O.S. engine MAX-91SX-HRING C Spec PS VIPER Guida all'installazione

CONTENTS

SAFETY INSTRUCTIONS AND

WARNINGS ABOUT YOUR O.S. ENGINE

NOTES ON INSTALLING,

COOLING-FAN AND CLUTCH

NOTES ON INSTALLING THE ENGINE,

NOTES ON HEATING THE GLOW PLUG

INTRODUCTION

BASIC ENGINE PARTS,

INSTALLATION OF THE CARBURETOR

INSTALLATION OF THE ENGINE

ABOUT THE PUMP SYSTEM

CARE OF FUEL PUMP

FUEL TANK AND PIPING

BEFORE STARTING

2-5

16 18

20-21

FACTS ABOUT GLOWPLUG

CARBURETOR CONTROLS

STARTING, RUNNING-IN ("Breaking-in")

ADJUSTMENT

SUBSEQUENT READJUSTMENTS

CARBURETOR CLEANLINESS

ADJUSTMENT CHART

INSTALLATION OF THROTTLE SERVO

CARE AND MAINTENANCE

EXPLODED VIEW & PARTS LIST

O.S. GENUINE PARTS & ACCESSORIES

THREE VIEW DRAWING

MEMO

13-16

22-24

24-27

32-35

It is of vital importance, before attempting to

operate your engine, to read the general

'SAFETY INSTRUCTIONS AND WARNINGS'

section on pages 2-5 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.

It is suggested that any instructions supplied

with the model, radio control equipment, etc.,

are accessible for checking at the same time.

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.

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

Never touch, or allow any

object to come into contact

with, the rotating parts.

Model engine fuel is poison-

ous. Do not allow it to come

into contact with the eyes or

mouth. Always store it in a

clearly marked container and

out of the reach of children.

Model engine fuel is also

highly flammable. Keep it

away from open flame,

excessive heat, sources of

sparks,or anything else which

might ignite it. Do not smoke

or allow anyone else to smoke,

near to it.

Model engines generate

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 result in a

serious burn.

Never operate your engine in an en-

closed space. Model engines, like auto-

mobile engines, exhaust deadly carbon-

monoxide. Run your engine only in an

open area.

NOTES

These engine were designed for model

helicopters. Do not attempt to use it for any

other purpose.

Mount the engine in your model securely, fol-

lowing the manufacturers' recommendations,

using appropriate screws and locknuts.

Install an effective silencer (muffler). Frequent

close exposure to a noisy exhaust (especially

in the case of the more powerful high-speed

engines) may eventually impair your hearing

and such noise is also likely to cause

annoyance to others over a wide area.

Check the linkage to the throttle arm before

each flight.

Avoid sudden high r.p.m. immediately after the

engine is started, as the clutch will engage and

you may be struck by the rotor.

After starting the engine, carry out any needle-

valve readjustments after stopping the rotor by

closing the throttle to the lowest r.p.m..

Stop the engine before attempting to make

other adjustments to the carburetor.

Use an electric starter. The wearing of safety

glasses is also strongly recommended.

Press the rotor head down securely.

Take care that the glow plug clip or battery

leads do not come into contact with rotating

parts.

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.

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.

For their safety, keep all onlookers (especially

small children) well back (at least 20 feet or 6

meters) when preparing your model for flight. If

you have to carry the model to the take-off point

with the engine running, be especially cautious.

Hold the rotor securely and keep well clear of

spectators.

Warning! lmmediately after a glowplug-ignition

engine has been run and is still warm,

conditions sometimes exist whereby it is just

possible for the engine to restart when turned

over WITHOUT the glowplug battery being

reconnected. Remember this if you wish to

avoid the risk of accidents.

Notes on installing cooling fan and clutch

Do not use a tool which

locks piston when

installing a cooling-fan

and clutch, or top of

the piston may be

damaged. Also, do not

insert a screw driver or

the similar into the

exhaust port.

It is recommended to use Crankshaft

Clamp 7091 (Code No.71530500) available

as an optional tool.

It is made of durable engineering plastic

and locks the crankshaft without risk of

damage to any part of the engine.

Application is as follows:

Remove the crankcase rear cover plate from the

engine and rotate the crankshaft to the bottom

dead center (BDC) position.

Insert the crankshaft clamp so that its grooved

portion surrounds the crankpin and lower end of

the connecting rod and securely tighten the fan

or clutch onto the crankshaft.

Insert this groove onto

the connecting rod.

BDC position

Rotate the crankshaft so that the

connecting rod comes to this position.

Note on installing the engine

Note on heating the glow plug

Cooling fan cover from

some helicopter models

interferes the heatsink

head. In this case, cut out

the cover as illustrated.

Example

Cut out according to the heatsink head.

Heatsink head, crankcase and cover

plate of the engine are treated with

Alumite which does not conduct

current. Therefore, when heating a

glow plug, connect one lead to the

glow plug and the other to the head

of cover plate fitting screw.

First, heat the center plug and start the

engine. Then, heat the second plug while

running the engine at idle. When the

second plug is ignited, idling sound

changes. After confirming this change,

disconnect battery lead to the plugs. If

the idling mixture is rich, it is necessary

to heat the second plug for about 5-10

seconds to ignite. Carefully listen to the

idling sound to confirm the change.

Example

BASIC ENGINE PARTS

Heatsink Head

Carburetor

Typr 60M

Crankshaft

Propeller nut

Crankcase

Thrust Washer

Glowplug

Beam Mount

Pump

As delivered, the carburetor is not fit to the engine.

Secure it as follows.

INSTALLATION OF THE CARBURETOR

Retainer Nut Carburetor Rubber

Gasket

0.2mm gap

Loosen the retainer nut, press the carburetor well

down into the intake boss, compressing the rubber

gasket as shown in the sketch, before re-tightening

Nut.

Rotate the retainer nut gently until it stops, then

tighten a further 90-120 degrees. Do not over-

tighten the screw as this will damage the carburetor

body.

Pump Holder

60M One-way Valve

Return Screw

Cover Plate

Press down until the gasket becomes almost invisible.

Because of initial tightness, a standard

electric starter may have difficulty in

rotating the engine when cold, before it

has been adequately run-in. In this

case, use a high-torque type starter.

DO NOT, however, confuse tightness

with the symptoms of hydraulic lock

caused by an excess of fuel within the

cylinder - often the result of over-

priming.

Attempting to force the engine to turn

over in this condition may cause

internal damage. Instead, remove the

glowplug, invert the engine and eject

surplus fuel from the combustion-

chamber.

Note:

FEATURES

As delivered, the carburetor is not fit to

the engine.

Standard accessories

Glow Plugs No.8 (1 pc.), A5 (1 pc.)

Woodruff Key

Needle Adjusting Screw (M2.6x5 1pc.)

Silicone tube

Note:

Carburetor Complete 60M

T nipple

Instruction manual

( 2.5x 5.5xL300mm)

The MAX-91SX-H RING C-Spec PS VIPER is

installed with VIPER twin-plug head made

by OMI, USA instead of the original head.

Twin-plug haw power increase effect and

special head material develops extreme

cooling effect. Another difference from the

standard version is it employs matched

new design low friction piston which offers

stable hovering as wellas powerfull flight.

Also, Return Needle Valve Holder which

makes the adjustement range wider, is

supplied as stantard.

INSTALLING THE GLOWPLUG

Install the washer on the

glowplug and screw

carefully into cylinder-

head, making sure that it

is not cross-threaded

before tightening firmly.

Glow plug

Washer

INSTALLATION OF THE ENGINE

The under-surfaces of all O.S. engine beam

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

itself, probably resulting in loss of performance and

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.

Front view

CORRECT

Side view

Top surfaces are in the same plane.

Re-align the surfaces as necessary

INCORRECT

Top surfaces are not

in the same plane. Top surfaces are not in the

same plane.

Engine does not rest firmly.

Make sure that only the under-

surfaces of the engine’s mounting

lugs are in contact with the engine

mount.

ABOUT THE PUMP SYSTEM

Please understand the pump construction before

piping.

Pump functions in accordance with the engine

r.p.m. Rotating the engine by an electric starter

without connecting battery to a plug sucks fuel.

Prolenged this action may result in over priming.

Attempt to start the engine with over-priming may

result in bending a connecting rod and damaging

the engine.

NOTE:

Fuel is pumped from the tank and delivered to the

carburetor. Set the main needle a little rich at early

stage.

With this system the pump delivers the fuel at

constant pressure even at idling. Then,

unconsumed fuel is returned to the tank ria one-

way valve which avoids getting rich at around

idling.

If the main needle is set correctly, fuel return will

stop at around 60% throttle opening. Therefore, in

the high air flight that requires wider throttle

opening the engine runs under the effects of

muffler pressure, pump pressure and main needle.

During hovering that requires around half throttle

the engine runs under the effects of muffler

pressure, main needle, mixture control and retur

fuel volume.

Install A 5 at center and

No.8 a t s e c o n d p o sition.

CARE OF FUEL PUMP

NEVER disassemble the fuel pump or pressure

regulator. Their original performance may not be

restored after reassembly.

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.

Do not clean the pump with organic solvent such

as kerosene, light machine oil, gasoline, thinner or

crc or the silicone rubbur parts inside is

detoriorated. Be sure to use methanol or fuel.

Do not more the pump adjusting screw at the

center a the adjustment gets out of order and the

parts inside is damaged.

Do not remain fuel in the pump. After finishing the

day's flight session, be sure to use out the fuel in

the pump. Stop the fuel flow to the pump with the

stopper and run the engine at idling to use out the

fuel in the pump. After stopping the engine, rotate

the engine by electric starter to eject fuel inside the

engine.

Pressure adjusting screw

IN OUT

FUEL TANK AND PIPING

Install the engine and a muffler according to the

instructions supplied with the model. Then, connect

piping between tha muffler and fuel tank for muffler

pressurized fuel feed. Then, cut the silicone tube

supplied to 96mm and connect the pump and

carburetor with it.

Pump has fuel flow direction as shown in the sketch.

Be sure to connect between out nipple and carburetor

inlet nipple.

Next, connect piping from one-way valve for fuel

retur. There are two ways.

To return the fuel to the tank.

Connect between one-way valve and fuel tank. Fit a

nipple on the tank. This system ensures stable fuel

supply even with the 3D flight which requires

successire big throttle works.

Clear the burr, if any, off the hole to fit the nipple

with a cutter knife. Also clean the tank with

methanol to remove the dust or tank cut-off

particle.

Fuel tank

Commercialy

available nipple

Nut

Washer

BEFORE STARTING

Tools, accessories, etc.

The following items are necessary for operating the

engine.

1 Fuel

Select, by practical tests, the most suitable fuel from

among the best quality fuels available in your country

for helicopter use. For the best throttle response, a

fuel containing 10% to 30% nitromethane is

preferable. Lubricants may be either castor-oil or a

suitable synthetic oil (or . a blend of both) provided

that they are always of top quality. For consistent

performance and long engine life, it is essential to use

fuel containing AT LEAST 18% lubricant by volume.

Some fuels containing coloring additives tend to

deterriorate and may adversely affect running

qualities. If in doubt compare to a fuel known to be

good.

Model engine fuel is poisonous. Do not allow

it to come into contact with the eyes or

mouth. Always store it in a clearly marked

container and out of the reach of children.

Reminder!

The pump requires running-in as with the engine. Be

sure to check the silicone tubes and connections

carefully for any cracks on the tubes and loose

connections as the engine runs ejecting excess fuel.

4 Glowplug battery

The power source for heating the glowplug may be

either a large heavy-duty 1.5volt dry cell, Ni-cd battery

or battery integrated booster.

1.5 volt dry cell

2 Glowplug

O.S. No.8 glowplug is installed in the engine.

3 Battery leads

These are used to conduct current

from the battery to the glowplug.

Basically, two leads, with clips, are

required, but, for greater conve-

nience, twin leads with special

glowplug connectors, as shown on

the right, are commercially available.

Model engine fuel is also highly flammable.

Keep it away from open flame, excessive

heat, sources of sparks, or anything else

which might ignite it. Do not smoke, or allow

anyone else to smoke, near to it.

Battery Integrated booster

Battery leads

Make sure glowplug element

glows bright red inside room

or shadow.

Battery leads

12V Battery

Starter

6 Electric starter and starter

battery

An electric starter is recom-

mended for starting.

5 Hexagon starting shaft

This shaft mounted on an

electric starting motor is driven

into the shaft cup to turn the

engine.

In case of 1.5volt dry cell

10 Plug wrench

Used for tightening glowplug. The

O.S. long plug wrench is available

as an optional accessory.

7 Fuel pump

For filling the fuel tank one of the

purpose-made manual or electric fuel

pumps may be used to transfer fuel

directly from your fuel container to the

fuel tank.

For tightening

glowplug

Manual

Electric

Fuel pumps

Fuel Can Filter

8 Fuel container filter

Install a filter on the outlet tube of your

refuelling container to prevent entry of

foreign matter into the fuel tank

9 Silicone tubing

This is required for the connection

between the fuel tank and engine.

ID 2.5mm and OD 5-5.5mm one

would be suitable.

Silicone tubing

2x 5xL12mm

Silicone Tube

Joint Nipple

(Joint nipple and silicone tube are fit

on the cover plate.)

If the silicone tube on the cover plate is damaged,

use commercially available 2mm ID and 5mm OD

silicone tube by cutting to 12mm length.

FACTS ABOUT GLOWPLUGS

The role of the glowplug

Glowplug life

Particularly in the case of very high performance

engines,

glowplugs must be regarded as expendable

items.

With a glowplug engine, ignition is initiated by the

application of a 1.5-volt power source. When the

battery is disconnected, the heat retained within the

combustion chamber remains sufficient to keep the

plug filament glowing, thereby continuing to keep the

engine running. Ignition timing is 'automatic' : under

reduced load, allowing higher rpm, the plug becomes

hotter and, appropriately, fires the fuel/air charge

earlier; conversely, at reduced rpm, the plug become

cooler and ignition is retarded.

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. Recommended O.S. plugs

are No.8 and A5. Carefully install plug finger-tight,

before final tightening with the correct size plug

wrench.

Install a plug suitable for the engine.

Use fuel containing a moderate percentage of

nitromethane.

Do not run the engine too lean and do not leave the

battery connected while adjusting the needle.

However, plug life can be extended and engine

performance maintained by careful use, i.e.:

Apart from when actually burned out, a plug may

need to be replaced because it no longer delivers its

best performance, such as when:

When to replace the glowplug

Filament surface has roughened and turned white.

Filament coil has become distorted.

Foreign matter has adhered to filament or plug

body has corroded.

Engine tends to cut out when idling.

Starting qualities deteriorate.

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