CSGI600 Engine Installation & Testing Teaching Video Series—Installation Video Before Testing

Sep. 14, 2023

Welcome to the CSGI600 engine installation and testing teaching video series. In this episode, we will introduce the installation of the engine on the test bench, electrical and oil circuit connections, and sensor calibration.


Preparation before engine installation

Install the engine and electrical oil circuit on the test bench

(1)Engine Installation

1. Install the CSGI600 engine on the mounting base at the front end of the test bench, adjust the engine position to align the engine mounting pillar hole with the mounting seat hole on the test bench, and tighten the connection by using matching bolts.


Attention: If the engine undergoes durability testing (continuous working time exceeding 6 hours and cumulative working time exceeding 30 hours), the fastening bolts should be coated with medium and low strength thread sealant to prevent loosening of the bolts.


2. Check and tighten the four bolts connecting the engine base to the mounting studs.


 Engine installation completed


(2)Spark plug installation

3. Install the spark plug


4. Remove the dust plug from the spark plug installation hole and perform preliminary installation of the spark plug.


5. Adjust the torque value of the torque wrench to 12 N * m.


6. Using a torque wrench to tighten the spark plug


Spark plug installation completed.


(3)Installation of exhaust funnel

7. Install the engine exhaust pipe and tighten it with special gaskets and matching bolts.


8. Insert the exhaust temperature sensor connector into the interface on the same side.


9. The other side installation method is the same way to install.


Installation of exhaust funnel completed.


(4)ECU and circuit installation


10. Install the ECU main control box and paste 3M double-sided adhesive on the back of the ECU main control box.


Attention: The adhesive area of 3M double-sided adhesive needs to be cleaned with alcohol and a wiping cloth to ensure the secure installation.


11. Install the ECU on one side of the main support plate of the test bench.


Attention: The installation of ECU should be as far away from the collection motherboard of the test bench as possible to avoid interference with data collection.


12.  Bus interface for connecting ECU


13. Connect the "ENGINE" connector of the ECU output line to the engine control interface.


14. Tighten and connect the engine ground wire to the engine housing terminal.


(5)Installation of ignition coil assembly


15. Install the ignition coil assembly


16. Install the high-voltage cap of the 4-way ignition coil assembly onto the spark plug and press it into place.


17. Connect the plug of the ECU outlet to the ignition coil.


18. Install and fix the ignition coil assembly onto the mounting base of the test bench.


Attention: The connection of the circuit and oil circuit should avoid contact with the engine exhaust pipe to prevent burns or danger.


Installation of ignition coil assembly completed.


(6)Installation of starting card and circuit.


19. Place the starter card on the mounting plate at the top of the test bench.


20. Secure with ties.


21. Connect and tighten the starting card to the three-phase wire of the engine starting motor according to the joint markings S, R, and T.


22. Seal the joints with insulating tape to prevent leakage.


23. Secure with ties.


24. Connect the starter motor control line connector to the engine starter motor control interface.


25. Connect the starting switch wire to the electric starting switch. The green button represents the electric starting switch button, and the line connection must be in a path state when pressed, and an open circuit state when popped up.


Start card and circuit installation completed.


(7)Oil circuit connection of the Engine:


26. Install the oil circuit assembly


27. The inlet of the oil circuit is connected to the outlet of the fuel tank.


28. Connect the return port of the oil circuit to the inlet of the fuel tank.


29. Secure the fuel pump with a tie.


30. Connect the oil supply port of the oil circuit to the engine oil inlet port.


31. Connect the ECU outlet "oil pressure sensor" connector to the oil pressure sensor interface.


32. Oil circuit installation completed.


33. At this point, all engine circuits and oil circuits are connected.


Attention: The connections of the circuit and oil circuit should be kept loose with the engine to avoid dragging and causing inaccurate test data on the test bench.


(8)Propeller Installation


34. The installation of the propeller should be kept the heading on the propeller consistent with the aircraft's heading.


35. Assemble by using matching installation bolts and propeller pads, and tighten the bolts in sequence.


Attention: When tightening the bolts, tighten them in stages in a diagonal and clockwise direction.


Propeller installation completed.

Sensor Calibration Method


(1)Power on the test bench


36. Connect one end of the test bench adapter to the test bench and the other end to a 220V power socket.


After powering on, when you hear "drip, drip, drip", the indicator light changes from yellow fast flashing to blue slow flashing, indicating that the device has successfully powered on.


Connect the network port end of the data cable to the test bench.


Connect the USB end of the data cable to the computer, and the device emits a "beep" sound.


The software automatically connects successfully.  (if it is the first time to connect the software, you need to manually select the port com in the software to connect.)


(2)Calibration of Photoelectric RPM Sensors


37. pply reflective stickers to the position where the photoelectric sensor beam is focused on the propeller, rotate the blade, and apply reflective stickers to another blade.


Note: The number of photoelectric stickers to be pasted needs to be set in the software.


38. Move the beam of the photoelectric sensor away from the propeller and aim it at the non sensing surface (air).


39. Open the sensor debugging cover, press the SET button once, and the SET value will be displayed on the sensor.


40. Move the beam of the photoelectric sensor onto the reflective sticker of the propeller.


41. Press the SET button again to complete the setup and close the sensor debugging cover.


Photoelectric RPM sensor calibration completed

(3)The instruction of Temperature Sensor


42. The engine test bench adopts an infrared detection temperature collection method, aligning the mirror surface of the infrared sensor parallel to the root of the engine cylinder block at a distance of 1-3cm. Pay attention to keeping the mirror clean and avoiding oil stains from blocking it.


Temperature sensor adjustment completed.


CSGI600 engine installation, electrical, oil circuit connections, and sensor calibration instruction have been completed.


Thank you for watching this engine testing and installation video. If you want to know more information, please click on the image below to get more details:

CSGI600 Engine Installation

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