Austro Engine E4 Series User manual
Maintenance Manual
E4.08.04
Issue date: 14-Apr-2015
Page: Intro-1
Revision no: 25
–Intentionally left blank –
Maintenance Manual
E4.08.04
Issue date: 14-Dec-2015
Page: Intro-2
Revision no: 26
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
Maintenance Manual
E4.08.04
Issue date: 24-Oct-2014
Page: Intro-3
Revision no: 24
Introduction
All revisions of this manual must be recorded in chapter “List of Revisions“.
All incorporated Temporary revisions must be recorded in chapter “List of incorporated Temporary
Revisions”.
The new or amended text is indicated by a vertical black line at the left hand side of the revised page,
with the revision number and date appearing at the bottom of the page.
Cover pages of Temporary revisions are inserted in front the cover page of this manual. The other
pages of Temporary revisions are inserted adjacent to or in front of the corresponding MM pages.
Temporary revisions are used to provide information on systems or equipment until the next
‘permanent’ revision of the Engine Manual.
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.
Maintenance Manual
E4.08.04
Issue date: 05-Dec-2012
Page: Intro-4
Revision no: 17
List of Revision
Rev.
No.
Reason
Chapter
Page(s)
Date of
Revision
Approval
Date of
Approval
Date
Inserted
Signatur
1
Authority
remarks
updated
All
All
07.May.
2009
DOA *)
-
3
Authority
remarks
included
Intro
01
02
03
04
05
12
24
51
71
73
76
77
78
79
80
81
85
92
2,4,5,6,7,
10,11,12,
13,14
1,2
1,2,3,4
1,2
1
1,2,3,4,5,
6,7
1,2
1,2
1,2,3,4,5,
6,8
1,2,4,5
1,2,3,4,5,
6,7,8,9
1,2,3,4
1
1,2
1,2,3,4,5,
6,7,8,9,
10,11,12,
13,14,15,
16,17,18
1,2,3
1,2,3
1,2,3,4,5,
6,7,8,9,1
0,11,12,
13,14,15,
16,17,18,
19,20,21,
22
1,2,3,4,5
09.Sep.
2009
DOA *)
-
4
MDC-E4-
117
Intro
02
05
12
24
51
71
73
76
78
79
2,4-16
3
4,5
1
2,3,4
1-6,8
2-25
1,2,4, 6-9
1-4
1,2
1-3, 5,
7-17
04.May.
2010
DOA *)
-
Maintenance Manual
E4.08.04
Issue date: 05-Dec-2012
Page: Intro-5
Revision no: 17
Rev.
No.
Reason
Chapter
Page(s)
Date of
Revision
Approval
Date of
Approval
Date
Inserted
Signatur
4
MDC-E4-
117
80
81
85
92
Last page
2,3
1-4
1-5,7-9,
11,13,14
16-18,
20-22,
1-10
04.May.
2010
DOA *)
-
5
MDC-E4-
199
Intro
05
73
76
79
85
2,5,6,7,8,
12-16
4,8,9
1
4-6
2
9
27.Jan.
2011
DOA *)
-
6
MDC-E4-
220
Intro
05
2,5,6
3,5
08.Mar.
2011
DOA *)
-
7
MDC-E4-
221
Intro
01
05
85
2,5,6,7
1
4
3-4,6-23
16.May.
2011
DOA *)
-
8
MDC-E4-
212
Intro
24
2,5,6,7
11-16
3-5
19.May.
2011
DOA *)
-
9
MDC-E4-
241
Intro
01
02
05
24
71
76
78
81
92
2, 5-9,
12-18
2-39
1-6
4,5
4
1
1
1
1
4-11
11.Aug.
2011
DOA *)
-
10
MDC-E4-
237
Intro
71
81
85
92
2,5-8,
12-17
3-4,22-46
1,2,4
14-16,23
1-13
15.Nov.
2011
DOA *)
-
11
MDC-E4-
257
Intro
01
03
05
12
24
71
73
76
78
79
2, 5-9
13-21
1-2,4-46
1
2-9
2
1, 4-6
2-5,22,24
2-4,6-8
1,4-6
1
1,4,7-14
19.Jan.
2012
DOA *)
-
Maintenance Manual
E4.08.04
Issue date: 28-May-2013
Page: Intro-6
Revision no: 20
Rev.
No.
Reason
Chapter
Page(s)
Date of
Revision
Approval
Date of
Approval
Date
Inserted
Signatur
80
81
85
16-20
1
1,3
1,3,4,
7-11,13,
16, 19-24
DOA *)
-
12
MDC-E4-
269
Intro
73
79
81
2, 6-9,15
4
8
1-5
27.Feb.
2012
DOA *)
-
13
MDC-E4-
270
Intro
05
73
81
85
92
2, 6-9,
16-21
2-4
4-5
3-6
16
14
10.Apr.
2012
EASA
12.Apr.
2012
14
MDC-E4-
274
Intro
24
71
73
85
92
2,6-9,
16-22
6-23
26
1-2,6
11-43
13,14
10.Jul.2012
DOA *)
-
15
MDC-E4-
219
Intro
05
12
77
79
85
92
2,6-9
16-22
3,4
2
1
18
4,7-45
14
05.Sep.
2012
DOA *)
-
16
MDC-E4-
283
Intro
05
85
2, 6-9
4
1,11
03.Oct.
2012
DOA *)
-
17
MDC-E4-
289
Intro
85
4-9
16-22
8-10
05.Dec.
2012
DOA *)
-
18
MDC-E4-
285
Intro
05
2, 6-9
2-3
22.Jan.
2013
EASA
14.Feb.
2013
19
MDC-E4-
300
Intro
01
24
71
85
2, 6-9;
15-21
1
11
4;22;23;
26;45-52
10
01.Mar.
2013
DOA *)
20
MDC-E4-
302
Intro
05
76
85
2, 6-9
15-21
8-9
3
5,9,10,12,
20
28.May.
2013
DOA *)
Maintenance Manual
E4.08.04
Issue date: 14-Dec-2015
Page: Intro-7
Revision no: 26
Rev.
No.
Reason
Chapter
Page(s)
Date of
Revision
Approval
Date of
Approval
Date
Inserted
Signatur
21
MDC-E4-
275
Intro
05
24
2,7-22
2-10
15
06.Sep.
2013
EASA
23.Sep.201
3
22
MDC-E4-
318 and
MDC-E4-
238c
Intro
73
79
85
2,7-10
6
12
20-26,
29-31,
33,35,36,
38-40,
42-44
19.Nov.
2013
DOA *)
23
MDC-E4-314
Intro
05
85
2,7-10,
16-22
4,6
1-47
14.Jan.
2014
DOA *)
24
MDC-E4-343
Intro
01
03
05
24
71
73
79
81
85
2,3,7-24
31-42
1
4-6,8
1,2,3,5
7-38
3-61
6-10
4,5
5
4,44-65
24.Oct.
2014
DOA *)
25
MDC-E4-356
Intro
01
02
03
04
05
24
71
77
79
80
85
92
1,2,7-12,
18-25
9,12,15,
16,19-22,
24,26,29,
30,32-34,
36-42
6
2
2
2-5
37
4-68
2
17
4
7-72
13
14.Apr.
2015
DOA *)
26
MDC-E4-359
14.Dec.
2015
DOA *)
*) The technical content of this document is approved under the authority of DOA ref. EASA.21J.0399.
Maintenance Manual
E4.08.04
Issue date: 14-Apr-2015
Page: Intro-8
Revision no: 25
List of incorporated Temporary Revisions
Temporary Revision Number
Title of Temporary Revision
MM-TR-MDC-E4-309b
Oil baffle panel installation
MM-TR-MDC-E4-314b
Injector cover with maintenance lid &
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
Sealant engine
MM-TR-MDC-E4-342
Lifetime extension of HPP spur gear
MM-TR-MDC-E4-345
Service interval extension Two-Mass-Flywheel
MM-TR-MDC-E4-346
EECU Time Limits
MM-TR-MDC-E4-353
TBO extension to 1800 hours
MM-TR-MDC-E4-358
Water pump bearing housing replacement
MM-TR-MDC-E4-362
Model E4P
MM-TR-RDC-E4-038
Engine Harness alternator connector repair kits
MM-TR-RDC-E4-041
Repair connector alternator E4A-91-000-000
MM-TR-RDC-E4-043
Engine harness FMU connector repair kit
MM-TR-RDC-E4-045
Repair kit fluid temperature sensor
MM-TR-ODC-E4-008
Gearbox Oil Cooler
Maintenance Manual
E4.08.04
Issue date: 14-Dec-2015
Page: Intro-9
Revision no: 26
List of Valid Pages
Chapter
Page
Revision
Date
Introduction
1
25
14.Apr.2015
2
26
14.Dec.2015
3
24
24.Oct.2014
4
17
05.Dec.2012
5
17
05.Dec.2012
6
20
28.May.2013
7
26
14.Dec.2015
8
25
14.Apr.2015
9
26
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10
26
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11
26
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12
26
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13
24
24.Oct.2014
14
24
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15
24
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16
24
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24
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25
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01-00-00
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26
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2
26
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3
26
14.Dec.2015
4
11
19.Jan.2012
5
11
19.Jan.2012
6
11
19.Jan.2012
7
11
19.Jan.2012
8
11
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9
25
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11
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11
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02-00-00
1
9
11.Aug.2011
2
9
11.Aug.2011
3
9
11.Aug.2011
4
9
11.Aug.2011
5
26
14.Dec.2015
6
25
14.Apr.2015
03-00-00
1
26
14.Dec.2015
2
25
14.Apr.2015
04-00-00
(Authority
approved
chapter)
1
3
09.Sep.2009
2
25
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05-00-00
1
3
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2
25
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26
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21
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11
26
14.Dec.2015
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26
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Maintenance Manual
E4.08.04
Issue date: 14-Dec-2015
Page: Intro-10
Revision no: 26
12-00-00
1
5
27.Jan.2011
2
15
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24-00-00
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Maintenance Manual
E4.08.04
Issue date: 14-Dec-2015
Page: Intro-11
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Maintenance Manual
E4.08.04
Issue date: 14-Dec-2015
Page: Intro-12
Revision no: 26
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68
26
14.Dec.2015
69
26
14.Dec.2015
70
26
14.Dec.2015
71
26
14.Dec.2015
72
26
14.Dec.2015
73
26
14.Dec.2015
74
26
14.Dec.2015
75
26
14.Dec.2015
76
26
14.Dec.2015
77
26
14.Dec.2015
78
26
14.Dec.2015
79
26
14.Dec.2015
80
26
14.Dec.2015
81
26
14.Dec.2015
82
26
14.Dec.2015
83
26
14.Dec.2015
84
26
14.Dec.2015
85
26
14.Dec.2015
86
26
14.Dec.2015
87
26
14.Dec.2015
88
26
14.Dec.2015
89
26
14.Dec.2015
90
26
14.Dec.2015
91
26
14.Dec.2015
92
26
14.Dec.2015
93
26
14.Dec.2015
92-00-00
1
10
15.11.2011
2
10
15.11.2011
3
10
15.11.2011
4
10
15.11.2011
5
10
15.11.2011
6
10
15.11.2011
7
10
15.11.2011
8
10
15.11.2011
9
10
15.11.2011
10
10
15.11.2011
11
10
15.11.2011
12
10
15.11.2011
13
25
14.Apr.2015
14
26
14.Dec.2015
Maintenance Manual
E4.08.04
Issue date: 24-Oct-2014
Page: Intro-13
Revision no: 24
List of Abbreviation
AE
Austro Engine
BATT
Battery
BPA
Boost Pressure Actuator
BPS1
Boost Pressure Sensor 1
BPS2
Boost Pressure Sensor 2
CAD
Computer Aided Design
CAN
Controller Area Network
CAS 1
Camshaft Sensor 1
CAS 2
Camshaft Sensor 2
CCW
Counter-Clockwise
CPC
Connector Type
CRS 1
Crankshaft Sensor 1
CRS 2
Crankshaft Sensor 2
CS
Certification Specification
CTS
Coolant Temperature Sensor
CTS_GPC
GPC Coolant Temperature
DOHC
Double Overhead Camshaft
EASA
European Aviation Safety Agency
EECS
Electric Engine Control System
EECU
Electric Engine Control Unit
ECU
Electric Control Unit
EMI
Electromagnetic Interference
EPC
Electric Pneumatic Converter
ESD
Electrostatic Sensitive Device
FAR
Federal Aviation Regulations
FMU
Fuel Metering Unit
FPS
Fuel Pressure Sensor
FTS
Fuel Temperature Sensor
GBTS
Gearbox Temperature Sensor
GEN
Alternator Plug
GND
Ground
GOV
Governor Actuator
GPC
Glow Plug Control Unit
GP 1
Glow Plug 1
GP 2
Glow Plug 2
GP 3
Glow Plug 3
GP 4
Glow Plug 4
HIRF
High Intensity Radiated Field
HPP
High Pressure Pump
IAT 1
Intake Air Temperature 1
IAT 2
Intake Air Temperature 2
INJ 1
Fuel Injector 1
INJ 2
Fuel Injector 2
INJ 3
Fuel Injector 3
INJ 4
Fuel Injector 4
MA
Manual Amendments
MBN
Mercedes Benz Norm
MDC
Mandatory Design Change Advisory
Maintenance Manual
E4.08.04
Issue date: 24-Oct-2014
Page: Intro-14
Revision no: 24
MOK
Oil Combinant Sensor Temperature
ODC
Optional Design Change Advisory
OPS
Oil Pressure Sensor
PCV
Pressure Control Valve
RPM
Revolutions Per Minute
RPS
Rail Pressure Sensor
SB
Service Bulletin
SL
Service Letter
SW
Soft Ware
TDD
Type Design Definition
TC
Turbo Charger
TVD
Torsional Vibration Damper
Ubatt
Battery Voltage
Maintenance Manual
E4.08.04
Issue date: 24-Oct-2014
Page: Intro-15
Revision no: 24
Conversion Table of Given Torque Values
Newton Meter (Nm)
Pound-force inch (lbf in)
1
9
2
18
3
27
4
35
5
44
6
53
7
62
8
71
9
80
10
89
11
97
12
106
13
115
14
124
15
133
16
142
17
150
18
159
19
168
20
177
21
186
22
195
23
204
24
212
25
221
26
230
27
239
28
248
29
257
30
266
35
310
40
354
50
443
Maintenance Manual
E4.08.04
Issue date: 24-Oct-2014
Page: Intro-16
Revision no: 24
Conversion Table of Given Pressure Values
Pressure
[bar]
Pressure
[psi]
Pressure
[lbf/ft²]
0,0
0
0
0,3
4
627
0,5
7
1044
1,0
15
2089
1,5
22
3133
2,0
29
4177
2,5
36
5221
3,0
44
6266
3,5
51
7310
4,0
58
8354
4,5
65
9398
5,0
73
10443
5,5
80
11487
6,0
87
12531
6,5
94
13576
7,0
102
14620
7,5
109
15664
8,0
116
16708
8,5
123
17753
9,0
131
18797
9,5
138
19841
10,0
145
20885
Maintenance Manual
E4.08.04
Issue date: 24-Oct-2014
Page: Intro-17
Revision no: 24
Consumable List
Various types of consumables are necessary for the engine maintenance defined in this manual. These
consumables are listed in the table below including the applicability reference.
Consumables
Material definition
Parts applicability
Sealant
MERCEDES BENZ A003989982010
Or
LOCTITE 5970 black
Oil Sump
Crankcase end cover (rear & front)
DOW CORNING 736
Heat Resistant/Sealant
Fire Sleeve
Grease /
Lubricant
(acid free lubrication)
Released AE300 engine oils which are
defined in the AE300 Operation
Manual.
O-ring and Rubber Gaskets
A001 989 42 51 10 - Mercedes Benz
special grease
Injectors (see chapter 73-00-22
Installation of the Injektor Seal)
Loctite
No. 243
No. 542
No. 2710
For the respective Loctite applicability
refer to the relevant chapters of this
manual.
Safety Wire
Suitable for flight purposes stainless
safety wire.
Wire thickness 0.81 mm
For applicability refer to the relevant
chapters of this manual.
+43 (0) 2622 23000 2525 in case of material availability.
Maintenance Manual
E4.08.04
Issue date: 14-Apr-2015
Page: Intro-18
Revision no: 25
Contents
Introduction 3
List of Revision 4
List of incorporated Temporary Revisions.........................................................................................8
List of Valid Pages 9
List of Abbreviation 13
Conversion Table of Given Torque Values ......................................................................................15
Conversion Table of Given Pressure Values ....................................................................................16
Consumable List 17
Contents......................................................................................................................................18
Chapter 01-00-00 General..........................................................................................................1
01-10-00 General Engine Description .................................................................................... 2
01-10-10 Intake/Exhaust System Description........................................................................13
01-10-20 Fuel System Description........................................................................................15
01-10-30 Exhaust System Description ..................................................................................18
01-10-40 Coolant System Description...................................................................................18
01-10-50 Lubricating System Description..............................................................................21
01-10-60 Electrical System Description.................................................................................22
01-10-70 Governor Description ............................................................................................42
Chapter 02-00-00 Transport and Packaging ................................................................................1
02-00-10 Packaging ............................................................................................................. 1
02-00-20 Transport.............................................................................................................. 4
02-00-30 Protective Covers .................................................................................................. 5
02-00-40 Storage................................................................................................................. 5
02-00-50 Return Parts Shipping Instruction ........................................................................... 5
Chapter 03-00-00 Engine Installation..........................................................................................1
Chapter 04-00-00 Airworthiness Limitation..................................................................................1
Chapter 05-00-00 Time Limits and Maintenance Check ................................................................1
05-00-01 General................................................................................................................. 1
05-10-00 Time Limits of engine model E4.............................................................................. 2
05-10-01 Time Limits of engine model E4P............................................................................ 2
05-10-02 Claimable Exceed of Maintenance Actions ............................................................... 3
05-10-03 Engine Time between Overhaul.............................................................................. 3
05-20-00 Schedule Maintenance Inspections and Checks of engine model E4 .......................... 4
05-20-01 Two Mass Flywheel................................................................................................ 5
05-20-02 Alternator ............................................................................................................. 5
05-20-03 Engine Harness and Sensors .................................................................................. 5
05-20-04 EECU .................................................................................................................... 5
05-20-05 EECU Read Out ..................................................................................................... 5
05-20-06 Gearbox –Oil........................................................................................................ 5
05-20-07 Gearbox Oil Filter .................................................................................................. 6
05-20-08 V-Ribbed Belt........................................................................................................ 6
05-20-09 Engine –Oil .......................................................................................................... 6
05-20-10 Engine Oil Filter..................................................................................................... 6
05-20-11 High Pressure Pump .............................................................................................. 6
05-20-12 Cylinder Head Drain............................................................................................... 7
05-20-13 Fuel System .......................................................................................................... 7
Maintenance Manual
E4.08.04
Issue date: 14-Apr-2015
Page: Intro-19
Revision no: 25
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......................................................................................................... 9
05-30-00 Schedule Maintenance Inspections and Checks of engine model E4P .......................10
05-30-01 Gearbox...............................................................................................................11
05-30-02 Injectors..............................................................................................................11
05-30-03 Turbo Charger......................................................................................................11
05-30-04 Cylinder head.......................................................................................................12
05-50-00 Unscheduled Maintenance Checks .........................................................................13
05-50-01 Performance Deterioration ....................................................................................13
05-50-02 Violation of Temperature Limits.............................................................................13
05-50-03 Sudden Stoppage Inspection.................................................................................13
05-50-04 Propeller Strike.....................................................................................................13
05-50-05 Lightning Strike ....................................................................................................13
05-50-06 High Engine Oil Consumption Inspection................................................................14
05-50-07 Engine Oil System Contaminated...........................................................................14
05-50-08 Engine Oil Pressure Loss Inspection.......................................................................14
05-50-09 Inability to Start the Engine ..................................................................................14
Chapter 12-00-00 Servicing........................................................................................................1
12-20-00 Engine Oil Servicing............................................................................................... 1
12-20-01 Check the Oil Level................................................................................................ 1
12-20-10 Gearbox Oil........................................................................................................... 2
12-20-11 Check the Gearbox Oil Level................................................................................... 2
12-40-00 Engine Coolant Servicing........................................................................................ 2
Chapter 24-00-00 Electrical Power..............................................................................................3
24-00-01 General................................................................................................................. 3
24-30-00 Alternator E4A-91-000-000 .................................................................................... 3
24-30-01 Replacement of Alternator E4A-91-000-000 ............................................................ 3
24-30-10 Removal of the Alternator E4A-91-000-000 ............................................................. 3
24-30-20 Installation of the Alternator E4A-91-000-000 ......................................................... 4
24-30-30 Inspection of Alternator E4A-91-000-000 and the Carbon Brushes............................ 4
24-30-31 Tools necessary..................................................................................................... 5
24-30-32 Removal of the Brush Holder Assembly................................................................... 5
24-30-33 Visual Inspection of Alternator Housing and Pulley .................................................. 6
24-30-34 Inspection of Contact Ring and Brushes.................................................................. 7
24-30-35 Disassembly of Brush Holder.................................................................................. 8
24-30-36 Measuring the Length of Carbon Brushes ...............................................................10
24-30-37 Evaluation Criteria ................................................................................................11
24-30-38 Completion of Brush Holder ..................................................................................12
24-30-39 Completion of Alternator (Integration of Brush Holder) ...........................................14
24-30-40 Functionality Check ..............................................................................................16
24-30-50 Marking of maintained Alternator E4A-91-000-000..................................................17
24-31-00 Alternator E4A-91-400-000 ...................................................................................18
24-31-10 Removal of Alternator E4A-91-400-000..................................................................18
24-31-20 Installation of the Alternator E4A-91-400-000 ........................................................18
24-31-30 Inspection of Alternator E4A-91-400-000 and Carbon Brushes.................................20
24-31-31 Tools necessary....................................................................................................20
24-31-32 Removal of Brush Holder Assembly .......................................................................20
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