Austro Engine TBO and Maintenance Intervals Extended

Posted on September 28, 2012

As of April 2012, Austro Engine company has extended the TBO and some key component replacement/inspection intervals. The purpose of this communication is to not only ensure you are aware of these new developments, but also to ensure you fully understand how this impacts your operation of your DA42-NG aircraft(s).  Please find attached a copy of the Austro Scheduled Exchange Parts Program (SEPP) Phase II Communication, and Austro Service Information Letter SI-E4-001 for reference.

In addition, Austro Engine has published a Austro AE300  Scheduled Maintenance Costs document for various utilization rates.

·         Time Before Overhaul (TBO) – Austro Engines has successfully obtained approval to extend the current engine (including gearbox & EECU) TBO from 1,000 hours to 1,200 hours.  This is a remarkable achievement in such a short time frame, however the long term goal is still engine TBO at 2,000 hours.  Please also keep in mind that maintenance (mx) events are scheduled based on air time (wheels up to wheels down), as opposed to flight time (engine on to engine off) which is typically used for pilot’s logbooks and billing purposes.

·         High Pressure Fuel Pump (HPP) – Austro Engines has successfully obtained approval to extend the HPP lifetime from 300 hours to 600 hours.  This marks completion of the Austro Engines’ SEPP for this part, and as such replacement of this part will no longer be covered under this program.  Current list price for this part is €1,103.29, or approximately $1,456.34 USD (at today’s exchange rate of €1.00 = $1.32 USD).  Please keep this in mind when planning scheduled mx.

·         Torsional Vibration Damper (TVD) – Austro Engines has successfully obtained approval to remove the life limit for this component.  Instead of replacement, the TVD will simply be inspected/tested every 300 hours by the shop carrying out the aircraft mx.  The inspection process is detailed in Austro Engine’s most recent mx manual E4.08.04 (rev 13).  The tools needed to complete this inspection will be supplied upon request, however it will not be available for several weeks.  Until such time as the necessary tooling can be delivered, Austro Engines will still provide full credit (parts, labour, & shipping costs) for replacement of any TVD’s as per the original SEPP.  At the time you request the parts & tooling for your 300 hour inspection, you will be advised of tooling availability, and the course of action needed at that time to complete your 300 hour inspection.

·         Alternator – Austro Engines has successfully obtained approval to remove the life limit for this component.  Instead of replacement, the alternator brushes will simply be inspected every 300 hours by the shop carrying out the aircraft mx. This process is detailed in Austro Engine’s most recent mx manual E4.08.04 (rev 13).  Currently, the parts needed to complete this inspection will not be available for the next several weeks.  Until such time as the necessary parts can be delivered, Austro Engines will still provide full credit (parts, labour, & shipping costs) for replacement of any alternators as per the original SEPP.  At the time you request the parts & tooling for your 300 hour inspection, you will be advised of parts availability, and the course of action needed at that time to complete your 300 hour inspection.

·         V-Ribbed Belt –  Austro Engines has successfully obtained approval to extend the V-Ribbed belt lifetime from 600 hours to 1,200 hours.  This means the previous costs associated with the replacement of this belt are no longer applicable at 600 hours, and replacement is now carried out when the engine is sent for overhaul, further mitigating the labour costs.

·         Parts Kits – In anticipation of the described changes to the life limited components above, Austro Engines has revised their schedule mx parts kits, as detailed in the attachment.  Current stock of earlier kits can still be used up, and standard compensation will be applicable from Austro Engines in these cases.  Once existing stock is consumed, please ensure you order future mx kits in accordance with the attachment, or latest documentation available at the time.  Please take note that the TVD, alternator, & HPP are now separate line items and are no longer incorporated in the kits.  You will also note that the new 600 hour kit (p/n E4A-00-601-KIT) contents in the attachment, still includes the V-Ribbed belt;  this is simply an error and will be corrected shortly.

·         Processes –  In an effort to stay abreast of any issues experienced in the field, and to better streamline the process for ease of use for our customers, we would like to remind everyone that Diamond Aircraft Industries – Canada should be your primary point of contact for all support needs.  This includes parts ordering, warranty processing, and technical support.  We would encourage you to keep our partners at Austro Engine involved from the outset by including the e-mail address service@austroengine.at with any correspondence you send us.  We (DAI-C & AE) have found that this has worked exceptionally well so far for supporting the North American DA42-NG fleet, and we would like to ensure this continues to be the case.

·         DAI Technical Publications – The DA42-NG Aircraft Maintenance Manual (AMM) currently indicates the previous lifetimes for the components discussed above.  We have confirmed with our partners at Diamond Austria that these passages will be revised in the very near future.  If you need to consider a 300/600/overhaul before the DAI technical publications are revised to reflect the new Austro time limits, and have concerns about any disparities with the available approved data, please contact us to discuss.

In conclusion, we are very excited to bring you this news, as we feel this marks a significant milestone in the history of Austro Engines & Diamond Aircraft!  Please don’t hesitate to contact us with any questions or concerns you may have.

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