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Austro Engine AE50R Installation, Operation & Maintenance Manual

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Doc. No.
Revision
Date of Revision
The technical information contained in this document has been approved under the
authority of DOA No. EASA.21J.399 in conjunction with the Mandatory Design
Change MDC E1 - 116.
Affected Pages:
Instruction:
Austro Engine GmbH
Rudolf - Diesel – Straße 11
A – 2700 Wiener Neustadt
Austria
ENGINE MANUAL
Operation / Maintenance / Installation
AE50RAB
: E1.01.01 – E
: 6
: 10 March 2011
Chapter
all
- Replace the affected pages of the original manual with the
pages contained in this revision.
AE50R
AE50RA
Page
all

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Summary of Contents for Austro Engine AE50R

  • Page 1 Change MDC E1 - 116. Affected Pages: Chapter Page Instruction: - Replace the affected pages of the original manual with the pages contained in this revision. Austro Engine GmbH Rudolf - Diesel – Straße 11 A – 2700 Wiener Neustadt Austria...
  • Page 2 Engine Manual AE50RAB FOREWORD We congratulate you on the acquisition of your new Austro Engine AE50R. Skillful operation of the engine increases both safety and the enjoyment of flying. Please take the time therefore, to familiarize yourself with your new AE50R.
  • Page 3 It is the responsibility of the operator to ensure that this manual is maintained to a current status. If you move, or the ownership of the engine/aircraft changes, please complete the change of address card and send it to Austro Engine GmbH. Doc. No. E1.01.01-E Rev. 6...
  • Page 4 AE50R, AE50RA Engine Manual AE50RAB Rev. Reason Chapter Page(s) Date of Approval Date of Date In- Signature Revision Approval serted Editorial 5.2.3 changes 5.2.4 15-02-06 Part No 11.1 Correction Page numbering 8.1.5 8.5.4 9.5. 9.5.1 Editorial 9.5.2 10-04-06 Changes 9.5.3 13.5.5...
  • Page 5 AE50R, AE50RA Engine Manual AE50RAB All Diamond Logos changed to Austro Engine 10-03-11 Logo. specification changed Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 1-4...
  • Page 6 AE50R, AE50RA Engine Manual AE50RAB LIST OF EFFECTIVE PAGES Page Date Page Date 10-March-2011 17-1 10-March-2011 10-March-2011 17-2 10-March-2011 10-March-2011 18-1 10-March-2011 10-March-2011 18-2 10-March-2011 10-March-2011 18-3 10-March-2011 10-March-2011 18-4 10-March-2011 10-March-2011 18-5 10-March-2011 10-March-2011 18-6 10-March-2011 10-March-2011 18-7 10-March-2011...

  • Page 7: Table Of Contents

    AE50R, AE50RA Engine Manual AE50RAB TABLE OF CONTENTS Chapter INTRODUCTION (a non-approved chapter) ......................1 PREFACE (a non-approved chapter) ......................2 SAFETY INFORMATION (a non-approved chapter) ......................3 (RESERVED) (a non-approved chapter) ......................4 GENERAL ENGINE DATA (a non-approved chapter) ......................5 OPERATING DATA / LIMITATIONS (an approved chapter) .......................
  • Page 8 AE50R, AE50RA Engine Manual AE50RAB ENGINE INTERNAL INSPECTION (a non-approved chapter) ......................14 GROUND RUN (a non-approved chapter) ......................15 MAINTENANCE AND OVERHAUL (a non-approved chapter) ......................16 TROUBLE SHOOTING (a non-approved chapter) ......................17 NOTES FOR INSTALLERS OF ENGINES (a non-approved chapter) ......................

  • Page 9: Preface

    Every reasonable effort has been made to ensure that the information contained in this publication is correct when going to print. However, as Austro Engine GmbH policy is one of continuous improvement, the information given here may be superseded over a period of time by manual revisions or temporary by Service Bulletins.

  • Page 10: Safety Information

    Austro Engine personnel are always happy to answer queries or give advice on individual service problems. All queries to Austro Engine GmbH should be accompanied by details of the engine model and serial number, hours operated and any other relevant information.
  • Page 11 The use of parts not approved by Austro Engine GmbH may significantly affect the performance, reliability and life of the engine and may hazard the operator. WARNING! The use of parts not approved by Austro Engine GmbH may invalidate the Engine Certification.

  • Page 12: Reserved

    AE50R, AE50RA Engine Manual AE50RAB Reserved Intentionally left blank Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 4-1...

  • Page 13: General Engine Data

    AE50R, AE50RA Engine Manual AE50RAB GENERAL ENGINE DATA Description Wankel type rotary, single rotor, dual spark ignition, liquid cooled rotor housing, forced air cooled rotor, normal aspirated. 5.2. Technical data 5.2.1 Design Responsibility Austro Engine GmbH Rudolf – Diesel – Straße 11 A –...
  • Page 14 AE50R, AE50RA Engine Manual AE50RAB Eccentric Shaft Hardened and ground alloy steel. The complete rotating assembly is in full dynamic balance to minimise vibration, achieved by counter weighting each end of the assembly. Both the main and rotor bearings are rolling element types.
  • Page 15 AE50R, AE50RA Engine Manual AE50RAB 5.2.8 Pressure to Carburettor 0.276 bar (4 psi) 0.414 bar (6 psi) 5.2.9 Lubrication Lubrication of all bearings and rubbing surfaces is achieved via two lines from the oil metering unit driven off the water pump. The flow rate of the metering unit is calibrated and must not be adjusted.

  • Page 16: Operating Data / Limitations

    AE50R, AE50RA Engine Manual AE50RAB OPERATING DATA / LIMITATIONS: Static sea level ratings under the following conditions: - International Standard Atmospheric conditions at seal level - Generator functioning - Liquid coolant outlet temperature 65 °C (± 5 °C) - Standard induction pipe fitted with filter...
  • Page 17 AE50R, AE50RA Engine Manual AE50RAB 6.2.1 Power Curve Operating Limitations 6.3.1 Engine RPM Maximum for take–off (for 3 mins) 7 500 RPM Maximum Continuous 6 900 RPM Maximum Overspeed (20 sec. limit) 7 800 RPM Idle Minimum 1 750 RPM 6.3.2...
  • Page 18 AE50R, AE50RA Engine Manual AE50RAB 6.3.3 Liquid Coolant Temperature Limits Maximum for Take–off 90 °C Minimum for Take–off 60 °C Maximum continuous 100 °C 6.3.4 Rotor Cooling Air Outlet Temperature Limits Maximum for Take–off (3 minutes) 120 °C Maximum Continuous 110 °C...

  • Page 19: Components

    AE50R, AE50RA Engine Manual AE50RAB COMPONENTS Location of Components Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 7-1...
  • Page 20 AE50R, AE50RA Engine Manual AE50RAB Description of Components 7.1.1 Rear Assemblies These assemblies comprise of a back plate, with integral mounting lugs, water pump, alternator, speed sensors, rotor cooling air fan assembly, oil pump and starter motor. 7.1.2 Front Assemblies The front assemblies comprise of a water cooled end plate, temperature transmitter.
  • Page 21 AE50R, AE50RA Engine Manual AE50RAB DESCRIPTOPN OF SYSTEMS Ignition System 8.1.1 Supply The CDI Unit receive their supply via duplicated feeds from the aircraft bus bar (2 x 1 amps circuit breakers). 8.1.2 Triggering Two steps in the rim of the flywheel, nominally 180° apart, inductive fixed timing sensors.
  • Page 22 AE50R, AE50RA Engine Manual AE50RAB Fuel System 8.4.1 Fuel Pressure The fuel system requires clean fuel with a minimum fuel flow capability of 45 liters per hour at working pressure. Cooling System 8.5.1 Liquid Cooling System Coolant Circuit Items Doc. No. E1.01.01-E Rev.
  • Page 23 AE50R, AE50RA Engine Manual AE50RAB 8.5.2 Water Pump A water pump impeller, driven from the eccentric shaft via a tufnol drive coupling (a shear point) is mounted at the rear of the engine and circulates coolant through the engine casting and radiator.
  • Page 24 AE50R, AE50RA Engine Manual AE50RAB 8.5.8 Rotor Cooling Air Parts Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 8-4...

  • Page 25: Operating The Engine

    The settings, start and warm–up procedures for the first start of a newly installed engine are obviously to be treated with the greatest care. However, all engines supplied by Austro Engine GmbH will have been fully run–in and performance–tested prior to shipping.
  • Page 26 AE50R, AE50RA Engine Manual AE50RAB Engine Start down to Approximately -10 °C The engine will start equally well with either permitted fuels. Ground Tests (See 15.0) 9.3.1 Full Power Check Set WOT and note rpm achieved in relation to the minimum acceptable value as defined in the aircraft operating manual.
  • Page 27 AE50R, AE50RA Engine Manual AE50RAB Power Loss at Altitude Performance at altitude is degraded due to a reduction in air density. The approximate power available (at given RPM / throttle setting) is given in 6.1.1 for Sea Level. Doc. No. E1.01.01-E Rev.
  • Page 28 AE50R, AE50RA Engine Manual AE50RAB Storage General (installed engine). Proper steps must be taken, on engines used infrequently, to lessen the possibility of corrosion. This is especially true if the aircraft is based near the sea coast or in areas of high humidity.
  • Page 29 AE50R, AE50RA Engine Manual AE50RAB Blank off all open holes. To protect the outside of the engine, anti corrosion oils of well–known oil companies are recommended, such as: Anticorit 5 of Messrs FUCHS, D – 6600 Mannheim, Germany Lubrication Oil MTL – L – 644 B of MOBIL–OIL...

  • Page 30: Engine Emergency Procedures

    AE50R, AE50RA Engine Manual AE50RAB 10.0 ENGINE EMERGENCY PROCEDURES 10.1 Fan Belt Failure In the unlikely event of a fan belt failure, the indication will be a sudden rise in Rotor Cooling Air temperature. The engine load / RPM should be reduced as much as is practical to prevent further heat build up.

  • Page 31: Maintenance Notes

    R1A-09-000-801 Spark Plug (NGK) K&N Filter Oil Air Filter Oil R1A-30-000-801 Injector For further part replacement contact Austro Engine GmbH. 11.2 General Torque Settings Bolts / Socket Head Cap Screw 4 mm 2.0 Newton Metres (Nm) 5 mm 4.5 Nm 6 mm 8.5 Nm...
  • Page 32 AE50R, AE50RA Engine Manual AE50RAB 11.3 Checking & Setting Fan Belt Tension NOTE ! The silicon rubber tube and the tie wraps are left in place during the test. Slacken the three attachments numbered 1, 2 and 3 above. Attach a loop of suitable material around the fan outlet duct.

  • Page 33: Scheduled Maintenance

    AE50R, AE50RA Engine Manual AE50RAB 12.0 SCHEDULED MAINTENANCE 12.1 Maintenance Schedule ALL HOURS QUOTED ARE ENGINE HOURS ITEM a) Engine oil level / coolant level check aircraft manual b) Coolant leak check 13.4 c) Insp. / clean / replace air filters 13.5.4...
  • Page 34 AE50R, AE50RA Engine Manual AE50RAB 12.2 Typical 50 Hours Check NOTE ! Visual Checks Only unless stated! All Checks to include Fastenings, Cracking, Leaks, Discoloration and Wire Locking! ITEM CHECKS / COMMENTS Water Outlet Cover Leakage Water Hoses Security of all clips – leaks...
  • Page 35 AE50R, AE50RA Engine Manual AE50RAB Engine Alarms, Transducers and Signs of deterioration Cables Oil Tank and Vent Security – Leaks – Level - Connections Radiator and Overflow Tank Security – Damage – Leaks – Debris – Level Oil Separator Hoses...

  • Page 36: Cooling System

    AE50R, AE50RA Engine Manual AE50RAB 13.0 COOLING SYSTEM 13.1 Liquid Cooling System Coolant Level Check: Refer to Aircraft Manufacturer’s Instructions. In a fault free system, the coolant level will not alter significantly. Any unusual drop in the coolant level in the tank indicates a fault in the system that must be rectified before further flights.
  • Page 37 AE50R, AE50RA Engine Manual AE50RAB CAUTION ! If coolant temperature rises rapidly shut down the engine and bleed the system again! WARNING ! Risk of scalding – do not remove the pressure cap from the radiator until the engine and radiator have cooled.
  • Page 38 Care should be taken in withdrawing the assemblies due to the loose internal tufnol drive coupling! Fit the new Fan Belt (using Austro Engine GmbH “Fan Belt Kit”). Reassemble using the reverse procedure for items (2) to (5) inclusive, above, and tension the belt as in 11.3 Fig.
  • Page 39 Advice should be sought from Austro Engine GmbH on the significance of this material and the effect it may have on the engine. Either or both filters should be replaced if their condition is suspect.
  • Page 40 AE50R, AE50RA Engine Manual AE50RAB 13.5.5 Rotor Cooling Air Fan Impeller At the intervals stated in 12.1 the fan impeller should be inspected. The complete fan should be removed from the engine and the bearing housing assembly removed from the fan housing.

  • Page 41: Engine Internal Inspection

    Austro Engine GmbH should be consulted if this condition is found.
  • Page 42 AE50R, AE50RA Engine Manual AE50RAB CAUTION ! Fitting other types of spark plug may cause damage to the engine! NOTE ! Do not sand blast, or clean with steel or brass wire brush, or use abrasive materials! If due to local conditions, the plug connections become corroded then the corrosion may be removed from the plug nipple with a wire brush and the inside of the plug cap cleaned with a dry cloth or paper wiper.

  • Page 43: Ground Run

    AE50R, AE50RA Engine Manual AE50RAB 15.0 GROUND RUN 15.1 Pre–start Checks Outside Aircraft Position aircraft into wind Brakes fully on and wheels chocked Check fuel drains, (no water) Check coolant level at overflow tank Check oil tank level Check fuel level 15.2 Pre –...
  • Page 44 AE50R, AE50RA Engine Manual AE50RAB 15.4 Ground Run Check List (example) ENGINE GROUND RUND RESULTS Date:……………….. A/C Reg……………….. Engine No……………….. Flight Hours……………….. Total Running Time (hrs meter)……………….. QFE……………….. Outside Air Temperature……………….. Instrumentation – Gauge / Alarm Function Test Pressure Temperature...

  • Page 45: Maintenance And Overhaul

    AE50R, AE50RA Engine Manual AE50RAB 16.0 MAINTENANCE AND OVERHAUL For maintenance of particular system or for overhauling the engine please contact Austro Engine GmbH or engine installer. Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 16-1...

  • Page 46: Trouble Shooting

    AE50R, AE50RA Engine Manual AE50RAB 17.0 TROUBLE SHOOTING 17.1 General NOTE ! This section is included as an aid although some items may be carried out by the owner / pilot, most would be carried out by a maintenance organisation.
  • Page 47 Replace assembly Stuck side seal(s) Investigate outlet for black carbon deposits If found please contact Austro Engine GmbH. Investigate possible exhaust leakage within the engine bay area. 17.6 Liquid Coolant Overheats on Medium and High Power Restricted radiator core...

  • Page 48: Notes For Installers Of Engines

    AE50R, AE50RA Engine Manual AE50RAB 18.0 NOTES FOR INSTALLERS OF ENGINES Section Page 18.1 General Notes 18.2 Engine Overall Dimensions 18.3 Cooling System 18.4 Fuel System 18.5 Procedure for Setting Carburettor 18.6 Oil System 18.7 Electrical System 18.8 Ignitions System 18.9...

  • Page 50: Engine Overall Dimensions

    AE50R, AE50RA Engine Manual AE50RAB 18.2 Engine Overall Dimensions Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 18-3...

  • Page 51: Cooling System

    AE50R, AE50RA Engine Manual AE50RAB 18.3 Cooling System 18.3.1 General Arrangement must be made by the engine installer to carry the rotor cooling air out from the front plate elbow, if fitted, to the oil separator or to some suitable mean of the removing the oil entrained in the cooling air before allowing it to vent overboard.
  • Page 52 AE50R, AE50RA Engine Manual AE50RAB CAUTION ! Radiator. The optimum radiator design will vary with each installation. It is the responsibility of the installer to provide an adequate cooling system and thus ensure that the maximum recommended coolant temperature is never exceeded even under the most adverse operation conditions.
  • Page 53 AE50R, AE50RA Engine Manual AE50RAB 18.3.4 Cooling Circuit Schematic Typical Cooling Circuit Fig. 10 Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 18-6...

  • Page 54: Fuel System

    18.4.3 Fuel filters No fuel filters are provided by Austro Engine GmbH. Therefore a filter of 40 microns or better with a flow capacity of least 50 liters per hour at 0.1 bar pressure drop must be fitted in the fuel delivery line after the pumps.

  • Page 55: Procedure For Setting Carburettor

    AE50R, AE50RA Engine Manual AE50RAB 18.4.6 Fuel Lines Fuel lines must be routed away and protected from hot engine and exhaust components. Fuel line should be of sufficient quality and appropriate to the pressures transmitted. Fuel hose end connections must be of threaded taper seat type and should be permanently swaged to the hoses.
  • Page 56 The aircraft manufacturer’s required idle speed should then be set with the engine warm. If one has not been supplied then Austro Engine GmbH recommend 2250 rpm (with a minimum of 1750 rpm) if necessary, adjust the idle stop screw to achieve the appropriate speed.

  • Page 57: Oil System

    AE50R, AE50RA Engine Manual AE50RAB 18.5.3 Setting the ‘H’ Screw Slowly increase the throttle to the WOT position. The maximum engine speed should be as stated in the aircraft manufacturer’s handbook. If no flowmeters are fitted, reduce the fuel flow from the high-speed system until the engine just begins to falter.

  • Page 58: Electrical System

    18.7 Electrical System The installation of the electric system and the Flytronic Engine Management System should be done in accordance with Austro Engine GmbH drawings. Please contact Austro Engine GmbH therefore. No electrical circuit protection is provided by Austro Engine GmbH.
  • Page 59 18.7.1 Voltage regulator wiring NOTE ! Circuit diagram refers to Austro Engine GmbH (part number E_R2 B 014) plug type CDI boxes. Coil wires at terminal C ignition box 1 and coil wire B at ignition box 2 have no connection.
  • Page 60 18.7.2 Suggested Circuit Protection (Two wire alternator) NOTE ! Austro Engine GmbH provide NO circuit protection. Diode A protects bus bar from short in the generator side. Breaker A is isolator for generator and protects bus bar from regulator failure.
  • Page 61 AE50R, AE50RA Engine Manual AE50RAB CAUTION ! Capacitor 22,000 F must be fitted. Failure to fit will result in damage. NOTE ! Temperature limits -30 °C to +65 °C (outer surface) and adequate cooling must be arranged. Doc. No. E1.01.0-E Rev.

  • Page 62: Ignitions System

    18.8. Ignition 18.8.1 CDI units Part Number E_R2 B 014 NOTE ! Circuit Diagram refers to Austro Engine GmbH part number R1B006/R1B007 flying lead type CDI boxes. Coil wires at terminal C ignition box 1 and coil wire B at ignition box 2 have no connection.
  • Page 63 AE50R, AE50RA Engine Manual AE50RAB 18.8.2 Connection Plug Wiring Ignition CDI control E_R2 B 014 connection plug wiring Terminal G and D are linked and have no connection to the PCB Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 18-16...
  • Page 64 AE50R, AE50RA Engine Manual AE50RAB 18.8.3 Ignition CDI Part No R1 B 006 / R1 B 007 Circuit Diagram refers to Austro Engine GmbH Part No R1 B 006 / R1 B 007 flying lead boxes. Doc. No. E1.01.0-E Rev. 6...

  • Page 65: Engine Mounting

    Exhaust design and fitting remains the responsibility of the aircraft manufacturer / engine installer. Limitations must be regarded. 18.11 Air Filters Supplied by Austro Engine GmbH as part of design. For other air filters Austro Engine GmbH must be consulted. 18.12 Drive interface The output shaft is parallel, fitted with a woodruff key for load transmission.

  • Page 66: Form Sheets

    AE50R, AE50RA Engine Manual AE50RAB 19.0 FORM SHEETS Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 19-1...
  • Page 67 Rudolf -Diesel – Straße 11 A – 2700 Wiener Neustadt Austria Tel: +43 – 2622 – 23 000 Fax: +43 – 2622 – 23 000 Internet: www.austroengine.at Engine Manual AE50R – AB NOTIFICATION OF RECEIPT Copy Number:……………………. Signature:…………………….. Date:………………………………. Name:……………………………………………………………………………………… On behalf of:……………………………………………………………………………….
  • Page 68 AE50R, AE50RA Engine Manual AE50RAB 19.2 Problem Report Austro Engine GmbH Rudolf – Diesel – Straße 11 A – 2700 Wiener Neustadt Austria Tel: +43 – 2622 – 23000 Fax: +43 – 2622 – 23000 2711 Internet: www.austroengine.at PROBLEM REPORT...

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