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.
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 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.
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.
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.
INTRODUCTION This is the FS-91S -FI (fuel injection) engine equipped with a revolutionary fuel supply system that was jointly developed by Futaba, a manufacturer of Radio control equipment, and O.S. Engines, a manufacturer of model engines. This system detects engine speed with a sensor based on throttle signals transmitted from a transmitter.
BASIC ENGINE PARTS Accessories EC-2 Assembly Y harness Duble-sided spongebacked cushioning tape Check Valve Fuel Filter Driver to push Limit Setting Switch Glow plug TYPE F F-4020 Silencer Rocker Cover Glow plug TYPE F Temperature Sensor Cylinder Head Propeller Washer Lock Nut Propeller Nut Drive Hub Injector Air Valve 60T Injector Crankcase Beam Mount RPM Sensor Electronic Control Unit Injector Never attempt to disassemble the injector. It may not be able to be reassembled.
CONNECTING WITH THE EC-2 Connect the receiver and servo-related components (rudder section) in the same manner as in the past. (8) Integrated Buzzer (3) Injector output terminal (INJECTOR) (4) Temperature sensor input terminal (Temp) (5) RPM sensor input terminal (r.p.m.) (2) Injection trim input terminal (AUX:TRIM) (1) Injection time input terminal (CH3:THRO) (6) Limit Setting Switch(LIMIT) (7) L.E.D.
(7) L.E.D.(Display of green and red) It flashes or changes color when setting and cheking limit, and adjusting injection trim. It flashes with the color of the injection trim when the engine is running. LED Display Transmitter Operation Turn the dial right to reduce injection volume. When the engine is not running When the engine is running Turn the dial left to increde injection volume.
Injection trim adjustment corresponds to needle-valve adjustment of conventional carburetor) Fuel injection volume Fig.2 Full high Intermediate slow Injection trim can be adjusted independently for two area as shown in the graph. Intermediate slow and full high are adjusted with the injection trim adjustment dial (spare channel dial) on the transmitter.
BEFORE INSTALLING THE ENGINE In addition to the general tools, the following tools are convenient to use. 12-14mm open end wrench Large capacity electric starter and battery INSTALLING THE GLOW PLUG Carefully insert plug, with washer, fingertight only, before final tightening with the correct size plug wrench. Glow plug Washer INSTALLATION PROCEDURE NOTE: Be sure to secure large enough air intake and outlet area for cooling the engine in order not to overheat the engine.
Make sure that the mounting beams are parallel and that their top surfaces are in the same plane. INCORRECT CORRECT Fig.4 FS FS SERIES SERIES Front view Top surfaces are not in the same plane. Side view Opposite beam Top surfaces are not in the same plane. Top surfaces are in the same plane. Re-align the surfaces as necessary Engine does not seat firmly. How to fasten the mounting screws. 5mm steel nuts Spring washer or lock washer Steel washer Tighten second nut firmly down onto first nut.
(3) Fuel Tank and Lines A fuel tank of approximately 450cc capacity is suggested. This allows up to 14-15 minutes flying time, dependent upon the type of fuel used, the size of the propeller and on the proportion of full-throttle to partthrottle operation through the flight. 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 (see sketch).
(4) EC-2 Install the EC-2 in a location that is not susceptible to the effects of heat, fuel or vibrations while allowing easy manipulation. Always make sure to attach double-sided, sponge-backed cushioning tape or Velcro tape between the airframe and EC-2 as measures against vibrations. (5) EXHAUST HEADER PIPE & SILENCER Fit these in the following sequence.
LINKAGE AND INITIAL SETTINGS (with Futaba PCM 1024ZA T9Z transmitter) Call up the ATV menu on the condition menu and select THR. Confirm that it is in the center of the throttle curve when the stick is in the center position. The nalign the mark in the center of the air valve at that point. The center of the curve is the center, and if the stick is shifted out of position, give priority to the center of the throttle curve.
(4) Adjustment of Amount of Throttle Servo and Air Valve Angle Move the throttle stick on the transmitter to slow and then full high. If there is excessive or insufficient opening of the air valve, adjust the opening with the throttle angle adjustment function (ATV). Confirm that the servo is not subjected to an excessive load due to tugging or pulling. An excessive load on the servo can cause the battery to discharge and air valve to lock.
ENGINE STARTING AND AIR-FUEL MIXTURE ADJUSTMENT (1) Switch on the transmitter then the receiver. (2) Make sure the Limit is set. Make sure that LED flashes when the throttle stick is at the full slowposition as well as at the tull high position. Flashing color is the color at the injection trim set position. (3) Confirm that the rotor mark on the air valve is located at the center mark on the air valve body when the throttle stick on the transmitter is in the center position.
ENGINE STARTING (RPM shown are with the standard setting.) Basic setting It is suggested to start with this setting. General reference for engine speed Case of a 13 x 9, 2-blade propeller Full slow engine speed 2,000-2,100r.p.m. Intermediate slow engine speed 6,500-7,000r.p.m. Full high engine speed 8,900-9,200r.p.m.
This engine employs pressurized fuel feed system, applying high pressure to the fuel tank from the crankcase. When starting first time or starting after long, storage or starting in winter when the temperature is less than 100C, it makes a start easy to apply an electric starter for about 5 to 10 seconds without connecting the plug battery. (1) Always be sure to close the throttle stick to idle position before applying the starter and starting battery.
FLIGHT ADJUSTMENT The next step is to take the airplane on an actual flight. Although the adjustments have been already made, recheck the Limit setting. Put the throttle stick in the slow position and after starting the engine and allowing it to warm up, check the stability of engine speed in the slow position (by confirming that the engine does not stall) and try flying the airplane. After taking off, fly level for several minutes. Next, repeat flying level in a straight line at full speed.
GLOWPLUGS Since the compatibility of glowplug and fuel may have a marked effect on performance and reliability, it may be worthwhile to choose the R/C type plug found most suitable after tests. O.S. TYPE F plug is supplied with the engine. Recommended O.S. plug Type F is suitable to use for richer mixture. Carefully install plug finger-tight, before final tightening with the correct size plug wrench. The role of the glowplug With a glowplug engine, ignition is initiated by the application of a 1.
CARE AFTER USE First vent the pressure from the fuel tank. Next, drain any fuel in the fuel tank. Turn on the transmitter and receiver switches but do not heat the plug. Move the transmitter engine control lever to the center position without heating the plug, and then turn the engine over with the electric starter several times. (This is done to discharge any fuel between the tank and the injector.) Pour a little after-run oil in the air valve and turn over the engine with the starter several times.
TROUBLESHOOTING Problem Confirmation Engine does not start Is the power turned on? Are the connectors securely connected? Is the lead wire broken? Is the plug burned out? Has Limit been set? Are the connections correct? Recheck the Buzzer sounds and LED display.
O.S. GENUINE PARTS & ACCESSORIES O.S.
ENGINE EXPLODED VIEW C.M2.6X12 2 C.M3.5X20 C.M3.5X15 3-2 3-1 3 4-1 4 4-2 5-4 5-3 6-4 6-3 6-2 5-2 5 6 1 5-1 8 6-1 7 11-1 9 11 C.M2.6X8 11-2 13 14 12 N.+M3X22 26 27-2 15 10 16 27-1 27 27-2 28 32 17 29 Type of screw 30 C...Cap Screw M...Oval Fillister-Head Screw F...Flat Head Screw N...Round Head Screw S...Set Screw 31 20 23 24 22 23 25 21 19 C.M2.6X8 33 18 C.M3.
ENGINE PARTS LIST No. 1 2 3 3-1 3-2 4 4-1 4-2 5 5-1 5-2 5-3 5-4 6 6-1 6-2 6-3 6-4 7 8 9 10 11 11-1 11-2 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 27-1 27-2 28 29 30 31 31-1 32 33 Code No.
INJECTOR AIR VALVE (60T) EXPLODED VIEW & PARTS LIST 1 2 3 4 5 N.+M3X6 N.+M3X22 C.M2.6X8 6 8 7 No. Code No. 1 2 3 4 5 6 7 27881400 45985200 45915000 27981600 45985100 45985110 29483300 Description Throttle Lever Assembly Roter Valve Gasket Roter Guide Screw Injector Air Valve Body Injector Set Injector Holder The specifications are subject to alteration for improvement without notice.
THREE VIEW DRAWING Dimensions(mm) Specifications 14.95 cc (1.60cu.in.) 27.7 mm (1.323in) 24.8 mm (1.165in) 2,000-12,000 r.p.m. 1.6 ps / 11,000r.p.m. 680g (24.0oz.) F-4020 (47g 1.66oz) 52 4- 4.2 25 101 54 UNF 5/16-24 FS SERIES MADE IN JAPAN 22 Displacement Bore Stroke PracticalR.P.M. Output Weight Silencer 42.6 66.
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TA BL ISH ING NC ES E E ANC UNEQ UA M L Y PRECISION & PER UAL I T DQ FO E L R L CEL THE STANDARDS OF EX E 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 C Copyright 2001 by O.S.Engines Mfg. Co., Ltd. All rights reserved. Printed in Japan.
