HKS 700E Operation Manual Download

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Operations Manual

HKS700E

Operations Manual

Please read this manual before using.

Engine S/N:

2014 February
Ver.7.00 ASTM F2339

HKS CO.,LTD
7181 KITAYAMA FUJINOMIYA
SHIZUOKA
JAPAN 418-0192
FAX: +81-(0)544-54-1410
E-MAIL: [email protected]
http://www.hks-power.co.jp/hks_aviation/

Summary of Contents for 700E

Page 1: ...al Please read this manual before using Engine S N 2014 February Ver 7 00 ASTM F2339 HKS CO LTD 7181 KITAYAMA FUJINOMIYA SHIZUOKA JAPAN 418 0192 FAX 81 0 544 54 1410 E MAIL aircraft engine hks power co jp http www hks power co jp hks_aviation ...

Page 2: ...tations 3 5 Fuel consumption 3 6 Information about fuels and lubricants 3 7 The cooling system 3 8 Cylinder head temperatures 3 9 Propeller reduction unit 3 9 1 Propeller mass moment of inertia 3 10 Exhaust gas temperature 4 PERFORMANCE CURVE 11 5 MANUAL OF INSTRUCTION HKS 700E 12 5 1 Before starting the engine 5 2 Starting the engine 5 3 Warm up and run up 5 4 Take off and climbing flight 5 5 Eng...

Page 3: ...arting 6 4 3 Carburetor icing 7 MAINTENANCE 20 7 1 Changing oil 7 2 Air intake filter s 7 3 Compression test 7 4 Carburetor adjustment 7 4 1 Idle speed adjustment 7 4 2 Throttle cable adjustment 7 4 3 Carburetor setting table 7 5 Spark plugs 7 6 Exhaust system 7 7 Bolts and nuts 7 8 Resistance of the electrical equipment 8 OVERHAULS 25 8 1 Thorough inspections TBO 8 2 Major repairs and major modif...

Page 4: ...ngine over terrain where a safe power off landing cannot be performed The operating and maintenance instructions supplied with this engine must be followed at all times Flying any aircraft involves the risk of injury or death building and maintaining your own aircraft requires great personal responsibility ...

Page 5: ...scription 3 00 2003 09 P9 Change the oil temperature 4 00 2004 12 01 TBO extended 5 00 2006 07 01 5 10 2008 01 14 P9 P21 P31 Max percentage of alcohol in fuel Oil viscosity Carburetor setting Interval of Compression check 6 00 2009 01 01 TBO extended 7 00 2014 02 19 P7 P23 Change the Spark Plug ...

Page 6: ...c c 2 2 Description of the HKS 700E Air cooled four stroke Cylinder arrangement 2 cylinders horizontally opposed One central camshaft pushrods OHV hydraulic lifters Oil cooled cylinder head Dual CDI capacitive discharge ignition Electric starter Alternator Nickel ceramic composite coated cylinders Dry sump forced lubrication ...

Page 7: ...Operations Manual HKS 700E 6 2 3 Views of the engine ...

Page 8: ...rox 55kg 121 LBS Total system with exhaust oil tank and oil cooler 3 2 Equipment Ignition unit Dual CDI capacitive discharge type Minimum voltage for the ignition systems operating is 9 volts Ignition timing 10 DEG B T D C below 2000r min 23 DEG B T D C over 4000r min Spark plugs HKS SUPER FIRE RACING Electrode spacing 0 7 mm 028 Alternator performance 210W DC at 4000 to 6200 r min 120W at 1750 r ...

Page 9: ...00 r min 3 4 RPM limitations Max permissible r min 6200 r min Max continuous r min 5800 r min Idle r min 1400 to 1750 r min Within 1900 r min if necessary for low vibration 3 5 Fuel consumption With full throttle loaded Consumption max permissible r min 24 L H 6 3 GPH Consumption max continuous r min 16 L H 4 2 GPH Consumption 75 13 L H 3 4 GPH ...

Page 10: ...arts This will vary based on the oil line layout and oil cooler size used Oil level is between 1 2 and 2 3 of oil tank after 3 minutes idling Oil consumption Max 0 1 L h 1 10th quart per hour Oil pressure Min 490 kPa 5 0 kgf cm2 71psi 6200 r min Min 118 kPa 1 2 kgf cm2 17 psi idle r min Oil temperature readings off of the feed line into engine Min 50 Deg C 122 Deg F Max 120 Deg C 248 Deg F Optimum...

Page 11: ...HT probe 3 9 Propeller drive reduction gear Reduction ratio crankshaft to prop shaft 2 58 1 or 3 47 1 Torsional shock absorption is based on progressive cushioning from an axial spring loaded hub with dogs 3 9 1 Propeller mass moment of inertia Max permissible propeller mass moment of inertia 2 58 1 3000 kg cm 2 3 47 1 6000 kg cm 2 3 10 Exhaust gas temperature Max permissible exhaust gas temperatu...

Page 12: ...Operations Manual HKS 700E 11 4 PERFORMANCE CURVE ...

Page 13: ...ement of the throttle lever Turn the propeller by hand check the engine for unusual noises or hard movement 5 2 Starting the engine Parking brake Set or aircraft chocked Fuel shutoff valve OPEN Choke On if necessary Throttle Closed Master switch ON Ignition Both ON Starter Engage Let engine run at approx 2000 r min Oil pressure Check nominal See Sec 3 6 CAUTION z Crank the starter for a maximum of...

Page 14: ...ion and then reduce power slightly to the maximum continuous RPM See Sec 3 3 CAUTION z Engine direction within 20 degrees from vertical of gravitational force direction z Observe RPM oil temperature cylinder head temperature exhaust gas temperature and oil pressure The limits must not be exceeded If the temperatures are moving towards exceeding the described limitations reduce engine power if poss...

Page 15: ...n and restarting in flight Let the engine cool sufficiently Wait for the cylinder head temperature to reach less than 120Deg C 248 Deg F Throttle IDLE Ignitions OFF The in flight re start procedure is the same as on the ground Use choke if necessary ...

Page 16: ...the breather hoses of carburetors The breather hoses must not choke The breather hoses must stay correct position The correct position of end of hose is the place between a spring yoke and side of the float chamber Reattach the engine cowling if equipped With the ignition off turn the propeller by hand and check the engine for unusual noises or hard movement and proper compression Before flight en...

Page 17: ...e magnet of oil drain screw for the metal contamination Change the oil filter Fuel lines check the standoffs safeties leaks and wear Fuel filter check clean Clean the float chamber of the carburetors and clean if necessary Check the ignition harness for damage and tight connections at spark plug cap Air filter check clean Check the mounting of the carburetors and the insulator rubber for cracks Ch...

Page 18: ...pection Carry out the 50 hour check Perform a compression check See Sec 7 3 6 2 3 200 hour inspection Carry out the 100 hour inspection Check the spark plug caps Change if necessary Change the spark plugs Change the fuel filter Change the air filter ...

Page 19: ...filters Protect them against dirt and moisture 6 Coat all the steel engine parts with engine oil Bringing the engine back to operation 1 Remove all the plugs and fasteners CAUTION For longer storage periods the preservation procedures must be performed at least annually 6 4 Winter operation 6 4 1 Care of the electrical system Generally in the beginning of the winter an engine inspection shall be p...

Page 20: ... 50 hour inspection Prevent fuel tank condensation by keeping the fuel tank full when in short term storage drain the fuel tank when not in use for longer periods Avoid temperature differences between aircraft and fuel CAUTION Fuels containing alcohol always carry a small amount of water in solution Temperature changes or an increase of alcohol content may cause water or a mixture of alcohol and w...

Page 21: ...level should be between 1 2 and 2 3rd of the oil tank CAUTION 1 Use only multi grade brand name oils for automobile engines Oil type See Sec 3 6 2 Don t use any aircraft engine oils and or additives 7 2 Air filter For operation in heavy dust conditions clean the air filter at shorter intervals or replace 7 3 Compression test Measure the engine compression using a compression gauge with a recording...

Page 22: ...prox 1 1 2 turn Warm the engine up Keep throttle lever OFF Keep idle revolution of low vibration between 1400 and 1750 r min adjusting both idle stop screws so that the vacuum readings are same Confirm smooth running at idling 7 4 2 Throttle cable adjustment NOTE This adjustment is very important Both throttle valves must start to open at the same time After idle adjustment let the engine run at 2...

Page 23: ... 1 Upper manifold Horizontal manifold MAIN JET MJ 125 130 1 135 140 1 NEEDLE JET NJ 2 7 DIFFUSER CK 10 IDLE JET PK 45 IDLE MIXTURE SCREW 1 1 2 turn JET NEEDLE JN 251 4th groove from top STARTING JET 75 PISTON SB 6 1 Change the MAIN JET when using the fuel with alcohol ...

Page 24: ...hite Spark plugs and carburetor adjustment is correct Velvety black Electrode gap too wide or the mixture is too rich Reduced air intake air filter dirty the proper exhaust gas temperature of engine is not reached Oily The spark plug is not firing or worn cylinder and piston rings Pearly or glazed Wrong type of spark plug or the Spark plug not torqued properly the mixture is a too lean or badly cl...

Page 25: ...of the electrical equipment according to TABLE 2 TABLE 2 EQUIPMENT LOCATION OF MEASUREMENT RESISTANCE VARIATION AC Magnetic White White of 3 phase 0 4ohms 20 stator connector Pulse detector White Red 310 ohms Brown Green Ignition coil Orange center core 0 2 ohms High tension coil 4 9 K ohms ...

Page 26: ...rized by the manufacturer In case of prop strikes or sudden stoppage the engine must be disassembled and the crankshaft must be checked for cracks This is considered a major repair and must be performed by the manufacturer or an approved service center If stoppage of the engine is concealed when ordering a repair or major overhaul the responsibility for the damage and subsequent costs still exists...

Page 27: ...s Check the oil grade Use a top on cold engine quality low friction oil Spark plugs wet from condensation Dry plugs inside and outside Spark plugs wet with fuel over choked Dry spark plugs follow up and overflow of carburetor Correct trouble in the fuel system Float valve dirty or defective Clean or replace valve Carburetor jets blocked Remove and clean the jets Water in carburetor Clean and empty...

Page 28: ...defective parts Carburetor Insulator damaged Check mounting of carburetors and the insulator rubber for cracks 10 3 Engine runs erratic or misfires occasionally Cause Action Spark plug failure Clean plugs inside and outside Replace if necessary Ignition wire breaks down Check ignition wire and replace if necessary Ignition troubles Check complete ignition system and replace parts if necessary Fuel...

Page 29: ...rhaul is necessary Bearings defective If there is metal contamination in the crankcase sump a major overhaul is necessary Intake manifold leaky Tighten all connections of the intake Replace any defective parts Carburetor Insulator damaged Check mounting of carburetors and the insulator rubber for cracks 10 5 The engine does not develop full power Cause Action Ignition trouble Tighten all connectio...

Page 30: ... 7 The engine does not stop immediately Cause Action Idle speed too high Adjust proper idle speed between 1400 and 1750 r min Ignition switch defective Replace the switch Engine overheated Let the engine cool sufficiently Wait for the cylinder head temperature to reach less than 120Deg C 248 Deg F Using fuel with a low octane rating Use fuel with a higher octane rating 10 8 Excessive oil consumpti...

Page 31: ...170 Deg C 338 Deg F Intake manifold leaky Tighten all connections of the intake Replace any defective parts Carburetor Insulator damaged Check mounting of carburetors and the insulator rubber for cracks 10 10 Engine hard to start at low temperatures Cause Action Starting speed too low Preheat the engine Low battery charge Replace battery or recharge High oil pressure During a cold start a pressure...

Page 32: ...ness for damage and tight connections at spark plug cap O O O O 12 Air filter check clean or replace O O O O 13 Check mounting of carburetors and the insulator rubber for cracks O O O O 14 General condition of the exhaust system Check muffler and attaching flanges at exhaust port on cylinder for leakage O O O O 15 Check ignition coils for wear and security of attachment O O O O 16 Check for leaks ...

Page 33: ...operty of HKS 3 Condition to have warrantee work performed You must present to an authorized HKS service center the hard copy of the HKS warrantee registration card and or proof of purchase delivered to the customer from the selling dealer at time of purchase 4 Exclusion are not warranted Normal wear on all items Replacement parts and or accessories that are not genuine HKS parts and or accessorie...

Page 34: ...rantees This warrantee gives you specific rights and you may also have other legal rights which may vary from state to state or province to province Where applicable this warrantee is expressly in lieu of all other expressed or implied warrantees of HKS its distributors and the selling distributor including any warrantee of merchantability or fitness for any particular purpose otherwise the implie...

Page 35: ...irstly operated 8 This warrantee will be effective for all non certified aircraft engines delivered by HKS as of September 1st 1997 9 WARNING This is a non certified aircraft engine the possibility of engine failure exists at all times Do not operate this engine over densely populated areas Do not operate this engine over terrain where a safe power off landing cannot be performed The operating and...

Page 36: ...rtner of the area of the permanent residence of the end user and or in which this non certified aircraft engine is firstly operated within 30 days as of date of purchase 2 No other warrantees and or guarantees than defined in the actual warrantee conditions are made 3 Engine type HKS700E Engine S N Date of purchase Buyer Address Telephone Seller I have read and understood the operations manual in ...

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