O.S. engine MAX-40FX, Owner'S Instruction Manual

Page 1: ...ontained 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 aircraft radio control equipment etc are accessible for checking at the same time ...

Page 2: ...RTING RUNNING IN Breaking in IDLING ADJUSTMENT CHART MIXTURE CONTROL VALVE ADJUSTMENT REALIGNMENT OF MIXTURE CONTROL VALVE SUBSEQUENT STARTING PROCEDURE SUBSEQUENT READJUSTMENT CARBURETOR CLEANLINESS ENGINE CARE AND MAINTENANCE ENGINE EXPLODED VIEWS ENGINE PARTS LISTS CARBURETOR EXPLODED VIEWS PARTS LISTS GENUINE O S PARTS ACCESSORIES ENGINE THREE VIEW DRAWINGS MEMO STARTING CONTENTS 17 18 2 6 7 8...

Page 3: ...e 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 co...

Page 4: ... head or exhaust header pipe in particular may result in a serious burn 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 A weakened or loose propeller may disintegrate or be thrown off and since propeller tip speeds with powerful engines may exceed 600 feet 180 metres per second it will be understood that such a f...

Page 5: ...aring Such noise is also likely to cause annoyance to others over a wide area Install a top quality propeller of the diameter and pitch specified for the engine and aircraft Locate 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 nut using the correct size wrench If you remove the glowplug from the engine and...

Page 6: ... wearing of safety glasses is also strongly recommended 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 unless you are highly experienced in tuning propellers for specialized competition work such as pylon racing Take care that the glow plug clip or battery leads do not...

Page 7: ... sand The propeller may throw such material in your face and eyes and cause injury 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 Keep the propeller pointed away from you and walk well clear of spectators Warn...

Page 8: ...g with washer fingertight only before final tightening with the correct size plug wrench BEFORE INSTALLING THE ENGINE Installing the glowplug Connect the short length of fuel tubing supplied securely between the needle valve outlet and carburetor inlet as shown in the illustration on the next page In the event of the tubing becoming damaged it should be replaced with a suitable length as indicated...

Page 9: ...nsion enables adjustments to be made without risk of burning one s fingers on the cylinder head NEEDLE VALVE LOCATION BASIC ENGINE PARTS Cylinder head Carburetor Silicone Tube Crankshaft Propeller nut Propeller washer Drive Hub Crankcase Needle valve Cover Plate Fuel outlet Fuel inlet Glowplug Fuel inlet Beam Mount MAX 61FX Throttle Lever Throttle Stop Screw Using 8mm wrench remove complete needle...

Page 10: ...older Fuel Inlet Needle Valve Assembly 45mm Fuel Inlet Needle Valve Assembly Plug Screw 50SX 91FX Fuel Inlet Needle Valve Assembly Needle Extension 45mm 61FX 50SX 91FX Use hexagon head brass inlet holder 61FX or plug screw 50SX 91FX to blank off side boss vacated by needle valve assembly 4 9 ...

Page 11: ...first nut Tighten this nut first Steel washer 3 4mm steel screw Spring washer or lock washer Hardwood such as cherry or maple Spring washer 3 5mm steel Allen screw 3 4mm steel nuts Use mounting screws of a diameter between 3mm and 4mm appropriate to engine size see table left Mounting Screw Size 50SX 40 46FX 61 91FX 3mm 4mm INSTALLATION OF THE ENGINE Rigid hardwood e g maple At least 15mm 5 8 At l...

Page 12: ... wiring etc when the throttle is fully open or fully closed Set the throttle lever linkage so that the throttle ro tor is a fully open when the transmitter throttle stick is fully advanced and b fully closed when the throttle stick is fully retarded Adjustment of the throttle rotor opening at the idling position can then be made with the throttle trim lev er on the transmitter Select throttle leve...

Page 13: ...the vent pipe of the fuel tank Suggested Fuel Tank Capacities 50SX 40 46FX approx 300cc approx 350cc approx 450cc 61FX 91FX FUEL TANK LOCATION Attention to tank height Fuel level 10mm 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 Keep...

Page 14: ...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 p...

Page 15: ...ar to it Select by practical tests the most suitable fuel from among the best quality fuels available in your country for model use For the best performance a fuel containing 5 to 20 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 essentia...

Page 16: ...establishes the basic fuel air mixture strength The correct mixture is then maintained by the carburetor s built in automatic mixture control system to cover the engine s requirements at reduced throttle settings The Mixture Control Valve carburetor This meters fuel flow at part throttle and idling speeds to ensure reliable operation as the throttle is opened and closed The Mixture Control Valve i...

Page 17: ...to reduce brightness Warning Very hot Never touch the nichrome wire while the battery is connected 1 5 volt heavy duty dry battery or 2 volt rechargeable lead acid cell at least 5Ah If a 2 volt cell is employed use a resistance wire as shown to reduce applied voltage otherwise element will overheat and burn out 4 Glowplug battery The power source for heating the glowplug may be either a large heav...

Page 18: ...er Fit a filter to the outlet tube of your refuelling container to prevent entry of foreign matter into the fuel tank Fuel Can Filter 10 Silicone tubing This is required for the connection between the fuel tank and engine 11 Plug wrench Used for tightening glowplug The O S long plug wrench is available as an optional accessory For tightening glowplug STARTING Install appropriate propeller and tigh...

Page 19: ...VERY IMPORTANT Before being operated at full power i e at full throttle and with the needle valve closed to its optimum setting the engine must be adequately run in otherwise there is a danger of it becoming overheated and damaged Fill the fuel tank Do not allow fuel to overflow into the silencer otherwise the engine may become flooded and difficult to start Check that the needle valve is closed D...

Page 20: ...where the en gine does not stop Run the engine for one minute with the throttle fully open but with the needle valve adjusted for rich slow four cycle operation 1 Now close the needle valve until the engine speeds up to two cycle operation and allow it to run for about 10 seconds then reopen the needle valve to bring the engine back to four cycle operation and run it for another 10 seconds Repeat ...

Page 21: ... the needle valve about 30 and restart As the needle valve is closed slowly and gradually the engine r p m will increase and a continuous high pitched exhaust note only will be heard Close the needle valve 10 15 and wait for the change of r p m After the engine r p m increases turn the needle valve another 10 15 and wait for the next change of r p m As the speed of the engine does not instantly ch...

Page 22: ...te Maximum rpm setting Lean STARTING Rich needle valve setting when starting the engine The engine may stop if the battery leads are disconnected from the glowplug while the engine is running rich Engine stops R e v o l u t i o n s s t a r t t t o d e c r e a s e t o d e 6 7 1 2 5 4 3 Intermittent high pitched two stroke note superimposed on low four stroke sound Note Although this is a two stroke...

Page 23: ...nds Does the engine stop Apply full throttle Does the engine regain full power immediately OK Refer to the next section Re set the idling position at a little higher r p m Set the throttle opening by means of the throttle trim on the transmitter so that the lowest practical speed without risk of the engine stopping is obtained The position where the lowest possible r p m with steady running is obt...

Page 24: ...ture Control Screw counter clockwise 90 to positively enrich the idle mixture then turn the screw clockwise gradually until the engine regains full power cleanly when the throttle is reopened Carry out adjustments patiently until the engine responds quickly and positively to the throttle control Note Mixture Control Valve adjustments should be made in steps of 15 30 initially carefully checking th...

Page 25: ...ing Once the engine has been run in and the controls properly set up it should be unnecessary to alter the mixture settings except to make minor adjustments to the Needle Valve occasionally to take account of variations in climatic conditions The use of a different fuel however particularly one containing more or less nitromethane and or a different type or proportion of lubricating oil is likely ...

Page 26: ... inside the carburettor to deteriorate These procedures will reduce the risk of starting difficulties and of internal corrosion after a period of storage The correct functioning of the carburetor depends on its small fuel orifices remaining clear The minute particles of foreign matter that are present in any fuel can easily partially obstruct these orifices and upset mixture strength so that engin...

Page 27: ... e w q 0 7 6 5 4 3 2 1 C M3 15 C M2 6 18 i u C M3 8 S M3 3 9 8 q 1 i 1 i 2 i 3 i 4 i 5 i 6 i 7 i 8 i 9 i 10 o Type of screw C Cap Screw F Flat Head Screw N Round Head Screw S Set Screw EXPLODED VIEW 50SX 26 ...

Page 28: ...crew Pressure Fitting 873 Silencer Assembly Glow Plug No 8 Screw Set Needle Valve Holder Assembly Set Screw O Ring Needle Plug Screw Fuel Inlet Fuel Outlet Ratchet Spring Cover Plate Body Cover Plate Assembly Gasket Set Crankshaft Crankshaft Ball Bearing R Crankcase Crankshaft Ball Bearing F Thrust Washer Propeller Nut Carburetor Type 40B Connecting Rod Piston Pin Piston Piston Ring Cylinder Liner...

Page 29: ... 0 9 8 7 5 4 3 2 1 6 6 2 6 1 q t e w r 7 r 6 r 5 r 4 r 3 r 2 r 1 r C M3X15 N M3 5X6 S M3X3 C M3X8 Type of screw C Cap Screw F Flat Head Screw N Round Head Screw S Set Screw EXPLODED VIEW 40 46FX 28 ...

Page 30: ...15000 25081700 23210007 23209003 25608000 46120000 26731002 25601100 26730005 25602020 25614010 25607000 25607100 22681953 22681980 24981837 26381501 27381940 26711305 25613000 25425000 22681957 25425310 25425400 40FX 46FX Retaining Screw 2pcs Assembly Screw Pressure Fitting 873 Silencer Screw Set Ratchet Spring Needle Valve Holder Assembly Set Screw O Ring Needle Fuel Outlet Cover Plate Body Cove...

Page 31: ...ED VIEW 61FX Type of screw C Cap Screw F Flat Head Screw N Round Head Screw S Set Screw C M3 15 1 e t 2 4 3 5 6 1 6 2 6 7 w 8 9 0 q N M3 5 6 r 1 r 5 r 3 r 4 r 2 r 10 r 11 r 6 r 7 r 8 C M3 8 C M3 5 8 r r 9 30 ...

Page 32: ...1305 27913000 71608001 26028000 22681953 26028100 26625210 Retaining Screw 2pcs Assembly Screw Pressure Fitting E 4010 Silencer Glow Plug No 8 Screw Set Needle Valve Holder Assembly Set Screw O Ring Needle Inlet Holder Fuel Inlet Fuel Inlet Assembly Fuel Outlet Ratchet Spring O Ring Cover Plate Body Cover Plate Assembly Gasket Set Crankshaft Crankshaft Ball Bearing R Crankcase Crankshaft Ball Bear...

Page 33: ...VIEW 91FXRING Type of screw C Cap Screw F Flat Head Screw N Round Head Screw S Set Screw C M3 15 y y 2 3 4 7 r 6 5 8 1 8 2 8 N M3 5 6 q 9 0 0 1 e t 10 t 1 t 8 t 5 t 2 t 3 t 4 t 7 t t 9 C M3 5 10 S M3 3 t 6 w 32 ...

Page 34: ...mbly Screw Pressure Fitting E 4020 Silencer Assembly Glow Plug No 8 Screw Set Needle Valve Holder Assembly Set Screw O Ring Needle Plug Screw Fuel Inlet Fuel Outlet Ratchet Spring Cover Plate Body Cover Plate Assembly Gasket Set Crankshaft Crankshaft Ball Bearing R Crankcase Crankshaft Ball Bearing F Thrust Washer Propeller Lock Nut Set Carburetor Type 60F Connecting Rod Piston Pin Piston Piston R...

Page 35: ...27783600 22781800 25681200 26781506 25681100 25681620 22681953 46215000 25081700 CARBURETOR 60C 61FX 22781401 22781411 22781420 27783600 22781800 27783200 26781506 27783100 25681620 22681953 46215000 25081700 Throttle Lever Assembly Throttle Lever Throttle Lever Fixing Screw Mixture Control Valve O Ring Carburettor Rotor Rotor Spring Carburettor Body Throttle Stop Screw W Spring Fuel Inlet W Washe...

Page 36: ...Ring S Carburettor Body Rotor Guide Screw Fuel Inlet W Washer Carburetor Gasket Carburetor Retaining Screw 2pcs No Code No 27881400 29581200 45582300 46066319 24881824 29581100 45581820 22681953 29015019 25081700 Description Type of screw C Cap Screw F Flat Head Screw N Round Head Screw S Set Screw Specifications are subject to alteration for improvement without notice 35 ...

Page 37: ... E 4020 Length 35mm 61FX E 4010 91FX E 4020 A3 71605300 O S GLOW PLUGS O S GENUINE PARTS ACCESSORIES SPINNER NUT 23024009 45024000 1 4 28 L 5 16 24 50SX 40 46FX 61FX 91FX Code No Size Type of Engine LONG PROPELLER NUT SETS Code No Size Type of Engine SILENCER EXTENSION ADAPTORS Code No Type of Engine Silencer SILENCER EXHAUST ADAPTORS Code No Type of Engine Silencer PROPELLER NUT SETS FOR TRUTURN ...

Page 38: ... 61FX 91FX 25425020 26028010 873S E 4010S 50SX 40 46FX 61FX For 61FX EXHAUST HEADER PIPE Code No Size Type of Engine SUPER SILENCERS Code No Size Type of Engine Code No Type of Engine O S SILICONE TUBE ASSEMBLY SUPER FI LTER BUBBLE ELIMINATING TANK WEIGHT LOCK WASHER 10Sets LONG SOCKET WRENCH WITH PLUG GRIP T 4010 TUNED SILENCER 37 ...

Page 39: ...ke Practical R P M Power output Weight 8 17 cc 0 499 cu in 22 0mm 0 866 in 21 5mm 0 847 in 2 000 20 000 r p m 1 8 bhp 17 000 r p m 390g 13 76 oz SPECIFICATIONS Dimensions mm UNF1 4 28 52 36 44 17 5 60 7 25 18 3 28 70 5 121 7 5 37 7 21 38 ...

Page 40: ...c 0 395 cu in 20 5mm 0 807 in 19 6mm 0 772 in 2 000 17 000 r p m 1 36 bhp 16 000 r p m 386g 13 6 oz SPECIFICATIONS Displacement Bore Stroke Practical R P M Power output Weight 7 45 cc 0 455 cu in 22 0mm 0 866 in 19 6mm 0 772 in 2 500 17 000 r p m 1 62 bhp 16 000 r p m 375g 13 2 oz SPECIFICATIONS Dimensions mm THREE VIEW DRAWING 39 ...

Page 41: ...9 1 43 79 100 5 ø4 2 42 25 ø4 2 52 Displacement Bore Stroke Practical R P M Power output Weight 9 95 cc 0 607 cu in 24 0mm 0 945 in 22 0mm 0 866 in 2 000 17 000 r p m 1 9 bhp 16 000 r p m 550g 19 42 oz SPECIFICATIONS Dimensions mm 40 ...

Page 42: ...t Bore Stroke Practical R P M Power output Weight 14 95 cc 0 912 cu in 27 7mm 1 091 in 24 8mm 0 976 in 2 000 16 000 r p m 2 8 bhp 15 000 r p m 550g 19 42 oz SPECIFICATIONS 41 4 φ4 2 66 5 29 5 UNF5 16 24 24 7 42 6 43 5 61 25 52 103 81 5 21 5 ...

Page 43: ...eserved Printed in Japan 110101 TEL 06 6702 0225 FAX 06 6704 2722 6 15 3 Chome Imagawa Higashisumiyoshi ku Osaka 546 0003 Japan U N E Q U A LLED QUALITY PRECISION PERFOR M A N C E E S T A BLISHING THE STANDARDS OF EXCELLE N C E URL http www os engines co jp ...