Owners manual

Version 1.4/2019
This version replaces the previous versions with lower numbers.

helvenco AG
Buchmattstrasse 46, 3400 Burgdorf, Switzerland
www.helvenco.com / [email protected] / +41 34 426 66 66

1
 Index

Page
3 Important terms
4 System installation
5 System dimensions
6-9 Engine preparation
10 Wiring diagram
11 Fuel pump installation
12-14 Exchange of PTO pulley
15 Clutch drum position
16-18 Exchange of propeller pulley
19 Belt tension
20-21 EFI installation guide
22-23 Start-up
24-25 Maintenance & Oil change
26 Speed Conversion table & Reset ECU DTC codes
27 Goodwill and warranty regulations
28 Voucher

2
 Important terms

helvenco AG assumes that the user has read, understood and accept the terms below
before operating the engine. They are helpful for a better understanding of the product
and useful to prevent and to minimize the risks.

helvenco AG only supplies OEM’s and specialized aviation engine distributors that have
sufficient technical knowledge to ensure the AERO products of helvenco AG are installed and
serviced/repaired correctly.

helvenco AG emphasizes that the AERO product line is not certified and is made for
experimental aircraft only. It is important the user understands that the engine can stall/or break
with an emergency landing as a result; this can occur to injuries or death! The AERO1000/1500
should be used in open spaces only and during daylight. This product is neither covered by
product nor public liability.

Who flies with a paramotor/experimental aircraft/ULM or even just starts it, automatically
assumes all the risks inherent to these sports and all the responsibilities for damages to yourself
or to third parties, accidents, injuries or death caused by using such products.
To fly with a paramotor/experimental aircraft/ULM always needs great attention. Be aware that
you fly at your own risk; always check if your machine is in good condition before use.

helvenco AG doesn’t assume any responsibility for damages caused by poor servicing or wrong
assembly.
Any modification on the standard AERO product made by any party other than helvenco AG can
make the product dangerous to be used and is on own risk.
Wrong mounted, bad balanced or unproportioned propellers can lead to serious damage of the
AERO1000/1500 products.

The engine can’t be used for acrobatic maneuverings.

Don’t use the AERO1000/1500 in bad weather conditions such as rain or snowfall.

Not limitative list of possible reasons leading to premature engine failures:

• Engine modifications not approved by helvenco AG.

• Carelessness, lack of servicing, accidents, installations or wrong maintenance.
• Accidental falls or engine drop or drop of its components.
• Improper use or misusage of the engine.
• Assembly of parts or components not specified for the engine use.
• Engine overheating or stop after long usage, beyond the term indicated by helvenco AG.
• Use of improper petrol or oils, presence of dirty parts or foreign bodies in the engine.
• Permanent/ too long running into the rpm limiter.
• Engine or parts deterioration because of improperly storage.
• Wrong engine assembly, including the use of not original helvenco AG parts.
• Damages to the engine caused by foreign bodies.
• Usage of wrong spark plugs.
• Not respecting the manual in general.

3
 System installation

The system comes with 8 pre-installed silent blocks on the front plate. These are the fixation
points to install the AERO1000 system on your vehicle! You can change the position of the silent
blocks on the front plate. Below you find the dimension sheet!
The OEM must use an optional backup system (Ex. steel tie-wraps or tension strap) between
the AERO1000/1500 system and the frame it is attached to. If not, the user must contact the
OEM.

4
System dimensions

5
Engine preparation

Remove all plugs:

-Intake port
-Exhaust port
-Breather tube

6
Engine preparation

Place the system on the table as

shown.

Install the 2 feet and the exhaust

manifold.

Screw on the 2 self-locking M6 nuts.

Just tighten them a little bit so you can
still turn the manifold by hand.

Tighten them correctly after

installation of the exhaust muffler.

7
Engine preparation

Install the exhaust muffler.

Connect the 2 cradles with the silent

blocks below the engine mounts and
push the manifold into the exhaust
muffler.
Tighten all 4x M6 lock-nuts

Add the 2 exhaust springs

Finally tighten the 2 M6 lock-nuts at

the engine exhaust port.

8
 Engine preparation

Install the other 2 feet. Now you can

place the engine upright.

Once the engine is installed on the

frame you can remove the feet.

We have prepared installation points for the start/stop switch, the starter relais
and the ECU. You see them on the photos above. They are not installed!
Depending to the installation setup you have the choice to go to our positions or
to your own installation.

9
Wiring diagram

10
 Fuel pump installation

The fuel pump isn’t self-bleeding!

Pump and all fuel hoses must be filled with fuel before running. Else the pump
gets damaged.

The pump must be installed below the fuel tank in the shown orientation!
To avoid engine stall, Port C must be higher or equal level with Port B!

Only use the quick release connectors that came along with the fuel pump.
The pump creates 2,5bar on the pressure line Port C! Only use the supplied
pressure hose and secure it on both sides with hose clamps to the connectors.

11
Exchange of PTO pulley

Unbolt the M8 self-locking nut

(Don’t remove)

Remove the M8 self-locking nut at the

back of engine back plate.

12
 Exchange of PTO pulley

Release the belt tension by moving

#1 the belt tensioner lever.

Remove the circlip and the distance

shim from the PTO shaft.

Remove all 6x M6 screws from the

PTO support plate.

ATTENTION!
Hold the distance sleeves when
remove the 6x M6 screws else the
#2 will drop!

At re-installation of the PTO plate:

For correct outlining, always
tighten first screw #1 & #2 before
all others!

Remove the PTO support plate incl.

belt tensioner.

Remove the belt.

13
Exchange of PTO pulley

Remove the circlip and the distance

shim from the PTO shaft.

Remove the pulley and add the new

one.

ATTENTION! For correct belt

alignment mount the offset at the
pulley to engine side.
Always put anti-seize grease or
copper grease on the PTO shaft
before adding the pulley and PTO
plate.

Re-mount distance shim and circlip.

Install the PTO support plate inclusive

the belt tensioner.

Add the 6x M6 screws inclusive its

distance sleeves.

Fit the M8 self-locking nut at the back

of engine back plate.

Tighten the 6x M6 with following

torque: 10Nm / 7,37 ft-lb

14
Clutch drum position

For correct alignment of the clutch

drum use a screw driver and pull out
the PTO shaft as shown.
It should easily move ± 0,5mm / 0,02
inches.

Now you can add the distance shim

and the circlip.

15
Exchange of propeller pulley

Remove the clip, unbolt the M12 self-

locking nut.
Remove washer and the black
pressure bush.

Now it is possible to remove the

complete propeller hub from the shaft
by pulling.

16
Exchange of propeller pulley

Remove the circlip and the distance

shim on the back of the propeller hub.

Attention! Circlip is curved; the

circlip must give an axial force to
the shim!
(If wrong assembled the circlip is
loose)

Push the propeller pulley away from

the hub.

Now you can exchange the pulley.

ATTENTION:
Remove the 6 rubbers from the old
pulley and install them into the new
one.
Lubricate the rubbers and the bolts
before assembly by using white
grease.

Push the new pulley on the hub!

The bolts must be positioned into
the rubbers!

Re-mount the distance shim and the

circlip.
Ensure the circlip is correctly
fixated into the groove!

17
Exchange of propeller pulley

Push the propeller hub back on the

propeller shaft.
Use white grease to lubricate the
inner ring of the oil seal before
mounting.

ATTENTION:
Don’t forget to install the black
distance sleeve into the hub before
adding the shim and the M12 self-
locking nut.

Tighten the M12 with following torque:

20Nm / 15 ft-lb

Add the clip

18
Belt tension

Place the M8 self-locking nut at the

back of engine back plate. Don’t
tighten it yet.

Use a screw driver and place it into

the tensioner lever as shown.

Push the lever down to tighten the

belt. (The tension is OK when the belt
in the center between both pulleys
can be twisted between 90° & 45°)

Once the belt tension is set tighten

the M8 lock-nut.

Remove the screw driver and tighten

the M8 bolt with the self-locking nut
on the back plate.

Tighten the M8 with following torque:

24Nm / 17,7 ft-lb

19
EFI installation guide
Push the throttle body on the intake
port and tighten the clamp. (Use the
clamp from the carb rubber)

Put on the air filter on the throttle body

and use the supplied hose to connect
the engine breather tube with the air
filter.

Cut the tube to correct length.

ATTENTION: Be sure there is no

blocking in this breather tube to
avoid engine failure!

Connect the engine ground cable to

the engine or the aluminium frame.

Connect the water temperature

sensor.

Connect the crank trigger sensor.

20
EFI installation guide

Connect the generator stator to the

wiring harness.

It’s absolutely necessary to have a

full equipped generator containing
all 16 magnets. (Otherwise the battery
will not charge what will cause the
engine to stop)

Connect the injector nozzle, throttle

position sensor, MAP sensor and the
ignition coil to the wiring loom.

Install the ignition coil as shown.

Use the M6x40mm screw and tighten it
with following torque: 10Nm / 7,37 ft-lb

21
 Start-up

OIL:

Break-in: Fill in 0,9l / 0,23 gal

helvenco W-001 racing oil 0W30

Note: To avoid overfill, it is better to

start with 0,7l / 0,18 gal and add oil
after first idle run when necessary.

Normal use: See service plan

Coolant:

Fill the radiator with ± 0,7l / 0,18 gal

of antifreeze coolant.

Fuel:

Use unleaded fuel with minimum

RON 95 octane or alternative Avgas
100LL
Battery:

Only use 12V lead batteries with minimum 4Ah! Ideally we recommend a
12V-8Ah (type: YTX9-BS) or similar!

Knowledge:

Although the battery is charging during engine run, it is recommended to charge

it before every flight (Reason: The battery always discharge itself slowly)

First start (after oil fill):

Starting the engine is done by placing the metal switch in the middle position and
wait for 5 seconds to allow the pump to build up sufficient fuel pressure. Then
proceed pushing the switch until the engine runs. If it is new (and after each oil
service) let it idle run (DO NOT REV IT!) for about 15 seconds; then turn it off and
check the oil level again.

In case the oil level is not slightly above the middle of the oil show glass, add
extra oil and repeat the previous action.

22
 Start-up
Slightly too much oil in the engine isn’t a problem; in this case the engine will
eject some oil by the breather tube into the air filter. Although excess amounts of
oil must be removed! Practical: if the oil is hot, the oil level should never pass the
upper edge of the oil inspection glass. (It is important that an air bubble stays
visible at the upper edge.) If this is not the case, then remove the excessive oil
until the reference level is reached (see picture below).

Important: Check oil before every flight; too less and excessive oil will both
lead to massive engine failure!

Max. oil level warm

Min. oil level warm

Oil drain plug

The cooling system is self-venting. However, it is recommended to check the

radiator’s surface during warm up in order to check if both, upper and lower parts
of the radiator, are heating simultaneously.

During load(flight), the ideal cooling water temperature should be:

• Summer: between 60°C & 75°C or 140°F & 165°F
• Winter: between 75°C & 90°C or 165°F & 195°F

If the engine temperature is too low, cover the radiator in such a way that you
achieve to run it within the above mentioned temperature range.

Break-in the engine during 3 hours.

23
 Maintenance & Oil change
The maintenance of the ’’AERO1000” is substantial for the lifespan of it.
If maintenance is carried out incorrectly or insufficiently the longevity of the
engine might be reduced; therefore a basic mechanic knowledge is required.
So if there are points which are not clear, always contact your local dealer.

Oil change: 1. Remove both oil plugs, engine

front & oil tank, and drain oil.
Clean the magnets of the oil
plugs end. Note: In case you
observe excessive wear contact
your dealer.

Important! DO NOT drain oil via

the oil filter screen.

2. Remove injector cable and spark-

plug cap.

3. Press starter switch to pump oil

from active chamber to passive
oil chamber (± 100ml) so the
remaining oil can run out.

4. Remove oil screen to clean.

5. Remount both oil screen and oil

drain plugs and tighten these with
26Nm / 19,5 ft-lb.

Important: Be careful not to

damage the oil screen by hitting
the internal suction tube inside
the passive oil chamber!

6. Fill in oil confirm the explanation

on page 18 of this manual.

7. Re-install injector cable and

spark-plug cap and start the
engine.

8. Control the oil level conform the

explanation on pages 18 & 19 of
this manual.

24
0

Service plan for engine AERO1000

Every after all all 500

Maintenance works
use 3 hours 25 hours 100 hours hours
Check all bolts conform to the technical sheet •
Throttle smooth to full and return to idle,
•
idle must hit stop
Spark plug cap all the way in and tight •
Visual control on leakage (fuel, coolant and oil) •
Check the condition of the frame silent blocks / belt
•
and control belt tension
Check the condition of the exhaust system (springs and
•
cradles)
Oil change ZDDP rich (break-in) oil type helvenco W-001 •
Oil change 0,9l Mobil1 FS 0W-40 full synthetic engine oil •
Oil filter cleaning • •
Check magnet at drain plug for magnetic debris • •
Check valve clearance conform to the technical sheet • •
Check wear of camshaft and chain-wheel(s) •
Replace spark plug and exhaust springs •
Replace air filter and oil filter screen •
Remove and clean out external oil tank •
Optical check of the complete engine incl. exhaust
•
silencer and primary tube
Replace the 6 shock absorber rubbers in propeller hub •
Replace clutch friction plates and check drum condition •
Change drive belt •
Complete engine re-build (AP500) at the local dealer •
Recommended Flat Rate Time (1 FRT = 10min) 1 3 3 9 45

This service plan can only be used as a guideline and is not binding. Although it is based on the technical
experience of the manufacture and can be altered at any moment.
All parts defined as “wear and tear” such as clutch, belt, drive train bearings, rubbers and air filter etc. are not part
of the service schedule and should be replaced when necessary.
Above listed summary is not limitative.
Note: In case of significant power loss, stop the engine ASAP and contact your local dealer.

25
 Speed Conversion table

Engine rpm Aera of maximum

Propeller pulley PTO pulley Ratio
7000 7500 8000 8500 9000 9500 10000 Torque
50 4,20 1667 1786 1905 2024 2143 2262 2381
52,5 4,00 1750 1875 2000 2125 2250 2375 2500
210 55 3,82 1833 1964 2095 2226 2357 2488 2619
58,25 3,61 1942 2080 2219 2358 2496 2635 2774
61,75 3,40 2058 2205 2352 2499 2646 2793 2940
Propeller speed
50 4,60 1522 1630 1739 1848 1957 2065 2174
52,5 4,38 1598 1712 1826 1940 2054 2168 2283
230 55 4,18 1674 1793 1913 2033 2152 2272 2391
58,25 3,95 1773 1899 2026 2153 2279 2406 2533
61,75 3,72 1879 2014 2148 2282 2416 2551 2685

Reset ECU DTC codes

When a sensor or its connection fails, a DTC (Diagnostic trouble code) is written into the ECUs memory.
This error code can create mal behaviour of the software, therefore it can be helpful to do the following procedure:

1. Turn on the ignition by moving the start witch into the middle position.
The fuel pump should run now for 5 sec. if not check if ECU is connected!
2. Wait 5 seconds before to go to the next action!
3. Turn ignition off
4. After 5 seconds move start switch 3 times as follow:
• Ignition on/off + on/off + on/off
5. Wait 10 seconds
6. Ignition “On”
7. Wait 5 second to start.

This is just a reboot of the ECU, the mapping will not be removed or erased!

26
 Goodwill and warranty regulations

What concerns the engine:

The helvenco250 race engine is developed for national and international racing purposes only; it is a high-
performance product, even if it’s solely used in recreational activities.
From this point of view, the company helvenco AG declares that the race engine and all belonging genuine spare
parts are not covered by any warranty even if the engine has been rebuilt or maintained by an authorised dealer
(Also the service plan is no warranty agreement and is not mandatory, so the service times and intervals can only
be used as a guideline towards the customer).

Although, in case of damage, every customer has the right to claim a goodwill request within the first 6 months
following the date of invoice. To activate the possibility for goodwill the client must fill in and return the voucher:
”Warranty and goodwill regulation read confirmation” immediately after purchase to helvenco AG.
This document can be found back on the last page of this manual.
Note that the official invoice with corresponding engine number must also be included.

We also point out that the run time of the engine is not determining for the goodwill decision because it can’t be
checked by helvenco AG. (So even if it ran only 10 minutes, past 6 months goodwill requests will be invalid).

Once the goodwill request is accepted we can go to the next step. Here it must be clear that only helvenco AG is
authorised to recognize an assembling or material defect and this in all cases. For verification purposes, the engine
must stay completely closed and must contain the oil that was used when the problem occurred.

Engines that are modified, tuned and/or contain non-genuine spare-parts will be disregarded.

What concerns the AERO1000 components:

What concerns the AERO1000 cage we can offer you a warranty of 12 months starting from the date of purchase
on condition the end user has signed and returned the voucher with the original invoice in addition to helvenco AG.
It’s must be clear this warranty is limited to the cage and his components only and not to the engine!

In both cases, engine goodwill and AERO warranty, the coverage is limited to the spare parts needed to repair it.
Labour costs, oil, freight costs (go and return) and eventual custom clearance will be charged to the customer.

If clear that the damage is caused by improper use/handling, wrong installation/assembly, accidents or lack of
servicing by the user, helvenco AG will refuse all warranty/goodwill request and an extra cost of CHF 250,- for
inspection will be charged if the client decides not to rebuild it.

Excluded are all wear and tear parts (ex. the clutch and its components, the spark plug, all components made of
rubber or silicones, belts and bearings etc.)

Note that helvenco AG reserves itself the right to refuse any goodwill request/warranty claim without notice; this
decision can’t be contested by the customer.

27
 Voucher
Warranty and goodwill regulation read confirmation

Purchasing date (invoice):

Customer (first & last name):

Signature:

Dealer:

Engine number:

This document must be sent to helvenco AG within 5 days following the date of purchase. By absence of this act, no goodwill or warranty
request will be granted.

helvenco AG, Buchmattstrasse 46, 3400 Burgdorf, Switzerland

Phone. +41 34 426 66 66 Fax. +41 34 426 66 69
E-mail: [email protected]

28