ULPOWER 260 series User manual

Interactive
Troubleshooting Guide
Version 2.0
Click an engine or scroll to next page to continue

Contents:
Instructions
Before first start checks
Trouble shooting guide

Welcome to the ULPower troubleshooting guide 2.0
The first section covers ‘procedures to follow before first start’ this is a reminder for those who are not yet ready to
start –to make sure that they have covered the basics. Your particular installation may vary slightly, and we refer you to
your engine and OEM installation guides for further details.
Please keep in mind that your engine has been fully tested at factory before shipment.
The Troubleshooting guide starts immediately after and is linked between topics. You may always return to the
‘Troubleshooting Start Page’ for troubleshooting by clicking on the ULPower logo on the top right of each page.
You may also simply ‘scroll’ through the guide. If you are using this guide on a mobile phone or tablet you may need to
download the Adobe Acrobat Reader to enable the links.
This document is provided as a guide. Please let us know if you find any errors or provide ideas for improvement.
The abbreviation “i.a.w. … manuals” means ‘in accordance with… manuals”
Please ALWAYS cross check with the latest installation, maintenance , operating manuals, available from
http://ulpower.com
Regards
The ULPower Team (email [e-mail] ) E&OE Mar 2019

BEFORE FIRST START:
During installation consult and work i.a.w. the various
installation manuals
1. Battery/Oil:
Check if the battery is fully charged and oil level is sufficient
2. Calibrate senders/sensors:
Oil temperature, EGT and CHT senders using boiling water
(100°C/ 212 F)
3. Check the Fuel System with a fuel flow test:
Disconnect return line and put into measuring jug
Run pump 1, collecting fuel
Measure fuel flow coming out of the return line +/- 120 l/h or 1
liter(quart) in 30 seconds
Repeat for pump 2
Reconnect lines and check fuel pressure (+/- 3.3bar/49psi)
(without starting the engine)
4. Check ECU warning light:
Power ON to ECU
UL check light should NOT light up
Disconnect Air box temp sensor –if working, the UL check light
comes on. Reconnect sensor –light goes off.
5. Start-up routine with COIL checks
•Ignition coils : set coil 1 ON / coil 2 OFF
•Throttle max 30% open (normally cracked open)
•Safety check –area clear and shout ‘clear prop’
•Master ON
•Main Fuel pump selected ON
•ECU ON
•Activate ‘Start’ - max 5 sec –wait 15 sec - repeat max. 4 times
•Engine should be running. Wait 15+ seconds, stop engine (ECU OFF)
•Repeat with coil 1 OFF / coil 2 ON. Wait 15+ seconds, stop engine
•Repeat with coil 1 ON / coil 2 ON. Leave engine running
6. Other first start checks
•If possible connect with ULread .
•Visual check for oil leaks / fuels leaks / mechanical interference
•Measure oil pressure and to check with instruments/readout
•Run the engine at +/- 1200 rpm until oil temp. is 60°C (140°F)
•Shutdown (switch ECU OFF, Fuel pump OFF, coil 1 OFF , coil 2 OFF
Master OFF
•Adjust idle if necessary
•Allow engine to cool and ‘finger test’ for oil leaks.
7. Running in: Avoid full throttle (max 2800rpm) for the first 10 hours

What to do if your engine won’t start or runs rough?
at first start after first start
TROUBLESHOOTING STARTS HERE
Remember to always work i.a.w. the latest manuals. If you are unsure of what action to take or unable to resolve your
problem, contact your local ULPower Aero Engine dealer http://ulpower.com/en/dealers

Trouble shooting when your engine fails to
start at FIRST START
Start button,
Grounding &
ECU
connection
Ignition
cables
Fuel
system
Sparkplugs Coils ECU Wiring
loom
Injectors
Click text or the image above for an aspect you suspect –or, if
unsure follow the sequence from left to right...

Start button, Ground cable & ECU connection
1. Check that the start button closes the circuit to the starter relay –disconnect at starter relay and check
using continuity on a multimeter. Reconnect if good.
2. Visually check for presence and connection of ground cable between the engine and the airframe.
3. Check using a multimeter check for ‘continuity’, i.e. that there is no break from engine to the negative
terminal on the battery. This may require sequential readings, depending on the installation.
4. Check both ECU connectors are connected and that all wires are routed and connected i.a.w. the latest
installation manual for the engine. (available from ULPower.com )

Ignition cables
Check the ignition cables and connections
•Make sure that both connectors (coil side and spark
plug side) are installed i.a.w. the installation manual. If
not installed properly, no contact or an incorrect contact
may occur.
•To check if the connectors are installed properly, pull
fairly hard on both ends of the ignition cable.(coil side +
sparkplug side). The connectors will remain in place if
installed correctly. If they break free –REMAKE THE
CONNECTION
•Check if both connectors from the wiring loom are well
connected/seated to the coil
•For 4 cylinder engines (260 and 350 series) make sure
that the supplied aluminium coil bracket is installed.
(Omitting the coil bracket may result in a deformed coil
with loss of contact inside the coil.) 4 cylinder coils require the aluminium
brackets for correct operation

Ignition cables
Check HT cable orientation (are HT cables correctly installed between cylinders/spark plugs and coils)
4 Cylinder
260/350 series
6 Cylinder
390/520 series
NOTE: for RR engines see relevant installation manuals

Fuel system
UNDERSTAND THE INSTALLATION
Normally two fuel pumps are installed, at times only one
is installed. CHECK before continuing.
Depending on the installation, the main and/or auxiliary
fuel pump may be commanded by the ECU via a relay.
Depending on the installation there may be a DPST
switch to select pumps and/or an ‘over-ride switch’.
UNDERSTAND THE INSTALLATION YOU ARE WORKING ON
BEFORE TROUBLESHOOTING.
Fuel Pump Control Relay (FPCR)
With the FPCR is fitted, when switching the ECU ON: the
FPCR protected pump(s) run(s). If the engine is not
started, the ECU will switch off the FPCR protected
pumps after 15 seconds. If this is part of your installation
–CHECK it functions correctly.