DLE 61 User Manual

DLE-61

Operator’s Manual

Specifications

Displacement: 60cc 3.66 cu in Performance: 6 HP/7,500 RPM Idle Speed: 1,400RPM

Ignition Style: Electronic Ignition

Recommended Propellers: 22x10,23x8,23x10,24x8 Sparkplug Type: NGK CM6

(Gap) 0.018in.– 0.020 in. [0.45mm – 0.51mm] Diameter × Stroke: 1.85 in(47mm) x .98 in(35mm)

Compression Ratio: 10.5: 1

Carburetor: DLE with Manual Choke

Weight: Main Engine – 2.8 lb [1273g] Mufflers – 3.9oz [110g] Electronic Ignition – 3.9 oz [110g]

Engine Mount Standoffs – 4.5 oz [128g]

™Fuel: 87− 93 Octane Gasoline with a 30:1

gas/2-stroke (2-cycle) oil mixture

1	®	DLEG0061 Mnl
	© 2014 Hobbico, Inc.

Parts List

(1)DLE-61 Gas Engine with DLE Carburetor

(1)CM6 Spark Plug with Ignition Wire Spring

(1)Muffler w/Gasket

(2)5x20mm SHCS (muffler mounting)

(1)Electronic Ignition Module w/ Additional Tachometer Lead

(4)68mm Engine Mounting Standoffs

(8)5x20mm SHCS with 5mm washers (engine mounting)

(4)5x40mm SHCS with 5mm 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

2	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 first 3-5 gallons you run through the engine.

●For your safety and the safety of others, please do not stand in front of or in line 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 and propeller combination will cause high levels of vibration and may cause the propeller shaft to break. Always use a lightweight spinner on your engine. Lightweight spinners are considered to be those with a cone wall of 1mm or less. Heavy spinners could cause the propeller shaft to break. Securely tighten the spinner and propeller on the engine to prevent it 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.

●Make sure the fuel line is well-secured to the engine and to the fuel tank so that it won’t come off in flight.

●Do not use silicone fuel line because it will be dissolved by the fuel. Use gasoline approved vinyl or neoprene 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. Install all electronic radio devices at least 305mm [12"] away from the engine.

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

●In case the engine is not to be used for more than a month, drain

3	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 filter. Use a filter intended to be used with gasoline engines. Metal filters intended for glow engines 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 gas mixture will cause the engine to overheat and burn the electrode of the spark plug. Pay close attention to the High-Speed Needle adjustment. Running the engine with the proper gas 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 gas/oil 2-stroke (2-cycle) mixture.

GAS/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 a seriously carbonized spark plug.

●Keep the surface of the engine clean to ensure proper heat dissipation.

●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 optionalTX activated gas engine kill switch (DLEG9205) it is strongly recommended that you install the TX activated kill switch between the with a manual on/off switch and the ignition. The manual 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 manual on/off switch to be in the ON position before ignition can occur.

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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 motor (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 connector securing clip.

3. Connect the manual on/off switch lead to the red connector from the electronic ignition system using the lead from the kill switch or with the included three pin connector with pig tail. Use one of the included three pin securing clips to secure the connection.

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4. Connect the ignition module battery to the kill 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 manual on/off switch and the ignition as shown above.This is especially important during the starting sequence as it requires the manual 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 through the cowling or the fuselage.

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 thatVelcro® strap is used to hold the module in place.

7.Install the remaining silicone wire cover over the ignition wire.

8.Install the spark plug into the engine head (7– 8 lbs torque). Do not overtighten.

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Switch (Not included)

Charge Lead

Battery Lead

	Ignition	OPTO Gas Engine Kill Switch	LED
	Battery Lead	(DLEG9205, not included)
		KILL
		SWITCH
	Ignition	Rx	Rx Batt
			Lead

Ignition Control Switch Wire (To On/Off Switch)

ELECTRONIC IGNITION

SYSTEM

		Pick-Up
	Ignition Wire	Sensor Wire
		(To Sensor
	(To Spark Plug)
		On Engine)

Tachometer Lead/

RPM Signal Output

	OPTIONAL	Tachometer
		(Not included) DLEG5525

	Installing the DLE-61 on Your Airplane
		Note: The DLE-61 must be installed on at least a 9.5mm [3/8"]
		thick 5-ply 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-61 onto a firewall thinner than specified because it may fail
		due to the power of the engine.
		Note:The length of the engine from the back of the engine mount
		stand offs to the propeller drive washer is 9.44" [240 mm].
	1. Use the supplied template (on the back cover of this manual) to
		drill the engine mounting bolt holes.
			2. Install the standoffs to the
			firewall using (4) 5x20mm SHCS
			with 5mm lock washers (not
			included) and 5mm washers from
			the back side and through the
			firewall into the standoffs. Use
			threadlocking compound, such as
	Great Planes® Pro™ Threadlocker (GPMR6060), on the screws. Next
		install the DLE-61 to the standoffs using the included (4) 5x20mm
		SHCS with 5mm washers. Be sure to also use threadlocker when
7		mounting the engine to the standoffs.

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 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 a T-fitting approved for gasoline use. Be sure to use a filler plug with either a 2 line or 3 line set-up.

2-LINE SET UP

3-LINE SET UP

Fuel Tank

Clunk Line

Drain/Vent Pressure Relief Line

Route to top-front of fuel tank interior, to prevent siphoning (2-Line Set-up)

Fuel Tank

Clunk Lines

Fuel fill line

Plug

	Supply Line					Make connection line
	to T-Fitting
		Carb				between T-Fitting and
						Carburetor as short
							as possible.
	T-Fitting
							Filler Cap
		Fuel fill line
							or Plug

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.

4. Install the manual on/off switch on the aircraft so that it is easily accessible from outside the plane.

5. Install the throttle servo at least 305mm [12"] 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.

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