Magnum XL 1.80RFS Operating Instructions Manual

SINGLE CYLINDER

FOUR-STROKE ENGINE

OPERATING INSTRUCTIONS

(P/N 210989)

XL 1.80RFS ENGINE SPECIFICATIONS

Displacement .......................... 29.52cc

Bore: ........................................ 36mm

Stroke: ..................................... 29mm

Practical RPM: ........................ 1,800 - 10,000

Weight w/Muffler: .................... 38.9oz

Features

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Ringed-Piston Design for Long Life and High Power

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Rear-Updraft, Dual-Needle Carburetor

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High-Flow Quiet Muffler

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Dual Ball Bearing-Supported Crankshaft & Camshaft

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Dual Bushing-Supported Connecting Rod

XL 1.80RFS

INTRODUCTION

Thank you for choosing a Magnum XL RFS series aircraft engine. The XL

1.80RFS is a single cylinder, four-stroke engine incorporating an aluminum

piston, iron ring and steel sleeve for long life and high power output. A

dual-needle valve carburetor for precise fuel/airflow metering is standard.

The engine features a dual-ball bearing-supported crankshaft and camshaft,

dual bushing-supported connecting rod, and a high-flow muffler for more

power and reduced noise. Your Magnum XL RFS series engine was designed

by expert engineers and built by master craftsmen using only the highest

quality materials and CNC machinery. These qualities provide the long life

and dependability you have come to expect from an engine of this caliber.

BECOMING FAMILIAR WITH YOUR ENGINE

If you are familiar with the operation of model engines or just can’t wait to

run your new engine, please read through the Quick-Start Guide included.

This guide will help you get started right away and also includes some good

recommendations. We do recommend reading through these Operating

Instructions in their entirety to familiarize yourself with the features and

operation of your new engine. We have also included a Troubleshooting

Guide should you encounter any problems.

Please use the photos below to familiarize yourself with the components of

your new Magnum XL RFS series engine.

http://globalservices.globalhobby.com

CAUTION - PLEASE READ!!

Magnum XL RFS series model airplane engines will consistently give you

dependable performance and reliability and will be a source of satisfaction

and pleasure if you follow these instructions as to the engine’s proper and

safe use. You alone are responsible for the safe operation of your engine,

so act sensibly and with care at all times. This Magnum XL RFS series

model airplane engine is not a toy. It is a precision-built machine whose

power is capable of causing serious injury to yourself and others if abused or

misused, or if you fail to observe proper safety precautions while using it.

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Keep spectators, especially small children, at least 20 feet away from the

engine while it is running.

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Mount the engine securely in the airplane or on a suitable engine test
stand to run the engine. Follow the mounting instructions in your kit's
instruction manual or on the plans for individual mounting recommendations.
Do not clamp the engine in a vise to test-run it.

●

Use the recommended size propeller and follow the proper procedure for
mounting the propeller. Use the correct size wrench to tighten the propeller
nut and the safety nut. Do not use pliers.

●

Inspect the spinner, propeller, and propeller and safety nuts on a regular
basis, looking for any signs of nicks, cracks or loosening.

●

To stop the engine, adjust the throttle linkage to completely close the throttle
barrel and therefore cut off the fuel/air supply. You can also pinch the fuel
line to stop the engine, but only if it is accessible. Do not throw anything into
the spinning propeller or attempt to use your hands to stop the engine.

●

While the engine is running, stand behind the engine to make any
adjustments to the needle valves. Do not reach over or around the propeller.
Do not lean toward the engine. Do not wear loose clothing or allow anything
to be drawn into the spinning propeller while the engine is running.

●

If you need to carry your model while the engine is running, be conscious
of the spinning propeller. Keep the airplane pointed away from you and
others at all times.

●

Do not use tight-fitting cowls over the engine. They can restrict air from
flowing over the engine, which could result in engine damage from overheating.

Global Services 18480 Bandilier Circle Fountain Valley, CA 92708 Phone: [phone] Fax: [phone] Email: [e-mail]

ENGINE INSTALLATION

Engine Orientation

Your XL RFS series engine can be orientated in any position on the firewall.

Keep in mind that when the engine is mounted inverted, carburetor

adjustments will need to be made differently and the fuel tank may need to be

lowered. (See fuel tank size and orientation to carburetor on the next page.)

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Engine Bolts & Firewall Requirements

The engine should be mounted to either a heavy-duty, glass-filled nylon
engine mount, a machined aluminum engine mount or an integrated hardwood
beam mount. Use only high-quality steel cap screws and related hardware
to mount the engine to the engine mount. The firewall in the airplane should
be aircraft grade 5-ply plywood no less than 5/16" thick and the firewall should
be reinforced to meet the torque and weight of the engine.

Muffler Installation

NOTE: EXHAUST PIPE THREAD SIZE IS M14x0.75mm

The muffler threads onto the exhaust pipe, which then threads into the engine's
cylinder head. First thread one cinch nut onto each end of the exhaust pipe,

then thread the muffler onto one
end. The muffler should be
threaded on at least 5/16" to
prevent vibration from damaging
the threads. Once you have
threaded the muffler onto the
exhaust pipe, use an open end
wrench to firmly tighten the cinch
nut up against the muffler. The

exhaust pipe is adjustable to
better suit the installation of your particular application. Thread the exhaust
pipe into the engine’s cylinder head. The exhaust pipe should be threaded
in no less than 5/16" to prevent vibration from damaging the threads in the
cylinder head. Once you have threaded the exhaust pipe into place and into
the proper position for your application, use an open end wrench to firmly
tighten the cinch nut against the cylinder head.

Fuel Tank Size & Orientation to Carburetor

Ideally, the stopper in the fuel tank should be even with the high speed needle
valve or just slightly below it. Some models will only allow the fuel tank to be
mounted higher than the ideal location. A fuel tank that is positioned higher
than the ideal location usually doesn’t pose any problem except when it is
mounted excessively higher and/or is used in conjunction with an inverted
mounted engine or during extreme aerobatic flight. If you mount the engine
inverted, we strongly suggest lowering the fuel tank so the stopper assembly
is slightly below the high speed needle valve. Doing this will prevent fuel
from siphoning into the engine and flooding it when the fuel tank is full. If
you cannot lower the fuel tank far enough, we suggest lowering it as far as
can be allowed in your particular application.

The size of the fuel tank used should be 20oz. - 24oz., depending on the
model and the length of flights desired. Use of a 24oz. tank will provide
approximately 15 minutes of run time at full throttle. Use of a fuel tank any
larger than 24oz. can lead to excessive leaning of the engine during flight
and is not recommended.

Carburetor Orientation

In some cases you may want the throttle arm on the opposite side of the

engine from how it comes

preinstalled. You can remove the

carburetor and reinstall it in the

opposite direction with no effect on

performance. To remove the

carburetor, loosen the two screws

holding the intake manifold in

place. Next, remove the two

screws holding the carburetor to the

engine and remove it by gently
pulling it down off the intake pipe. Installation is the reverse of disassembly.
Be careful not to damage the O-ring when reinstalling the carburetor.

Rotor Bolt

The rotor bolt holds the throttle barrel in the carburetor body and prevents
the throttle barrel from being over-rotated in either direction. It does not require
adjustment. Periodically check the rotor bolt to ensure that it is tight.

Optional Needle Valve Extension

If an extension is required to
adjust the high speed needle
valve, use a 1.5mm diameter wire
of the necessary length. Loosen
the grub screw in the side of the
needle valve (using a 1.5mm hex
wrench), insert the wire into the
end of the needle valve and
tighten the set screw firmly. If the

extension is more than 3" long we
recommend supporting the outer end of the extension to prevent excessive
vibration from damaging the needle valve assembly.

Crankcase Return Tube

A silicone crankcase return tube

is attached to the engine, between

the crankcase and the intake pipe.

This tube carries excess oil back

into the intake so it can be

redistributed thr o u g h o u t t h e

engine. This system keeps the

engine better-lubricated. DO NOT

plug the tube or run the engine

without the tube attached.

Propeller Installation

NOTE: PROPELLER SHAFT THREAD SIZE IS 3/8"-24

Your engine comes equipped with a main propeller nut and one safety nut.
For your safety, we recommend using both the propeller nut and the safety
nut to secure the propeller into place.

✦✦

✦WARNING

✦✦

Running your engine using an out-of-balance propeller can lead to
excessive vibration, which will result in excessive stress and wear on both
the engine and the airframe. Balance the propeller using the method
recommended by the propeller manufacturer. Several products are
available to properly balance propellers. Ask your local retailer for more
information about these items.

The diameter of the crankshaft is 3/8". Using a 3/8" drill bit or a prop reamer,

When tightening the nuts, use an adjustable wrench. Do not use pliers.

✦✦

✦WARNING

✦✦

of the spinner must not rub against the propeller. Allowing the spinner
cone to rub against the propeller could lead to propeller damage and
eventual propeller failure.

✦✦

✦ Before installing the propeller it must be properly balanced.

✦✦

enlarge the hole in the propeller

hub to fit the crankshaft. Slide the

propeller onto the crankshaft, up

against the drive washer. Slide

the propeller washer up against

the propeller and thread the main

prop nut into place. Tighten the

prop nut firmly to secure the propeller

into place, then install and tighten

the safety nut against the prop nut.

✦✦

✦ If you are installing a spinner onto your engine, the cone

✦✦

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For More Information on Magnum engines, Please Visit Our Website at http://globalservices.globalhobby.com

PROPELLER, GLOW PLUG & FUEL

Propeller Recommendation

The diameter and pitch of the propeller needed for your XL RFS series
engine will vary greatly depending on the application the engine is used in.
The weight, drag and the type of model and how you intend to fly it are all
factors in determining the correct size propeller to use. Experimentation
will be necessary to find the optimal size propeller for your particular
application. Ideally you want a propeller that will allow the engine to turn in
the 8,000 - 10,000 rpm range on the ground, yet power the airplane
sufficiently. Using a propeller that is too small will cause the engine to run at
too high an rpm. Using a propeller that is too large will cause the engine to
run at too low an rpm and cause it to lug down too much. In both instances

this can lead to premature engine wear and eventual failure.

PROPELLER SIZE RECOMMENDATIONS FOR XL 1.80RFS

Use for

Break-In

16 x 6

16 x 8

16 x 10

18 x 4-5

18 x 6

Glow Plug Recommendation

We recommend using a hot heat-range glow plug intended specifically for

four-stroke engines. Do not use a cold heat-range plug or a plug designed

for two-stroke engines. This can lead to erratic engine runs and eventual

engine wear and failure. Thunderbolt 4-Stroke, O.S. Type-F and Fox

Miracle Plugs are good choices.

Fuel Recommendation

Fuel can make a big difference in the way your engine performs. We

recommend using two types of fuel with your XL RFS series engine. For the
break-in period you should use a fuel containing no more than 10% nitro

methane and no less than 18% Castor/synthetic blend lubricant. Use of fuel
containing more than the recommended percentage of nitro methane or only

synthetic lubricants will cause the engine to run too hot and result in excessive
wear and engine failure in a very short period of time. Once the engine has been

adequately broken in (about 1/2 gallon of the recommended break-in fuel),
a fuel containing 5% - 30% nitro methane and 16% -22% Castor or synthetic

blend lubricant fuel can be used.

✦✦

✦WARNING

✦✦

that contains only synthetic lubricants. Synthetic lubricants have a much

lower flash point than Castor Oil lubricants. Flash point is the point at
which the lubricant begins to actually burn and lose its lubricating qualities.

Using fuel containing a blend of Castor Oil and synthetic lubricants results
in an engine that runs cooler and lasts longer. One lean run using a fuel

containing only synthetic lubricants can cause engine failure. Using fuels
with a Castor Oil and synthetic blend of lubricants greatly reduces this chance.

✦✦

✦ For the break-in period, we do not recommend using fuel

✦✦

HIGH & LOW SPEED NEEDLE VALVES

High Speed Needle Valve

The high speed needle valve is used to meter the air/fuel mixture at full

throttle. Turn the needle valve clockwise to lean the mixture or turn the needle

valve counterclockwise to richen the mixture. When you start the engine for

the very first time the needle valve should be turned in completely, then backed

out 2-1/2 turns. When you start the engine after that, leave the needle valve

in the same position it was in when you shut down the engine.

Low Speed Needle Valve

The low speed needle valve is preset from the factory for initial starting and
break-in. Do not adjust it until after the engine is broken in. The low speed
needle valve regulates the air/fuel mixture at idle and during transition from
idle to full throttle. Turn the needle valve screw clockwise to lean the
mixture. Turn it counterclockwise to richen the mixture. The low speed
needle valve screw is preset from the factory, but minor adjustments may
need to be made after the engine is broken in. To reset the low speed

needle valve screw to the factory setting, follow these procedures:

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Open the carburetor barrel completely.

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●

●●

While holding the barrel open, turn the needle valve screw IN
(clockwise) GENTLY until it stops. From this point, while still holding
the barrel open, turn the needle valve screw OUT (counter-clockwise)
2 full turns. This is the factory setting.

✦✦

✦WARNING

✦✦

✦✦

✦ It is possible to turn the low speed needle valve screw so

✦✦

lean that the engine will not draw fuel. The low speed needle valve screw
should not need to be adjusted more than one full turn in either direction
from the factory setting. If the engine does not idle or transition, reset the
low speed needle valve screw to the factory setting.

STARTING PROCEDURE

Your XL RFS series engine can be started using an electric starter or it can
be started by hand. For safety and ease of starting, especially when the
engine is new, we recommend using an electric starter. The following two
procedures should be done with the power to the glow plug off.

Starting Using an Electric Starter

When using an electric starter it is not necessary to choke and prime the
engine. The starter turns the engine over fast enough that the engine draws
fuel on its own. Priming the engine prior to using an electric starter can
cause the engine to "hydro-lock" or flood. This is a result of too much fuel in
the engine before it actually fires. Turning the engine over with an

electric starter while the engine is flooded can cause extreme damage
to the engine and/or cause the propeller assembly to come loose. Turn
the propeller through the compression stroke one time by hand to check
for a hydro-locked state before applying the starter.

Starting by Hand

When starting the engine by hand always use a chicken stick or a heavy
leather glove. Never just use your bare hand or serious injury could result.
To make the engine easier to start by hand it should first be primed. This is
done by opening the carburetor barrel completely and covering the tip of the
exhaust pipe with your finger. Fuel can then be drawn into the engine by
"pulling" the propeller through the compression stroke 2 - 3 times. This will
draw fuel into the engine. After fuel begins to enter the carburetor, remove
your finger from the exhaust pipe and pull the propeller through the
com pression stroke once to check for a hydro-locked condition.

WARNING ABOUT ENGINE HYDRO-LOCKING

If the engine becomes hydro-locked, do not force the propeller through
the compression stroke. The excess fuel should be expelled from the
engine before attempting to start it.

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Completely close the high speed needle valve until it bottoms out, then

remove the glow plug from the cylinder head.

●

With a rag over the top of the engine, turn the crankshaft several times,
using your electric starter or flipping the propeller by hand. The excess
fuel will be expelled out of the engine and into the rag.

●

Check to make sure that the glow plug has not been fouled, then reinstall it.
Reset the high speed needle valve.

Global Services 18480 Bandilier Circle Fountain Valley, CA 92708 Phone: [phone] Fax: [phone] Email: [e-mail]

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