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
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.
Engine Manual
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 : office@austorengine.at
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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.
Engine Manual
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superseded.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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Rev.
No.
Reason Chapter Page(s) Date of
Editorial
changes
1
Part No
Correction
5.2.3
5
6
5.2.4 6
11.1 26
Revision
15-02-06
Approval Date of
Approval
- -
- -
Engine Manual
Date Inserted
Signature
Page
numbering
Editorial
2
Changes
Maintenance
Interval
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
9.5.3 9-5
13.5.5 13-5
14.1
18.7.1 18-12
18.8.1 18-15
18.8.2 18-16
12.1 12-1
9-4
14-1
14-2
10-04-06
New spark
3
plug
implemented
4 No. changed
5
Editorial
change
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1.1 1-3
1.2 1-4
11.1 11-1
1.1
1.2
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11.1
1.1
1.2
8.3
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11.1
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8-1
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8-1
9-3
11-1
22-11-06
10-11-08
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All Diamond
Logos
changed to
Austro
6
Engine
Logo.
Oil
specification
changed
Engine Manual
all all 10-03-11
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1.2 LIST OF EFFECTIVE PAGES
Engine Manual
Ch. Page Date
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Engine Manual
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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Engine Manual
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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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
Engine Manual
Rudolf – Diesel - Straße 11
A – 2700 Wiener Neustadt
Tel.: +43 (0) 2622 – 23000
Fax.: +43 (0) 2622 – 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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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.
Engine Manual
3.1 Safety Symbols
A note symbol shows an additional significant information.
A caution symbol indicates special procedures which should be
followed to avoid the risk of serious damage to engine or to
components.
A warning symbol indicates special procedures, which must be
followed to avoid the risk of death or serious injury to persons.
NOTE !
CAUTION!
WARNING!
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3.2 Model Designation Breakdown
Engine Manual
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
Engine Manual
Intentionally left blank
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5.0 GENERAL ENGINE DATA
Engine Manual
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
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.
Austro Engine GmbH
Rudolf – Diesel – Straße 11
A – 2700 Wiener Neustadt
Austria
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
Engine Manual
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.
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
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
Flywheel Cast iron fitted with an induction–hardened steel
starter ring gear.
when viewed from the driving side of the engine.
liquid cooling system; the balance is rejected via rotor
cooling air.
Coolant 50 : 50 Distill ed 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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Engine Manual
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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Engine Manual
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. RPM 6,900 RPM
Fuel consumption (max) 12 - 15 liters / hr
Max. Cont. Power 34.3 kW (46 BHP)
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6.2.1 Power Curve
Engine Manual
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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Engine Manual
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
Engine Manual
Location of Components
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Engine Manual
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.
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8.0 DESCRIPTOPN OF SYSTEMS
8.1 Ignition System
8.1.1 Supply
The CDI Unit receive their supply via duplicated feeds from the aircraft bus bar (2 x 1 amps
circuit breakers).
8.1.2 Triggering
Two steps in the rim of the flywheel, nominally 180° apart, inductive fixed timing sensors.
8.1.3 Ignition
The spark plug pair are fired simultaneously, each by its own coil, triggered by the output from
the CDI unit. Each ignition switch interrupts the supply to its coil.
8.1.4 H.T. Leads
Engine Manual
The inductive H.T. coils are connected to the spark plugs by copper–cored cable and resistive
plug caps.
8.1.5 Spark plugs
The specified spark plug type must be used; substitution with a non–approved type may
reduce engine power and reliability, and may cause mechanical damage to the engine.
8.2 Generator System
A flywheel mounted 18 amp brushless / bearing less generator, with a separate voltage control
regulator / rectifier unit, provides 14 volt DC supply to the aircraft bus bar.
8.3 Starter
The starter is an electric starter operated with 12 V, 50 A. It is of a Bendix Type, engaging the
gear when operated (refer to drawing no. R1A-90-000-000).
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8.4 Fuel System
8.4.1 Fuel Pressure
The fuel system requires clean fuel with a minimum fuel flow capability of 45 liters per hour at
working pressure.
8.5 Cooling System
8.5.1 Liquid Cooling System
Coolant Circuit Items
Engine Manual
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Engine Manual
8.5.2 Water Pump
A water pump impeller, driven from the eccentric shaft via a tufnol drive coupling (a shear
point) is mounted at the rear of the engine and circulates coolant through the engine casting
and radiator.
8.5.3 Temperature Regulation
No thermostat is fitted. A minimum coolant temperature of 60 °C must be maintained and a
normal operating temperature of 70 °C is desirable.
8.5.4 Coolant Temperature Sensor
A temperature sensor is fitted to the engine in the front plate, for connecting to a temperature
gauge.
8.5.5 Coolant
Coolant is a 50 / 50 water – ethylene glycol mix. For details refer to Chapter 5.2.6
The use of a pre–mix solution such as Silkolene Pro–Cool is
strongly recommended so that there is no variation in the
strength or the heat transfer properties of the coolant.
8.5.6 System Pressure
The cooling system is a closed loop system, designed for a working pressure of 0.9 bar
(13 psi).
8.5.7 Air cooling system
Lubrication of the eccentric shaft rear bearings is achieved by direct injection of oil from the
metering oil unit and results in an oil mist being entrained into the rotor cooling air system. The
oil mist, in turn, lubricates the rotor bearing, front main bearing and cools the inside of the
rotor.
CAUTION !
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8.5.8 Rotor Cooling Air Parts
Engine Manual
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9.0 OPERATING THE ENGINE
9.1 Starting Procedure and Warm–up
Starting
The settings, start and warm–up procedures for the first start of a newly installed engine are
obviously to be treated with the greatest care. However, all engines supplied by Austro Engine
GmbH will have been fully run–in and performance–tested prior to shipping.
NOTE !
If the engine fails to start after three attempts (normal maximum
starter engagement per attempt of five seconds) there is
something incorrect! (Fuel, ignition, or outside air temperature).
Starting between -5 °C and -10 °C may require assistance for the
aircraft battery!
Engine Manual
1) Check coolant level, that the engine oil tank level is sufficient for flight / test and that
the fuel is sufficient, on, and water free.
2) Set throttle slightly off the idle stop.
3) Switch on battery and alternator.
4) Switch on ignition – verify that all gauges / alarms are correct.
5) Switch on both fuel pumps – verify that all gauges / alarms are correct.
WARNING !
Ensure all personnel are clear of propeller and aware that the
engine is to be started.
6) Operate fuel primer to aircraft manufacturers instructions (if installed)
9) Crank the engine for 5 seconds (or less if the engine starts).
10) If the engine fails to start, recheck switch positions and alarms.
11) If cold start – repeat (6 & 7) at 15 second intervals.
12) See NOTES above for starting limitations.
13) Allow engine to warm up at approximately 3000 RPM to 50°C.
14) Check that the rpm rise is smooth and trouble free.
15) A sudden liquid coolant temperature rise indicates air trapped in the system. In this
case the bleed procedure should be carried out without further running (see 13.3).
CAUTION !
During cold starts not more than 5 x 5 second start attempts in
any 3 minute period.
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9.2 Engine Start down to Approximately -10 °C The engine will start equally well with either permitted fuels.
9.3 Ground Tests (See 15.0)
9.3.1 Full Power Check
Set WOT and note rpm achieved in relation to the minimum acceptable value as defined in the
aircraft operating manual. Check that all instrumentation is functioning and that all parameters
are within limits. Check that single ignition drops are less than 300 RPM at 6200 RPM.
9.3.2 Idle Check
Fully close the throttle and note rpm; it should be 2300 RPM ± 100 RPM. Adjustment, if
required, is by the throttle stop screw on the throttle body. For method, and precautions, see
Engine Manual
the aircraft manufacturer’s manual.
9.3.3 Stopping the Engine
It is usual to idle the engine for 2 to 3 minutes before stopping (to dissipate internal heat prior
to shut down) [see aircraft manufacturers operating manual].
Switching off either the ECU power, or ignition switches, or the fuel pumps will stop the
engine. The latter gives a short run down and dissipates pressure in the fuel lines.
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9.4 Power Loss at Altitude
Performance at altitude is degraded due to a reduction in air density. The approximate power
available (at given RPM / throttle setting) is given in 6.1.1 for Sea Level.
Engine Manual
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Engine Manual
9.5 Storage General (installed engine).
Proper steps must be taken, on engines used infrequently, to lessen the possibility of
corrosion. This is especially true if the aircraft is based near the sea coast or in areas of high
humidity.
In all geographical areas the best method of preventing corrosion of internal parts of the
engine is to fly the aircraft at least once a week. Alternatively the engine should be run long
enough to reach normal operating temperatures.
9.5.1 Storage up to 90 Days No special treatment is required for storage periods of up to 90 days.
The aircraft should be protected from the weather and excessively damp conditions.
9.5.2 Storage over 90 Days
NOTE !
The following procedures may require that the engine is
removed from the aircraft – see aircraft manufacturer’s
instructions.
CAUTION !
Never rotate the engine with the oil can nozzle still in the spark
plug or exhaust / inlet ports!
1) To protect the internal of the engine it is recommended that additional engine oil be
introduced. This can, for example, be via the spark plug holes, the throttle body or the
exhaust and is determined by the aircraft manufacturer.
2) Where appropriate, ensure all electrical circuits are off, and then manually rotate the
propeller shaft and engine.
3) Inject 5cc of the prescribed engine lubrication oil through either spark plug hole in the
rotor housing. (See CAUTION! above)
4) Rotate the engine through 1/3 revolution of the flywheel (by turning the propeller or
propeller shaft and hence the eccentric shaft, by hand).
5) Repeat (3 & 4) five times.
6) Rotate the engine through 6 revolutions of the flywheel then refit the spark plugs.
7) Seal all inlets and exhaust openings to prevent moisture ingress.
8) To protect the bearings and associated parts, engine oil should be introduced into the
area. The aircraft manufacturer describes the method by which this is achieved and
the instructions must be followed carefully.
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Engine Manual
9) Blank off all open holes.
10) To protect the outside of the engine, anti corrosion oils of well–known oil companies
are recommended, such as:
Anticorit 5 of Messrs FUCHS, D – 6600 Mannheim, Germany
Lubrication Oil MTL – L – 644 B of MOBIL–OIL
Shell ENSIS Fluid 2360 of SHELL
RUST BAN 395 of ESSO
It is also ESSENTIAL that the fuel system be drained.
Items (1) to (3) should be carried out every 90 days.
9.5.3 Returning to Service from Storage
1) Restore the engine to operation according to the Aircraft Manufacturers instructions.
2) If the aircraft been laid–up for more than 6 months, please carry out 9.5.2 ((1) to (6)).
3) Rotate the engine by hand several times to ensure that all excess oil is drained via the
spark plug holes.
4) Clea n and refit, or replace, the spark plugs.
5) Check the engine for external damage or deterioration suffered during storage, and
rectify as necessary.
6) Clea n engine to remove inhibitor and remove all storage blanks.
7) Refit engin e in accordan ce with the aircraft manufacturer’s instructions.
CAUTION !
Stale fuel must NOT be reused!
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10.0 ENGINE EMERGENCY PROCEDURES
10.1 Fan Belt Failure
In the unlikely event of a fan belt failure, the indication will be a sudden rise in Rotor Cooling
Air temperature. The engine load / RPM should be reduced as much as is practical to prevent
further heat build up. If the rotor cooling outlet air temperature reaches 120 °C the engine
should, if possible, be switched off. Continued running of the engine under these conditions
will cause damage.
10.1.2 Charge Circuit Fail Alarm
In the unlikely event of a charging circuit failure, indicated by the appropriate alarm, the
electrical bus bar will be fed automatically from the battery. Any non–essential electrical items
should be switched off. The battery should be capable of providing sufficient power to run the
CDI unit etc. for a minimum of ½ hour. Reducing power will not significantly increase engine–
running time.
Engine Manual
10.1.3 Low Oil in the Tank
In the unlikely event of low oil alarm the engine RPM should be reduced as much as is
practical. Flying time should be limited to a total of 10 minutes at this reduced power. Flying
under such conditions may cause damage to the engine.
10.1.4 Low Fuel Pressure
If low fuel pressure is indicated, the engine may stop or operate at reduced power and may
also indicated an excessively high exhaust temperature. Throttle setting should be adjusted, if
practical, to minimise excess temperature.
Continued operation at excess exhaust temperature will cause damage to the engine.
10.1.5 Rotor Cooling Air Temperature
If the rotor cooling air temperature rises above the specified limit, the engine should be shut
down as soon as possible. Continued operation at excess temperature is likely to cause
damage to the engine.
10.1.6 Water Temperature
If the water–cooling temperature rises above the specified limit, the engine should be shut
down as soon as possible. Continued operation at excess temperature is likely to cause
damage to the engine.
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11.0 MAINTENANCE NOTES
11.1 Austro Engine GmbH Available Consumables
R1A-06-000-803 Rotor Cooling Air Filter
R1A-06-000-805 Induction Air Filter
Engine Oil see Chapter 5.2.10
Glysantin Aluprotect Premium Engine Coolant (One Litre Container)
Copper ease Copper ease
Loctite 243 Screw locking
Loctite 595 Sealing silicone
R1A-09-000-801 Spark Plug (NGK)
K&N Filter Oil Air Filter Oil
R1A-30-000-801 Injector
For further part replacement contact Austro Engine GmbH.
11.2 General Torque Settings Bolts / Socket Head Cap Screw
4 mm 2.0 Newton Metres (Nm)
5 mm 4.5 Nm
6 mm 8.5 Nm
8 mm 21.5 Nm
10 mm 30.0 Nm
11.2.1 Specific Torque Settings
Nuts and Stiff Nuts – as above.
Spark Plug 10.0 Newton meters (Nm)
Coolant Temperature Sender 4.5 Nm
Starter Motor Terminal 8.0 Nm
Oil Pump Inlet Fitting 2.5 Nm (caution)
Oil Pump Outlet Banjo 2.5 Nm (caution)
Oil Pipe Nut & Olive 3.0 Nm (caution)
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11.3 Checking & Setting Fan Belt Tension
Engine Manual
NOTE !
The silicon rubber tube and the tie wraps are left in place during
the test.
1) Slacken the three attachments numbered 1, 2 and 3 above.
2) Attach a loop of suitable material around the fan outlet duct.
3) Using a suitable spring balance, apply a force to the loop of 6 – 7 Kilograms.
4) With this force still applied, tighten the 3 housing attachments.
5) Confirm the attachments are not at the end of their adjustment slots.
6) If a new belt is required, see Section 13.5.2
11.2.4 Adjusting engine idle speed
For adjusting procedure, and precautions, see the aircraft manufacturer’s instructions.
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12.0 SCHEDULED MAINTENANCE
12.1 Maintenance Schedule ALL HOURS QUOTED ARE ENGINE HOURS
ITEM 1A 1B 2 3 4
a) Engine oil level / coolant level check X X X X aircraft manual
b) Coolant leak check X X X 13.4
c) Insp. / clean / replace air filters X X 13.5.4
d) Insp. engine, mountings and all external fasteners X X aircraft manual
e) Check fan belt condition & tension X X 13.5.1
f) Check cooling system condition and security X X 13.0
g) Inspect / clean / replace spark plugs X X 14.1
h) Full engine ground run X X 15.0
i) End plates – examine seals & seal faces X 14.0
j) Inspect fan impeller (300 hours) 13.5.5
k) Renew coolant, pressure test system (annual) 13.3
l) Replace fan belt (earlier of 300 hrs or 5 yearly) 13.5.2
m) Replace in line fuel filter X aircraft manual
1A = Check A (every flight)
1B = Check B (every flying day)
2 = every 50 hrs OR annually
3 = every 150 hrs or 3 yearly
4 = Section Reference
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12.2 Typical 50 Hours Check
Visual Checks Only unless stated! All Checks to include Fastenings, Cracking,
Leaks, Discoloration and Wire Locking!
Engine Manual
NOTE !
REF ITEM CHECKS / COMMENTS
1 Water Outlet Cover Leakage
2 Water Hoses Security of all clips – leaks
3 Oil Separator Leakage and temperature sensor connection
4 Oil Pump – Lines and
Terminations
5 Spark Plug Coils and Plug Caps Cables and terminations
6 Spark Plug Condition Connection & gap area
7 Engine Mounts – Starboard Side Nuts, bolts secure
8 Starter Motor Mounts and Cable Bolts and cable connections
9 Starter Pinion – Condition and
10 Generator (Stator / Rotor) Note any debris in the area
Laxity
Leakage
Teeth, free movement, play
WARNING !
Ensure that all switches are OFF before rotating the engine.
11 Starter Rin g – rotate Engine via Prop Chipped or missing teeth
12 Gene rator Cables Signs of contact and chafing/cracking
13 Lower Timin g Sensor and Cables Signs of contact and chafing/cracking
14 Wate r Pump Housing Vent hole
15 Upp er Timing Sensor and cables Signs of contact and chafing/cracking
16 Fan Housing Cracks
17 Fan Belt Check tension and condition
18 Fan Filter – remove and check View fan impeller – Debris – Cracks
19 Engine Mo unts – port side Nuts, bolts
20 Fuel Rail, Inje ctor, Pressure Regulator Leaks – Cracks – Cable Connection
21 Linkage, Throttle Stops
22 Ram Pipe Check temperature sensor connection
23 Inductio n Air Filter Cleanliness and damage
24 Rotor Housing drain screw Security – leaks
25 Exhaust System - co mplete Overheat adjacent parts – security
26 Voltage Re gulator and Cables Signs of deterioration
27 CDI and Trigger Cables Signs of deterioration
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28 Engine Alarm s, Tran sducers and
Cables
29 Oil Tan k and Vent Security – Leaks – Level - Connections
30 Radi ator and Overflow Tank Security – Damage – Leaks – Debris –
31 Oil Separator Hoses Leakage
32 Rotate Pro peller by Hand Check 6 x Compression o n prop
Signs of deterioration
Level
NOTE !
Carry out engine ground run according to check list!
12.3 Mandatory Life Limitation There is no life limit of the engine, engine operation is on condition.
Engine Manual
NOTE !
Reliable operation of this engine is dependent upon injector
replacement in accordance with maintenance
recommendations.
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13.0 COOLING SYSTEM
13.1 Liquid Cooling System Coolant Level Check: Refer to Aircraft Manufacturer’s Instructions.
In a fault free system, the coolant level will not alter significantly. Any unusual drop in the
coolant level in the tank indicates a fault in the system that must be rectified before further
flights.
13.2 Coolant Hose Inspection
Check all hoses for cracks, wear, security and leaks (a white crust around a hose joint is an
indication of a leak!). Refer also to engine installers handbook. If a leak is found, replace hose
and hose clips, tighten hose – clips etc. as necessary and check / bleed / pressure test the
system as detailed below:
13.3 Coolant System Filling and Bleeding
NOTE !
This test should be carried out if leaks are suspected after any
part of the coolant system has been disturbed.
NOTE !
This is a guide, any variations in the aircraft manual should be
followed!
1) Slowly fill the system with the coolant mix
2) Undo bleed plugs until fluid escapes, then tighten.
3) Top up radiator header tank with coolant mix.
4) Check for coolant leaks at all connections / interfaces.
If in doubt fit a coolant pressure tester
5) If required fit a coolant system pressure tester (Blue Point No STV 262 or simila r) to
the header tank and pressure test.
6) Recheck bleed points for air after the first engine run.
7) Repeat (6) until no further air is emitted from the bleed point(s). When running the
engine ensure that coolant temperature rise is slow and consistent with warm up and
no sudden temperature jumps occur. If the coolant temperature suddenly rises then
there will still be entrained air in existence and the cycle must be repeated.
8) Top up header tank with coolant mix. Refit the filler cap and wire lock if appropriate.
9) Fill the overflow tank with coolant mixture within the MINIMUM and MAXIMUM levels.
10) Carry out full engine ground run.
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CAUTION !
If coolant temperature rises rapidly shut down the engine and
bleed the system again!
WARNING !
Risk of scalding – do not remove the pressure cap from the
radiator until the engine and radiator have cooled.
13.4 Coolant System Pressure Test
1) Remove header tank pressure cap and fit a Coolant System Tester (Blue Point No.
SVT262 or equivalent) in its place.
2) Apply pressure of 17 p.s.i (1.2 bar) to the system.
3) This pressure is to be held for 5 minutes during which time it must not drop by more
Engine Manual
than 0.5 p.s.i (0.03 bar)
4) Whilst under pressure the coolant system should be checked visually for any leaks for
weeps at all connections.
13.5 Air Cooling System
13.5.1 Fan Belt
Check fan belt condition. Examine belt for fraying, cracks or broken strands. If in doubt replace
it. Check belt tension as in 11.3. Adjust as necessary.
Need for significant or regular adjustment indicates need for
belt replacement! When changing a fan belt, see 11.2 for torque
settings!
NOTE !
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13.5.2 Fan Belt Replacement
1) Drain off the coolant & remove connections to the water pump.
2) Disconnect alternator leads and oil pipes.
3) Remove the fan assembly and check bearings for play / roughness.
4) Remove the water pump housing along with the alternator stator assembly and check
the water pump bearings for play.
NOTE !
Care should be taken in withdrawing the assemblies due to the loose internal
tufnol drive coupling!
5) Fit the new Fan Belt (using Austro Engine GmbH “Fan Belt Kit”).
6) Rea s semble using the reverse procedure for items (2) to (5) inclusive, above, and
tension the belt as in 11.3 Fig. 8
NOTE !
Replace tufnol drive coupling from the fan belt kit and assemble with the
reduced diameter towards the water pump!
Fit the new O–Rings in the water pump housing with those from the fan belt kit
using compatible grease to hold in place!
Use Loctite 242 on all fixings!
IF IN DOUBT PLEASE CONTACT Austro Engine GmbH!
7) Connect services, as appropriate and fill with coolant.
8) Ensure that the coolant lines and oil lines are bled.
9) If necessa ry, pressure test the coolant system as per aircraft manual or chapter
above, and check for leaks.
10) Test run the engine to verify satisfactory operation before flight.
13.5.3 Air Filters
The two air filters, induction and rotor cooling air, should be visually inspected at the specified
intervals for contamination, large pieces of debris and cracks. Both filters may be cleaned and
re–used, although great care must be taken to correctly follow the manufacturer’s instructions.
Damaged filters should be replaced.
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13.5.4 Air Filter Cleaning Procedure:
1) Tap filter gently, and then brush outside of filter with a soft bristle brush, to remove
loose dirt.
2) Wash the outside of the filter with mild liquid soap and warm (maximum 40°C) water,
by agitating the filter in the solution.
3) Ensure that the contaminated solution does not come in contact with the inside
surfaced of the filter.
4) Rinse off the filter, from the inside, with clean low pressure water – from a tap or a
similar supply. Rinse thoroughly to ensure all soap is removed.
5) Examine filter and if necessary repeat stages 2 and 3.
6) Shake off all surplus water and allow filter to dry naturally.
7) Re–oil element: Aerosol – Spray one pass per pleat into each pleat, from the
Liquid – One bead of oil every 6 mm down each pleat.
8) Check that no white patches remain after 10 minutes.
Engine Manual
outside
9) Re–oil where necessary. A red dye in the oil clearly shows those areas that have been
correctly oiled.
10) Reinstall air filter and tighten all clips and fittings.
NOTE !
Do not use harsh detergents, caustic solutions, solvents, fuel, steam, or
pressure washers!
CAUTION !
Excess heat (over 40°C), or compressed air will damage the filter:
Do not use without re – oiling!
Only use filter oil from Austro Engine GmbH or K & N!
CAUTION !
Once the filters have been removed, the associated duct and fan impeller
should be inspected for dust or debris of any type. If found, it indicates
inadequate filter care or a damaged filter and could have serious consequences.
Advice should be sought from Austro Engine GmbH on the significance of this
material and the effect it may have on the engine. Either or both filters should be
replaced if their condition is suspect.
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13.5.5 Rotor Cooling Air Fan Impeller
1) At the intervals stated in 12.1 the fan impeller should be inspected. The complete fan
should be removed from the engine and the bearing housing assembly removed from
the fan housing.
2) Carefully examine the impeller for cracks with a X 10 magnifying glass, particularly on
the fan blade – back plate, root radius. No cracks are allowed.
NOTE !
If in doubt change the impeller / bearing housing assembly!
The impeller cannot be removed from spindle!
3) Refit and check the fan belt tension (see section 11.3).
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14.0 ENGINE INTERNAL INSPECTION
Remove all dirt from the exterior of the engine and inspect for evidence of overheating or other
unsatisfactory conditions.
Inspect rotor tip seals and internal side plate faces.
1) It will be necessary to remove the throttle body and the exhaust pip t o carry out this
inspection. The use of a ‘Boroscope’ or fibre optic probe facilitates viewing.
NOTE !
Care must be taken to ensure the probe is withdrawn before the
engine is rotated!
2) Once the openings are exposed, rotate the eccentric shaft by hand to view the rotor tip
Engine Manual
seals. Each seal should not be stuck in the groove and free to spring. The side plate
seal faces inside the engine should not exhibit significant distress. Minor scoring and
scuffing is acceptable. It is important to obtain a good view of the side faces above the
centre line of the engine, where the cooling medium is air. This can only be achieved
through the inlet port.
3) If there is any doubt about the acceptability of the faces or the seals, then access
should be gained to the air outlet of the front plate by removal of the oil separator. If
there are any hard carbon deposits on the internal walls of the duct in the front plate
then the side seals may have allowed combustion gas to blow by. Austro Engine
GmbH should be consulted if this condition is found.
14.1 Spark Plug
The spark plug is of the surface discharge type with a long life platinum centre electrode.
See 11.1 for the replacement Part Number.
The spark plugs must be removed for inspection at the intervals required in the maintenance
schedule.
1) Check the electrical connections for corrosion and lightly smear with silicone grease.
2) Clean the electrode area of the plugs with gasoline if required.
3) If possible check plug function under pressure.
4) Replace spark plug in engine, (torque to value as in 11.2.1).
5) Anti–seize grease must be used on the threads. See 11.1 for Part Number.
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If due to local conditions, the plug connections become corroded then the corrosion may be
removed from the plug nipple with a wire brush and the inside of the plug cap cleaned with a
dry cloth or paper wiper. When complete, re–smear the connections with fresh silicone grease.
Torque to the value given in 11.2.1. If the plug are unserviceable they should be replaced with
new ones.
Engine Manual
CAUTION !
Fitting other types of spark plug may cause damage to the
engine!
NOTE !
Do not sand blast, or clean with steel or brass wire brush, or
use abrasive materials!
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15.0 GROUND RUN
15.1 Pre–start Checks Outside Aircraft
1) Position aircraft into wind
2) Brakes fully on and wheels chocked
3) Check fuel drains, (no water)
4) Check coolant level at overflow tank
5) Check oil tank level
6) Check fuel level
15.2 Pre – start Checks Inside Aircraft
1) Close and lock canopy if appropriate
2) Record outside air temperature (minimum limit -10 °C for normal starts)
3) Battery Master ON
4) Che c k / note all indicators and alarms, as indicated in the aircraft manufacturers
manual
5) Re cord fuel gauge reading
6) Che c k both ignitions ON
7) Che c k fuel pump ON
8) Alternator M aster ON
9) Avionics off
15.3 Ground Run
Start the engine (see also 9.1). When the coolant temperature has reached 50 °C, ca rry out
and record the following ground run checks.
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15.4 Ground Run Check List (example)
ENGINE GROUND RUND RESULTS
Date:……………….. A/C Reg……………….. Engine No………………..
Flight Hours……………….. Total Running Time (hrs meter)………………..
QFE……………….. Outside Air Temperature………………..
Instrumentation – Gauge / Alarm Function Test
Pressure Temperature Others
RCAO Battery Fail Alarm
Low Fuel Pressure Alarm Engine Coolant Charge System Fail Alarm
OAT Flytronic Error Warning
EGT 1 (optional) Fuel Flow
Oil Low Alarm
Record data after 1 minute steady running at each condition after warm – up
Engine Coolant RCAO Remarks
RPM Temp Temp
Warm – up ………. ………… ………. ……………
Idle ………. ………… ………. ……………
5000 ……….. ………… ………. ……………
6000 ……….. ………… ………. ……………
Max ………. ………… ………. ……………
Idle ………. ………… ……….. ……………
Ign. 1 Ign. 2
Mag Drops at 6000 RPM ………. ……….
Acceleration tests (3 off) Remarks
(Idle to Max RPM response) ………………………………………………….
(1 sec throttle time) ………………………………………………….
Comments If any adjustments are made as a result of this ground run they
should be recorded and the ground run repeated
…………………………………………………………………………………………………………….
…………………………………………………………………………………………………………….
…………………………………………………………………………………………………………….
Record results in engine maintenance file !
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16.0 MAINTENANCE AND OVERHAUL
For maintenance of particular system or for overhauling the engine please contact Austro
Engine GmbH or engine installer.
Engine Manual
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17.0 TROUBLE SHOOTING
17.1 General
This section is included as an aid although some items may be
carried out by the owner / pilot, most would be carried out by a
maintenance organisation.
Replace alls gaskets, seals and joint material if disturbed!
Coolant, fuel & oil systems MUST be bled if disturbed!
Engine Manual
NOTE !
NOTE !
CAUTION !
If, during troubleshooting, any foreign object fall into the engine
internals, through the spark plug holes, the inlet or exhaust
ports, or the rotor air cooling inlet and exit passages, they must
be removed before attempting to turn or run the engine!
Failure to do so may result in considerable damage to the
engine!
WARNING !
Do not stand within the area of the propeller AT ANY TIME,
unless it is essential and you have confirmed that both ignition
switches are ‘OFF’!
17.2 Rough Idle Ignition failure - Check continuity of wiring and connectors.
- Check spark plugs.
- Check CDI Unit
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17.3 Engine Misfires on One Spark Plug Dirty plug cap / terminal - Clean / replace
Wiring fault - Wiring to earth or open circuit
Faulty spark plug - Clean / replace
HT fault - Check / replace spark plug / HT lead /
plug cap for arcing
CDI Unit - Check operation
17.4 Engine Cannot Develop Full Power
HT fault - Check/ replace spark plug/ HT lead/ plug cap
Increase in exhaust back pressure - Investigate exhaust / replace
Loss of compression - Investigate
Blocked induction filter - Replace / clean filter
Low fuel pressure - Investigate fuel system / replace fuel filter
Incomplete throttle opening - Adjust throttle linkage
17.5 Excessive Rotor Cooling Outlet Temperatures Excessive back pressure in outlet duct - Rectify before continuing running engine
Blocked rotor air inlet filter - Clean or replace filter
Slipping / broken fan belt - Adjust / replace
Fan failure / impeller failure
bearing failure - Replace assembly
Stuck side seal(s) - Investigate outlet for black carbon deposits
If found please contact Austro Engine GmbH.
Investigate possible exhaust leakage within the engine bay area.
17.6 Liquid Coolant Overheats on Medium and High Power Restricted radiator core - Rectify
Constricted radiator hose - Rectify
Water pump drive failure - Overhaul pump
Air in system - Vent / Bleed
Coolant leak - Rectify
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18.0 NOTES FOR INSTALLERS OF ENGINES
Engine Manual
Section Page
18.1 General Notes 41
18.2 Engine Overall Dimensions 42
18.3 Cooling System 43
18.4 Fuel System 46
18.5 Procedure for Setting Carburettor 47
18.6 Oil System 49
18.7 Electrical System 50
18.8 Ignitions System 54
18.9 Engine Mounting 57
18.10 Exhaust System 57
18.11 Air Filters 57
18.12 Drive Interface 57
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18.2 Engine Overall Dimensions
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18.3 Cooling System
18.3.1 General
Arrangement must be made by the engine installer to carry the rotor cooling air out from the
front plate elbow, if fitted, to the oil separator or to some suitable mean of the removing the oil
entrained in the cooling air before allowing it to vent overboard.
Cooling air should be arranged to flow over the engine and exhaust system whenever the
engine is in operation.
An ample supply of cold air must be available to the induction air and rotor cooling fan filters
whenever the engine is in operation.
On no account should this rotor cooling air be used directly for
Engine Manual
CAUTION !
cabin heating it may contain products of combustion including
CO & CO
On no account should the engine be run without either of the air
intake filters in place.
A VDO temperature sensor is fitted to the engine in the front end plate. Provision of a
compatible gauge is the responsibility of the engine installer.
Coolant 50/50 water/ethylene glycol mix (A corrosion inhibiting anti–freeze must be used, refer
to 5.2.6). This water/glycol mix will provide protection down to -36 °C.
Operating temperature is in the range of 60 °C to 90 °C after warm up. Maximum continuous
100 °C.
Heat rejection rate approximately 25 kW of heat is rejected to the coolant when the engine is
operated at max continuous power (50 BHP).
2
An integral water pump is provided with the engine. This provides a water flow of approx. 40
liters per minute at 7000 RPM.
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CAUTION !
Radiator. The optimum radiator design will vary with each
installation. It is the responsibility of the installer to provide an
adequate cooling system and thus ensure that the maximum
recommended coolant temperature is never exceeded even
under the most adverse operation conditions. The design
should also ensure that the minimum operating temperature
can be achieved under all flying weather conditions.
Flight trials will probably be necessary to confirm that the
design caters for the above conditions.
18.3.2 Suggested pipe bore Outlet from engine and return from radiator 25-28 mm.
Engine Manual
Header tank to radiator 5 mm minimum.
18.3.3 Max burst pressure 45 psi at 150 C
Expansion tank at the highest point
Positive head at pump entry is necessary to ensure zero cavitation
Air volume in expansion tank should allow
1) Rapid pressure rise is possible as coolant warm up
2) No coolant is ejected during / after boil
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18.3.4 Cooling Circuit Schematic Typical Cooling Circuit
Fig. 10
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18.3.5 Temperature Sensor
Air Temperature sensor
Supplied by Austro Engine GmbH and should be installed with its probe in the induction
airflow.
Rotor cooling air out temperature sensor
Supplied by Austro Engine GmbH and should be mounted in the rotor cooling air flow within
100mm or less downstream from outlet.
18.4 Fuel System
18.4.1 Fuel Specification Refer to chapter 5.2.7
18.4.2 Fuel delivery
No fuel pumps are provided by Austro Engine GmbH. Therefore electric pumps each capable
of delivering 45 liters an hour at working pressure.
18.4.3 Fuel filters
No fuel filters are provided by Austro Engine GmbH. Therefore a filter of 40 microns or better
with a flow capacity of least 50 liters per hour at 0.1 bar pressure drop must be fitted in the fuel
delivery line after the pumps.
18.4.4 Pressure Regulator
No fuel pressure regulator is supplied with this engine. It is the responsibility of the aircraft
manufacturer / installer to provide the engine with fuel regulated at working pressure.
18.4.5 Water in Fuel
The fuel system shall incorporate suitable means of isolating, removing, and checking for the
presence of water in the fuel system before each flight.
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18.4.6 Fuel Lines
Fuel lines must be routed away and protected from hot engine and exhaust components. Fuel
line should be of sufficient quality and appropriate to the pressures transmitted. Fuel hose end
connections must be of threaded taper seat type and should be permanently swaged to the
hoses. Push–on type hose connections are not acceptable fuel systems.
NOTE !
The whole fuel system must be able to allow a minimum fuel
flow rate of 45 liters per hour.
18.5 Procedure for Setting Carburettor
The following parameters will effect the required carburettor settings for correct and optimum
engine operation:
Engine Manual
Engine fuel supply pressure The fuel pressure should be 5 ± 1 psi static
Carburettor Air Filter If an air filter other than that supplied is fitted this may
effect the mixture screw settings. There should not be
a pressure drop across the filter of more than 1” Water
Gauge at 7000 RPM (approx. 70 cfm airflow).
Ram Pipe length This should be 14.5 inches. Variations will seriously
effect engine performance.
18.5.1 Basic Settings The following sequence of action should now be followed:
Set carburettor fuel control needle to basic setting as follows:
High Speed settings H Screw 1 3/8 turns out
Low Speed settings L Screw ¾ turns out
Idle stop 2 turns in from just moving the throttle valve
Start the engine
Turn fuel supply on
Turn ignition switch on
Operate the primer to the manufacturer’s instruction before cranking engine
Set throttle 10% open position during engine cranking
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AE50RAB
Ensure all personnel are clear of propeller and aware that the
engine is to be started.
Choking the carburettor by covering the carburettor inlet will
not enrich the fuel supply, due to internal venting of the dry side
of the fuel-metering diaphragm to the carburettor mouth.
Engage the starter
If the engine does not start immediately, the throttle should be opened to WOT and slowly
closed whilst cranking the engine. If the engine does not start within three attempts, there i s
probably a fault and this should be investigated.
Engine Manual
WARNING !
NOTE !
Warming up
Having started the engine allow it to warm through at approx. 4000 rpm for 3-4 minutes, or
until the engine reaches operating temperature (60 C).
18.5.2 Setting the ‘L’ screw system
Return the throttle to idle. The low speed system is set by weakening the mixture (screwing
the L screw clockwise) until the engine just begins to falter. Then increase the flow (turn
anticlockwise) by the minimum amount to just achieve smooth running.
The Settings can be expected to be within ± 1/8 of the original settings.
The aircraft manufacturer’s required idle speed should then be set with the engine warm. If
one has not been supplied then Austro Engine GmbH recommend 2250 rpm (with a minimum
of 1750 rpm) if necessary, adjust the idle stop screw to achieve the appropriate speed.
If significant adjustment is required then also re-check the low speed (L) settings at this
corrected idle speed.
Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 18-9
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AE50RAB
18.5.3 Setting the ‘H’ Screw
Slowly increase the throttle to the WOT position. The maximum engine speed should be as
stated in the aircraft manufacturer’s handbook.
If no flowmeters are fitted, reduce the fuel flow from the high-speed system until the engine
just begins to falter. Then increase the fuel flow until maximum engine rpm is just achieved.
The ‘H’ screw should be as weak (turned clockwise) as it can reasonably be, consistent with
maximum engine rpm being achieved.
The maximum adjustment required is normally ± 1/8 turn from the initial basic setting.
Return to idle and repeat section 18.5.2 to recheck the low speed setting.
Check the snap throttle response by moving the throttle from the idle to WOT in approx. 1
Engine Manual
second. If the engine exhibits unacceptable hesitation, the low speed systems should be
richened very slightly. Any such adjustment can be expected to be less than 1/16 turn.
18.6 Oil System
18.6.1 Oil tank
Oil tank is supplied by the aircraft manufacturer but must have a minimum usable capacity of
500 ml for each hour of engine running with a strainer of mesh size not larger than 0.5 mm.
18.6.2 Oil Separator
An oil separator may be fitted to remove oil from the rotor cooling air after is has passed
through the engine. The recovered oil is returned to the induction system, this provides
additional lubrication for the rotor seals, and is then burned in the combustion chamber. The
cleaned rotor cooling air cools the exhaust system.
18.6.3 Line connections
The oil connection line between the tank and the pump should be calculated to provide AT
THE PUMP INLET a minimum flow of 8 ml per minute at -10 °C by gravity.
Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 18-10
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AE50RAB
18.6.4 Flow rate The flow rate of the pump is pre-set and will not require adjustment.
18.7 Electrical System
The installation of the electric system and the Flytronic Engine Management System should be
done in accordance with Austro Engine GmbH drawings. Please contact Austro Engine GmbH
therefore.
No electrical circuit protection is provided by Austro Engine GmbH.
Voltage regulator connections are shown in wiring diagram. Fig. 11. Its temperature operation
range is -30 °C to +65 °C (outer surface). Adequate cooling should be provided.
Engine Manual
Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 18-11
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AE50RAB
18.7.1 Voltage regulator wiring
Engine Manual
NOTE !
Circuit diagram refers to Austro Engine GmbH (part number
E_R2 B 014) plug type CDI boxes. Coil wires at terminal C
ignition box 1 and coil wire B at ignition box 2 have no
connection.
Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 18-12
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18.7.2 Suggested Circuit Protection (Two wire alternator)
Engine Manual
NOTE !
Austro Engine GmbH provide NO circuit protection.
Diode A protects bus bar from short in the generator side.
Breaker A is isolator for generator and protects bus bar from regulator failure.
Line from battery to bus bar is double insulated.
Breaker C allows battery charge but trips if battery short circuit.
Diodes should be on insulated heat sinks.
Engine will run with either battery or generator inoperative.
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AE50RAB
Engine Manual
CAUTION !
Capacitor 22,000 F must be fitted. Failure to fit will result in
damage.
NOTE !
Temperature limits -30 °C to +65 °C (outer surface) and
adequate cooling must be arranged.
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AE50RAB
18.8. Ignition
18.8.1 CDI units Part Number E_R2 B 014
Engine Manual
NOTE !
Circuit Diagram refers to Austro Engine GmbH part number
R1B006/R1B007 flying lead type CDI boxes.
Coil wires at terminal C ignition box 1 and coil wire B at ignition
box 2 have no connection.
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18.8.2 Connection Plug Wiring Ignition CDI control E_R2 B 014 connection plug wiring
Engine Manual
Terminal G and D are linked and have no connection to the PCB
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AE50RAB
18.8.3 Ignition CDI Part No R1 B 006 / R1 B 007
Engine Manual
Circuit Diagram refers to Austro Engine GmbH Part No R1 B 006 / R1 B 007 flying lead
boxes.
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AE50RAB
18.9 Engine mounting
The engine mounting points on the engine have been designed and tested to meet the
required 15 g load test. Engine location and fitting remain the responsibility of the aircraft
manufacturer. Contact Austro Engine GmbH for installation details.
18.10 Exhaust system
Exhaust design and fitting remains the responsibility of the aircraft manufacturer / engine
installer. Limitations must be regarded.
18.11 Air Filters
Supplied by Austro Engine GmbH as part of design. For other air filters Austro Engine GmbH
must be consulted.
18.12 Drive interface
Engine Manual
The output shaft is parallel, fitted with a woodruff key for load transmission. For more details
contact Austro Engine GmbH.
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19.0 FORM SHEETS
Engine Manual
Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 19-1
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Engine Manual
19.1 Notification of Receipt
Austro Engine GmbH
Rudolf -Diesel – Straße 11
A – 2700 Wiener Neustadt
Austria
Tel: +43 – 2622 – 23 000
Fax: +43 – 2622 – 23 000
Internet: www.austroengine.at
Engine Manual AE50R – AB
NOTIFICATION OF RECEIPT Copy Number:…………………….
Signature:…………………….. Date:……………………………….
Name:………………………………………………………………………………………
On behalf of:……………………………………………………………………………….
Address:……………………………………………………………………………………
………………………………………………………………………………………………
Austro Engine GmbH
Rudolf - Diesel – Straße 11
A – 2700 Wiener Neustadt
Austria
Tel: +43 – 2622 – 23000
Fax: +43 – 2622 – 23000 2711
Internet: www.austroengine.at
Engine Manual AE50R – AB
NOTIFICATION OF RECEIPT Copy Number:…………………….
Signature:…………………….. Date:……………………………….
Name:………………………………………………………………………………………
On behalf of:……………………………………………………………………………….
Address:……………………………………………………………………………………
………………………………………………………………………………………………..
Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 19-2
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AE50RAB
19.2 Problem Report
Engine Manual
Austro Engine GmbH
Rudolf – Diesel – Straße 11
A – 2700 Wiener Neustadt
Austria
Tel: +43 – 2622 – 23000
Fax: +43 – 2622 – 23000 2711
Internet: www.austroengine.at
PROBLEM REPORT
Austro Engine
Doc. No. E1.01.0-E Rev. 6 10-March-2011 Page 19-3
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