O.S. Engines IL-300 User Manual
It is of vital importance, before attempting to
operate your engine, to read the general
'SAFETY INSTRUCTIONS AND WARNINGS'
section on pages 2-4 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.
Inline four-cylinder overhead-valve
four-stroke-cycle engine
1
SAFETY INSTRUCTIONS AND
WARNINGS ABOUT YOUR O.S. ENGINE
NOTES WHEN APPLYING AN
ELECTRIC STARTER
ABOUT THE ENGINE
ENGINE PARTS NAME
INSTALLATION
FUEL TANK & LINES
GLOWPLUG
MIXTURE CONTROLS
PROPELLER
GLOWPLUG HEATING
FUEL AND LUBRICATION
CONTENTS
STARTING
RUNNING-IN ("Breaking-in")
THROTTLE VALVE ADJUSTMENT
FLIGHT & MAINTENANCE
VALVE CLEARANCE ADJUSTMENT
ENGINE EXPLODED VIEW
ENGINE PARTS LIST
CARBURETOR EXPLODED VIEW
& PARTS LIST
O.S. GENUINE PARTS & ACCESSORIES
ENGINE THREE VIEW DRAWINGS
2-4
5
6
7-8
9-10
11
12
13
14-15
16-17
18
19-22
23
24-26
27
28-29
30
31
32
33
34
2
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.
SAFETY INSTRUCTIONS AND
WARNINGS ABOUT YOUR
O.S. ENGINE
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
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.
Model engine fuel is also highly flammable. Keep it
away from an 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
coole d. Contact with the mu ffler(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.
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.
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.
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.
Use an electric starter for this engine. The wearing of safety glasses is also strongly recommended.
4
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.
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 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 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!
NOTES
5
NOTES WHEN APPLYING
AN ELECTRIC 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.
6
The O.S. IL-300 (Dia-Star) is a four-cylinder inline
overhead-valve four-stroke-cycle engine of 50cc
displacement. The engine maintains the same
features of stress free starting, super smooth idling
and high torque power which is always the hallmark
of O.S. large size multi-cylinder engines. With it’s
finely detailed design and outstanding scale
appearance, the engine’s quality is second to none.
ABOUT THE ENGINE
STANDARD ACCESSORIES
Glow Plug Type F
(installed on the engine)
Valve adjusting tool kit
(4pcs.)
Exhaust Pipe Assembly
Exhaust Pipe
Exhaust Pipe Lock Nut
Exhaust Gasket
Feeler gauge 0.04mm
Feeler gauge 0.1mm
Hex. key 1.5mm
Wrench 5mm
Booster Cable Set
Leads for glow plug with clip
Lead for earth (ground)
(4pcs.)
(1pc.)
Radial Motor Mount Set
Mount attachment Screws
Engine mounting screws (M5X25)
Lock washers (ø5)
Blind nuts (M5)
(4pcs.)
(4pcs.)
(4pcs.)
(4pcs.)
7
ENGINE PARTS NAME
Crankcase
Rear Housing
Carburetor Type 80P
Intake Manifold
Gear Cover
Center Manifold
Carburetor Extention Pipe
Push Rod
8
Lock Nut
Propeller Washer
Propeller Nut
Cylinder Jacket
Front Housing
Exhaust Pipe
Cylinder Head 1
Drive Hub
Crankcase Under Cover
Cylinder Head 2
Cylinder Head 3
Cylinder Head 4
9
Needle-valve extension
The needle-valve 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. An L-shaped rod, of 1.6-1.8mm dia. and
appropriate length, should be inserted into the needle's
center hole and secured by tightening the set-screw in the
needle-valve knob with a small Allen key. If a longer
extension cable is required it is suggested that one be
fabricated as per the illustration.
NOTE:
O.S. does not offer the extension cable as an accessory
item.
Do not use an excessively long unsupported extension as
this may vibrate and cause the needle-valve setting to vary
or even damage the needle-valve thread. Always provide a
suitable support at the outer end.
It is essential that the firewall is strong and rigid (e.g. at
least 15mm thick) and firmly integrated with the structure of
the aircraft.
INSTALLATION
M5 Blind nut
Firewall
M5x25 screw
5 Lock washer
At least 15mm (0.6")
rigid hard wood
It is suggested to install the engine upright.
M5x15 screw
Lock washer
Set-screw
Set-screw
Hook
Knob
Cable
Needle
It is suggested to use Lock Washers (available as an
optional extra) with engine installing screws or apply
LOCTITE to the screws to prevent them from loosening.
10
Exhaust pipe adjustment
The direction of the exhaust pipes may be altered in
accordance with individual installation requirements. The
angle is easily adjusted by loosening the nut that secures
the exhaust pipe to the cylinder head. Use a 12mm
wrench.
12mm wrench
Loosen
Tighten
Lock nut
Exhaust pipe
Carburetor cleanliness
It is recommended that the fuel is passed through a filter
when the tank is filled and that a good in-line filter is
installed between the fuel tank and carburetor.
Occasionally remove the needle-valve holder from the
carburetor and rinse out the locations shown below with
methanol or fuel. Be careful not to lose the gasket when
removing the needle-valve holder from the carburetor.
Squeeze bottle
Dirt and fibrous matter
mostly accumulate here.
Dirt and fibrous matter
mostly accumulate here.
Needle-valve holder
11
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.
Locate the fuel tank as close as possible
to the carburetor, or the fuel level
difference will affect the engine running
when the model is upright or inverted.
Set the fuel tank position so that the
carburetor center line is 1/3 lower than
from the tank top when the model is
placed horizontal.
Approx. 15mm
1/3
Be sure to follow the instructions concerning the
relationship between fuel tank and carburetor position, or
the expected stable idle running will not be obtained even
with adequate carburetor adjustment.
For plumbing, use heavy duty silicone tube of 2.5mm inner
dia and 5mm outer dia.
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