Operation Manual E4.01 - Austro Engine

1 Operation Manual Issue date: Page: 1 Revision no: 20 Operation Manual Issue date: Page: Intro 1 Revision no: 20 Intentionally left blank Operation Manual Issue date: Page: Intro 2 Revision no: 20 Date: Wiener Neustadt, Author: Austro Engine GmbH Rudolf Diesel Stra e 11 A-2700 Wiener Neustadt Document number: Revision: 20 Operation Manual Issue date: Page: Intro 3 Revision no: 20 Intentionally left blank Operation Manual Issue date: Page: 1-1 Revision no: 20 1 Index 1 Index .. 1-1 2 Identification .. 2-1 Type Designation .. 2-1 Engine Identification .. 2-1 Record of Revision .. 2-2 List of Revision .. 2-3 List of incorporated Temporary Revisions .. 2-6 Design Holder .. 2-7 2-7 List of Abbreviations .. 2-7 3 General Information .. 3-1 Description and Using .. 3-1 Safety .. 3-2 Safety Information .. 3-2 Dimension and Volume.

2 3-3 Technical Data Sheet .. 3-4 Engine Performance .. 3-4 High power performance .. 3-5 Fuel consumption .. 3-6 Propeller Setpoint Curve .. 3-6 Engine and Gearbox Data Sheet .. 3-7 Limitation Section .. 3-8 Oil .. 3-8 Coolant .. 3-10 Fuel .. 3-10 Fuel Grade .. 3-11 Speed .. 3-12 Voltage .. 3-12 Performance .. 3-12 Information Section .. 3-13 Engine Oil .. 3-13 Coolant .. 3-14 Fuel .. 3-14 Operating Envelope .. 3-15 4 Delivery, Storage and Standstill Period .. 4-1 Delivery .. 4-1 Storage up to 6 months .. 4-1 Storage over 6 months .. 4-1 Engine depreservation .. 4-1 Standstill Period .. 4-2 5 Operating Instructions .. 5-1 Engine Start Procedure .. 5-1 Pre-Start Inspection .. 5-1 Engine Start .. 5-2 Warm Up .. 5-2 Before Take-off Check .. 5-3 During Flight 5-3 Engine OFF .. 5-3 Low Oil Pressure .. 5-3 Operation Manual Issue date: Page: 1-2 Revision no: 20 Restart in 5-3 Restart of Engine by starter.

3 5-4 6 Emergency Procedures .. 6-1 Power loss and abnormal Engine behaviour .. 6-1 Low Oil Pressure .. 6-1 High Oil Temperature .. 6-1 High Gearbox Oil Temperature .. 6-1 Low fuel pressure .. 6-2 High Fuel Temperature .. 6-2 High Coolant 6-2 Engine Fire .. 6-2 Electric power supply out of range .. 6-2 Restart of Engine by windmilling .. 6-2 7 System Description .. 7-1 Intake System .. 7-1 Exhaust System .. 7-1 Fuel System .. 7-2 Coolant System .. 7-4 Standard Coolant System .. 7-4 Coolant System with optional Gearbox Oil Cooler .. 7-5 Lubricating System .. 7-6 Electrical System .. 7-7 EECU Functions .. 7-9 Engine Speed and Power Regulation .. 7-13 Error Handling .. 7-15 Description of ECU Switch Over .. 7-15 Resetting ECU caution in Operation .. 7-16 Caution Handling Table Software VC33_x_05_17 .. 7-17 8 Additional Information .. 8-1 Propeller Self Test (Automatic Run-Up Test) .. 8-1 Operation Manual Issue date: Page: 2-1 Revision no: 20 2 Identification Type Designation TC-Designation: E4 Model: E4 (Sales Name AE300) For detailed information about available configurations refer to latest revision of Austro Engine Service Bulletin MSB E4-002.

4 If not otherwise stated this Manual is applicable to all available configurations. 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. : Engine Identification Operation Manual Issue date: Page: 2-2 Revision no: 20 Record of Revision 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 OM pages.

5 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 Issue date: Page: 2-3 Revision no: 20 List of Revision Re. No. Reason Chapter Page(s) Date of Revision Approval Date of Approval Date Inserted Signature 0 First Release all all 1 Authority remarks updated all all 2 Authority remarks updated 1 2 3 6 7 Cover page2 1,.2 1,3,4,6,7 2,4,6,8,9,11 13 1,2 2,3,5,6,7,9, 12,14,15,1617 3 Type plate updated, details to negative g and low oil pressure added, Add. Info Propeller Self Test added. Worm Up rpm changed. Engine Perform. curve changed. 1 2 3 4 5 7 8 Cover page2 1,2 1,3,4 4,8,9,13 1 2,3 13,14 1 4 Oil temperature changed form 125 to 130.

6 2 3 Cover Page2 3,4 8,9 2010-02-03 EASA 5 Design holder updated. Text at propeller and Engine off corrected. 2 3 5 Cover Page2 3,4,5 2 3 2010-05-05 Operation Manual Issue date: Page: 2-4 Revision no: 20 Re. No. Reason Chapter Page(s) Date of Revision Approval Date of Approval Date Inserted Signature 6 TS-1 Qualification and Gearbox oil temp. added. 2 3 5 Cover Page 2 4,5 8,9 2,3 2010-06-24 EASA 7 MDC-E4-126 2 3 Intro. 2 4,5 7,8,9 2010-09-07 EASA 8 MDC-E4-196 1 2 3 Intro. 2 1,2 4,5 9,10 2011-01-25 EASA 9 MDC-E4-239 2 3 Intro. 2 4,5 8,9 2011-07-19 DOA *) 10 MDC-E4-249 2 3 Intro. 2 4,5 8-14 2011-10-24 DOA *) 11 MDC-E4-172 1 2 3 7 Intro. 2 1-2 4,5 9-15 3-19 2012-03-08 EASA 12 MDC-E4-281 1 2 7 Intro 2 1-2 4,5 14-23 2012-06-27 DOA *) 13 MDC-E4-219 2 3 Intro 2 4,5 9 2012-09-05 DOA *) 14 MDC-E4-279 2 3 Intro 2 4,5 11 2012-09-24 EASA 15 MDC-E4-288 2 3 Intro 2 4,5 8,9 2013-04-30 EASA 16 MDC-E4-297 2 3 Intro 2 4,5 11,12 2013-05-27 EASA 17 MDC-E4-307 1 2 3 4 Intro 2 1,2 4,5 12,14 1,2 2013-06-04 DOA *) 18 MDC-E4-306 2 3 Intro 2 4,5 8,9,12 10-12-2013 EASA Operation Manual Issue date: Page: 2-5 Revision no: 20 Re.

7 No. Reason Chapter Page(s) Date of Revision Approval Date of Approval Date Inserted Signature 19 ODC-E4-006 2 3 Intro 2 5-9 14 12-12-2013 DOA *) 20 MDC-E4-377 All All EASA *) The technical content of this document is approved under the authority of DOA ref. Operation Manual Issue date: Page: 2-6 Revision no: 20 List of incorporated Temporary Revisions Temporary Revision Number Title of Temporary Revision Incorporated with Manual Rev. OM-TR-MDC-E4-217d Engine Preservation 20 OM-TR-MDC-E4-334a EECU Software VC33_x_05_17 20 OM-TR-MDC-E4-359b EECU Software VC33_x_05_19 20 OM-TR-ODC-E4-008 Gearbox Oil Cooler 20 Operation Manual Issue date: Page: 2-7 Revision no: 20 Design Holder Austro Engine GmbH Rudolf Diesel Stra e 11 A-2700 Wiener Neustadt DOA Nr. Manufacturer Austro Engine GmbH Rudolf Diesel Stra e 11 A-2700 Wiener Neustadt POA NR. 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 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 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 Issue date: Page: 2-8 Revision no: 20 Intentionally left blank Operation Manual Issue date: Page: 3-1 Revision no.

8 20 3 General Information In the present Operation Manual the proper Operation of the aircraft Engine E4 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. If there are any problems with the Operation or any further questions about the Engine , Austro Engine GmbH can be contacted. Unless otherwise specified all pressure values given for system installations within this Manual are gauge pressures. 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.

9 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. Description and Using The E4 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.

10 Only the use of recommended equipment and fluids grants a save run of the Engine . Operation Manual Issue date: Page: 3-2 Revision no: 20 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 local flight agency has to be contacted. 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.