DLE 120 User Manual

DLE-120

Operator’s Manual

				Specifications
				Displacement: 120cc 7.32 cu in
				Performance:		12 HP/7,500 RPM
				Idle speed:		1,300RPM
				Ignition Style:		Electronic Ignition
				Recommended Propellers:		26u10, 26u12, 27u10, 28u10
				Spark Plug Type: NGK CM6
				Diameter x Stroke:		(Gap) 0.018in.– 0.020 in. [0.45mm – 0.51mm]
						1.85 in(47mm) x 1.38 in(35mm)
				Compression Ratio: 10.5: 1
				Carburetor: DLE with Manual Choke
				Weight: Main Engine – 5.08lb [2306g]
						Mufflers – 15.6oz [440g]
						Electronic Ignition − 6 oz [170g]
						Engine Mount Standoffs − 1.4 oz [41g]
						Fuel: 87− 93 Octane Gasoline with a 30:1
					Fuel: gas/2-stroke (2-cycle) oil mixture
				™
1			© 2014 Hobbico, Inc. All rights reserved.			DLEG0120 Mnl v2.0

Parts List

(1)DLE-120 Gas Engine with DLE Carburetor

(2)CM6 Spark Plugs with Spare Ignition Wire Springs

(2) Mufflers w/Gaskets

(4) 4x20mm SHCS (muffler mounting)

(1)Electronic Ignition Module w/ Additional Tachometer Lead

(4)25mm Engine Mounting Standoffs

(6)5x50mm SHCS with 4mm Lock Washers & Flat Washers (propeller mounting)

(1)Silicone Pick-up Wire Cover / Ignition Wire Cover

(1)Red Three Pin Connector Lead w/ Pig Tail (for ignition switch)

(2)Three Pin Connector Securing Clips

(1) DLE Decal (not pictured)

Safety Tips and Warnings

●This engine is not a toy. Please place your safety and the safety of others paramount while operating. DLE will not be held responsible for any safety issues or accidents involving this engine.

●Operate the engine in a properly ventilated area.

●Before starting the engine, please make sure all components including the propeller and the engine mount are secure and tight. It is strongly recommended that a screw sealant is used (Great PlanesThreadlocker GPMR6060) during engine installation.

●During the break-in period, it is recommended that the engine be installed on the aircraft or a test stand with an appropriate shock absorber. Otherwise it is probable that vibration could rebound

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back to the engine and serious damages may occur during the break-in period. Break-in should be considered about the first 3-5 gallons you run in the engine.

● For your safety and the safety of others, please do not stand in front of the propeller or inline with the propeller when the engine is running. Keep onlookers away from the running engine, especially small children.

● Always use a balanced spinner and a balanced propeller. An unbalanced spinner or propeller combination will cause high levels of vibration and may cause the propeller shaft to break. Always use a lightweight, high quality spinner on your engine. Heavy spinners could cause the propeller shaft to break. Evenly and securely tighten the spinner and propeller to the engine to prevent them from being thrown off the engine while running.

● Never use a propeller that has hit the ground. Even though it may look good from the outside, it may be cracked on the inside which may cause it to disintegrate while in use. Do not use a nicked, cracked or split propeller.

● Keep foreign objects away from the propeller. Make sure that nothing can be “sucked in” by the propeller.

● Never start the engine on loose gravel or sand.

● Do not attempt to stop the engine by throwing anything into the path of the propeller.

● Do not use silicone fuel line because it will be dissolved by the fuel. Use gasoline approved rubber fuel line. Always secure the fuel line away from the cylinder head. The engine’s heat can damage the fuel line.

● Never touch the engine immediately after a run.The engine will be hot.

● Before transporting your model, remove all the fuel from the fuel tank and fuel lines.

● Always use high-quality oil intended for 2-stroke (2-cycle) engines. It's a good idea to use a petroleum-based 2-cycle motor oil like Lawn Boy All Season - Ashless oil for the break-in period.

● Do not install your throttle servo inside the engine compartment. Doing so could cause radio interference. When practical, install all electronic radio devices at least 12" [305mm] away from the engine.

● The throttle and choke pushrods should be non-metallic.

● If the engine is not to be used for more than a month, drain the fuel tank and remove any fuel from inside the carburetor. Do this

by running the engine at idle until it quits by running out of fuel.

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Keeping gasoline inside the carburetor over an extended period of time will damage the diaphragm valve and clog passages inside the carburetor. Because the carburetor is more complicated than those used in glow engines, keep the fuel clean by using a fuel filter. Use a filter intended to be used with gasoline engines. Metal filters intended for glow engine are too coarse and will not screen out finer particles.

●Always filter your fuel by using an appropriate filter before putting it into the airplane’s fuel tank.

●Gasoline is extremely flammable. Keep it away from an open flame, excessive heat or sources of sparks.

●Do not smoke near the engine or the fuel tank.

●This engine was designed for use in a model aircraft. Do not attempt to use it for any other purpose.

●Always install an ignition system on/off switch on the aircraft used.

●Caution: Running the engine with a lean fuel mixture will cause the engine to overheat and burn the electrode of the spark plugs. Pay close attention to the High-speed Needle adjustment. Running the engine with the proper fuel mixture will make the spark plugs appear yellow at the ignition point.

●For optimum performance please use fresh or recently purchased 87-93 octane gasoline with a 30:1 fuel/oil mixture.

Fuel/Oil Mixing Chart

1 Gallon Gasoline (128 fl oz/3.78L) / 2-Cycle Oil

(4.26fl oz/125.68ml) = 30:1 ratio

●Excessive running of the engine at idle speed can result in carbonized spark plugs.

●Keep the surface of the engine clean to ensure proper heat dissipation. Ensure proper cooling/ventilation around both cylinders with adequate air exhaust.

●To avoid permanent damage to the electronic ignition system, NEVER rotate the propeller on your DLE engine with the electronic ignition system switched on and the plug not installed in the plug cap.

●If you choose to use the optional TX activated Gas Engine Kill Switch (DLEG9205) it is strongly recommended that you install the TX activated kill switch between the on/off switch and the ignition. The on/off switch provides an added safety feature in the event theTX activated kill switch does not function properly.

	This is especially important during the starting sequence as it
	requires the on/off switch to be in the ON position before ignition
4	can occur.

Installation Instructions

Prepare the engine for installation

1. Check to see that all screws and bolts are tight. Check carefully for any cracks, broken or missing parts.Tighten or replace any damaged or missing parts before proceeding.

2. Install the silicone wire cover over the pick-up lead coming from the engine (cut the excess silicone wire cover) and connect the lead to the pick-up lead from the Electronic Ignition Module. Secure the connection with the included three pin connection securing clips.

3. Connect the on/off switch lead to the red connector from the Electronic Ignition Module using the lead from the on/off switch or with the included three pin connector with pigtail. Use one of the included three pin securing clips to secure the connection.

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OPTIONAL

	On/Off Switch		Charge Lead
		(Not included)
			Battery Lead
	Ignition	OPTO Gas Engine Kill Switch	LED
	Battery Lead	(DLEG9205, not included)
		KILL
		SWITCH
			Rx Batt
	Ignition	Rx	Lead
	Ignition Control Switch Wire
		(To On/Off Switch)

ELECTRONIC IGNITION

SYSTEM Tachometer

Lead/RPM Signal

Output

Ignition Wires

(To Spark Plugs)

Pick-Up

Sensor Wire

(To Sensor

On Engine)

OPTIONAL

Tachometer

(DLEG5525, not included)

	4. Connect the ignition module battery to the on/off switch. Any
	4.8-8.4V, 1000mAh and above capacity battery will work well for
		this. Use heat shrink tubing to secure this connection. Optional:
		Install theTX activated gas engine kill switch (DLEG9205) between
		the on/off switch and the ignition as shown above.This is especially
		important during the starting sequence as it requires the on/off
		switch to be in the ON position before ignition can occur. The kill
		switch LED should be installed on the exterior of the aircraft so that
		it’s visible from the front of the aircraft. This is to ensure that the
		person starting the engine is aware that the ignition is armed. If
		properly installed as shown above an illuminated red LED indicates
		that that the ignition is armed.
		5. Install the ignition on/off switch on the aircraft so that it is easily
		accessible.
			6. Install the ignition module and battery
			securely in the airplane forward area.
			It is recommended that a thin piece
			of foam rubber is placed between the
			module and the mounting surface and
6			that Velcro® strap is used to hold the
			module in place.

7.Secure all connections with heat shrink tubing. (not supplied).

8.Install the remaining silicone wire covers over the ignition wires.

9.Install the spark plugs into the cylinders (7-8lbs torque). Do not overtighten.

Installing the DLE-120 on Your Airplane

Note:The DLE-120 must be installed on a minimum 3/8" [9.5mm] plywood firewall.The firewall must be securely glued to the airplane. Use triangle stock and pin the firewall with hardwood dowels to reinforce the firewall glue joints. Never install the DLE-120 onto a firewall thinner than specified because it may fail due to the power of the engine.

Note:The overall length of the engine from the back of the engine mount to the face of the propeller drive hub is 7.32" [186 mm].

1. Use the supplied template (on the back cover of this manual) to drill the engine mounting bolt holes.

2. Install (4) 5mm blind nuts (not included) into the back side (nonengine side) of the firewall. Install the engine to the firewall using

(4) 5x45mm SHCS with 5mm lock washers and flat washers (not included) with the included standoffs. Use threadlocking

compound, such as Great Planes® Pro™ Threadlocker (GPMR6060), on the screws where they thread into the blind nuts.

3. Install the fuel tank in the airframe. Use only 1/8" [3.175 mm] gasoline-safe fuel lines and a gasoline safe fuel tank stopper. One line should go to the carburetor (see page 14, Fuel Inlet) and the other is to be used as a vent (a vent line is simply an open ended fuel line from the fuel tank which exits the engine compartment or the fuselage; most vent lines exit at the bottom of the firewall).You can fill the tank by using the carburetor line as fill line if you have access to it or install a third line to be used as fill line. Installing a third line is the cleanest and easiest way to add fuel. An alternative fueling set up is a 2-line system with aT-fitting approved for gasoline use. Be sure to use a filler plug with either a 2 line or 3 line set-up. It is a good idea to add an extension to the vent line as shown, that goes up and to the rear of the tank.This helps to avoid draining fuel

from the tank when the model is pointed down.

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2-LINE SET UP

Fuel Tank

Clunk Line

Drain/Vent Pressure Relief Line

Route to top-front of fuel tank interior, to prevent siphoning.

Supply Line				Make connection line
to T-Fitting	Carb			between T-Fitting and
				Carburetor as short
				as possible.

T-Fitting
Fuel fill line	Filler Cap
	or Plug

This line must be extended to exit the bottom of the aircraft.

3-LINE SET UP

Fuel Tank

Clunk Lines

Fuel fill line

Plug

Drain/Vent Pressure Relief Line

Route to top-front of fuel tank interior, to prevent siphoning.

Carb

Supply Line to Carburetor

This line must be extended to exit the bottom of the aircraft.

4. Install the throttle servo at least 12" [305mm] away from the engine. Make sure that you get the carburetor’s full range of rotation with your servo travel. Be sure to use a non-metallic linkage (as shown below). A high torque metal gear servo is recommended to operate the throttle. Install a ball link and lock

nut on the throttle arm (available at your local hobby shop). Next, install the linkage from the servo to the throttle arm. Removal of the throttle return spring is optional. Removing the spring reduces the load on the throttle servo, but also bypasses a necessary safety feature. Remove the throttle return spring at your own risk.

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