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Austro Engine E4 Series Maintenance Manual

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  • Page 2 Maintenance Manual E4.08.04 – Intentionally left blank – Issue date: 14-Apr-2015 Revision no: 25 Page: Intro-1...
  • Page 3 Maintenance Manual E4.08.04 Maintenance Manual E4 Date: Wiener Neustadt, 14.Dec.2015 Author: Austro Engine GmbH Rudolf – Diesel – Straße - 11 A-2700 Wiener Neustadt Document number: E4.08.04 Revision: 26 Issue date: 14-Dec-2015 Revision no: 26 Page: Intro-2...

  • Page 4: Introduction

    It is the responsibility of the installer to ensure that this manual is maintained to a current status. If the address or the ownership of the engine/aircraft changes, an address card has to be sent to Austro Engine GmbH. Issue date: 24-Oct-2014...

  • Page 5: List Of Revision

    Maintenance Manual E4.08.04 List of Revision Rev. Reason Chapter Page(s) Date of Approval Date of Date Signatur Revision Approval Inserted Authority 07.May. remarks DOA *) 2009 updated Intro 2,4,5,6,7, 10,11,12, 13,14 1,2,3,4 1,2,3,4,5, 1,2,3,4,5, 1,2,4,5 1,2,3,4,5, 6,7,8,9 Authority 1,2,3,4 09.Sep. remarks DOA *) 2009...
  • Page 6 Maintenance Manual E4.08.04 Rev. Reason Chapter Page(s) Date of Approval Date of Date Signatur Revision Approval Inserted 1-5,7-9, MDC-E4- 11,13,14 04.May. DOA *) 16-18, 2010 20-22, 1-10 Last page Intro 2,5,6,7,8, 12-16 4,8,9 MDC-E4- 27.Jan. DOA *) 2011 MDC-E4- Intro 2,5,6 08.Mar.
  • Page 7 Maintenance Manual E4.08.04 Rev. Reason Chapter Page(s) Date of Approval Date of Date Signatur Revision Approval Inserted 16-20 DOA *) 1,3,4, 7-11,13, 16, 19-24 Intro 2, 6-9,15 MDC-E4- 27.Feb. DOA *) 2012 Intro 2, 6-9, 16-21 MDC-E4- 10.Apr. 12.Apr. EASA 2012 2012 Intro...
  • Page 8 Maintenance Manual E4.08.04 Rev. Reason Chapter Page(s) Date of Approval Date of Date Signatur Revision Approval Inserted Intro 2,7-22 MDC-E4- 06.Sep. 23.Sep.201 2-10 EASA 2013 Intro 2,7-10 MDC-E4- 318 and 20-26, 19.Nov. DOA *) MDC-E4- 29-31, 2013 238c 33,35,36, 38-40, 42-44 Intro 2,7-10,...

  • Page 9: List Of Incorporated Temporary Revisions

    Maintenance Manual E4.08.04 List of incorporated Temporary Revisions Temporary Revision Number Title of Temporary Revision MM-TR-MDC-E4-309b Oil baffle panel installation Injector cover with maintenance lid & MM-TR-MDC-E4-314b change of breather hose oil separator MM-TR-MDC-E4-317 LETRIKA Alternator MM-TR-MDC-E4-325d Exchange of timing chain MM-TR-MDC-E4-326a Mounting Instructions Engine Harness MM-TR-MDC-E4-331...

  • Page 10: List Of Valid Pages

    Maintenance Manual E4.08.04 14.Apr.2015 19.Jan.2012 List of Valid Pages 14.Apr.2015 19.Jan.2012 Chapter Page Revision Date 19.Jan.2012 14.Apr.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 24.Oct.2014 24.Oct.2014 05.Dec.2012 14.Apr.2015 05.Dec.2012 14.Apr.2015 28.May.2013 14.Apr.2015 14.Dec.2015 24.Oct.2014 14.Apr.2015 14.Apr.2015 14.Dec.2015 14.Dec.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 24.Oct.2014 14.Apr.2015 24.Oct.2014...
  • Page 11 Maintenance Manual E4.08.04 27.Jan.2011 11-Aug-2011 05.Sep.2012 14-Dec-2015 12-00-00 24.Oct.2014 14.Apr.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Dec.2015 14.Apr.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Dec.2015 14.Apr.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Dec.2015 14.Apr.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015...
  • Page 12 Maintenance Manual E4.08.04 14.Apr.2015 27.Feb.2012 14.Apr.2015 19.Jan.2012 14.Apr.2015 19.Jan.2012 14.Apr.2015 19.Jan.2012 14.Apr.2015 19.Nov.2013 14.Apr.2015 19.Jan.2012 14.Apr.2015 19.Jan.2012 14.Apr.2015 27.Jan.2011 14.Apr.2015 19.Jan.2012 14.Dec.2015 14.Apr.2015 14.Apr.2015 05.Sep.2012 14.Apr.2015 19.Jan.2012 14.Apr.2015 14.Dec.2015 14.Apr.2015 27.Jan.2011 80-00-00 14.Apr.2015 27.Jan.2011 14.Apr.2015 14.Apr.2015 14.Apr.2015 27.Feb.2012 14.Apr.2015 27.Feb.2012 10.Apr.2012 10.Jul.2012 10.Apr.2012...
  • Page 13 Maintenance Manual E4.08.04 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Dec.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Dec.2015 14.Apr.2015 14.Apr.2015 14.Apr.2015 14.Dec.2015 15.11.2011 14.Dec.2015 15.11.2011 14.Dec.2015 15.11.2011 14.Dec.2015...

  • Page 14: List Of Abbreviation

    Maintenance Manual E4.08.04 List of Abbreviation Austro Engine BATT Battery Boost Pressure Actuator BPS1 Boost Pressure Sensor 1 BPS2 Boost Pressure Sensor 2 Computer Aided Design Controller Area Network CAS 1 Camshaft Sensor 1 CAS 2 Camshaft Sensor 2 Counter-Clockwise...
  • Page 15 Maintenance Manual E4.08.04 Oil Combinant Sensor Temperature Optional Design Change Advisory Oil Pressure Sensor Pressure Control Valve Revolutions Per Minute Rail Pressure Sensor Service Bulletin Service Letter Soft Ware Type Design Definition Turbo Charger Torsional Vibration Damper Ubatt Battery Voltage Issue date: 24-Oct-2014 Revision no: 24 Page: Intro-14...

  • Page 16: Conversion Table Of Given Torque Values

    Maintenance Manual E4.08.04 Conversion Table of Given Torque Values Newton Meter (Nm) Pound-force inch (lbf in) Issue date: 24-Oct-2014 Revision no: 24 Page: Intro-15...

  • Page 17: Conversion Table Of Given Pressure Values

    Maintenance Manual E4.08.04 Conversion Table of Given Pressure Values Pressure Pressure Pressure [bar] [psi] [lbf/ft²] 1044 2089 3133 4177 5221 6266 7310 8354 9398 10443 11487 12531 13576 14620 15664 16708 17753 18797 19841 10,0 20885 Issue date: 24-Oct-2014 Revision no: 24 Page: Intro-16...

  • Page 18: Consumable List

    For applicability refer to the relevant Safety Wire safety wire. chapters of this manual. Wire thickness 0.81 mm Please contact the Austro Engine GmbH customer support under service@austroengine.at +43 (0) 2622 23000 2525 in case of material availability. Issue date: 24-Oct-2014 Revision no: 24...

  • Page 19: Table Of Contents

    Maintenance Manual E4.08.04 Contents Introduction List of Revision List of incorporated Temporary Revisions ..................8 List of Valid Pages List of Abbreviation Conversion Table of Given Torque Values ..................15 Conversion Table of Given Pressure Values ..................16 Consumable List Contents ............................18 Chapter 01-00-00 General ......................1 01-10-00...
  • Page 20 Maintenance Manual E4.08.04 05-20-14 Fuel Filter ......................7 05-20-15 Waste Gate Controller .................... 7 05-20-16 Exhaust System ..................... 7 05-20-17 Coolant ......................... 7 05-20-18 Cooling System ..................... 8 05-20-19 Breather Line ......................8 05-20-20 Zonal Inspection ....................8 05-20-21 Injector Cover ....................... 8 05-20-22 Timing Chain ......................
  • Page 21 Maintenance Manual E4.08.04 24-31-33 Visual Inspection of Alternator Housing and Pulley ..........22 24-31-34 Inspection of Contact Ring and Brushes ..............23 24-31-35 Disassembly of ASSY Brush Holder ................24 24-31-36 Measuring the Length of Carbon Brushes ...............25 24-31-37 Evaluation Criteria ....................26 24-31-38 Completion of Alternator (Installation of Brush Holder ASSY) ........27 24-31-40 Functionality Check ....................30...
  • Page 22 Maintenance Manual E4.08.04 71-50-805 Exchange of Connector for Alternator E4A-91-000-000 ...........57 71-50-806 Exchange of Connector to Fuel Metering Unit (FMU) ..........60 71-50-900 Repair of the Engine Wiring Harness E4A-95-000-000 und E4B-95-000-000 .....64 71-50-901 Exchange of Connector of Gearbox Temperature Sensor (GBTS), Fuel Temperature Sensor (FTS), Coolant Temperature Sensor (CTS) and Glow Plug Coolant Temperature Sensor (CTS_GPC).
  • Page 23 Maintenance Manual E4.08.04 78-00-12 Installation of the Exhaust Manifold ................ 1 78-00-20 Exhaust Manifold Gasket Exchange ................. 2 Chapter 79-00-00 Engine Oil ......................1 79-00-01 General ......................... 1 79-00-10 Oil-Filter Housing Draining Line ................1 79-00-11 Removal of the Oil-Filter Housing drain line ............. 1 79-00-12 Installation of the Oil-Filter Housing drain line ............
  • Page 24 Maintenance Manual E4.08.04 Chapter 81-00-00 Turbocharging ....................1 81-00-01 General ......................... 1 81-00-10 Turbo Charger Complete ..................1 81-00-11 Removal of the Turbo Charger ................1 81-00-12 Installation of the Turbo Charger ................1 81-00-13 Removal of the Waste Gate Controller ..............1 81-00-14 Install new Waste Gate Controller ................
  • Page 25 Maintenance Manual E4.08.04 85-20-11 Removal of the Crankshaft Cover ................39 85-20-12 Installation of the Crankshaft Cover ...............39 85-30-00 Reciprocating Engine Cylinder Section ..............41 85-30-10 Intake Air......................41 85-30-11 Removal of the Intake Air Manifold ................41 85-30-12 Installation of the Intake Air Manifold ..............41 85-30-13 Removal of the Air Intake Manifold (if optional Gearbox Oil Cooler installed) ....42 85-30-14...
  • Page 26 Maintenance Manual E4.08.04 85-40-45 Assembly of engine after timing chain check ............74 85-40-50 Exposure of timing chain and camshaft chain wheel ..........75 85-40-51 Exchange of timing chain ..................77 85-40-52 Replacing of timing chain wheel ................83 85-40-53 Check of engine timing ..................85 85-40-54 Reassembly of engine ...................86 85-70-00...

  • Page 27: General

    Maintenance Manual E4.08.04 Chapter 01-00-00 General This Maintenance Manual contains all instructions necessary for continued airworthiness. In addition this Maintenance Manual contains repair procedures for certain engine components, which are detailed in a separate section of the chapter related to the engine component. The engine installation instructions for the engine are given in the engine Installation Manual E4.02.01.

  • Page 28: General Engine Description

    Maintenance Manual E4.08.04 01-10-00 General Engine Description Type Designation: TC-Designation: Models: (Sales Name AE300) (Sales Name AE330) For detailed information about available configurations refer to MSB E4-002 in its latest revision. If not otherwise stated this manual is applicable to all available configurations. Brief Description: The engine is a liquid-cooled, in-line four-stroke four cylinder engine with a double overhead camshaft (DOHC).
  • Page 29 Maintenance Manual E4.08.04 Scope of Supply: The following components and assemblies are included as part in the Type Design of the E4 engine series:  Core engine  Turbocharger  Thermostat  Water Pump  Fuel injection system  Starter ...
  • Page 30 Maintenance Manual E4.08.04 Engine Front View: Fig. 01 - 1 Engine Front View Issue date: 19-Jan-2012 Revision no: 11 Page: 01-4...
  • Page 31 Maintenance Manual E4.08.04 Engine Top View: Fig. 01 - 2 Engine Top View Issue date: 19-Jan-2012 Revision no: 11 Page: 01-5...
  • Page 32 Maintenance Manual E4.08.04 Engine Left Side View: Fig. 01 - 3 Engine Left Side View Issue date: 19-Jan-2012 Revision no: 11 Page: 01-6...
  • Page 33 Maintenance Manual E4.08.04 Engine Right Side View: Fig. 01 - 4 Engine Right Side View Issue date: 19-Jan-2012 Revision no: 11 Page: 01-7...
  • Page 34 Maintenance Manual E4.08.04 Engine Top View with removed Injector Cover: Fig. 01 - 5 Detailed Top View with removed Injector Cover Issue date: 19-Jan-2012 Revision no: 11 Page: 01-8...
  • Page 35 Maintenance Manual E4.08.04 Dimensions: Bore: 83 mm (3.268 in) Stroke: 92 mm (3.622 in) Cylinder spacing (center to center): 90 mm (3.543 in) Displacement total: 1991 cm³ (121,5 in³) Displacement (per cylinder): 498 cm³ (30,4 in³) Compression ratio: 17.5:1 Gearbox ratio: 1,69 Weight (dry): 185 kg...
  • Page 36 Maintenance Manual E4.08.04 Gearbox: The AE300 is equipped with a gearbox to reduce RPM from the 3880 RPM maximum of the engine to 2300 RPM at the propeller. The reduction ratio of the gearbox is 1.69:1. The figure shows the gearbox case and the gearbox case cape of the disassembled gearbox.
  • Page 37 Maintenance Manual E4.08.04 Torsion Vibration Damper (TVD) Between gearbox and crankshaft a torsion vibration damper is implemented to reduce torsion vibration. On one hand the crankshaft is protected from vibrations coming from the propeller, on the other hand the gearbox is protect from vibrations coming from the crankshaft and the combustion process.
  • Page 38 Maintenance Manual E4.08.04 Crank Case The AE300 Crankcase is a single piece, squeeze casted part. Based on this design ( cast iron) separate cylinder liners are not necessary. The cast iron design of the crank case has good failsafe running functions and also a reduced noise emission. The design of the AE300 is an inline, liquid cooled engine, the crankcase incorporates the cylinders as well as the coolant passages.

  • Page 39: Intake/Exhaust System Description

    Maintenance Manual E4.08.04 01-10-10 Intake/Exhaust System Description General: For operation the engine has to be supplied by the intake system with compressed air at manifold pressures up to 2660 mbar (38,57 psi), which varies with altitude and power setting. The increased manifold pressure is accomplished with an exhaust driven turbo charger.
  • Page 40 Maintenance Manual E4.08.04 Components of the A/C System: (For installation and maintenance details refer to the applicable Aircraft Maintenance Manual)  Air filter  Intercooler  Hoses  Alternate Air intake if required Part of the engine TDD:  Turbocharger ...

  • Page 41: Fuel System Description

    Maintenance Manual E4.08.04 01-10-20 Fuel System Description General: The AE 300 is equipped with a common rail fuel injection system. In such a system the common rail is a high-pressure fuel reservoir that supplies fuel to solenoid type injectors. Fuel enters the common rail directly from the high-pressure pump which compresses the fuel up to 1600 bar.
  • Page 42 Maintenance Manual E4.08.04 Components of the A/C System: (For installation and maintenance details refer to the applicable Aircraft Maintenance Manual)  Feed pump  Fuel feed line  Fuel filter  Fuel return line  Fuel shut off valve  Fuel pulsation damper ...
  • Page 43 Maintenance Manual E4.08.04 Fuel Distribution System: There must be a shut-off valve on the feed line. In case of an emergency it must be possible for the pilot to shut of the fuel flow. In the return line a provision must be provided to cut off fuel flowing back to engine in case of an engine fire (e.g.

  • Page 44: Exhaust System Description

    Maintenance Manual E4.08.04 01-10-30 Exhaust System Description General: The exhaust system is necessary to release the exhaust fumes in a safe and proper way into the environment. Wrong installation and maintenance can lead to vibrations, which can cause serious damage in the exhaust system. Excessive tension at exhaust system mounting points could cause cracks and be a potential fire hazard.
  • Page 45 Maintenance Manual E4.08.04 Components of the A/C System: (For installation and maintenance details refer to the applicable Aircraft Maintenance Manual)  Coolant radiator  Cabin Air Heat Exchanger  Coolant expansion Tank  Overpressure Valve  Low pressure Valve  Silica Reservoir ...
  • Page 46 Maintenance Manual E4.08.04 Thermostat Opening Temperature: Small Cooling Circuit without Radiator: <80 °C (<176 °F) Mixed Operation: 80 °C – 95 °C (176 °F – 203°F) Radiator Through-Flow >95 °C (>203°F) To prevent the system from to much coolant flowing through the vent line an orifice is installed with an inner diameter of 2 mm (0.079 in) within the line between expansion tank and radiator.

  • Page 47: Lubricating System Description

    Maintenance Manual E4.08.04 01-10-50 Lubricating System Description General: The lubricating system of the AE300 consists of an internal chain driven oil pump, which pumps the engine oil through the oil filter, the coolant/oil heat exchanger and the lubrication ports of the engine. The lubricating system is part of the engine.

  • Page 48: Electrical System Description

    Maintenance Manual E4.08.04 01-10-60 Electrical System Description The Electrical System consists of the following major Components: Starter – Generator – GPC – Glow Plug Control Unit – EECU – Electronic Engine Control Unit – Sensors & Actuators – The EECS Block Diagram shows the connection between the EECS components which are used in the AE 300 Engine and displays also the Interface from the Airframe to the EECS of the AE 300.
  • Page 49 Maintenance Manual E4.08.04 The starter is manually controlled by the pilot. The EECU will detect a running engine at 600rpm (Propeller) and further activation is not necessary. The Generator is a 28V/70A power supply which consists of an alternator mounted to the engine and an external regulator.
  • Page 50 Maintenance Manual E4.08.04 EECU Functions Sensors and Actuators Sensors ECU A Camshaft Sensor EECU Crankshaft Sensor Intake Air Temperature Sensor Boost Pressure Sensor Power Lever Sensor Actuators ECU A Shared Sensors Injectors (4) Gearbox Temperature Sensor Boost Pressure Acutator Oil Temperature Sensor Rail Pressure Relay Fuel Pressure Sensor...
  • Page 51 Maintenance Manual E4.08.04 Sensors Power Lever Sensor Power Lever Sensor position evaluation Hall Effect Sensor with dual output Crank Shaft Sensor Engine speed evaluation Cam Shaft Sensor Engine position evaluation Fuel Pressure Sensor Used for evaluation of the fuel pressure after the pre-supply pump Oil Pressure Sensor Used for evaluation of the engine oil pressure Rail Pressure Sensor...
  • Page 52 Maintenance Manual E4.08.04 EECU Power Supply ECU A ECU A Sensors ECU A Relay Shared Sensors Voter Actuators Matrix Sensors ECU B ECU B Power Supply ECU B 3way Cockpit Engine Switch Power Indications / Sensor A Sensor B Lever Auto Annunciations ECU A...
  • Page 53 Maintenance Manual E4.08.04  Failure monitoring / Fault Code Memory Reported Failures are stored in the Fault Code Memory   Up to 20 entries Can lead in an ECU switch over  Can activate the ECU caution  Can cause a substitute function (e.g. substitute value) ...
  • Page 54 Maintenance Manual E4.08.04 Engine Speed and Power Regulation The desired propeller speed set point is calculated depending on the power lever sensor position. The current engine speed is used to compute the deviation of the actual propeller speed from the set point.
  • Page 55 Maintenance Manual E4.08.04 Fig. 01 - 18 EECU and Governor Issue date: 14-Apr-2015 Revision no: 25 Page: 01-29...
  • Page 56 Maintenance Manual E4.08.04 Propeller Self Test (Automatic Run-Up Test) Description: The propeller governor self test has been designed to emulate the manual run-up test performed by the pilot of an aircraft equipped with a conventional (mechanical) propeller control lever. With the single power lever installation of the AE300 engine, the self test button must be pressed during the automatic run up.
  • Page 57 Maintenance Manual E4.08.04 Error Handling For the list of engine control system errors and their error handling refer to chapter 7 of Operation Manual E4-01-01. Three different types errors are known: Errors which lead to a latched caution indication  Errors which lead to a non-latched caution indication ...
  • Page 58 Maintenance Manual E4.08.04 Electrical System Installation Requirements: The following requirements have to be observed to ensure a proper performance of the AE 300 in the installation environment. Pay attention that the entire electrical system and wiring harness is protected against chafing at hot parts or sharp edges.
  • Page 59 Maintenance Manual E4.08.04 Technical Data of the Electrical System Components: EECU: The EECU is the Electrical Engine Control Unit which is used to control the engine actuators (e.g. fuel injectors) according to the engine sensor information. The EECU consists of two similar ECUs (Engine control Units). A voter is integrated in the EECU and proposes an ECU to control the engine regarding the ECU operating hours or in case of a failure the ECU with better engine control capability.
  • Page 60 Maintenance Manual E4.08.04 Display and Diagnostic Interface: The Display and diagnostic interface is a High Speed CAN Bus (with 500k Baud) which is used to transmit all information to a display/indication panel. A BUS termination is required at the physical end of the BUS. CAN-termination resistors 60R (2x 120R in parallel, 120R in EECU included) (CAN Bus according to ISO 11898) For Example:...
  • Page 61 Maintenance Manual E4.08.04 Alternator: The alternator system consists of an alternator and an alternator-regulator device. The alternator provides the following main properties:  Air-cooled synchronous three-phase alternator with a claw-pole rotor  Built-in semiconductor rectifier  Stator winding circuit: delta connection ...
  • Page 62 Maintenance Manual E4.08.04 Electrical starter: The main power supply to the starter cannot be protected with a fuse. Thus the routing must ensure that there is no increased risk of fire in the event of a short circuit. The electrical connection of the starter is shown in Chapter 92-00-00 Wiring diagrams. Fig.
  • Page 63 Maintenance Manual E4.08.04 Governor Interface: This EECU is able to actuate the electric motor which changes the governor-set point. According to power lever position the related propeller speed is controlled by the EECU see Fig. 01-18. A more detailed description can be found in section Governor Functional description. As long as the actual propeller speed is different to the predefined propeller set point curve, the EECU provides a signal to drive the electric motor which is part of the governor.
  • Page 64 Maintenance Manual E4.08.04 The governor must have two mechanical stops which can be detected by the EECU through sensing pins. If one of these stops is reached the electric motor will not be actuated into the direction of the detected stop, only movement into direction of the opposite stop is possible. The EECU also detects mechanical jamming of the electrical motor.
  • Page 65 Maintenance Manual E4.08.04 The connector equipped on the harness is a Deutsch AS 008 35 PN. Each compatible connector can be used on a governor. Description Feather Valve Feather Valve Motor + Motor - Governor Stop Sensing Governor Pin Assignment Electrical Drawing Example EECU E4 Input Circuit...
  • Page 66 Maintenance Manual E4.08.04 Engine Selftest Pushbutton: The engine is able to perform a Selftest. For this a normally open closer pushbutton is installed. Activation of the Selftest via the Selftest Pushbutton is only be possible if the VOTER Switch is in AUTO Position (logical AND relation).
  • Page 67 One applicable engine display system consists of a Main Engine Display (MED) and a Secondary Engine Display (SED) device, which is offered by Austro Engine (part no. MED: A1A-10-100-000; part no. SED: A1A-10-200-000). This system is proven to display the relevant engine parameters in consistence with the engine operation limitations as described in the Operation Manual.

  • Page 68: Governor Description

    Maintenance Manual E4.08.04 01-10-70 Governor Description An electrically controlled hydro mechanical governor is installed. The governor is not part of the engine. Approved governors for installation: MT-propeller P-877-16 MT-Propeller P-853-16 The EECU provides a signal for the governor to adjust the required rpm set point (refer to Fig.01-18) Governor drive: Flange of the backside of the gearbox:...
  • Page 69 Maintenance Manual E4.08.04 Governor Functional Description: The propeller speed is conventionally controlled and kept by a mechanical propeller governor but the set point of the governor is adjusted by an electric motor controlled by the EECU. This electric motor substitutes the conventionally used Bowden cable and if e.g. the connection to the set point actuator fails, the set point remains unchanged and the governor controls the propeller speed to the last set-point.
  • Page 70 Maintenance Manual E4.08.04 – Intentionally left blank – Issue date: 14-Apr-2015 Revision no: 25 Page: 01-44...

  • Page 71: Transport And Packaging

    Maintenance Manual E4.08.04 Chapter 02-00-00 Transport and Packaging 02-00-10 Packaging The engine is packed in a wooden crate and will be shipped attached to the corresponding mountings. If not declared otherwise the engine is shipped without any liquids. Fig.02 - 1 The box containing the supplied parts is filled with filler material and closed with adhesive tape.
  • Page 72 Maintenance Manual E4.08.04 Fig.02 - 3 This box is positioned in the slope below the injector cover. Fig.02 - 4 Then the engine is covered by a special VCI foil. Issue date: 11-Aug-2011 Revision no: 9 Page: 02-2...
  • Page 73 Maintenance Manual E4.08.04 Fig.02 - 5 Fig.02 - 6 The whole engine is enclosed by a wooden box. Issue date: 11-Aug-2011 Revision no: 9 Page: 02-3...

  • Page 74: Transport

    Maintenance Manual E4.08.04 02-00-20 Transport The engine has to be lifted with the transport eyelets. The used hoisting device must be suitable for the weight of the engine. Lifting eyelet Fig.02 - 7 Lifting eyelet 1 Lifting eyelet Fig.02 - 8 Lifting eyelet 2 The lifting eyelet at the cylinder head must be dismounted after installing the engine.

  • Page 75: Protective Covers

    For storage requirements refer to the Operation Manual E4-01-01. of the E4 engine or E4- 01-02 of the E4P engine. 02-00-50 Return Parts Shipping Instruction If you have to return parts to Austro Engine, please follow these instructions:  Clean the part, especially oil contaminated arts like Governors ...
  • Page 76 Maintenance Manual E4.08.04 – Intentionally left blank – Issue date: 14-Apr-2015 Revision no: 25 Page: 02-6...

  • Page 77: Engine Installation

    Maintenance Manual E4.08.04 Chapter 03-00-00 Engine Installation For detailed engine installation instructions refer to the Installation Manual E4.02.01 for the E4 engine series or the applicable Aircraft Maintenance Manual. Issue date: 14-Dec-2015 Revision no: 26 Page: 03-1...
  • Page 78 Maintenance Manual E4.08.04 – Intentionally left blank – Issue date: 14-Apr-2015 Revision no: 25 Page: 03-2...

  • Page 79: Airworthiness Limitation

    Maintenance Manual E4.08.04 Chapter 04-00-00 Airworthiness Limitation No Limitation. EASA Approval Statement: This Airworthiness Limitation Section is approved by European Aviation Safety Agency (EASA) in accordance with the applicable certification procedures and the type certification basis. Any changes must be documented and approved by the local airworthiness agency. FAA Approval Statement: The Airworthiness Limitation Section is FAA approved and specifies maintenance required under Sec.
  • Page 80 Maintenance Manual E4.08.04 – Intentionally left blank – Issue date: 14-Apr-2015 Revision no: 25 Page: 04-2...

  • Page 81: Time Limits And Maintenance Check

    With the publication of the Maintenance Manual, Austro Engine GmbH ensures the correctness of the instruction. In case of changes Austro Engine GmbH will inform with Service Bulletins, Service Letters or manual amendments, if it is necessary. If there are any problems with the maintenance and repair or any further questions about the engine, Austro Engine GmbH can be contacted.

  • Page 82: Time Limits Of Engine Model E4

    Maintenance Manual E4.08.04 05-10-00 Time Limits of engine model E4 The time limits below must be followed to obtain the max. service life of the E4 engine. Every 600 operating hours:  Replace the High Pressure pump – refer to Chapter 73-00-40 Every 1800 operating hours: ...

  • Page 83: Claimable Exceed Of Maintenance Actions

    For warranty reasons the overhaul has to be conducted by trained personnel only in accordance with the instructions given in the overhaul manual of Austro Engine GmbH. The Shipment to an authorized overhaul facility must include the following: ...

  • Page 84: Schedule Maintenance Inspections And Checks Of Engine Model E4

    Maintenance Manual E4.08.04 05-20-00 Schedule Maintenance Inspections and Checks of engine model E4 The following service intervals are mandatory to obtain the maximum service life of the engine. If the engine has not been in operation for a certain time a service interval based on time become effective.

  • Page 85: Two Mass Flywheel

    05-20-05 EECU Read Out Read out EECU using the AE 300 Wizard and send data to Austro Engine GmbH. For usage instructions of the AE 300 Wizard refer to the AE 300 Wizard User Guide E4.Aug.Sep. Data to be sent: ...

  • Page 86: Gearbox Oil Filter

    Engine Oil Filter Replace Oil filter according to Chapter 79-00-70. Use only original Austro Engine oil filter insert: E4A-52-100-802 Conduct a visual inspection of the used oil filter for contamination and metal abrasion. If unusual contamination (metal shavings exceeding 1,5 mm; concentration of particles; clogged filter) is found, the root cause has to be eliminated permanently (e.g.

  • Page 87: Cylinder Head Drain

    Maintenance Manual E4.08.04 05-20-12 Cylinder Head Drain Disconnect Cylinder Head Drain Line from cylinder head. Blow through the drain hole using compressed air. Blow through the Cylinder Head Drain line using compressed air to ensure an unobstructed line. Connect Drain line. Cylinder Head Drain line Cylinder Head Drain line Fig.

  • Page 88: Cooling System

    Maintenance Manual E4.08.04 05-20-18 Cooling System Conduct a visual inspection of the Cooling System. Inspect especially for signs of wear and leakage. If leakage is detected the affected connections have to be inspected for tight fit or damaged hoses must be replaced. 05-20-19 Breather Line Inspect the outlet of the Breather Line for abnormal quantity of oil (oil dust has to be expected).

  • Page 89: Timing Chain

    Maintenance Manual E4.08.04 05-20-22 Timing Chain Conduct a visual and functional inspection of the chain tensioner in course of the timing chain check. Replace the chain tensioner: ● if the thrust bolt is separated or can be pulled out from the chain tensioner housing. ●...

  • Page 90: Schedule Maintenance Inspections And Checks Of Engine Model E4P

    Maintenance Manual E4.08.04 05-30-00 Schedule Maintenance Inspections and Checks of engine model E4P The following service intervals are mandatory to obtain the maximum service life of the engine. If the engine has not been in operation for a certain time a service interval based on time become effective.

  • Page 91: Gearbox

    Maintenance Manual E4.08.04 100 h Activities/Services Interval 300 h 600 h 900 h Chapter 12 Months Check Change Check Change Check Change Check Change refer to ENGINE Zonal Inspection ● 05-20-20 Injector Cover ● 05-20-21 Timing chain ● 05-20-22 Cylinder head ●...

  • Page 92: Cylinder Head

    Conduct the power evaluation described in chapter 85-50-00 after the replacement of the cylinder head. Before determining the airworthiness Austro Engine GmbH has to check the collected power evaluation data and confirm that no power loss has occurred. Issue date: 14-Dec-2015...

  • Page 93: Unscheduled Maintenance Checks

    Maintenance Manual E4.08.04 05-50-00 Unscheduled Maintenance Checks 05-50-01 Performance Deterioration Analyse EECU data using the AE 300 Wizard to detect root cause. Austro Engine GmbH may assist for this analysis on request. Data to be used:  Engine log ...

  • Page 94: High Engine Oil Consumption Inspection

    Maintenance Manual E4.08.04 05-50-06 High Engine Oil Consumption Inspection  Inspect engine for oil leakage.  Inspect the compression.  Analyse EECU data using the AE 300 Wizard to detect root cause. If the root cause cannot be found, the engine has to be replaced. 05-50-07 Engine Oil System Contaminated ...

  • Page 95: Servicing

    Maintenance Manual E4.08.04 Chapter 12-00-00 Servicing 12-20-00 Engine Oil Servicing 12-20-01 Check the Oil Level 1. For checking the oil level the oil dipstick has to be taken out. 2. For optimum run, the oil level should be in the middle of the min / max mark. 3.

  • Page 96: Gearbox Oil

    Maintenance Manual E4.08.04 12-20-10 Gearbox Oil 12-20-11 Check the Gearbox Oil Level The quantity of the gearbox oil has to be checked. Oil Level Oil inspection window Fig. 12 - 3 In case gearbox E4A-70-000-000 Rev. 60 or lower is installed (refer to Engine Log) gearbox oil has to be refilled (refer to Chapter 85-10-53) if the oil level is visible in the inspection window.

  • Page 97: Electrical Power

    Maintenance Manual E4.08.04 Chapter 24-00-00 Electrical Power 24-00-01 General For general description of the Electrical Power System refer to the E4 Operation Manual E4.01.01 - Chapter 7 or E4P Operation Manual E4.01.02 Chapter 6. During all work on the electrical system the power supply must be disconnected. First disconnect the negative pole and second the positive pole of the battery.

  • Page 98: Installation Of The Alternator E4A-91-000-000

    Maintenance Manual E4.08.04 24-30-20 Installation of the Alternator E4A-91-000-000 1. Carefully install the Alternator [5] and install the mounting screws [4]. 2. Torque the screws [2] and [4] with 20 Nm. 3. Connect the electrical cable marked with “GEN/G2”. Ensure that the connector is locked.

  • Page 99: Tools Necessary

    Maintenance Manual E4.08.04 24-30-31 Tools necessary Number Description Dimensions Screw Driver Slotted Screw Driver (~2mm) Thin Metal ~0,3mm x ~8mm Sheet Sliding Caliper Multimeter Wrench Size 8 (hexagonal) Wrench Size 7 (hexagonal) 24-30-32 Removal of the Brush Holder Assembly Remove the two screws G and G2. Remove the black plastic cover on the back side of the alternator with wrench size 8.

  • Page 100: Visual Inspection Of Alternator Housing And Pulley

    Maintenance Manual E4.08.04 ASSY brush holder E4A-91-300-000 Fig. 24 - 5 Alternator with removed plastic cover 24-30-33 Visual Inspection of Alternator Housing and Pulley Check the alternator housing for mechanical damages such as cracks, broken casing ribs, damages threads, etc. If there are any damages on the housing, which impair the functionality, the cooling or the rigidity of the alternator, replace the alternator.

  • Page 101: Inspection Of Contact Ring And Brushes

    Maintenance Manual E4.08.04 24-30-34 Inspection of Contact Ring and Brushes When brush holder assembly E4A-91-300-000 is removed the contact ring can be inspected. Check for grooving (>0,5mm) on the contact ring. If grooving (>0,5mm) are visible the alternator must be replaced. Grooving (<0,5mm) caused by abrasion of carbon brushes are acceptable.

  • Page 102: Disassembly Of Brush Holder

    Maintenance Manual E4.08.04 Contact ring Fig. 24 - 7 Contact ring 24-30-35 Disassembly of Brush Holder To check the length of carbon brushes further disassembly of brush holder assembly E4A-91-300-000 is necessary. Push upper carbon brush with a small screw driver and hold them in end position below the cover rib. Cover Rib Upper Brush Lower Brush...
  • Page 103 Maintenance Manual E4.08.04 Insert thin metal sheet between cover rib and brush holder E4A-91-300-801. Push the metal sheet forward to hold down the upper brush. Push Direction Thin Metal Sheet Cover Rib Fig. 24 - 9 Brush holder Push lower carbon brush down with small screw driver. Push the metal sheet forward to hold down the lower carbon brush.

  • Page 104: Measuring The Length Of Carbon Brushes

    Maintenance Manual E4.08.04 Clean the brush holder and the brush rip with a soft brush. Do not use a steal brush for cleaning to avoid any damage. Carbon Brush Cover Fig. 24 - 11 Brush holder with cover 24-30-36 Measuring the Length of Carbon Brushes Measure the length of both carbon brushes with a calibre gauge.

  • Page 105: Evaluation Criteria

    Completion of Brush Holder Fig. 24 - 13 Flow chart It is not allowed to replace the carbon brushes! Only brush holder assemblies E4A-91-300-000 provided by Austro Engine GmbH must be used for maintenance. Issue date: 14-Dec-2015 Revision no: 26...

  • Page 106: Completion Of Brush Holder

    Maintenance Manual E4.08.04 24-30-38 Completion of Brush Holder Press down the brushes with metal sheet and place the cover into the brush holder. Thin Metal Sheet Push Direction Upper Brush Position Lower Brush Position Cover Fig. 24 - 14 Brush holder Don’t push the cover down to the end position.
  • Page 107 Maintenance Manual E4.08.04 Assure the correct fitment of the cover (direction) as shown in the picture below. Backside of Cover Backside of ASSY Brush Holder Fig. 24 - 16 Brush holder and hover Issue date: 14-Dec-2015 Revision no: 26 Page: 24-13...

  • Page 108: Completion Of Alternator (Integration Of Brush Holder)

    Maintenance Manual E4.08.04 24-30-39 Completion of Alternator (Integration of Brush Holder) If the brushes are not pushed back into the assembly position, it is not possible to mount the brush holder assembly E4A-91-300-000. Fig. 24 - 17 Brush holder assembly mounted onto the alternator (brushes are not released) Assemble the brush holder with screws R1;...
  • Page 109 Maintenance Manual E4.08.04 Push down the cover to its end position. Brushes are released only if the cover reaches the end position. If the cover is not pushed down to its end position, the carbon brushes won’t be released. Push Direction Fig.

  • Page 110: Functionality Check

    Maintenance Manual E4.08.04 24-30-40 Functionality Check After assembly the alternator has to be checked if the full functionality is given. Excitation Winding Fig. 24 - 21 Alternator E4A-91-000-000 Measure the resistance of the excitation winding. Test Case 1: Adjustment Multimeter: Resistance Measuring points: Excitation Winding...

  • Page 111: Marking Of Maintained Alternator E4A-91-000-000

    Maintenance Manual E4.08.04 24-30-50 Marking of maintained Alternator E4A-91-000-000 For each time when ASSY brush holder E4A-91-300-000 is checked an X (cross) has to be engraved on the bottom of the alternator. The dimension of the marking is described in Fig. 24.-31. ~10 mm ~10 mm Fig.

  • Page 112: Alternator E4A-91-400-000

    Maintenance Manual E4.08.04 24-31-00 Alternator E4A-91-400-000 Fig. 24 - 24 Alternator E4A-91-400-000 24-31-10 Removal of Alternator E4A-91-400-000 1. Disconnect the battery according to the applicable Aircraft Maintenance Manual. 2. Remove the power line from the B+ terminal according to the applicable Aircraft Maintenance Manual.
  • Page 113 Maintenance Manual E4.08.04 6. Perform an engine ground run according to the Chapter 71-00-03. Observe the output voltage of the alternator, which has to be in the typical operating range as described in the E4 Installation Manual E4.02.01. Figures for Chapter 24-31-10 and 24-31-20 Fig.

  • Page 114: Inspection Of Alternator E4A-91-400-000 And Carbon Brushes

    Maintenance Manual E4.08.04 24-31-30 Inspection of Alternator E4A-91-400-000 and Carbon Brushes This chapter describes the steps how to disassemble the alternator and its components (e.g.: brush holder) for checking the length of the carbon brushes. The criteria for replacing the Brush Bolder Assembly E4A-91-410-000 is also included in this chapter.
  • Page 115 Maintenance Manual E4.08.04 Brush Holder Assembly E4A-91-410-000 Fig. 24 - 30..Alternator with removed plastic cover Remove Brush Holder Assembly E4A-91-410-000 carefully. Remove Direction of Brush Holder Assembly Fig. 24 - 31 Alternator with removed plastic cover Issue date: 14-Dec-2015 Revision no: 26 Page: 24-21...
  • Page 116 Maintenance Manual E4.08.04 24-31-33 Visual Inspection of Alternator Housing and Pulley Check the alternator housing for mechanical damages such as cracks, broken casing ribs, damages threads, etc. If there are any damages on the housing, which impair the functionality, the cooling or the rigidity of the alternator, replace the alternator.
  • Page 117 Maintenance Manual E4.08.04 24-31-34 Inspection of Contact Ring and Brushes When Brush Holder Assembly E4A-91-410-000 is removed, the contact ring can be inspected. Check for grooving (>0,5mm) on the contact ring. If grooving (>0,5mm) is visible, the alternator must be replaced. Grooving (<0,5mm) caused by abrasion of carbon brushes are acceptable.

  • Page 118: Disassembly Of Assy Brush Holder

    Maintenance Manual E4.08.04 24-31-35 Disassembly of ASSY Brush Holder To check the length of carbon brushes no further disassembly of Brush Holder Assembly E4A-91-410- 000 is necessary. The picture below shows the released carbon brushes. Clean the brush holder and the brush rip with a soft brush. Do not use a steal brush for cleaning to avoid any damage.

  • Page 119: Measuring The Length Of Carbon Brushes

    Maintenance Manual E4.08.04 24-31-36 Measuring the Length of Carbon Brushes Measure the length of both carbon brushes with a calibre gauge. Carbon brush Brush Holder Fig. 24 - 35 Brush length Ensure to measure the length of the carbon brushes at the points shown in the picture above. The evaluation criteria can be found in Chapter24-31-37.

  • Page 120: Evaluation Criteria

    Completion of Generator (Integration Completion of Brush Holder of Brush Holder) Fig. 24 - 36 Flow chart Only Brush Holder Assemblies E4A-91-410-000 provided by Austro Engine GmbH must be used for maintenance. Issue date: 14-Dec-2015 Revision no: 26 Page: 24-26...

  • Page 121: Completion Of Alternator (Installation Of Brush Holder Assy)

    Maintenance Manual E4.08.04 24-31-38 Completion of Alternator (Installation of Brush Holder ASSY) Place Brush Holder Assembly E4A-91-410-000 carefully onto the alternator. Make sure that the guide rail of alternator and brush holder E4A-91-410-000 are placed exactly! Guide rail Guide rail Fig.
  • Page 122 Maintenance Manual E4.08.04 The picture below shows the correctly placed Brush Holder Assembly on the alternator. Fig. 24 - 39 Correctly placed Brush Holder ASSY Fix the Brush Holder Assembly with screws R1; R2 and R3 using fastening torque 1,6 – 2,3 Nm, and terminal screw T2 with fastening torque 9 - 13 Nm.
  • Page 123 Maintenance Manual E4.08.04 Place the black plastic cover of the alternator on the alternator backside. Screw down the torx screws G and G2 using fastening torque 1,6 – 2,3 Nm. Screw down the nut of W (mounted above R1) wit 2,7 – 3,8 Nm. Fig.

  • Page 124: Functionality Check

    Maintenance Manual E4.08.04 24-31-40 Functionality Check After assembly the alternator has to be checked if the full functionality is given. Excitation Winding Fig. 24 - 42 Alternator E4A-91-400-000 Measure the resistance of the excitation winding. Test Case 1: Adjustment Multimeter: Resistance Measuring points: Excitation Winding...

  • Page 125: Marking Of Maintained Alternator E4A-91-400-000

    Maintenance Manual E4.08.04 24-31-50 Marking of maintained Alternator E4A-91-400-000 For each time when Brush Holder Assembly E4A-91-410-000 is checked an X (cross) has to be engraved on the bottom of the alternator. The dimension of the marking is described in Fig. 24 - 51 ~10 mm ~10 mm Fig.

  • Page 126: Alternator-Regulator Adjustment E4A-91-100-000

    Maintenance Manual E4.08.04 24-60-01 Alternator-Regulator Adjustment E4A-91-100-000 Fig. 24 - 45 Issue date: 14-Dec-2015 Revision no: 26 Page: 24-32...

  • Page 127: Adjustment Procedure Of Voltage Regulation E4A-91-100-000

    Maintenance Manual E4.08.04 24-60-02 Adjustment procedure of voltage regulation E4A-91-100-000 The engines should be brought up to full operation coolant temperatures prior to adjustment. With one engine at cruising speed, the voltage on the operating system is adjusted to 28 volts at a typical electrical load by a replace of the set screw (see Fig.

  • Page 128: Alternator-Regulator Adjustment E4A-91-200-000

    Maintenance Manual E4.08.04 24-61-01 Alternator-Regulator Adjustment E4A-91-200-000 There is no regulator adjustment (e.g.: by potentiometer) required to establish a stable voltage regulation. 24-61-02 Paralleling for twin engine system E4A-91-200-000 A current-regulator is implemented, which enables the adjustment of the load balancing in twin- engine applications with high accuracy and fault-tolerance against single faults at the load-balancing adjustment structure.

  • Page 129: Standard Practices

    Maintenance Manual E4.08.04 Chapter 51-00-00 Standard Practices 51-00-10 Safety Wiring Safety wire is used to secure fasteners to prevent them from coming lose. It's used a lot in aviation and racing. To safety wire fasteners you will need safety wire, safety wire pliers, wire cutters (dykes), and needle nose pliers.

  • Page 130: Single Wire Safe Tying

    Maintenance Manual E4.08.04 51-00-12 Single Wire Safe Tying Insert the wire through each part consecutively in the direction that will prevent the part from loosening. Draw the wire tightly around each bend and twist the ends into a tight pigtail close to one of the safe tied parts.

  • Page 131: Double Wire Safety Wiring Using Pliers

    Maintenance Manual E4.08.04 Fig. 51 - 4 51-00-14 Double Wire Safety Wiring Using Pliers Start by looping the wire through the fastener, using a little extra wire, because you don't want to be short at the end. Loop the wire coming out of the bottom hole around the bolt head clockwise and pull the wire tight with needle nose pliers in the direction of the second bolt.

  • Page 132: Samples Of Safety Wiring

    Maintenance Manual E4.08.04 51-00-15 Samples of Safety Wiring Fig. 51 - 7 Issue date: 27-Jan-2011 Revision no: 5 Page: 51-4...
  • Page 133 Maintenance Manual E4.08.04 Fig. 51 - 8 Issue date: 27-Jan-2011 Revision no: 5 Page: 51-5...
  • Page 134 Maintenance Manual E4.08.04 Fig. 51 - 9 Issue date: 27-Jan-2011 Revision no: 5 Page: 51-6...

  • Page 135: Torque Standards

    Maintenance Manual E4.08.04 51-00-20 Torque Standards The importance of correct torque application cannot be overemphasized. Under torque can result in unnecessary wear of nuts and bolts, as well as the parts they secure. Over torque can cause failure of a bolt or nut from overstressing the threaded areas. Uneven or additional loads that are applied to the assembly may result in wear or premature failure.
  • Page 136 Maintenance Manual E4.08.04 Torque wrench with various adapters. Fig. 51 - 10 Elimination of friction in interference fit applications may sometimes be attained by placing the bolt in a freezer prior to installation. When this procedure is used, the bolt should be allowed to warm up to ambient temperature before torque.

  • Page 137: Power Plant

    These work steps must be taken with utmost care. Wrong maintenance of the engine can cause heavy engine damage even to engine stop during aviation. To award the warranty approved parts from the Austro Engine GmbH must be used. Issue date: 11-Aug-2011...

  • Page 138: Engine Ground Run

    Maintenance Manual E4.08.04 71-00-03 Engine Ground Run After work on the engine it is recommended to perform a ground run. Aircraft engine ground run must be performed in a secure and save area protected against movements of unauthorised persons. Accidents can cause severe injury or even death. Aircraft engine ground run must be performed by authorised persons only.
  • Page 139 Maintenance Manual E4.08.04 In case of any maintenance on the camshaft sensor, conduct the following procedure: Switch ECU-Voter to ECU_A Crank the engine Check engine Engine start‘s mechanical / electrical System Turn off engine Switch ECU-Voter to ECU_B Crank the engine Check ECU_B sensor Engine start‘s Target wheel and/or...

  • Page 140: Electrical Harness

    Maintenance Manual E4.08.04 71-50-00 Electrical Harness 71-50-01 General The harness provides electrical interconnection between all system components. Also it is an important part for HIRF & lightning protection. 71-50-02 General Information -> Wiring Harness The wiring harness has to be fixed at several points to avoid harness damage caused by normal engine operation (e.g.: due to vibration).

  • Page 141: Engine Harness Routing

    Maintenance Manual E4.08.04 71-50-03 Engine harness routing Ensure that wires and cables are routed in such a manner that chafing will not occur against the engine or other components. Ensure that wires and cables are routed in such a manner that in no circumstances a contact to extreme hot engine areas (exhaust pipes) is possible to prevent insulation break down.

  • Page 142: Engine Wiring Harness E4A-90-000-000

    Maintenance Manual E4.08.04 71-50-10 Engine Wiring Harness E4A-90-000-000 Inspect the engine harness for chafing, damage or missing clamps. In case of signs of wear or damage replace the engine wiring harness. INJ 4 GP 4 CAS 1 INJ 3 GP 3 INJ 2 GP 2 GBTS...

  • Page 143: Sensor - Check

    Maintenance Manual E4.08.04 71-50-20 Sensor – Check The sensors have to be inspected for loosened, chafed or damaged connectors according to the attached list and schematic. Be aware of, that some connectors have interlocks which need to be checked. Damaged sensors have to be replaced. 71-50-30 Description Plug Connector Wiring Harness Wiring...

  • Page 144: Material And Saving Material For The Engine Wiring Harness

    Maintenance Manual E4.08.04 71-50-40 Material and saving material for the Engine Wiring Harness Part number Description Torque specification Tool E4A-90-000-000 Engine wiring harness E4A-90-000-801 Hex-head screw with 6 Nm tooth lock M6x10 DIN3016-W1-DM Clamp 12 Nm 12x15 DIN3016-W1-DM Clamp 5 Nm 6x15 DIN3016-W1- Clamp...

  • Page 145: Mounting Backbones

    Maintenance Manual E4.08.04 71-50-60 Mounting Backbones Fig. 71 - 2 Use the screw to fix the clamp and torque it with 10 Nm (see Fig. 71-3) Fig. 71 - 3 Use the screw of the engine fastener to fix the clamp and torque it with 12 Nm (see Fig.71-3).

  • Page 146: Intake Air Manifold

    Maintenance Manual E4.08.04 71-50-70 Intake Air Manifold Fig. 71 - 4 Fig. 71 - 5 Use Clamp to fix the sub-backbone (intake air manifold) and the wire for glow-plug 4 and torque it with 12 Nm. Issue date: 14-Apr-2015 Revision no: 25 Page: 71-10...
  • Page 147 Maintenance Manual E4.08.04 Fig. 71 - 6 Fig. 71 - 7 Use the screw and torque it with 12 Nm to fix the clamp (see Fig. 71-7). Issue date: 14-Apr-2015 Revision no: 25 Page: 71-11...
  • Page 148 Maintenance Manual E4.08.04 Fig. 71 - 8 Fig. 71 - 9 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-12...
  • Page 149 Maintenance Manual E4.08.04 Fig. 71 - 10 Fig. 71 - 11 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-13...
  • Page 150 Maintenance Manual E4.08.04 Fig. 71 - 12 Fig. 71 - 13 Clamp is screwed on the fastener of the alternator (see Fig. 71 – 13). Issue date: 14-Apr-2015 Revision no: 25 Page: 71-14...
  • Page 151 Maintenance Manual E4.08.04 Fig. 71 - 14 Use the screw (Pos. 02) to fix the clamp and torque it with 6 Nm (see Fig. 71 - 14). Fig. 71 - 15 Clamp is screwed on the Oil level sensor. Issue date: 14-Apr-2015 Revision no: 25 Page: 71-15...
  • Page 152 Maintenance Manual E4.08.04 Fig. 71 - 16 Use the screw to fix the Clamp and torque it with 6 Nm (see Fig. 71 - 16). Fig. 71 - 17 Fix the clamp on the oil filter housing. The clamp-bow is orientated to the engine block (see Fig.

  • Page 153: Alternator

    Maintenance Manual E4.08.04 71-50-80 Alternator Fig. 71 - 18 Fig. 71 - 19 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-17...

  • Page 154: Gpc

    Maintenance Manual E4.08.04 71-50-90 Fig. 71 - 20 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-18...
  • Page 155 Maintenance Manual E4.08.04 71-50-100 CRS 1 & 2 Fig. 71 - 21 Fig. 71 - 22 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-19...

  • Page 156: Mechanical Protection (Mesh Tube)

    Maintenance Manual E4.08.04 71-50-110 Mechanical protection (Mesh tube) Fig. 71 - 23 Fig. 71 - 24 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-20...
  • Page 157 Maintenance Manual E4.08.04 Fig. 71 - 25 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-21...
  • Page 158 Maintenance Manual E4.08.04 Fig. 71 - 26 Fig. 71 - 27 Fig. 71 - 27 shows the CORRECT mounting of the EPW wire. Fix the cable by the usage of cable strap and mind a sufficient distance between cable and turbo charger case.
  • Page 159 Maintenance Manual E4.08.04 Fig. 71 - 28 Fig. 71 – 28 shows the WRONG mounting of the EPW wire. Caution: The wire must not touch the turbo charger housing! Fig. 71 - 29 Fig. 71 – 29 shows the laying and the fixing point of the shielding cable. Issue date: 14-Apr-2015 Revision no: 25 Page: 71-23...

  • Page 160: Fastening Point In The Aircraft (E4A-90-000-000)

    Maintenance Manual E4.08.04 71-50-111 Fastening point in the aircraft (E4A-90-000-000) The wiring harness has to be fixed at several points to avoid harness damage. Fixing points are marked in Fig 71 - 30, Fig. 71 - 31 and Fig. 7 - 32. Fig.
  • Page 161 Maintenance Manual E4.08.04 Fig. 71 - 32 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-25...

  • Page 162: Engine Wiring Harness E4A-95-000-000 And E4B-95-000-000

    Maintenance Manual E4.08.04 71-50-120 Engine Wiring Harness E4A-95-000-000 and E4B-95-000-000 Inspect the engine wiring harness for chafing, damage or missing clamps. In case of signs of wear or damage replace the engine wiring harness. Block diagram E4A Fig. 71 - 33 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-26...
  • Page 163 Maintenance Manual E4.08.04 Block diagram E4B Fig. 71 - 34 Pay attention for correct interlocking and snapping of the plug and socket connections (e.g. ECU connector or Injector connector). Issue date: 14-Apr-2015 Revision no: 25 Page: 71-27...

  • Page 164: Sensor - Check

    Maintenance Manual E4.08.04 71-50-130 Sensor – Check The sensors have to be inspected for loosened, chafed or damaged connectors according to the attached list and schematic. Damaged sensors have to be replaced. 71-50-140 Description Plug Connector Wiring Harness Wiring Description long version German description diagram Fuel Pressure Sensor...

  • Page 165: Material And Saving Material For The E4A Engine Wiring Harness

    Maintenance Manual E4.08.04 71-50-150 Material and saving material for the E4A Engine Wiring Harness Teilenummer Bezeichnung Drehmoment in Nm Werkzeug Sicherung E4A-95-000-000 LU Kabelbaum DIN3016-W1- Schelle 28 DM28-20 DIN3016-W1-DM Schelle 22 22x15 DIN3016-W3-DM Schelle 8 8x15 PLT4S-M30 Kabelbinder E4A-90-100-808 Edge Clip E4A-90-000-809 Edge Clip 50266513...

  • Page 166: E4 Engine Wiring Harness Mounting Instruction

    Maintenance Manual E4.08.04 71-50-170 E4 Engine Wiring Harness mounting instruction For Harness Routing see Chapter 71-50-03. On the following pages the mounting of the engine wiring harness is described in detail. The mounting instruction is identical for both versions of E4 wiring harness (E4A-95-000-000 and E4B-95-000-000). Pigtail RPS Fig.
  • Page 167 Maintenance Manual E4.08.04 Fig. 71 - 36 Ensure sufficient space between the wiring harness and the engine block as shown below to avoid chafing of the engine harness. Fig. 71 - 37 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-31...
  • Page 168 Maintenance Manual E4.08.04 Fig. 71 - 38 A clamp which is mounted to the lifting eyelet (12 Nm) is used for fixation wiring harness and RPS pigtail as shown at Fig. 71 -35. CAS1 Fig. 71 - 39 The wiring harness has to be placed above the pipes for each injector. CAS1 pigtail has to be connected to the fastening screw (14 Nm) of CAS1.
  • Page 169 Maintenance Manual E4.08.04 Fig. 71 - 40 Fig. 71 - 41 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-33...
  • Page 170 Maintenance Manual E4.08.04 Fig. 71 - 42 The branch for the glow plugs shall be placed behind the thermostat as shown at Fig. 71 - 40, Fig. 71 – 41 and Fig. 71 – 42. Rail Fig. 71 - 43 The wiring harness has to be placed on the rail and fixed with 3 cable ties It has to be ensured that the branches and cable ties do not constrain the mounting of the injector cover.
  • Page 171 Maintenance Manual E4.08.04 Pigtails BPS1 & IAT2 Pigtails BPS2 & IAT2 Fig. 71 - 44 The mounting screws (5 Nm) of sensors, BPS 1 and BPS 2 shall be used to connect the pigtails of IAT 1, IAT 2, BPS 1 and BPS 2 with the intake air manifold. Fig.
  • Page 172 Maintenance Manual E4.08.04 Fig. 71 - 46 The pigtails of FTS and PCV have to be screwed (12 Nm) as shown at Fig. 71 – 46. Fig. 71 - 47 The pigtails of FMU and CTS have to be screwed (12 Nm) to the lifting eyelet shown at Fig. 71 – 47. Issue date: 14-Apr-2015 Revision no: 25 Page: 71-36...
  • Page 173 Maintenance Manual E4.08.04 For the engine harness E4A-95-000-000 and E4B-95-000-000 the fuel pressure sensor (FPS) and fuel pressure sensor cable have to be covered by an additional shielding (E4A- 95-100-000), which is provided with the engine if applicable. If the engine harness E4A-90-000-000 is installed this procedure is not applicable. Fig.
  • Page 174 Maintenance Manual E4.08.04 Fig. 71 - 50 For fixation the branch of CRS1 sensor the edge clips has to be placed as shown at Fig. 71 – 50. Pigtail CRS1 Pigtail CRS1 Fig. 71 - 51 The pigtail of CRS1 (crankshaft sensor) has to be connected to the screw of EGR cover (21 Nm). The edge clips shall be used to fix the branch of CRS1.
  • Page 175 Maintenance Manual E4.08.04 EGR Cover Fig. 71 - 52 The engine harness has to be fixed (9 Nm) with a clamp to the EGR cover. The rest of the branch located in that area are fixed after starter, gearbox and GPC are mounted. Fig.
  • Page 176 Maintenance Manual E4.08.04 Pigtail BPA Pigtail CAS 2 Fig. 71 - 54 Pigtail of CAS2 has to be connected sensor mounting screw (12 Nm), pigtail of BPA has to be connected to injector cover plate (9Nm), as shown at Fig. 71 -54. Branch of CRS2 has to be placed as shown on picture above.
  • Page 177 Maintenance Manual E4.08.04 BPA Filter Fig. 71 - 56 BPA filter has to be fixed with a cable tie as shown at Fig. 71 – 56. Only the connector adapter (of PBA filter) is allowed to be used for fixation with the cable tie. Oil filter housing Alternator Fig.
  • Page 178 Maintenance Manual E4.08.04 Heat exchanger Pigtail OPS Fig. 71 - 58 The pigtail of OPS has to be connected to the heat exchanger (9 Nm). The engine harness has to be fixed with cable tie to the starter. Pigtail MOK Pigtail GEN W11/1 Oil sump...
  • Page 179 Maintenance Manual E4.08.04 GBTS W11/2 Fig. 71 - 60 2 edge clips have to be mounted to the GPC holder. The edge clips shall be used for fixation the branch of GBTS and W11/2 as shown at Fig. 71 – 60. GBTS Pigtail Fig.
  • Page 180 Maintenance Manual E4.08.04 Branch CRS2 Fig. 71 - 62 One edge clip has to be mounted as shown at Fig. 71 – 62. It shall be used to fix the branch of CRS2. Branch CRS2 GPC Holder Fig. 71 - 63 One edge clip has to be mounted as shown at Fig.
  • Page 181 Maintenance Manual E4.08.04 Branch CRS2 Pigtail CRS2 CRS2 Fig. 71 - 64 One edge clip has to be mounted as shown at Fig. 71 – 64. It shall be used to fix the branch of CRS2. The pigtail of CRS2 has to be connected to the screw (11 Nm) of CRS2. Governor Fig.
  • Page 182 Maintenance Manual E4.08.04 Fig. 71 - 66 The installer of the engine harness is allowed to use the same cable tie type for additional fixation, if the described fixation points are not sufficient. It has to be ensured by installer that the additional cable ties are not directly mounted to driven or hot parts of the engine.

  • Page 183: Remove The Wiring Harness

    Maintenance Manual E4.08.04 71-50-190 Remove the Wiring Harness DISCONNECT the power source prior to the remove of the wiring harness.  Remove the Injector Cover – refer to Chapter 85-00-11 Removal of the Injector Cover  Remove all clamps. (Pos. 03, 04, 05, 09, 11, 12). ...
  • Page 184 Maintenance Manual E4.08.04 Connectors locked Connectors unlocked Fig. 71 - 69 Issue date: 14-Apr-2015 Revision no: 25 Page: 71-48...

  • Page 185: Repair Of The Engine Wiring Harness E4A-90-000-000

    Maintenance Manual E4.08.04 71-50-800 Repair of the Engine Wiring Harness E4A-90-000-000 Herein described repair procedures for exchange of connectors can only be conducted once. 71-50-801 Exchange of Connector to “Intake Air Temperature”-Sensors Pos. Partnumber Description Qty. E4A-90-R16-000 Assy Repair Kit Cable Cutter Hot Air Gun Crimp Tool for...
  • Page 186 Maintenance Manual E4.08.04 Step 5: Step 6 Strip the insulation behind the inline crimp (5mm Move the solder sleeve, which was putted over the ± 2mm) which was mounted as described in wire of the reaming harness (see Step 3), over the Step 4.

  • Page 187: Exchange Of Connector To Fuel Pressure Sensor (Fps)

    Maintenance Manual E4.08.04 71-50-802 Exchange of Connector to Fuel Pressure Sensor (FPS) Pos. Partnumber Description Qty. E4A-90-R18-000 Assy Repair Kit Cable E4A-95-100-000 Assy Shielding Fuel Pressure Cutter Hot Air Gun Crimp Tool for TE (Tyco)D-436-36 crimp Step 1: Step 2: Cut off the old connecter Remove the black and white cable insulation.
  • Page 188 Maintenance Manual E4.08.04 Step 5: Step 6: Remove the isolation of all single wires on the end The inline crimp consists of the splice crimp and the of the engine harness and the repair kit cable E4A- isolation sleeve. Put the isolation sleeve of the inline 90-R18-000 as shown below.

  • Page 189: Exchange Of Connector To Boost Pressure Actuator (Bpa)

    Maintenance Manual E4.08.04 71-50-803 Exchange of Connector to Boost Pressure Actuator (BPA) Pos. Partnumber Description Qty. E4A-90-R17-000 Assy Repair Kit Cable Cutter Hot Air Gun Crimp Tool for TE (Tyco) D-436-37 crimp Step 1: Step 2: Cut off the old solder sleeve of the BPA branch. Remove the black and white cable insulation.
  • Page 190 Maintenance Manual E4.08.04 Step 7: Step 8: Connect the singles wires of the engine wiring Put the isolation sleeve of the inline crimp over the harness with the repair kit cable by use of the inline crimp sleeve. Heat the isolation sleeve (300°C inline crimp sleeve.

  • Page 191: Exchange Of Connector For Alternator E4A-91-400-000

    Maintenance Manual E4.08.04 71-50-804 Exchange of Connector for Alternator E4A-91-400-000 Pos. Partnumber Description Qty. E4A-90-R21-000- Assy Repair Kit Cable Cutter Hot Air Gun Crimp Tool for TE (Tyco)D-436-37 crimp Step 1: Step 2: The black backsheel needs to be removed. Cut off the connector G2/Gen as close as possible at the connector housing.
  • Page 192 Maintenance Manual E4.08.04 Step 5: Step 6: Use the crimp tool Mil Standard Part Number: Put the blue isolation sleeve of the inline crimp M22520/37-01 to connect the repair kit cable (A) and D-436-37 directly over the splice crimp. the remaining engine harness (B). Heat the inline crimp isolation sleeve (300°C –...

  • Page 193: Exchange Of Connector For Alternator E4A-91-000-000

    Maintenance Manual E4.08.04 71-50-805 Exchange of Connector for Alternator E4A-91-000-000 Pos. Partnumber Description Qty. E4A-90-R22-000-000 Assy Repair Kit Cable Cutter Hot Air Gun Crimp Tool for TE (Tyco)D-436-37 crimp Step1: Step2: Cut off the “damaged” part at the solder sleeve of the The following pictures are example pictures, to engine harness.
  • Page 194 Maintenance Manual E4.08.04 Step3: Step4: Remove the white cable insulation down to the shielding Put the solder sleeve over the cable of the of the cable as shown in the picture below. remaining engine harness. Heat the solder sleeve (300°C – 350°C) with a “hot air gun”.
  • Page 195 Maintenance Manual E4.08.04 Step 9: Step10: Put the chafing protection ROUNDIT 2000NX5-5 over the Use a Multimeter to check connection between repair kit cable and the engine harness. The length of the pins stated below: the chafing protection ROUNDIT 2000NX5-5 can be Connector Connector reduced if necessary.

  • Page 196: Exchange Of Connector To Fuel Metering Unit (Fmu)

    Maintenance Manual E4.08.04 71-50-806 Exchange of Connector to Fuel Metering Unit (FMU) Pos. Partnumber Description Qty. E4A-90-R23-000 ZB-Repair_kit_Connector_FMU Cutter Hot Air Gun Crimp Tool for TE (Tyco) D-436-36 crimp Multimeter Step1: Cut off the “damaged” FMU connector from the engine harness as required. The old connector will not be used for repair.
  • Page 197 Maintenance Manual E4.08.04 Step2: Remove the black isolation as shown in the picture below (~50mm from remaining harness). 50mm (+5) Step3: Remove the white cable isolation down to the shielding of the cable as shown in the picture below. 50mm (+5) 10mm (+5) Step4: Put the solder sleeve over the cable of the remaining engine harness.
  • Page 198 Maintenance Manual E4.08.04 Step6: Remove the remaining shielding. Remove the single wire insulation of both wires. 5mm (+/-1) Step7: The part number of the inline crimp is D-436-37. This number includes the splice crimp and the isolation sleeve. Put the blue isolation sleeve of the inline crimp D-436-37 over the single wire of the engine harness. Place the splice crimp at the end of the single wires of the repair kit cable.
  • Page 199 Maintenance Manual E4.08.04 Step9: Put the blue isolation sleeve of the inline crimp D-436-37 directly over the splice crimp. Heat the inline crimp isolation sleeve (300°C – 350°C) with a “hot air gun” until the inline crimp isolation seals the inline crimp barrel and the single wires. Isolation sleeve Step10: Put the chafing protection ROUNDIT 2000NX5-5 over the repair kit cable and the engine harness.

  • Page 200: Repair Of The Engine Wiring Harness E4A-95-000-000 Und E4B-95-000-000

    Maintenance Manual E4.08.04 71-50-900 Repair of the Engine Wiring Harness E4A-95-000-000 und E4B-95-000-000 Herein described repair procedures for exchange of connectors can only be conducted once. 71-50-901 Exchange of Connector of Gearbox Temperature Sensor (GBTS), Fuel Temperature Sensor (FTS), Coolant Temperature Sensor (CTS) and Glow Plug Coolant Temperature Sensor (CTS_GPC).

  • Page 201: Cts_Gpc

    Maintenance Manual E4.08.04 Step 5: Step 6: Connect the single wires of the repair kit E4A-95- Move the blue isolation sleeve over the inline crimps and R12-000 with the remaining engine wiring heat them with a hot air gun (300 °C). harness as shown in the table below using the inline crimps and crimp tool.

  • Page 202: Exchange Of Connector For Alternator E4A-91-400-000

    Maintenance Manual E4.08.04 71-50-902 Exchange of Connector for Alternator E4A-91-400-000 Pos. Partnumber Description Qty. E4A-95-R11-000- Assy Repair Kit Cable Cutter Hot Air Gun Crimp Tool for TE (Tyco)D-436-37 crimp Step 1: Step 2: The black backsheel needs to be removed. Cut off the connector G2/Gen as close as possible at the connector housing.
  • Page 203 Maintenance Manual E4.08.04 Step 5: Step 6: Use the crimp tool Mil Standard Part Number: Put the blue isolation sleeve of the inline crimp M22520/37-01 to connect the repair kit cable (A) and D-436-37 directly over the splice crimp. the remaining engine harness (B). Heat the inline crimp isolation sleeve (300°C –...
  • Page 204 Maintenance Manual E4.08.04 – Intentionally left blank – Issue date: 14-Apr-2015 Revision no: 25 Page: 71-68...

  • Page 205: Engine Fuel And Control

    Maintenance Manual E4.08.04 Chapter 73-00-00 Engine Fuel and Control 73-00-01 General For detailed description refer to the AE 300 Operation Manual E4-01-01 – Chapter System Description. For approved fuels refer to the AE 300 Operation Manual E4-01-01 Chapter Fuel Grade. 73-00-10 Injector 73-00-11...
  • Page 206 Maintenance Manual E4.08.04 If a new injector is installed, record IQA-code given at the top of the injector. The IQA-code has to be programmed into the EECU with the AE 300-Wizard. 1. Put on the new gasket rings [1] of the injectors - refer to Chapter 73-00-22. 2.

  • Page 207: Injector Seals

    5. After the ground run inspect fuel system for leakage. Fig. 73 - 2 Fig. 73 - 3 Fig. 73 - 4 Injector grease [3] is available at Austro Engine GmbH. Refer to the consumable list. Issue date: 14-Dec-2015 Revision no: 26 Page: 73-3...

  • Page 208: Fuel Return Line

    Maintenance Manual E4.08.04 73-00-30 Fuel Return Line 73-00-31 Removal of the Fuel Return Line 1. Remove the injector cover - refer to Chapter 85-00-11. 2. Remove the clips [1] from the 4 injectors. 3. Pull down the return line assy. 4.
  • Page 209 Maintenance Manual E4.08.04 Figures for Chapter 73-00-31 and 73-00-32 Fig. 73 - 5 Fig. 73 - 6 Fig. 73 - 7 Issue date: 10-Apr-2012 Revision no: 13 Page: 73-5...

  • Page 210: High Pressure Pump

    Maintenance Manual E4.08.04 73-00-40 High Pressure Pump 73-00-41 Removal of the High Pressure Pump 1. Disconnect the cable plug connection [8] (FPS). 2. Disconnect the cable plug connection [7] (FTS). 3. Disconnect the cable plug connection [1] (FMU). 4. Unscrew the fuel connection [2] - refer to the applicable Aircraft Maintenance Manual. 5.

  • Page 211: Removal Of The Spur Gear From High Pressure Pump

    Maintenance Manual E4.08.04 73-00-42 Removal of the spur gear from High Pressure Pump 1. Unscrew hexagon nut [1]. Use the special tool AE300T-012-1 as counter torque wrench. 2. Remove the spur gear [2] from the High Pressure Pump. Fig. 73 - 11 3.

  • Page 212: Installation Of The Spur Gear Onto High Pressure Pump

    Maintenance Manual E4.08.04 73-00-43 Installation of the spur gear onto High Pressure Pump For references refer to figure of Chapter 73-00-42 – Removal of the spur gear. 1. Put the spur gear [2] onto the High Pressure Pump [3]. 2. Screw on the hexagon nut M14x1.5 [1]. Check the fit of the spur gear. 3.

  • Page 213: Low Fuel Pressure Sensor

    Maintenance Manual E4.08.04 73-00-50 Low Fuel pressure sensor 73-00-51 Removal of the Fuel pressure sensor 1. Disconnect the cable plug connection [8] (FPS). 2. Screw out the FPS. Whenever loosening or tightening hose connections fitted with a twin nipple, always hold the twin nipple steady.

  • Page 214: Rail Pressure Sensor

    Maintenance Manual E4.08.04 73-00-60 Rail Pressure Sensor 73-00-61 Removal of the Rail Pressure Sensor 1. Remove the connectors (RPS), (PCV). 2. Remove the injector cover - refer to Chapter 85-00-11. 3. Open the coupling nuts [1]. 4. Loose the coupling nuts [2] at the injectors to have more space during removal the common rail.

  • Page 215: Engine Control

    The Software-file for updating the EECU will be part of a Flash Container (FCT) which is used by the AE300-Wizard. This FCT is available at the Austro Engine Homepage / Client Area. Use the appendix of MSB E4-003 “Execution Report” to document the performed update.
  • Page 216 Maintenance Manual E4.08.04 Refer to MSB E4-003 for current software versions. Software updates may only be performed by an Austro Engine GmbH service partner. EECU Software Update Procedure 1. Connect AE 300 Wizard to EECU a. AE300 Wizard at least version 1.2.0.0 required.

  • Page 217: Glow Plug Control

    Maintenance Manual E4.08.04 76-00-20 Glow Plug Control 76-00-21 Removal of the Glow Plug Control 1. Remove the plug connection [1] (GPC). 2. Remove the screws [2]. 3. Remove the glow control box [3]. 76-00-22 Installation of the Glow Plug Control 1.

  • Page 218: Crankshaft Sensor

    Maintenance Manual E4.08.04 76-00-30 Crankshaft Sensor 76-00-31 Removal of the Crankshaft Sensor 1. Remove the electrical lines [1].”CRS1 or CRS2”. 2. Remove the screw [2]. 3. Remove the crankshaft-sensors [3]. 76-00-32 Installation of the Crankshaft Sensor 1. Install the crankshaft-sensors. 2.

  • Page 219: Camshaft Sensor Cas 1

    Maintenance Manual E4.08.04 76-00-40 Camshaft Sensor CAS 1 76-00-41 Removal of the Camshaft Sensor CAS 1 1. Remove the injector cover - refer to Chapter 85-00-11. 2. Pull down the electrical connector CAS 1. 3. Remove the locking screw from the sensor [1]. 4.

  • Page 220: Camshaft Sensor Cas 2

    Maintenance Manual E4.08.04 76-00-50 Camshaft Sensor CAS 2 76-00-51 Removal of the Camshaft Sensor CAS 2 1. Pull down the electrical connector CAS 2. 2. Remove the locking screw from the sensor [1]. 3. Pull the camshaft sensor out. 76-00-52 Installation of the Camshaft Sensor CAS 2 1.

  • Page 221: Engine Indicating

    Maintenance Manual E4.08.04 Chapter 77-00-00 Engine Indicating 77-00-01 General The engine indicating is realized by the EECU. The EECU gathers the required information from engine sensors and passes it through the CAN-Bus to an engine display. If a failure in indication is suspected maintain the relevant sensor (Rely on EECU sensor failure detection to identify electrically defect sensors.) 77-00-10 Gearbox Temperature Sensor...
  • Page 222 Maintenance Manual E4.08.04 – Intentionally left blank – Issue date: 14-Apr-2015 Revision no: 25 Page: 77-2...

  • Page 223: Engine Exhaust

    Maintenance Manual E4.08.04 Chapter 78-00-00 Engine Exhaust 78-00-01 General For detailed description refer to Chapter 01-10-10 Intake/Exhaust System Description. 78-00-10 Exhaust Manifold 78-00-11 Removal of the Exhaust Manifold 1. Remove the exhaust pipe from the turbo charger - refer to the applicable Aircraft Maintenance Manual.

  • Page 224: Exhaust Manifold Gasket Exchange

    Maintenance Manual E4.08.04 Figures for Chapter 78-00-11 and 78-00-12 Fig. 78 - 2 Fig. 78 - 3 Fig. 78 - 4 78-00-20 Exhaust Manifold Gasket Exchange For Removal and Installation refer to Chapter 78-00-00. Issue date: 27-Jan-2011 Revision no: 5 Page: 78-2...

  • Page 225: Engine Oil

    Only engine oils conforming to MB 229.5 specification are approved by Austro Engine GmbH to be used for operation. Austro Engine GmbH will not assume any liabilities if other types of oil are used. 79-00-10 Oil-Filter Housing Draining Line...
  • Page 226 Maintenance Manual E4.08.04 Figure for Chapter 79-00-11 and 79-00-12 Fig. 79 - 1 Issue date: 27-Jan-2011 Revision no: 5 Page: 79-2...

  • Page 227: Drain Of Engine Oil

    Maintenance Manual E4.08.04 79-00-20 Drain of Engine Oil 1. Remove the safety wire [1]. 2. Put a container (min. 8,5 l) below the drain plug. 3. Open the oil drain plug [2]. 4. Open the Oil Dip Stick 5. Let the oil drain off. Fig.

  • Page 228: Oil Sump

    Maintenance Manual E4.08.04 79-00-40 Oil Sump 79-00-41 Removal of the Oil Sump 1. Remove the engine - refer to the applicable Aircraft Maintenance Manual. 2. Remove the gearbox - refer to Chapter 85-10-11. 3. Remove the belt tensioner - refer to Chapter 85-40-21. 4.

  • Page 229: Oil Sump Gasket Exchange

    Maintenance Manual E4.08.04 10. Install the oil filter housing drain line – refer to Chapter 79-00-12. 11. Install the return line – refer to Chapter 79-00-112 Installation of the Oil Return Line. 12. Install the belt tensioner – refer to Chapter 85-40-22. 13.
  • Page 230 Maintenance Manual E4.08.04 Figures for Chapter 79-00-41 and 79-00-42 16 * Fig. 79 - 3 17 * Fig. 79 - 4 Tighting Diagram Issue date: 27-Jan-2011 Revision no: 5 Page: 79-6...

  • Page 231: Oil-Filter Housing

    Maintenance Manual E4.08.04 79-00-60 Oil-Filter Housing 79-00-61 Removal of the Oil-Filter Housing 1. Remove the oil filter housing drain line – refer to Chapter 79-00-11. 2. Remove the fitting [9] from the oil filter housing drain line. 3. Remove the oil filter – refer to Chapter 79-00-71. 4.

  • Page 232: Oil-Filter

    Maintenance Manual E4.08.04 79-00-70 Oil-Filter 79-00-71 Remove and discard of the Oil-Filter 1. Remove oil filter by unscrewing of the oil filter cover [1]. 2. Detach the oil filter from the oil filter cover by pulling them off. 3. Discard the oil filter [2]. 79-00-72 Installation of the Oil-Filter 1.

  • Page 233: Oil Separator

    Maintenance Manual E4.08.04 79-00-80 Oil Separator 79-00-81 Removal of the Oil Separator 1. Remove the injector cover - refer to Chapter 85-00-11. 2. Remove the screws [8]. 3. Remove the oil separator [1]. 4. Open the steel tape clamp and pull down the hose [6]. 5.

  • Page 234: Installation Of The Oil Separator By-Pass Valve

    Maintenance Manual E4.08.04 79-00-84 Installation of the Oil Separator By-Pass Valve 1. Install the new by-pass valve. 2. Screw it down carefully by hand torque. 3. Use Loctite 243. When using Loctite, make sure, that the thread is free of grease and apply only a thin film of Loctite.

  • Page 235: Oil Separator Return Line

    Maintenance Manual E4.08.04 79-00-90 Oil Separator Return Line 79-00-91 Removal of the Oil Separator Return Line 1. Remove the safety wire [2]. 2. Remove the banjo bolt [1] at the camshaft sensor housing. 3. Remove the screw from the injector cover. 4.

  • Page 236: Lubricant Line

    Maintenance Manual E4.08.04 79-00-100 Lubricant Line 79-00-101 Removal of the Lubricant Line 1. Remove the safety wire [1]. 2. Remove the banjo bolt [2]. 3. Remove the screw [3] with the clip [4]. 4. Remove the screw [5]. 5. Dismount the oil lubricant line [6]. 79-00-102 Installation of the Lubricant Line 1.

  • Page 237: Removal Of The Lubricant Line Sealing Ring

    Maintenance Manual E4.08.04 79-00-103 Removal of the Lubricant Line Sealing Ring 1. Remove the lubricant line [1] – refer to Chapter 79-00-101. 2. Remove the sealing ring [3] at the banjo bolt [4]. 3. Remove the O-ring. [2]. 79-00-104 Installation Lubricant Line Sealing Ring 1.

  • Page 238: Oil Return Line

    Maintenance Manual E4.08.04 79-00-110 Oil Return Line 79-00-111 Removal of the Oil Return Line 1. Drain engine oil – refer to Chapter 79-00-20 2. Remove the wire protection [1]. 3. Remove the banjo bolt [2] at the oil sump. 4. Remove the screw [2] at the turbo charger. 5.

  • Page 239: Removal Of The Oil Return Line Gasket

    Maintenance Manual E4.08.04 79-00-113 Removal of the Oil Return Line Gasket 1. Remove the oil return line – refer to Chapter 79-00-111. 2. Remove the O-ring [1] 3. Remove the gasket [2] 4. Remove the sealing rings [3]. 79-00-114 Installation of the Oil Return Line Gasket 1.

  • Page 240: Oil Level Sensor

    Maintenance Manual E4.08.04 79-00-120 Oil Level Sensor 79-00-121 Removal of the Oil Level Sensor 1. Disconnect the electrical connector (MOK). 2. Disconnect the screws. 3. Remove the cover and the oil-level sensor. 4. Remove and fit the oil-level-sensor. 79-00-122 Installation of the Oil Level Sensor 1.

  • Page 241: Oil Pressure Sensor

    Maintenance Manual E4.08.04 79-00-130 Oil Pressure Sensor 79-00-131 Removal of the Oil Pressure Sensor 1. Disconnect the electrical connector (OPS) [1]. 2. Remove the sensor [2]. Use a clean cloth during removal of the oil-level-sensor. Some oil may be discharged by the oil-level-sensor.

  • Page 242: Governor

    Maintenance Manual E4.08.04 79-00-140 Governor The Governor is not part of the engine. For detailed information refer to the applicable Aircraft Maintenance Manual. 79-00-141 Removal of the Governor 1. Remove the electrical connector (GOV) [1]. 2. Remove the oil hose [2] (if installed) – refer to the applicable Aircraft Maintenance Manual.

  • Page 243: Starting

    Maintenance Manual E4.08.04 Chapter 80-00-00 Starting 80-00-01 General For detailed description refer to the Chapter “Operating Instructions” of the referring Operation Manual for the engine model. 80-00-10 Starter 80-00-11 Removal of the Starter 1. Disconnect the battery – refer to the applicable Aircraft Maintenance Manual. First disconnect the negative pole and second the positive pole.
  • Page 244 Maintenance Manual E4.08.04 Figure for Chapter 80-00-11 and 80-00-12. Fig. 80 - 1 Issue date: 27-Jan-2011 Revision no: 5 Page: 80-2...

  • Page 245: Glow Plugs

    Maintenance Manual E4.08.04 80-00-20 Glow Plugs 80-00-21 Removal of the Glow Plugs 1. Remove the cable connector [1] carefully with a gripper (GP1/GP2/GP3/GP4). 2. Remove the glow plugs. 80-00-22 Installation of the Glow Plugs 1. Screw in the glow plugs and torque them with 11 Nm. 2.
  • Page 246 Maintenance Manual E4.08.04 – Intentionally left blank – Issue date: 14-Apr-2015 Revision no: 25 Page: 80-4...

  • Page 247: Turbocharging

    Maintenance Manual E4.08.04 Chapter 81-00-00 Turbocharging 81-00-01 General For description refer to Chapter 01-10-10 Intake/Exhaust System Description. 81-00-10 Turbo Charger Complete 81-00-11 Removal of the Turbo Charger 1. Remove the exhaust manifold including turbo charger – refer to Chapter 78-00-11. 2.
  • Page 248 Maintenance Manual E4.08.04 1. Install the bracket with the M6 bolts [2] and torque them with 7 Nm. 2. Chose a suitable air pressure device (see Fig. 81 – 4) as described in Chapter 81-00-32. 3. Attach the chosen device to the top of the waste gate controller and apply pressure till the rod starts to move.

  • Page 249: Boost Pressure Actuator

    Maintenance Manual E4.08.04 81-00-20 Boost Pressure Actuator 81-00-21 Removal of the Boost Pressure Actuator (BPA) There are actually two different BPA installation versions on the E4 engine. At the previous version the BPA inlet is connected to the turbocharger (see Fig. 81 – 3). The BPA inlet of the latest version is connected to the Manifold and therefore the BPA is installed twisted.
  • Page 250 Maintenance Manual E4.08.04 Fig. 81 - 4 Latest BPA installation version Fig. 81 - 5 Scrub screw installation Issue date: 10-Apr-2012 Revision no: 13 Page: 81-4...

  • Page 251: Waste Gate Controller

    81-00-31 Inspection If you have problems with the waste gate controller, remove the complete turbo charger (refer to Chapter 81-00-11) and send it to an Austro Engine GmbH – Service Center. 81-00-32 Check /Adjust of the Waste Gate Controller 1. For checking the waste gate controller, remove the clip [1] and pull off the hose [2].
  • Page 252 Maintenance Manual E4.08.04 Figures for Chapter 81-00-31 and 81-00-32 Fig. 81 - 6 Fig. 81 - 7 incorrect correct Fig. 81 - 8 Fig. 81 - 9 Issue date: 10-Apr-2012 Revision no: 13 Page: 81-6...

  • Page 253: Reciprocating Engine

    Maintenance Manual E4.08.04 Chapter 85-00-00 Reciprocating Engine 85-00-10 Injector Cover 85-00-11 Removal of the Injector Cover In case the injector cover has a maintenance lid installed, remove the maintenance lid as described in section 85-00-13 for the following work steps. 1.
  • Page 254 Maintenance Manual E4.08.04 Figures for Chapter 85-00-11 and 85-00-12 Fig. 85 - 1 Injector Cover without maintenance lid Fig. 85 - 2 Fig. 85 - 3 Above figures show oil separator hose E4A-53-100-501 rev. 020. Issue date: 14-Jan-2014 Revision no: 23 Page: 85-2...

  • Page 255: Removal Of The Maintenance Lid

    Maintenance Manual E4.08.04 85-00-13 Removal of the Maintenance Lid Only applicable to injector covers with maintenance lid installed. 1. Remove safety wire and the 3 screws. 2. Remove the maintenance lid by pushing it towards the direction of the screw holes. Fig.

  • Page 256: Installation Of The Maintenance Lid

    Maintenance Manual E4.08.04 5. Screw down the injector cover with 9 Nm. 6. Install the maintenance lid – refer to Chapter 85-00-15. 7. Attach the breather line to the injector cover - refer to the applicable Aircraft Maintenance Manual. 8. Install the oil-separator return line - refer to Chapter 79-00-92. 9.
  • Page 257 Maintenance Manual E4.08.04 Fig. 85 - 8 Fig. 85 - 9 Issue date: 14-Jan-2014 Revision no: 23 Page: 85-5...

  • Page 258: Reciprocating Engine Front System

    Maintenance Manual E4.08.04 85-10-00 Reciprocating Engine Front System 85-10-10 Gearbox 85-10-11 Removal of the Gearbox 1. Apply a container with minimum 3 litres below the gearbox drain plug. 2. Open the gearbox filler plug [1]. 3. Open the gearbox drain plug [2] 4.

  • Page 259: Removal Of The Gearbox With Optional Gearbox Oil Cooler

    Maintenance Manual E4.08.04 10. Install the gearbox magnetic drain plug – refer to Chapter 85-10-22. 11. Fill the gearbox according to Chapter 85-10-51 General 12. Install the filling plug [1] with 12 Nm and apply safety wire according to the standard practices.
  • Page 260 Maintenance Manual E4.08.04 3. Pull the connecting hose [17] over the hose connector at the gearbox. 4. Fix the connecting with the spring band clamp [20]. 5. Put the second spring band clamp [16] for installation purposes on the connecting hose as near as possible towards the previously installed spring band clamp.
  • Page 261 Maintenance Manual E4.08.04 Figures for Chapter 85-10-11, 12, 13 and 14. Fig. 85 - 10 Fig. 85 - 11 Fig. 85 - 12 Fig. 85 - 13 Issue date: 14-Dec-2015 Revision no: 26 Page: 85-9...
  • Page 262 Maintenance Manual E4.08.04 Additional Figures for Chapter 85-10-11, 12, 13 and 14. Fig. 85 - 14 (Installation of GBTS on gearbox Rev. 65 or lower or Rev. 100 and higher) Fig. 85 - 15 Issue date: 14-Dec-2015 Revision no: 26 Page: 85-10...
  • Page 263 Maintenance Manual E4.08.04 Fig. 85 - 16: Gearbox with optional Oil Cooler “-A” engine configuration Fig. 85 - 17: Gearbox with optional Oil Cooler “-B/-C” engine configurations Issue date: 14-Dec-2015 Revision no: 26 Page: 85-11...

  • Page 264: Removal Of The Optional Gearbox Oil Cooler

    Maintenance Manual E4.08.04 85-10-15 Removal of the optional Gearbox Oil Cooler 1. Remove the gearbox – refer to chapter 85-10-13. 2. Remove the screws [05] and the washers [04]. 3. Remove the oil cooler [01] with the O-Rings carefully from the gearbox [06]. 4.

  • Page 265: Gearbox Magnet-Drain Plug

    5. Remove the magnet drain plug. [2]. 6. Drain the gearbox oil through the included filter which is included in the scheduled maintenance kit of Austro Engine for bigger pieces of material and non magnetic material. 7. Dip the magnetic drain plug in a solvent of remove oil contamination for better debris inspection.

  • Page 266: Installation Of The Gearbox Magnet-Drain Plug

    Maintenance Manual E4.08.04 Fig. 85 - 21 Accumulation of allowable debris Following types of particles are allowable: - Small quantities that are like thin pieces of hair (see Fig. 85 – 20). - Small quantities that are like powder (see Fig. 85 – 21). Following types of particle are not allowable: - Large quantities that are like thin pieces of hair.

  • Page 267: Gearbox Oil Filter (Gearbox Rev. 70 Or Higher)

    Maintenance Manual E4.08.04 85-10-30 Gearbox Oil Filter (Gearbox Rev. 70 or higher) 85-10-31 Removal of the Gearbox Oil Filter If Gearbox is mounted on an “-B” or “-C” engine, the gearbox temperature sensor (GBTS) is installed instead of the plug screw. Disconnect the GBTS prior conduction of further work steps.

  • Page 268: Installation Of The Gearbox Oil Filter

    Maintenance Manual E4.08.04 85-10-32 Installation of the Gearbox Oil Filter Fig. 85 - 24 Filter [2] installation with screw (e.g. M8x50 or longer) Fig. 85 - 25 Check for tightness Fig. 85 - 26 Plug screw [1] Fig. 85 - 27 1.

  • Page 269: Gearbox Temperature Sensor

    Maintenance Manual E4.08.04 85-10-40 Gearbox Temperature Sensor 85-10-41 Removal of the Gearbox Temperature Sensor 1. Disconnect the electrical connector [1] (GBTS). 2. Remove the temperature sensor [2]. 85-10-42 Installation of the Gearbox Temperature Sensor 1. Use new sealing ring [3]. 2.

  • Page 270: Gearbox Oil

    Maintenance Manual E4.08.04 85-10-50 Gearbox Oil 85-10-51 General Gearbox Oil Information: Gearbox oil type: Shell Spirax GSX 75W-80 Oil volume: 2,3 l For checking the gearbox oil level- refer to Chapter 12-20-11. 85-10-52 Exchange of the Gearbox Oil For exchange of the gearbox oil refer to Chapter 85-10-21. 85-10-53 Refill of the Gearbox Oil 1.

  • Page 271: Two-Mass-Flywheel

    Maintenance Manual E4.08.04 85-10-60 Two-Mass-Flywheel 85-10-61 Removal of the Two-Mass-Flywheel 1. Remove the starter - refer to Chapter 80-00-11. 2. Remove the gearbox – refer to Chapter 85-10-11. 3. Disconnect the ground strip of the crankshaft senor plugs 4. Disconnect the crankshaft sensor plugs. 5.

  • Page 272: Removal And Disassembly

    Maintenance Manual E4.08.04 85-10-63 Removal and Disassembly The two–mass-flywheel has to be handled with dry and clean gloves. For removal of the two-mass-flywheel refer to Chapter 85-10-61. 85-10-64 Cleaning Before the two–mass-flywheel is cleaned the visual inspection has to be finished. Cleaning agent or grease-dissolving materials must not be get to the inside of the Two-Mass-Flywheel.
  • Page 273 Maintenance Manual E4.08.04 At the engine side at first the flange has to be cleaned with WD40 and a cleaning cloth. To remove the rust from the surface WD40 has to be dispersed over the whole surface of the flange with slightly pressure. Thereafter the rust can be removed with a Scotch-Brite hand pad.

  • Page 274: Inspection

    Maintenance Manual E4.08.04 85-10-65 Inspection Overview: To describe the investigation points an overview of the two-mass-flywheel is given in the following picture. The flywheel is build up out of two discs (masses) which are connected together with springs at the inside of the bigger disc. The bigger disc with the starter and pick up ring is called primary mass and sign with the number 1 (E4A-73-300-201-002) in the following figure.
  • Page 275 Maintenance Manual E4.08.04 Fig. 85 - 36 Two-Mass-Flywheel (Back Side) Starter and Pick-up ring: Starter and Pick-up ring are located at the outside contour of the primary mass. The pick-up ring has a gap of two teeth which are required for engine speed measuring. Fig.
  • Page 276 Maintenance Manual E4.08.04 Visual Inspection: Before the two-mass-flywheel is cleaned a visual inspection has to be done. The two-mass-flywheel must not have any traces of thermal damage at the rear side or at the outside coverage. Otherwise the two-mass-flywheel has to be replaced. Friction control cam (E4A-73-212-402): Residual of molten plastic between primary and secondary mass of the two-mass-flywheel.
  • Page 277 Maintenance Manual E4.08.04 Wear of the inner rivet head: Due to possible interference between the inner components of the primary mass with the rivets which connect the primary with the secondary mass an additional visual and dimensional inspection is required. min.
  • Page 278 Maintenance Manual E4.08.04 Friction traces: The gap between primary and secondary mass has to be checked. If there are traces of wear at the surface of the primary mass, caused by friction of the secondary mass at the surface of the primary mass, the two-mass-flywheel has to be replaced.
  • Page 279 Maintenance Manual E4.08.04 Bearing Friction Ring: The friction ring has to be in the correct position. If the friction ring has contact to the bearing bushing as seen in the following figure the ring has to be repositioned. Therefore lift the secondary mass slightly thus the ring can be repositioned with a small screwdriver.
  • Page 280 Maintenance Manual E4.08.04 For further operation of the Two-Mass Flywheel the ring has to be reworked. Use a sharp knife to cut off the ragged area of the ring. If the width of the ring is less than 50% or the ring gets broken, the Two-Mass-Flywheel has to be replaced.
  • Page 281 Maintenance Manual E4.08.04 Take care that also small bending of a pick-up ring teeth could lead to engine running problems. Fig. 85 - 46 Fig. 85 - 47 Issue date: 14-Apr-2015 Revision no: 25 Page: 85-29...
  • Page 282 Maintenance Manual E4.08.04 Starter ring: Traces of wearing or damage at the gear tooth of the starter ring. If traces are present the two-mass- flywheel has to be replaced. Less than 95% of the present volume of each tooth is not acceptable. If teeth are damaged the starter has to be checked.
  • Page 283 Maintenance Manual E4.08.04 Balancing weights: If the balancing weights are missing the two-mass-flywheel has to be replaced. This is noticeable if weld points can be seen without the balancing weights. If the weld points are broken the flywheel has to be replaced as well. Fig.
  • Page 284 Maintenance Manual E4.08.04 Mechanical Inspection: To control the mechanical function the two-mass-flywheel has to be tested in a special testing rig – AEP-0061. The wheel is build up and fixed with its primary mass and loaded with defined torque loads. The deflection between the primary and secondary mass will be measured at the defined torque (see Table 1) and recorded.
  • Page 285 Maintenance Manual E4.08.04 Fig. 85 - 51 To measure the deflection between the primary and secondary mass an angle measuring instrument is attached at the input shaft. Fig. 85 - 52 The torque will be attached with a torque wrench at the angle measuring instrument according to the required torque values in Table 1: Tolerance Values.
  • Page 286 Maintenance Manual E4.08.04 Before the measuring is started the spring packages at the inside of the two-mass-flywheel have to be positioned. Therefore the flywheel has to be turned not more than three times into the desired direction with a torque of about 350 Nm. After this the angle measuring system has to be reset to null.
  • Page 287 Maintenance Manual E4.08.04 After the measuring the inspection is finished and the two-mass-flywheel can be dismounted from the test rig. Issue date: 14-Apr-2015 Revision no: 25 Page: 85-35...

  • Page 288: Repair And Replacement

    Maintenance Manual E4.08.04 85-10-66 Repair and Replacement If the two-mass-flywheel has passed the visual and mechanical inspection the flywheel is qualified for a further use in an E4 engine. Otherwise the two-mass-flywheel has to be replaced. A repair of a flywheel is not possible. 85-10-67 Marking of Inspected Two-Mass-Flywheel If the two-mass-flywheel has passed the visual and mechanical inspection the flywheel needs to be...

  • Page 289: Reassembly

    Maintenance Manual E4.08.04 85-10-68 Reassembly Always use new screws (E4A-73-000-801) for a reinstallation of the Two-Mass-Flywheel. After the Flywheel is attached at the crankshaft hub check the position of the friction ring. The ring must be positioned that no tapped hole is covered by the ring. The ring must not be screwed down by one of the screws.

  • Page 290: Packing And Shipping

    Maintenance Manual E4.08.04 85-10-70 Packing and Shipping The overhauled two mass flywheel is packed in a bubble wrap and marked with a label indicating part number, name, S/N number and revision status. Fig. 85 - 54 Fig. 85 - 55 Issue date: 14-Apr-2015 Revision no: 25 Page: 85-38...

  • Page 291: Reciprocating Engine Power Section

    5. Clean the sealing surface for oil sump. 6. Apply engine sealing material at the joint [4]. The recommended engine sealing material is available at Austro Engine GmbH. Refer to the consumeable list for details. 7. Use new oil sump gasket.
  • Page 292 Maintenance Manual E4.08.04 Figures for Chapter 85-20-11 and 85-20-12. Fig. 85 - 56 Fig. 85 - 57 Fig. 85 - 58 Issue date: 14-Apr-2015 Revision no: 25 Page: 85-40...

  • Page 293: Reciprocating Engine Cylinder Section

    Maintenance Manual E4.08.04 85-30-00 Reciprocating Engine Cylinder Section 85-30-10 Intake Air 85-30-11 Removal of the Intake Air Manifold 1. Remove the intake hoses - refer to the applicable Aircraft Maintenance Manual. 2. Put a container below the engine coolant drain. 3.

  • Page 294: Removal Of The Air Intake Manifold (If Optional Gearbox Oil Cooler Installed)

    Maintenance Manual E4.08.04 85-30-13 Removal of the Air Intake Manifold (if optional Gearbox Oil Cooler installed) 1. Remove the intake hoses - refer to the applicable Aircraft Maintenance Manual. 2. Put a container below the engine coolant drain. 3. Drain the engine coolant - refer to the applicable Aircraft Maintenance Manual. 4.
  • Page 295 Maintenance Manual E4.08.04 Intake Air Version E4-A Fig. 85 - 59 Intake Air Inlet E4-A Fig. 85 - 60 Issue date: 14-Apr-2015 Revision no: 25 Page: 85-43...
  • Page 296 Maintenance Manual E4.08.04 Intake Air Version “-A” engine configuration – optional gearbox oil cooler installation with 10 9x 07 2x 12 2x Fig. 85 - 61 Issue date: 14-Apr-2015 Revision no: 25 Page: 85-44...
  • Page 297 Maintenance Manual E4.08.04 Intake Air Version E4-B Fig. 85 - 62 Intake Air Inlet E4-B Fig. 85 - 63 Issue date: 14-Apr-2015 Revision no: 25 Page: 85-45...

  • Page 298: Boost Pressure Sensor

    Maintenance Manual E4.08.04 85-30-20 Boost Pressure Sensor 85-30-21 Removal of the Boost Pressure Sensor 1. Disconnect the electrical connector “BPS1 + BPS2” 2. Remove the screws [3] and [7]. 3. Remove the boost pressure sensor [4] and the spacer [8]. 85-30-22 Installation of the Boost Pressure Sensor 1.

  • Page 299: Cylinder Head

    Maintenance Manual E4.08.04 85-30-40 Cylinder head Before replacement of the cylinder head a power evaluation has to be done to get data for comparison purposes. The data collected before the replacement will be compared to data collected after the replacement to ensure that the engine performs properly after the replacement.

  • Page 300: Removal Of Parts Attached To The Cylinder Head

    Maintenance Manual E4.08.04  Timing chain  Chain tensioner  Fastening bolt for timing chain guide  High pressure pump, if not otherwise instructed in Schedule Maintenance Table Chapter 05-30-00.  Injectors, otherwise instructed Schedule Maintenance Table Chapter 05-30-00.  Glow plugs ...

  • Page 301: Removal Of The Cylinder Head Cover

    Maintenance Manual E4.08.04 85-30-43 Removal of the cylinder head cover 1. Remove the screw [07]. 2. Remove the camshaft position sensor (CAS 1) [06] according to Chapter 76-00-41. 3. Remove the screws [02] and [03]. 4. Remove the cylinder head cover [01] and the inside sealing [04] and the outside sealing [05] from the engine.

  • Page 302: Removal Of The Back Cylinder Head Cover

    Maintenance Manual E4.08.04 Fig. 85 - 65 85-30-45 Removal of the back cylinder head cover 1. Remove the screws [02] and [03]. 2. Remove the back cylinder head cover [01] and the O-ring [04]. Fig. 85 - 66 Issue date: 14-Dec-2015 Revision no: 26 Page: 85-50...

  • Page 303: Removal Of The Front Cylinder Head Cover

    Maintenance Manual E4.08.04 85-30-46 Removal of the front cylinder head cover 1. Remove the screws [02]. 2. Remove the front cylinder head cover [01] and the O-ring [03]. Fig. 85 - 67 85-30-47 Removal of the chain tensioner 1. Remove the chain tensioner with the sealing ring [01] from the cylinder head. Fig.

  • Page 304: Removal Of The Chain Gear

    Maintenance Manual E4.08.04 85-30-48 Removal of the chain gear 1. Remove the fastening bolt by using hammering tool AE300T-010. 2. Remove the screws [02]. Remove the chain gear [01] together with the timing chain from the intake camshaft. 02 3x Chain guide fastening bolt Fig.

  • Page 305: Removal Of The Egr Closing Cover Top

    Maintenance Manual E4.08.04 85-30-50 Removal of the EGR closing cover top 1. Remove screws [02]. 2. Lift off EGR cover [01]. Fig. 85 - 71 85-30-51 Removal of the EGR closing cover bottom 1. Remove screws [02]. 2. Lift off EGR cover [01]. Fig.

  • Page 306: Removal Of The Cylinder Head Sub-Assembly From The Crank Case

    Maintenance Manual E4.08.04 85-30-52 Removal of the cylinder head sub-assembly from the crank case Fig. 85 - 73 1. Remove the screws [03] and [04]. 2. Remove the cylinder head screws [02] in the sketched order from the outside to the inside of the cylinder head.

  • Page 307: Installation Of The Cylinder Head

    Maintenance Manual E4.08.04 85-30-53 Installation of the cylinder head 85-30-54 Installation of the cylinder head pre-assembly on the crank case Fig. 85 - 75 1. Turn the crankshaft in TDC (top dead center) position. Fig. 85 - 76 Issue date: 14-Dec-2015 Revision no: 26 Page: 85-55...
  • Page 308 Maintenance Manual E4.08.04 2. Clean the sealing surface of the crankcase. The sealing surface of the crankcase must be absolutely free of scratches, cracks, debris or any other failures. The cylinder head gasket must be absolutely be free of damage. Blow out the bores for the expansion bolts in the crankcase.
  • Page 309 Maintenance Manual E4.08.04 5. Insert the cylinder head screws [02] and tighten the screws in the sketched order from the inside to the outside of the cylinder head with the following torques. Only use new cylinder head screws. Phase 1: 10 Nm Phase 2: 80 Nm...

  • Page 310: Installation Of The Egr Closing Cover Top

    Maintenance Manual E4.08.04 85-30-55 Installation of the EGR closing cover top 1. Put the closing cover [01] next to the outlet. 2. Screw down the cover with both screws [02]. Tighten the screws with 9 Nm. Fig. 85 - 79 85-30-56 Installation of the EGR closing cover bottom 1.

  • Page 311: Installation Of The Camshafts

    Maintenance Manual E4.08.04 85-30-57 Installation of the camshafts Pairing of a standard camshaft with an alternative camshaft is not permitted! Fig. 85 - 81 1. Insert the front [01] and back camshaft bearing brackets [05] in the cylinder head. 2. Carefully put the camshafts [09] and [10] in position. The camshafts are very breakable! The camshafts must be positioned using the marks on their gears.
  • Page 312 Maintenance Manual E4.08.04 Fig. 85 - 82 Fig. 85 - 83 4. Put the front and back camshaft bearing covers [02] and [04] and the bracket [03] on the camshafts. Mount the camshafts stress-free. The camshafts may not be canted. Ensure that all bearings are located on the place where they have been disassembled.

  • Page 313: Installation Of The Chain Gear

    Maintenance Manual E4.08.04 85-30-58 Installation of the chain gear 1. Put the timing chain on the chain gear [01]. Align the timing chain until the chain gear fits on the fitted bolt on the camshaft. 2. Torque the screws [02] with 18 Nm. 3.

  • Page 314: Installation Of The Front Cylinder Head Cover

    Maintenance Manual E4.08.04 85-30-60 Installation of the front cylinder head cover 1. Clean the sealing surface of the front cylinder head cover [01]. 2. Apply engine sealant (see consumable list) on the sealing surface. 3. Check the correct installation of the O-ring [03]. Only use a new O-ring. 4.
  • Page 315 Maintenance Manual E4.08.04 Sealing surface Fig. 85 - 88 Fig. 85 - 89 85-30-62 Installation of the Camshaft Sensor Housing for CAS 2 1. Apply the gasket [06] in the groove of the housing [01]. Only use a new gasket. 2.

  • Page 316: Installation Of The Cylinder Head Cover

    Maintenance Manual E4.08.04 Fig. 85 - 90 85-30-63 Installation of the cylinder head cover 1. Put the inside [04] and outside [05] sealing in the cylinder head cover. Only use new sealing. 2. Torque the screws [02] and [03] with 12 Nm according to the tightening pattern, starting at 01. Prior to the installation of the cylinder head cover put some oil on the screws.
  • Page 317 Maintenance Manual E4.08.04 Fig. 85 - 91 Tightening pattern for the cylinder head cover Tightening order ; Part number Fig. 85 - 92 Issue date: 14-Dec-2015 Revision no: 26 Page: 85-65...

  • Page 318: Installation Of Parts Attached To The Cylinder Head

    ● Smooth engine run on ECU B (camshaft system correctly configured). Before determining the airworthiness Austro Engine has to check the collected power evaluation data and confirm that no power loss has occurred. Issue date: 14-Dec-2015 Revision no: 26...

  • Page 319: Reciprocating Engine Rear Section

    Maintenance Manual E4.08.04 85-40-00 Reciprocating Engine Rear Section 85-40-10 V-Ribbed Belt 85-40-11 Removal of the V-Ribbed Belt 1. Move the v-belt tensioner [1] clockwise by turning the screw [2] to release the belt tension 2. Secure the v-belt tensioner with a locking pin [3]. 3.

  • Page 320: Belt Tensioner

    Maintenance Manual E4.08.04 85-40-20 Belt Tensioner 85-40-21 Removal of the Belt Tensioner 1. Remove the v-ribbed belt - refer to Chapter 85-40-11. 2. Remove the Alternator - refer to Chapter 24-00-11. 3. Remove the screw from the tensioner [5]. 4. Remove the tensioner. 85-40-22 Installation of the Belt Tensioner 1.

  • Page 321: Belt Tensioner - Roller

    Maintenance Manual E4.08.04 85-40-30 Belt Tensioner – Roller 85-40-31 Removal of the Belt Tensioner – Roller 1. Remove the v-ribbed belt - refer to Chapter 85-40-11. 2. Remove the screw [1] from the roller. 3. Remove the roller. 85-40-32 Installation of the Belt Tensioner – Roller 1.

  • Page 322: Check Of Timing Chain

    Maintenance Manual E4.08.04 85-40-40 Check of timing chain 85-40-41 Preparations prior check of timing chain Engine configuration “–A” Expose the engine according to aircraft maintenance instructions (AMM) to allow access to the chain tensioner of the engine. Engine configuration “–B” or “–C” Expose the engine according to aircraft maintenance instructions (AMM).

  • Page 323: Timing Chain Measuring Tool (Tcmt)

    Maintenance Manual E4.08.04 85-40-42 Timing Chain Measuring tool (TCMT) To conduct the checking procedure the required tool is shown below. Aluminium seal Fig. 85 - 98 Timing Chain Measuring Tool (TCMT) Remove the chain tensioner from the engine and screw the TCMT into the chain tensioner socket. Make sure that the aluminium seal is installed at the Timing Chain Measuring Tool as shown in figure above.

  • Page 324: Checking Procedure Of Timing Chain

    Maintenance Manual E4.08.04 85-40-43 Checking procedure of timing chain To conduct the checking procedure the engine has to be hand turned at the propeller to the top dead center (TDC) position:  Turn the engine into TDC position To detect the engine position in reference to the TDC position, an indication scale is attached at the belt pulley at the rear end of the engine.

  • Page 325: Results Of The Timing Chain Check

    Maintenance Manual E4.08.04 Check the indicator scale of the TCMT according to figure 85 - 99 and repeat turning the engine according to the described checking sequence: • Checking sequence • Turn the engine at the propeller two times and adjust it at the first TDC point. •...

  • Page 326: Assembly Of Engine After Timing Chain Check

    Maintenance Manual E4.08.04 85-40-45 Assembly of engine after timing chain check All engine configurations Remove the TCMT by hand turning and follow the instructions given below: • Place chain tensioner at the depending socket in the engine (See part 04 in figure below). Use a new Gasket for the chain tensioner.

  • Page 327: Exposure Of Timing Chain And Camshaft Chain Wheel

    Maintenance Manual E4.08.04 85-40-50 Exposure of timing chain and camshaft chain wheel For detailed information use the maintenance manuals of aircraft and engine. Remove the following components from the top of the engine to expose the chain drive: • Intake air hoses (refer to Aircraft Maintenance Manual). •...
  • Page 328 Maintenance Manual E4.08.04 • Front side cover E4-A-14-000-000: Loosen all five screws of the front side cover of the cylinder head. Do not cant the cover whilst removing. The drain plug must not be damaged (See drain plug at Figure 85 – 103). Fig.

  • Page 329: Exchange Of Timing Chain

    Maintenance Manual E4.08.04 • To maintain the chain at the camshaft, fasten the chain to the chain wheel with a cable retainer. The position of the cable retainer must be at the 11 o’clock position of the chain wheel seen from the rear side of the engine. The position of the cable retainer is shown in Figure 85 - 105.
  • Page 330 Maintenance Manual E4.08.04 Duct tape Cable retainer Fig. 85 - 105 Position of the chain opening tool at the chain wheel  Connect the new timing chain with the replacing timing chain by use of a chain coupling (AEP-00160). Position the chain in a way that the holes in the pin sleeves of the link are on the outside of the chain as shown in Figure 85 - 106.
  • Page 331 Maintenance Manual E4.08.04  Remove the cable retainer. Pull out the existing timing chain whilst ensuring permanent contact between chain and chain wheel. Turn the engine clockwise in flight direction (as shown in Figure 85 - 107) and feed in the new chain. The chain shall be pulled beyond the guiding tool.
  • Page 332 Maintenance Manual E4.08.04 Open chain link Fig. 85 - 108 Both ends of the new chain connected with the open chain link  Close the chain by mounting the chain clip at the open link. Therefore place the clip at the chain closing tool.
  • Page 333 Maintenance Manual E4.08.04 • Position the chain closing tool with the clip over the free ends of the link’s pins. The riveted ends of the connection link must sit in the groove of the tool as shown in Figure 85 - 81. •...
  • Page 334 Maintenance Manual E4.08.04 Fig. 85 - 111 Riveting slot at the chain closing tool • To rivet the pins place the chain closing tool back on the chain. Place the pressure pad centered over the head of one of those pins, which have to be riveted, as the pins have to be riveted one by one.

  • Page 335: Replacing Of Timing Chain Wheel

    Maintenance Manual E4.08.04 • Remove the chain guiding bar. Clean the surfaces of shell and camshaft and use fresh oil for the reassembly on the bearing surfaces of camshaft and bearing shell. Remount the bearing shell. Turn in the screws equally and fasten them with correct tightening torque. •...
  • Page 336 Maintenance Manual E4.08.04 Fig. 85 - 114 Punch marks at timing wheels of both camshafts Fig. 85 - 115 AE-300-T009 placed at the camshafts Issue date: 14-Dec-2015 Revision no: 26 Page: 85-84...

  • Page 337: Check Of Engine Timing

    Maintenance Manual E4.08.04 • Loosen all three screws of the chain wheel. • Remove the chain wheel. Do not let the chain fall into the chain slot. • Assemble the new chain wheel. Therefore place the teeth of the timing wheel in the chain at first.

  • Page 338: Reassembly Of Engine

    Maintenance Manual E4.08.04 All three points must be obeyed at the same time. • If the timing setup is ok, remove tool AE-300-T009 from the timing wheels. • Turn the engine two turns in clockwise direction Turn the engine very carefully. If there is a stop or resistance TURN BACK and check the timing setup once again! Remove the materials, which were used to cover the chain slot before you turn the engine!
  • Page 339 Maintenance Manual E4.08.04 • Apply oil at the slot of the cam shaft (See Figure 85 - 117) and attach the sensor cover. Apply Loctite 243 to the screws and tighten them with correct torque. • Tightening torque screws: 5 Nm (44 inch-Ibs.) •...

  • Page 340: Reciprocating Engine Liquid Cooling

    Maintenance Manual E4.08.04 85-70-00 Reciprocating Engine Liquid Cooling 85-70-10 Coolant Temperature Sensor 85-70-11 Removal of the Coolant Temperature Sensor 1. Drain the coolant - refer to applicable Aircraft Maintenance Manual. 2. Disconnect the electrical connector “CTS, CTS _ GPC”. 3. Remove the coolant water temperature sensor [5] from the intake air manifold. 85-70-12 Installation of the Coolant Temperature Sensor 1.

  • Page 341: Water Pump

    Maintenance Manual E4.08.04 85-70-20 Water Pump 85-70-21 Removal of the Water Pump 1. Drain the coolant - refer to the applicable Aircraft Maintenance Manual. 2. Remove the coolant pipe - refer to the applicable Aircraft Maintenance Manual. 3. Remove the v-ribbed belt - refer to Chapter 85-40-11. 4.

  • Page 342: Removal Of The Water Pump Bearing Housing Assembly

    Maintenance Manual E4.08.04 85-70-23 Removal of the Water Pump Bearing Housing Assembly 12. Drain the coolant - refer to the applicable Aircraft Maintenance Manual. 13. Remove the coolant pipe - refer to the applicable Aircraft Maintenance Manual. 14. Remove the v-ribbed belt - refer to Chapter 85-40-11. 15.
  • Page 343 Maintenance Manual E4.08.04 Fig. 85 - 120 Issue date: 14-Dec-2015 Revision no: 26 Page: 85-91...

  • Page 344: Heat Exchanger

    Maintenance Manual E4.08.04 85-70-30 Heat Exchanger 85-70-31 Removal of the Heat Exchanger 1. Remove the oil filter housing drain line - refer to Chapter 79-00-11. 2. Remove the oil filter housing - refer to Chapter 79-00-61. 3. Remove the screws [1] from the heat exchanger [2]. 4.

  • Page 345: Coolant Thermostat

    Maintenance Manual E4.08.04 85-70-40 Coolant Thermostat 85-70-41 Removal of the Coolant Thermostat 1. Drain the coolant - refer to the applicable Aircraft Maintenance Manual. 2. Remove the coolant hoses attached to the coolant thermostat - refer to the applicable Aircraft Maintenance Manual. 3.

  • Page 346: Chapter 92-00-00 Additional Information

    Maintenance Manual E4.08.04 Chapter 92-00-00 Additional Information Engine Wiring Diagrams for E4A-90-000-000 Fig. 92 - 1 Issue date: 15-Nov-2011 Revision no: 10 Page: 92-1...
  • Page 347 Maintenance Manual E4.08.04 Fig. 92 - 2 Issue date: 15-Nov-2011 Revision no: 10 Page: 92-2...

  • Page 348: Engine Wiring Diagrams For E4A-95-000-000 Und E4B-95-000-000

    Maintenance Manual E4.08.04 Engine Wiring Diagrams for E4A-95-000-000 und E4B-95-000-000 Fig. 92 - 3 Issue date: 15-Nov-2011 Revision no: 10 Page: 92-3...
  • Page 349 Maintenance Manual E4.08.04 Fig. 92 - 4 Issue date: 15-Nov-2011 Revision no: 10 Page: 92-4...

  • Page 350: Aircraft Interface Wiring

    Maintenance Manual E4.08.04 Aircraft Interface Wiring A/C Interface CPC connector 1 EECU Sensor Supply Power Lever Sensor Signal Sensor Sensor GND ECU A Sensor Supply Sensor Signal Sensor GND Display and Connect to display unit and provide separate CAN L Diagnostic Interface SUB D (RS232) connector (female) CAN BUS Interface 1...
  • Page 351 Maintenance Manual E4.08.04 Aircraft Interface Wiring Alternator Regulator E4A – 91-200-000 Supply Voltage Bus Voltage Lamp Alternator Enable Alternator CPC connector 2 Alternator Feather Feather Valve Used in twin engine installations Valve Switch Fuel Pump Relay Output A Fuel Pump Relay A Fuel Pump Relay Output B Fuel Pump Relay B Sensor Supply...

  • Page 352: Aircraft Interface Wiring

    Maintenance Manual E4.08.04 Aircraft Interface Wiring Regulator Plane Power R1224 Lamp Alternator Enable Alternator CPC connector 2 Alternator Feather Feather Valve Used in twin engine installations Valve Switch Fuel Pump Relay Output A Fuel Pump Relay A Fuel Pump Relay Output B Fuel Pump Relay B Sensor Supply Power Lever...

  • Page 353: Propeller Self Test (Automatic Run-Up Test)

    Maintenance Manual E4.08.04 Propeller Self Test (Automatic Run-Up Test) Self Test Overview: The following diagram shows the sequence of events, checks and results expected by the EECU software while running the propeller self test procedure. Begin ü A/C on the ground ü...
  • Page 354 Maintenance Manual E4.08.04 Diagnostic Trouble Code (DTC) = 1C01 Propeller self test failure (MAX: Timeout during propeller self test) Time of first and last occurrence Day, hour, minutes and second Propeller speed = 1886 rpm Propeller self test internal state = 03 (refer to picture “Self Test Overview”) Timeout error flags = 00000001 Self test release status = 01111111...
  • Page 355 Maintenance Manual E4.08.04 Trouble Shooting Steps: 1. Display the FCM entry (fault details) 2. The “propeller self test internal state” provides the number of the phase which has been aborted. Refer to the “Self Test Overview” to understand what the expected result of the phase was.
  • Page 356 Maintenance Manual E4.08.04 Diagnosing Self Test Failures using the Data Logger: If the FCM entry of a self test failure is not available or if trouble shooting multiple events from past flight cycles, using the Data Logger function of the EECU is recommended. The Data Logger information can be downloaded and displayed by the “AE 300 Wizard”...
  • Page 357 Maintenance Manual E4.08.04 The AE 300 Wizard will display the Data Logger record of a failure during the propeller self test similar to the following example (a faulty propeller governor): The self test occurrence can be found by looking for the characteristic two “humps” in the propeller speed-line when at the same time the power lever is at “0%”.

  • Page 358: List Of Tools

    Maintenance Manual E4.08.04 List of Tools Title: Tool: Remark: AE 300 Wizard EECU Software Read Out Program For installation and The user guide E4.Aug.09 of the AE 300 Wizard will be usage of the delivered with the program Software refer to the user guide E4.Aug.09 Flywheel Locking Tool...
  • Page 359 Maintenance Manual E4.08.04 Title: Tool: Remark: Hammering tool AE300T-010 Camshaft locking tool AE300T-009 Issue date: 14-Dec-2015 Revision no: 26 Page: 92-14...
  • Page 360 These technical data and the information contain therein are the property of Austro Engine GmbH and may not be reproduced either in full or in part or passed on to a third party without written consent from Austro Engine GmbH.

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