1,800 Hr Inspection Costs

Discussions specific to Austro engines

Moderators: Rick, Lance Murray

User avatar
VickersPilot
2 Diamonds Member
2 Diamonds Member
FIRST NAME: David
Aircraft: DA62
Registration: N00TBC

Posts: 29
Joined: Wed Oct 14, 2020 6:41 pm
Has thanked: 10 times
Been thanked: 11 times

1,800 Hr Inspection Costs

Post by VickersPilot »

What inspections are due at 1,800hr on the DA62/AE330. Is it correct to say the the annual/200hr, 900hr and engine overhaul are due but not the 600hr LLPs? If to include the inspections due, what is the appropriate cost at overhaul time given the potential overlap between the 900hr and engine OH?

In respect of the 900hr inspection, is this likely to become a permanent feature of the higher HP Austros or is there an extension in the pipeline?
User avatar
CFIDave
5 Diamonds Member
5 Diamonds Member
FIRST NAME: Dave
Aircraft: DA62
Registration: N62DV
Airport: KJYO

Posts: 2091
Joined: Wed Nov 07, 2012 3:40 pm
Has thanked: 131 times
Been thanked: 853 times

Re: 1,800 Hr Inspection Costs

Post by CFIDave »

My understanding (since I've yet to own an Austro that reached TBO) it that the overhaul cost at 1800 hours TBO includes all of the "lesser" items that occur more frequently in the maintenance schedule. Assume about $30K+ for an Austro overhaul.

Where the AE330 (E4P-C) engine of the DA62 requires more frequent parts replacement than the AE300 (E4-A, E4-B, E4-C) engines of the DA40NG/DA42NG/DA42-VI, I always assumed that this was because Austro is still collecting engine history and experience with the fleet for the higher HP engines -- that have only been shipping since the DA62 was introduced in 2016. With only about 10 hp difference between AE330 and AE300, the slight additional stresses on the DA62 engines shouldn't make much difference in how they wear. I've been hoping that by the time my DA62 hits 900 hours that Austro will have changed the recommended AE330 maintenance to match that of the lower-powered AE300 units.

However, all of this is likely being affected by two related developments:
1. Austro ran out of genuine Mercedes-produced OM640 core engines and is now assembling its own virtually identical engines.
2. There's a new part number E4A-12-500-000 for E4P-C "Version 2" engine heads for the DA62. New Version 2 heads appear to be good for 1800 hours rather than only 900 hours for original Version 1 heads, according to a June 2020 revision made to the engine maintenance manual: MM-TR-MDC-E4-520a.
N62DV DA62 62.056
N42DA DA42-VI 42.N117 (sold)
N811ET DA40 XLS 40.874 (sold)
KJYO Leesburg, Virginia
User avatar
neema
3 Diamonds Member
3 Diamonds Member
FIRST NAME: Neema
Aircraft: DA42-VI
Registration: N112NG
Airport: KFAT

Posts: 188
Joined: Fri Dec 05, 2014 5:43 am
Has thanked: 32 times
Been thanked: 34 times

Re: 1,800 Hr Inspection Costs

Post by neema »

If $30k per engine is an "all-in" cost, that's pretty good.

You still have risk of the gearboxes or TVDs not passing an inspection (adding 10k and 5k, respectively, to the overhaul). We've gone through a few TVDs and a couple gearboxes already at ~1250 hours on engines, so I'm already gearing up for a worst case of $45k/side. Still have a couple years to go.
User avatar
ememic99
5 Diamonds Member
5 Diamonds Member
FIRST NAME: Emir
Aircraft: DA42
Registration: SEMAD
Airport: LDZA LDVA

Posts: 675
Joined: Wed Apr 09, 2014 10:31 am
Has thanked: 153 times
Been thanked: 224 times

Re: 1,800 Hr Inspection Costs

Post by ememic99 »

neema wrote:
Tue Oct 27, 2020 11:23 pm
I'm already gearing up for a worst case of $45k/side.
That't more than twice than estimated by Diamond few years ago.
User avatar
neema
3 Diamonds Member
3 Diamonds Member
FIRST NAME: Neema
Aircraft: DA42-VI
Registration: N112NG
Airport: KFAT

Posts: 188
Joined: Fri Dec 05, 2014 5:43 am
Has thanked: 32 times
Been thanked: 34 times

Re: 1,800 Hr Inspection Costs

Post by neema »

ememic99 wrote:
Wed Oct 28, 2020 1:57 pm
neema wrote:
Tue Oct 27, 2020 11:23 pm
I'm already gearing up for a worst case of $45k/side.
That't more than twice than estimated by Diamond few years ago.
It'd be worst case: two failed TVDs and two failed gearboxes.

Makes you want to fly around everywhere at max continuous power!
User avatar
VickersPilot
2 Diamonds Member
2 Diamonds Member
FIRST NAME: David
Aircraft: DA62
Registration: N00TBC

Posts: 29
Joined: Wed Oct 14, 2020 6:41 pm
Has thanked: 10 times
Been thanked: 11 times

Re: 1,800 Hr Inspection Costs

Post by VickersPilot »

neema wrote:
Fri Oct 30, 2020 6:31 pm
ememic99 wrote:
Wed Oct 28, 2020 1:57 pm
neema wrote:
Tue Oct 27, 2020 11:23 pm
I'm already gearing up for a worst case of $45k/side.
That't more than twice than estimated by Diamond few years ago.
It'd be worst case: two failed TVDs and two failed gearboxes.

Makes you want to fly around everywhere at max continuous power!
Are you suggesting we SHOULD fly at MCT given the TVDs and Gearboxes are effectively considered disposable at inspection? CFIDave helpfully pointed to a new part number for the cylinder head that should fix their issue. Is there a design update pending for TVDs or Gearboxes so they are more likely to pass inspection?

Also, the Fuel Injectors have become an 900hr LLP since Diamond published their overhaul pricing. Are new injectors included in the published OH price or do we need to add them to the overhaul as well as 900hr cost?
User avatar
neema
3 Diamonds Member
3 Diamonds Member
FIRST NAME: Neema
Aircraft: DA42-VI
Registration: N112NG
Airport: KFAT

Posts: 188
Joined: Fri Dec 05, 2014 5:43 am
Has thanked: 32 times
Been thanked: 34 times

Re: 1,800 Hr Inspection Costs

Post by neema »

VickersPilot wrote:
Fri Oct 30, 2020 7:56 pm
neema wrote:
Fri Oct 30, 2020 6:31 pm
ememic99 wrote:
Wed Oct 28, 2020 1:57 pm


That't more than twice than estimated by Diamond few years ago.
It'd be worst case: two failed TVDs and two failed gearboxes.

Makes you want to fly around everywhere at max continuous power!
Are you suggesting we SHOULD fly at MCT given the TVDs and Gearboxes are effectively considered disposable at inspection? CFIDave helpfully pointed to a new part number for the cylinder head that should fix their issue. Is there a design update pending for TVDs or Gearboxes so they are more likely to pass inspection?

Also, the Fuel Injectors have become an 900hr LLP since Diamond published their overhaul pricing. Are new injectors included in the published OH price or do we need to add them to the overhaul as well as 900hr cost?
I think fuel injectors are included in the OH, but I don't have the Austro mx manual handy to check. Not sure about any TVD or gearbox improvements.

My point on flying at MCP is that it doesn't cost much more per mile. For a 10k gearbox every 600 hours, you'd spend 4% more per mile in fuel and "hourly" gearbox costs between 75% and 92% power, but you'd also travel around 14 knots or 8% faster. For some, a worthwhile marginal gain

And that's not including any failed TVDs
User avatar
ememic99
5 Diamonds Member
5 Diamonds Member
FIRST NAME: Emir
Aircraft: DA42
Registration: SEMAD
Airport: LDZA LDVA

Posts: 675
Joined: Wed Apr 09, 2014 10:31 am
Has thanked: 153 times
Been thanked: 224 times

Re: 1,800 Hr Inspection Costs

Post by ememic99 »

neema wrote:
Sat Oct 31, 2020 6:58 am
VickersPilot wrote:
Fri Oct 30, 2020 7:56 pm
neema wrote:
Fri Oct 30, 2020 6:31 pm


It'd be worst case: two failed TVDs and two failed gearboxes.

Makes you want to fly around everywhere at max continuous power!
Are you suggesting we SHOULD fly at MCT given the TVDs and Gearboxes are effectively considered disposable at inspection? CFIDave helpfully pointed to a new part number for the cylinder head that should fix their issue. Is there a design update pending for TVDs or Gearboxes so they are more likely to pass inspection?

Also, the Fuel Injectors have become an 900hr LLP since Diamond published their overhaul pricing. Are new injectors included in the published OH price or do we need to add them to the overhaul as well as 900hr cost?
I think fuel injectors are included in the OH, but I don't have the Austro mx manual handy to check. Not sure about any TVD or gearbox improvements.

My point on flying at MCP is that it doesn't cost much more per mile. For a 10k gearbox every 600 hours, you'd spend 4% more per mile in fuel and "hourly" gearbox costs between 75% and 92% power, but you'd also travel around 14 knots or 8% faster. For some, a worthwhile marginal gain

And that's not including any failed TVDs
Same as with CD engines - every calculation shows that the cheapest is to run them at MCP. However, that's not always convenient due to possible unnecessary fuel stop needed on longer flight.
User avatar
Davestation
3 Diamonds Member
3 Diamonds Member
FIRST NAME: David
Aircraft: D-JET
Registration: NDJET
Airport: KFTW

Posts: 161
Joined: Tue Mar 12, 2019 7:49 pm
Has thanked: 68 times
Been thanked: 54 times

Re: 1,800 Hr Inspection Costs

Post by Davestation »

The engines are replaced in entirety, LEPs and all, so the entire engine clock resets at 1800 - no additional flywheel inspections etc.
User avatar
Boatguy
5 Diamonds Member
5 Diamonds Member
FIRST NAME: Russ
Aircraft: DA40NG
Registration: N454M
Airport: O69

Posts: 617
Joined: Mon Jan 22, 2018 4:48 am
Has thanked: 277 times
Been thanked: 401 times

Re: 1,800 Hr Inspection Costs

Post by Boatguy »

Davestation wrote:
Sat Jan 16, 2021 6:12 am
The engines are replaced in entirety, LEPs and all, so the entire engine clock resets at 1800 - no additional flywheel inspections etc.
Are you referring to TDIs or Austro?
Post Reply