DLE 85 User Manual

DLE

Operator’s Manual

Specifications

Displacement:

Performance:

Idle Speed:

Ignition Style:

Recommended Propellers:

Sparkplug Type:

Diameter × Stroke:

Compression Ratio:

Carburetor:

Weight:

™

84.88cc 5.18 cu in

8.5HP/7,500 RPM 1,5 00 RP M Electronic Ignition 25×10, 26×9, 27×8 NGK CM6 (Gap) 0.018in.– 0.020 in. [0.45mm – 0.51mm]

2.05in(52mm) × 1.57in(40mm)

9.5: 1 DLE with Manual Choke Main Engine – 68oz [1930g] Muffler – 8.8oz [250g] Electronic Ignition – 4.58oz [110g] Engine Mount Standoffs – 28oz [454g] 87− 93 Octane Gasoline with a 30:1

Fuel:

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

Parts List

(1) DLE-85 Gas Engine with DLE Carburetor (1) CM6 Spark Plug with Ignition Wire Spring (1) Mufﬂ er w/Gasket (1) 30mmx120mm Exhaust Tube with Clamp (2) 5x20mm SHCS (mufﬂ er mounting) (1) Electronic Ignition Module w/ Additional Tachometer Lead (4) 68mm Engine Mounting Standoffs (1) Isolation Engine Mount (8) Isolation Mount Grommets (4) Isolation Mount Spacers (5mmX9mmx15mm) (8) 5x25mm SHCS (engine mounting) (4) 5x20mm SHCS (engine mounting) (4) 5x10mm Washers (4) 5x19mm Flat Washers (6) 5x50mm 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 (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

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.

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 ﬂ ight.

● 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.

Break-in should be considered about the ﬁ rst 3-5

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

●

In case 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 engines 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 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 optional TX 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 the TX 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.

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 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.

4. Connect the ignition module battery to the kill switch. Any

4.8-8.4 V, 1000 mAh 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 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 that Velcro® 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.

Switch (Not included)

Charge Lead

Battery Lead

ELECTRONIC IGNITION

Ignition Wire

(To Spark Plug)

Ignition

Ignition Control Switch Wire (To On/Off Switch)

SYSTEM

OPTO Gas Engine Kill Switch

(DLEG9205, not included)

KILL

SWITCH

Tachometer Lead/

RPM Signal Output

Tachometer

Pick-Up

Sensor Wire

(To Sensor On Engine)

(Not included) DLEG5525

OPTIONAL

Rx Batt

Lead

Installing the DLE-85 on Your Airplane

Note: The DLE-85 must be installed on at least a 9.5mm [3/8"] thick 5-ply 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-85 onto a ﬁ rewall thinner than speciﬁ ed because it may fail due to the power of the engine.

Note: The length of the engine from the back of the engine mount to the propeller drive washer is 7.87" [200 mm].

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

Install (4) 5mm blind nuts on the back side (non-engine side of the ﬁ rewall) in the holes drilled in step 1.

3. Install the 8 grommets and

4 spacers to the anitvibration mount as shown.

Install the 4 standoffs to the engine in the orientation shown using the (4) 5x20mm SHCS and 5mm washers. Be sure to use

threadlocker.

LED

Install the standoffs to the mount by inserting (4) 5x25mm SHCS and (4) 5x19mm ﬂ at washers through the backside isolation mount. Mount the engine standoffs and isolation mount to the ﬁ rewall by installing the (4) 5x25mm SHCS through the isolation mount and into the ﬁ rewall into the 5mm blinds nuts (not included). Note:

The proper orientation of the mount can be seen on the front of

this manual. Be sure to use threadlocker.

Mount the engine to the aircraft by installing the (4) 5x25mm SHCS through the isolation mount and into the ﬁ rewall. Secure the SHCS to the 5mm blind nuts (installed on step 2). Be sure to use threadlocker.

7. 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 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.

Fuel Tank

2-LINE

SET UP

Route to top-front of fuel tank interior,

to prevent siphoning (2-Line Set-up)

3-LINE

Clunk Line

Drain/Vent Pressure Relief Line

Fuel Tank

Clunk Lines

SET UP

Fuel fill line

Plug

Supply Line

to T-Fitting

Carb

T-Fitting

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.

Supply Line

to Carburetor

This line must be extended

to exit the bottom of the aircraft.

Make connection line

between T-Fitting and

Carburetor as short

Fuel fill line

as possible.

Filler Cap

or Plug

Carb

+ 16 hidden pages

DLE 85 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual