O.S.Engines 160FX-FI Manual
Contents
1. 50 5 UNF3 8 24 a Va MI _ 65 3 2 5 0 8 Ya BY sa TO OSOH YA EN 5 PUE E MO oui e L 80 4 In 8 o Q O E 115 5 120 6 O S GENUINE PARTS 8 ACCESSORIES HO S GLOW PLUG W RADIAL MOTOR MOUNT W BOOSTER TERMINAL KIT No 8 71920000 72200130 71608001 71615009 BOOSTER CABLE SET W PROPELLER LOCKNUT E NON BUBBLE 72200110 SET FOR TRUTURN SPINNER WEIGHT 3 8 M5 S 71531000 29310110 LOCK WASHER H SUPER FILTER L LONG SOCKET WRENCH 10sets 72403050 WITH PLUG GRIP 5 55500004 71521000 17 9 ENGINES 6 15 3 Chome Imagawa Higashisumiyoshi ku Osaka 546 0003 Japan TEL 06 6702 0225 FAX 06 6704 2722 URL htip www os engines co jp Copyright 2001 by O S Engines Mfg Co Ltd All rights reserved Printed in Japan 0401002. Note When engine speed is abnormally high always make sure to stop the engine and inspect the problem since this can cause damage to the engine In cases when there are considerable temperature changes during the course of a day such as in the spring and autumn the fuel injection volume may not be able to keep with engine performance to a certain extent If this happens readjust the injection trim adjustment dial spare channel dial before further use 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 10 it makes a start easy to apply an electric stater 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 Do not attempt to start the engine manually since this is potentially dangerous After the engine has started gradually move the throttle stick on the transmitter to the full high position Then gradually move the throttle stick to the full slow position and disconnect the starting battery Again move the throttle stick to the full high position and check the engine speed NOTE Avoid moring throttle stick to higher than intermediate slow position after injection trim adjustment is completed Adjust the injection trim
3. Electronic Fuel Injection System OWNER S INSTRUCTION MANUAL 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 e Also please study the entire contents of this instruction manual so as to familiarize yourself with the controls and other features of the engine e Keep these instructions in a safe place so that you may readily refer to them whenever necessary elt is suggested that any instructions supplied with the aircraft radio control equipment etc are accessible for checking at the same time CONTENTS SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O S ENGINE 2 4 INTRODUCTION FEATURES 5 BASIC ENGINE PARTS 6 CONNECTING WITH THE EC 2 LED Display Buzzer hotes and status 7 8 LIST 160FX FI USAGE CONDITIONS 9 BEFORE INSTALLING THE ENGINE 10 INSTALLATION PROCEDURE 10 12 LINKAGE AND INITIAL SETTINGS 13 14 ENGINE STARTING AND AIR FUEL MIXTURE ADJUSTMENT 14 ENGINE STARTING EE 15 16 FLIGHT ADJUSTMENT en 17 GLOW PLUG CARE AFTER USE 18 TROBLESHOOTING 19 ENGINE amp INJECTOR
4. appropriate reamer checking that the hole is exactly Lock Nut Propeller Washer centered AN 2 Fit the prop to the engine shaft followed by the retaining 6 Se washerandpropnutandtightenfirmlywitha17mmwrench E 3 Add the special tapered and slotted locknut and secure with a 14mm wrench while holding the prop nut with the 17mm wrench Since the engine is intended to be started with an electric starter the addition of a spinner assembly for centering the starter sleeve is desirable Special propeller locknut set Code No 29310110 is available as optional extra for use with spinners LINKAGE AND INITIAL SETTINGS Ensuring a proper linkage is important in the 160RX FI system in terms of a proper air fuel mixture In other words it is necessary to maintain the proper relationship between opening of the air valve stick position and fuel injection by the injector Call up the ATV menu on the 2 Rotor mark condition menu and select THR Confirm that it is in the center of Center mark the throttle curve when the stick is in the center position 55 Then align the mark in the center S of the air valve at that point e 5 The center of the curve is the A center and if the stick is shifted out of position give priority to the A Slow mark center of the throttle curve Throttle stick position Make the settings according to the procedures described below 1
5. AIR VALVE EXPLODED VIEW 20 PARTS LISI ee 21 THREE VIEW DRAWING 22 O S GENUINE PARTS 8 ACCESSORIES 23 AIS Te 24 SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR 0 5 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 The advice which follows is grouped under two headings according to the degree of damage or danger which might arise through misuse or neglect These cover events which might involve A W A R N N G 6 serious 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 A WARNINGS eNever touch or allow any object to come into contact with the rotating propeller and do not crouch over the engine when it is running e A weakened or loose propeller may disintegrate or be thrown off and since propeller tip speeds with powerful engines may exceed 600
6. feet 180 metres per second it will be understood that such a failure could result in serious injury see NOTES section relating to propeller safety 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 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 eNever operate your engine in an enclosed space Model engines like automobile engines exhaust deadly carbon monoxide Run your engine only in an open area 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 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 Install a top quality propeller of the diameter and pitch specified for the engine and
7. from a transmitter It then determines the fuel injection volume based on the required amount of fuel to be supplied for that engine speed as calculated by an electronic control unit referred to as the EC 2 after which fuel is injected into the engine from an injector In addition adjustments can also be made using dial on the transmitter The result is an engine for Aerobatic and big scale models that features excellent engine speed linearity relative to throttle operation under all types of flight conditions FEATURES Supplies the Proper Amount of Fuel at all Times Easier starting Greater stability during idling Excellent linearity and response relative to stick operation Simple Adjustment Using Dials on the Transmitter Air fuel mixture at medium and high speeds be safety and easily adjusted from the transmitter Adjustments be made while on the ground and during flight Stable Supply of Fuel at all Times Pressurized fuel is controlled at a constant pressure with respect to all types of movement during flight allowing stable engine performance at all times Light Weight and Easy Installation The sensor and injector mounted on the engine are both compact and lightweight while the electronic control unit EC 2 is also lightweight enabling various connections to be made easily the same as plugging in a servo Glow plug No 8 BASIC ENGINE PARTS Accessories Cylinder Head EC 2 A
8. is turned off Repeat steps through when the throttle linkage has been changed 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 When the settings of 2 and 3 are unable to be made repeat linkage of the throttle servo and air valve as well as the Limit settings 4 Make sure that injection trim functions correctly when the throttle stick is at full high position as well as at the center position First make sure that LED lights red when the dial is turned right and LED lights green when the dial is turned loft with the throttle stick at full high position In case of other maks if the direction is reverse it is necessary to reverse the setting Even if the direction is reverse there is no functional problem Then set the dial at the position where the Buzzer sounds two successive notes PiPi turning the dial right and left Then more the throttle stick to the full slow position and set the dial at 0 position Now the 0 setting at full high position is completed Then carry out the same procedure wi
9. part See parts list Rigid hardwood e g maple At least ONG Atleast 15mm 5 8 15mm 5 8 Make sure that the mounting beams are parallel and that their top surfaces are in the same plane CORRECT INCORRECT Fig 4 8152 di surfaces are not Opposite beam Front view Side view in the same plane Top surfaces are not in the Top surfaces are in the same plane same plane tf Re align the surfaces Engine does not seat firmly as necessary How to fasten the mounting screws Tighten second nut firmly Fig 5 down onto first nut 5mm steel Allen screw i Tighten this nut first Spring washer or 82 9 lock washer A 5mm steel nuts Spring washer Hardwood such as cherry or maple Steel washer al O S radial motor mount Hardwood mounting beams cast aluminum A soft engine mount is recommended but should be made of firm enough meterial to prevent excessive engine movement but still minimize engine vibration If engine vibration is excessive the opening angle of the air valve may vary causing unstable engine operation and possible stalling In addition adequate clearance must be provided to ensure there is no contact between the injector temper
10. volume with the injection trim adjustment dial spare channel dial so that engine speed stabilizes at around 7 500 7 800 rpm this may vary slightly depending on the propeller used If LED lights green mixture can be adjusted richer and it LED lights red mixture can be adjusted leaner The contents of the adjustment are instantanously stored in memory Move the stick to the slow position At this time return the injection trim adjustment dial spare channel dial to the center 0 position 2 Put the throttle stick in the center position After a short time 5 10 seconds check the engine speed Adjust the injection trim volume with the injection trim adjustment dial spare channel dial so that engine speed stabilizes in the vicinity of 6 100 6 300 rpm this may vary depending on the propeller used The contents of the adjustment are instantaneously stored in memory 3 Put the throttle stick in the full slow position Return the injection trim adjustment dial spare channel dial to the center 0 position Adjust the throttle trim so that engine speed at full slow stabilizes in the vicinity of 1 800 rpm 4 Reconfirm whether engine speed reliably responds to throttle operation at all speeds and whether the throttle stick responds from slow operation to quick operation Adjustments are satisfactory if engine speed remains stable Note Injection trim adjustment uses the same adjustment dial for both intermediate slow and high The u
11. 0 spare channel NORM direcion In case of other marks it is necessary to change setting it the direction is reverse SANWA STYLUS Only Z connectors can be used check whether polarity matches Aircraft Sport Big Scale Aerobatic Wingspan 1 7 2 0m Weight 4 7 5 8kg The contents of the user s manual are based on those products indicated with an asterisk BEFORE INSTALLING THE In addition to the general tools the following tools are convenient to use 14 17mm open end wrench Large capacity electric starter and battery Hex wrench to secure the silencer supplied with the engine INSTALLING THE GLOW PLUG Carefully insert plug with washer fingertight only before final tightening with the correct size plug wrench Glow plug Washer s 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 Install the 160FX FI while taking the following matters into consideration 1 MAX 160FX FI Engine The following components are required during installation EC 2 y harness check valve fuel filter E 5010 silencer extension cord sold separately double sided sponge backed cushioning tape 2 Engine Mount Installation in the model A typical method of beam mounting O S radial motor mount Fig 3 is shown below left Available as an optional extra
12. Transmitter Trim Adjustment Adjust the throttle trim on the transmitter to 0 2 Confirmation of Amount of Throttle Angle Set the angle adjustment of all throttle channels AFR to 100 and sub trim to 0 Set mixing of the throttle curve expo channel and so forth to off 0 and set the throttle trim in the center 3 Throttle Servo and Air Valve Linkage Method Align the throttle stick on the transmitter at the center position as shown in the figure Accurately align the throttle servo and air valve sections as shown in the figure Vertical position of air valve horn Rotor mark is at the position of the center mark on Fig 8 the body 90 relative to the throttle linkage rod Transmitter Throttle servo Center position Rotor mark Right angle Right angle B8 L Center Right angle Right angle Stick position Set to the center position 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 5 Engine Cutoff Adjustment When using a transmitter equipped with an engine cutoff function
13. Two extension cords sold separately of a length corresponding to the airframe are required for connecting 1 and 2 1 Injection Time Input Terminal lt Black gt CH3 THRO Connect the y harness provided with the CH3 THRO input terminal to throttle channel of the receiver throttle CH3 connect the wiring connector from the throttle servo to one of the double opening connectors on the opposite side and connect the other double opening connector to CH3 THRO of EC 2 Use the separately sold extension cord if the wiring cords are too short 2 Injection Trim Input Terminal lt Red gt AUX TRIM Connect a spare channel for dial use of the receiver e g channel 7 to the AUX TRIM terminal Use the separately sold extension cord if the wiring cords are too short 3 Injector Output Terminal Connect the injector connector to the injector output terminal Protect the lead wire with a heat resistant be etc if it makes contact with the engine mount 4 Temperature Sensor Input Terminal Connect the temperature sensor connector to the temperature sensor input terminal 5 Rotation Sensor Input Terminal Connect the rotation sensor connector to the rpm input terminal 6 Limit Setting Switch LIMIT Push with driver supplied when setting limit 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
14. 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 Always check the tightness of the propeller nut and retighten it if necessary before restarting the engine particularly in the case of four stroke cycle engines A safety locknut assembly is provided Always use it This will prevent the propeller from flying off in the event of a backfire even if it loosens If you install a spinner make sure that it is a precision made product and that the slots for the propeller blades do not cut into the blade roots and weaken them 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 Use an electric starter for this engine The wearing of safety glasses is also strongly recommended Take care that the glow plug clip or battery leads do not come into contact with the propeller Also check the linkage to the throttle arm A disconnected linkage could also foul the propeller e 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 f
15. ature sensor and rotation sensor with the airframe 3 Fuel Tank and Lines Fuel filter provided T nipples sold separately i Check MA Non provided Fuel supply line Caps sold separately Connect all lines securely as shown in the figure above Since high pressure is applied to the fuel tank from the engine crankcase make connections using a commercially available thick walled silicon tube In addition make sure to securely seal the area around the cap If the outlet of the nipples is left accessible from outside the airplane it will make venting tank pressure and refueling easier Always make sure to use the check valve and fuel filter provided connections in the following order Engine carburetor nipple check valve provided T nipple and fuel tank air chamber side Make connections in the following order Injector fuel tank provided T nipple and fuel tank weighted side NOTE Always make sure to release any pressure remaining in the tank when adding fuel and following engine operation Silicon tubing is easily damaged by sharp objects that can lead to the formation of holes and cracks Check the surrounding area of the presence of potentially harmful sharp objects 4 2 Install the 2 in location that is not susceptible to the effects of heat fuel or vibrations while allowing easy manipulation Always make sure t
16. ble Do not use paint thinner gasoline or other cleaners that erode plastic when cleaning 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 Engine operation is unstable at low speeds Are the rubber dampers of the engine soft mount too soft Are the rubber dampers of the soft mount damaged 15 the throttle linkage sticking 15 the linkage too weak causing it to be affected by vibrations Is the check valve normal 15 thefuel tank pressurized 15 the servo malfunctioning or is the servo mount loose Engine operation is unstable at high speeds Engine stalls Is the propeller size correct Is the engine running at 8 500 rpm or higher 15 there an abnormality in the engine soft mount cracked When there are occasional disturbances in engine speed when the air fuel mixture is rich at high speeds there may be a problem with the temperature sensor Is an abnormal temperature 300 C or higher displayed for Tmax Tmp Is the filter clogged Are the rubber dampers of the engine soft mount too soft Are the rubber dampers of the soft mount damaged Has the plug deteriorated Is there any sticking or abnormaliti
17. e the glowplug Apart from when actually burned out a plug may need to be replaced because it no longer delivers its best performance such as when lt 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 CARE AFTER USE e 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 In order to maintain the engine in the optimum state it is important to vent any residual gas generated during engine operation as quickly as possible In addition since this engine uses a manifold and tuned silencer residual gas may be present in these components as well It is recommended to remove the tuned silencer after use and store it Connectors and leads are arranged in the engine compartment They be soiled with dust or other debris This can cause a malfunction Clean these components to prevent them from becoming soiled as much as possi
18. es in the linkage Is the oil content of the fuel correct not too much Is the idling speed too low e Is the check valve functioning properly Is the air control servo operating abnormally hunting If the sound of the engine remains unchanged when diving during flight and stick response is lost this indicates that there is too much fuel being supplied to the engine Try adjusting intermediate slow trim in the direction right lt Is the air control linkage to weak so that the operation of the air valve either stops or is delayed relative to the operation of the servo Try using a thicker component for the linkage Is the carburetor secured Check the carburetor retainer ENGINE amp INJECTOR AIR VALVE EXPLODED VIEW C M4x12 e Type of screw 2122 C Cap Screw M Qval Fillister Head Screw F Flat Head Screw N Round Head Screw S Set Screw ENGINE PARTS LIST No Code No Description 29604 000 Cylinder Head 2 9603 100 Cylinder Liner 29603400 Piston Ring 2 9603 200 Piston 2 9606 000 Piston Pin 28117000 Piston Pin Retainer 2 9405 000 Connecting Rod 2 9483 010 Injector Air Valve Set 700 29610100 Lock Nut Set 2 9608 000 Drive Hub 1 45508 200 Woodruf Key GD 29320000 Th
19. gine speed is then calculated based on that signal which is then used to determine the timing at which fuel is injected Electronic Control Unit lt EC 2 gt abbreviated as simply EC 2 The EC 2 transmits fuel injection signals to the injector to ensure the proper amount of fuel injection based on basic fuel injection data that has been previously entered and constantly changes with position of throttle stick heck Val This one way valve s function is to pressurize the fuel tank by crankcase Chec alve pressure and prevent fuel from returning to the engine crankcase This fine mesh filter prevents foreigh matter from the fuel tank from plugging Fuel Filter the small injector valve Y harness This cord is used to connect the receiver throttle channel throttle servo and EC 2 6 WITH THE 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 Injection INJECTOR 2 Injection trim input terminal 160 4 Temperature sensor input terminal AUX TRIM S 2 R C ENGINE CONTROL UNIT OS anan LIMIT SW v 5 RPM sensor input terminal r p m L E D Vv THR 1 Injection time input terminal CH3 THRO 6 Limit Setting Switch LIMIT 7 L E D
20. gine with level flight 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 5 No 8 plug is supplied with the engine Recommended 5 plug are No 8 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 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 rom the plug becomes hotter and appropriately fires the fuel air charge earlier conversely at reduced rpm the plug become cooler and ignition is retarded Glowplug life Particularly in the case of very high performance engines glowplugs must be regarded as expendable items However plug life can be extended and engine performance maintained by careful use i e e Install a plug suitable for the engine Use fuel containing a moderate percentage of nitromethane unless more is essential for racing events Do not run the engine too lean and do not leave the battery connected while adjusting the needle When to replac
21. ion igetion MAX 160FX FI 2 ent contro van VER AUXx manm Samome GE E 2 Spare Channel 2 Injection trim adjustment corresponds to needle valve adjustment of conventional carburetor Intermediate slow Fuel injection volume Injection trim can be adjusted independently Fig 2 for two area as shown in the graph Intermediate slow and full high are adjusted with the injection trim adjustment dial spare Full high channel dial on the transmitter 1 2 3 4 5 6 7 8 9 Lo Mi Throttle stick position Hi LIST 160 USAGE CONDITIONS Part Manufacturer Name Remarks Silencer O S E 5010 Glow plug O S No 8 Propeller Commercially General references Maximun speed should be available 17 12 Basi between 7 300 and 8 500 high quality x12 Basic propeller rom product 16x12 14 16 5x12 13 17x10 13 18x8 10 Fuel Commercially 10 25 nitromethane Adjustment may vary slightly available according to the amounts of high quality 15 20 oil nitromethane and oil product Use a fuel containing as low nitromethane 5 possible within the percentage shown left Too much oil may cause malfunction Transmitter FUTABA 1024ZA 92 Spare channel dial used at 100 by canceling mixing E expo etc when used JR PCM10S alone JR 10 case of FUTABA set with JR X381
22. n direction right by about 10 about 2 clicks with the throttle stick in the full high position Then repeat flying straight in the same manner as before Repeat this adjustment procedure until engine speed has stabilized The engine speed will not change immediately after the air fuel mixture has been changed Fly the airplane straight several times to confirm that engine speed has become stable When flying straight as described above fly both into the wind and with the wind Adjustment is completed when there are no disturbances in engine speed when flying level If the engine produces a higher pitch sound immediately after taking off or if the engine appears to lose power and exhaust cannot be seen at all although varying somewhat depending on the fuel turn the injection trim adjustment dial spare channel dial in the rich direction left by about 45 with the throttle stick in the full high position and reconfirm engine operation by continuing to fly for 3 4 minutes When this is difficult to evaluate land the airplane and recheck engine speed with the throttle stick in the center and full high positions When there is still no change even when the above adjustment has been made land the airplane and try readjusting from the first step of the adjustment procedure This completes the adjustment procedure NOTE Repeat this procedure when changing propeller or fuel Torgne Roll maneurre increases engine temperature Cool the en
23. o attach double sided sponge backed cushioning tape or Velcro tape between the airframe and EC 2 as measures against vibrations 5 INSTALLATION OF SILENCER MUFFLER To fit the standard silencer 1 Fix the exhaust adaptor plate to the engine with the two M5 x15 Allen screws supplied 2 Now fit the silencer to the exhaust adaptor with M5x20 Allen screws also provided NOTE In order to prevent the leakage of exhaust oil from between the engine and adaptor and between the adaptor and silencer apply a suitable silicone sealant to the joint faces during assembly Fig 7 Turn to required position Exhaust adaptor Lock SCH Exhaust Outlet Assembly screw The angled exhaust outlet is agjustable and can be rotated to any desired position in the following manner 1 Loosen locknut and assembly screw 2 Set the exhaust outlet at the required angle by rotating the rear part of the silencer 3 Re tighten the assembly screw followed by the locknut 6 PROPELLER amp SPINNER ATTACHMENT 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 Fit this as follows 1 Ream the propeller shaft hole to 9 6mm bore with an N
24. running LED Display Transmitter Operation LED Status Turn the dial right to reduce injection volume Red lights When the engine Turn the dial left to increde injection volume Green lights is not running Flashes Limit position color depends or the dial position When the engine the dial right to reduce injection volume Red flashes is running Turn the dial left to increde injection volume Green flashes Turning direction of dial shows the standard setting direction Dial position shows plus green rich or minus red lean from the zero position basis injection volume 7 8 Integrated Buzzer Buzzer sounds when setting Limit dial is set nnetral a error happens Buzzer notes and status Notes Status Nil Normal One note Pi Limit at Low is set Two successive notes PiPi Dial neutral Limit at High is set Repeated one note Pi Pi Temperature Sensor is disconnected Repeated two successive notes PiPi PiPi Error on setting Limit Repeated three successive notes PiPiPi PiPiPi Battery voltage falls down below 3 8v mark shows alarm for error Fig 1 Injector Rotation Sensor AUX Throttle Channel Temperature Sensor Transmitter Throttle Servo Branched Cord Receiver Inject
25. rust Washer GD 4 6231 000 Crankshaft Ball Bearing Front 29601 010 Crankcase 2 9081 719 Carburettor Retainer 05 2 9401 200 Temperature Sensor Set 2 9630 000 Crankshaft Ball Bearing Rear 29602000 Crankshaft 29614000 Gasket Set 29607200 Cover Plate RPM Sensor Set 29407300 Pressure Fitting 21 2 9613 000 Screw Set G 74001010 Electronic Control Unit EC 2 2 9325 000 E 5010 Silencer Assembly 2 9325 300 Assembly Set 2 9325 400 Retaining Screw 2 9326 000 Adaptor 7 1608 001 Glow Plug No 8 7 2403 061 Check Valve 7 2403 060 Fuel Filter INJECTOR AIR VALVE 70C PARTS LIST No Code No Description O 2 7381 400 Throttle Lever Assembly 2 9483 210 Roter Valve 45581 820 Roter Guide Screw 2 9483 110 Injector Air Valve Body 5 2 9483 Injector Holder 2 9484 000 Injector Set 29015 019 Gasket The specifications are subject to alteration for improvement without notice THREE VIEW DRAWING Specifications E Displacement Bore Stroke HPracticalR P M E Output E Weight Silencer 26 23 cc 1 60cu in 33 6 mm 1 323in 29 6 mm 1 165in 1 800 9 000 r p m 3 7 ps 8 500r p m 945g 33 30z 5010 300g 10 602 Dimensions mm
26. se of an incremental system allows the same dial to be used for both H adjustment is still not adequate when the dial is turned all the way to the right or left during adjustment temporarily move the throttle stick to the full slow position and move the dial to the center 0 position This also allows adjustment of the air fuel mixture The injection trim volume at intermediate slow and full high do not change even if the adjustment trim dial is moved with the throttle stick in the full slow position In the case of a new engine start adjustment of injection trim volume on the rich side LED lights green and then readjust after making 3 or 5 flights 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 This is one way to check the difference in engine speeds when on the ground and in flight If it appears that engine speed fluctuates while flying straight this indicates that excessive fuel is being supplied to the engine Turn the injection trim adjustment dial spare channel dial in the lea
27. ssembly Crankcase Temperature Sensor harness Injector si ressure Fitting Duble sided sponge Air Valve 70C backed cushioning tape Check Valve Fuel Filter Driver to push Limit Setting Switch Glow plug No 8 E 5010 Silencer RPM Sensor AY Propeller Washer LT TF Crankshaft Ee Nut Electronic Control Unit lt EC 2 gt Lock Nut INSTALLATION OF THE AIR VALVE As delivered the engine has its air valve lightly installed into the intake boss Secure it as follows 1 Loosen the retainer nut rotate the air valve to its correct position and make sure that it is pressed well down into the intake boss compressing the rubber gasket before retightening nut 2 Rotate the retainer nut gently until it stops then tighten a further 90 120 Do not overtighten the screw as this will damage the thermo insulator Never attempt to disassemble the injector Injector It may not be able to be reassembled The injector consists of a solenoid valve with built in regulator It controls pressurized fuel at a constant pressure and accurately injects fuel based on signals from the electronic control unit EC 2 Tem perature Sensor This measures the temperature of the engine exhaust unit RPM Sensor The RPM sensor is provided with a power generating sensor When the crankshaft passes in front of the sensor the signal that is generated is transmitted to the electronic control unit EC 2 En
28. switch the transmitter to the engine cutoff position and adjust the air valve so that it is fully closed at that time Confirm that the servo is not subjected to an excessive load due to pulling 6 Confirmation of Throttle and Air Valve Operation When the stick is in the slow position The rotor mark should be located at the slow mark of the body When the stick is in the center position The rotor mark should be located at the center position of the body When the stick is in the full high position The air valve should be fully open Recheck these positions 7 Lmt Setting The movemnt of engine control has considerable significance with respect to the injection operation Since there may be errors in operation depending on the direction and movement always make sure to perform the Lmt setting when the engine is not running Switch on the transmitter then the receiver Move the throttle stick on the transmitter to the full slow position and push the Limit setting switch to set Low Limit At this time Buzzer sounds one note Pi and LED flashes green Then move the throttle stick to the full high position and push the Limit setting switch to set High Limit At this time Buzzer sounds two successive notes PiPi and LED flashes red If the setting is failed Buzzer sounds repeated twosuccessive notes PiPi PiPi and LED flashes red In this case start again with Low Limit setting Memory contents remain intact even if the power
29. th the throttle stick at the center position 2027210242 S gt W VE VRIB This adjustment function employs the incremental system Therefore it is normal if the injection trim dial 0 position changes during operation Repeat the above procedures if 0 setting is reguired LED color does not show engine adjustment condition Note This injection system was developed for use in model airplanes All adjustments are not performed automatically Always make sure to check the contents of adjustments prior to use ENGI NE STA RTI NG 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 17 x 12 2 blade propeller Full slow engine speed 1 700 1 800r p m Intermediate slow engine speed 6 100 6 300r p m Full high engine speed 7 500 7 800r p m 10 15 nitromethane 15 20 Silencer E 5010 Fuel Note The engine speed will not be the same depending on propeller variations engine mounting method linkage method between the throttle servo and air valve and differences in the fuel used If the engine speed is quite different from those shown above it may mean that the setting for the throttle servo and air valve linkage is incorrect or the fuel injection trim volume has changed considerably Check these items by returning to the procedure for readjustment
30. uel 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 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 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 Warning Immediately after a glowplug ignition engine has been run and is still warm conditions sometimes exist whereby it is just possible for the engine to abruptly restart if the propeller is casually flipped over compression WITHOUT the glowplug battery being reconnected Remember this if you wish to avoid the risk of a painfully rapped knuckle INTRODUCTION This engine is the MAX 160FX 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
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O.S.Engines 160FX FI Manual