Austro Engine E4P User manual

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: Intro 1
Revision no: 1
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Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: Intro 2
Revision no: 1
Date: Wiener Neustadt, 15.Nov.2016
Author: Austro Engine GmbH
Rudolf –Diesel –Straße –11
A-2700 Wiener Neustadt
Document number: E4.01.02
Revision: 1

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: Intro 3
Revision no: 1
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Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 0-1
Revision no: 1
0Index
0Index ................................................................................................... 0-1
1Identification ....................................................................................... 1-1
1.1 Type Designation..........................................................................................1-1
1.2 Engine Identification.....................................................................................1-1
1.3Record of Revision........................................................................................1-2
1.3.1 List of Revision ................................................................................................... 1-3
1.3.2 List of incorporated Temporary Revisions ............................................................. 1-4
1.4 Design Holder ..............................................................................................1-5
1.5 Manufacturer ...............................................................................................1-5
1.6 List of Abbreviations .....................................................................................1-6
2General Information............................................................................ 2-1
2.1 Description and Using ...................................................................................2-1
2.2 Safety..........................................................................................................2-2
2.3 Safety Information........................................................................................2-2
2.4 Dimension and Volume .................................................................................2-3
2.5 Technical Data Sheet for E4P Engine..............................................................2-4
2.5.1 Engine Performance............................................................................................ 2-4
2.5.2 High power performance..................................................................................... 2-5
2.5.3 Fuel consumption ............................................................................................... 2-6
2.5.4 Propeller Setpoint Curve...................................................................................... 2-6
2.5.5 Engine and Gearbox Data Sheet .......................................................................... 2-7
2.5.6 Limitation Section ............................................................................................... 2-8
2.5.6.1 Oil .............................................................................................................. 2-8
2.5.6.2 Coolant ....................................................................................................... 2-9
2.5.6.3 Fuel ...........................................................................................................2-10
2.5.6.4 Fuel Grade .................................................................................................2-10
2.5.6.5 Speed ........................................................................................................2-11
2.5.6.6 Voltage ......................................................................................................2-11
2.5.6.7 Performance...............................................................................................2-11
2.5.7 Information Section ...........................................................................................2-12
2.5.7.1 Engine Oil ..................................................................................................2-12
2.5.7.2 Coolant ......................................................................................................2-12
2.5.7.3 Fuel ...........................................................................................................2-12
2.5.8 Operating Envelope ...........................................................................................2-13
3Delivery, Storage and Standstill Period .............................................. 3-1
3.1 Delivery .......................................................................................................3-1
3.2 Storage up to 6 months ................................................................................3-1
3.3 Storage over 6 months..................................................................................3-1
3.4 Engine depreservation ..................................................................................3-1
3.5Standstill Period ...........................................................................................3-2
4Operating Instructions ........................................................................ 4-1
4.1 Engine Start Procedure .................................................................................4-1
4.1.1 Pre-Start Inspection ............................................................................................ 4-1
4.1.2 Engine Start ....................................................................................................... 4-2
4.1.3 Warm Up ........................................................................................................... 4-2
4.1.4 Before Take-off Check......................................................................................... 4-3
4.1.5 During Flight Check ............................................................................................ 4-3
4.1.6 Engine OFF ........................................................................................................ 4-3
4.2 Low Oil Pressure...........................................................................................4-3
4.3 Restart in flight ............................................................................................4-4
4.3.1 Restart of engine by starter................................................................................. 4-4

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 0-2
Revision no: 1
5Emergency Procedures ........................................................................ 5-1
5.1 Power loss and abnormal engine behaviour ....................................................5-1
5.2 Low Oil Pressure...........................................................................................5-1
5.3 High Oil Temperature....................................................................................5-1
5.4 High Gearbox Oil Temperature.......................................................................5-1
5.5 Low fuel pressure .........................................................................................5-2
5.6 High Fuel Temperature .................................................................................5-2
5.7 High Coolant Temperature ............................................................................5-2
5.8 Engine Fire ..................................................................................................5-2
5.9 Electric power supply out of range .................................................................5-2
5.9.1 Restart of engine by windmilling .......................................................................... 5-2
6System Description.............................................................................. 6-1
6.1 Intake System..............................................................................................6-1
6.2 Exhaust System............................................................................................6-1
6.3 Fuel System .................................................................................................6-2
6.4 Coolant System ............................................................................................6-3
6.4.1 Standard Coolant System .................................................................................... 6-3
6.4.2 Coolant System with optional Gearbox Oil Cooler .................................................. 6-4
6.5 Lubricating System .......................................................................................6-5
6.6 Electrical System ..........................................................................................6-6
6.6.1 EECU Functions .................................................................................................. 6-8
6.6.2 Engine Speed and Power Regulation ...................................................................6-12
6.6.3 Error Handling ...................................................................................................6-14
6.6.3.1 Description of ECU Switch Over ...................................................................6-14
6.6.3.2 Resetting ECU caution in Operation .............................................................6-15
6.6.3.3 Caution Handling Table Software VC33_0_05_18_pre1 .................................6-16
7Additional Information ........................................................................ 7-1
7.1 Propeller Self Test (Automatic Run-Up Test) ...................................................7-1

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 1-1
Revision no: 1
1Identification
1.1 Type Designation
TC-Designation: E4
Model: E4P(Sales Name AE330)
For detailed information about available configurations refer to latest revision of Austro Engine Service
Bulletin MSB E4-002.
If not otherwise stated this manual is applicable to all available configurations.
1.2 Engine Identification
Relevant data for engine identification including the serial number is stated on an engine identification
plate, which is fixed onto the crankcase beneath the starter. For further questions contact Austro
Engine GmbH.
Fig. 1.1: Engine Identification plate

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 1-2
Revision no: 1
1.3 Record of Revision
All revisions of this manual are recorded in chapter “List of Revisions”.
All incorporated temporary revisions are recorded in chapter “List of incorporated Temporary Revisions”.
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 OM 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
Engines GmbH.

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 1-3
Revision no: 1
1.3.1 List of Revision
Re.
No.
Reason
Chapter(s)
Page(s)
Date of
Revision
Approval /
Date
0
First Release
All
All
26.Mar.2015
EASA /
26.Mar.2015
1
MDC-E4-377
All
All
15.Nov.2016
EASA /
29.Nov.2016
*) The technical content of this document is approved under the authority of DOA ref. EASA.21J.0399

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 1-4
Revision no: 1
1.3.2 List of incorporated Temporary Revisions
Temporary Revision Number
Title of Temporary Revision
Incorporated with
Manual Rev.
OM-TR-MDC-E4-217d
Engine preservation
1
OM-TR-MDC-E4-359b
EECU Software VC33_x_05_19
1
OM-TR-MDC-E4-378
TBO extension of engine components
1
OM-TR-MDC-E4-382
EECU Software VC33_x_05_20
1
OM-TR-ODC-E4-008
Gearbox Oil Cooler
1

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 1-5
Revision no: 1
1.4 Design Holder
Austro Engine GmbH
Rudolf –Diesel –Straße 11
A-2700 Wiener Neustadt
DOA No.: EASO.21J.399
1.5 Manufacturer
Austro Engine GmbH
Rudolf –Diesel –Straße 11
A-2700 Wiener Neustadt
EASA POA No.: AT.21G.0010

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 1-6
Revision no: 1
1.6 List of Abbreviations
AE
Austro Engine
BATT
Battery
CAD
Computer Aided Design
CAN
Controller Area Network
CCW
Counter-Clockwise
CPC
Connector Type
CS
Certification Specification
DOHC
Double Overhead Camshaft
EECS
Electronic Engine Control System
EECU
Electronic Engine Control Unit
ECU
Electronic Control Unit
EMI
Electromagnetic Interference
EPC
Electric Pneumatic Converter
ESD
Electrostatic Sensitive Device
FAR
Federal Aviation Regulations
GND
Ground
GPC
Glow Plug Control Unit
HIRF
High Intensity Radiated Field
HPP
High Pressure Pump
MBN
Mercedes Benz Norm
MDC
Mandatory Design Change
ODC
Optional Design Change
RPM
Revolutions Per Minute
SW
Soft Ware
TDD
Type Design Definition
TC
Turbo Charger
Ubatt
Battery Voltage

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 2-1
Revision no: 1
2General Information
In the present Operation Manual the proper operation of the aircraft engine E4P is documented.
With the publication of the Operation Manual Austro Engine GmbH ensures the correctness of the
instructions. In case of changes Austro Engine GmbH will inform with Service Bulletins, Service Letters
or manual amendments, if it is necessary.
In case of problems with the engine operation or any further questions about the engine,
contact Austro Engine GmbH.
The following symbols and warning signs are used in the manual to point out important instructions.
They must be heeded strictly to prevent personal injury and material damage, to insure operational
safety of the aircraft and to avoid any damage to the aircraft as a result of incorrect handling.
Warning: Disregarding these safety rules can cause personal injury or even death.
Caution: Disregarding these special instructions and safety measures can damage the
engine or other components.
Note: Additional not or instruction for better understanding of an instruction.
2.1 Description and Using
The E4P is a liquid-cooled, in-line four-stroke four cylinder engine with a double overhead camshaft
(DOHC) with four valves per cylinder. The valves are actuated by the cam follower
The direct fuel injection is realized by means of a common rail technique and the engine is charged by
a turbo charger in combination with an intercooler.
The propeller is activated by a directly integrated gearbox with an integral torsional vibration damper.
All engine components are controlled by an EECU system.
●This engine is only designed for pull propeller installations.
●The engine should not be operated without propeller.
●Only useable in aircraft.
●It is not capable for aerobatics use
●It is not allowed to run the engine without the specified quality and quantity of fluids.
●Only the use of recommended equipment and fluids grants a save run of the engine.

Operation Manual
E4P
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Page: 2-2
Revision no: 1
2.2 Safety
The required provisions of the employer’s liability insurance organization and the other relevant safety
rules, like for example the trade supervision authority have to be kept in mind.
The described work steps, contained in this Operation Manual have to be performed only by trained,
qualified persons and / or specialized companies, with a current and valid license from the aviation
authority to do such work
For further information the national aviation authority has to be contacted.
2.3 Safety Information
●To prevent personal injury and damage secure all tools before starting the engine.
●The pertinent accident prevention regulations as well as other commonly accepted safety,
occupational health and air traffic legal requirements must be observed.
●Operators must also observe any additional regulations and requirements which are applicable
in their territory.
●The engine has to be protected against contamination and potentially hazardous manipulation.
●Rotation of the propeller by hand is not recommended.

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 2-3
Revision no: 1
2.4 Dimension and Volume
For further information about measurements refer to the Installation Manual of the E4 series (Doc. No.:
E4.02.01).
Fig. 2.1: Engine view
Fig. 2.2: Engine view

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
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Revision no: 1
2.5 Technical Data Sheet for E4P Engine
All speed information’s refer to the revolution speed of the propeller. The revolution speed of the engine
is declared separately.
For detailed manifold data and dimensions refer to the “Installation Manual” of the E4 engine (Doc. No.:
E4.02.01).
2.5.1 Engine Performance
Fig. 2.3: Engine Performance
Low and Idle Power Correction
Below 850 mbar ambient ECU pressure the low power output is increased and below 800
mbar ECU pressure the idle power output is increased regarding to the desired power
(power lever position) to prevent the engine from combustion extinction.

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 2-5
Revision no: 1
2.5.2 High power performance
Fig. 2.4: Power Curve RPM 2300
Fig. 2.5: Power Curve RPM 2200
Rated Power (100%):
132 kW
(177,0 hp)

Operation Manual
E4P
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Issue date: 15.Nov.2016
Page: 2-6
Revision no: 1
2.5.3 Fuel consumption
Fig. 2.6: Fuel consumption
2.5.4 Propeller Setpoint Curve
Fig. 2.7: Propeller Setpoint Curve E4P
The propeller setpoint is set on the governor by the EECS on the basis of power lever position. This
propeller speed (rpm) is held at any airspeed as long as the propeller is within the range of stops.
0%
20%
90%
100%
1600
1650
1700
1750
1800
1850
1900
1950
2000
2050
2100
2150
2200
2250
2300
2350
2400
0% 20% 40% 60% 80% 100%
Propeller Speed [rpm]
Power Lever [%]
Propeller Setpoint Curve E4P

Operation Manual
E4P
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Issue date: 15.Nov.2016
Page: 2-7
Revision no: 1
2.5.5 Engine and Gearbox Data Sheet
Max. take-off power (max. 5 min.):
132 kW
Max. continuous power:
126 kW
Max. recommended cruising power:
93,8 kW
Max. prop. Over speed:
2500 rpm
Max. take-off speed:
2300 rpm
Max. continuous speed:
2200 rpm
Max. recommended cruising speed:
2123 rpm
Idling prop speed:
710 rpm
Gearbox ratio:
I = 1.69

Operation Manual
E4P
E4.01.02
Issue date: 15.Nov.2016
Page: 2-8
Revision no: 1
2.5.6 Limitation Section
All temperature and pressure limits must not be exceeded. The limits have to be
shown to the pilot in a red range.
2.5.6.1 Oil
Oil temperature (start):
min.
-30 ºC
(-22 ºF)
Oil temperature
max.
139 ºC
(282 ºF)
Oil pressure:
at idle
min.
0,9 bar
(21.75 psi)
(at max. cont. conditions)
min.
2.5 bar
(36.26 psi)
max.
6.5 bar
(94.25 psi)
Approved engine oil types:
Brand name
SAE Grade
AUSTRO ENGINE Aero
recommended by Austro Engine GmbH
5W-40
CASTROL Edge Professional A3
5W-40
CASTROL Magnatec Professional A3
5W-40
GULF Formula GX
5W-40
LIQUI MOLY Leichtlauf High Tech
5W-40
LUKOIL Luxe synthetic
5W-40
MEGOL Motorenoel High Condition
5W-40
SHELL Helix Ultra
5W-40
VALVOLINE SynPower HST
5W-40
AEROSHELL Oil Diesel Ultra
5W-30
ADDINOL Super Power MV 0537
5W-30
BP Visco 5000
5W-30
CASTROL Edge 5W-30 A3
5W-30
CASTROL Edge Professional A3
5W-30
G-ENERGY F Synth
5W-30
GULF Formula GMX
5W-30
REPSOL Elite Common Rail
5W-30
SHELL Helix Ultra
5W-30
Table to be continued on the next page!