Professional Documents
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Safety Instructions and Warnings
Safety Instructions and Warnings
CONTENTS
SAFETY INSTRUCTIONS AND
WARNINGS ABOUT YOUR O.S. ENGINE 2-5 STARTING, RUNNING-IN ("Breaking-in") 23-25
INSTALLATION OF THE ENGINE, ENGINE EXPLODED VIEW & PARTS LIST 38-39
FACTS ABOUT GLOWPLUGS 16-17
CARBURETOR EXPLODED VIEW & PARTS LIST 40-41
CARBURETOR CONTROLS 18-19
O.S. GENUINE PARTS & ACCESSORIES 42
ABOUT THE PUMP SYSTEM
CARE OF FUEL PUMP AND REGURETOR 20 THREE VIEW DRAWING 43
1
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.
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 ! NOTES
These cover events which These cover the many other
might involve serious (in possibilities, generally less obvious
extreme circumstances, even sources of danger, but which, under
fatal) injury. certain circumstances, may also
cause damage or injury.
! WARNINGS
• Never touch, or allow any • Never operate your engine in an en-
object to come into contact closed space. Model engines, like auto-
with, the rotating parts. mobile engines, exhaust deadly carbon-
monoxide. Run your engine only in an
open area.
• Model engine fuel is poison-
ous. Do not allow it to come
• Model engines generate
into contact with the eyes or
considerable heat. Do not
mouth. Always store it in a
touch any part of your
clearly marked container and
out of the reach of children. engine until it has cooled.
Contact with the muffler
• Model engine fuel is also (silencer), cylinder head or
highly flammable. Keep it exhaust header pipe, in
away from open flame,
particular, may result in a
excessive heat, sources of
serious burn.
sparks, or anything else which
might ignite it. Do not smoke
or allow anyone else to smoke,
near to it.
3
! NOTES
• This engine was designed for model • After starting the engine, carry out any needle-
helicopters. Do not attempt to use it for any valve readjustments after stopping the rotor by
other purpose. closing the throttle to the lowest r.p.m..
Stop the engine before attempting to make
• Mount the engine in your model securely, fol- other adjustments to the carburetor.
lowing the manufacturers' recommendations,
using appropriate screws and locknuts. • Use an electric starter. The wearing of safety
glasses is also strongly recommended.
• Install an effective silencer (muffler). Frequent Press the rotor head down securely.
close exposure to a noisy exhaust (especially
in the case of the more powerful high-speed • Take care that the glow plug clip or battery
engines) may eventually impair your hearing leads do not come into contact with rotating
and such noise is also likely to cause parts.
annoyance to others over a wide area.
• Adjust the throttle linkage so that the engine
stops when the throttle stick and trim lever on
• Check the linkage to the throttle arm before
the transmitter are fully retarded. Alternatively,
each flight.
the engine may be stopped by cutting off the
• Avoid sudden high r.p.m. immediately after the fuel supply. Never try to stop the engine
engine is started, as the clutch will engage and physically.
you may be struck by the rotor.
! NOTES
• 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 pen-
cils, screwdrivers, etc.) in a shirt pocket from
where they could fall through the rotor disc.
5
Notes on installing cooling fan and clutch
Application is as follows:
Do not use a tool which Remove the crankcase rear cover plate from the
locks piston when engine and rotate the crankshaft to the bottom
installing a cooling-fan dead center (BDC) position.
and clutch, or top of Insert the crankshaft clamp so that its grooved
the piston may be portion surrounds the crankpin and lower end of
the connecting rod and securely tighten the fan
damaged. Also, do not or clutch onto the crankshaft.
insert a screw driver or
the similar into the
BDC position
exhaust port.
7
Note on heating the glow plug
Example
INTRODUCTION
This is a high performance engine
expressly designed for 3D flight with 90 Standard accessories
size helicopters basing on the MAX-91SZ-H
Carburetor Complete 60M-P
RING and equipping O.S.'s original PD-07
pump and regulator system. The pump Carburetor Rubber Gasket
feeds fuel stably irrespective of violent
changes in model attitude and the regulator Carburetor Retainer Assembly
regulates fuel pressure from the pump (M2.6x18)
keeping the pressure at a set level.
The 60M-P carburetor with twin needles Head Gasket
enables adjustment of idling, hovering and
0.2mm 0.1mm
the 'in air flight' independently.
9
BEFORE STARTING
Tools, accessories, etc.The following items are In case of 1.5volt dry cell
necessary for operating the engine. Battery leads
10
11
TOOLS
Socket Drivers
5mm, 5.5mm, 7mm Needle Nose Pliers
12
Thrust Washer
Cover Plate
Reguretor
Pump Holder
Beam Mount
Crankcase
Propeller nut Pump Unit (PD-07)
Crankshaft
13
INSTALLATION OF THE STANDARD ACCESSORIES
INSTALLATION OF THE CARBURETOR 2. Insert the carburetor rubber
gasket on the carburetor
1. Insert the carburetor retainer as illustrated.
Unscrew the retainer screw a little. body securely.
Then, insert the carburetor JAPAN
in the crankcase.
Carburetor Rubber
Gasket
Carburetor Retainer 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.
3. Rotate the retainer screw gently until it stops, then
tighten a further 90-120 degrees.
Retainer screw Do not over-tighten the screw as this will damage
the carburetor body.
14
15
INSTALLATION OF THE ENGINE
The under-surfaces of all O.S. engine beam CORRECT
mounting lugs are precision machined flat and
exactyly parallel to the engine's horizontal axis. It is
essential that the engine mounts in the model are
also accurately made and aligned. If they are not,
they will cause stress and distortion within the engine Front view Side view
Top surfaces are in the same plane.
itself, probably resulting in loss of performance and
INCORRECT
internal damage.
The recommended screws for securing the engine to
the engine mounts in the model are 4mm or 4-40
steel Allen type. It is also advisable to use lock
washers or LOCTITE to prevent nuts from loosening.
Top surfaces are not Top surfaces are not in the
in the same plane. same plane.
Engine does not rest firmly.
16
17
C The Medium Speed Needle Valve
CARBURETOR CONTROLS This is an extra control that can be brought into
With a fixed-wing model, power failure is rarely a play, if necessary, after adjusting A and B above. It
serious threat to the safety of the aircraft since it can
provides the means of fine-tuning mixture strength
usually glide down to a safe landing. In a helicopter,
over that all-important part of a helicopter's throttle
on the other hand, it is vitally imporant that the engine
range where the model is flying in, or near, the
keeps running and that there is a quick and reliable
response to the throttle in order to ensure safe ascent hovering mode.
and descent of the model. Idle MIxture Control Screw
Three adjustable mixture controls are incorporated in the
Type 60M-C. They are as follows.
High Speed Needle Valve
A The High-Speed (Main) Needle Valve (Main Needle)
When set to produce maximum power at full
Medium Speed Needle
throttle, this establishes the basic fuel/air mixture Needle Valve Adjusting screw
strength. This is then maintained by the carburetor's
automatic mixture control system to cover the NOTE
engine's requirements at reduced throttle settings. As the idle mixture control screw is installed with
LOCTITE, it may initialy feel stiff, and it is suggested
B The Idle Mixture Control Screw to use a littli oversized screwdriver. The screw can be
This provides the means of manually adjusting the turned only 90 degrees either way. Do not force to turn
60M's mixture control valve. By setting the Mixture further, or it may break or cause trouble.
Control Screw for the best idling performance, the
90 degrees 90 degrees
mixture control valve automatically ensures that fuel is
accurately metered to maintain the correct mixture
strength as the throttle is opened.
18
19
ABOUT THE PUMP SYSTEM Rectangular hole
Fuel passing direction is set in the pump. Do not
mistake piping.
Coming in (IN)
Going out (OUT)
(Connect to regulator nipple.)
ALWAYS use fuel filters. Keep the fuel tank scru-
pulously 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
CARE OF FUEL PUMP AND REGURETOR tank and pump. Remember to inspect filter screens
NEVER disassemble the fuel pump or pressure at regular intervals and rinse clean as necessary.
regulator. Their original performance may not be Do not clean the pump with organic solvent such
restored after reassembly. as kerosene, light machine oil, gasoline, thinner or
NEVER insert anything into the inlet or outlet nipples crc or the silicone rubbur parts inside is
in an attempt to clear a suspected obstruction. detoriorated. Be sure to use methanol or fuel.
DO NOT allow foreign matter to enter the fuel Do not allow fuel to remain in the pump. After
system. Dirt inside the pump or regulator, no matter finishing the day's flight session, be sure to run out
how small, may obstruct the flow of fuel and the fuel in the pump. Stop the fuel flow to the pump
prevent these components from working properly. with a stopper and run the engine at idling to use
DO NOT obstruct the small rectangular hole at the up the fuel in the pump. After stopping the engine,
bottom of the regulator, nor the regulator will not rotate the engine by electric starter to eliminate
function correctly. fuel inside the engine.
20
Silencer
JAPAN
Fuel Filter
Fuel tank (commercially available)
Pump
Fuel Stopper
Piping 1 (commercially available)
21
Piping 2 When an engine r.p.m. control equipment (generally called as
Governor) is used, it is expected that the engine runs stably
without employing the silencer pressurized system because
the engine r.p.m. will not exceed the setting r.p.m. In this
case, carry out piping as illustrated. Be sure to use a check
valve to prevent the fuel coming out during inverted flight.
Also, it is expected to open the needle a little more than
Piping 1. In either case, carry out running-in referring to
STARTING section.
Silencer
JAPAN
Fuel Filter
(commercially available)
Fuel tank
22
STARTING
Be sure to use a muffler pressurized fuel feed. Use 3. Preparation of the starter
the same fuel as you intend to employ for actual Install the starting shaft to the
operation of your model. starter securely.
1. Opening and closing of the Needle-Valve Improper installation will allow the
shaft to swing creating a
Turn the needle clockwise to Close dangerous situation.
close the needle-valve, and turn
the needle counter-clockwise to
open the needle-valve as shown 4. Checking the rotating direction of the starter
in the sketch. Make sure that the starter rotates
Open
to the direction shown in the
2. High Speed needle-valve: sketch. If the direction is reverse,
exactly 2 1 2 turns open from the fully closed reverse the leads on battery.
position.(Note: If a different muffler is used, this
setting may require readjustment)
Idle Mixture Control Screw: 5. Inserting the starter shaft
Insert the starting shaft into the
at basic position when the engine leaves the
shaft cup securely.
factory.
23
6. Priming In case the engine does not stop.
Without energizing the glowplug, open the throttle Hold the rotor head, and pinch the fuel line to stop the
a little from the idle position. Turn the engine over fuel supply. If it still does not stop, pull off the fuel line
using the starter until the fuel is seen to reach from the carburetor.
carburetor. It is necessary to readjust the throttle linkage so that
the carburetor rotor is fully closed when the throttle
7. Preparation of starting stick and throttle trim on the transmitter are fully
Make sure that the transmitter pulled Down.
throttle stick is at the fully closed
position and the throttle trim at center NOTE:
position, and make sure that idle-up If the throttle response is poor or the engine
switch on the transmitter is off. Hold stops due to a temporarily over-rich mixture im-
the rotor head by hand so that rotor mediately after the engine is started, pinch the
cannot rotate when the engine is Started. Also, steady fuel line for one or two seconds until the engine
the model with a foot on the landing gear skid. r.p.m. increase and the engine runs steadily.
8. Starting Reminder!
Connect the battery to the glowplug and start the Never touch, or allow any object to
engine by applying the starter. When started, switch come into contact with, the rotating
off the starter and withdraw the starting shaft after rotor.
making sure the rotation of the starter shaft stops.
24
25
The general course of adjustment procedure is ADJUSTMENT PROCEDURE
shown in the ADJUSTING CHART and is correct As a safety measure, first check the transmitter
for a fuel containing 20% lubricant and 15-30% controls, including the throttle stick and trim lever
nitromethane. positions, and hold the main rotor securely before
starting the engine.
Bear in mind that fuels containing relatively large
percentages of power-boosting nitromethane operate 1. Warm the engine by allowing it to idle for about 30
at richer mixture settings than are needed for mild seconds. If the engine stops, advance the throttle
fuels and will, therefore, require the High-Speed trim lever slightly to increase the idle rpm. Then
Needle Valve to be readjusted accordingly. The type open the throttle sufficiently to 'float' the model
and percentage of lubricant used is also a factor above the ground. lf, at this time, the engine is
here, as noted later in these instructions. slow to pick up and produces an excess of
exhaust smoke, the mixture is too rich. Correct
This carburetor is not equipped with a throttle this condition by turning the Mixture Control Screw
stop screw. Instead, idle speed is adjusted by clockwise 5 degrees. lf the mixture is extremely
means of the throttle trim lever on the trans- rich, engine rpm will become unstable: opening
mitter. the throttle will produce a great deal of smoke and
rpm may drop suddenly or the engine may stop.
This condition may also be initiated by an
excessively prolonged warming-up period. lf, on
the other hand, the mixture is too Iean, this wiIl be
indicated by a marked lack of exhaust smoke and
a tendency for the engine to cut out when the
throttle is opened. ln this case, turn the Mixture
Control Screw counter-clockwise 5 degrees to
enrich the mixture.
26
2. Having provisionally set the idle mixture, the next After about 10 seconds of idling, open the throttle to
step is to adjust the mixture for hovering flight. 'float' the model. lf the transition is smooth, the idle
Hover the model and actuate the throttle to mixture is O.K. If the symptoms of either rich or Iean
observe response over the medium speed range. running are observed, readjust the Idle Mixture
lf the engine smokes excessiveIy and throttle Control Screw accordingly.
response is poor, the mixture is too rich ; in which
case, land the model and turn the High-Speed Needle Valve too
Maximum
far open
Needle Valve clockwise. Do not close the High-
Adjustment range of Medium High Speed Needle
Speed NeedIe Valve more than the recommended Speed Needle Valve Valve Setting varies
initial adjustment (3 to 4 clicks) at a time, keeping according to the curve.
it a little on the rich side at this stage. DO NOT Needle Valve too
Fuel Flow
far closed
touch the Medium Speed Needle Valve.
lf, on the other hand, hovering is not stable and
response to the throttIe is over-sensitive, or if the
Minimum
engine tends to overheat, this indicates that the Adjustment range of Idle Mixture
Control Screw
mixture is too lean and should be corrected by
Fully Closed 1/3 2/3 Fully Open
turning the High-Speed Needle Valve counter-
Throttle Opening
clockwise.
When satisfactory hovering flight has been achieved, NOTE: With this carburetor, neither the Idle
land the modeI again and re-check the engine's idle Mixture Control Screw adjustment, nor the
qualities. Medium Speed Needle Valve adjustment will have
any effect on mixture strength when the throttle is
fully (or almost fully) open.
27
3. Now adjust the High-Speed Needle Valve to It is at this point that the Medium Speed Needle
achieve the best performance when the model is Valve, previously kept 1 1 2 turn open, may be
flying at full throttle. lf, at full throttle, acceleration brought into operation. Open the Medium Speed
is poor, the exhaust unduly smoky and the model Needle Valve 30 degrees, or 3-4 clicks, then fine
fails to reach expected straight line speed, the tune until the optimum hovering performance is
mixture is too rich and the High-Speed Needle obtained. If on the other hand, hovering reveals
Valve setting will need to be reduced. rich running, close the Medium Speed Needle
lf, however, after smoothly acceIerating to Valve gradually until the optimum hovering
satisfactory high-speed straight and level flight, performance is obtained.
power is lost when the model is puIled up into a
climb, the mixture is too lean. ln this case, land the
model immediately and readjust thw High-Speed
Needle Valve to a richer setting.
4. Having now found the optimum setting for the
High-Speed Needle Valve, re-check the engine's
idle performance, fine tuning the Idle Mixture
Control Screw, if necessary, to perfect the idle.
5. Now re-check hovering performance It may be
found that (with the High-Speed Needle Valve
now set for optimum full-throttle performance)
hovering will reveal symptoms of slightly lean
running at medium speeds. DO NOT touch the
High-Speed Needle Valve.
28
SUBSEQUENT READJUSTMENTS
Once the engine has been run-in and the
carburetor controls properly set up, it should be
unnecessary to alter the mixture settings, except to
make minor changes to the Main (High-Speed)
Needle Valve occasionally, to take account of
differences in climatic condisitions.
However, as previously mentioned, the use of a
different fuel, particularly one containing more, or
less, nitromethane and / or a different type or
proportion of lubricating oil, is likely to call for some
modification to the High-Speed Needle-Valve
adjustment.
As a safety measure, it is advisable to increase the
High-Speed Needle Valve setting by an extra half-
turn counter-clockwise, prior to establishing the
new setting. The same applies if the silencer type is
changed. A different silencer may alter the exhaust
pressure applied to the fuel feed and call for a
revised Needle-Valve setting.
The use of a different glowplug, or changes to the
main rotor and its pitch angles may also require
compensating carburetor readjustments.
29
CARBURETOR CLEANLINESS
The correct functioning of the carburetor depends on
its small fuel orifices remaining clear.
The minute particles of foreign matter that are present Remove this with
an 8mm wrench
in any fuel can easily partially obstruct these orifices
and upset mixture strength so that engine
performance becomes erratic and unreliable.
It is recommended that fuel is passed through a filter
when the tank is filled and that a good in-line filter is
Dirt and fbrous matter
installed between the fuel tank and carburetor and,
mostly accumulate here
furthermore, that this filter is frequently cleaned to
remove dirt and lint that accumulates on the filter
screen.
Finally, occasionally remove the needle-valve holder
from the carburetor as shown in Photo and extract
any remaining foreign matter that may have lodged in
the location shown in Photo, right.
30
ADJUSTING CHART
High Speed Needle Valve - 21 2 turns opened from fully closed position.
Medium Speed Needle Valve - 11 2 turns opened from fully closed position.
Adjustment completed
INSTALLATION OF THROTTLE SERVO
After the engine is installed in the helicopter, please
observe the following recommendations when linking
the throttle servo to the carburetor.
Servo output arm
Throttle arm
m
27m
Locate the servo so that its output arm and the Throttle control rod A and B should be equal length.
throttle pushrod are, as close as possible, Set the linkage so that the servo output arm and
directry in line with carburetor's throttle arm, throttle arm are parallel when the throttle stick on the
as shown. transmitter is at middle position. If differential throttle
movement is required, make necessary adjustment
at the transmitter.
32
33
Symptom
TROUBLE SHOOTING
Engine fails to fire.
Cause Corrective action
Fuel tank is empty. Fill the tank with fuel and repeat
Fuel not reaching the engine. Priming procedure.
Glowplug element is burnt out. Replace glowplug.
Glowplug battery discharged Recharge or replace the battery.
Clogged fuel filter Clean or replace fuel filter.
Silencer inside is dirty. Clean inside silencer.
34
Symptom
Engine fires intermittently but does not run.
Cause Corrective action
35
Symptom
Unstable idle
Cause Corrective action
Unsuitable fuel Do not use extremely high nitro or low oil fuel.
Symptom
Not reaching expected peak r.p.m.
Cause Corrective action
Set the needle only after warming up.
Insufficient warming up or running-in.
Complete running-in.
Silencer or manifold is not securely connected
Check the connections and secure them.
or disconnected.
36
Symptom
Poor response
Cause Corrective action
37
ENGINE EXPLODED VIEW
ENGINE PARTS LIST
39
4
15 29062000 Crankshaft
16 29061400 Gasket Set
6
17 29067010 Cover Plate
7 Nipple (No.1)
18 22681953
19 29067100 Pump Holder
C.M3x15
20 72508001 Pump Unit (PD-07)
8 21 29067110 Pump Retaining Screw Assembly
71608001 Glow Plug No.8
C.M2.6x18 15
27708200 Woodruff Key
20
2.5x 5.5xL23mm 41621100 Needle Adjusting Screw
C.M3x12
14
The specifications are subject to alteration for improvement without notice.
19
10
9 13 18 21
11 17
12
9
1-1
9-1
1 4
2
3-3 C.M2.6x10
6
8-4
7 8-5
11 8-3 8-2
3-2
10-4 3-1 8-1
10-2
8
10-3 10-1
Type of screw 10
C...Cap Screw M...Oval Fillister-Head Screw
3
F...Flat Head Screw N...Round Head Screw S...Set Screw
40
41
O.S. GENUINE PARTS & ACCESSORIES
GLOWPLUG DRIVE HUB ASSEMBLY IN-FLIGHT CONTROL SUPER FILTER
No.8 (w / woodruff key) NEEDLE VALVE (L) (72403050)
(71608001) (71705000)
Drive Hub (27708010)
A5 Woodruff Key
(71605100) (27708200)
CRANKSHAFT CLAMP LONG SOCKET WRENCH LOCK WASHER CAP SCREW SET
91 (For 91SZ-H) WITH PLUG GRIP (10set) M3x12 (10pcs.)
(71530510) (71521000) (79871140)
M4 (55500003)
M3x15
(79871150)
42
56
42.5 42
87.4
UNF 5/16-24
42.8
JAPAN
12
JAPAN
44
C Copyright 2006 by O.S.Engines Mfg. Co., Ltd. All rights reserved. Printed in Japan. 60091750 030600