Saito FA-60T, FA-90TS, FA-100T, FA-182TD, FA-130TD Instruction Manual

TWIN-CYLINDER FOUR-STROKE ENGINES

INSTRUCTION MANUAL

• FA-60T

• FA-90TS

• FA-100T

• FA-130TD

• FA-182TD

• FA-300TL

• FA-300TTDP

VERY
IMPORTANT

Failure to read
and follow these
instructions before
you proceed may
result in engine
damage and the
voiding of your
warranty.

SAFETY INSTRUCTIONS

1

Introduction

Congratulations on purchasing a Saito
4-cycle engine. Cared for properly,
these high-quality, finely crafted
engines offer many years of modeling
enjoyment.

This instruction manual has been
developed to ensure optimum
performance from the Saito engine
you have purchased. The instructions
must be read through completely and
understood thoroughly prior to
mounting and running the engine.

Safety Instructions

This model engine will give you
considerable pleasure, satisfaction
and performance if you strictly follow
these safety instructions and take heed
of the warnings as to its safe and
proper use. Remember at all times,
IT IS NOT A TOY,but a precision­built machine with more than enough
power to cause harm if misused, or
if the safety precautions are not
observed.

You should always:

1. Mount the engine securely on the
test bench using the high-quality Saito
motor mount supplied. Never clamp
the engine in a vice.

2. When running the engine, be sure
that all spectators, especially children,
are at least 20 feet away.

3. Use the correct size and pitch of
propeller for your engine; refer to the
propeller chart on page 18 of this manual.

4. It is extremely important to
balance the propeller prior to
installation. Failure to do so may
cause damage to the Saito engine
and/or the airframe. Install the
propeller with the convex (curved)
side facing forward. Securely tighten
the propeller nut against the washer
and propeller. A “jam” nut is
suggested for all 4-cycle engines.

5. Inspect the tightness of the
propeller nut prior to each flight.

6. Keep your face and body away
from the path of the propeller blades
when starting or running your engine.

7. Never allow your hands to come
close to the propeller. Use either a
“chicken stick” or electric starter to
start the engine.

8. Make all carburetor adjustments
from behind the propeller.

9. To stop the engine, cut off the fuel
supply (pinch or disconnect the fuel
line to the carburetor), or use the
throttle linkage to shut off the air.

SAFETY INSTRUCTIONS

2

DO NOT USE HANDS, FINGERS
OR ANY OTHER PART OF
THE BODY TO STOP THE
PROPELLER. DO NOT THROW
ANY OBJECT INTO A
PROPELLER TO STOP IT.

10. Discard any propeller that is
nicked, scratched, cracked or
damaged in any way.

It is highly recommended
that:

1. Safety glasses or goggles be worn
when starting and running your
engine.

2. You do not run the engine in the
vicinity of loose gravel or sand. The
propeller may throw such materials
into your face and eyes. The engine
may also ingest these harmful
materials.

3. Loose clothing should be avoided
when operating your model engine.
Loose clothing may become
entangled in the propeller, creating
the possibility of bodily harm. Also,
all loose objects (screwdrivers,
pencils, nickel cadmium starters, etc.)
should be removed from your pockets
so they do not fall into the propeller.

4. Glow plug clips and cords are
kept well away from the propeller.

5. Your glow fuel is kept in a safe
place well away from sparks, heat or
anything which can ignite the fuel.

Beware:

1. Model engines get very hot while
running. Do not attempt to handle
them until they have cooled.

2. Always run your model engines in
a well-ventilated area. Similar to
automotive engines, model engines
produce possibly harmful carbon
monoxide fumes.

3. Remember that model engines
produce a substantial amount of
power, more than enough to seriously
injure people and/or do considerable
damage to property. Always use
common sense, skill and constant
observation of safety precautions.

Disassembly

Do not needlessly disassemble your
Saito engine. Engine repairs should
be performed only by qualified
individuals. Damage due to improper
disassembly will not be covered under
the warranty.

SUPPORT EQUIPMENT

3

Engine Parts
Identification

It is important to be able to identify
the parts of your Saito engines. In the
back of this manual you will find an
exploded view of Saito twin-cylinder
engines, as well as a chart which
includes part numbers and
descriptions. This will assist you in
easily and rapidly identifying the
respective parts of your Saito engine.

Support Equipment

The following items, which are not
included with your Saito engine, are
necessary in order to operate the
model engine:

1. Fuel. For maximum protection
and longevity of Saito engines, Saito
recommends a fuel containing 20%
oil and 10–15% nitro methane. If this
blend is not readily available, the next
best selection is a high quality 2­cycle glow fuel, such as Cool Power,
K&B, Power Master, etc. Fuels
composed entirely of castor oil are
not recommended. Use of such fuels
will void the warranty.

2. Propeller. Refer to the Propeller
Selection Chart, located on page 18,
to determine the best initial propeller
for your particular application.

3. Glow Plug Battery. Your glow
plug may be properly heated by several
different sources. The Hangar 9 Po wer
Panel (HAN106), when accompanied
by a 12V sealed lead acid battery
(HAN102) and a glow plug locking
socket (HAN120), is an ideal source of
heat for your glow plug. A
conventional 1.5V hea vy-duty dry cell
battery with a glow plug locking
socket (HAN120) or alligator clips can
also be used. Additionally, there are
several very good glo w-starters (nick el
cadmium powered glow plug ignitors)
which work well.

4. Glow Plug Wrench.A glow plug
wrench is used to remove and tighten
glow plugs. The Hangar 9 Long
Reach Plug Wrench (HAN2510) is an
excellent wrench to utilize as a longer
shaft may be necessary to access the
glow plug. This depends mostly upon
engine installation.

5. Manual or Electric Starter. For
manual starts, a “chicken stick” is
highly recommended. never use your
fingers to start any model engine, as
doing so invites injury. There are a
variety of electric starters on the
market. The Hangar 9 12V Heavy­Duty Super Starter (HAN110) will
work perfectly on all of the twin­cylinder Saito engines.

STARTING THE ENGINE

4

Break-In

The first run on any engine, whether
2-cycle or 4-cycle, is critical to the
future of the engine itself. During this
time, metal mating parts (piston and
cylinder, ball bearings, etc.) wear in.
Care must be taken that the engine is
clean and free of any dust or grit that
may have accumulated while
building the model.

There are two accepted methods for
breaking in a new engine: test stand
mounted and run or aircraft mounted
and run. Either method is acceptable,
however, mounting the engine to a test
stand allows the engine to be observed
throughout its operation, as well as
elevating it above the ground and away
from harmful dust and dirt.

NOTE: Because your engine may
have been sitting for an extended
period of time prior to running it, a few
drops of light oil applied through the
crankcase breather nipple (19 on the
exploded view),if applicable,and down
the pushrod tubes (40) will ensure
proper lubrication for the first run.

Regardless of the mounting method
chosen for break-in, the following
procedures are applicable:

1. Use a break-in fuel as described
in the “Support Equipment” Section
on page 3 of this manual.

2. Use the proper glow plugs. Your
engine includes the Hangar 9/McCoy
MC-4C (HAN3010) glow plugs,
which are also the standard
replacement glow plugs for these
engines.

3. Select the correct propeller. To do
so, refer to the Propeller Selection
Chart on page 18 of this manual.

4. Make sure that the high speed
needle valve(s) (85) are opened
(turned counterclockwise) five full
turns. This guarantees a very rich
setting.

Do not adjust the low-speed needle
valve(s) or airbleed screws (89) at
this time. The low speed needle
valve(s), or airbleed screws, are pre­adjusted at the factory for initial
break-in.

5. The use of a tachometer is highly
recommended since the adjustment
of a 4-cycle engine, while similar to
that of a 2-cycle engine, is more
difficult to “set by ear,”therefore
making it easier to damage the
engine by “over leaning.”

STARTING THE ENGINE

5

Starting The Engine

1. Make sure the glow plugs are
installed and tightened.

2. Be sure the propeller is properly
secured. The use of a “jam nut” is
encouraged on 4-cycle engines.

3. Make sure the fuel tank
line(s) are properly connected. The
main line should be connected to the
carburetor spray bar (84).

NOTE: If your Saito engine is
equipped with dual carburetors it’s
imperative that the fuel lines are
identical in length from the Y-fitting
to the fuel inlets.

Connect the fuel tank lines as shown in
Figures 1, 2 and 3.

The proper “plumbing” of the lines
is extremely important to the
performance of any engine.

Figure 2

FA-300TTDP

Air out nipple

Air intake nipple

Vent line

Excess pressure outlet

Pressure adjusting valve

Figure 1

Connect this end of fuel tubing to the
nipple on the muffler conncected to the
right cylinder. This connection will carry
the fuel residue away from your aircraft.

Breather
nipple

FA-300TL

Vent line

Figure 3

FA-100T

Tank vent line

Figure 4

FA-182TD

Aluminum stopper

Right carb spray bar

STARTING THE ENGINE

6

4. Be certain the mufflers are
installed properly by oiling the
threads and inserting the muffler
gasket (79) if applicable, and that the
lines are properly connected.

5. Fill the fuel tank.

6. Prime the engine:

• check to make sure the glow
plugs are not connected to the
heat source (glow plug
clip/locking socket)

• open throttle fully

• close choke valve (92), if
applicable

• rotate propeller in a counter­clockwise direction 2–3 times
or until fuel begins to drain
from the carburetor

• open choke valve (92), if
applicable

NOTE: The 90-TS is primed by
inserting approximately 1–2cc of fuel
into the priming nipple on the
carburetor with a syringe.

NOTE: This process is not
applicable for owners of the Saito
FA-130 and FA-182TD. Instead,
remove the aluminum stopper from
the silicone tubing leading to the right
cylinder/carburetor spray bar. Inject
approximately 5cc of fuel into the
silicone tubing. Replace the
aluminum stopper. Please refer to

Figure 4.

7. Start the engine:

• close the throttle to

1

/

4

–

1

/

3

open

position

• rotate propeller clockwise until
it’s against the compression
stroke

• connect the heating source to
the glow plugs

NOTE: It is not necessary to ignite
all four glow plugs in the dual
plugged versions (two glow plugs per
cylinder) of the Saito engines. It’s
only necessary to apply heat to the
two rear plugs. The front glow plugs
will ignite once the engine reaches
operating temperature.

NOTE: A very common error is to
remove the glow plug ignitor too
early. It is suggested that the ignitor is
left attached until after the engine has
been run up and the high speed needle
valve(s) has been properly adjusted.

STARTING THE ENGINE

7

• Using either the “chicken stick”
or electric starter, spin the
propeller until the engine is
running.

NOTE: When using an electric
starter, care should be taken to be sure
that the engine does not become
“hydro-locked.” While the electric
starter will turn the engine over,it
may damage the connecting rod or
other components. If the engine
becomes hydro-locked, simply
remove the glow plugs and turn the
engine over a few times with the
“chicken stick” or electric starter. The
excess fuel will be forced to exit the
engine via the cylinder heads.

8. Initial break-in:
Do not exceed 4,000 rpm for the first

ten (10) minutes of operation. This
allows all parts to mate properly with
good lubrication.

NOTE: Due to the excessively “rich”
mixture setting, it may be necessary
to leave the heat source attached to
the glow plugs.

Subsequent runs may be made while
slightly leaning out the mixture with
each tank full of fuel. Generally, 40
minutes is considered sufficient for
normal break-in prior to the first
flight.

9. After break-in:

If a test stand was used for the break-in
procedure, the engine may now be
mounted in the aircraft using the integral
motor mount and mounting hardware
supplied with the Saito engine.

NOTE: Always use the engine’s
mounting spacers. Place the mounting
spacer between the integral motor
mount and the firewall of the aircraft.

The spacers will minimize firewall
depression and serve to reinforce.
Soft mounting of Saito engines is not
required due to low vibration levels
found in the Saito twins. The idle
needle valve(s) (89) may now be
refined. Please refer to the Carburetor
Adjustments Section on pages 8 & 9
for information on how to do so.

The valves may be checked at this
time. Refer to the Engine
Maintenance Section on page 13 for
information on the valve adjustment.

Figure 5

When tightening bolts, put washers between the engine mount and
firewall to minimize depression on the firewall and for reinforcement.

Engine mounting
spacer (washer)

Engine

Firewall