCE
Figure 6-2.--B1eed-air and vane control system.
Variable-Area Exhaust Nozzles
BASIC ELECTRICITY
Figure 6-5.-Typical sealed ignition exciter box.
Figure 6-6.-Functional schematic diagram of a capacitor discharge ignition system.
Figure 6-7.-Jet engine electronic ignition system.
ENGINE IGNITION EXCITER.
Figure 6-8.-Air turbine starting system.
Electrical Starters
BLEED-AIR SYSTEMS (ENGINE)
Figure 6-11. - Bleed-air system.
Anti-icing System
Figure 6-13.-Inlet guide vane anti-icing system.
Figure 6-14. - Environmental Control System
Airframe Deicing and Anti-icing Systems
Figure 6-16.-Deicing system.
Figure 6-17.-Ice protection system.
Figure 6-18.-Typical onboard auxiliary power unit (APU).
HELICOPTERS AND TURBOSHAFT POWER PLANTS
FACTORS AFFECTING HELICOPTER FLIGHT
Figure 7-2.-Symmetry of lift.
FACTORS AFFECTING ROTOR BLADE LIFT
Figure 7-4. Typical flight control system.
FLIGHT CONTROL SYSTEM
Figure 7-5. Types of naval helicopters.
THE T58-GE-10 TURBOSHAFT ENGINE
Figure 7-6. t58-GE-10 turboshaft gas turbine engine (cutaway view)
Figure 7-7. T700-GE-401 turboshaft gas turbine engine (cutaway view)
Figure 7-8.-Inlet particle separator (IPS) airflow.
Figure 7-9.-Engine control quadrant.
Figure 7-10.-SH-3 power transmission system.
Figure 7-11.-SH-60 power transmission system.
Figure 7-12.-SH-3 main gearbox.
INTERMEDIATE GEARBOX
MAIN DRIVE SHAFT
TAIL DRIVE SHAFT
MAIN TRANSMISSION INSTALLATION
Figure 7-17.-Rotary wing head assemblies; (A) Self-lubricating head; (B) Grease-lubricated head.
MAIN ROTOR BLADES
Figure 7-19.-Blade pressure indicator (BIM).
ROTOR SYSTEM MAINTENANCE
Figure 7-22.-Electronic tracking.
ELECTRONIC TRACKING
TURBOPROP ENGINES AND PROPELLERS
Figure 8-1.-Four types of turboprop aircraft.
Figure 8-2.-Turboprop engine major assemblies.
TURBOPROP SAFETY SYSTEMS
Figure 8-5.-Reduction gear and torquemeter assemblies.
Figure 8-6.-Control schematic.
Figure 8-7.-Coordinator quadrant markings.
Fuel Control
BASIC PROPELLER PARTS
PROPELLER MODEL DESIGNATION
Figure 8-12.-Natural forces acting upon propeller blades.
PROPELLER SYSTEM ASSEMBLIES
Figure 8-13.-Propeller system.
PITCHLOCK REGULATOR ASSEMBLY.
Figure 8-14.-Variable pitch aircraft propeller.
Figure 8-15.-Propeller control assembly.
VALVE HOUSING ASSEMBLY
Figure 8-16.-Propeller blade damage rework limits.
Figure 8-17.-Propeller rework guide.
Propeller Cleaning
Figure 8-19.-Propeller removal.
Feathering Check
Figure 8-21.-Valve housing assembly (adjustments).
Preliminary Balance
EXTERNAL LEAKAGE TEST
INTERNAL FLOW AND LEAKAGE TEST
GENERAL ENGINE TROUBLESHOOTING
Table 9-1.-Oil Pressure Troubleshooting Chart
Compressor Section
TROUBLESHOOTING PROCEDURES
USE OF DIAGRAMS, DRAWINGS, AND CHARTS IN TROUBLESHOOTING
Samples of Various Troubleshooting Charts
Aeronautical Mechanical Symbols
Fuel control schematic.
Pictorial diagram of a fuel distributor.
Turbofan, cutaway view.
Fluid line color codes and symbols.
Fluid line identification group (A) using tape and decals; (B) using metal tags; (C) using paint.
GENERAL RULES FOR ELECTRICAL TEST METERS
Standard multimeter.
Digital multimeter.
Continuity test.
High-voltage insulation tester.
Figure 9-14.-Rigid borescope.
Figure 9-16.-Engine inspection ports.
Borescope view of thermocouple and turbine blades.
Examples Of Serviceability Limits
WATER WASHING
POWER PLANT INSPECTION, REPAIR, AND TESTING
SECOND-DEGREE REPAIR
Vapor Decreasing
Abrasive Blasting
COMPRESSOR SECTION REPAIRS
Compressor Failures
Blade Maintenance Terms
Repairable limits and examples of maximum repair.
Compressor blade repair.
Combustion Chamber Liners
Combustion chamber liner limits.
Combustion chamber support limits.
Combustion chamber inner and outer duct.
Examples of unacceptable sulfidation of turbine blades and vanes.
Stress rupture cracks.
Turbine Blade Replacement
Turbine rotor blade removal and replacement.
EXHAUST SECTION INSPECTION
JET ENGINE TEST CELLS
Variable Height Stand Assembly
Control board.
Exhaust Augmenter Assembly and Exhaust Gas Cooling System Assembly
Fuel System Monitoring Assembly
Portable universal engine runup test system.
Turboprop engine test system.
Portable engine runup test system.
Engine test and runup system.
Engine runup test log sheet.
ENGINE TEST LOG SHEETS
GLOSSARY
GLOSSARY - Continued
GLOSSARY - Continued
GLOSSARY - Continued
GLOSSARY - Continued
GLOSSARY - Continued
