DLE 40 User Manual

DLE

Operator’s Manual

Specifications

Displacement:

Performance:

Idle speed:

Ignition Style:

Recommended Propellers:

Spark Plug Type:

Diameter x Stroke:

Compression Ratio:

Carburetor:

Weight:

™

40cc 2.44 cu in

4.8 HP/8,500 RPM 1,5 00 RP M Electronic Ignition 19x8,19x10,20x8,20x10 NGK CM6 (Gap) 0.018in.– 0.020 in. [0.45mm – 0.51mm]

1.26 in(32mm) x .98 in (25mm)

10.5: 1 DLE with Manual Choke Main Engine – 2.58 lb [1450g] Mufflers − 7.76oz [110g] Electronic Ignition − 6 oz [170g] Engine Mount Standoffs − 3.06 oz [87g] 87− 93 Octane Gasoline with a 30:1 gas/2-stroke (2-cycle) oil mixture

Fuel:

Parts List

(1) DLE-40 Gas Engine with DLE Carburetor (2) CM6 Spark Plug with Spare Ignition Wire Springs (2) Mufﬂ er w/Gaskets (4) 4x20mm SHCS (mufﬂ er mounting) (1) Electronic Ignition Module w/ Additional Tachometer Lead (4) 25mm Engine Mounting Standoffs (4) 4x30mm 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

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 Planes Threadlocker 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 back to the engine and serious damages may occur during the break-in period. Break-in should be considered about the ﬁ rst

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. 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 ﬁ lter. Use a ﬁ lter intended to be used with gasoline engines. Metal ﬁ lters intended for glow engine are too coarse and will not screen out ﬁ ner particles.

● Always ﬁ lter your fuel by using an appropriate ﬁ lter before putting

it into the airplane’s fuel tank.

● Gasoline is extremely ﬂ ammable. Keep it away from an open

ﬂ ame, 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 the TX 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 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.

On/Off Switch

(Not included)

Charge Lead

Battery Lead

Ignition

Battery Lead

OPTIONAL

Ignition

Ignition Control Switch Wire

ELECTRONIC IGNITION

SYSTEM

Ignition Wires

(To Spark Plugs)

OPTO Gas Engine Kill Switch

(DLEG9205, not included)

KILL

SWITCH

(To On/Off Switch)

Pick-Up

Sensor Wire

(To Sensor

On Engine)

Rx Batt

OPTIONAL

Lead

Tachometer

Lead/RPM Signal

Output

Tachometer

(DLEG5525, not included)

LED

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 the TX 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 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-40 on Your Airplane

Note: The DLE-40 must be installed on a minimum 3/8" [9.5mm] plywood ﬁ rewall.The ﬁ rewall must be securely glued to the airplane. Use triangle stock and pin the ﬁ rewall with hardwood dowels to reinforce the ﬁ rewall glue joints. Never install the DLE-40 onto a

ﬁ rewall thinner than speciﬁ ed because it may fail due to the power

of the engine.

Note: The overall length of the engine from the back of the engine standoffs 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 ﬁ rewall. Install the engine to the ﬁ rewall using (4) 5x45mm SHCS with 5mm lock washers and ﬂ at 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 gasoline approved fuel tank and lines and a gasoline safe fuel tank stopper. One line should go to the carburetor 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 ﬁ rewall).You can ﬁ ll the tank by using the carburetor line as ﬁ ll line if you have access to it or install a third line to be used as ﬁ ll 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 a T-ﬁ tting approved for gasoline use. Be sure to use a

ﬁ ller 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.

Fuel Tank

2-LINE SET UP

Supply Line

to T-Fitting

Carb

Make connection line

between T-Fitting and

Carburetor as short

as possible.

Clunk Line

Drain/Vent Pressure Relief Line

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

3-LINE SET UP

Fuel Tank

Clunk Lines

Fuel fill line

Plug

T-Fitting

Fuel fill line

This line must be extended

to exit the bottom of the aircraft.

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.

Filler Cap

or Plug

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.

+ 16 hidden pages

DLE 40 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual