2203

• Manufacturer's overhaul manual


  Provides information on all procedures of a special nature and on general procedures for the disassembly, cleaning, inspection, repair, modification, reassembly, and testing of engines
• Non-destructive inspection and testing equipment

  • Magnetic particle testing
  • Liquid penetrant inspection
  • Ultrasonic inspection
  • Radiography
• Top Overhaul


  An overhaul of those parts on top of the crankcase, without completely dismantling the engine
• Major Overhaul


  The complete reconditioning of the powerplant, where the crankcase is disassembled
• Major Repairs


  Not generally a major overhaul, but can be performed by a certified powerplant-rated technician
• Receiving the Engine


  1. Receiving inspection

  2. Inventory

  3. Organization of Engine Records
• Extensive records must be kept as the engine progresses through the overhaul process
• The repair station should maintain a complete record of all repair operations and inspections performed on each engine or component overhauled
• Reciprocating Overhaul


  A complete overhaul process includes the following ten steps: receiving inspection; disassembly; visual inspection; cleaning; structural inspection; non-destructive testing (NDT) inspection; dimensional inspection; repair and replacement; reassembly; and testing and break in.
• Receiving Inspection


  The receiving inspection consists of determining the general condition of the total engine as received, along with an inventory of the engine’s components.
• Inspection


  The general condition of the engine should be carefully noted on the receiving report. If the engine has been in a crash, fire, or other situation where damage may have been caused, such conditions have to be recorded.
• Inventory


  It is essential that every part be accounted for, because an owner may not be aware that certain parts or accessories were removed before the engine was delivered to the overhaul facility.
• Engines are designed and built to provide many years of service. For an engine to remain in airworthy condition, it should be operated in accordance with the recommendations of the manufacturer and cared for with sound inspection and maintenance practices.
• Visual inspection


  Needed to determine the current condition of the engine and its components
• Abrasion


  An area of roughened scratches or marks usually caused by foreign matter between moving parts or surfaces
• Brinelling


  One or more indentations on bearing races, usually caused by high static loads or application of force during installation or removal
• Burning


  Surface damage due to excessive heat, usually caused by improper fit, defective lubrication, or over-temperature operation
• Burnishing


  Polishing of one surface by sliding contact with a smooth, harder surface, usually no displacement nor removal of metal
• Burr


  A sharp or roughened projection of metal usually resulting from machine processing
• Chafing


  A condition caused by a rubbing action between two parts under light pressure that results in wear
• Chipping


  Breaking away of pieces of material, usually caused by excessive stress concentration or careless handling
• Corrosion


  Loss of metal by a chemical or electrochemical action, the corrosion products are easily removed by mechanical means
• Crack


  A partial separation of material usually caused by vibration, overloading, internal stresses, defective assembly, or fatigue
• Cut


  Loss of metal, usually to an appreciable depth over a relatively long and narrow area, by mechanical means
• Dent


  A small, rounded depression in a surface usually caused by the part being struck with a rounded object
• Erosion


  Loss of metal from the surface by mechanical action of foreign objects, such as grit or fine sand
• Flaking


  The breaking loose of small pieces of metal or coated surfaces, usually caused by defective plating or excessive loading
• Fretting


  A condition of surface erosion caused by minute movement between two parts usually clamped together with considerable unit pressure
• Galling


  A severe condition of chafing or fretting in which a transfer of metal from one part to another occurs, usually caused by a slight movement of mated parts having limited relative motion and under high loads
• Gouging


  A furrowing condition in which a displacement of metal has occurred, usually caused by a piece of metal, or foreign material, between close moving parts
• Grooving


  A recess, or channel, with rounded and smooth edges usually caused by faulty alignment of parts
• Inclusion


  Presence of foreign or extraneous material entirely within a portion of metal, introduced during the manufacture of rod, bar, or tubing by rolling or forging
• Nick


  A sharp-sided gouge or depression with a V-shaped bottom, generally the result of careless handling of tools and parts
• Peening


  A series of blunt depressions in a surface
• Pick up or scuffing


  A buildup or rolling of metal from one area to another, usually caused by insufficient lubrication, clearances, or foreign matter
• Pitting


  Small hollows of irregular shape in the surface, usually caused by corrosion or minute mechanical chipping of surfaces
• Scoring


  A series of deep scratches caused by foreign particles between moving parts or careless assembly or disassembly techniques
• Scratches


  Shallow, thin lines or marks, varying in degree of depth and width, caused by presence of fine foreign particles during operation or contact with other parts during handling
• Stain


  A change in color, locally, causing a noticeably different appearance from the surrounding area
• Upsetting


  A displacement of material beyond the normal contour or surface (a local bulge or bump), usually indicates no metal loss