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ULPOWER UL350i Maintenance Manual

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© 2024 ULPower Aero Engines, All rights reserved
MM2.7
1
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Description generated with very high confidence
Interactive Maintenance
Manual
M0360 - Version 2.7
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Summary of Contents for ULPOWER UL350i

  • Page 1 © 2024 ULPower Aero Engines, All rights reserved MM2.7 A close up of a logo Description generated with very high confidence Interactive Maintenance Manual M0360 - Version 2.7 Click an engine or scroll to next page to continue...

  • Page 2: Non-Routine Maintenance

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Contents: Introduction Maintenance Schedule ‘How to…’ section Non-routine maintenance...
  • Page 3 Your particular installation may vary slightly, and we refer you to your engine and OEM installation guides for further details. You may always return to the ‘Contents Page’ for maintenance by clicking on the ULPower logo on the top right of each page.
  • Page 4 We wish you many happy hours of flying behind our engines. Before carrying out maintenance work on the engine, carefully read the Maintenance Manual. If you are unsure about the procedures mentioned in this manual, please contact a ULPower authorised service point. Remarks The diagrams and other pictures in this manual show the typical construction.

  • Page 5: Safety Information

    Spare parts must meet with the requirements defined by the engine manufacturer. This is only warranted by use of genuine ULPower spare parts and/or accessories. They are available at the authorized ULPower distribution- and service partners. The use of anything other than genuine ULPower spare parts and/or accessories will render any warranty relating to this engine null and void.

  • Page 6: Authorized Personnel

    Requisite knowledge of the task through: Experience in performing the task Formal instruction from a ULPower authorized training facility or "on-the-job" instruction by a ULPower or authorized ULPower distributor representative. Suitable work environment to prevent contamination or damage to engine parts.

  • Page 7: Procedure Notes

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Procedure Notes • Prior to maintenance or service work, make absolutely sure to comply with the stated safety instructions. Ensure the following at each maintenance event: • All electrical systems "OFF“ (Key switch off) •...

  • Page 8: Standard Limited Engine Warranty & Warranty Conditions

    (15) days of a suspected defect in material or workmanship towing, communication costs, taxis, hotels, food or any other incidental or them will be binding on ULPower unless made in writing by a duly and the engine, accessory or part must be made available for ULPower's consequential damage..
  • Page 9 ). For engines with a serial number higher than 250000 TBO is 2000 hours or 12 years – 1500 hours or 12 years for the UL520T. After reaching this time limit the engine should be shipped to an authorized ULPower overhaul facility.

  • Page 10: Inspection Sheet

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Inspection sheet Dowload a printable version of this document from www.ulpower.com Einde Einde...
  • Page 11 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Maintenance Schedule for ULPower Aero Engines Check (hr.) Inspection Items 15 50 100 200 Visual inspection of the engine a) General inspection of the engine for damage and abnormalities, including obstructions, cracks, wear and condition of cooling air ducts, baffling cylinder cooling and oil cooler .
  • Page 12 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Maintenance Schedule for ULPower Aero Engines Check (hr.) Inspection Items 15 50 100 200 Verification of engine suspension a) Inspect engine mounts, dampers and fasteners for secure fit, including damage from heat, deformation, cracks.

  • Page 13: Oil Filter

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Maintenance Schedule for ULPower Aero Engines Check (hr.) Inspection Items 15 50 100 200 Oil level a) Remove magnetic drain plug from bottom of oil sump inspect and clean magnetic pickup.

  • Page 14: Air Filter

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Maintenance Schedule for ULPower Aero Engines Check (hr.) Inspection Items 15 50 100 200 Air Filter a) Inspection of the air filter. Replace as necessary. b) Replace air filter. Fuel Filters...

  • Page 15: Throttle Valve

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Maintenance Schedule for ULPower Aero Engines Check (hr.) Inspection Items 15 50 100 200 Throttle Valve a) Inspect free movement of throttle lever. b) Inspect that throttle cable allows full travel of throttle lever.
  • Page 16 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Maintenance Schedule for ULPower Aero Engines Check (hr.) Inspection Items (for UL520T only) 15 50 100 200 Turbo compressor a) Inspection of the turbo bracket for secure fit b) Inspection oil supply/oil return line from turbo...
  • Page 17 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Maintenance Schedule for ULPower Aero Engines Check (hr.) Inspection Items (external drive/alternator only) 15 50 100 200 External drive/alternator a) Inspection of pulleys (visual) b) Inspection of drive/alternator brackets (visual) c) Inspection of drive/alternator (visual)
  • Page 18 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Maintenance Schedule for ULPower Aero Engines Check (hr.) Inspection Items 15 50 100 200 Engine Test Run a) Start the engine and run to operating temperature. Smoothly apply throttle to full power.
  • Page 19 © 2024 ULPower Aero Engines, All rights reserved MM2.7 How to… In order to discover more about each task, click on the relevant link below A picture containing indoor, motorcycle, object Description generated with very high confidence Air Filter inspection /Replacement...
  • Page 20 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Visual Inspection… A picture containing indoor, motorcycle, object Description generated with very high confidence Start at one point and work systematically around the engine looking for evidence of interference abrasion (where parts have rubbed on cowlings/hoses/etc) as well as signs of leaks of oil or combustion gasses.
  • Page 21 © 2024 ULPower Aero Engines, All rights reserved MM2.7 ECU… The ‘old black ECU’ requires that you disconnect the connectors from ECU, check the contacts ECU- side and connector side, make sure that they are clean and there is no oxidation, replace both if necessary and re-connect the connectors to the ECU.
  • Page 22 © 2024 ULPower Aero Engines, All rights reserved Tools Needed MM2.7 Oil (Aeroshell 15W50 or Motul (Competition) 300V 15W50 ) Oil Filter Funnels Oil… S3142015 copper sealing ring Oil pan/receptacle Filter Wrench Filter socket Torque wrench (15Nm / 25Nm) 1. Carefully remove cowling and place a clean oil pan/receptacle ready to catch the old oil (make sure that it is able to contain all of the oil drained).
  • Page 23 MM2.7 Air Filter… The ULPower air filter is NOT a serviceable item. It is normally replaced at 200 hours, however, it may require more frequent changes dependent on operational conditions. It is not normally necessary to remove the filter for inspection. If you do remove the filter ensure that it is correctly re-installed/replaced.
  • Page 24 MM2.7 Fuel Filters… ULPower engines have a ‘pre-filter’ installed at the entry to each fuel pump and a ‘fine filter’ after the pumps and before the fuel rail. The Naturally aspirated engines do not have washable filters. The turbo engines have washable Fuel Filters (=reusable) prefilters.
  • Page 25 As part of regular maintenance, check the torque on the FOUR easily accessible cylinder head bolts. If these four are torqued correctly, there is no further action required. If they are NOT then refer to your nearest ULPower dealer for assistance.
  • Page 26 © 2024 ULPower Aero Engines, All rights reserved Tools Needed MM2.7 T063018 Torque Key Cylinder head Torque wrench (36Nm) Cylinder Heads… Set the torque wrench to 36Nm and fit the special tool T063018 Torque Key Cylinder head (supplied with first service kit).
  • Page 27 © 2024 ULPower Aero Engines, All rights reserved Tools Needed MM2.7 13mm ring spanner 3mm & 5mm Allen Key [O ring(s) S1100020] Feeler Gauge (0.1/0.15/0.2mm) Rocker /Tappet Torque wrench (20Nm / 6Nm) Checking the rocker/tappet clearance is a simple procedure that allows for adjustment of the correct valve opening and proper functioning of your engine.
  • Page 28 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Rocker/Tappet… 1. On a cold engine (>10C and <25C) remove all the valve covers. Make a note of which cover goes where (you may use an indelible felt marker such as a ‘Sharpie’ to label the inside with the cylinder number, after wiping the oil away) Unscrew all three bolts on each valve cover with a 4mm Allen Key.
  • Page 29 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Rocker/Tappet… HINT: To check that you are ready for gapping on the cylinder you are looking at, rock the prop back and forth. If the rockers DO NOT move on the cylinder you are working on then you are ready for gapping.
  • Page 30 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Rocker/Tappet… HINT: The adjustment is VERY small, only a fraction of a turn on the Allen key, so try not to make big movements and keep tools and hands stable. 4. To adjust clearance, place a 13mm ring spanner over the lock nut and a 5mm Allen LOOSEN key in the adjustment screw.
  • Page 31 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Rocker/Tappet… 6. Using a Torque wrench tighten the lock nut to 20Nm (14.7 ft lbs). 7. Use the feeler gauge to check that the adjustment is correct AFTER torqueing. If not correct, redo.
  • Page 32 CAUTION: When the same tappets are in need of adjustment every time maintenance is performed, it can be indicative of a developing problem. Contact your nearest ULPower dealer who may inspect the valve train for abnormal wear. Do check for proper lubrication and clogged oil lines.
  • Page 33 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Throttle… Check that your throttle cable has no signs of fraying, kinks or compromised travel. Ensure that the installation allows full and free movement and that all attachments are appropriate for your installation.
  • Page 34 © 2024 ULPower Aero Engines, All rights reserved Tools Needed MM2.7 Anti -seize paste (e.g. Wacker P12) 16mm Spark plug socket (with rubber insert) Spark Plugs… Torque wrench (21Nm) New Spark Plugs (E070502) As in any modern automobile, sparkplugs do NOT normally need cleaning. It is generally better to REPLACE spark plugs unless there is an exceptional reason to clean them.
  • Page 35 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Spark Plugs … 1. Unplug ignition leads (noting positions) and remove old spark plugs with 16mm Plug Socket 2. Before inserting new spark plugs back into the cylinder head, apply an anti-seize compound on the thread –...
  • Page 36 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Tools needed : tester consisting of two separate pressure gauges Compression… pressure regulator calibrated restrictor orifice (0,040” / 1 mm) an on/off valve (see schematic drawing). A source of compressed air (minimum 100psi /7 bar) The leak test should be done after the engine has run to operating temperature.
  • Page 37 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Compression… Move the prop slightly away from TDC by turning clockwise. Adjust the pressure regulator to about 20 psi and slowly open the air shutoff valve. Carefully rotate the prop in the turning direction (anti- clockwise) against the 20 psi pressure towards TDC until you feel a "flat spot"...
  • Page 38 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Compression… Gently move the prop tip back and forth, just a tiny amount. Watch the cylinder pressure gauge. (double check that regulator pressure gauge is at 80psi ) Write down the peak steady pressure.
  • Page 39 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Compression… What if I have 1 low cylinder value ? Start the engine and run it on the ground until warm. Test it again. If it is still low, use a length of garden hose as a "stethoscope" and listen at the exhaust of the ailing cylinder.
  • Page 40 © 2024 ULPower Aero Engines, All rights reserved HINT: When doing the engine run make sure to LISTEN to the engine MM2.7 during start-up and when running. For example, leave the headset off during the start-up, and then lift ‘one ear’ to listen to the engine when Engine run…...

  • Page 41: Idle Speed Adjustment

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Idle speed adjustment Idle speed can only be tested when engine is at operating temperature. Apply a little throttle so idle speed is at least 1000 rpm during warm-up. The throttle lever stop (1) is factory set to a position that should correspond to a warm engine idle speed of approx. 850 rpm.
  • Page 42 Given the variety of applications (types of alternators, drives, pulleys, belts,...) and the many different installations applied to ULPower engines, it is impossible to list specific data (e.g. belt tension). We therefore refer to existing literature or the belt manufacturer.
  • Page 43 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Non-Routine maintenance… P1020326 BILD0752E Change O rings in the oil return tubes Change of oil seal at the alternator of the engine Alternator Flange Replacement Change O rings in Change of oil seal at the...

  • Page 44: Removal Procedure

    © 2024 ULPower Aero Engines, All rights reserved Tools Needed MM2.7 T063002 Alternator removal tool set Breaker bar(s) Allen Key Spanners Alternator rotor flange replacement… Torque Wrench (280Nm/10Nm) REMOVAL PROCEDURE 1. Unscrew the 8 cap screws with an Allen key to remove alternator fan and starter ring gear.
  • Page 45 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Alternator rotor flange replacement … 5. Remove the holder tool and insert the bolt that came with the tools. Remember you have to turn it anticlockwise to screw in the left hand thread. It does not have to be tight; just hand screw it in.
  • Page 46 © 2024 ULPower Aero Engines, All rights reserved MM2.7 NOTE: Make sure you have cleaned all Alternator rotor flange replacement surfaces before applying Loctite! INSTALLATION PROCEDURE NOTE: You will have to turn the alternator a bit so that the flat faces on the flange and A.
  • Page 47 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Alternator rotor flange replacement… INSTALLATION PROCEDURE (cont.) D. Torque the central bolt to 280Nm (anticlockwise) while holding the flange with the holder tool as used to unscrew the bolt in step 3 & 4 E.
  • Page 48 © 2024 ULPower Aero Engines, All rights reserved MM2.7 NOTE: Use the latest Parts catalogue as a guide and for torque Change O-rings in the oil return tubes… values. Here we have pictures from a UL350 parts catalogue. 1. Unscrew the 3 bolts (11) to remove the valve cover (10) 2.
  • Page 49 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change O-rings in the oil return tubes… 7. Use screwdriver to bend the locking plate (7). Then unscrew screw (8) and remove locking plate (7). 8. Now you can slowly slide out the tubes (5) of the crankcase and remove the O-ring (6) from the tube (side engine casing ) 9.
  • Page 50 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change O-rings in the oil return tubes… 16. Use a soft hammer and 19mm diameter ‘driver’ to gently knock the tube slowly to the bottom its crankcase seat. 17. Repeat for the second tube 18.

  • Page 51: Table Of Contents

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at alternator side of engine… FIRST: Follow the ‘Removal of alternator flange procedure CLICK HERE FOR INSTRUCTIONS Parts needed FIRST: Follow the ‘Removal of alternator flange procedure S2506207 Oil seal Viton 50 x 62 x 7 CLICK HERE FOR INSTRUCTIONS S700001 Sealing silicone Elring n°030.792...
  • Page 52 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at alternator side of engine… 2. To remove the alternator stator spacer, install the alternator flange pulley removal tool and fix it to the spacer. For the 30a stator use 3 bolts M6 x 60 For the 50a stator use 4 bolts M5 X 60 Don’t forget to mark the position from the spacer...

  • Page 53: Click Here For Instructions

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at alternator side of engine… 5. Put some sealing silicone (S700001) on the surface that will be in contact with the engine mount plate 6. Install special tool T063007 over the crankshaft gear and put some oil on the external surface.

  • Page 54: Parts Needed

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at prop side of engine… Parts needed Tools Needed BE010509 Thrust bearing mount (only when T063006 Prop flange holder engine serial number is below 120000) 40mm socket Allen Key 3mm...
  • Page 55 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at prop side of engine… REMOVAL PROCEDURE 1. Unscrew the 8 retaining bolts (4) 2. Carefully tap thrust bearing mount (3) with a rubber or soft nylon hammer to loosen the thrust bearing from the...
  • Page 56 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at prop side of engine… 4. Remove the thrust bearing disc (16) from the crankshaft 5. Take the retention ring (7) from the crankshaft 6. Take the O-ring (6) out of the groove...
  • Page 57 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at prop side of engine… 7. Carefully clean the crankcase and thrust bearing house until all sealing silicone is gone. 8. Carefully remove the old seal (2) without damaging the aluminium housing.
  • Page 58 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at prop side of engine… INSTALLATION PROCEDURE 1. Apply clean oil (you can use the same oil as you use in the engine) on the outer and inner side of the retention ring.
  • Page 59 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at prop side of engine… 3. Apply sealing silicone (S700001 Elring n° 030.792 ) onto the housing mating surface 4. Clean the crankshaft and O-ring groove. 5. Oil the O-ring and carefully install...

  • Page 60: Click Here For Instructions

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Change oil seal at prop side of engine… 6. Install the new thrust 9. Push the retention ring over the O-ring bearing disc in the housing 7. Push the ring 10. Re-install the 8 bolts and torque to against the collar 10Nm –...

  • Page 61: Tools Needed

    © 2024 ULPower Aero Engines, All rights reserved MM2.7 Tools Needed T063006 Prop flange holder Propeller Flange Replacement… 40mm socket Allen Key 3mm Torque Wrench (300Nm) / Breaker bar(s) Spanners 1. Unscrew the M6 screw using a 3mm Allen key 4.
  • Page 62 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Propeller Flange Removal… 9. Carefully clean the bolt, especially cleaning the flat 7. Carefully clean the prop contact surface shown here. flange paying particular attention to the flat mating Apply a small amount of...
  • Page 63 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Propeller Flange Removal… 13. Place the locking plate over the hex top of 11. Attach the propeller the bolt. Find out if the existing M6 hole in the flange holder (T063006)
  • Page 64 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Check torque bottom/top cylinder head screw… Tools Needed Top cylinder head screw T063018 Torque Key Cylinder head Allen Key Torque wrench (See IPC) 1. Unscrew the socket cap screws from all manifold inlet tubes 3.
  • Page 65 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Check torque bottom/top cylinder head screw… Tools Needed Top cylinder head screw T063018 Torque Key Cylinder head Allen Key Torque wrench (See IPC) 4. During re-installation: make sure that the O-ring of the inlet tube(s) is/are still in the correct position 5.
  • Page 66 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Tools Needed T063018 Torque Key Cylinder head Check torque bottom/top cylinder head screw… Allen Key Hammer Bottom cylinder head screw E012503 locking plate Screwdriver (flat) Torque wrench (See IPC) 7 mm socket wrench 1.
  • Page 67 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Tools Needed T063018 Torque Key Cylinder head Check torque bottom/top cylinder head screw… Allen Key Hammer Bottom cylinder head screw E012503 locking plate Screwdriver (flat) 4. Remove the cylinder head plug.
  • Page 68 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Revisions Revision 2.1 - September 2019 Removal of the prop flange check at 5 / 15 hours Add extra info into the prop flange removal procedure (m5 for engines with serial number above 193801 Revision2.2 - July 2020...
  • Page 69 © 2024 ULPower Aero Engines, All rights reserved MM2.7 Revision 2.5 - June 2022 Slide 13 : NOTE: Turbo engine = replace oil every 50 hours or annually Slide 16 : visual inspection turbo compressor: add “check free spinning wheel”...

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