O.S. Engines 91SZ-H User Manual
It is of vital importance, before attempting to
operate your engine, to read the general
'SAFETY INSTRUCTIONS AND WARNINGS'
section on pages 2-5 of this booklet 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.
Keep these instructions in a safe place so that
you may readily refer to them whenever
necessary.
It is suggested that any instructions supplied
with the model, radio control equipment, etc.,
are accessible for checking at the same time.
SAFETY INSTRUCTIONS AND
WARNINGS ABOUT YOUR O.S. ENGINE
NOTES ON INSTALLING,
COOLING-FAN AND CLUTCH
NOTES WHEN APPLYING AN ELECTRIC STARTER,
NOTES ON HEATING THE GLOW PLUG
INTRODUCTION, BEFORE STARTING
ENGINE PARTS NAME, INSTALLATION OF
THE STANDARD ACCESSORIES
INSTALLATION OF THE ENGINE,
FACTS ABOUT GLOWPLUGS
CARBURETOR CONTROLS
ABOUT THE PUMP SYSTEM
CARE OF FUEL PUMP AND REGURETOR
ABOUT THE PLUMBING
CONTENTS
2-5
7-8
9-12
13-15
16-17
18-19
20
21-22
STARTING, RUNNING-IN ("Breaking-in")
ADJUSTMENT
6
CARBURETOR CLEANLINESS
ADJUSTMENT CHART
INSTALLATION OF THROTTLE SERVO
CARE AND MAINTENANCE
TROUBLE SHOOTING
ENGINE EXPLODED VIEW & PARTS LIST
CARBURETOR EXPLODED VIEW & PARTS LIST
O.S. GENUINE PARTS & ACCESSORIES
THREE VIEW DRAWING
MEMO
1
23-25
25-29
30-31
32
33
34-37
38-39
40-41
42
43
44
SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O.S. ENGINE
Remember that your engine is not a "toy", but a highly efficient internalcombustion machine whose power is capable of harming you, or others, if it is
misused.
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.
The advice which follows is grouped under two headings according to the
degree of damage or danger which might arise through misuse or neglect.
WARNINGS
!
These cover events which
might involve serious (in
extreme circumstances, even
fatal) injury.
!
•
Never touch, or allow any
object to come into contact
with, the rotating parts.
Model engine fuel is poison-
•
ous. 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.
These cover the many other
possibilities, generally less obvious
sources of danger, but which, under
certain circumstances, may also
cause damage or injury.
2
WARNINGS
•
Never operate your engine in an enclosed space. Model engines, like automobile engines, exhaust deadly carbonmonoxide. Run your engine only in an
open area.
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.
!
NOTES
3
!
This engine was designed for model
•
helicopters. Do not attempt to use it for any
other purpose.
Mount the engine in your model securely, fol-
•
lowing the manufacturers' recommendations,
using appropriate screws and locknuts.
Install an effective silencer (muffler). Frequent
•
close exposure to a noisy exhaust (especially
in the case of the more powerful high-speed
engines) may eventually impair your hearing
and such noise is also likely to cause
annoyance to others over a wide area.
Check the linkage to the throttle arm before
•
each flight.
Avoid sudden high r.p.m. immediately after the
•
engine is started, as the clutch will engage and
you may be struck by the rotor.
NOTES
After starting the engine, carry out any needle-
•
valve readjustments after stopping the rotor by
closing the throttle to the lowest r.p.m..
Stop the engine before attempting to make
other adjustments to the carburetor.
Use an electric starter. The wearing of safety
•
glasses is also strongly recommended.
Press the rotor head down securely.
Take care that the glow plug clip or battery
•
leads do not come into contact with rotating
parts.
Adjust the throttle linkage so that the engine
•
stops when the throttle stick and trim lever on
the transmitter are fully retarded. Alternatively,
the engine may be stopped by cutting off the
fuel supply. Never try to stop the engine
physically.
4
!
Take care that loose clothing (ties, shirt sleeves,
•
scarves etc.) do not come into contact with the
rotor. Do not carry loose objects (such as pencils, screwdrivers, etc.) in a shirt pocket from
where they could fall through the rotor disc.
For their safety, keep all onlookers (especially
•
small children) well back (at least 20 feet or 6
metres) when preparing your model for flight. If
you have to carry the model to the take-off point
with the engine running, be especially cautious.
Hold the rotor securely and keep well clear of
spectators.
Warning! lmmediately after a glowplug-ignition
•
engine has been run and is still warm,
conditions sometimes exist whereby it is just
possible for the engine to restart when turned
over WITHOUT the glowplug battery being
reconnected. Remember this if you wish to
avoid the risk of accidents.
NOTES
5
Notes on installing cooling fan and clutch
Do not use a tool which
locks piston when
installing a cooling-fan
and clutch, or top of
the piston may be
damaged. Also, do not
insert a screw driver or
the similar into the
exhaust port.
It is recommended to use Crankshaft
Clamp 91 (Code No.71530510) available as
an optional tool.
It is made of durable engineering plastic
and locks the crankshaft without risk of
damage to any part of the engine.
Application is as follows:
Remove the crankcase rear cover plate from the
engine and rotate the crankshaft to the bottom
dead center (BDC) position.
Insert the crankshaft clamp so that its grooved
portion surrounds the crankpin and lower end of
the connecting rod and securely tighten the fan
or clutch onto the crankshaft.
BDC position
Rotate the crankshaft so that the
connecting rod comes to this position.
Insert this groove onto
the connecting rod.
6
NOTES WHEN APPLYING AN ELECTRIC STARTER
Because of this initial tightness, a
standard electric starter may have
difficulty in rotating the engine when
cold, before it has been adequately
run-in. In this case, use a high-torque
type starter.
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 pumped out fuel from
getting into your eyes.
7
Note on heating the glow plug
The heatsink head on the engine is
treated with Alumite which does not
conduct current. Therefore, when
heating a glow plug, connect one
lead to the glow plug and the other
to the head of cover plate retaining
screw.
Example
8
INTRODUCTION
This is a high performance engine
expressly designed for 3D flight with 90
size helicopters basing on the MAX-91SZ-H
RING and equipping O.S.'s original PD-07
pump and regulator system. The pump
feeds fuel stably irrespective of violent
changes in model attitude and the regulator
regulates fuel pressure from the pump
keeping the pressure at a set level.
The 60M-P carburetor with twin needles
enables adjustment of idling, hovering and
the 'in air flight' independently.
Note:
As delivered, the carburetor is not
installed on the engine. Install the
carburetor securely on the engine
referring to the INSTALLATION OF THE
CARBURETOR section.
Standard accessories
Carburetor Complete 60M-P
Carburetor Rubber Gasket
Carburetor Retainer Assembly
(M2.6x18)
Head Gasket
0.2mm
Glow Plug No.8
Woodruff Key
Needle Adjusting Screw (M2.6x5 2pcs.)
Instruction manual
9
0.1mm
BEFORE STARTING
Tools, accessories, etc.The following items are
necessary for operating the engine.
Items necessary for starting
Glow Plug
O.S. No.8 is supplied with the engine.
Battery leads
These are used to conduct current
from the battery to the glowplug.
Basically, two leads, with clips, are
required, but, for greater convenience, twin leads with special
glowplug connectors, as shown on
the right, are commercially available.
Glowplug battery
The power source for heating the glowplug may be
either a large heavy-duty 1.5volt dry cell, Ni-cd battery
or glowplug Igniter.
1.5 volt dry cell
Battery leads
glowplug Igniter
In case of 1.5volt dry cell
Make sure glowplug element
glows bright red inside room
or shadow.
Hexagon starting shaft
This shaft mounted on an
electric starting motor is driven
into the shaft cup to turn the
engine.
Electric starter and starter
battery
An electric starter is recommended for starting.
10
Battery leads
12V Battery
Starter
Fuel
Select, by practical tests, the most suitable fuel from
among the best quality fuels available in your country
for helicopter use. For the best throttle response, a
fuel containing 10% to 30% nitromethane is
preferable. Lubricants may be either castor-oil or a
suitable synthetic oil (or . a blend of both) provided
that they are always of top quality. For consistent
performance and long engine life, it is essential to use
fuel containing AT LEAST 18%
lubricant by volume. Some fuels
containing coloring additives tend to
deterriorate and may adversely affect
running qualities. If in doubt compare
to a fuel known to be good.
Reminder!
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.
Fuel Pump
Alternatively, one of the purposemade manual or electric fuel pumps
may be used to transfer fuel directly
from your fuel container to the fuel
tank.
O.S. Super Filter (Fuel Can Filter)
Install a filter to the outlet tube of your
refueling container to prevent entry of
foreign matter into fuel tank. O.S. ‘Super
Filters’ (large and small) are available as
optional extras.
Fuel Filter
It is recommended to install a good inline filter between the fuel tank and the
PD-07 pump to prevent entry of foreign
matter into the carburetor.
Silicone Fuel Line
Heatproof silicone tubing of approx.
5mm o.d. and 2.5mm i.d. is required
for the connection between the fuel
tank and engine.
11
Manual
Electric
TOOLS
Hex Drivers
Necessary for engine installation.
1.5mm, 2mm, 2.5mm, 3mm
Phillips Screwdriver
No.1, No.2, etc.
Screwdriver
Necessary for carburetor adjustments.
No.1, No.2, etc
Socket Drivers
5mm, 5.5mm, 7mm
Long Socket Wrench With Plug Grip
Recommended for easy removal and replacement of
the angled and recessed glowplug, the O.S.Long
Socket Wrench incorporates a special grip.
8mm
End Wrenches
8mm, 13mm, 14mm, etc.
Needle Nose Pliers
12
ENGINE PARTS NAME
Heatsink Head
Carburetor
Typr 60M-P
Thrust Washer
Crankcase
Propeller nut
Crankshaft
Glowplug
Reguretor
Beam Mount
Throttle Lever
Idle Mixture Control Screw
Mixture Control Valve
Carburetor Rubber Gasket
Cover Plate
13
Reguretor
Mixture Control
Valve Stopper
Medium Speed Needle Valve
Pump Unit (PD-07)
Fuel Inlet
High Speed
Needle Valve
Pump Holder
JAPAN
INSTALLATION OF THE STANDARD ACCESSORIES
Insert the carburetor rubber
INSTALLATION OF THE CARBURETOR
Insert the carburetor retainer as illustrated.
1.
Unscrew the retainer screw a little.
Carburetor Retainer
Retainer screw
2.
gasket on the carburetor
body securely.
Then, insert the carburetor
in the crankcase.
Note: In case it is hard to insert the carburetor in
the crankcase, apply oil on the carburetor body.
Do not force it, or damage to the carburetor body
and/or crankcase can occur.
Rotate the retainer screw gently until it stops, then
3.
tighten a further 90-120 degrees.
Do not over-tighten the screw as this will damage
the carburetor body.
Retainer screw
14
Carburetor Rubber
Gasket
Carburetor Rubber
Gasket
0.2mm gap
INSTALLING THE GLOWPLUG
Install washer on glowplug
and insert carefully into
Heatsink-head, making sure
that it is not cross-threaded
before tightening firmly.
Glow plug
Washer
ABOUT THE HEAD GASKET
The engine is installed with a 0.2mm thick head
gasket at the factory. If necessary according to the
fuel used, atmospheric conditions and glow plug
used, adjust the thickness with the extra 0.2mm and
0.1mm gasket supplied with the engine.
ABOUT THE WOODRUFF KEY
Use the woodruff key supplied with the engine if the
fan pulley of the model has a groove to accept it.
HEX KEY NEEDLE ADJUSTMENT
The knurled heads of the two needle valves (HighSpeed and Medium Speed) are provided with
diagonal slots for use with a screwdriver.
Alternatively, formore positive location via an Allen
hexagonal key, these heads also have M2.6 internal
threads, into which M2.6x5mm Allen cap-head screw
may be installed. To avoid risk of damage to the fuel
passages when tightening these screws, remove the
needle valves from the carburetor and use 'Loctite'
thread-lock compound to secure the screw.
Needle Adjusting screw
15
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