O.S. engine GF40U-FI, Instruction Manual

Page 1: ...2021 08 01 O S ENGINES MFG CO LTD 4 stroke gasoline engine for UAV GF40U FI With EC11 ECU INSTRUCTION MANUAL version 2 46E...

Page 2: ...vided About the engine 1 The engine is equipped with electronic fuel injection system to correspond to environmental changes during a long flight This is a four stroke gasoline engine but runs on a pr...

Page 3: ...manifold Cylinder Connector Injector Intake air temperature sensor Air inlet Engine bracket Mounting plate R Mounting plate F Crankcase Crankshaft rotation sensor Generator support R OGR 100A Generat...

Page 4: ...sure sensor Throttle servo Throttle linkage rod Spark plug CM 6 Cylinder head temperature sensor F 6040 Silencer Generator mount Reinforcement beam Engine mount 32 33 28 30 31 32 33 34 27 28 29 30 31...

Page 5: ...ine control unit ECU ECU connector CN1 ECU connector CN2 Status display LED Fuel pump unit Fuel pressure sensor unit Pressure release valve 38 38 37 34 33 33 34 35 36 37 Names of the parts 4 39 35 36...

Page 6: ...in fuel line Hose clamp To be used to fix pressurized tubes to joints Recommended tube EIGHTRON Flexible Fluorine ETFE Resin Tubing Clear made by HAKKO CORPORATION JAPAN Code No 28382303 FLUORINE ETFE...

Page 7: ...6 Accessories CAN communication code the connector for CAN communication...

Page 8: ...Cap screw Hex socket head bolts Follow the above tightning torque unless otherwise specified Standard screw tightening torque 7 M5 0 7 2 screw size N m M2 6 1 1 M3 0 1 5 M4 0 3 6...

Page 9: ...Use standoff mounts with 18mm or more outer diameter made of A2017 aluminum or stronger material Use 25mm in length standoff mounts to be able to detatch the injector connector to space the engine fr...

Page 10: ...two types of Engine brackets Engine bracket A and B are different in direction of Engine support bolts Choose the proper engine bracker A or B to use on the Mounting plate R as shown below Engine sup...

Page 11: ...lts next Do not forget to use Nord Lock washers otherwise engine vibration will loosen the bolts and cause a failure Make sure of the Manifold pressure tube is installed as shown below Engine support...

Page 12: ...sily come off Use clamps or wire ties if necessary Be sure to use Code No 28382303 FLUORINE ETFE RESIN TUBING 2m for piping between the fuel pump unit and engine through which pressurized fuel passes...

Page 13: ...ir bubbles in the tube between the fuel tank and the fuel pressure sensor unit after filling up the fuel tank when the ECU switch is turned on for the first time open the valve until the screw top bec...

Page 14: ...nd twist the tube strongly to pull it out Do not give damage to a nipple when you use a nipper or a knife to cut the end of the tube Installation Be sure to use Code No 28382303 FLUORINE ETFE RESIN TU...

Page 15: ...tallation 14 The position of the generator OGA 100A is choosable from the three positions shown above Right side left side Lower M4x30 Bolt M4x25 Bolt 4 5mm Spacer 15mm Spacer Use four screw holes for...

Page 16: ...by rotating the generator body 8 Rotate the generator body clockwise viewing from the front of the engine and adust the belt tension Press on the middle point of the belt with a finger and set deflec...

Page 17: ...re sensor Cylinder head temperature sensor Manifold air pressure sensor Crankshaft rotation sensor A 5 CAN communication B wiring harness B Drive section CN2 B 1 Power supply DC10V 17V MAX 1 5A B 2 Fu...

Page 18: ...ottle signal input A 1 In case manual adjustment of fuel injection is necessary connect to a receiver or fuel injection signal cable from flight controller ECU controls quantity of fuel injection norm...

Page 19: ...n Engine control unit ECU A A 4 To be connected to Crankshaft rotation sensor Specification Crankshaft rotation sensor A 5 Specification CAN communication B B 1 Specification Power supply Supply power...

Page 20: ...Brown White Stripe Engine control unit ECU To be connected to the rotation signal input cable of Igniter Specification Ignition signal C C 1 B B 3 To be connected to Fuel pump Specification Fuel pump...

Page 21: ...inks 5 The Fuel pump starts working as soon as the ECU is turned on If the Pressure release valve is open close it only after airbubles in the system are gone When fuel pressure reaches specified valu...

Page 22: ...a buzzer sounds at the same time a buzzer sounds at the same time a buzzer sounds at the same time a buzzer sounds Blink System error 2 On Off Blink Blink Off System error 1 On Blink Blink Blink Off T...

Page 23: ...engine have not been set yet in this prototype 2 The ECU stops the fuel pump and emits Beep sound intermittently when it detects engine stop 3 Turn off the ECU 4 Release the residual pressure in the...

Page 24: ...20 circled in the drawing below Disconnect the cable connectors and the fuel tubes before removing the bolts After removing the bolts disconnect the Manifold pressure tube to separate the Mounting pl...

Page 25: ...ighten them later in the process Tighten the 4 bolts on the front of the reinforcement beams temporarily so that the Reinforcement beam and the front bolt does not turn together when you tighten the r...

Page 26: ...SKET 30 49404200 ROCKER COVER 28 4AD04100 CYLINDER HEAD GF40U 27 4AD07001 PCV VALVE SET GF40U 26 29122540 COVER GASKET 1pcs 25 4AD07000 COVER PLATE GF40U 23 29717000 PISTON PIN RETAINER 2pcs 24 494050...

Page 27: ...25200 EXHAUST HEADER PIPE ASSY GF40U 93 94 44525110 SILENCER BODY GASKET 2pcs 49425100 SILENCER BODY F 6040 92 74003540 M5 STAND OFF ENGINE MOUNT 1 25 4mm 4pcs 1sets 91 55500004 NORD LOCK WASHER M5 10...

Page 28: ...IGHT S F8 70000002 CONECTOR LOCK 5pcs F9 28382303 FLUORINE ETFE RESIN TUBING 2m F4 71669000 SPARK PLUG CM 6 NGK F5 70000001 HOSE CLIP 6 5pcs F6 78300000 GASOLINE FUEL FILTER S F1 75001009 PUMP CONNECT...

Page 29: ...ing torque 1 0 N m Use Loctite 242 or 243 Tightening torque 2 2 N m thread 25 27 C12 63 C13 62 64 65 66 70 C7 69 68 67 C8 C8 C1 10 11 9 6 46 49 58 1 15 4 F4 26 50 50 1 Use Loctite 242 or 243 left hand...

Page 30: ...EC 11 ENGINE CONTROL UNIT E8 ECU WIRE HARNESS A EC 11 POWER SUPPLY CORD EC 11 CAN COMMUNICATION CODE ECU WIRE HARNESS B EC 11 SERIAL SIGNAL CONVERTER Engine parts list E1 E3 E5 29 E4 E6 E7 E2...

Page 31: ...PM 02 FUEL PUMP UNIT SP 01 FUEL PRESSURE SENSOR UNIT Engine parts list P1 30 S1 S4...

Page 32: ...ATURE SENSOR SPARK PLUG CM 6 NGK HOSE CLIP 6 5pcs GASOLINE FUEL FILTER S NON BUBBLE WEIGHT S CONECTOR LOCK 5pcs FLUORINE ETFE RESIN TUBING 2m F5 Engine parts list F1 F2 F3 F4 31 F6 F7 F8 F9 EIGHTRON F...

Page 33: ...VALVE ADJUSTING TOOL KIT GF 32 Engine parts list F10...

Page 34: ...Demantions 33 Unit mm Unit mm...

Page 35: ...Demantions 34 Unit mm...

Page 36: ...MEMO 35...