O.S. Engines 21XZ-B User Manual

Expressly for 1/8 off-road buggy racing competitions
MAX-21XZ-B Ver.
It is of vital importance, before attempting to operate your engine, to read the general 'SAFETY INSTRUCTIONS AND WARNINGS' in the following section and to strictly adhere to the advice contained therein.
Also, please study the entire contents of this instruction manual, so as to familiarize yourself with the controls and other features of the engine.
SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O.S. ENGINE
Remember that your engine is not a " toy ", but a highly efficient internal-combustion machine whose power is capable of harming you, or others, if it is misused or abused. As owner, you, alone, are responsible for the safe operation of your engine, so act with discretion and care at all times. If at some future date, your O.S. engine is acquired by another person, we would respectfully request that these instructions are also passed on to its new owner.
WARNINGS
These cover events which might involve serious (in extreme circumstances, even fatal) injury.
NOTES
These cover the many other possibilities, generally less obvious sources of danger, but which, under certain circumstances, may also cause damage or injury.
With this engine, the piston will feel tight at the top of its stroke (TDC) when the engine is cold. This is normal. The cylinder bore has a slight taper. The piston and cylinder are designed to achieve a perfect running clearance when they reach operating temperature.
When the engine is cold.
NOTES WHEN APPLYING AN ELECTRIC STARTER
ENGINE CONSTRUCTION
Near TDC
Cylinder Liner
Crankshaft
Slight taper
Do not over-prime. This could cause a hydraulic lock and damage the engine on application of the electric starter. If over-primed, remove glowplug, close needle-valve and apply starter to pump out surplus fuel. Cover the head with a rag to prevent any pumped out fuel from getting into your eyes.
Piston
When the engine is hot.
WARNINGS
Model engine fuel is poisonous. Do not allow it to come into contact with the eyes or mouth. Always store it in a clearly marked container and out of the reach of children.
Model engine fuel is also highly flammable. Keep it away from open flame, excessive heat, sources of sparks, or anything else which might ignite it. Do not smoke or allow anyone else to smoke, near to it.
Model engines generate considerable heat. Do not touch any part of your engine until it has cooled. Contact with the muffler (silencer), cylinder head or exhaust header pipe, in particular, may result in a serious burn.
Never operate your engine in an enclosed space. Model engines, like automobile engines, exhaust deadly carbon-monoxide. Run your engine only in an open area.
NOTES
This engine is intended for model cars. Do not attempt to use it for any other purpose.
Mount the engine in your model securely, following the manufacturers' recommendations, using appropriate screws and locknuts.
NOTES ON OPERATION
This engine is constructed from the very best materials available and to the very highest engineering standards, using the most advanced precision machinery. However, the extremely high stresses imposed by car racing operation under very severe conditions, as well as stresses which are exacerbated by the use of powerful fuels containing very high concentrations of nitromethane, constitute hazards which are beyond a manufacturer's control. Accordingly, we regret that it is not possible to extend our usual warranty terms to this particular engine -i.e. no guarantee is offered against material wear, or damage resulting therefrom, in actual use.
Please do not run on a public street, this could cause serious accidents, personal injuries and/or propetry damage.
Please do not run near pedestrians or small children.
Please do not run in small or confined areas.
Please do not run where loud noises can disturb others, such as hospitals and residential areas.
NOTE As delivered, the engine has the carburetor lightly fit into its intake. Secure it changing its angle according to the car chassis.
ABOUT THE ENGINE
The MAX-21XZ-B Ver.II is expressly designed for 1/8 off-road racing buggy featuring smooth acceleration and easy handling. Newly designed single-adjust carburetor ensures easier adjusting.
Glow Plug P3 T-type head (Turbo head) 1piece
Exhaust Seal Ring 1piece
O.S. SPEED Dust Cap Set For 12-30 Class 3mm, 16mm, 18mm 1piece each
GUARANTEE
While Operating
Standard accessories
(Hot Type)
Install an effective silencer (muffler). Frequent close exposure to a noisy exhaust (especially in the case of the more powerful highspeed engines) may eventually impair your hearing and such noise is also likely to cause annoyance to others over a wide area.
The wearing of safety glasses is also strongly recommended.
Take care that the glowplug clip or battery leads do not come into contact with rotating parts. Also check that the linkage to the throttle arm is secure.
For their safety, keep all onlookers (especially small children) well back (at least 20 feet or 6 meters) when preparing your model for running.
Before starting the engine, always check the tightness of all the screws and nuts especially those of joint and movable parts such as throttle arm. Missing retightening the loose screws and nuts often causes the parts breakage that is capable of harming you.
To stop the engine, fully retard the throttle stick and trim lever on the trans-mitter, or, in an emergency, cut off the fuel supply by pinching the fuel delivery line from the tank.
Warning! Immediately after a glowplug-ignition engine has been run and is still warm, conditions sometimes exist whereby it is just possible for the engine to abruptly restart if it is rotated over compression WITHOUT the glowplug battery being reconnected.
TOOLS, ACCESSORIES, etc.
The following items are necessary for operating the engine.
Items necessary for starting
FUEL
Generally, it is suggested that the user selects a fuel that is commercially available for model two-stroke engines When the brand of fuel is changed, or the nitro content increased, it is advisable to repeat the running-in procedure referred to in the RUNNING-IN paragraphs. Please note that with high-nitro fuels, although power may be increased for competition purposes, glowplug elements do not last as long and engine life will be shortened.
FUEL FILTER
To installed in the fuel line between fuel tank and carburetor to prevent foreign matter from entering the carburetor.
GLOWPLUG IGNITER
Commercialy available handy glowplug heater in which the glowplug battery and battery leads are integrated.
STARTER BOX
For starting the engine.
FUEL PUMP
For filling the fuel tank, a simple, polyethylene "squeeze" bottle, with a suitable spout, is required.
O.S. SPEED SILICONE FUEL LINE
The connection between the fuel tank and the engine.
2.5mm ID
TOOLS
O.S. SPEED DRIVER TOOLS
O.S. SPEED FLYWHEEL KEY
O.S. SPEED CLUTCH WRENCH & ADJUSTER
O.S. SPEED FLYWHEEL PULLER
O.S. SPEED PLUG WRENCH
(optional extra)
BASIC ENGINE PARTS
Outer Head
Carburetor Type 22B2
Crankshaft
Crankshaft Bearing (Front)
CARBURETOR CONTROLS STANDARD POSITIONS (POSITIONS WHEN THE ENGINE LEAVES THE FACTORY)
Three adjustable controls are provided on this carburetor.
Needle Valve
Dust Cover
Throttle Stop Screw
Thermo Insulator
The Needle-Valve:
For adjusting air/fuel ratio (air-fuel mixture) at maximum rpm (fully opened throttle).
Close (Clockwise)
Open (Counter-clockwise)
[Standard Position]
3 and 1/4 turns opened from the fully closed position.
[Fully closed position]
Turn the needle-valve clockwise until it stops. This is the fully closed position. Do not force it to turn further.
The Metering Needle:
For adjusting idle and acceleration feeling.
Carburetor Body
The Throttle Stop Screw:
For setting the minimum idle speed:
Note: Sketch shows the carburetor reducer removed.
NOTE: The Metering Needle Valve is set at the standard position when the engine leaves the factory, readjustment may be necessary, occasionally to allow for changes in fuel formula and climatic conditions Readjust the controls only when satisfactory results cannot be obtained with the standard positions following the instructions mentioned in the “CARBURETOR ADJUSTMENT” section.
Needle Valve
Ball Link
[Standard Position]
Flush with the ball link body.
Metering Needle
Slide Valve
[Standard Position]
Approx 0.5mm
Carburetor Body
Slide Valve
Exhaust
Cover Plate
Mounting Lugs
Crankcase
Carburetor Reducer
Ball Link
Metering Needle
INSTALLATION OF THE CARBURETOR
As delivered, the engine has its carburetor lightly installed in the intake boss. Secure it as follows.
Rotate the retainer nut gently until it stops.
Tighten a further 120-180
"O" Ring
Loosen the retainer screw, rotate the carburetor to its
1. correct position and make sure that it is pressed well down into the intake boss, compressing the rubber gasket, before retightening screw.
Rotate the retainer screw gently until it stops, then
2.
tighten a further 120-180 . Do not overtighten the screw as this will damage the thermo insulator.
Note Be careful not to damage the O rings when removing the carburetor retainer from the engine. First, remove the retainer Retaining screw, then pull out each part. Do not push the part in or damage the O rings.
ENGINE INSTALLATION
Make sure that the vehicle's engine mounting surfaces are level and in the same plane. Poor installation may cause distortion of the crankcase, bearings, etc., resulting in erratic running and loss of performance. The recommended screws for securing the engine are 3mm or 4-40 steel Allen hexagon socket type. If existing holes in the engine mount do not align perfectly with engine mounting lugs, enlarge them slightly with a needle-file so that screws are in alignment with the mounting holes.
Chamfer inside edges of bearers.
The engine bottom may interfere with chassis of some models. In this case, file off the chassis so that the engine may not interfere with the chassis when it is installed.
Note: Be sure to use a collet supplied when use a optional 28XZ Hyper Flywheel Set.
STARTING THE ENGINE & RUNNING-IN ('Breaking-in)
Running- in is a procedure for an engine to come close to actual running conditions (fuel, r.p.m., engine temperature, etc.).
Excessively rich running and prolonged low speed running should be avoided. Prolonged low speed running and low temperature running may result in the oil in the fuel becoming gelled and the piston/liner becoming stuck together.
"O" Ring
Retaining Screw
Do not allow bottom of crankcase to touch chassis.
NOTE
PRESSURIZED FUEL SYSTEM
It is recommended that a muffler pressurized fuel feed system be used so that the fuel may be stably fed to the carburetor.
The following procedure is suitable when a fuel containing 30% nitro-methane is used.
Set the carburetor controls at the standard positions
1. (positions when the engine leaves the factory.)
Switch the transmitter and make sure that each
2. linkage moves correctly.
Make sure rotating direction of the starter box is
3. correct (counter-clockwise seen from the front edge of the crankshaft), and turn the engine with the starter box to draw fuel into the engine.
Connect glowplug battery lead to heat the plug and
4. start the engine with the starter box. When the engine does not start or stops right after being started, try the followings.
Close the needle-valve approx. 90° from the standard position.
Set the throttle opening a little wider (approx. 1mm) than the standard setting by adjusting the Throttle Stop Screw.
5.
When the engine starts, warm it up by repeatedly increasing the rpm to medium speed and back again to a fast idle with the mixture set very rich, glowplug connected, and the driving wheels clear of the ground. The rich mixture will provide adequate lubrication and cooling, indicated by profuse exhaust smoke.
Attention:
It is vitally important to set the throttle at the correct position before starting the engine. If the engine is allowed to run with the throttle too far open under ''no load'' conditions (i.e. with the driving wheels not in contact with the ground) it will rapidly over-heat and may be seriously damaged.
6.
When the engine is warmed up, disconnect the glowplug battery and try running the car on the track. If the engine stops soon after running at around mid speed, the mixture is too rich. Close the needle-valve 15~30°. If the engine still stalls, close the metering needle 15~30°. Run the car on the track until one tank of fuel has been consumed, then close the needle-valve very little (within 10°).
7.
Repeat this procedure (close needle-valve very little after one tank of fuel has been consumed) until approx. 2 liters of fuel have been consumed, extending gradually the full throttle running time at the straight. Carefully observe the exhaust smoke. Be sure to run the engine with visible white smoke at all times. If the smoke is not visible, the needle-valve is closed too far.
Now the RUNNING-IN (Breaking-in) is completed.
Note: In the event of any major working parts (e.g. piston/cylinder liner assembly) being replaced or the fuel being changed, especially to high nitro fuel, the complete running-in should be repeated.
How to stop the engine
To stop the engine, close the throttle to idle speed and shut it off completely with the trim lever on the transmitter then cut off the fuel supply by pinching the fuel delivery tube to the carburetor.
Warning! Do not touch rotating parts, engine and silencer when stopping the engine as they become very hot, and contact with them may result in a serious burn.
approx 1mm
Fuel
CARBURETOR ADJUSTMENT
Carburetor adjustment should be carried out only after the running-in has been completed.
Needle Valve
Open
More fuel
1.
NEEDLE VALVE ADJUSTMENT
Close
Less fuel
Metering Needle
Open
Close
More fuel Less fuel
Run the vehicle (with throttle fully open) over the longest available straight course a few times to observe the model’s speed. Return the vehicle to the starting point and close the Needle-valve 15°and repeat the run, taking note of the improvement in performance. Continue with further runs, gradually reduce the Needle-valve setting aiming to achieve the highest straight-line speed (optimum position). Remember, however, if the Needle-valve is closed too far, the engine will overheat, accompanied by visibly diminished exhaust smoke and the model will lose speed. At this point, throttle down immediately, stop the vehicle and reopen the Needle-valve 30~45°.
METERING NEEDLE ADJUSTMENT
2.
After setting the Needle-valve at optimum position, run the vehicle a few times at the straight line. With the engine running, close the throttle and allow it idle for about five seconds, then reopen the throttle fully. If, at this point, the engine puffs out an excessive amount of smoke and the vehicle does not accelerate smoothly and rapidly or even stops, it is probable that the idle mixture is too rich. In this case, turn the Metering needle clockwise 15~30°. If, on the other hand, the engine tends to speed up momentarily and then cut out abruptly when the throttle is opened, the idle mixture is too lean. In this case, turn the Metering needle counter-clockwise 15~30°.
3.
THROTTLE STOP SCREW ADJUSTMENT
If the engine runs too fast with the throttle closed, the throttle stop screw should be turned counter-clockwise to allow the throttle opening to be reduced.
OPTIMUM MIXTURE CONTROL POSITION
With the optimum mixture control position, light smoke is visible during high speed running and the engine rpm increase smoothly during acceleration. Carry out adjustment 1.~3. patiently until the engine responds quickly and positively to the throttle control. Remember that, if the engine is operated with the fuel/air mixture slightly too lean, it will overheat and run unevenly. As with all engines, it is advisable to set both the needle-valve and metering needle slightly on the rich side of the best rpm setting, as a safety measure. Finally, beyond the normal break-in period, a slight readjustment toward a leaner needle setting may be required to maintain maximum performance.
Note: Please regard the standard positions in the instruction manual as just a guide. Positions will vary due to the fuel and silencer used. In general, if a fuel containing less nitromenthane is used, the needlevalve will need to be closed further. Remember, closing the needlevalve too far can cause rusting and damage to the engine.
CARE AND MAINTENANCE
The minute particles of foreign matter, that are present in
1. any fuel may, by accumulating and partially obstructing fuel flow, cause engine performance to become erratic and unreliable. O.S. 'Super-Filters' (large and small) are available, as optional extras, to deal with this problem. One of these filters installed to the pickup tube inside your refueling container, will prevent the entry of foreign material into the fuel tank. It is also recommended that a good in-line filter be installed between the tank and carburetor.
Do not forget to clean the filters regularly to remove
2. dirt and lint that accumulate on the filter screens. Also, clean the carburetor itself occasionally.
At the end of each operating session, drain out any fuel
3.
that may remain in the fuel tank. Afterwards,energize the glow-plug and try to restart the engine, to burn off any fuel that may remain inside the engine. Repeat this procedure until the engine fails to fire. Do this while the engine is still warm.
Then, inject some after-run oil into the engine, and
4. rotate the engine with an electric starter for 4 to 5 seconds to distribute the oil to all the working parts.
Note: Do not inject after-run oil into the carburetor as
this may cause the O-rings inside the carburetor to deteriorate. These procedures will reduce the risks of starting difficulties or corrosion after a period of storage.
5.
Finally, when cleaning the exterior of the engine, use methanol or a household cleaning agent. Do not use gasoline, kerosene, or any petroleum based chemical which can damage silicone fuel tubing.
Dirt and dust may lodge in marked places.
INATALLING DUST CAPS
When storing the engine, install the cap on the exhaust port, carburetor, etc. to prevent dust from entering the engine.
CHECKING THE ENGINE
If the engine will not develop normal performance after long time running due to wearing of parts. It is suggested to replace necessary parts when the following symptoms are detected.
Engine sound changes and easily overheats.
Power has dropped extremely.
Idle is unstable and/or engine tends to stop at idle.
In most cases, ball bearings, cylinder & piston assembly, connecting rod and/or crankcase have become worn. Check the parts carefully and replace them if necessary.
O.S. GENUINE PARTS & ACCESSORIES
O.S. GLOW PLUG
(71641300)
P3
(71641400)
P4
CARBURETOR REDUCER
(71533255)
5.5
(71533260)
6
(71533265)
6.5
(71533270)
7
CERAMIC REAR BEARING FOR 21
(23730050)
O.S. SPEED CARBURETOR REPAIR KIT 21
(71490000)
O.S. SPEED Carburetor Repair Parts Set 21
(71491000)
O.S. SPEED CARBURETOR REPAIR PARTS SET 21
(71491000)
O.S. SPEED CLUTCH BEARING (1050ZZ 4pcs.)
(71550001)
O.S. SPEED CLUTCH BEARING (1050ZZ 10pcs.)
(71550002)
O.S. SPEED CILICONE TUBE
(72506100)
2.5mm x 1000mm
O.S. SPEED EXHAUST SEAL RING 21
(22826145)
O.S. SPEED PISTON PIN RETAINER 4mm
(21817010)
O.S. SPEED DUST CAP SET FOR 12-30 CLASS
3mm(2pcs.) / 16mm(2pcs.) / 18mm(1pc.) (22884254)
DUST CAP SET 3mm
(5pcs.)
(73300305)
DUST CAP SET 16mm
(73301612)
DUST CAP SET 18mm
(73301812)
(3pcs.)
(3pcs.)
(71533280)
8
(71533085)
8.5
(71533290)
9
(71641500)
P5
(10pcs.)
(6pcs.)
M2002SC EXHAUST HEADER PIPE ASSEMBLY
(72106480)
Header Pipe Spring (2pcs.) Exhaust Seal Ring (2pcs.)
T-2060SC WNI TUNED SILENCER COMPLETE SET
(72106137)
Exhaust Seal Ring (2pcs.) Joint Spring (3pcs.) Header Pipe Spring (2pcs.)
(72101272)
(22826140)
(22826140)
(72106042)
(72101272)
T-2090SC TUNED SILENCER COMPLETE SET
(72106192)
T-2090SC Tuned Silencer Assembly
(72106190)
Exhaust Seal Ring (2pcs.) Joint Spring (3pcs.)
M2000SC Exhaust Header Pipe Assembly
(72106440)
Header Pipe Spring (2pcs.) Exhaust Seal Ring (2pcs.)
(22826140)
(72106042)
(72101272)
(22826140)
28XZ HYPER FLYWHEEL SET
(For MUGEN)
28XZ Hyper Flywheel MUGEN
(71812100)
Collet
(For KYOSHO)
28XZ Hyper Flywheel KYOSHO
(71813100)
Collet
SUPER AIR CLEANER 203
(72413000)
203 Filter Element (4pcs.)
(72413200)
SUPER AIR CLEANER 204
(72415000)
204 Filter Element (4pcs.)
(72415200)
O.S. SPEED CLUTCH WRENCH & ADJUSTER
(71415300)
O.S. SPEED FLYWHEEL KEY
(71415200)
O.S. SPEED FLYWHEEL PULLER
(71415100)
O.S. SPEED PLUG WRENCH
(71520100)
O.S. SPEED DRIVER TOOLS
Code No.
71410150 71410200 71410250 71410300 71411200 71411250 71412300 71413550 71413600 71413700
Code No. Description
71414015 71414020 71414025 71414030 71414120 71414125 71414230 71414355 71414360 71414370
The specifications are subject to alteration for improvement without notice.
O.S. SPEED HEX WRENCH TIP ONLY 1.5
O.S. SPEED HEX WRENCH TIP ONLY 2.0
O.S. SPEED HEX WRENCH TIP ONLY 2.5
O.S. SPEED HEX WRENCH TIP ONLY 3.0
O.S. SPEED HEX BALL WRENCH TIP ONLY 2.0
O.S. SPEED HEX BALL WRENCH TIP ONLY 2.5
O.S. SPEED FLAT HEAD SCREWDRIVER TIP 3.0
O.S. SPEED NUT DRIVER TIP ONLY 5.5
O.S. SPEED NUT DRIVER TIP ONLY 6.0
O.S. SPEED NUT DRIVER TIP ONLY 7.0
(71812000)
(71801100)
(71813000)
(71801100)
Description
O.S. SPEED HEX WRENCH DRIVER 1.5
O.S. SPEED HEX WRENCH DRIVER 2.0
O.S. SPEED HEX WRENCH DRIVER 2.5
O.S. SPEED HEX WRENCH DRIVER 3.0
O.S. SPEED HEX BALL WRENCH DRIVER 2.0
O.S. SPEED HEX BALL WRENCH DRIVER 2.5
O.S. SPEED FLAT HEAD SCREWDRIVER 3.0
O.S. SPEED NUT DRIVER 5.5
O.S. SPEED NUT DRIVER 6.0
O.S. SPEED NUT DRIVER 7.0
ENGINE EXPLODED VIEW
Type of screw
C...Cap Screw
5-3
7
8
CARBURETOR EXPLODED VIEW
1
1-1
THREE VIEW DRAWING
Dimensions (mm)
Specifications
Displacement
■
Bore
Stroke
PracticalR.P.M.
■
Output
Weight
3.49 cc (0.213 cu.in.
16.27 mm (0.641 in.
16.8 mm (0.661 in. 3,000-41,500 r.p.m.
2.6 ps / 2.56 hp / 34,000 r.p.m. 362 g (12.77 oz.)
6
5-2
)
31.6
45
)
)
2
9
2-1
3
C.M3x18
3
4
5-1
5-4
7-1
Type of screw
S...Set Screw
S.M3x3
1
2
10
4
9
5
11
C.M2.6x18
5
5-1
9-1
10
11
UNF1/4-28
29.5
ENGINE PARTS LIST
16mm
Description
(2pcs.)/
18mm (1pc)
Code No.
No.
22414040
1
22424104
2
22014160
3
22014170
4
22423110
5
22423100
5-1
22016000
5-2
21817010
5-3
22425000
5-4
22282000
6
23981740
7
24881824
7-1
23731020
8
22411030
C.M2.6x7
9 10 11 12 13
23730020 22412010 23107100 22417100 71641300
13
12
22826140
22884254
The specifications are subject to alteration for improvement without notice.
CAP SCREW SETS
Code No.
79871020
M2.6x7
79871055
M2.6x18
79871180
M3x18
Outer Head Inner Head Head Gasket (0.2mm) Head Gasket (0.1mm) Built-up Parts Set Cylinder & Piston Assembly Piston Pin O.S. SPEED Piston Pin Retainer 4mm(6pcs.) Connecting Rod Carburetor Complete (Type 22B2) Carburetor Retainer Assembly "O" Ring (2pcs.) Crankshaft Ball Bearing (Front) Crankcase Crankshaft Ball Bearing (Rear) Crankshaft Cover Gasket Cover Plate Glow Plug P3 (Turbo) Exhaust Seal Ring (2pcs.) O.S. SPEED Dust Cap Set For 12-30 Class
3mm
(2pcs.)/
(
)
10pcs./set
Size Pcs. used in an engine
Cover Plate Retaining Screw (4pcs.)
Carburetor Retainer Retaining Screw (1pc.)
Cylinder Head Retaining Screw (4pcs.)
CARBURETOR PARTS LIST
Description
6-15 3-Chome Imagawa Higashisumiyoshi-ku Osaka 546-0003, Japan
http://www.os-engines.co.jp
TEL. (06)6702-0225 FAX. (06)6704-2722
60092980 011401
8-1
Code No.
No.
1
23818340
1-1
6
6-1
8
28.5
44
20.5
4- 3.3
37
21
27881820
2
23781400
2-1
26381501
3
23981520
4
22848210
5
71533272
5-1
22615000
6
23618197
6-1
46066319
7
22082940
7-1
22082950
8
22848160
8-1
27881820
9
22282100
9-1
23781110
10
29015019
11
23818190
The specifications are subject to alteration for improvement without notice.
86.5
15.6
Copyright 2013 by O.S. Engine Mfg. Co., Ltd. All rights reserved.
Metering Needle Assembly "O" Ring (2pcs.) Ball Link No.3 Retaining Screw Dust Cover Slide Valve Carburetor Reducer 7mm (YELLOW) "O" Ring Needle Assembly "O" Ring Needle Holder Assembly Fuel Inlet (No.15) Throttle Stop Screw "O" Ring Carburetor Body (w/Thermo Insulator) Thermo Insulator Carburetor Rubber Gasket Carburetor Sealing Washer
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