O.S. Engines GF30 User Manual

Four stroke gasoline engine

600930100000

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.

for airplanes

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.

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.

NOTES

These cover the many other possibilities, generally less
obvious sources of danger, but which, under certain
circumstances, may also cause damage or 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.

Gasoline is poisonous. Do not allow it
come into contact with the eyes or mouth.
Always store it in a clearly marked
container in a cool and dark place and out
of the reach of children. There is a
possibility that it may damage your health.

Gasoline is highly flammable. Keep it away
from an open flame, excessive heat,
sources of sparks, or anything else which
might cause it to ignite. Do not smoke or
allow anyone else to smoke near to it.

GF30

Carry out the mixing of the gasoline and
oil outdoors or in a well ventilated place
away from any source of fire to prevent the
possibility of a fire.

Refill the fuel tank only after the engine is
well cooled down, or there is a danger of fire.

Model engines generates 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 results in a serious
burn.

Observe the laws and regulations in each
country and district concerning the usage,
transportation and storage of gasoline. Ask
details at fire station in each district.

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.

Do not operate the engine nor model alone, or
there is a possibility of injury.

NOTES

Any propeller requires utmost attention to handle.
Be sure to follow the instruction manual supplied with
a propeller.

This engine was designed for model aircraft.
Do not attempt to use it for any other purpose.

Start the engine only after installing it in the model.
Do not start the engine before installing it in the
model, or there is a possibility of injury.

Be sure to use an effective silencer (muffler).
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.

Mount the engine in your model securely, following
the manufacturers’ recommendations.

For their safety, keep all onlookers (especially small
children) well back (at least 10 meters) when
preparing your model for flight.

When checking a spark plug with the power source
on, do not hold the plug, plug cap, high tension cord ,
or you will get a shock.

Install a top-quality propeller of the diameter and
pitch specified for the engine and aircraft.

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.

Install 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 washer and
propeller installing screws using the correct size
wrench. Always check the tightness of propeller
installing screws and retighten them, if necessary,
before starting the engine. Also, check the tightness
of all the screws and nuts before restarting the
engine.

Always check the throttle linkage.If it is disconnected,
throttle action becomes uncontrollable, which may
result in a serious accident.

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.

Use an electric starter for this engine. The wearing of
safety glasses is also strongly recommended.
If you try hand starting, be sure to use a chicken stick
or heavy glove. Never attempt to start the engine
with a bare hand.

Be sure to carry out adjustments of the needle valve
and mixture control valve after stopping the engine.

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.

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.

Switch off the ignition module to stop the engine or
fully close the throttle valve via the transmitter to
shut off the fuel supply. Otherwise there is a
possibility of injury.

Immediately after the engine is stopped, the engine
may start with a crank even when the igniter switch
is off. Do not crank the engine, or there is a
possibility of injury.

Be sure to install an externally operable switch for
the ignition system battery to stop the engine if it is
started unintentionally with the radio transmitter
turned off or there is the possibility of injury.

Connect the throttle linkage so that the engine can
be stopped via radio operation.

ABOUT THE ENGINE

While this is a four stroke gasoline engine,
use the same oil mixed gasoline for two
stroke gasoline engines.

This engine is designed for experienced fliers.
Beginners and newcomers should not use this engine.

The engine unit, silencer, carburetor and ignition
module are specially designed.

The normal rotation direction of the engine is
counterclockwise facing to the propeller.

It offers broad power characteristics suitable for sport
flight as well as acro flight.

The specially designed ignition module “IG-07” is
equipped with a micro computer and designed not to
operate below 120 rpm.

The new F-6040 silencer is supplied with the engine.
It develops very efficient silencing effect.

STANDARD ACCESSORIES

Spark Plug 1/4-32

Ignition module
Assembly (IG-07)

F-6040 Silencer Assembly

Silencer Body
Exhaust Header Pipe Assembly
Exhaust Header Pipe Nut (M16)

ENGINE PARTS NAME

Cylinder Head

Drive Hub

Propeller Nut

Lock Nut

Crankshaft

Spark Plug

Intake Manifold

Carburetor
Type 70T

Pump Unit PD-08

High Tension Cord

Propeller Washer

Crankcase

RPM Sensor

Cover Plate

Beam Mount

Cam Cover

Battery Leads

Sensor
Leads

INSTALLATION

It is suggested to use as heavy and rigid as possible
engine mounting for highest performance and safe
running. Install the engine on a mount using at least
4mm steel screws, such as Allen type, with locknuts,
for bolting the engine to the bearers.

Also, use the Nord Lock Washers (optional extra) and
other anti-loosening washers or apply locking agent.

Be sure that there is sufficient air intake and outlet
area on the model for engine cooling to avoid
overheating. (Pay careful attention to the cooling
since a gasoline engine generates more heat than a
glow engine.)

INSTALLATION OF SPARK PLUG

Install the supplied spark plug firmly on the engine with
O.S. Long Socket Wrench (optional: code no. 71521000),
or with a commercially available 8mm deep socket wrench.

INSTALLING SILENCER

Screw the exhaust manifold in the exhaust port of
the cylinder head as far as possible and fix it with
the lock nut. (Insufficient screwing in may result in
damaging the screw threads of the exhaust port due
to vibration.)

Screw the silencer on the exhaust manifold within
more than 10mm and less than 25mm range. Set
the required outlet angle and fix it with the lock nut.

It is suggested to apply locking agent to the screw
threads to prevent loosening and also to make sure no
loosening from time to time and retighten if necessary.

PCV VALVE
This engine is employed with PCV (Positive
Crankcase Ventilation) valve.

Ventilation in the crankcase is positively done with the
change of pressure in the crankcase and one-way
check valve. Blow-by gas and oil waste are returned to
the combustion chamber via intake port.

FUEL TANK & LINES

Use a tank designed for gasoline. (Tanks designed
for glow fuel use a rubber cap which is deteriorated
by gasoline.)

A 230cc tank will provide 10~15 minutes flight.
(With full throttle, it will provide 7~8 minutes flight.)

Install a commercially available gasoline fuel filter
between fuel tank and carburetor. (Clean the filter
from time to time.)

For plumbing, use TYGON F-4040A tube (yellow
color) or O.S. fluolorubber tube (I.D. 3mm, O.D. 5mm,
500mm length: code no. 28382200). Replace tubing
periodically as it becomes hardened. (Replace tubing
inside the fuel tank every six months.)

Use fuel line keepers of stainless wire, etc. at the end
of the tubing to prevent the tubing from coming off.

This engine does not require a muffler pressurized
fuel system but be sure to provide an air vent.
Be sure to install a fine in-line fuel filter between the tank
and carburetor to prevent foreign matter in the tank from
entering the carburetor. Clean the filter periodically.

Be sure to equip
air vent pipe.

To carburetor
fuel inlet

tubing for
re-fuelling

CARBURETOR PARTS NAME

Roter Guide Screw

Throttle Lever

Nipple for PCV
(to be connected
to the PCV valve)

Two adjustable controls are provided on this
carburetor.

The Needle-Valve

For adjusting the mixture strength when the throttle is
fully open Needle-valve adjustment effect the mixture
strength at round mid speed.

The Mixture Control Valve

For adjusting the mixture strength at part-throttle and
idle speed, to obtain steady idling and smooth
acceleration to mid speed.

Please note with this carburetor, needle-valve
adjustment does not effect the mixture control valve
adjustment but the mixture control valve adjustment
effects the needle-valve adjustment. Therefore, it is
required to adjust also the needle-valve when the
mixture control valve is adjusted. Mixture control valve
is pre-set at nearly best position when the engine leaves
the factory. Therefore, it is not necessary to adjust the
mixture control valve until running-in is completed.

CARE OF FUEL PUMP & REGULATOR

NEVER disassemble the fuel pump or pressure
regulator. Their original performance may not be
restored after reassembly.

DO NOT allow foreign matter to enter the fuel
system. Dirt inside the pump or regulator, no matter
how small, may obstruct the flow of fuel and prevent
these components from working properly.

NEVER insert anything into the inlet or outlet nipples
in an attempt to clear a suspected obstruction.

DO NOT obstruct the small rectangular hole at the
bottom of the regulator, nor the regulator will not
function correctly.

Be sure to use fuel line keepers of
stainless wire, etc. to prevent tubing
from coming off.

Be sure to replace tubing
inside periodically.

Be sure to use a gasoline
resistant fuel tank cap.

Needle Valve

Regulator

Mixture Control
Valve

Fuel Inlet
(to be connected to the
outlet of PD-08 pump)

Rectangular hole

ALWAYS use fuel filters. Keep the fuel tank
scrupulously clean and filter all fuel as it enters the
tank (e.g.via an O.S.'Super-Filter' Code No.72403050)
and use a good quality in-line filter between the tank
and pump. Remember to inspect filter screens at
regular intervals and rinse clean as necessary.

NEVER use kerosene, thinner or any organic solvent
for cleansing the pump. Rubber parts will be ruined
by these materials. Use only alcohol (methanol) or
gasoline.

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
fully-open position. Carefully align the appropriate holes
in the throttle arm and servo horn so that they move
symmetrically and smoothly through their full travel.

IGNITION MODULE

Major specifications

Consumption current is 400mA/6,000rpm/6V. Use a
power source of more than 1000mAh capacity.

The ignition module is set not to operate below
120rpm for safety.

The voltage of power source is 4.8~8.4V (rated).
(Ni-Cd, Ni-MH 4~6 cells, Li-Po, Li-Fe 2 cells)

Installation

Install the ignition module taking sufficient anti
vibration measures.

Install the ignition module at least 100mm away
from the engine and in a place where there is airflow
so that engine exhaust heat and radiation heat may
not affect its operation.

Do not share the power source with receiver and
use a separate power source.

Equip an ON/OFF switch between the ignition
module and its power source, and install it in a place
where can be operated from outside the model.

Install the ignition module and its power source as
far as possible away from the servos and receiver
power source.

Connect the sensor leads of the igniter module
(white, red black three parallel wires) to the sensor
leads from the engine.

Connect the battery leads of the ignition module
(red, black two parallel wires) to the power source.

Make sure the jackets of high tension cord do not
touch the engine and cowl to avoid accidental short
circuit.

Press the plug cap on the spark plug firmly fitting the
hexagon shaped plug cap to the hexagonal body of
the spark plug. The plug cap is snap-lock type. Turn
the plug cap 60 degrees clockwise to lock it over the
spark plug.

Precautions

Do not disassemble the ignition module and plug
cap. (The ignition module is irreparable. Replace it
when necessary.)

Be careful not to mount the ignition module so that it
can be hit by water, gasoline or exhaust.

Avoid using the engine when the external
temperature is over 40 C.

Do not move the rpm sensor as it is placed at it's
optimum position, otherwise the engine will not run
properly.

Do not pull on the high tension cord to remove the
plug cap, or the wire will break. Be sure to hold the
plug cap to remove it. Be careful not to damage
your fingers while removing it.

Do not connect nor disconnect the rpm sensor with
the ignition module on, or there is a possibility it will
fire and the engine start.

Check the ignition module for spark when installing
the plug cap on the plug and be careful about
getting a shock. Make sure there is no flammable
material or gasoline vapors near by that could
ignite.

Do not turn the propeller with the ignition module
on, or there is a possibility the engine will start.

PROPELLER

The choice of propeller depends on the design and
weight of the aircraft and on the type of flying in which
you will be engaged. Determine the best size and type
after practical experimentation. As starting point, refer
to the props listed in the table shown below. Slightly
larger, or even slightly smaller props than those shown
in the table may be used, but remember that propeller
noise will increase if blade tip velocity is raised due to
high rpm or if a larger diameter/lower pitch prop is used.
Be well aware propeller rotating arc is very large due to
a large propeller used with this engine. Carry out
adjustments of the needle valve and mixture control
valve after stopping the engine. Do not allow your face
or hands to come close to the rotating prop.

Type

Sport / Acro / Scale

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-control
system. Do not use any propeller which has become
split, cracked or nicked even very slightly, or received
strong impact even if no apparent damage is visible.

PROPELLER & SPINNER ATTACHMENT

There is a risk, particularly with powerful four-stroke
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.
Install this as follows:

Install the propeller to the engine shaft, followed by

1.
retaining washer and propeller nut and tighten
firmly with a 14mm wrench (not supplied).

Add the special tapered and slotted locknut and

2.
secure with a 12mm wrench (not supplied) while
holding the propeller nut with the 14mm wrench.

Note:
Some spinners which are retained at the top of the
cone cannot be used with the propeller locknut
supplied with the engine. In this case, optional
locknut sets are available from O.S. – Propeller
Locknut Set for Spinner (Code No.45910200 4mm)
and (Code No.45913000 5mm).

NOTE:
Make a habit of always checking the tightness of
the propeller 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.
Retighten the propeller nut if necessary after
loosening the Safety Propeller Locknut.
The locknut should be tightened firmly after
retightening the propeller nut.

FUEL

Use regular gasoline. (No need to use high octane
gasoline.)

Alcohol based glow fuel cannot be used in this
engine. Not only will the engine not work properly
but the internal carburetor plastic parts will be
damaged.

Use high quality commercially available 2 stroke
engine oil.

Follow the oil manufacturer’s recommendations
concerning the mixture ratio of gasoline and oil. If
there is no recommendation, mix with a 30:1 ratio.
We have checked and approved the following oil
mixture ratio. Zenoah genuine 2 stroke engine oil
(40:1) and KLOTZ ModelLube (50:1).
(This does not mean we guarantee the quality of
these oils.) Follow the instructions in the running-in
section concerning the mixture for running-in.

With a gasoline engine, passages in the carburetor
are narrower than that of a glow engine, and
therefore very sensitive against foreign matter such
as dust. It is suggested to use optional accessory
Super Filter L (Code No. 72403050) when filling a
tank in the model from a container used for
transportation or storing.

16×10-12, 17×8-10, 18×6W-8

Size (DxP)