ULPOWER UL260i User manual

UL26Oi
UL26OiF
UL26OiS
UL26OiSA
Operating
Manual
MO 260A01 Revision No: 6 Date: 2014-09-15

Operating Manual ULPOWER UL260i UL260iFUL260iSUL260iSA
MO 260A01 Revision No: 6 Date: 2014-09-15 Page: 1 of 22
Preface
Thank you for deciding to use a ULPower engine.
Before starting the engine, carefully read this manual. The Manual will provide you with basic
information on the safe operation of the engine.
If any passages of the manual are not completely understood or in case of questions, please contact
a ULPower authorised representative.
We hope you will have much pleasure and satisfaction flying your aircraft powered by a ULPower
engine.
Remarks
The images in this manual show the typical construction. They may not represent in full detail or
the exact shape of the parts which have the same or similar function.
Specifications are given in the SI metric system with the USA equivalent in parenthesis. Where
precise accuracy is not required, some conversions are rounded off for easier use.
In addition to this Operating Manual, please refer to the following:
Installation Manual
Maintenance Manual
Please make sure you have the latest version available of the applicable manual.
Modifications
The information and components/system descriptions contained in this Operating Manual are
correct at the time of publication. ULPower, however, maintains a policy of continuous
improvement of its products without imposing upon itself any obligation to install them on its
products previously manufactured.
ULPower reserves the right at any time to discontinue or change specifications, designs, features,
models or equipment without incurring obligation.
Engine serial number
On all enquiries or spare parts orders, always indicate the engine serial number, as the
manufacturer makes modifications to the engine for further development.
Repeating symbols
This manual uses the following symbols to emphasize particular information. These indications are
important and must be respected.
WARNING : Identifies an instruction which, if not followed, may cause serious injury
including the possibility of death.
Attention : Denotes an instruction which, if not followed, may severely damage the engine
or other components.
Note : Indicates supplementary information which may be needed to fully complete or
understand an instruction.

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Safety information
The engine should only be installed and placed into operation by persons familiar with the use of
the engine and informed with regard to possible hazards.
Only ULPower authorized service centres are qualified to work on these engines.
This engine is designed for possible application on aircraft used in VFR conditions which have the
capabilities of controlled gliding without engine power.
You should be aware that any engine may seize or stall at any time. This could lead to a crash
landing and possible severe injury or death. For this reason, we recommend strict compliance
with the maintenance and operation and any additional information which may be given to you by
your dealer.
Never fly the aircraft equipped with this engine at locations, airspeeds, altitudes, or other
circumstances from which a successful no-power landing cannot be made, after sudden engine
stoppage.
This engine is not suited for acrobatics (inverted flight, etc.).
It should be clear that the choice, selection and use of this particular engine on any aircraft is at
the sole discretion and responsibility of the aircraft manufacturer, assembler and owner/user.
ULPower makes no warranty or representation on the suitability of its engine's use on any
particular aircraft. Furthermore, ULPower makes no warranty or representation of this engine's
suitability with any other part, component or system which may be selected by the aircraft
manufacturer, assembler or user for aircraft application.
Never run the engine without a propeller or flywheel as this will inevitably cause engine damage
and present a hazard of explosion.
Propeller/flywheel and its attachment with a moment of inertia in excess of the specified value
must not be used and releases engine manufacturer from any liability.
Improper engine installation and use of unsuitable piping for fuel-, cooling- and lubrication system
releases engine manufacturer from any liability.
Unauthorized modifications of engine or aircraft will automatically exclude any liability of the
manufacturer for direct, indirect and/or sequential damage.
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.
Respect all government or local rules pertaining to flight operation in your flying area. Fly only
when and where conditions, topography, and airspeeds are safest.
Select and use proper and calibrated aircraft instrumentation. This instrumentation is not
included with the basic ULPower engine.
Before flight, ensure that all engine controls are operative. Make sure all controls can be reached
in case of an emergency.
Unless in a run up area, never run the engine with the propeller turning while on the ground. Do
not operate engine if bystanders are close.
In the interest of safety, the aircraft must not be left unattended while the engine is running.
Keep an engine log and respect engine and aircraft maintenance schedules. Keep the engine in
top operating condition at all times. Do not operate any aircraft which is not properly maintained
or has engine operating irregularities which have not been corrected.

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To eliminate possible injury or damage, ensure any loose equipment or tools are properly secured
before starting the engine.
When in storage protect the engine, fuel, lubrication, induction and exhaust system from
contamination and exposure.
Never operate the engine without sufficient quantities of lubricating oil and cooling air.
Allow the engine to cool at idle for several minutes before turning off the engine.

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Table of contents
Preface ..................................................................................................................1
Remarks...............................................................................................................1
Modifications.........................................................................................................1
Engine serial number ...............................................................................................1
Repeating symbols ..................................................................................................1
Safety information....................................................................................................2
Table of contents .....................................................................................................4
Engine description ....................................................................................................6
General Description ................................................................................................6
Specifications ........................................................................................................6
Description of basic standard engine and accessories........................................................7
Engine views ...........................................................................................................8
Denomination of cylinders..........................................................................................9
Description of systems...............................................................................................9
Lubricant system ....................................................................................................9
Fuel system ..........................................................................................................9
Electronic Engine Management system........................................................................ 10
Cooling system..................................................................................................... 10
General operating limits .......................................................................................... 11
Speed................................................................................................................ 11
Running in .......................................................................................................... 11
Performance (ISA)................................................................................................. 11
Acceleration ....................................................................................................... 11
Oil pressure ........................................................................................................ 11
Oil level............................................................................................................. 11
Oil temperature ................................................................................................... 11
Cylinder head temperature ..................................................................................... 11
Manifold air temperature........................................................................................ 12
Outside air temperature ......................................................................................... 12
Relative fuel pressure ............................................................................................ 12
Deviation from bank angle ...................................................................................... 12
Electrical power ................................................................................................... 12
Maintenance ......................................................................................................... 12
Engine performance................................................................................................ 13
Performance graphs for standard conditions (ISA) .......................................................... 13
Performance graph for non-standard conditions ............................................................ 14
Operating media .................................................................................................... 16
Fuel.................................................................................................................. 16
Lubricants .......................................................................................................... 16
Standard operation ................................................................................................. 17
Daily/Pre-flight checks........................................................................................... 17
Engine start ........................................................................................................ 17
Prior to take-off................................................................................................... 18
Warming up period:............................................................................................ 18
Idle speed:....................................................................................................... 18
Throttle response: ............................................................................................. 18
Ignition test: .................................................................................................... 18
Take-off............................................................................................................. 18
Cruise ............................................................................................................... 18

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Engine shut-down ................................................................................................. 18
Engine storage ..................................................................................................... 19
Abnormal operation ................................................................................................ 20
Abnormal running on ignition check ........................................................................... 20
Sudden engine stop ............................................................................................... 20
Nearing maximum engine speed ............................................................................... 20
Exceeding of max. admissible cylinder head temperature ................................................ 20
Exceeding of max. admissible oil temperature .............................................................. 21
Oil pressure below minimum.................................................................................... 21
Exceeding of max. admissible oil pressure ................................................................... 21
Relative fuel pressure deviates from normal ................................................................ 21
Single CHT and/or EGT drop .................................................................................... 22
Knocking ............................................................................................................ 22
Low battery voltage .............................................................................................. 22

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Engine description
General Description
4 stroke, 4 cylinder, horizontally opposed
Electronic multipoint fuel injection (pressure and temperature compensated)
Electronic spark ignition (variable timing)
Electronic RPM limiter
Direct propeller drive
5 bearing crankshaft with a 6th large thrust bearing (ball bearing type)
Single central camshaft
Push rods, Solid Tappets (no hydraulic compensation) and Over head valves
Wet sump forced lubrication with integrated pressure regulator
Ram air cooled cylinders and cylinder heads
Integrated AC generator, external rectifier-regulator
Electric starter
Electric fuel pump and pressure regulator
Specifications
UL260i
UL260iF
UL260iS
UL260iSA
Displacement:
2592 cc
Bore:
105.6 mm
Stroke:
74 mm
Compression Ratio:
8,16 : 1
9,1:1
Firing order:
1 –3 –2 –4
Direction of Rotation:
Clockwise –Pilot's view –Tractor configuration
Torque (ISA conditions):
217 Nm @ 2500 rpm
237Nm @ 2800 rpm
Power rating (ISA conditions):
97 hp @ 3300 rpm
(85 hp @ 2800 rpm)
100 hp @ 3100 rpm
(92 hp @ 2800 rpm)
107 hp @ 3300 rpm
(93 hp @ 2800 rpm)
Basic standard engine weight:
60,1 kg (including starter motor and alternator)
61 kg
DC output:
30 Amp
Oil capacity:
3 L
Fuel (unleaded):
MOGAS with min. 95
octane rating or
AVGAS ( 95 octa =
87Mon = 91AKI )
MOGAS with
min. 98 octane rating or AVGAS ( 98 Oct =
90MON = 94 AKI )

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Description of basic standard engine and accessories
The basic standard engine assembly consists of the following:
Engine assembly
Injectors, fuel pressure regulator and spark plugs
Intake manifold, throttle and air filter
Electric starter motor
Integrated AC generator
Propeller flange
In addition to the basic standard engine assembly, following external items are necessary
accessories:
ECU, ignition coils and electrical wiring
Fuel pump, filters and fuel lines
Exhaust system
Cooling ducts for cylinders and cylinder heads
Temperature and pressure sensors, wiring (and gauges)
External rectifier-regulator
Optional oil cooler and connections

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Engine views
(*) Dimension for standard prop flange l =55
Different prop flange are available

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Denomination of cylinders
Description of systems
Lubricant system
The oil is drawn from the wet sump through a coarse filter on the oil pickup tube to the oil pump.
From the pressure side of the pump, the oil passes the oil cooler (optional) and oil filter, after
which it enters the main oil gallery to flow to various points of lubrication in the engine. The surplus
oil emerging from the points of lubrication accumulates back into the wet sump on the bottom of
the engine.
Note: The oil pump unit is equipped with an integrated pressure release valve limiting the
pressure at cold starts or in the event of blocked oil lines.
Note: A pressure sensor should be installed to measure the pressure in the oil gallery, while a
temperature sensor should be installed to measure the oil temperature in the oil sump.
Fuel system
Fuel flows from the tank through a coarse filter to the electrical fuel pump. From the pressure side
of the pump it passes through a fine filter, on to the injectors and integrated pressure regulator,
after which it returns to the fuel tank and suction side of the fuel system.
Note: The constant flow and pressure helps eliminate the possibility of a vapour lock within the
fuel line circuit.
Note: The fuel pressure regulator causes a 3 bar pressure difference between the pressure in the
fuel lines and the varying pressure in the inlet manifold causing a constant pressure flow
through the injectors.

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Note: The fuel pressure sensor should measure the pressure in the fuel line between the electric
fuel pump and the engine.
Electronic Engine Management system
The UL260i is equipped with an electronic injection and ignition system. RPM and Throttle Position
are the main inputs to the ECU (Engine Control Unit). The pre-programmed fuel map in the ECU
regulates the amount of fuel that is injected through the injectors and the pre-programmed
advance map decides on ignition timing. On a signal of the ECU the ignition coils convert the
incoming current of the alternator or battery into a high voltage current to generate a spark in the
sparkplugs.
Note: The injection system is pressure and temperature compensated and has an automatic choke
function for cold starts.
Note: Since the engine is managed electronically and a current is needed to generate the sparks
and operate the fuel pump, the engine cannot run without a working electrical system.
The engine and fuel pump use about 15 Amps (12V DC) to operate.
Note: The engine comes with an integrated AC generator with external rectifier/regulator that
can supply up to 30 Amps. This should be sufficient to charge the battery while the engine
is operating and other electrical aircraft systems are in use.
Cooling system
The UL260i is an air cooled engine. Ram air ducts/chamber should guide(s) the incoming air
sufficiently and equally over the cylinders and cylinder heads. Oil is cooled by fresh cool air flowing
over the oil sump. Depending on flying conditions a supplementary oil cooler may be necessary and
can be connected and placed in fresh airflow.
Note: Cylinder head temperatures are measured by means of temperature probes inserted in the
cylinder heads with a bayonet fitting or alternately with ring-probes positioned under the
spark plugs on the exhaust side.

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General operating limits
Speed
Max. engine speed ...................... 3300 rpm
Recommended prop speed ............ 2400 - 2800 rpm
Normal idle speed ....................... 850 rpm
Min. idle speed .......................... 700 rpm
Running in
To run in a new engine, it is recommended to limit the speed at 3000 rpm for the first 5 hours.
Performance (ISA)
a) UL 260i Maximum (for 5 minutes) : 97 hp @ 3300 Rpm
Maximum continuous power : 87 hp @ 2800 Rpm
b) UL 260is Maximum (for 5 minutes) : 107 hp @ 3300 Rpm
Maximum continuous power : 95 hp @ 2800 Rpm
Acceleration
Limit of engine operation at zero gravity and in negative "g" conditions
Max. ....................................... 3 seconds at max. –0.5 g
Oil pressure
Max. ....................................... 8 bar (115.0 psi) (cold start)
Normal .................................... 2–5 bar (30–75 psi) —above 2000 rpm
Min. ........................................ 1 bar (14,5 psi) —below 2000 rpm/above 900 rpm
Oil level
Max. ....................................... 3,5 litres (3,7 quarts)
Min. ........................................ 2,5 litres (2,6 quarts)
Oil temperature
Max. ....................................... 120°C (248°F)
Min. ........................................ 50°C (122°F)
Normal .................................... 80-100°C (175-212°F)
Cylinder head temperature
Max. ....................................... 190°C (375°F)
Max. continuous ......................... 160°C (320°F)
Min. ........................................ 50°C (125°F)

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Manifold air temperature
Max. ....................................... 40°C (104°F)
May not exceed outside air temperature
Outside air temperature
Max. ....................................... 65°C (150°F)
Min. ........................................ -25°C (-15°F)
Relative fuel pressure
Relative fuel pressure is the difference between the pressure in the
fuel line and the pressure in the intake manifold
Max. ....................................... 3.8 bar (55 psi)
Min. ........................................ 2.4 bar (35 psi)
Normal .................................... 3 bar (43.5 psi)
Deviation from bank angle
Value to which the wet sump lubrication system warrants lubrication in positive "g" flight situation
Max. ....................................... 30°
Electrical power
Min.: 12 VDC
Be sure the battery is completely loaded before take off with an output voltage min = 12 VDC
WARNING: Make sure operating limits are respected at all times. Running the engine outside of
the limits set by the manufacturer may severely damage the engine and will render
any warranty relating to this engine null and void.
Maintenance
Maintenance should be performed at regular intervals to keep the engine in top operating condition.
Please refer to the last published Maintenance Manual of the engine for maintenance schedule.

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30
40
50
60
70
80
90
100
110
120
1500 1700 1900 2100 2300 2500 2700 2900 3100 3300
RPM
Power (HP)
100
120
140
160
180
200
220
240
260
280
300
Torque (Nm)
Power 260IS (HP)
Torque 260IS (Nm)
30
40
50
60
70
80
90
100
110
1500 1700 1900 2100 2300 2500 2700 2900 3100 3300
RPM
Power (HP)
150
160
170
180
190
200
210
220
230
240
250
Torque (Nm)
Power 260i (HP)
Torque 260i (Nm)
Engine performance
Performance graphs for standard conditions (ISA)
The following graphs shows the performance of the UL260i
The following graphs shows the performance of the UL260iS

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Performance graph for non-standard conditions
The following graph shows the calculated performance drop with increasing flight altitude. The
curves show the performance at 3300, 2800, 2500 and 2200 rpm, at full throttle.
UL260i:
0
10
20
30
40
50
60
70
80
90
100
110
0 2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000
Density Altitude (ft)
Performance (hp)
3300 RPM
2800 RPM
2500 RPM
2200 RPM
UL260iS:
0
10
20
30
40
50
60
70
80
90
100
110
0 2.000 4.000 6.000 8.000 10.000 12.000 14.000 16.000 18.000 20.000
Density Altitude (ft)
Performance (hp)
3300 RPM
2800 RPM
2500 RPM
2200 RPM

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At deviation of temperature conditions from standard atmosphere conditions the engine
performance to be expected can be calculated from the performance indicated, multiplied by
standard temperature in °K, divided by actual temperature in °K.
Pactual = Pstandard . ( Tstandard / Tactual )
T[°K] = t[°C] + 273.15

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Operating media
Fuel
UL260i
Regular unleaded automotive fuel with a minimum of 95 octane RON (= 87 MON=91AKI) should be
used to operate the engine.
AVGAS 100 LL my be used if regular fuel is not available.
Note: Due to higher lead content in AVGAS, the wear of the valve and valve seats, the deposits in
combustion chamber and lead sentiments in the lubrication system will increase.
UL260iF/UL260iS/UL260iSA
Regular unleaded automotive fuel with a minimum of 98 octane RON(=90 MON=94AKI) should be
used to operate the engine.
AVGAS 100 LL may be used if regular fuel Is not available.
Note: Due to higher lead content in AVGAS, the wear of the valve and valve seats, the deposits in
combustion chamber and lead sentiments in the lubrication system will increase.
Lubricants
High quality full synthetic or semi synthetic multi grade oil should be used to guarantee the quality
of lubrication on all moving and rotating parts of the engine.
Note: We recommend the use of Motul 300V (15W50) oil or Aeroshell SAE15W50 oil
as most of our engine testing has been done with these types with good
results.
Attention: Do not use special brake-in oils as these don't guarantee the same quality of
lubrication to crankshaft, camshaft and tappets.
Attention: Do not fill the oil sump with more than 3,5 litres (3,7 quarts) of oil as more could
cause the oil to constantly be whipped by camshaft gear. The absolute minimum
quantity in the oil sump (before take-off) should be 2,5 litres (2,6 quarts), so be
sure to add sufficient oil to compensate the quantity of oil that remains in the oil
cooler, -lines and -galleries.
Attention: If AVGAS 100 LL is used frequently, we advise not to use full synthetic oil, as the oil
does not handle the lead deposits as well. More frequent oil changes are also
recommended.

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Standard operation
Daily/Pre-flight checks
WARNING: Conduct checks on cold engines only as there could be a risk of burns and scalds!
Turn the propeller by hand in the direction of engine rotation several times and observe engine for
odd noises or excessive resistance and normal compression. If irregular, first check tappet
adjustment.
WARNING: Make sure ignition is turned OFF when inspecting the engine. Have the cockpit
occupied by a competent person.
Check that all spark plugs, leads and electrical connections are secure.
Verify the free movement of the throttle cable over the complete range. Check from cockpit.
Check for any oil and fuel leaks.
Note: Fuel pump must have been switched on to ensure the fuel lines are under pressure.
Check oil level and replenish as required.
Note: The oil level should be between the min. and max. marks. Before long periods of operation
ensure the level is at least up to mid position. Difference in oil quantity between min. and
max. level is 0.8 litres.
Inspect exhaust system for damage, leakage and general condition.
WARNING: Do not release the engine into service before rectification of any possible problem
found during the daily/pre-flight checks.
Engine start
WARNING: Do not start the engine if any person is near the aircraft.
1. Fuel tap ............................... OPEN
2. Master switch ......................... ON
3. ECU ..................................... ON
3. Ignition Coils .......................... ON
4. Fuel pump ............................. ON (if not connected to ECU steering relay)
Attention:Pump fuel around for a few seconds before starting the engine to avoid vapour lock
and ensure fresh fuel from the tank is available.
5. Throttle lever ........................ set to 10% position
6. Starter ................................. ENGAGE
Attention: Activate starter for max. 5 seconds only (without interruption), followed by a
cooling period of 15 seconds if restart is necessary. Do not engage starter as long as
engine is turning. Wait until complete stop of engine.
As soon as engine is running adjust throttle to achieve smooth running at approximately 1200 rpm.
Check if oil pressure has risen within 5 seconds (if not: shut down). Verify pressure remains within
the limits.
Attention: Increase of engine speed is only permitted when oil pressure reading remain below
maximum.
Check fuel pressure (2.4 à 3.8 bar)

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Prior to take-off
Warming up period:
Start warming up period with engine running between 1200 and 1500 rpm, duration depending on
ambient temperature, until:
oil temperature reaches at least 40°C (105°F)
cylinder head temperatures are not less than 50°C (125°F)
Attention: Always check temperatures and pressures are within limits.
Idle speed:
When warm, engine can be set at idle speed.
Note: Although engine idle speeds of 700 rpm can be obtained, we recommend the ground idle to
be at least 850 rpm for smooth running.
Throttle response:
When ready for take-off do a short full throttle ground test. No irregularities may occur.
Note: Check with aircraft/propeller operating handbook, since engine speed depends on the
propeller used.
Ignition test:
The engine is equipped with double redundant ignition. Switch off one ignition coil at the time and
verify that engine remains operation normally on both ignition coils separately.
RPM difference between running with coil 1, with coil 2 or both may not exceed 5% of nominal RPM.
Take-off
Climbing with the engine at maximum take-off power (3300 rpm @ full throttle) is permitted during
a time period of max. 5 minutes.
Depending on propeller setting take-off power at 2800 rpm @ full throttle is permitted with no time
limitation.
Attention: Observe that all temperatures and pressures remain within limits at all times. If
CHT’s exceed maximum, reduce power.
Cruise
Set power as required.
Attention: Respect operating limits at all times.
Avoid operating with oil temperature below normal operation (80-100°C / 175-212°F), as low
operating temperatures may not eliminate any accumulated water in the engine. The formation and
presence of condensation water in the lubrication system badly influences the oil quality.
Engine shut-down
Shut down engine by switching off power to ECU before eventually cutting off fuel/ignition.
Normally the cooling down of the engine during the descent and taxiing will be sufficient to allow
the engine being shut-down (by switching the ignition off) as soon as the aircraft has stopped.