Austro Engine AE300

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Maintenance Manual

E4.08.04

Issue date: 19-Jan-2012

Page: 01-5

Revision no: 11

Engine Top View:

Fig. 01 - 2 Engine Top View

Main Page

Introduction4
List of Revision5
List of Incorporated Temporary Revisions9
List of Valid Pages10
List of Abbreviation14
Conversion Table of Given Torque Values16
Conversion Table of Given Pressure Values17
Consumable List18
Table of Contents19
General27
General Engine Description28
Intake/Exhaust System Description39
Fuel System Description41
Exhaust System Description44
Coolant System Description44
Lubricating System Description47
Electrical System Description48
Governor Description68
Transport and Packaging71
Packaging71
Transport74
Protective Covers75
Storage75
Return Parts Shipping Instruction75
Engine Installation77
Airworthiness Limitation79
Time Limits and Maintenance Check81
General81
Time Limits of Engine Model E482
Time Limits of Engine Model E4P82
Claimable Exceed of Maintenance Actions83
Engine Time between Overhaul83
Schedule Maintenance Inspections and Checks of Engine Model E484
Two Mass Flywheel85
Alternator85
Engine Harness and Sensors85
Eecu85
EECU Read out85
Gearbox - Oil85
Gearbox Oil Filter86
V-Ribbed Belt86
Engine - Oil86
Engine Oil Filter86
High Pressure Pump86
Cylinder Head Drain87
Fuel System87
Fuel Filter87
Waste Gate Controller87
Exhaust System87
Coolant87
Cooling System88
Breather Line88
Zonal Inspection88
Injector Cover88
Timing Chain89
Schedule Maintenance Inspections and Checks of Engine Model E4P90
Gearbox91
Injectors91
Turbo Charger91
Cylinder Head92
Unscheduled Maintenance Checks93
Performance Deterioration93
Violation of Temperature Limits93
Sudden Stoppage Inspection93
Propeller Strike93
Lightning Strike93
High Engine Oil Consumption Inspection94
Engine Oil System Contaminated94
Engine Oil Pressure Loss Inspection94
Inability to Start the Engine94
Servicing95
Engine Oil Servicing95
Check the Oil Level95
Gearbox Oil96
Check the Gearbox Oil Level96
Engine Coolant Servicing96
Electrical Power97
General97
Alternator E4A-91-000-00097
Replacement of Alternator E4A-91-000-00097
Removal of the Alternator E4A-91-000-00097
Installation of the Alternator E4A-91-000-00098
Inspection of Alternator E4A-91-000-000 and the Carbon Brushes98
Tools Necessary99
Removal of the Brush Holder Assembly99
Visual Inspection of Alternator Housing and Pulley100
Inspection of Contact Ring and Brushes101
Disassembly of Brush Holder102
Measuring the Length of Carbon Brushes104
Evaluation Criteria105
Completion of Brush Holder106
Completion of Alternator (Integration of Brush Holder)108
Functionality Check110
Marking of Maintained Alternator E4A-91-000-000111
Alternator E4A-91-400-000112
Removal of Alternator E4A-91-400-000112
Installation of the Alternator E4A-91-400-000112
Inspection of Alternator E4A-91-400-000 and Carbon Brushes114
Tools Necessary114
Removal of Brush Holder Assembly114
Disassembly of ASSY Brush Holder118
Measuring the Length of Carbon Brushes119
Evaluation Criteria120
Completion of Alternator (Installation of Brush Holder ASSY)121
Functionality Check124
Marking of Maintained Alternator E4A-91-400-000125
Alternator-Regulator Adjustment E4A-91-100-000126
Adjustment Procedure of Voltage Regulation E4A-91-100-000127
Adjustment of Alternator Balancing E4A-91-100-000127
Replacing Alternator-Regulator E4A-91-100-000127
Alternator-Regulator Adjustment E4A-91-200-000128
Paralleling for Twin Engine System E4A-91-200-000128
Standard Practices129
Safety Wiring129
The Following Alternator Rules Apply to Safety Wiring129
Single Wire Safe Tying130
Double Wire Safety Wiring Using Pliers131
Samples of Safety Wiring132
Torque Standards135
Power Plant137
General137
Instruction137
Engine Ground Run138
Electrical Harness140
General140
General Information -> Wiring Harness140
Engine Harness Routing141
Engine Wiring Harness E4A-90-000-000142
Sensor - Check143
Description Plug Connector Wiring Harness143
Material and Saving Material for the Engine Wiring Harness144
Mounting Backbones145
Intake Air Manifold146
Alternator153
Gpc154
Mechanical Protection (Mesh Tube)156
Fastening Point in the Aircraft (E4A-90-000-000)160
Engine Wiring Harness E4A-95-000-000 and E4B-95-000-000162
Sensor - Check164
Description Plug Connector Wiring Harness164
Material and Saving Material for the E4A Engine Wiring Harness165
Material and Saving Material for the E4B Engine Wiring Harness165
E4 Engine Wiring Harness Mounting Instruction166
Remove the Wiring Harness183
Repair of the Engine Wiring Harness E4A-90-000-000185
Exchange of Connector to "Intake Air Temperature"-Sensors185
Exchange of Connector to Fuel Pressure Sensor (FPS)187
Exchange of Connector to Boost Pressure Actuator (BPA)189
Exchange of Connector for Alternator E4A-91-400-000191
Exchange of Connector for Alternator E4A-91-000-000193
Exchange of Connector to Fuel Metering Unit (FMU)196
Repair of the Engine Wiring Harness E4A-95-000-000 und E4B-95-000-000200
Exchange of Connector of Gearbox Temperature Sensor (GBTS), Fuel Temperature200
Cts_Gpc201
Exchange of Connector for Alternator E4A-91-400-000202
Engine Fuel and Control205
General205
Injector205
Removal of the Injector205
Installation of the Injector205
Injector Seals207
Removal of the Injectors Seals207
Installation of the Injectors Seals207
Fuel Return Line208
Removal of the Fuel Return Line208
Installation of the Fuel Return Line208
High Pressure Pump210
Removal of the High Pressure Pump210
Removal of the Spur Gear from High Pressure Pump211
Installation of the Spur Gear Onto High Pressure Pump212
Installation of the High Pressure Pump212
Low Fuel Pressure Sensor213
Removal of the Fuel Pressure Sensor213
Installation of the Fuel Pressure Sensor213
Rail Pressure Sensor214
Removal of the Rail Pressure Sensor214
Installation of the Rail Pressure Sensor214
Rail Pressure Control Valve214
Engine Control215
General215
Engine Electronic Control Unit (EECU)215
Software Updates215
Glow Plug Control217
Removal of the Glow Plug Control217
Installation of the Glow Plug Control217
Crankshaft Sensor218
Removal of the Crankshaft Sensor218
Installation of the Crankshaft Sensor218
Camshaft Sensor CAS 1219
Removal of the Camshaft Sensor CAS 1219
Installation of the Camshaft Sensor CAS 1219
Camshaft Sensor CAS 2220
Removal of the Camshaft Sensor CAS 2220
Installation of the Camshaft Sensor CAS 2220
Engine Indicating221
General221
Gearbox Temperature Sensor221
Engine Exhaust223
General223
Exhaust Manifold223
Removal of the Exhaust Manifold223
Installation of the Exhaust Manifold223
Exhaust Manifold Gasket Exchange224
Engine Oil225
General225
Oil-Filter Housing Draining Line225
Removal of the Oil-Filter Housing Drain Line225
Installation of the Oil-Filter Housing Drain Line225
Drain of Engine Oil227
Refill of Engine Oil227
Oil Sump228
Removal of the Oil Sump228
Installation of the Oil Sump228
Oil Sump Gasket Exchange229
Oil-Filter Housing231
Removal of the Oil-Filter Housing231
Installation of the Oil-Filter Housing231
Oil-Filter232
Remove and Discard of the Oil-Filter232
Installation of the Oil-Filter232
Oil Separator233
Removal of the Oil Separator233
Installation of the Oil Separator233
Removal of the Oil Separator By-Pass Valve233
Installation of the Oil Separator By-Pass Valve234
Oil Separator Return Line235
Removal of the Oil Separator Return Line235
Installation of the Oil Separator Return Line235
Lubricant Line236
Removal of the Lubricant Line236
Installation of the Lubricant Line236
Removal of the Lubricant Line Sealing Ring237
Installation Lubricant Line Sealing Ring237
Oil Return Line238
Removal of the Oil Return Line238
Installation of the Oil Return Line238
Removal of the Oil Return Line Gasket239
Installation of the Oil Return Line Gasket239
Oil Level Sensor240
Removal of the Oil Level Sensor240
Installation of the Oil Level Sensor240
Oil Pressure Sensor241
Removal of the Oil Pressure Sensor241
Installation of the Oil Pressure Sensor241
Governor242
Removal of the Governor242
Installation of the Governor242
Starting243
General243
Starter243
Removal of the Starter243
Installation of the Starter243
Glow Plugs245
Removal of the Glow Plugs245
Installation of the Glow Plugs245
Turbocharging247
Turbo Charger Complete247
Removal of the Turbo Charger247
Installation of the Turbo Charger247
Removal of the Waste Gate Controller247
Install New Waste Gate Controller247
Boost Pressure Actuator249
Removal of the Boost Pressure Actuator (BPA)249
Installation of the Boost Pressure Actuator249
Waste Gate Controller251
Inspection251
Check /Adjust of the Waste Gate Controller251
Reciprocating Engine253
Injector Cover253
Removal of the Injector Cover253
Installation of the Injector Cover Without Maintenance Lid253
Removal of the Maintenance Lid255
Installation of the Injector Cover with Maintenance Lid255
Installation of the Maintenance Lid256
Reciprocating Engine Front System258
Gearbox258
Removal of the Gearbox258
Installation of the Gearbox258
Removal of the Gearbox with Optional Gearbox Oil Cooler259
Installation of the Gearbox with Optional Gearbox Oil Cooler259
Removal of the Optional Gearbox Oil Cooler264
Installation of the Optional Gearbox Oil Cooler264
Gearbox Magnet-Drain Plug265
Removal of the Gearbox Magnet-Drain Plug265
Installation of the Gearbox Magnet-Drain Plug266
Gearbox Oil Filter (Gearbox Rev. 70 or Higher)267
Removal of the Gearbox Oil Filter267
Installation of the Gearbox Oil Filter268
Gearbox Temperature Sensor269
Removal of the Gearbox Temperature Sensor269
Installation of the Gearbox Temperature Sensor269
Gearbox Oil270
General270
Exchange of the Gearbox Oil270
Refill of the Gearbox Oil270
Two-Mass-Flywheel271
Removal of the Two-Mass-Flywheel271
Installation of the Two-Mass-Flywheel271
Removal and Disassembly272
Cleaning272
Inspection274
Repair and Replacement288
Marking of Inspected Two-Mass-Flywheel288
Reassembly289
Special Tools289
Packing and Shipping290
Reciprocating Engine Power Section291
Crankshaft Cover291
Removal of the Crankshaft Cover291
Installation of the Crankshaft Cover291
Reciprocating Engine Cylinder Section293
Intake Air293
Removal of the Intake Air Manifold293
Installation of the Intake Air Manifold293
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 Sensor298
Removal of the Boost Pressure Sensor298
Installation of the Boost Pressure Sensor298
Intake Air Temperature Sensor298
Removal of the Intake Air Temperature Sensor298
Installation of the Intake Air Temperature Sensor298
Cylinder Head299
Removal of the Cylinder Head299
Removal of Parts Attached to the Cylinder Head300
Removal of the Cylinder Head Cover301
Removal of the Camshaft Sensor Housing for CAS 2301
Removal of the Back Cylinder Head Cover302
Removal of the Front Cylinder Head Cover303
Removal of the Chain Tensioner303
Removal of the Chain Gear304
Removal of the Camshafts304
Removal of the EGR Closing Cover Top305
Removal of the EGR Closing Cover Bottom305
Removal of the Cylinder Head Sub-Assembly from the Crank Case306
Installation of the Cylinder Head307
Installation of the Cylinder Head Pre-Assembly on the Crank Case307
Installation of the EGR Closing Cover Top310
Installation of the EGR Closing Cover Bottom310
Installation of the Camshafts311
Installation of the Chain Gear313
Installation of the Chain Tensioner313
Installation of the Front Cylinder Head Cover314
Installation of the Back Cylinder Head Cover314
Installation of the Cylinder Head Cover316
Installation of Parts Attached to the Cylinder Head318
Reciprocating Engine Rear Section319
V-Ribbed Belt319
Removal of the V-Ribbed Belt319
Installation of the V-Ribbed Belt319
Belt Tensioner320
Removal of the Belt Tensioner320
Installation of the Belt Tensioner320
Belt Tensioner - Roller321
Removal of the Belt Tensioner - Roller321
Installation of the Belt Tensioner - Roller321
Check of Timing Chain322
Preparations Prior Check of Timing Chain322
Timing Chain Measuring Tool (TCMT)323
Checking Procedure of Timing Chain324
Results of the Timing Chain Check325
Assembly of Engine after Timing Chain Check326
Exposure of Timing Chain and Camshaft Chain Wheel327
Exchange of Timing Chain329
Replacing of Timing Chain Wheel335
Check of Engine Timing337
Reassembly of Engine338
Reciprocating Engine Liquid Cooling340
Coolant Temperature Sensor340
Removal of the Coolant Temperature Sensor340
Installation of the Coolant Temperature Sensor340
Water Pump341
Removal of the Water Pump341
Installation of the Water Pump341
Removal of the Water Pump Bearing Housing Assembly342
Installation of the Water Pump Bearing Housing Assembly342
Heat Exchanger344
Removal of the Heat Exchanger344
Installation of the Heat Exchanger344
Coolant Thermostat345
Removal of the Coolant Thermostat345
Installation of the Coolant Thermostat345
Chapter 92-00-00 Additional Information346
Engine Wiring Diagrams for E4A-90-000-000346
Engine Wiring Diagrams for E4A-95-000-000 und E4B-95-000-000348
Aircraft Interface Wiring350
Aircraft Interface Wiring352
Propeller Self Test (Automatic Run-Up Test)353
List of Tools358

Austro Engine AE300 - Page 31

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