O.S. Engines FL-70 User Manual

It is of vital importance, before attempting to operate your engine, to read the general
'SAFETY INSTRUCTIONS AND WARNINGS'
section on pages 2-6 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 aircraft, radio control equipment, etc., are accessible for checking at the same time.
CONTENTS
SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O.S. ENGINE
ENGINE CONSTRUCTION NOTES WHEN APPLYING AN ELECTTRIC STARTER INTRODUCTION BEFORE STARTING ENGINE PARTS NAME INSTALLATION SILENCER & EXHAUST HEADER PIPE INSTALLATION
FUEL TANK & LINES
THROTTLE LINKAGE, NEEDLE-VALVE EXTENSION
PROPELLER & SPINNER ATTACHMENT
GLOWPLUG
2-6
10-13
15-16
18-20
22-23
TYPE 60W CARBURETOR, STARTING RUNNING -IN, CARBURETOR
7
CARBURETOR AIR-BLEED ADJUSTMENT
8
TROUBLE SHOOTING WHEN THE
9
ENGINE FAILS TO START
14
17
21
24
VALVE ADJUSTING HOW TO SET THE CAMSHAFT TIMING CARE AND MAINTENANCE ENGINE EXPLODED VIEWS & PARTS LIST CARBURETOR EXPLODED VIEWS
& PARTS LIST GENUINE PARTS & ACCESSORIES THREE VIEW DRAWING
25-27 27-30
31
32-33
34
35 36-37 38-39
40-41 42-43
44
1
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.
WARNINGS
Never touch, or allow any object to come into contact with, the rotating propeller and do not crouch over the engine when it is running.
A weakened or loose propeller may disintegrate or be thrown off and, since propeller tip speeds with powerful engines may exceed 600 feet(180 metres) per second, it will be understood that such a failure could result in serious injury, (see 'NOTES' section relating to propeller safety).
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.
NOTES
These cover the many other possibilities, generally less obvious sources of danger, but which, under certain circumstances, may also cause damage or injury.
2
Model engine fuel is also highly flammable. Keep it away fr om 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.
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.
3
NOTES
This engine was designed for model aircraft. 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.
Be sure to use the silencer (muffler) supplied with the engine. Frequent exposure to an open exhaust may eventually impair your hearing. Such noise is also likely to cause annoyance to others over a wide area.
If you remove the glowplug from the engine and check its condition by connecting the battery leads to it, do not hold the plug with bare fingers.Use an appropriate tool or a folded piece of cloth.
Install a top-quality propeller of the diameter and pitch specified for the engine and aircraft. Locate the propeller on the shaft so that the curved face of the blades faces forward-i.e. in the direction of flight. Firmly tighten the propeller nut, using the correct size wrench.
4
NOTES
Always check the tightness of the propeller nut and retighten it, if necessary, before restarting the engine, particularly in the case of four-stroke-cycle engines. If a safety locknut assembly is provided with your engine, always use it. This will prevent the propeller from flying off in the event of a "backfire", even if it loosens. Also, check the tightness of all the screws and nuts before restarting the engine.
If you install a spinner, make sure that it is a precision made product and that the slots for the propeller blades do not cut into the blade roots and weaken them.
Preferably, use an electric starter. The wearing of safety glasses is also strongly recommended.
Discard any propeller which has become split, cracked, nicked or otherwise rendered unsafe. Never attempt to repair such a propeller: destroy it. Do not modify a propeller in any way, unless you are highly experienced in tuning propellers for specialized competition work such as pylon-racing.
Take care that the glow plug clip or battery leads do not come into contact with the propeller. Also check the linkage to the throttle arm. A disconnected linkage could also foul the propeller.
After starting the engine, carry out any needle-valve readjustments from a safe position behind the rotating propeller. Stop the engine before attempting to make other adjustments to the carburetor.
5
NOTES
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.
Take care that loose clothing (ties, shirt sleeves, scarves, etc.)do not come into contact with the propeller.Do not carry loose objects (such as pencils, screwdrivers, etc.) in a shirt pocket from where they could fall through the propeller arc.
Do not start your engine in an area containing loose gravel or sand. The propeller may throw such material in your face and eyes and cause injury.
For their safety, keep all onlookers (especially small children) well back (at least 20 feet or 6 meters) 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. Keep the propeller pointed away from you and walk well clear of spectators.
Warning! Immediately after a glowplug­ignition engine has been run and is still warm, conditions sometimes exist whereby it is just possible for the engine to abruptly restart if the propeller is casually flipped over compression WITHOUT the glowplug battery being reconnected. Remember this if you wish to avoid the risk of a painfully rapped knuckle!
6
NOTE
ENGINE CONSTRUCTION
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.
Near TDC
Cylinder Liner
Crankshaft Slight taper
When the engine is cold.
7
Piston
When the engine is hot.
NOTES WHEN APPL YING AN ELECTRIC STARTER
Do not over-prime. This could cause 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 coming into your eyes.
8
INTRODUCTION
The FL-70 is an air-cooled, overhead­valve four stroke engine for model aircraft use. This engine is suitable for trainer, sport and scale models. This engine reduces maintenance by incorporating the first O.S. ringless piston/liner assembly. Also, a sealed front bearing prevents oil leaks. The engine is fitted with the new easy-to use O.S. 60W airbleed carburetor. This engine is designed so that more R/C pilots, from hobby beginners to skilled Sunday fliers may enjoy the performance advantages of four stroke engines – greater fuel economy, higher torque, lower noise and realistic sound.
Please note that this engine is not supplied with any tools (e.g. Allen keys, wrenches, etc.)
STANDARD ACCESSOIES
Glow Plug Type F (included with the engine)
F-4030 Silencer Assembly
T Nipple
9
BEFORE STARTING
Tools, accessories, etc.The following items are necessary for operating the engine.
Items necessary for starting
GLOW PLUG
O.S. Type F glowplug is installed in the engine.
GLOWPLUG IGNITER
Commercialy available handy glowplug heater in which the glowplug battery and battery leads are integrated.
FUEL PUMP
Alternatively, one of the purpose-made manual or electric fuel pumps may be used to transfer fuel directly from your fuel container to the fuel tank.
Manual
Electric
FUEL
The FL-70 should be operated on a methanol based fuel containing not less than 20% (volumetric) castor oil, or a top quality synthetic lubricant (or a mixture of both), plus a small percentage (5-15%) of nitromethane for improved flexibility and power. (The carburetor is adjusted at the factory for a fuel containing 20% lubricant and 15% nitromethane.) Some commercial fuels also contain coloring additives as an aid to fuel level visibility. In some cases, these additives have indicated slightly negative effects on the performance. We would suggest that you use such fuels only if you are satisfied that they do not adversely affect running qualities when compared with familiar standard fuels. When changing to a fuel brand or formula that is different from the one to which you are accustomed, it is a wise precaution to temporarily revert to in-flight running-in procedures, until you are sure that the engine is running entirely satisfactorily.
10
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.
Electric Starter and Starter Battery
Required when starting the engine.
12-Volt lead-acid battery
Electric Starter
O.S. Super Filter (Fuel Can Filter)
Install a filter on 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.
O.S. Non-Bubble Weight
To prevent the pickup from adhering to the tank wall under suction and restricting fuel flow, slots may be filed I the end of the weight. Alternatively, O.S. Non-Bubble Weight is available as an optional extra.
Fuel Filter
It is recommended to install a good in-line filter between the fuel tank and carburetor to prevent entry of foreign matter into the carburetor.
Fuel Tank
A fuel tank of approximately 300cc capacity is suggested. This allows around 10 minutes flying time, dependent upon the type of fuel used, the size of propeller and on the amount of full-throttle to part-throttle operation throughout the flight.
11
Spinner
Since the FL-70 is intended to be started with an electric starter, the addition of a spinner assembly for centering the starter sleeve is desirable. Use a heavy-duty, well balanced spinner either of metal or plastic.
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.
Propellers
The choice of propeller depends on the design and weight of the aircraft and the type of flying in which you will be engaged. Determine the best size and type after practical experimentation. As a starting point, refer to the props listed in the accompanying table. Slightly larger, or even slightly smaller,
props than those shown in the table may be used, but remember that the propeller noise will increase if blade tip is raised, due to higher rpm or if a larger-diameter/lower-pitched prop is used.
Sport & Aerobatic
Trainer & Scale
12X7, 12.5X6, 13X6
12.5X6, 13X6-7
Warning: Make sure that the propeller is well balanced. An unbalanced propeller and/or spinner can cause serious vibration which may weaken parts of the airframe or affect the safety of the radio-controlled system. DO NOT forget the WARNINGS and NOTES on propeller and spinner safety given on front pages.
Reminder!
Never touch, or allow any object to come into contact with, the rotating propeller and do not crouch over the engine when it is running.
12
TOOLS
HEX WRENCH
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 Wrenches
5.5mm, 7mm, 8mm
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
13
Engine Parts Name
Glow Plug
Rocker Cover
Lock Nut Set
F-4030 Silencer Assembly
Nipple No.5 (Smaller hole)
Propeller Washer
Nipple No.1 (Larger hole)
Exhaust Header Pipe
Lock Nut
Silencer Body
Carburetor Type 60W
Drive Hub
Crankcase
Beam Mount
Cover Plate
Rotor Guide Screw
Needle
Throttle Lever
Airbleed Screw
14
INSTALLATION
Because the FL-70 is a powerful, large-displacement, single-cylinder four-stroke-cycle engine, it is essential to use very substantial engine mounting. Conventional wooden mounting beams should be of rigid hardwood and of at least 15mm or 5/8-in square section.
Make sure that the mounting beams are parallel and that their top surfaces are in the same plane.
CORRECT
Front view
Top surfaces are in the same plane.
Side view
Top surfaces are not in the same plane.
Re-align the surfaces as necessary
15
INCORRECT
Opposite beam Top surfaces are not in the same plane.
Engine does not rest firmly.
How to fasten the mounting screws.
Hardwood mounting beams
Tighten second nut
3mm steel nuts
Spring washer or lock washer
15mm min.
15mm min.
Radial motor mount (cast aluminum)
firmlydown onto first nut.
Tighten this nut first.
Hardwood such as cherry or maple.
Steel washer
3mm steel screw
3mm steel Allen screw
Spring washer
●
Make sure that these mounting beams are accurately aligned and firmly integrated with the airframe, reinforcing the adjacent structure to absorb vibration. Use 3mm or larger steel screws, preferably Allen type hexagon socket head cap screws, with washers and locknuts, for bolting the engine to the bearers.
INSTALLING THE GLOWPLUG
Install washer on glowplug and insert carefully into cylinder-head, making sure that it is not cross­threaded before tightening firmly.
Glow plug
Washer
16
SILENCER & EXHAUST HEADER PIPE INSTALLATION
Screw the header pipe into the cylinder head until it “bottoms” , then unscrew sufficiently to achieve the desired exhaust angle and tighten the lock nut securely with a 14mm wrench. Screw the silencer onto the outer end of the header pipe and tighten the other locknut. The application of a heatproof silicone sealant to the threads of the exhaust system is recommended to reduce the risk of joints loosening and the leakage of exhaust gasses and oil residue.
Reminder: Model engines generate considerable heat and contact with the header pipe or silencer may result in a serious burn. If you need to tighten the silencer joints, which may loosen when they are hot, use a thick folded cloth for protection.
17
Lock Nut
Exhaust Header Pipe
Apply silicone sealant.
FUEL TANK & LINES
Make sure that the tank is well rinsed out with methanol or glow fuel before installation and that the pickup weight is well clear of the bottom of the tank when held vertically.
Be sure to install a fuel tank following the instructions shown in Fig. 1 and Fig.2. If a fuel tank is installed off the instructed position, stable idling will not be able to be secured even if proper adjustment is made.
Connect fuel line between the pressure nipple on the silencer (large i.d. hole) and the tank to supply muffler pressurized fuel for more stable fuel delivery.
Connect fuel line between the breather nipple on the back cover and silencer breather nipple (smaller i.d. hole).
General Plumbing
Make connections as shown in fig.1. With the airbleed type carburetor it is necessary to set the idle rpm a little higher to prevent engine cutting.
Plumbing suitable for aerobatic flights
With the general plumbing the fuel in the tank may flow into the silencer when the throttle is reduced to low speed during inverted flight or vertical dive which may result in the engine stopping. Plumbing shown in fig.2 prevents fuel from flowing into the silencer and stopping the engine. This plumbing also allows the idle speed to be set a little lower and also results in longer flying time due to excess fuel not flowing into the silencer.
When the tank is filled the fuel level is higher than the carburetor center line. To prevent the fuel from flowing into the cerburetor use a commercially available fuel shut off. Release the fuel shut off before starting the engine.
18
Fig. 1 General Plumbing
No.1 Nipple (larger hole)
No.5 Nipple (smaller hole)
Fuel Filter (commercially available)
Fuel Stopper (commercially available)
Note: When cutting silicone tubing, use knife or razor blade.
Silicone Tubing
l If you should need to clean out silicone tubes, use methanol or glow fuel, not gasoline or kerosene.
Install a fuel tank so that carburetor center line may be positioned approx. 10 to 15mm lower than fuel tank center line.
T Nipple (supplied)
Refueling tubing
Plug (commercially available)
Do not use wire cutter or pliers.
Fuel Tank Center Line
19
Carburetor Center Line
Approx. 10mm
Fig. 2 Plumbing suitable for aerobatic flights
No.5 Nipple (smaller hole)
No.1 Nipple (larger hole)
Fuel Filter (commercially available)
Install a fuel tank so that carburetor center line and fuel tank center line may come to as much close as possible (within 10mm lower or higher).
T Nipple (supplied)
Fuel Stopper (commercially available)
Plug (commercially available)
THROTTLE LINKAGE
Before connecting the throttle to its servo, make sure that the throttle arm and linkage safely clear any adjacent part of the airframe structure, etc., as the throttle is opened and closed. Connect the linkage so that the throttle is fully closed when the transmitter throttle stick and its trim lever are at their lowest settings and fully open when the throttle stick is in its fully­open position.. Carefully align the appropriate holes in the throttle arm and servo horn so that they move symmetrically and smoothly through their full travel.
Refueling tubing
T Nipple (commercially available)
Approx. 10mm
20
NEEDLE-VALVE EXTENSION
The needle-valve supplied with this engine is designed to incorporate an extension so that, when the engine is enclosed within the fuselage, the needle-valve may be adjusted from the outside. Cut a commercially available rod to the required length, bend one end to an L shape, insert it into needle's center hole and secure it by tightening the set-screw in the needle-valve knob with 1.5mm Allen key. Needle Valve Extension Cable Set (Code No.
72200080) is available from O.S. as an optional part.
1.5mm Allen key.
Needle Valve Extension Cable Set
21
PROPELLER & SPINNER ATTACHMENT
There is a risk, particularly with powerful four­stroke engines, of the propeller flying off if the prop nut loosens due to detonation ("knocking") in the combustion chamber when the engine is operated too lean, or under an excessively heavy load.
Obviously, this can be very hazardous. To eliminate such dangers, the O.S. Safety Locknut Assembly was devised.
Ream the propeller shaft hole to 6.4-6.5mm
1. bore with an appropriate reamer, checking that the hole is exactly centered.
2.
Install the prop to the engine shaft, followed by retaining washer and prop nut lightly. Turn the prop counter-clockwise slowly to locate the position where compression is felt. At this position, fit the prop horizontally and tighten firmly the prop nut with a 13mm wrench.
22
Add the specially tapered and slotted
3. locknut and secure with a 10mm wrench while holding the prop nut with the 13mm wrench.
Propeller Washer
Lock Nut
Propeller Nut
Fit a spinner assembly to start the engine
4. with an electric starter.
Note: Some spinners which are fixed at the top of the cone cannot be used with the prop locknut supplied with the engine. In this case, optional locknut sets are available from O.S. – Propeller Locknut Set for Spinner (Code No.45810200) and Propeller Locknut Set for Tru Turn Spinner (Code No.l45810300).
IMPORTANT Regardless of the type of propeller used, make a habit of always checking the tightness before starting the engine. Remember that, especially with wooden propellers, there is a tendency for the material to shrink, or for it to be reduced by the serrated face of the drive hub.
23
GLOWPLUG
The FL-70 is supplied with an O.S. Type F glowplug, specially designed for O.S. four-stroke engines.
The role of the glowplug
With a glowplug engine, ignition is initiated by the application of a 1.5-volt power source. When the battery is disconnected, the heat retained within the combustion chamber remains sufficient to keep the plug filament glowing, thereby continuing to keep the engine running. Ignition timing is 'automatic' : under reduced load, allowing higher rpm, the plug becomes hotter and, appropriately, fires the fuel/air charge earlier; conversely, at reduced rpm, the plug become cooler and ignition is retarded.
Glowplug life
Particularly in the case of very high performance engines,
glowplugs must be regarded as expendable However, plug life can be extended and engine performance maintained by careful use, i.e.:
Install a plug suitable for the engine. Use fuel containing a moderate percentage of
nitromethane unless more is essential for racing events.
Do not run the engine too lean and do not leave the battery connected while adjusting the needle.
When to replace the glowplug
Apart from when actually burned out, a plug may need to be replaced because it no longer delivers its best performance, such as when:
Filament surface has roughened and turned white. Filament coil has become distorted. Foreign matter has adhered to filament or plug
body has corroded. Engine tends to cut out when idling. Starting qualities deteriorate.
24
TYPE 60W CARBURETTOR
Two adjustable controls are provided on this carburettor. They are as follows:
The Needle Valve
This is used to establish the fuel/air mixture strength required for full power when the throttle is fully open.
The Airbleed Screw
This is used to establish the mixture strength required for steady idling and a smooth transition to medium speeds. (The varying mixture strength required between part­throttle and full-throttle running is automatically adjusted by coupled movement of the throttle.)
The sequence in which these controls are adjusted is explained in the succeeding sections, under Starting, Running-in and Idling Adjustment.
Needle Valve
Airbleed Screw
STARTING
The FL-70 is not equipped with manual choke controls, as it is intended for use with an electric starter only. A high-torque electric starter not only makes starting the engine easier, it dispenses with the need for a choke valve by turning the engine over fast enough to cause the fuel pump to prime the cylinder automatically. Starting procedure is as follows:
1.
Fill the fuel tank with fuel. When filled, prevent fuel flowing into the carburetor with a commercially available fuel stopper, etc. Release the stopper before starting the engine.
Make sure that plug element glows red, and
2. install the plug in the cylinder head.
25
Element glows when energized.
Pliers
Replace the plug when the element does not glow or is burnt out.
Glow Plug Igniter
WARNING When checking the plug element hold the plug with tools, such as pliers, etc. Do not hold near your face or the fuel remaining in the filament may burn you.
3.
Check that the current to the glowplug is switched off.
To close the needle-valve, turn it
4. clockwise, while to open the needle-valve, turn it counter­clockwise. Turn the needle-valve clockwise slowly until it stops. This is the fully closed position.
5.
Open the needle-valve 2-2.5 turns from the fully closed position and set the throttle in the fully open position.
Apply the starter and press the starter switch
6. for 5-6 seconds to prime the engine.
7.
Position the throttle stick at 2-3 scales advanced from the fully pulled down position. Turn the prop backwards (clockwise) by hand until it is against compression. This is to enable the kinetic energy of the prop to subsequently assist the starter through the compression stroke to start the engine.
26
Close
Open
Close
Fully opened position
8.
Make sure that the rotating direction of the electric starter is correct. Energize the glowplug and apply the starter.
9.
When the engine starts, slowly open the throttle to the mid speed position. Then, disconnect current to the glowplug. If at this pint the engine stalls, it is probable that the mixture is excessively rich. Close the needle-valve a little and restart the engine.
10.
Now close the needle-valve gradually so that the rpm increases.
How to stop the engine
Pull down the throttle lever and trim lever on the transmitter fully.
Note: Make sure that the throttle linkage is made so that the
Close
throttle is fully closed when the throttle lever as well as trim lever on the transmitter are fully pulled down.
RUNNING-IN (Breaking-in)
For long life and peak performance, every engine needs special treatment when new, know as “running-in” or “breaking-in”. This is a procedure during which the engine is operated under strictly controlled conditions at the beginning of its life, in order to avoid the risk of immediate damage to certain components through becoming overheated or stressed and to help working surfaces to become smoothed and aligned for maximum mechanical efficiency thereafter. With some engines, this can require a tediously protracted period of bench running, but, as O.S. engines are manufactured to fine tolerances and from the finest quality materials, a relatively brief running-in period is sufficient and can be completed with the engine installed in the aircraft. Prolonged running with too rich mixture and/or low speed will not complete the proper running-in.
27
On the contrary, prolonged low speed running may cause the oil in the fuel to congeal, which may result in seizure of the piston and cylinder liner. The recommended procedure is as follows:
1.
Use the same fuel and prop as you intend for flying your model.
2. Open the needle-valve 2.5 turns from the fully closed position and start the engine.
3. Open the throttle slowly to the mid speed position, and disconnect the current to the glowplug.
4. Now open the throttle slowly to the fully opened position and run the engine for no more than 5 seconds with the needle-valve tuned to produced near maximum r.p.m., then, immediately, slow the engine down again by opening the needle-valve approximately one turn. The rich mixture, so induced, will cool the engine, at the same time providing increased lubrication.
Repeat this process, alternately running the
5. engine fast and slow by means of the needle-valve, while keeping the throttle fully open, then begin to extend the short periods of high-speed operation until two tanks of fuel have been consumed.
WARNING: When ground running the engine, avoid dusty or sandy locations. If dust or grit is drawn into the engine, this can have a ruinous effect, drastically shortening engine life ion a matter of minutes.
Following the initial running-in session,
6. check for any looseness in the installation due to vibration, then allow the engine a period of moderately rich operation in flight.
7.
For the first flight, have the needle-valve set on the rich side and adjust the throttle trim on the transmitter so that the engine does not stop when the throttle is closed to the idle setting.
28
8.
With each successive flight, close the needle-valve very slightly until, at the end of about 10 flights, the needle is set for full power. Do not "over-lean" the mixture in an attempt to extract more power.
If overheating should be suspected at any time during flight (i.e.if the engine begins to "labor") reduce power by partially closing the throttle and land the aircraft to enable the needle-valve to be readjusted to a richer setting.
CARBURETOR
These engines are equipped with a throttle type carburetor which provides a wide range of engine speed control. With the throttle lever linked to a suitable servo in the model, movement of the throttle control on the transmitter will enable engine speed to be varied, proportionally, from idling speed to full power. The carburetor of your engine has been factory set for the approximate best results and no adjustment (except to the needle-valve) should be required provided that the fuel tank is correctly located, as previously described. After the engine has been run-in, check the operation of the throttle according to the following chart. Re-adjust the controls only when necessary.
29
Re-set the idling position at a little higher r.p.m.
Start the engine.
Make sure that the throttle is fully open.
Adjust the neede-valve.
Close the throttle gradually.
Find the idling position.
Fix the idling position.
20-30
˚
open from maximum
r.p.m. setting.
The position where the lowest possible r.p.m. ,with steady running, is obtained.
Set the throttle opening by means of the throttle trim on the transmitter so that the lowest practical speed, without risk of the engine stopping,is obtained.
CARBURETOR AIR-BLEED ADJUSTMENT
Pre-Flight Check
Start engine and adjust needle­valve as previously described.
Close the throttle gradually.
Find the idling position.
Repeat the procedure while opening and closing
the throttle until the best result is obtained.
Hold the model.
approx. 15˚
30
Refer to the CARBURETOR AIR-BLEED ADJUSTMENT section on page 31.
Engine stops.
Engine stops.
Engine stops.
Open the throttle fully.
Does the engine regain full power?
Continue running at high speed for 10 seconds.
Close the throttle.
Run at idling speed for 5 seconds.
Does the engine stop?
Apply full throttle.
Does the engine regain full power immediately?
OK
Yes.
No.
Yes.
Hold model level, then slowly raise its nose.
If rpm increases.
If engine runs unevenly or stops.
31
Stop the engine.
Note: Stop engine by pinching fuel line Do not touch needle-valve.
These adjustments can be made without stopping the engine. However, it is advisable for beginners to stop the engine for safety reasons.
Open air-bleed screw.
Half turn at a time.
Attention: Do not leave the glowplug connected to the
battery while adjusting the carburetor throttle.
approx. 15˚
Immediately point nose down, so that engine runs steadily again.
Stop the engine.
Close air-bleed screw.
Half turn at a time.
TROUBLE SHOOTING WHEN THE ENGINE FAILS TO START
Four key points
For quick, reliable starting, the following four conditions are required.
1 Good compression. 2 Adequate "glow" at glowplug. 3 Correct mixture. 4 Sufficient electric starter rotating speed.
If the engine fails to start, or does not keep running after being started, check symptoms against the following chart and take necessary corrective action. Note: The most common causes of trouble are marked with three asterisks, the less common problems with one or two asterisks.
Symptom
Engine fails to fire.
Symptom
Engine fires intermittently but does not run.
Engine fires once or twice, then fails to fire.
Engine starts but rpm decreases and engine eventually stops.
Engine starts, rpm increases and engine cuts out.
Engine stops when the current to the glowplug is discon­nected after starting.
Factor
1
2
3
Factor
2 3
1
2
3 3
3
3 2
Cause
Sluggish rotation
Glowplug battery discharged.
Glowplug element is burned out
Something wrong with battery leads. Engine "flooded" due to excessive priming.
Insufficient priming.
......
......
Cause
Incorrect heating of glowplug.
Over priming.
Sluggish rotation.
Glowplug battery discharged.
Insufficient priming.
Mixture too rich.
Fuel not reaching the engine.
Mixture too rich.
Mismatch of glow plug and fuel.
........
......
......
.......
.......
Corrective action
Recharge the electric starter battery.
Recharge lead-acid cell or replace dry battery. (Note: An unused, or almost unused, dry battery may sometimes be of insufficient capacity if it is "old stock".)
.....
Replace glowplug. Check that applied voltage is not too high.
....
Check glowplug heating using other leads.
....
Close needle-valve fully and remove glowplug, then flip propeller to pump out excess fuel. (Invert engine, if possible, while pumping out excess). Re­start engine. (Priming is not necessary at this time.)
.....
Repeat priming procedure referring to Priming.
32
Corrective action
.....
.....
.....
Voltage too high or too low. Re-check and readjust referring to "BEFORE STARTING" .
Continue applying an electric starter. If the engine dos not start after more than 4 tries, disconnect the current to the glowplug and leave for a few minutes., then re-energize plug and apply starter. If the engine still does not start, remove glowplug and pump out excess fuel by applying the starter.
Then re-start. (Priming is not necessary.) Recharge the electric starter battery.
Recharge lead-acid cell or replace dry battery. (Note: An unused, or almost unused, dry battery may sometimes be of insufficient capacity if it is "old stock".)
Repeat priming procedure referring to Priming.
Close needle-valve half turn (180˚) and wait for several minutes then re­start.(Priming is not necessary.)
Make sure that tank is filled with fuel. Check that there is not something wrong with the fuel line (kinked or split). Check that carburettor is not clogged with dirt.
Close the needle-valve a little before disconnecting current to the glowplug.
...
Change fuel or glowplug.
33
VALVE ADJUSTING
Valve clearances are correctly set before any O.S. engine leaves the factory and, in normal use, will seldom require adjustment. However, if, after a considerable amount of running time, a loss of power is detected, or if he engine has been disassembled for repair, these clearances should be checked and reset as necessary. For checking and adjusting the valve clearances, a VALVE ADJUSTING TOOL KIT is available as an optional accessory.
The kit comes in a plastic case and includes: (Code No.72200060)
Feeler gauge 0.04mm
Feeler gauge 0.1mm
Hex. key 1.5mm
Wrench 5mm
34
HOW TO SET THE CAMSHAFT TIMING
When replacing the camshaft, set the timing as follows.
Secure propeller.
1.
NOTE: If propeller is not secured, crankshaft may move backward and correct timing cannot be set.
2.
Turn the crankshaft so that 'T' mark on the drive hub may match crankcase center line. (This is engine T.D.C. position)
3.
Push the camshaft into camshaft housing until it stops. Locate ' ' mark on the side of camshaft gear in line with the push rod.
4.
Rotate crankshaft right and left a little and make sure that the ' ' mark on the gear is in line with the push rod when the ' T ' mark on the drive hub matches the crankcase center line.
5.
Secure cam cover with screws.
The relation of position between ' ' mark of the gear and teeth may differ from the sketch, by each model.
Fig.1
' ' mark
Fig.2
in line with the push rod
' ' mark of the camshaft gear
camshaft
crankcase center line
'T' mark on the drive hub
35
CARE AND MAINTENANCE
Please pay attention to the matters described below to ensure that your engine serves you well in regard to performance, reliability and long life.
As previously mentioned, it is vitally important to avoid operating the engine in conditions where dust, disturbed by the propeller, may be deposited on the engine and enter its working parts.
Install an in-line fuel filter between the tank and carburetor to prevent dirt and dust in the tank from entering the carburetor.
Clean these filters periodically. If these precautions are neglected, restriction
of fuel flow may cause the engine to cut out, or the fuel/air mixture to become too lean causing the engine to overheat.
Remember to keep your fuel container closed to prevent foreign matter from contaminating the fuel.
Install a fuel filter to prevent dirt and dust in the fuel container from entering the fuel tank. O.S. Super Filters (L) and (S) are available as optional extras.
The use of nitromethane in the fuel can also contribute to the problem.
Do not leave unused fuel in the engine at the conclusion of a days flying. Accepted practice is to cut off the fuel supply while the engine is still running at full throttle, then expel as much fuel residue as possible by turning the engine over 5-10 seconds with the electric starter. Finally, inject some after­run oil through the glowplug hole and turn the engine over several times by hand.
The use of modern high-performance alcohol based model engine fuels, while promoting cooler running, improved anti-detonation combustion and increased power, have the disadvantage of causing bottom end corrosion in a four-stroke engine. This is due to the acidic by products of combustion that accumulates in the engines crankcase and are not flushed out by fresh air/fuel mixture as in the case of a two-stroke engine.
36
When the engine is not to be used for some months (for example, as between flying seasons), a worthwhile precaution is to remove it from the airframe and, after washing off the exterior with alcohol (not gasoline nor kerosene), remove carefully the carburetor with intake pipe, glow plug and all silicone tubing and put them safely aside. Then, immerse the engine in a container of alcohol. Rotate the crankshaft while the engine is immersed. If foreign matter is visible in the alcohol, rinse the engine again in clean alcohol. Finally, shake off and dry the alcohol ,and inject some after-run oil from glowplug hold and rotate the crankshaft several times by hand. Re-fit the carburetor with intake pipe and glowplug with the engine and keep it dry place after putting in a vinyl bag.
37
ENGINE EXPLODED VIEW
2-2
2
4
7
8
6
38
C.M2.6x10
17
15
B.M3x6
14-1
14
13
Type of screw
C...Cap Screw B...Binding Head Screw M...Oval Fillister-Head Screw F...Flat Head Screw N...Round Head Screw S...Set Screw
16
No.
Code No.
44404200
1
45961400
39
2-1 2-2
3-1 3-2
4-1 4-2 4-3 4-4
5-1 5-2 5-3 5-4
10 11 12 13 14
14-1
15 16 17 18 19 20 21 22
23 23-1 23-2
24
25
26
27
28
29 29-1 29-2 29-3
2
3
4
5
6 7 8 9
45961410 45761600 44753000 44753100 45761200 44460000 44460100 45960210 45260350 46160400 44461000 44461100 45960210 45260350 46160400 44404100 44404000 44481000 44714100 44403000 45906000 44405000 44407009 44407010 44407020 44402000 44408100 44430000 44401000 44462000 44401100 44701109 44766000 44766100 44766110 24881824 45664000 44731000 44408000 23209003 44410000 44425000 44425100 45926100 45626030 71615009 29084610
C.M2.6x8
1
C.M3.5x20
C.M3x12
3-1
3
2-1
4-4 4-3 4-2
4-1
11
12
18
3-2
5-4 5-3 5-2
5-1
9
10
M11
5
22
23-2
23-1
23-2
24
25
27
26
F.+M2.6x6
19
20
21
29-3
29-2
29-1
29
23
28
Rocker Cover Rocker Support Assembly Rocker Support Rocker Arm Retainer(2pcs.) Rocker Arm Assembly(1pair) Rocker Arm(1pc.) Tappet Adjusting Screw Intake Valve Assembly(1pair) Intake Valve(1pc.) Valve Spring(1pc.) Valve Spring Seat(1pc.) Valve Spring Retainer(2ps.) Exhaust Valve Assembly (1pair) Exhaust Valve(1pc.) Valve Spring(1pc.) Valve Spring Seat(1pc.) Valve Spring Retainer(2ps.) Cylinder Head(W/Gasket) Cylinder Head (W/Gasket and Valve Assembly) Carburetor Complete (60W) Head Gasket Cylinder & Piston Assembly Piston Pin Connecting Rod Cover Plate Retaining Screw Cover Plate Cover Gasket Crankshaft Drive Pin Crankshaft Ball Bearing(Rear) Crankcase Camshaft Cam Cover Cam Cover Retaining Screw Push Rod(2pcs.) Push Rod Cover Assembly(2pcs.) Push Rod Cover(1pcs.) Push Rod Cover "O" Ring(2pcs.) Cam Follower(2pcs.) Crankshaft Ball Bearing(Front) Drive Hub Propeller Washer Lock Nut Set F-4030 Silencer Assembly Silencer Body Exhaust Header Pipe Assembly Manifold Nut (M11)(1pc.) Glow Plug Type F T Nipple (1pc.)
Description
Specifications are subject to alteration for improvement without notice.
CARBURETOR EXPLODED VIEW
N.+M3x6
1-1
Type of screw C...Cap Screw B...Binding Head Screw M...Oval Fillister-Head Screw
F...Flat Head Screw N...Round Head Screw S...Set Screw
C.M2.6x10
C.M2.6x7
2
1
B.M2.6x5
3
6-2
7
C.M2.6x15
40
4
6
6-3
6-1
5-1
S.M3X3
5-2
5
CARBURETOR PARTS LIST
No.
Code No.
22081408
1
22081313
1-1
44481200
2
44481100
3
45915000
4
24081970
5
24981837
5-1
26381501
5-2
44481960
6
26711305
6-1
45281920
6-2
22681953
6-3
44481310
7
Specifications are subject to alteration for improvement without notice.
Throttle Lever Assembly Throttle Lever Retaining Screw Carburetor Rotor Carburetor Body Carburetor Rubber Gasket Needle-valve Assembly "O" Ring (2pcs.) Set Screw Nozzle Assembly Ratchet Spring Nozzle Retaining Screw (2pcs.) Fuel Inlet (No.1) Air-bleed Screw
Description
41
O.S. GENUINE PARTS & ACCESSORIES
O.S.GLOW PLUG TYPE F
(71615009)
Needle Valve Extension Cable Set
(72200080)
RADIAL MOTOR MOUNT
(71905010)
BOOSTER CABLE SET
(72200110)
BOOSTER TERMINAL KIT
(72200130)
PROPELLER LOCKNUT SET
(45810100)
(45810200 For Spinner)
PROPELLER LOCKNUT SET FOR TRUTURN SPINNER
1/4"-M5
(45810300)
EX EXHAUST HEADER PIPES
(72109500)
(72109600)
42
NON-BUBBLE WEIGHT
(71531000)
SUPER FILTER (L
(72403050)
)
FLEXIBLE EXHAUST PIPES
Code.No.
72108100 72108110 72108120 72108130
Type
1111A 1111B 1111C 1111D
Length
120 240 170 330
(mm)
LONG SOCKET WRENCH WITH PLUG GRIP
(71521000)
Inside
VALVE ADJUSTING TOOL LIT
(72200060)
Outside
LOCK WASHER
(10sets)
(55500002)
M3
The specifications are subject to alteration for improvement without notice.
BLIND NUT
(10pcs./sets)
(79870030)
M3
CAP SCREW SETS
(10pcs./sets)
M2.6x8 M2.6x10 M3.5x12 M3.5x20
(79871025) (79871030) (79871080) (79871100)
43
THREE VIEW DRAWING
Specification
■
Displacement
■
Bore
■
Stroke
■
Practical R.P.M.
■
Power output
■
Weight
(Silencer including exhaust header pipe)
11.45 cc (0.698 cu.in.
27.7mm (1.090 in.
19.0mm (0.748 in. 2,300-12,000 r.p.m.
1.1ps / 11,000 r.p.m. (16
467g
.48 oz.
51.5g (1.8 oz.)
Approx. 85
Dimension(mm)
) ) )
)
59.5
4- 3.7
45
49.5
20
25.8
20
Approx. 44
58.9
28.5
35.4 54
UNF1/4-28
44
89.5
107.5
18
59.534.5
21.4
43.5
C
Copyright 2004 by O.S.Engines Mfg. Co., Ltd. All rights reserved. Printed in Japan.
6-15 3-Chome Imagawa Higashisumiyoshi-ku Osaka 546-0003, Japan
TEL. (06)6702-0225
FAX. (06)6704-2722
URL : http://www.os-engines.co.jp
60091500 010606
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