Jet Aircraft Maintenance Fundamentals ATA 79

Ameco Beijing Aviation College Training Manual Fundamentals Jet Aircraft Maintenance Fundamentals ATA 79 Lubrication System JAR-66 Book No: JAMF ATA 79 ALL Lufthansa Technical Training GmbH Lufthansa Base Issue: July 2000 For Training Purposes Only ã Lufthansa 1995 For training purpose and internal use only Copyright by Lufthansa Technical Training GmbH All rights reserved No parts of this training manual may be sold or reproduced in any form without permission of: Lufthansa Technical Training GmbH Lufthansa Base Frankfurt D-60546 Frankfurt/Main Tel +49 69 / 696 41 78 Fax +49 69 / 696 63 84 Lufthansa Base Hamburg Weg beim Jäger 193 D-22335 Hamburg Tel +49 40 / 5070 24 13 Fax +49 40 / 5070 47 46 Beijing Aviation College ATA 79 LUBRICATION SYSTEM For Training Purposes Only Lufthansa Technical Training Ameco Page Ameco Beijing Aviation College FUNDAMENTALS Lesson OIL GENERAL TASK OF ENGINE OIL HAM US sw Sept 98 Edited by Foxit Reader Copyright(C) by Foxit Software Company,2005-2008 For Evaluation Only In this segment you will learn about the main tasks of engine oil and the different characteristics of oils First let us look at the main tasks of oil on modern jet engines, include: lubricating, boi tron cooling, cleaning and corrosion protection chong an mon Generally, lubrication is needed to reduce friction between metal surfaces that move against each other You can see here, in this example, that the contact surfaces look very smooth but when you look more closely at them through a microscope, you can see that they are very rough When the surfaces move against each other they can cause very high friction and wear So the oil is needed to form a protective film This prevents the contact between the metal surfaces For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM OIL GENERAL Page Lufthansa Technical Training LUBRICATION SYSTEM OIL GENERAL Ameco Beijing FUNDAMENTALS Aviation College Lesson OIL PUMP For Training Purposes Only ENGINE OIL OIL FILM Figure HAM US sw Sept 98 Lubricating Page Ameco Beijing Aviation College FUNDAMENTALS Lesson task of engine oil cont Cooling is another task of the engine oil All the heat in the lubricating areas caused by the operating engine must be removed The heat of the materials is transferred to the oil when it is in contact with the metal surfaces For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM OIL GENERAL HAM US sw Sept 98 Page Lufthansa Technical Training Ameco LUBRICATION SYSTEM OIL GENERAL Beijing FUNDAMENTALS Aviation College Lesson OIL SUMP Edited by Foxit Reader Copyright(C) by Foxit Software Company,2005-2008 For Evaluation Only For Training Purposes Only ENGINE OIL Figure HAM US sw Sept 98 (bearing sump) Cooling Page Ameco Beijing Aviation College FUNDAMENTALS Lesson task of engine oil cont Oil is used to clean the system from contamination These contaminations can be caused by abrasions from the gears or bearings or by foreign objects like sand or dust particles The oil carries these particles until they are caught in an oil filter Sometimes, the particles are very small so that they are not caught by the filter These very small particles, which also indicate some internal wear can only be found by a special analysis in a laboratory Another important task of the oil is to protect the metal surfaces from corrosion You will find that many materials in the engine are not resistant to corrosion As you can see in this video, if oil is not used corrosion can occur For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM OIL GENERAL HAM US sw Sept 98 Page Lufthansa Technical Training Ameco LUBRICATION SYSTEM OIL GENERAL Beijing FUNDAMENTALS Aviation College Lesson ENGINE OIL For Training Purposes Only OIL LINE OIL FILTER Figure HAM US sw Sept 98 Cleaning and Corrosion Inspection Page Ameco Beijing Aviation College FUNDAMENTALS Lesson TYPES OF OIL There are two groups of engine oils, mineral oils and synthetic oils Mineral oils are generally not as capable as synthetic oils They are only used on piston type engines Synthetic oils are used on jet engines They are designed specially to meet the needs of the engine For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM OIL GENERAL HAM US sw Sept 98 Page Ameco Beijing Aviation College LESSON MAINTENANCE PRACTICES LUBRICATING SYSTEM SERVICING On long range aircraft the oil quantity in the engines is checked after each flight On medium and short range aircraft the oil quantity in the engines is checked at intervals specified in the maintenance schedule for the aircraft The oil quantity can be checked at the sight gages on the oil tanks of the engines or on the ECAM or EICAS displays in the cockpit You must wait at least five minutes after engine shutdown before you check the oil quantity On most engines the oil tank is located above the level of the gearbox There is a slow oil flow from the tank to the gearbox due to the siphon effect On these engines it is important to check the oil quantity between five and twenty minutes after engine shutdown when all of the oil is in the tank The oil can be refilled via the oil tank filler port Note that you must wait at least five minutes after engine shutdown before you open the oil tank filler cap If you don’t wait at least five minutes after engine shut down, hot oil can spray but of the filler port when you open it You should also observe the smell of the oil when you open the filler cap If you smell fuel this indicates a leakage in the fuel cooled oil cooler Further troubleshooting is required For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES HAM US sw Sept98 Page 96 Lufthansa Technical Training Ameco Beijing Aviation College LESSON For Training Purposes Only LUBRICATION SYSTEM MAINTENANCE PRACTICES Figure 48 HAM US sw Sept98 Oil Quantity Check Page 97 Ameco Beijing Aviation College LESSON lubrication system servicing cont You can refill the oil out of oil cans or you can use an oil servicing system You can refill the oil by gravity via the oil filler port, or on many engines you can also refill the oil by a pump via a pressure fill and overlow port Remember that you should always check that you are using the correct type of oil before you refill the tank You can find details of the required oil type on a label close to the oil tank filler cap The use of oil cans should be minimized for environmental reasons If you must use oil cans always use new, closed cans and open them immediately before the filling process You should put all empty oil cans in a special disposal container For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES HAM US sw Sept98 Page 98 Lufthansa Technical Training Ameco Beijing Aviation College LESSON For Training Purposes Only LUBRICATION SYSTEM MAINTENANCE PRACTICES Figure 49 HAM US sw Sept98 Oil Servicing by Cans Page 99 Ameco Beijing Aviation College LESSON lubrication system servicing cont If the oil servicing system is used the hoses are connected to the pressure fill port and to the overflow port of the oil tank It’s an advantage to use a transparent hose for the overflow port so that you can see directly when the tank is full On tanks with a sight gage however you fill the tank until the oil level reaches the full mark You should always check the oil level on the sight gage to prevent an overfill An overfill is dangerous because a large amount of oil can be pumped through the oil tank vent line into the forward bearing compartment or the de oiler It is important to monitor the oil consumption of the engine For this reason you must enter the quantity of oil added to the tank in the technical log book For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES HAM US sw Sept98 Page 100 Lufthansa Technical Training Ameco Beijing Aviation College LESSON For Training Purposes Only LUBRICATION SYSTEM MAINTENANCE PRACTICES Figure 50 HAM US sw Sept98 Oil Servicing by Servicing Sytem Page 101 Ameco Beijing Aviation College LESSON SOAP SAMPLING Oil samples is taken from the engine oil tank for the spectrometric oil analysis program A plastic bottle with a hose is used to take the oil sample The hose is inserted through the sampling tube of the filler assembly into the oil tank A number of safety precautions must be observed for SOAP sampling You should always use a new plastic bottle and a new hose to prevent contamination of the oil Remember to wait at least five minutes after engine shutdown before you open the oil tank filler cap You should wear gloves to protect your hands because the oil can be hot You must close the bottle and label it immediately after the sample is taken The label is necessary to prevent samples getting mixed up You can see that the label must have details of the aircraft registration the engine position the engine serial number the station where the sample is taken the date and the time of the sample When the label is completed the sample can be sent for analysis For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES HAM US sw Sept98 Page 102 Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES Ameco Beijing Aviation College LESSON For Training Purposes Only FILLER ASSEMBLY SAMPLING TUBE CHECK VALVE PROGRAM Figure 51 HAM US sw Sept98 Soap Sampling Page 103 Ameco Beijing Aviation College LESSON MAGNETIC CHIP DETECTORS INSPECTION Magnetic chip detectors are inspected at fixed intervals For safety reasons the detectors of one engine only are checked at a given inspection This is to minimize the effect of working errors A wrong detector installation can lead to a leak in the oil system and an inflight shutdown of the engine Typically the magnetic chip detectors are designed so that they can be removed without tools Note that the detectors may be hot from the oil so you should wear gloves to protect your hands You remove the magnetic chip detector by pressing it in and then by turning it counter clockwise When a detector is removed a check valve closes in the housing to prevent an oil leakage You must handle the magnetic chip detectors with care Any chips must be removed with a sheet of paper and secured for analysis and the detector must be cleaned before you install it again For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES HAM US sw Sept98 Page 104 Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES Ameco Beijing Aviation College LESSON For Training Purposes Only LUBRICATION UNIT Figure 52 HAM US sw Sept98 Magnetic Chip Detector Inspection Page 105 Ameco Beijing Aviation College LESSON magnetic chip detector inspection cont Some chip detectors have two seals a reusable seal and an o ring Other chip detectors just have two o rings like the one on the left of the screen The old o rings in the magnetic chip detectors must be replaced with new ones to help prevent leakage Keep in mind that the most common work error is to forget to install the o rings You must check that the detector has engaged correctly For Training Purposes Only Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES HAM US sw Sept98 Page 106 Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES Ameco Beijing Aviation College LESSON O-RINGS O-RING For Training Purposes Only O-RING GROOVES REUSABLE SEAL Figure 53 HAM US sw Sept98 Magnetic Chip Detector Installation Page 107 Lufthansa Technical Training LUBRICATION SYSTEM MAINTENANCE PRACTICES Ameco Beijing Aviation College LESSON For Training Purposes Only THIS PAGE INTENTIONALLY LEFT BLANK HAM US sw Sept98 Page 108 Ameco TABLE OF CONTENTS Beijing Aviation College ATA 79 LUBRICATION SYSTEM OIL GENERAL TASK OF ENGINE OIL TYPES OF OIL OIL SPECIFICATION 2 14 BASIC LUBRICATION SYSTEM INTRODUCTION OIL RESERVOIR AND SUPPLY SYSTEM BEARING COMPARTMENTS WITH LABYRINTH SEALS BEARING COMPARTMENTS WITH CARBON SEALS SCAVENGE SYSTEM VENT SYSTEM OIL SYSTEM MONITORING 22 22 24 26 28 30 32 34 OIL SUPPLY SYSTEM FULL FLOW CONSTANT PREESURE ADVANTAGES AND DISADVANTAGES CONSTANT PRESSURE FULL FLOW SYSTEM 36 36 38 40 41 43 SYSTEM COMPONENTS OIL TANK OIL PUMPS OIL FILTERS WIRE MESH FILTER ELEMENT PAPER FILTER ELEMENT HEAT EXCHANGER DE-OILER 44 44 52 60 63 63 64 72 ENGINE OIL MONITORING OIL QUANTITY OIL PRESSURE INDICATION OIL TEMPERATURE INDICATION OIL CONTAMINATION MONITORING 76 76 84 88 90 MAINTENANCE PRACTICES 96 LUBRICATING SYSTEM SERVICING SOAP SAMPLING MAGNETIC CHIP DETECTORS INSPECTION 96 102 104 Page i Ameco Beijing Aviation College TABLE OF FIGURES Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 10 Figure 11 Figure 12 Figure 13 Figure 14 Figure 15 Figure 16 Figure 17 Figure 18 Figure 19 Figure 20 Figure 21 Figure 22 Figure 23 Figure 24 Figure 25 Figure 26 Figure 27 Figure 28 Figure 29 Figure 30 Figure 31 Figure 32 Figure 33 Figure 34 Figure 35 Lubricating Cooling Cleaning and Corrosion Inspection Mineral and Synthetic Oil Different Types of Synthetic Oil Advantage and Disadvantage of Synthetic Oil Viscosity, Pour Point and Flashpoint Pressure Resistance Oxidation Resistance Thermal Stability Basic Lubrication System Pressure Oil System Schematic Bearing Compartment with Labyrinth Seals Bearing Compartment with Carbon Seal Oil Scavenge System Vent System Oil Indicating System Oil Supply Full Flow System Constant Pressure System Full Flow System Advantages / Disadvantages Constant Pressure Sytem Advantages / Disadvantages Oil Tank and Components Static Air / Oil Separator OIl Tank Drain and Coating Oil Tank Filler Assy Supply and Scavenge Pump in Separate Housings Supply Pump Scavenge Pump Lubrication Unit Last Chance Filters Filter Elements Hot Tank and Cold Tank Oil Cooler System Main Types of Oil Cooler Air Cooled Oil Cooler Fuel Cooled Oil Cooler 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43 45 47 49 51 53 55 57 59 61 63 65 67 69 71 Figure 36 Figure 37 Figure 38 Figure 39 Figure 40 Figure 41 Figure 42 Figure 43 Figure 44 Figure 45 Figure 46 Figure 47 Figure 48 Figure 49 Figure 50 Figure 51 Figure 52 Figure 53 De-Oiler in Bearing Compartment De-Oiler on Gearbox Oil Quantitiy Indiating Shematic Different Types of Quantity Transmitter Capacitance Type Transmitter Reed Switch Type Transmitter Oil Pressure Indication System Shematic Pressure Transmitter & Low Pressure Switch Location Different Location & Types of Temperature Sensor Spectrometric Oil Analysis Program Magnetic Chip Detectors Electronic Magnetic Chip Detectors Oil Quantity Check Oil Servicing by Cans Oil Servicing by Servicing Sytem Soap Sampling Magnetic Chip Detector Inspection Magnetic Chip Detector Installation 73 75 77 79 81 83 85 87 89 91 93 95 97 99 101 103 105 107 Page: cx