Catastrophic engine failure

[Michael Danielle]

'Hi Folks,

My '29 Great Lakes replica is powered by a 200hp Ranger. On 23 May
while at a cruise setting of 1950rpm, the No.6 connecting rod
broke. I have posted a new photo folder (Engine Destruction) to
show the folks here the results of the incident.

I was able to land in a hayfield without further incident.

I am the third owner of this aircraft and the engine has only about
80 hours on the clock. The engine was certified when installed (per
the FAA) but I have no history on the overhauler.

My best guess is that somewhere, sometime in it's past, the engine
was started with a minor hydraulic lock in the No. 6 cylinder which
bent the rod slightly. The damaged rod continued to degrade until
it gave up the ghost with the pictured results.

Guys, it's imperative to pull your Ranger's through all cylinders
before EVERY start (Warners too). If one jug is tight, STOP. Pull
it through in reverse to dump the oil into the intake or pull the
plug. My practice is to pull the engine through even if I'm only
shutdown for a 15 minute refuel. You only have to do this kind of
damage once to get a chance to test your off-field landing skills.

Fly safe,
Mike in Oregon'

[Tom Mueller]

'JESUS what a mess!! You must be applauded however, for your apparent
superior flying skills... Thanks for posting, and your advice is well
taken.
Tom
Hanford, Ca'

[danMichael]

'Mike:

Im glad you wallked away from this one. Thanks for posting the
pictures. Good luck with the rebuild or replacement.

> Guys, it's imperative to pull your Ranger's through all cylinders
> before EVERY start (Warners too). If one jug is tight, STOP. Pull
> it through in reverse to dump the oil into the intake or pull the
> plug.

I was taught that if you encounter hydraulic lock, you must pull the
spark plug to drain the trapped oil. If you reverse rotation to drain
the oil into the intake runner, a slug of oil could be drawn back into
the cylinder on engine start and cause damage. In fact, for this
reason, you should never turn the prop backwards, because it could
result in a latent hydraulic lock.

My own experience is that I never get oil in the cylinders if I dont
reposition the prop after shutting down. If I reposition the prop, I
do sometimes get oil draining out an exhaust stack.

Im not an expert, but I try to learn from them.

Good luck,

:Daniel Michael (your anti-namesake)
:NC81323'

[Jan Servaites]

'Did the rod break near the wrist pin area? It looks like a clean break
right across the I-beam. Do you think that just the power of the starter
against the hydraulic lock could bend a rod? I would think not unless
one of the cylinders fired?

--
Jan Servaites (Dayton OH - The Birthplace of Aviation)'

[danMichael]

'On Sunday, May 29, 2005, at 03:24 PM, Jan Servaites wrote:

> Do you think that just the power of the starter against the hydraulic
> lock could bend a rod? I would think not unless
> one of the cylinders fired?

The starter has a clutch that is supposed to prevent damage if a
cylinder locks. On the Eclipse E-80 the clutch is adjustable. I dont
remember the spec, but I think it is around 200 lb-ft for the Ranger.

On large radials where its impractical to clear the engine by hand,
they rely on the starter clutch. Normal starting procedure is to crank
the engine and count the requisite number of blades before turning on
the ignition.

:Dan
:NC81323'

[Jan Servaites]

'danMichael wrote:

> Normal starting procedure is to crank
> the engine and count the requisite number of blades before turning on
> the ignition.

I never thought of that. If you have watch the movie "Strategic Air
Command", the ground crew was counting the revs to the flight engineer
when they are starting a "Corn Cob" on the B36. I never understood why
until now....Thanks Dan

--
Jan Servaites (Dayton OH - The Birthplace of Aviation)'

[Mike Danielle]

'The break was just where it shows in the photo. I believe the starter
clutch would have slipped if it had encountered the lock. The problem
probably started with any other cylinder firing first. This is all just
conjecture, though. It could have just been a microscopic crack or flaw in
the rod casting. I'll probably never know.

Mike

----- Original Message -----
From: "Jan Servaites"
To:
Sent: Sunday, May 29, 2005 1:24 PM
Subject: Re: [fairchildclub] Catastrophic engine failure


> Did the rod break near the wrist pin area? It looks like a clean break
> right across the I-beam. Do you think that just the power of the starter
> against the hydraulic lock could bend a rod? I would think not unless
> one of the cylinders fired?
>
> --
> Jan Servaites (Dayton OH - The Birthplace of Aviation)
>
>
>
>
>
>
>
>
> Yahoo! Groups Links
>
>
>
>
>

'

[Mike Danielle]

'The E-80 Eclipse starter clutch is set for 285# for the Ranger. You are
correct about radials. I flew C-47's in 'Nam. Our procedure was to turn
the engine and count blades - 18, I believe - then turn on the mags. This
might not be a bad procedure with the Ranger. Don't know why the Ranger ops
manual doesn't call for it.

----- Original Message -----
From: "danMichael"
To:
Sent: Sunday, May 29, 2005 1:20 PM
Subject: Re: [fairchildclub] Catastrophic engine failure


> On Sunday, May 29, 2005, at 03:24 PM, Jan Servaites wrote:
>
> > Do you think that just the power of the starter against the hydraulic
> > lock could bend a rod? I would think not unless
> > one of the cylinders fired?
>
> The starter has a clutch that is supposed to prevent damage if a
> cylinder locks. On the Eclipse E-80 the clutch is adjustable. I dont
> remember the spec, but I think it is around 200 lb-ft for the Ranger.
>
> On large radials where its impractical to clear the engine by hand,
> they rely on the starter clutch. Normal starting procedure is to crank
> the engine and count the requisite number of blades before turning on
> the ignition.
>
> :Dan
> :NC81323
>
>
>
>
>
> Yahoo! Groups Links
>
>
>
>
>
>

'

[Tom Mueller]

'My Fairchild Instruction handbook produced by the Fairchild
Service Division states in the operating instructions section "Place
ignition switch on "BAT" and pull out the starter button to engage the
electric starter. When the electric starter has gained proper momentum
turn the ignition switch to "L" After the engine has caught and is
running smoothly, the ignition switch should be turned to "BOTH"

I never used the procedure because I felt it complicated the start
process, and left the door open to forgetting to put the mag in "BOTH"
after starting. Needless to say I'm rethinking my starting procedure.

Tom
Hanford, Ca.'

[John Amundsen]

'I follow the procedure in the Fairchild manual to spin the engine over with the mags off until enough momentum is gained and then switch to the left mag. I thne switch to both. I have forgotten to switch to both, but catch it on my engine runup. I pull the engine through before trying to start the engine.

----- Original Message -----
From: Mike Danielle
To: fairchildclub@yahoogroups.com
Sent: Sunday, May 29, 2005 4:39 PM
Subject: Re: [fairchildclub] Catastrophic engine failure


The E-80 Eclipse starter clutch is set for 285# for the Ranger. You are
correct about radials. I flew C-47's in 'Nam. Our procedure was to turn
the engine and count blades - 18, I believe - then turn on the mags. This
might not be a bad procedure with the Ranger. Don't know why the Ranger ops
manual doesn't call for it.
----- Original Message -----
From: "danMichael"
To:
Sent: Sunday, May 29, 2005 1:20 PM
Subject: Re: [fairchildclub] Catastrophic engine failure


> On Sunday, May 29, 2005, at 03:24 PM, Jan Servaites wrote:
>
> > Do you think that just the power of the starter against the hydraulic
> > lock could bend a rod? I would think not unless
> > one of the cylinders fired?
>
> The starter has a clutch that is supposed to prevent damage if a
> cylinder locks. On the Eclipse E-80 the clutch is adjustable. I dont
> remember the spec, but I think it is around 200 lb-ft for the Ranger.
>
> On large radials where its impractical to clear the engine by hand,
> they rely on the starter clutch. Normal starting procedure is to crank
> the engine and count the requisite number of blades before turning on
> the ignition.
>
> :Dan
> :NC81323
>
>
>
>
>
> Yahoo! Groups Links
>
>
>
>
>
>



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