User Manual

Four stroke gasoline engine
for airplanes
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.
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
NOTES
These cover events which might involve serious
(in extreme circumstances, even fatal) injury.
These cover the many other possibilities, generally less
obvious sources of danger, but which, under certain
circumstances, may also cause damage or injury.
WARNINGS
ABOUT THE ENGINE
STANDARD ACCESSORIES
ENGINE PARTS NAME
INSTALLATION
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.
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.
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.
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.
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.
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.
NOTES
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.
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.
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.
Spark Plug 1/4-32
Ignition module
Assembly (IG-07)
F-6040 Silencer Assembly
Battery Leads
Sensor
Leads
High Tension Cord
Spark Plug
Cylinder Head
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.)
FUEL TANK & LINES
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 use a gasoline
resistant fuel tank cap.
Be sure to equip
air vent pipe.
Be sure to use fuel line keepers of
stainless wire, etc. to prevent tubing
from coming off.
Be sure to replace tubing
inside periodically.
To carburetor
fuel inlet
tubing for
re-fuelling
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)
IGNITION MODULE
Major specifications
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.
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.
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
Size (DxP)
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
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.
Drive Hub
Propeller Washer
This engine is designed for experienced fliers.
Beginners and newcomers should not use this engine.
A modified new carburetor and a new pump PD-09
ensure the best performance of GF30II.
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.
An ignitor IG-07 is equipped with a new plug cap, whose
angle can be adjusted 360 degrees freely. It is easy to
attach to and detach from a spark plug. To avoid
accidental engine start, the ignitor controlled by a
micro-computer does not spark at very low speed rotation
for safety reason such as moving a propeller by hand.
The new F-6040 silencer is supplied with the engine.
It develops very efficient silencing effect.
Crankcase
Carburetor
Type 70T2
Cover Plate
Crankshaft
1.
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:
2.
Lock Nut
Intake Manifold
Cam Cover
PCV VALVE
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.
Make sure to connect the plug cap onto the spark
plug not to come off.
While this is a four stroke gasoline engine,
use the same oil mixed gasoline for two
stroke gasoline engines.
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.
Install the propeller to the engine shaft, followed by
retaining washer and propeller nut and tighten
firmly with a 14mm wrench (not supplied).
Add the special tapered and slotted locknut and
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).
Silencer Body
Exhaust Header Pipe Assembly
Exhaust Header Pipe Nut (M16)
Pump Unit PD-09
Beam Mount
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.
CARBURETOR PARTS NAME
Regulator
Needle Valve
Mixture Control
Valve
Throttle Lever
Fuel Inlet
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.
Two adjustable controls are provided on this
carburetor.
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.
Roter Guide Screw
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.
DO NOT obstruct the small rectangular hole at the
bottom of the regulator, nor the regulator will not
function correctly.
NEVER insert anything into the inlet or outlet nipples
in an attempt to clear a suspected obstruction.
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.
Rectangular
hole
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.
16×10-12, 17×8-10, 18×6W-8
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.
NOTE:
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
(50:1) 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.
Nipple for PCV
(to be connected
to the PCV valve)
Notice on 70T2 carburetor clogging
Gasoline engine carburetors generally have narrower
fuel passages for better fuel mileage than glow
engines. As a result, the passages clog easily if a fuel
filter is not used. You should insert a gasoline-resistant
fuel filter — finer than #200 mesh — between the fuel
tank and the engine (if a T-shaped tank nipple is used,
place the filter between the nipple and the engine).
When filling your fuel tank from a gasoline container,
always use the O.S. Super Filter L (part #72403050) to
prevent dust from entering the tank. A clogged
carburetor can cause inconsistent running, stalling,
and overheating. If your carburetor becomes clogged,
it must be disassembled and cleaned.When taking
apart the carburetor, remember the assembling order.
Be careful not to lose small internal parts. If you’ re
not confident performing this type of maintenance,
take the engine to the hobby shop where you
purchased it or send it to the service center of your
country’ s O.S. distributor.
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.
NEVER disassemble the fuel pump or pressure
regulator. Their original performance may not be
restored after reassembly.
CARE OF FUEL PUMP & REGULATOR
Hold the plug cap and pull it out to disconnect from
the spark plug. Be careful not to damage your
fingers while removing it.
GF30II W/F-6040 Silencer
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.