Austro Engine AE50R Instruction manual

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

AE50R, AE50RA
AE50RAB Engine Manual
Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page1-1
FOREWORD
We congratulate you on the acquisition of your new Austro Engine AE50R.
Skillful operation of the engine increases both safety and the enjoyment of flying. Please take
the time therefore, to familiarize yourself with your new AE50R.
This engine may only be operated in accordance with the procedures and operating limitations
of the Engine Manual.
This document is protected by copyright. All associated rights, in particular those of
translation, reprinting, radio transmission, reproduction by photo-mechanical or similar means
and storing in data processing facilities, in whole or part, are reserved.
Austro Engine is a part of Diamond Aircraft Industries GmbH.
Copyright © by: AUSTRO ENGINE GmbH
Rudolf-Diesel – Strasse 11
A – 2700 Wiener Neustadt
Austria
Phone : +43 – 2622 – 23000
Fax : +43 – 2622 – 23000 - 2711
E-Mail : offic[email protected]

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AE50RAB Engine Manual
Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page1-2
1.1 Record of Revisions
All revisions of this manual, with the exception of -
Temporary Revisions
must be recorded in the following table. Revisions of approved chapters require the
countersignature of Austro Control GmbH.
The new or amended text is indicated by a vertical black line at the right hand side of the
revised page, with the revision number and data appearing at the bottom of the page.
If pages are revised which contain information valid for your particular serial number
(modification level of the engine, Equipment Inventory, etc.), then this information must be
transferred to the new pages in hand–writing.
Temporary revisions, if applicable, are inserted behind the cover page of this manual.
Temporary revisions are used to provide information on systems or equipment until the next
‘permanent’ revision of the Engine Manual. When a ‘permanent’ revision covers a Mandatory
or Optional Design Change (MDC or ODC), then the corresponding temporary revision is
superseded.
It is the responsibility of the operator to ensure that this manual is maintained to a current
status.
If you move, or the ownership of the engine/aircraft changes, please complete the change of
address card and send it to Austro Engine GmbH.

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AE50RAB Engine Manual
Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 1-3
Rev.
No. Reason Chapter Page(s) Date of Revision Approval Date of Approval Date In- serted Signature
5
5.2.3 6
Editorial
changes 5.2.4 6
- -
1
Part No
Correction 11.1 26
15-02-06
- -
Page
numbering all all
1.2 1-4
8.1.5 8-1
8.5.4 8-3
9.4 9-3
9.5.
9.5.1
9.5.2
9-4
9.5.3 9-5
13.5.5 13-5
14-1
14.1 14-2
18.7.1 18-12
18.8.1 18-15
Editorial
Changes
18.8.2 18-16
2
Maintenance
Interval 12.1 12-1
10-04-06
1.1 1-3
1.2 1-4
3
New spark
plug
implemented 11.1 11-1
22-11-06
4 No. changed
1.1
1.2
8.3
11.1
1.3
1-4
8-1
11-1
10-11-08
5 Editorial
change
1.1
1.2
8.3
9.4
11.1
1-3
1-4
8-1
9-3
11-1

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Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 1-4
6
All Diamond
Logos
changed to
Austro
Engine
Logo.
Oil
specification
changed
all all 10-03-11

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AE50RAB Engine Manual
Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 1-5
1.2 LIST OF EFFECTIVE PAGES
Ch. Page Date
1-1 10-March-2011
1-2 10-March-2011
1-3 10-March-2011
1-4 10-March-2011
1-5 10-March-2011
1
1-6
1-7 10-March-2011 10-March-2011
2 2-1 10-March-2011
3-1 10-March-2011
3 3-2 10-March-2011
4 4-1 10-March-2011
5-1 10-March-2011
5-2 10-March-2011
5 5-3 10-March-2011
6-1 10-March-2011
6-2 10-March-2011
6 6-3 10-March-2011
7-1 10-March-2011
7 7-2 10-March-2011
8-1 10-March-2011
8-2 10-March-2011
8 8-3 10-March-2011
8-4 10-March-2011
9-1 10-March-2011
9-2 10-March-2011
9-3 10-March-2011
9-4 10-March-2011
9
9-5 10-March-2011
10 10-1 10-March-2011
11-1 10-March-2011
11 11-2 10-March-2011
12-1 10-March-2011
12-2 10-March-2011
12 12-3 10-March-2011
13-1 10-March-2011
13-2 10-March-2011
13-3 10-March-2011
13-4 10-March-2011
13
13-5 10-March-2011
14-1 10-March-2011
14 14-2 10-March-2011
15-1 10-March-2011
15 15-2 10-March-2011
16 16-1
10-March-2011
Ch. Page Date
17-1 10-March-2011
17 17-2 10-March-2011
18-1 10-March-2011
18-2 10-March-2011
18-3 10-March-2011
18-4 10-March-2011
18-5 10-March-2011
18-6 10-March-2011
18-7 10-March-2011
18-8 10-March-2011
18-9 10-March-2011
18-10 10-March-2011
18-11 10-March-2011
18-12 10-March-2011
18-13 10-March-2011
18-14 10-March-2011
18-15 10-March-2011
18-16 10-March-2011
18-17 10-March-2011
18
18-18 10-March-2011
19-1 10-March-2011
19-2 10-March-2011
19 19-3 10-March-2011

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Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 1-6
1.3 TABLE OF CONTENTS
Chapter
INTRODUCTION
(a non-approved chapter)..........................................................................................................1
PREFACE
(a non-approved chapter)..........................................................................................................2
SAFETY INFORMATION
(a non-approved chapter)..........................................................................................................3
(RESERVED)
(a non-approved chapter)..........................................................................................................4
GENERAL ENGINE DATA
(a non-approved chapter)..........................................................................................................5
OPERATING DATA / LIMITATIONS
(an approved chapter)...............................................................................................................6
COMPONENTS
(a non-approved chapter)..........................................................................................................7
DECRIPTIONS OF SYSTEMS
(a non-approved chapter)..........................................................................................................8
OPERATING THE ENGINE
(a non-approved chapter)..........................................................................................................9
ENGINE EMERGENCY PROCEDURES
(a non-approved chapter)........................................................................................................10
MAINTENANCE NOTES
(a non-approved chapter)........................................................................................................11
SCHEDULED MAINTENANCE
(a non-approved chapter)........................................................................................................12
COOLING SYSTEM
(a non-approved chapter)........................................................................................................13

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Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 1-7
ENGINE INTERNAL INSPECTION
(a non-approved chapter)........................................................................................................14
GROUND RUN
(a non-approved chapter)........................................................................................................15
MAINTENANCE AND OVERHAUL
(a non-approved chapter)........................................................................................................16
TROUBLE SHOOTING
(a non-approved chapter)........................................................................................................17
NOTES FOR INSTALLERS OF ENGINES
(a non-approved chapter)........................................................................................................18
FORM SHEETS
(a non-approved chapter)........................................................................................................19

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AE50RAB Engine Manual
Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 2-1
2.0 PREFACE
Every reasonable effort has been made to ensure that the information contained in this
publication is correct when going to print.
However, as Austro Engine GmbH policy is one of continuous improvement, the information
given here may be superseded over a period of time by manual revisions or temporary by
Service Bulletins.
THIS MANUAL IS PUBLISHED BY:
Austro Engine GmbH
Rudolf – Diesel - Straße 11
A – 2700 Wiener Neustadt
Tel.: [phone] – 23000
Fax.: [phone] – 23000 - 2711
Internet: www.austroengine.at
This manual is for use with engines specified by Engine Type Certificate Data Sheet No
EASA.E.085.

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AE50RAB Engine Manual
Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 3-1
3.0 SAFETY INFORMATION
The instructions in this manual have been compiled to assist pilots and personnel responsible
for maintenance in the correct operation of the engines produced by Austro Engine GmbH.
Only correct operation and maintenance can ensure optimum availability throughout engine
life.
No recommendation in this manual absolves operators from compliance with any official
directive that may be issued by the controlling aviation authority of any country concerned, or
with any relevant Austro Engine GmbH Service Bulletins.
Austro Engine personnel are always happy to answer queries or give advice on individual
service problems. All queries to Austro Engine GmbH should be accompanied by details of the
engine model and serial number, hours operated and any other relevant information.
3.1 Safety Symbols
NOTE !
A note symbol shows an additional significant information.
CAUTION!
A caution symbol indicates special procedures which should be
followed to avoid the risk of serious damage to engine or to
components.
WARNING!
A warning symbol indicates special procedures, which must be
followed to avoid the risk of death or serious injury to persons.

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Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 3-2
3.2 Model Designation Breakdown
3.3
NOTE!
It is strongly recommended that only genuine, quality–assured,
replacement spare parts are used when carrying out
maintenance operations on this engine.
The use of parts not approved by Austro Engine GmbH may
significantly affect the performance, reliability and life of the
engine and may hazard the operator.
WARNING!
The use of parts not approved by Austro Engine GmbH may
invalidate the Engine Certification.

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4.0 Reserved
Intentionally left blank

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Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 5-1
5.0 GENERAL ENGINE DATA
5.1 Description
Wankel type rotary, single rotor, dual spark ignition, liquid cooled rotor housing, forced air
cooled rotor, normal aspirated.
5.2. Technical data
5.2.1 Design Responsibility
Austro Engine GmbH
Rudolf – Diesel – Straße 11
A – 2700 Wiener Neustadt
Austria
5.2.2 Certification
Certification Basis: JAR – 22, Subpart H, at Change 4 effective 12/12/85 together with Orange
Paper amendment 22/01/90.
5.2.3 Engine Particulars
Design Single rotor Wankel–type rotary engine
Eccentricity 11.6 mm
Width of Housing 68.2 mm
Generating Radius 69.0 mm
Compression Ratio 9 : 1
Swept Volume 294 ccm
Rotor Cast iron internally cooled by a belt driven centrifugal
fan.
Main and End Housing Aluminium alloy castings, cooled with a pump
circulated pressurized water–glycol mixture and
supporting an optional oil separator assembly
(supplied by the installer mounted directly onto the
outlet casting).

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Eccentric Shaft Hardened and ground alloy steel. The complete
rotating assembly is in full dynamic balance to
minimise vibration, achieved by counter weighting
each end of the assembly. Both the main and rotor
bearings are rolling element types.
Flywheel Cast iron fitted with an induction–hardened steel
starter ring gear.
5.2.4 Out–put Drive
Take from the eccentric shaft via a woodruff key.
Rotation Direction The eccentric shaft rotate in a clockwise direction
when viewed from the driving side of the engine.
5.2.5 Net Dry Weight
Approximately 26,8 kg. (59,1 lbs)
5.2.6 Cooling
Approximately 90% of surplus heat is rejected into the
liquid cooling system; the balance is rejected via rotor
cooling air.
Coolant 50 : 50 Distilled Water – Ethylene Glycol mix
Silkolene PRO–COOL (or equivalent)
5.2.7 Fuel Specification
AVGAS 100LL
EUROSUPER, ROZ 95, in accordance with EN228
or equivalents.

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AE50RAB Engine Manual
Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 5-3
5.2.8 Pressure to Carburettor
min 0.276 bar (4 psi)
max 0.414 bar (6 psi)
5.2.9 Lubrication
Lubrication of all bearings and rubbing surfaces is
achieved via two lines from the oil metering unit driven
off the water pump. The flow rate of the metering unit
is calibrated and must not be adjusted. Use only
approved engines oils.
Oil Separator An optional oil separator is recommended. The
separator is to be supplied by the engine installer.
5.2.10 Oil Specification
Silkolene Comp 2 Premix (Not comp 2 Injector)
Castrol XR77 (EMPA specification 417478/01)
Castrol Power 1 Racing 2T (API TC+, JASO FD, ISO EGD)
AeroShell Oil Sport Plus2 (API TC)

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AE50RAB Engine Manual
Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 6-1
6.0 OPERATING DATA / LIMITATIONS:
Static sea level ratings under the following conditions:
- International Standard Atmospheric conditions at seal level
- Generator functioning
- Liquid coolant outlet temperature 65 °C (± 5 °C)
- Standard induction pipe fitted with filter
- Power measured at eccentric shaft output
- Approved fuels
- Test bed exhaust used
6.1 Maximum Take – off Rating
Max. T/O – Power (minimum) 36.5. kW (49 BHP)
(Value quoted includes losses associated
with intake exhaust conditions specified.)
Max. T/O – RPM 7 500 RPM
Fuel consumption (max) 19 - 21 liters / hr
Exhaust back pressure 0.21 bar ± 0.04 bar (3 psi ± 0.5 psi)
at 7500 RPM with test bed system
6.2 Maximum Continuous Rating
Max. Cont. Power 34.3 kW (46 BHP)
Max. Cont. RPM 6,900 RPM
Fuel consumption (max) 12 - 15 liters / hr

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6.2.1 Power Curve
6.3 Operating Limitations
6.3.1 Engine RPM
Maximum for take–off (for 3 mins) 7 500 RPM
Maximum Continuous 6 900 RPM
Maximum Overspeed (20 sec. limit) 7 800 RPM
Idle Minimum 1 750 RPM
6.3.2 Ambient Temperature Limits
Minimum Starting Ambient (without priming) -10 °C
Maximum Ambient +55 °C

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Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 6-3
6.3.3 Liquid Coolant Temperature Limits
Maximum for Take–off 90 °C
Minimum for Take–off 60 °C
Maximum continuous 100 °C
6.3.4 Rotor Cooling Air Outlet Temperature Limits
Maximum for Take–off (3 minutes) 120 °C
Maximum Continuous 110 °C
6.3.5 Exhaust Gas Temperature (EGT)
Maximum Exhaust Gas Temperature 950 °C
6.3.6 Fuel Pressure
min 0.276 bar (4 psi)
max 0.414 bar (6 psi)
6.3.7 Altitude
The engine has been tested for use up to 14.000 ft pressure altitude
6.4 Manuals
Operation / Maintenance / Installation Doc. No. E1.01.01–E
Overhaul Manual Doc. No. E1.04.01–E

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7.0 COMPONENTS
Location of Components

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Doc. No. E1.01.01-E Rev. 6 10-March-2011 Page 7-2
7.1 Description of Components
7.1.1 Rear Assemblies
These assemblies comprise of a back plate, with integral mounting lugs, water pump,
alternator, speed sensors, rotor cooling air fan assembly, oil pump and starter motor.
7.1.2 Front Assemblies
The front assemblies comprise of a water cooled end plate, temperature transmitter.
7.1.3 Center and Rotating Assembly
The center assembly comprises a rotor housing with passageways for liquid cooling.
Externally is the throttle body with fuel injector, spark plugs, and exhaust flange and, internally,
the eccentric shaft and rotor assembly.
7.1.4 Rotor Sealing
Rotor sealing is provided by the tip seals, side seals and corner seals with each seal being
spring loaded outwards. The corner seals placed at the junction of the side and tip seals
provide sealing at these critical locations.