Illustrated Parts Catalogue

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1 Illustrated Parts Catalogue UL39Oi/iS AERO ENGINE M030IPC 390A0 Revision No : 8 Date:

2

3 Please fill in your engine and aircraft details for further reference: Engine Serial No. :... Aircraft type :... Model :... Serial No. :... Registration :... Introduction Remarks The illustrations in this Illustrated Parts Catalogue 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. Modifications All efforts are made to ensure the accuracy of this Illustrated Parts Catalogue 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. The engine serial number is located at the front left side of the crankcase (above oil filter). Structure Each section of this Illustrated Parts Catalogue starts with an exploded view or assembly drawing on the left side. The corresponding heading and the listing of the parts is on the right side and the following pages. For each assembly drawing the right number of parts is listed in the relevant column. Because an engine can contain multiple times the illustrated assembly or a part can be used in several different applications, the total number of parts per engine is also given. Generally all fasteners are tightened with a torque wrench. The "Notes" column indicates the appropriate torque or refers to extra information at the end of the section. IPC 390A0 Revision No : 8 Date: Page of 34

4 Blank IPC 390A0 Revision No : 8 Date: Page 2 of 34

5 Table of Contents Introduction... Remarks... Modifications... Engine serial number... Structure... Table of Contents...3 Cylinder Head and Cylinder...5 Crankcase, Oil Sump and Dipstick...7 Oil Pump Assembly: SE Camshaft and Valve Train... Crankshaft, Conrod and Piston... 3 Inlet Manifold, Injectors and Throttle... 5 Fuel lines... 8 Engine Mount Plate, Starter and Alternator... 2 Exhaust System Breather and Oil/Air Separator Oil Thermostat Assembly: E04255A Ignition and Engine Control Unit Accessories... 3 Section of drawings Revision IPC 390A0 Revision No : 8 Date: Page 3 of 34

6 IPC 390A0 Revision No : 8 Date: Page 4 of 34

7 Cylinder Head and Cylinder Item Part No. Description Parts in assembly Note E0250 E02502 SE0252 E03500 E03450 E Cylinder Head Assembly Cylinder Head Right Cylinder Head Left Cylinder Head middle Valve Guide Exhaust Valve Seat Inlet Valve Seat 2 E Spark Plug 2 2Nm (5) 3 E02504 Cylinder Head Washer 6 4 F Socket Cap Screw M8xx Steel 6 36 Nm () 5 S00605 O-Ring Viton 6x.5 6 E02505 Cylinder Head Plug 7 E02503 Locking plate M4 bolt 8 F Hexagon head screw M4x6-8.8 Steel - Zinc Plated.5 Nm 9 S00020 O-Ring Viton 99x2 0 E02506 Valve Cover F00500 Socket Cap Screw M5x0-8.8 Steel - Yellow Passivated 3 6 Nm 2 S30820 Copper Sealing Ring ø8x2x 2 3 E04505 E04506 Cylinder Head Oil Line Left Assembly Cylinder Head Oil Line Right Assembly 4 F Banjo Bolt M8x 8 Nm 5 E0300 Cylinder Gasket (3) 6 SE02003 Cylinder (4) 7 E0003 Flanged Nut M0x 4 36 Nm 8 S05020 O-Ring Viton 05x2 9 E025 Cylinder Head Oil Filter 20 SE02530 Bracket oil line 2 F20050 Nordlock washer M F Cloth braided hose Ø5,5 x Ø0,5 () Apply high temperature resistant grease (2) Apply Loctite 266 (Loctite 26773) (3) Replace when removed (4) Quick gasket (Loctite 590) (Outer dia Seal) (5) Wacker P IPC 390A0 Revision No : 8 Date: Page 5 of 34

8 () Apply Sealing Silicone - Elring No (2) Apply Loctite 243 (3) Apply Engine oil (4) Apply Loctite 542 (5) Quick gasket (Loctite 590) (Outer dia Seal) IPC 390A0 Revision No : 8 Date: Page 6 of 34

9 Crankcase, Oil Sump and Dipstick Item Part No. Description SE00502 Crankcase Left () 2 S Oil Seal Viton 60x75x0 GR (5) 3 BE00509 Thrust Bearing Mount () 4 F Socket Cap Screw - M6x Steel - Yellow Passivated 8 0 Nm 5 S36205 Copper Sealing Ring ø6x20x F46265 Hexagon Socket Screw Plug - M6x Nm (2) 7 E Oil Filter Screw M20x.5 8 E Oil Filter 5 Nm (3) 9 E0856 Oil Temperature Sensor 20 Nm Parts in assembl 0 S005 O-Ring Viton øx.5 2 E08507 Oil Pressure Sensor 2 S3045 Copper Sealing Ring ø0x4x F Banjo Bolt M0x L = 25 0 Nm 4 S0020 O-Ring Viton øx2 0 (3) 5 E0002 Stud Short 4 6 E000 Stud Long 0 7 SE0050 Crankcase Right 8 F Socket Cap Screw - M6x Steel - Zinc Plated 6 0 Nm 9 E Dipstick Tube (4) 20 SE Dipstick 2 S02000 O-Ring Viton ø20x 22 SE04450 Oil Pickup Tube with Filter 23 F20050 NordLock Washer M F00506 Socket Cap Screw - M5x6-8.8 Steel - Yellow Passivated 2 6 Nm 25 SE04002 Oil Sump () 26 F00606 Socket Cap Screw - M6x6-8.8 Steel - Yellow Passivated 22 0 Nm 27 F Stud - M6x20 Yellow Passivated 0 Nm 28 F Hex Nut M6 Zinc Plated 0 Nm 29 F Nylon Cable Tie 30 F All Metal Prevailing Torque Hex Nut - M6 - Zinc Plated 3 S3485 Copper Sealing Ring ø4x8x.5 32 E04020 Carter plug magnet 25 Nm 33 SE04350 Oil breather tube 34 S38245 Copper sealing ring ø8x24x F25285 Banjo bolt M8x.5 36 E0435 Oil return tube sump 37 E0405 Plug 5/8 8UNF 38 S3275 Copper sealing ring d2xd7x.5 39 F20060 Nordlock Washer M6 40 S3275 Copper sealing ring d2xd7x.5 4 F46225 Hexagon socket screw plug M2x.5 25Nm (2) y Note IPC 390A0 Revision No : 8 Date: Page 7 of 34

10 IPC 390A0 Revision No : 8 Date: Page 8 of 34

11 Oil Pump Assembly: SE04055 Item Part No. Description Parts in assembly Note SE04050 Oil Pump Housing () 2 E04052 Oil Pump Rotor Set b = E Oil Pump Cover 4 F00506 Socket Cap Screw - M5x6-8.8 Steel - Yellow Passivated 4 6 Nm 5 F Socket Cap Screw M6x Steel - Yellow Passivated 4 0 Nm 6 S3275 Copper Sealing Ring ø2x7x.5 7 F46225 Hexagon Socket Screw Plug - M2x.5 25 Nm 8 SE04053 Oil Pump Shaft 9 F Parallel Key 4x4x35 0 S O-Ring Viton ø30x2 S02600 O-Ring Viton ø26x 2 S0020 O-Ring Viton øx2 2 3 BE0456 Plunjer oil pump 4 E Pressure Relief Spring 5 S36205 Copper Sealing Ring ø6xd20x.5 6 E04040 Hexagon Socket Screw Plug - M6x.5 25 Nm 7 S O-ring Viton 70x2 8 S06020 O-Ring Ø6x2 () Apply sealing silicone Elring No IPC 390A0 Revision No : 8 Date: Page 9 of 34

12 IPC 390A0 Revision No : 8 Date: Page 0 of 34

13 Camshaft and Valve Train Item Part No. Description Parts in assembly Note SE03050 Camshaft 3,9 2 SE0300 Camshaft Gear 3 F Socket Cap Screw - M6x2-2.9 Steel 6 8 Nm () 4 E0350 Cam Follower 2 5 E0450 Oil Return Tube 2 6 S07020 O-Ring Viton ø7x2 4 (3) 7 E Push Rod 2 8 E Tappet Adjusting Screw 2 9 F2306 Shim Ring 0.5mm - ø0x6 4 0 E Rocker Tappet Right E0003 Flanged Nut M0x 2 20 Nm 2 F Socket Cap Screw - M6x6-2.9 Steel 3 2 Nm () 3 E Rocker Shaft 4 E Rocker Tappet Left 5 E Collet Valve Spring Lock 4 6 E Valve Spring Retainer Top 2 7 E03350 Valve Spring 2 8 E03550 Valve Stem Seal 2 9 E03400 Valve Spring Retainer Bottom 2 20 E Inlet Valve 2 E03300 Exhaust Valve () Apply loctite 266 (Loctite 26773) (3) Apply engine oil IPC 390A0 Revision No : 8 Date: Page of 34

14 IPC 390A0 Revision No : 8 Date: Page 2 of 34

15 Crankshaft, Conrod and Piston Item Part No. Description Parts in assembly Note SE Crankshaft 2 3 BE Crankshaft Bearing Set ( contains piece 2, 3 ) Crankshaft Bearing Half Crankshaft Bearing Half 4 E02200 Thrust Bearing 2 5 E02502 Thrust Bearing Disc Spring 2 6 S O-Ring Viton ø50x.78 7 E02504 Thrust Bearing Retention Ring 8 E Prop Flange Drive Lug ø4 6 9 E02250 E E E Propeller Flange L = 55 (Standard) Propeller Flange L = 90 (6) Propeller Flange L = 35 (6) Propeller Flange L = 0 (6) 0 E02300 Prop Flange Bolt 300Nm (5) E02250 Locking propeller flange bolt 2 F Parallel Key 6x6x30 3 E0200E Crankshaft Gear 4 E E F E02400 E Connecting Rod Assembly Connecting Rod Bearing set (2) Socket Cap Screw - M8xx Steel Piston -8cc ( I engines) Piston -7cc ( is engines) 6 6 E02506 Thrust Bearing Disc 7 SE0255 Thrust Bearing Retention Ring Outer 8 E0250 Thrust Bearing Disc Spring Outer Nm (2+3) 9 E02050 Oil Stop M36x2 (4) 20 E0205 Oil Stop M24x,5L (4) 2 F30606 Hexagon Socket Cap Screw M6x6 (2) Loctite 266 (Loctite 26773) (3) Replace when removed (4) Apply Loctite 542 (5) Apply grease (6) Optional available: See Installation Manuel IPC 390A0 Revision No : 8 Date: Page 3 of 34

16 () Apply Sealing Silicone - Elring No (2) Apply Loctite 266 (Loctite 26773) (3) Apply engine oil IPC 390A0 Revision No : 8 Date: Page 4 of 34

17 Inlet Manifold, Injectors and Throttle Item Part No. Description SUSE0659 Inlet Collector 2 SE06504 SE06506 Injector Holder +sensor holder Injector Holder + sensor holder ( Forced Cooling) Parts in assembly 3 E06250 Injector 6 (3) 4 S3275 Copper Sealing Ring ø2x7x.5 5 E0855 Air Temperature Sensor 20 Nm 6 F Hose Clamp single use ø E065 Rubber Hose 38x3x E06509 Inlet Tube Right 2 () 9 SE06507 Injector + Fuel Pressure Regulator Holder 0 SE0652 Injector Holder Lock Plate 4 F00500 Hex Head Screw - M5x6-8.8 Steel - Yellow Passivated 8 6 Nm 2 E06450 Fuel Pressure Regulator - 3bar (3) 3 F Retaining Ring - bore 36mm 4 E06508 Inlet Tube Left 2 () 5 F00606 Socket Cap Screw - M6x6-8.8 Steel - Yellow Passivated 2 0 Nm (2) 6 F Fuel Pressure Regulator Hose (ø4.5x9.5 x 6cm) 0,3 7 S30820 Copper Sealing Ring ø8x2x 2 8 F Banjo Eye M8/Ø5 9 F Banjo Bolt M8x 6 Nm SUSE F00402 E08506 SE F SE B E0605 F E E E SE E SE0653 F SE SE Throttle assy 6cyl (contains piece 20-34) Socket cap screw M4x2 Yellow passivated Hall sensor + magnet Throttle Shaft Socket Cap Screw - M4x8-8.8 Steel - Yellow Passivated Throttle Lever Stop Flanged Bushing 8x0x5.5 Throttle Lever Spring Button Head Socket Cap Screw - M3x8-0.9 Steel - Zinc Plated Throttle lever outer plate hall sensor Throttle lever middle plate hall sensor Throttle lever inner plate hall sensor Throttle plate D45 Throttle bushing hall sensor Locking plate throttle shaft Prevailing torque type hexagon nut thin M6 Zinc plated Throttle connection Throttle housing D45 hall sensor 35 F Socket Cap Screw - M5x Steel - Yellow Passivated 4 6 Nm 36 F Hose clamp Ø S O Ring Viton 36 x SE06508 Inlet tube middle 2 39 SE06505 Injector holder single hole 2 40 SE0250 Baffle right 4 SE0252 Baffle left 42 SE Inlet hose Ø 60 L Note 2 Nm 3Nm IPC 390A0 Revision No : 8 Date: Page 5 of 34

18 Item Part No. Description 43 SE Inlet tube D60 x 44 SE Air filter D60 straight 45 E0257 Protection hose Fp-regulator 46 F Hose clamp single use Ø F20060 Nordlock washer 2 48 F Hex socket button head cap screw M4x8-0.2 Zn 2 49 M90006 Logo plaatje 50 S3045 Copper sealing ring d0xd4x.5 5 E08507 Fuel pressure sensor 52 SE0655 Overpressure valve 53 F Spring Ø4,2 x,2 L=40 54 SE0654 Overpressure valve body 55 F Self locking hexagon bolt M8x6 dacromet Parts in assembly Note IPC 390A0 Revision No : 8 Date: Page 6 of 34

19 IPC 390A0 Revision No : 8 Date: Page 7 of 34

20 IPC 390A0 Revision No : 8 Date: Page 8 of 34

21 Fuel lines Item Part No. Description Parts in assembly Note SE06300 Fuel line connection & feed line 2 SE0630 Fuel line side 3 E06302 Fuel line cross short 2 4 F25220 Banjo bolt M2x.5 - double 4 5 F Banjo bolt M2x.5 6 S3275 Copper sealing ring d2xd7x E06304 Fuel return line IPC 390A0 Revision No : 8 Date: Page 9 of 34

22 Assemble 25 & 27 IPC 390A0 Revision No : 8 Date: Page 20 of 34

23 Engine Mount Plate, Starter and Alternator Item Part No. Description Parts in assembly Note SE03506 SE03502 Engine Mount Plate Engine Mount Plate double sensor 2 F80300 Parallel Pin 3x0 2 3 E04002 Rubber Engine Mount (50/55 Shore) 8 4 F Parallel Pin 4x E07200 Locking plate hall sensor 6 E05050 Starter Engine 7 E Starter Cap () () 8 F Socket Cap Screw - M4x Steel - Zinc Plated 3 Nm 9 B20000 Bushing 2x4x0 0 F Socket Cap Screw - M5x Steel - Yellow Passivated 3 6 Nm F Socket Cap Screw - M8x Steel - Yellow Passivated 8 25 Nm 2 F Stud - M6x20 - Yellow Passivated 2 (2) 3 E08503 Hall Sensor 2 (4) 4 F Prevailing torque type hexagon nut - M6 Zinc plated 4 5 F Socket Cap Screw - M6x Steel - Yellow Passivated 2 0 Nm 6 S Oil Seal Viton 50x62x7 GR 7 S O-Ring Viton ø66x2 8 SE0550 Alternator Stator Spacer () 9 F Socket cap screw M6x Steel Yellow passivated 3 0 Nm 20 SE05200 Alternator Stator 2 F Hexagon head screw M5x Steel Zinc plated 4 0 Nm 22 SE Alternator Magnet Ring 23 SE Alternator rotor flange 24 F Socket cap screw thin M6x0 2,9 Steel Zinc plated 8 25 E0500 Starter Ring Gear 26 E Alternator Rotor Flange Bolt / Socket size 30 mm 280 Nm (3) E E E E Alternator Fan Assembly (Contains piece 27, 28, 29) Alternator fan base Spacer alternator fan Alternator fan top 30 F20060 NordLock Washer M6 8 3 F Socket Cap Screw - M6x Steel Zn 8 0 Nm 32 E03505 Engine Mount Washer 4 () Apply Sealing Silicone - Elring No (2) Apply Loctite 270 (3) Apply Loctite 266 (Loctite 26773) (4) Apply engine oil 8 IPC 390A0 Revision No : 8 Date: Page 2 of 34

24 IPC 390A0 Revision No : 8 Date: Page 22 of 34

25 Exhaust System Item Part No. Description Parts in assembly Note SE090 Stainless Steel Exhaust Tubes (set) 2 F20060 NordLock Washer M F00606 Socket Cap Screw - M6x6-8.8 Steel - Yellow Passivated 24 0 Nm () 4 E09300 Exhaust Spring 8 5 SE09508 Stainless Steel Muffler L=600 6 SE Exhaust Tube 7 E09200 Exhaust gasket ring d32xd38x F Hose clamp ø 90 0 / Stainless steel 2 9 E Muffler bracket F Cap Screw M8x25-8,8 Yellow 2 F Flat washer M8 2 2 F Prevailing Hexagon nut all metal M8 2 3 E Muffler heating box (Optional) () Apply high temperature resistant grease IPC 390A0 Revision No : 8 Date: Page 23 of 34

26 IPC 390A0 Revision No : 8 Date: Page 24 of 34

27 Breather and Oil/Air Separator Item Part No. Description Parts in assembly Note F Cloth Braided Hose ø5x20 2 F Rubber Hose ø6x3.5 (25 C) SE SE E E F F F Oil/Air separator assembly (Contains piece 3,4,5,6,7) Tube Ø5 x Ø 2.5 x 40 Elbow connection oil return (assembly) Oil/Air separator Hose clamp Ø20 Hose clamp Ø4.5 Hose clamp Ø IPC 390A0 Revision No : 8 Date: Page 25 of 34

28 IPC 390A0 Revision No : 8 Date: Page 26 of 34

29 Oil Thermostat Assembly: E04255A Item Part No. Description Parts in assembly Note E42520 Plug M22x,5 2 S Copper sealing 22x27x,5 () 3 F20000 Spring Ø 9,5 x,5; pitch=4; L=5 4 F Spring Ø 5 x,5; pitch=9; L=47 5 E Spring Holder 6 E04250 Bi metal 7 E Bimetal Cover 8 SE04250 Thermostat housing 9 F Socket Cap Screw - M6x Steel 0 S O-Ring Viton Ø 62x5 E Oil filter adapter screw M20 x.5 () Replace when removed IPC 390A0 Revision No : 8 Date: Page 27 of 34

30 IPC 390A0 Revision No : 8 Date: Page 28 of 34

31 Ignition and Engine Control Unit Item Part No. Description Parts in assembly Note SE07005 Ignition Coil 2 E0750 Ignition Coil Cover 3 E07505 Copper Clamp (for Ignition Coil Cover) 4 E07503 Ignition Lead Cable 5 E07504 Spark Plug Cover 6 SE Engine Control Unit UL 390i SE Engine Control Unit UL 390iS 7 SE08006 SE SE08007 SE08009 ECU Wiring loom engine L = 00 (Single ECU) ECU Wiring loom engine L = 00 (Double ECU) ECU Wiring loom cockpit (4 + 6 cylinder) L = 00 (Single ECU) ECU Wiring loom cockpit (4 + 6 cylinder) L=00 (Double ECU) 9 F Prevailing hexagon nut M4 4 4Nm 0 F26455 Silent bloc M4 type B hoogte 5 4 F cap screw M4x30-8,8 yellow 4 4Nm IPC 390A0 Revision No : 8 Date: Page 29 of 34

32 IPC 390A0 Revision No : 8 Date: Page 30 of 34

33 Accessories Item Part No. Description Parts in assembly Note SE Regulator 50A 2 SE05300 Cable regulator - battery 3 E Fuel Filter (Pre-filter) 4 E Fuel Pump 5 E06400 Fuel Filter (Fine) SE02507 SE02524 E0503 F F SE02508 SE02524 E0503 F F Assembly Cylinder Head Ram Air Box (Left) Cylinder Head Ram Air Box (Left) Reinforcing Rib Ignition Cable Grommet Cap screw M4x0 8.8 Zn Prevailing Hexagon nut M4 Assembly Cylinder Head Ram Air Box (Right) Cylinder Head Ram Air Box (Right) Reinforcing Rib Ignition Cable Grommet Cap screw M4x0 8.8 Zn Prevailing Hexagon nut M4 2 F00606 Cap Screw M6x6-8-8 Yellow 6 3 SE03002 Cylinder baffle 2 4 F Spring.0x8x E03025 Steel Cable IPC 390A0 Revision No : 8 Date: Page 3 of 34

34 Section of drawings IPC 390A0 Revision No : 8 Date: Page 32 of 34

35 Revision Revision 5 ( ) Inlet Manifold, injectors ad throttle => Single AND Double ECU Item 6: Hose clamp Ø44 => Hose clamp Ø47 Item 35: Hose clamp Ø62 => Hose clamp Ø63,5 Engine Mount Plate, starter and alternator Item 32: Engine Mount Washer Exhaust system New clamping of the Muffler bracket Breather and oil/air separator Item 7: Reduction Oil/air separator Oil thermostat Item 2: copper sealing 22x28x,5 => 22x27x,5 Item 0: S => S Igntion and engine control unit Item 0: Silent bloc Item : Cap screw M4 Item 2: Prevailing hexagon nut M4 Accesoires Item 7, 4: Air box Left/right => Reinforcing rib + clips + Ignition cable grommet Item 3: Cap Screw M4x6-8-8 Yellow Revision 6: (5/09/206) Pg 4 and pg 5:Cinlinder head and cylinder => nr 2 (nordlock washer M5) Pg 4 and pg5: Inlet manifold, injectors and throttle = > nr 47 (Nordlock washer M6)µ Just used the partnumber. (no version) Pg 28/29: Nr 6: E03025 (Steel Cable) Revision 7: (9/0/207) Pg 28 and pg 29: Nr 6: E03025 (Steel Cable) Revision 8: (0/06/208) Pg 4-5: Nr. 22 Pg 6 7: Nr : E08507 (Oil / Fuel Pressure Sensor ) / E0856 was E0850 / Nr 40 and 4 Pg 9: Nr 8: S06020 was S03020 Pg 9: Nr 6: E04040 was F46265 Pg 2-3: Nr 2 IPC 390A0 Revision No : 8 Date: Page 33 of 34

36 Pg 4 6: Nr : E0659 was E0650 / Nr 2: E was E Nr Pg 8: Detail Montage E05250 Pg 9: Nr 27: E was E Pg 25: Nr 7: =>2st Pg 27: SE08002 => SE08006 / SE08003 => SE08007 / SE08004 => SE08008 / SE08005 => SE08009 Pg 28-29: Nr 8: Clips deleted IPC 390A0 Revision No : 8 Date: Page 34 of 34

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