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Austro Engine AE300 Service Manual
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Maintenance Manu
al
E4
.08.
04
Issue da
te:
14
-D
ec-
2015
Page: Intr
o-
11
Revision no: 26
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13
Table of Contents
Introduction
4
List of Revision
5
List of Incorporated Temporary Revisions
9
List of Valid Pages
10
List of Abbreviation
14
Conversion Table of Given Torque Values
16
Conversion Table of Given Pressure Values
17
Consumable List
18
Table of Contents
19
General
27
General Engine Description
28
Intake/Exhaust System Description
39
Fuel System Description
41
Exhaust System Description
44
Coolant System Description
44
Lubricating System Description
47
Electrical System Description
48
Governor Description
68
Transport and Packaging
71
Packaging
71
Transport
74
Protective Covers
75
Storage
75
Return Parts Shipping Instruction
75
Engine Installation
77
Airworthiness Limitation
79
Time Limits and Maintenance Check
81
General
81
Time Limits of Engine Model E4
82
Time Limits of Engine Model E4P
82
Claimable Exceed of Maintenance Actions
83
Engine Time between Overhaul
83
Schedule Maintenance Inspections and Checks of Engine Model E4
84
Two Mass Flywheel
85
Alternator
85
Engine Harness and Sensors
85
Eecu
85
EECU Read out
85
Gearbox - Oil
85
Gearbox Oil Filter
86
V-Ribbed Belt
86
Engine - Oil
86
Engine Oil Filter
86
High Pressure Pump
86
Cylinder Head Drain
87
Fuel System
87
Fuel Filter
87
Waste Gate Controller
87
Exhaust System
87
Coolant
87
Cooling System
88
Breather Line
88
Zonal Inspection
88
Injector Cover
88
Timing Chain
89
Schedule Maintenance Inspections and Checks of Engine Model E4P
90
Gearbox
91
Injectors
91
Turbo Charger
91
Cylinder Head
92
Unscheduled Maintenance Checks
93
Performance Deterioration
93
Violation of Temperature Limits
93
Sudden Stoppage Inspection
93
Propeller Strike
93
Lightning Strike
93
High Engine Oil Consumption Inspection
94
Engine Oil System Contaminated
94
Engine Oil Pressure Loss Inspection
94
Inability to Start the Engine
94
Servicing
95
Engine Oil Servicing
95
Check the Oil Level
95
Gearbox Oil
96
Check the Gearbox Oil Level
96
Engine Coolant Servicing
96
Electrical Power
97
General
97
Alternator E4A-91-000-000
97
Replacement of Alternator E4A-91-000-000
97
Removal of the Alternator E4A-91-000-000
97
Installation of the Alternator E4A-91-000-000
98
Inspection of Alternator E4A-91-000-000 and the Carbon Brushes
98
Tools Necessary
99
Removal of the Brush Holder Assembly
99
Visual Inspection of Alternator Housing and Pulley
100
Inspection of Contact Ring and Brushes
101
Disassembly of Brush Holder
102
Measuring the Length of Carbon Brushes
104
Evaluation Criteria
105
Completion of Brush Holder
106
Completion of Alternator (Integration of Brush Holder)
108
Functionality Check
110
Marking of Maintained Alternator E4A-91-000-000
111
Alternator E4A-91-400-000
112
Removal of Alternator E4A-91-400-000
112
Installation of the Alternator E4A-91-400-000
112
Inspection of Alternator E4A-91-400-000 and Carbon Brushes
114
Tools Necessary
114
Removal of Brush Holder Assembly
114
Disassembly of ASSY Brush Holder
118
Measuring the Length of Carbon Brushes
119
Evaluation Criteria
120
Completion of Alternator (Installation of Brush Holder ASSY)
121
Functionality Check
124
Marking of Maintained Alternator E4A-91-400-000
125
Alternator-Regulator Adjustment E4A-91-100-000
126
Adjustment Procedure of Voltage Regulation E4A-91-100-000
127
Adjustment of Alternator Balancing E4A-91-100-000
127
Replacing Alternator-Regulator E4A-91-100-000
127
Alternator-Regulator Adjustment E4A-91-200-000
128
Paralleling for Twin Engine System E4A-91-200-000
128
Standard Practices
129
Safety Wiring
129
The Following Alternator Rules Apply to Safety Wiring
129
Single Wire Safe Tying
130
Double Wire Safety Wiring Using Pliers
131
Samples of Safety Wiring
132
Torque Standards
135
Power Plant
137
General
137
Instruction
137
Engine Ground Run
138
Electrical Harness
140
General
140
General Information -> Wiring Harness
140
Engine Harness Routing
141
Engine Wiring Harness E4A-90-000-000
142
Sensor - Check
143
Description Plug Connector Wiring Harness
143
Material and Saving Material for the Engine Wiring Harness
144
Mounting Backbones
145
Intake Air Manifold
146
Alternator
153
Gpc
154
Mechanical Protection (Mesh Tube)
156
Fastening Point in the Aircraft (E4A-90-000-000)
160
Engine Wiring Harness E4A-95-000-000 and E4B-95-000-000
162
Sensor - Check
164
Description Plug Connector Wiring Harness
164
Material and Saving Material for the E4A Engine Wiring Harness
165
Material and Saving Material for the E4B Engine Wiring Harness
165
E4 Engine Wiring Harness Mounting Instruction
166
Remove the Wiring Harness
183
Repair of the Engine Wiring Harness E4A-90-000-000
185
Exchange of Connector to "Intake Air Temperature"-Sensors
185
Exchange of Connector to Fuel Pressure Sensor (FPS)
187
Exchange of Connector to Boost Pressure Actuator (BPA)
189
Exchange of Connector for Alternator E4A-91-400-000
191
Exchange of Connector for Alternator E4A-91-000-000
193
Exchange of Connector to Fuel Metering Unit (FMU)
196
Repair of the Engine Wiring Harness E4A-95-000-000 und E4B-95-000-000
200
Exchange of Connector of Gearbox Temperature Sensor (GBTS), Fuel Temperature
200
Cts_Gpc
201
Exchange of Connector for Alternator E4A-91-400-000
202
Engine Fuel and Control
205
General
205
Injector
205
Removal of the Injector
205
Installation of the Injector
205
Injector Seals
207
Removal of the Injectors Seals
207
Installation of the Injectors Seals
207
Fuel Return Line
208
Removal of the Fuel Return Line
208
Installation of the Fuel Return Line
208
High Pressure Pump
210
Removal of the High Pressure Pump
210
Removal of the Spur Gear from High Pressure Pump
211
Installation of the Spur Gear Onto High Pressure Pump
212
Installation of the High Pressure Pump
212
Low Fuel Pressure Sensor
213
Removal of the Fuel Pressure Sensor
213
Installation of the Fuel Pressure Sensor
213
Rail Pressure Sensor
214
Removal of the Rail Pressure Sensor
214
Installation of the Rail Pressure Sensor
214
Rail Pressure Control Valve
214
Engine Control
215
General
215
Engine Electronic Control Unit (EECU)
215
Software Updates
215
Glow Plug Control
217
Removal of the Glow Plug Control
217
Installation of the Glow Plug Control
217
Crankshaft Sensor
218
Removal of the Crankshaft Sensor
218
Installation of the Crankshaft Sensor
218
Camshaft Sensor CAS 1
219
Removal of the Camshaft Sensor CAS 1
219
Installation of the Camshaft Sensor CAS 1
219
Camshaft Sensor CAS 2
220
Removal of the Camshaft Sensor CAS 2
220
Installation of the Camshaft Sensor CAS 2
220
Engine Indicating
221
General
221
Gearbox Temperature Sensor
221
Engine Exhaust
223
General
223
Exhaust Manifold
223
Removal of the Exhaust Manifold
223
Installation of the Exhaust Manifold
223
Exhaust Manifold Gasket Exchange
224
Engine Oil
225
General
225
Oil-Filter Housing Draining Line
225
Removal of the Oil-Filter Housing Drain Line
225
Installation of the Oil-Filter Housing Drain Line
225
Drain of Engine Oil
227
Refill of Engine Oil
227
Oil Sump
228
Removal of the Oil Sump
228
Installation of the Oil Sump
228
Oil Sump Gasket Exchange
229
Oil-Filter Housing
231
Removal of the Oil-Filter Housing
231
Installation of the Oil-Filter Housing
231
Oil-Filter
232
Remove and Discard of the Oil-Filter
232
Installation of the Oil-Filter
232
Oil Separator
233
Removal of the Oil Separator
233
Installation of the Oil Separator
233
Removal of the Oil Separator By-Pass Valve
233
Installation of the Oil Separator By-Pass Valve
234
Oil Separator Return Line
235
Removal of the Oil Separator Return Line
235
Installation of the Oil Separator Return Line
235
Lubricant Line
236
Removal of the Lubricant Line
236
Installation of the Lubricant Line
236
Removal of the Lubricant Line Sealing Ring
237
Installation Lubricant Line Sealing Ring
237
Oil Return Line
238
Removal of the Oil Return Line
238
Installation of the Oil Return Line
238
Removal of the Oil Return Line Gasket
239
Installation of the Oil Return Line Gasket
239
Oil Level Sensor
240
Removal of the Oil Level Sensor
240
Installation of the Oil Level Sensor
240
Oil Pressure Sensor
241
Removal of the Oil Pressure Sensor
241
Installation of the Oil Pressure Sensor
241
Governor
242
Removal of the Governor
242
Installation of the Governor
242
Starting
243
General
243
Starter
243
Removal of the Starter
243
Installation of the Starter
243
Glow Plugs
245
Removal of the Glow Plugs
245
Installation of the Glow Plugs
245
Turbocharging
247
Turbo Charger Complete
247
Removal of the Turbo Charger
247
Installation of the Turbo Charger
247
Removal of the Waste Gate Controller
247
Install New Waste Gate Controller
247
Boost Pressure Actuator
249
Removal of the Boost Pressure Actuator (BPA)
249
Installation of the Boost Pressure Actuator
249
Waste Gate Controller
251
Inspection
251
Check /Adjust of the Waste Gate Controller
251
Reciprocating Engine
253
Injector Cover
253
Removal of the Injector Cover
253
Installation of the Injector Cover Without Maintenance Lid
253
Removal of the Maintenance Lid
255
Installation of the Injector Cover with Maintenance Lid
255
Installation of the Maintenance Lid
256
Reciprocating Engine Front System
258
Gearbox
258
Removal of the Gearbox
258
Installation of the Gearbox
258
Removal of the Gearbox with Optional Gearbox Oil Cooler
259
Installation of the Gearbox with Optional Gearbox Oil Cooler
259
Removal of the Optional Gearbox Oil Cooler
264
Installation of the Optional Gearbox Oil Cooler
264
Gearbox Magnet-Drain Plug
265
Removal of the Gearbox Magnet-Drain Plug
265
Installation of the Gearbox Magnet-Drain Plug
266
Gearbox Oil Filter (Gearbox Rev. 70 or Higher)
267
Removal of the Gearbox Oil Filter
267
Installation of the Gearbox Oil Filter
268
Gearbox Temperature Sensor
269
Removal of the Gearbox Temperature Sensor
269
Installation of the Gearbox Temperature Sensor
269
Gearbox Oil
270
General
270
Exchange of the Gearbox Oil
270
Refill of the Gearbox Oil
270
Two-Mass-Flywheel
271
Removal of the Two-Mass-Flywheel
271
Installation of the Two-Mass-Flywheel
271
Removal and Disassembly
272
Cleaning
272
Inspection
274
Repair and Replacement
288
Marking of Inspected Two-Mass-Flywheel
288
Reassembly
289
Special Tools
289
Packing and Shipping
290
Reciprocating Engine Power Section
291
Crankshaft Cover
291
Removal of the Crankshaft Cover
291
Installation of the Crankshaft Cover
291
Reciprocating Engine Cylinder Section
293
Intake Air
293
Removal of the Intake Air Manifold
293
Installation of the Intake Air Manifold
293
Removal of the Air Intake Manifold (if Optional Gearbox Oil Cooler Installed)
294
Installation of the Air Intake Manifold (if Optional Gearbox Oil Cooler Installed)
294
Boost Pressure Sensor
298
Removal of the Boost Pressure Sensor
298
Installation of the Boost Pressure Sensor
298
Intake Air Temperature Sensor
298
Removal of the Intake Air Temperature Sensor
298
Installation of the Intake Air Temperature Sensor
298
Cylinder Head
299
Removal of the Cylinder Head
299
Removal of Parts Attached to the Cylinder Head
300
Removal of the Cylinder Head Cover
301
Removal of the Camshaft Sensor Housing for CAS 2
301
Removal of the Back Cylinder Head Cover
302
Removal of the Front Cylinder Head Cover
303
Removal of the Chain Tensioner
303
Removal of the Chain Gear
304
Removal of the Camshafts
304
Removal of the EGR Closing Cover Top
305
Removal of the EGR Closing Cover Bottom
305
Removal of the Cylinder Head Sub-Assembly from the Crank Case
306
Installation of the Cylinder Head
307
Installation of the Cylinder Head Pre-Assembly on the Crank Case
307
Installation of the EGR Closing Cover Top
310
Installation of the EGR Closing Cover Bottom
310
Installation of the Camshafts
311
Installation of the Chain Gear
313
Installation of the Chain Tensioner
313
Installation of the Front Cylinder Head Cover
314
Installation of the Back Cylinder Head Cover
314
Installation of the Cylinder Head Cover
316
Installation of Parts Attached to the Cylinder Head
318
Reciprocating Engine Rear Section
319
V-Ribbed Belt
319
Removal of the V-Ribbed Belt
319
Installation of the V-Ribbed Belt
319
Belt Tensioner
320
Removal of the Belt Tensioner
320
Installation of the Belt Tensioner
320
Belt Tensioner - Roller
321
Removal of the Belt Tensioner - Roller
321
Installation of the Belt Tensioner - Roller
321
Check of Timing Chain
322
Preparations Prior Check of Timing Chain
322
Timing Chain Measuring Tool (TCMT)
323
Checking Procedure of Timing Chain
324
Results of the Timing Chain Check
325
Assembly of Engine after Timing Chain Check
326
Exposure of Timing Chain and Camshaft Chain Wheel
327
Exchange of Timing Chain
329
Replacing of Timing Chain Wheel
335
Check of Engine Timing
337
Reassembly of Engine
338
Reciprocating Engine Liquid Cooling
340
Coolant Temperature Sensor
340
Removal of the Coolant Temperature Sensor
340
Installation of the Coolant Temperature Sensor
340
Water Pump
341
Removal of the Water Pump
341
Installation of the Water Pump
341
Removal of the Water Pump Bearing Housing Assembly
342
Installation of the Water Pump Bearing Housing Assembly
342
Heat Exchanger
344
Removal of the Heat Exchanger
344
Installation of the Heat Exchanger
344
Coolant Thermostat
345
Removal of the Coolant Thermostat
345
Installation of the Coolant Thermostat
345
Chapter 92-00-00 Additional Information
346
Engine Wiring Diagrams for E4A-90-000-000
346
Engine Wiring Diagrams for E4A-95-000-000 und E4B-95-000-000
348
Aircraft Interface Wiring
350
Aircraft Interface Wiring
352
Propeller Self Test (Automatic Run-Up Test)
353
List of Tools
358
4
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Austro Engine AE300 Specifications
General
Brand
Austro Engine
Model
AE300
Category
Engine
Language
English
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