DA62 Mx Intervals

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Jroseund
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DA62 Mx Intervals

Post by Jroseund »

Good Day everyone,

I tried searching for this but was not able to find anything.

I have seen plenty of information about the different maintenance intervals for the 42 model, especially the 300 / 600 / 900 hr intervals found in http://www.greatlakesdiamond.com/hourly ... -for-da42/

Going through the 62 AMM the only area I can find is 5-10-00, pg 2. Do I assume then that there are only the 100, 200, 1000, 2000, etc maintenance checks and not 300 / 600 / 900?

I have searched through chapters 71 & 72 in the AMM too. I don't have access to engine documents so maybe that's why I can't find anything on that. Needless to say going through a AMM makes my eyes start to go cross eyed after a while. I wasn't sure if there is other information buried someplace that I haven't searched yet.

Thanks everyone.
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CFIDave
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Re: DA62 Mx Intervals

Post by CFIDave »

For routine maintenance:

Every 100 hours: engine oil and filter change, fuel filter replacement, run gearbox oil through a "coffee filter" (included in Diamond's 100 hour kit) while checking for metal -- then pour gearbox oil back in (re-use)
Every 200 hours: replace air filter
Every 300 hours: replace gearbox oil (rather than just filter it and re-use) and replace gearbox oil filter
Every year (typically during annual inspection): replace 12V backup ECU batteries (x2 on DA40NG, x4 on DA42/DA62 twins). This is legally required since it's listed in Chapter 4 Instructions for Continued Airworthiness of each plane's AMM.

Austro engine component time limits recently revised by Austro Engine on 1/1/2021:

Replace High pressure fuel pump: every 600 hours
Replace circlip of waste gate controller: every 600 hours
Replace fuel injectors: every 900 hours
Replace gearbox: every 1800 hours (at engine TBO)
Replace cylinder head:
- for DA40NG and DA42 AE300 engines replace every 1800 hours (engine TBO)
- for DA62 AE330 engines replace every 900 hours, except for the newest AE330 engines with revised cylinder heads E4A-12-500-000 that are replaced every 1800 hours (engine TBO).
Replace timing chain:
- for DA40NG and DA42 AE300 engines replace every 1800 hours (engine TBO), except 900 hours if a windmilling restart occurred (per an AD)
- for DA62 AE330 engines replace every 900 hours
Replace EECU: every 1800 hours (engine TBO)
Replace Two-mass flywheel and hub:
- for DA40NG and DA42 AE300 engines replace every 1800 hours (engine TBO), except that it must also be removed for inspection every 600 hours
- for DA62 AE330 engines replace every 600 hours
Replace alternator: every 2400 hours
Replace V-ribbed belt: every 5 years calendar time
Replace engine coolant: every 600 hours
Overhaul engine: every 1800 hours (engine TBO)

Note that these time limits are "mandatory" according to Austro Engine, but when flying in the US under Part 91, it's up to the owner/operator to decide when these components should be replaced.

Personally, I have a hard time understanding why some of the DA62 AE330 components should be replaced more often than for AE300 Austro engines, since the engine hardware is really the same. The AE330 software provides only slightly more turbo boost to generate only about 5% more horsepower, and only at lower altitudes -- so it's not subjecting the DA62 AE330 engine to much additional stress.
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N811ET DA40 XLS 40.874 (sold)
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Re: DA62 Mx Intervals

Post by Jroseund »

Thanks Dave. Very detailed and will definitely be used down the road for me when it comes to maintenance planning. Guess I should have mentioned that I did see that in 5-10-00 further down.

Where do you find the information on 300 hr requirements for the gearbox oil / oil filter? Are they located in the same area that I referenced earlier or is it in documentation provided by Austro?

Thanks again Dave.
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Re: DA62 Mx Intervals

Post by CFIDave »

Jroseund wrote:
Thu Feb 25, 2021 5:42 am
Where do you find the information on 300 hr requirements for the gearbox oil / oil filter?
The Austro Maintenance Manual shows inspection of the small gearbox oil filter for debris every 100 hours, and replacement every 300 hours.

But it no longer seems to show re-use of the gearbox oil by draining it, running it through the filter provided as part of Diamond's 100 hour kit, and then pouring it back in every 100 hours -- and replacing with new gearbox oil only every 300 hours. This gearbox oil reuse was taught at Diamond's training course, and is what most service centers do. The maintenance manual now simply specifies gearbox oil draining and refilling every 100 hours. (If Diamond/Austro changed this practice to requiring fresh gearbox oil every 100 hours, then how come they provide the "coffee filter" as part of Diamond's 100 hour kits?)

Having said all that, I personally don't use 100 hour kits from Diamond anymore, since it's not very expensive to order a bucket of Shell Spirax gearbox oil from Amazon and simply replace 2.5L of gearbox oil with fresh oil every 100 hours -- with no need for the kit's "coffee filter." Genuine Mercedes oil filters are easy to purchase separately. I also have no need for the engine oil sampling bottle and mailing envelope included in Diamond's 100 hour kit that requires shipping oil samples all the way to Austria (after which you never get any reports or feedback). Instead, I prefer to send oil samples to Blackstone here in the US for analysis -- their reports are great.
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