Austro Engine E4 Series

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E4 Series

Maintenance Manual

Introduction

E4.08.04

Rev. 29

Page 3

01-Introduction

01-Jul-2020

Maintenance Manual E4

Date: Wiener Neustadt, 01-Jul-2020

Author: Austro Engine GmbH

Rudolf – Diesel – Straße - 11

2700 Wiener Neustadt

Austria

Document number: E4.08.04

Revision: 29

Main Page

Table of Contents7
Introduction9
General9
Warning, Cautions and Notes10
Manual Configuration10
Chapter Configuration11
Page Numbering System11
Figures11
Revisions12
List of Revisions13
List of Included Temporary Revisions19
List of Service Bulletins Included as Maintenance Procedures21
Abbreviations22
General22
Engine Harness23
Conversion Factors24
Conversion Table of Given Torque Values24
Conversion Table of Given Pressure Values25
Engine Power Conversions25
Consumable List26
General Description of the Engine27
Transport and Packaging39
General39
Packaging39
Transport43
Protective Covers44
Storage and Preservation45
Storage of a Received Engine45
Preservation of an Installed Engine45
Engine Depreservation47
Engine Storage48
Return Parts Shipping Instructions49
Time Limits and Maintenance Check63
General63
Words for Special Meanings64
Claimable Exceed of Maintenance Actions66
Component Time Limits and Maintenance Requirements67
Component Time Limits68
Component Maintenance Requirements69
Engine Time between Overhaul70
Scheduled Maintenance Checks71
Unscheduled Maintenance Checks76
Performance Deterioration76
Violation of Temperature Limits76
Sudden Stoppage Inspection76
Propeller Strike76
Lightning Strike76
High Engine Oil Consumption Inspection77
Engine Oil System Contaminated77
Engine Oil Pressure Loss Inspection77
Inability to Start the Engine77
Engine over Speed77
Servicing82
Engine Oil Servicing83
Complete a Check of the Oil Level83
Do a Check of the Gearbox Oil Level84
Engine Coolant Servicing84
Electrical Power89
Electrical System Description89
Electrical System Installation90
Alternator90
Alternator-Regulator Adjustment E4A-91-200-00091
Paralleling for Twin Engine System E4A-91-200-00091
Troubleshooting Information93
General93
Alternator E4A-91-000-00095
General95
Maintenance Procedures95
Remove the Alternator95
Install the Alternator96
Acceptance Criteria for Alternator Bench Tests98
Inspection of Alternator E4A-91-000-000 and the Carbon Brushes98
Special Tools98
Remove the Brush Holder Assembly98
Visually Examine the Alternator Housing and Pulley99
Examine the Contact Ring and Brushes100
Disassemble the Brush Holder Assembly E4A-91-300-000101
Measure the Length of Carbon Brushes104
Complete the Brush Holder104
Install the Brush Holder106
Functional Check109
Alternator E4A-91-400-000116
General116
Maintenance Procedures116
Remove the Alternator116
Install the Alternator117
Acceptance Criteria for Alternator Bench Tests120
Inspection of Alternator E4A-91-400-000 and Carbon Brushes120
Special Tools120
Remove the Brush the Holder Assembly120
Visually Examine the Alternator Housing and Pulley123
Examine the Contact Ring and Brushes124
Examine the ASSY Brush Holder E4A-91-410-000125
Measure the Length of Carbon Brushes125
Install the Brush Holder126
Functional Check130
Alternator-Regulator E4A-91-100-000135
General135
Adjust the Voltage Regulation E4A-91-100-000136
Adjust the Alternator Balancing E4A-91-100-000 (Only for Twin-Engine Applications)136
Replace Alternator-Regulator E4A-91-100-000136
Standard Procedures141
General141
Safetying Methods141
Standard Torque Values141
Troubleshooting Information143
General143
Safety Wiring145
General145
Special Tools145
Basic Rules145
Safety Wiring Methods146
Single Wire Locking147
Double Wire Locking148
Examples of Safety Wiring153
Torque Procedure157
Installation of Helical Threaded Inserts161
General161
Special Tools164
Install the Threaded Insert164
Examine the Threaded Insert for Correct Installation167
Remove the Threaded Inserts167
Safety the Rotating Threaded Inserts168
Power Plant173
General173
Description173
Electrical Harness173
Engine Harness Routing Overview177
Engine Harness Routing General Instructions183
Troubleshooting Information185
General185
Engine Ground Run187
General187
Engine Ground Run Instructions188
Electrical Harness190
General190
Maintenance Procedures190
Examine the Engine Wiring Harness190
Examine the Sensors / Actuators193
Install the Engine Wiring Harness for E4A-90-000-000194
Install the Engine Wiring Harness E4A-95-000-000 and E4B-95-000-000213
Engine Fuel and Control307
General307
System Description307
Troubleshooting Information311
General311
Engine Fuel Supply313
General313
Special Tools313
Injectors313
Remove the Injectors313
Install the Injectors314
Fuel Return Line320
Remove the Fuel Return Line320
Install the Fuel Return Line320
High Pressure Pump (HPP)324
Remove the High Pressure Pump (HPP)324
Install the High Pressure Pump (HPP)327
Remove the Spur Gear from High Pressure Pump328
Install the Spur Gear from High Pressure Pump329
Engine Fuel Control330
General330
Low Fuel Pressure Sensor (FPS)330
Remove the Fuel Pressure Sensor330
Install the Fuel Pressure Sensor330
Fuel Rail331
Remove the Fuel Rail331
Install the Fuel Rail331
Engine Control System337
General337
System Description/Operation337
Engine Electronic Control Unit (EECU)337
Troubleshooting Information349
General349
Engine Control351
General351
Engine Electronic Control Unit (EECU)351
Complete an EECU Software Update351
Examine the EECU Fault Log354
Glow Plug Control355
Remove the Glow Plug Control355
Install the Glow Plug Control355
Crankshaft Sensor356
Remove the Crankshaft Sensor356
Install the Crankshaft Sensor356
Camshaft Sensor CAS 2358
Engine Indicating365
General365
System Description/Operation365
Troubleshooting Information367
General367
Engine Exhaust System373
General373
System Description/Operation373
Troubleshooting Information375
General375
Engine Exhaust377
General377
Exhaust Manifold377
Remove the Exhaust Manifold377
Install the Exhaust Manifold378
Exhaust Manifold Gasket Exchange381
Engine Oil System387
General387
System Description/Operation387
Troubleshooting Information389
General389
Oil Storage391
General391
Special Tools391
Oil Sump391
Remove the Oil Sump391
Install the Oil Sump392
Oil Supply396
General396
Oil Filter Housing396
Remove the Oil Filter Housing396
Install the Oil Filter Housing396
Oil Filter396
Remove the Oil Filter396
Install the Oil Filter397
Oil Filter Housing Drain Line400
Remove the Oil Filter Housing Drain Line400
Install the Oil Filter Housing Drain Line401
Engine Oil403
Drain the Engine Oil403
Fill the Engine Oil403
Oil Separator405
Remove the Oil Separator405
Install the Oil Separator405
Remove the Oil Separator By-Pass Valve406
Install the Oil Separator By-Pass Valve406
Oil Separator Return Line408
Remove the Oil Separator Return Line408
Install the Oil Separator Return Line408
Turbocharger Oil Supply Line412
Remove the Turbocharger Oil Supply Line412
Install the Turbocharger Oil Supply Line412
Turbocharger Oil Return Line416
Remove the Turbocharger Oil Return Line416
Install the Turbocharger Oil Return Line416
Remove and Disassemble the Banjo Bolt/Adapter Assembly420
Install and Assemble the Banjo Bolt/Adapter Assembly420
Oil System Sensors424
General424
Oil Level Sensor424
Remove the Oil Level Sensor424
Install the Oil Level Sensor424
Oil Pressure Sensor426
Remove the Oil Pressure Sensor426
Install the Oil Pressure Sensor426
Starting432
General433
System Description433
Electrical Starter433
Glow Plug Control Unit433
Troubleshooting Information435
General435
Cranking437
General437
Starter437
Remove the Starter437
Install the Starter438
Glow System440
Examine the Glow Plug Control Unit (GPC)440
Remove the Glow Plugs441
Install the Glow Plugs441
System Description447
General447
Charged Air System447
Turbocharger447
Components of the Aircraft450
Part of the Engine450
Troubleshooting Information451
General451
Turbocharger451
General453
Special Tools453
Turbocharger453
Remove the Turbocharger454
Install the Turbocharger454
Boost Pressure Actuator (BPA)456
Remove the BPA456
Install the BPA456
Wastegate Controller460
Remove the Wastegate Controller460
Install and Adjust the Wastegate Controller462
Examine the Wastegate Controller Adjustment466
Install the Wastegate Controller Conrod Fail-Safe Bridge468
Reciprocating Engine479
System Description/Operation479
Governor485
Troubleshooting Information487
General487
Reciprocating Engine - Front Section489
General489
Special Tools489
Injector Cover489
Remove the Injector Cover489
Install the Injector Cover490
Gearbox495
Remove the Gearbox495
Install the Gearbox496
Remove the Optional Gearbox Oil Cooler501
Install the Optional Gearbox Oil Cooler501
Remove and Examine the Magnetic Drain Plug503
Install the Magnetic Drain Pug504
Remove the Gearbox Oil Filter506
Install the Gearbox Oil Filter507
Remove the Gearbox Temperature Sensor508
Install the Gearbox Temperature Sensor508
Gearbox Oil510
(A) Drain the Gearbox Oil510
(B) Fill the Gearbox Oil510
Two-Mass-Flywheel511
Remove the Two-Mass-Flywheel511
Install the Two-Mass Flywheel512
Examine the Hub517
Examine the Two-Mass Flywheel519
Replace the Two-Mass Flywheel521
Replace the Two-Mass Flywheel537
Clean the Two-Mass Flywheel538
Mark the Two-Mass Flywheel after Inspection540
Assembly the Two-Mass Flywheel541
Pack and Ship the Two-Mass Flywheel541
Engine Carrier Mounting Gearbox542
Repair the Damaged Threads542
Gearbox Shaft Seal545
Remove the Gearbox Shaft Seal545
Install the Gearbox Shaft Seal546
Reciprocating Engine - Power Section548
Crankshaft Cover548
Remove the Crankshaft Cover548
Install the Crankshaft Cover549
Reciprocating Engine - Cylinder Section551
Intake Air System551
Remove the Intake Air Manifold551
Install the Intake Air Manifold552
Boost Pressure Sensor (BPS)559
Remove the BPS559
Install the BPS559
Intake Air Temperature Sensor (IAT)561
Remove the IAT Sensor561
Install the IAT Sensor561
Cylinder Head562
Remove the Cylinder Head563
(A) Remove the Parts Attached to the Cylinder Head565
(B) Remove the Cylinder Head Cover566
(C) Remove the Camshaft Sensor Housing for CAS 2567
(D) Remove the Rear Cylinder Head Cover569
(E) Remove the Front Cylinder Head Cover570
(F) Remove the Chain Tensioner571
(G) Remove the Chain Gear571
(H) Remove the Camshafts572
(I) Remove the EGR (Exhaust Gas Recirculation) Closing Cover Top573
(J) Remove the EGR (Exhaust Gas Recirculation) Closing Cover Bottom573
(K) Remove the Cylinder Head Sub-Assembly from the Crankcase574
Install the Cylinder Head576
(A) Install the Cylinder Head Sub-Assembly on the Crankcase576
(B) Install the EGR Closing Cover Top580
(C) Install the EGR Closing Cover Bottom580
(D) Install the Camshafts581
(E) Install the Chain Gear585
(F) Install the Chain Tensioner586
(G) Install the Front Cylinder Head Cover587
(H) Install the Rear Cylinder Head Cover588
(I) Install the Camshaft Sensor Housing for CAS 2589
(J) Install the Cylinder Head Cover593
(K) Install the Parts Attached to the Cylinder Head596
Reciprocating Engine - Rear Section598
V-Ribbed Belt598
Remove the V-Ribbed Belt598
Install the V-Ribbed Belt598
Belt Tensioner600
Remove the Belt Tensioner600
Install the Belt Tensioner600
Belt Tensioner - Roller601
Remove the Belt Tensioner - Roller601
Install the Belt Tensioner - Roller601
Timing Chain602
Timing Chain Check602
(A) Prepare for Timing Chain Check602
(B) Timing Chain Measuring Tool (TCMT)603
(C) Complete a Check of the Timing Chain604
(D) Results of the Timing Chain Check606
(E) Assemble the Engine after the Timing Chain Check607
Replace the Timing Chain and the Camshaft Chain Wheel608
(A) Prepare for Timing Chain and Camshaft Chain Wheel Replacement609
(B) Replace the Timing Chain612
(C) Replace the Timing Chain Wheel619
(D) Assemble the Engine after Timing Chain and Chain Wheel Replacement623
Reciprocating Engine - Liquid Cooling625
Coolant Temperature Sensor625
Remove the Coolant Temperature Sensor625
Install the Coolant Temperature Sensor625
Water Pump626
Remove the Water Pump626
Install the Water Pump626
Wiring Diagrams641
Engine Wiring Diagrams for E4A-90-000-000641
Engine Wiring Diagrams for E4A(B)-95-000-000 Revision AA.1 and Subsequent643
Aircraft Interface Wiring647
Propeller Self-Test (Automatic Run-Up Test)650
Special Tools656

Austro Engine E4 Series - Page 3

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