TWIN-CYLINDER FOUR-STROKE ENGINES INSTRUCTION MANUAL ・FA-60T ・FA-182TD ・FA-90TS ・FA-300TL ・FA-100T ・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 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.
2 SAFETY INSTRUCTIONS 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.
SUPPORT 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.
4 S TA R T I N G T H E E N G I N E Break-In The first run on any engine, wheter 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.
S TA R T I N G T H E E N G I N E 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.
6 S TA R T I N G T H E E N G I N E 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.
S TA R T I N G T H E E N G I N E • Using either the“Start 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 “hybro-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 “Start stick”or electric starter.
8 E N G I N E O P E R AT I O N The use of a tachometer is encouraged for setting the high-speed needle valve(s)(85) prior to flight. The peak rpm should be obtained and then reduced by approximately 200-300 rpm by turning the high speed needle valve(s) counterclockwise. Low Speed Carburetor Adjustments The low speed, or idle needle valve(s), or airbleed screws(s)(89), is/are pre-adjusted at the factory for best performance during break-in.
E N G I N E FA-100T FA-182TD Dual Carburetor Adjustment Upon completing the break-in and carburetor adjustment procedures mentioned previously, the following method should be utilized to balance the dual carburetor Saito engines: 1. Start the engine and allow it to warm up prior to attempting any adjustments. 2. Rotate both high speed needle valves clockwise an equal amount until the engine reaches the peak rpm. 3.
10 E N G I N E O P E R AT I O N fuel mixture by rotating the high speed needle valve counterclockwise 3 clicks. Lean the left cylinder by turning the high speed needle valve clockwise until the rpms begin to drop. This time, however, richen the fuel mixture by rotating the high speed needle valve counterclockwise 3 clicks. The high speed needle valve adjustments are now completed. Idle Needle Valve Adjustment 1.
E N G I N E Normal Engine Operation If break in was accomplished on a test bench your engine may be mounted to the aircraft and flown. The initial flight should be performed with the engine adjusted for a rich fuel mixture. 1. Your Saito engine should be securely mounted to the aircraft using the motor mount and hardware kit provided. Soft mounting of the Saito twins is not necessary due to the extremely low vibration level of these engines.
12 ENGINE MAINTENANCE 2. Cam Gear Alignment-Refer to the specific section below pertaining to your Saito engine. it’s important that neither the crankshaft nor the cam gear are moved from their alignment marks. Refer to Figure 9. FA-60T/90TS a. The crankshaft alignment mark should line up with the crankcase mark when the crankshaft is at the top dead center. Refer to Figure 7. NOTE: Crankshaft alignment mark and cam gear reference mark are aligned with their respective crankcase marks.
ENGINE MAINTENANCE 13 3. Reassemble the piston, rod, rocker arm, pins, pushrod, tappet, etc. in their original positions. Engine parts are mated after running the engine, and they must be reassembled as close as possible to their original position. Figure 10 d. Position the left cam gear timing mark (etched line) at the 3 o’clock position (directly into the crankcase) and secure the left cam gear housing. See Figure 11. 4. Assemble the engine reversing the criss-cross pattern used in the disassembly.
14 CARBURETOR MAINTENANCE 1. Remove the high speed needle(s) (85) and flush out the spray bar with clean fuel. Replace the high speed needle(s) and follow the instructions in the carburetor adjustment section. 2. Always use a high-quality 4-cycle glow plug. The Hangar 9/McCoy MC-4C is highly recommended. Tips For Extended Engine Life To add longer life to your Saito engine, we recommend the following: 1. Use a fuel containing 20% lubricants. 2. Use the recommended glow plugs. 3.
T R O U B L E S H O O T I N G 15 SYMPTOM CAUSE CORRECTIVE ACTION Engine fails to fire Low voltage on starting battery Replace/recharge the starting battery Bad glow plug(s) Inspect/replace bad glow plug(s) Insufficient priming Repeat priming procedure “Flooded”due to excessive priming Disconnect battery, remove glow plugs, and rotate propeller several times to“clear”cylinder Over primed Disconnect battery and rotate propeller several times to “clear”cylinder Incorrect glow plugs Remove plug
16 T R O U B L E S H O O T I N G TWIN CYLINDER CROSS REFERENCE CHART (2006) ITEM 01 Cylinder, Left 02 Cylinder, Right 06 Piston 07 Piston Pin 08 Piston Pin Ret 09 Piston Ring 10 Con Rod 11 Linked Con Rod 12 Conrod Linkpin/Scr 13 Con Rod Screw 14 Cyl Screw Set 15 Crankcase 17 Rear Cover(A) 18 Rear Cover(B) 19 Breather Nipple 20 Frt Ball Bearing 21 Main Ball Bearing 22 Rear Ball Bearing 23 Crankshaft 24 Pinion-crankshaft 25 Pinion gear pin 26 Collar, Crankshaft 27 Tapered Collet & Drv 28 Prop Wash/Nut 29 Pr
P A R T S L I S T 17 TWIN CYLINDER CROSS REFERENCE CHART (2006) ITEM 72 Intake manif w/prim 73 Muffler, Left 74 Muffler, Right 79 Muffler gasket 80 Muffler nut 81 Priming hamess 821 Carb comp left 822 Carb comp Right 831 Carb body assy lft 832 Carb body assy rt 84 Spray bar assy 85 High spd need vlv 86 High spd nd vlv ext 87 Throttle barr assy 88 Throttle lever 89 ldle needle valve 90 Carb scr/spring set 91 Carb gasket set 92 Choke Valve assy 93 Intake velocity stk 94 Glow plug harness 95 Engine m
18 P A R T S L I S T Remember, it is imperative to balance each propeller prior to installation onto your Saito engine. Failure to do so may cause unwanted vibration in your aircraft. Propeller Selection Below you will find a propeller selection chart. This chart will enable you to select the best propeller for initial set-up of your Saito engine. You will note a letter (A, B, C. etc.) stamped on the top of the motor mount. This letter identifies the production version of your engine.
PROPELLER SELECTION 19 OUTSIDE DIMENSIONS (mm) Items A B1 B2 C D E F FA-60 Twin Cylinder 61 10 43 125 160 64 50 FA-90TS Twin Cylinder 61 10 42 121 170 64 52 FA-100 Twin Cylinder 50 35 35 100 169 80 63 FA-182 Twin Cylinder/Dual Plugs/Dual Carb 70 28 28 133 195 81 73 FA-300 Twin Cylinder 112 30 49 175 233 92 83 FA-300 Twin Cylinder/Dual Plugs/Fuel Pump/Dual Carb 112 30 49 175 233 102 83 K (ISO) Cylinder HP 0.
20 E N G I N E FA-60T S P E C S
P FA-90TS A R T S L I S T 21
22 P A FA-100T R T S L I S T
P FA-182TD A R T S L I S T 23
24 P A R T FA-300TL FA-300TTDP S L I S T
P A R T S L I S T 25 Consumer Warranty and Repair Policy Saito engines are guaranteed against workmanship and manufacturing defects for a period of 3 years from the original date of purchase. This warranty is limited to the original purchaser of the engine and is not transferable.
26 W A R R A N T Y & R E P A I R 3. Warranty Repairs To receive warranty service you must include your original dated sales receipt to verify your proofof-purchase date. Providing that warranty conditions have been met, your engine will be repaired without charge. 4. Non-Warranty Repairs Should your repair cost exceed 50% of the retail purchase cost, you will be provided with an estimate advising you of your options. Any return freight for non-warranty repairs will be billed to the consumer. 5.
Please cut on dotted line. City/State/Zip Street Address Dealer'S Name Purchased From: Daytime Phone Number City/State/Zip Street Address Owner's Name Date of Purchase Engine Type Complete this form and mail along with your dated sales receipt (send copy, keep original for your files) within 10 days of purchase to: Horizon Service Center Attn: Saito Warranty Dept.
Exclusively Distributed by Horizon Hobby, Inc.
