Gemini Industries FT-160 User's Manual
Contents
1. Saane FE T 16 0 Gemini 160 OWNER S INSTRUCTION MANUAL lt 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 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 lt is suggested that any instructions supplied with the aircraft radio control equipment etc are accessible for checking at the same time Horizontally opposed twin cylinder overhead valve four stroke cycle SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O S ENGINE 2 4 FLIGHT 20 222 nnnnc ence eee 22 INTRODUCTION TOOLS AND ACCESSORIES 5 CARE AND MAINTENANCE 22 ENGINE PARI NAME 7 7 6 7 VALVE CLEARANCE ADJUSTMENT 23 25 INSTALLATION 8 10 ENGINE EXPLODED VIEWS 26 PROPELLER FUEL TANK 10 11 ENGINE PARTS LISTS _ 27 GLOWPLUGS 12 CARBURETOR EXPLODED VIEWS amp PARTS LIST 28 GLOWPLUG HEATING 13 14 O S GENUINE PARTS amp ACCESSORIES 29 FUEL AND LUBRICATION STARTING 15 18 ENGINE THREE VIEW DRAWINGS 30 RUNNING IN2. starter Fig 21 Set at this position approximately 1 4 open from the fully closed position and re connect the glowplug battery Revolutions will increase when all cylinders are firing steadily e Make sure that the direction of rotation of the starter is correct e Connect the glowplug battery e Apply the electric starter Connect the battery to the glowplug Zz ee Z A E E erg Zz eS et l A slight spray of fuel may be emitted through the exhaust pipe if a cylinder is not firing 7 When the engine starts open the throttle valve fully and keep it running initially approx 10 seconds with original needle valve setting 9 Now disconnect the glowplug battery Open the throttle fully 17 10 Adjust the needle valve e Abrupt adjustment of the needle valve may cause the engine to stop especially when it is new and insufficiently run in e As the speed of the engine does not instantly change with needle valve readjustment small movements with pauses between are necessary to arrive at the optimum setting Practical best optimum needle valve setting Close the needle valve gradually and slowly Approx 40 Maximum rpm setting Lean Rich needle valbe setting when starting the engine Revolutions start to decrease Fig 24 Re starting the engine when warm To re start the engine when warm simply re energise the plugs and reapply the starter with the throttle in the idli
3. 30 TY PRECISION N ah X Re ais O NG THe Stapan0s 0 GS ENGINES mreco ro 6 15 3 Chome Imagawa Higashisumiyoshi ku Osaka 546 0003 Japan TEL 06 6702 0225 FAX 06 6704 2722 URL http www os engines co jp Copyright 2004 by O S Engines Mfg Co Ltd All rights reserved Printed in Japan p00 SOSAN P400
4. 9 26711305 Ratchet Spring 10 26781619 Throttle Stop Screw Assembly 10 1 26681305 Throttle Stop Screw 10 2 26681803 Throttle Stop Screw Holder 11 O S GENUINE PARTS amp ACCESSORIES E RADIAL MOTOR MOUNT E 5 16 M5 L PROPELLER 71910000 LOCKNUT SET FOR SPINNER 46110200 E O S GLOW PLUG TYPE F 71615009 QO F E BOOSTER TERMINAL KIT E BOOSTER CABLE SET 72200130 72200090 E VALVE ADJUSTING E SUPER FILTER L TOOL KIT 72200060 72403050 45581700 Carburetor Retaining Screw The specifications are subject to alteration for improvement without notice E BLIND NUT 10pcs E LOCK WASHER 10sets M5 M5 79870050 55500004 La a a E NEEDLE VALVE E NON BUBBLE WEIGHT EXTENSION CABLE SET 71531000 72200080 E CAP SCREW SET 10pcs E LONG SOCKET WRENCH 29 WITH PLUG GRIP M2 6x7 79871020 71521000 M3 5x10 79871070 M3 5x12 79871080 M3 5x15 79871090 M3 5x20 79871100 The specifications are subject to alteration for improvement without notice earn A THREE VIEW DRAWING WH Specifications 3 e U i 2 E Displacement 13 26cc x 2 1 218cu in x 2 ae Pz E Bore 27 7mm 1 091in ut Py E Stroke 22 0mm 0 866in Oh i E PracticalR P M 2 000 10 000r p m Hin Hn te i TH E Output E Weight 1 100g 38 80z ii Dimensions mm
5. Ss P e dl we Nig oO 39 r 3 C M2 6x7 Type of screw C Cap Screw M Oval Fillister Head Screw F Flat Head Screw N Round Head Screw S Set Screw 26 PARTS LIST No Code No Description 6 46160000 Valve Assembly pai 8 46104020 Cylinder Head W Valve Assembly _ _ 9 46168000 Intake Manifold Assembly _ _ 72200060 Valve Adjusting Kt Z o Z o 46166000 Push Rod 2pcs The specifications are subject to alteration for improvement without notice 2 No Code No Description 46103100 Cylinder Liner CARBURETOR EXPLODED VIEWS amp PARTS LIST Note The choke valve assembly is not included in the carburettor complete k Type of screw C Cap Screw M Oval Fillister Head Screw F Flat Head Screw N Round Head Screw S Set Screw 28 4 26381501 Set screw 46481310 Mixture Control Valve Assembly 1 1 46481330 Mixture Control Screw Holder Assembly 1 F 46481200 Carburetor Rotor 1 22781800 O Ring 2pcs 46481100 Carburetor Body 46281900 Needle Valve Assembly 1 29081952 Needle Assembly 1 2 3 4 5 6 46281340 Mixture Control Valve Pin 7 7 8 9 o 9 9 2 24981837 O Ring 2pcs 9 3 26381501 Set screw 9 4 46181940 Needle Valve Holder Assembly 9 46181941 Needle Valve Holder 5 9 6 46181950 Fuel Inlet
6. exceeds 0 1mm but is not more than 0 14mm i e the thickness of both feeler gauges inserted together it is not necessary to readjust the clearance if the engine runs satisfactorily I If a clearance is found to be outside either of these limits it should be reset as follows 1 Carefully loosen the locknut on rocker arm 1 4 1 2 turn with 5mm wrench Fig 30 Slacken approx 1 4 to 1 2 turn Locknut 24 2 Turn adjusting screw approx 1 2 turn counter clockwise to Open gap using appropriate tool i e Allen hex key Fig 31 Adjusting Screw Turn approx 1 2 turn Allen Key 3 Insert 0 04mm feeler gauge between valve stem and rocker arm and genily turn adjusting screw clockwise until it stops Fig 32 Turn with fingers until it stops 4 Re tighten locknut while holding adjusting screw stationary Fig 33 Hold at the screw head Tighten Locknut Fig 33 5 Remove 0 04mm feeler rotate prop through two revolutions and recheck gap 6 If clearance is correct loosen the locknut on the other rocker arm and repeat steps 1 to 5 above Finally replace rocker box cover Remember Excessive valve clearance will cause loss of power due to valve s not opening sufficiently On the other hand a total loss of clearance may cause difficult starting due to valves not closing properly resulting in loss of compression 25 EXPLODED VIEW SZ OM3x16 S j C M4 x AN AS M4x22 see
7. for a while more than two months remove the glowplugs and rinse out the interior with kerosene not gasoline by rotating the crankshaft Shake out residue then inject corrosion inhibiting oil preferably or light machine oil through glowplug cabities and breather hole again rotating the shaft to distribute the protective oil to all working parts CARE AND MAINTENANCE To ensure that you obtain long life and peak performance from your engine observe the following 1 Avoid running the engine under dusty conditions If necessary lay a sheet of plywood or hardboard in front and under the nose of the model when starting the engine 2 Foreign matter in the fuel can cause the carburetor jet to be partially clogged Therefore erinse out the fuel tank with methanol or fuel before installing it e fit a fuel filter in the uel delivery tube between tank and carburetor e fit a fuel filter to pump inlet of the manual or electric fuel pump e do not leave your fuel container open needlessly e check filters periodically and clean them when necessary 22 VALVE CLEARANCE ADJUSTMENT ALL O S four stroke engines have their valve tappet clearances correctly set before they leave the factory However if after many hours of running time have been logged a loss of power is detected or if the engine has to be disassembled or repaired as a result of an accident valve clearances should be checked and readjusted as 2 Remove all
8. it will be necessary to turn the Mixture Control Screw in the reverse direction from the mark i e clockwise to weaken the mixture About 1 12 turn 30 should be sufficient Fig 25 2 Alternatively if the engine stops or is slow to pick up speed without smoking or a strong exhaust note it is probable that the idling mixture is too lean Fig 26 In this case it will be necessary to turn the Mixture Control Screw Mixture Control Screw ah Fig 25 Realignment of mixture control screw In the course of making carburetor adjustments it is just possible that the Mixture Control Screw setting may be upset lts basic setting can be re established as follows With the basic position of Carefully turn the screw in the the screw this pin is located rection of the mark with Turn S in the direction of the mark i e counter clockwise approximately 1 12 turn 30 Fig 26 3 Thirdly if revolutions increase but the engine appears to at the centre the screw driver supplied until The pin is seen if the it stops then turn back again throttle lever is removed Xactly two revolutions j y run with reduced power it is probable that one of the Fig 27 Fig 28 cylinders has ceased firing You may detect this by the difference in exhaust note and revolutions compared with mark previous full throttle running The cutting out of the cylinder may be caused by the idling speed being set
9. needle valve and throttle lever locations are interchangeable by reversing the carburetor This can be done as follows Remove the carburetor carefully by unscrewing the two screws which secure both carburetor and choke valve After reversing the carburetor re insert it into the intake manifold taking care not to damage the O ring in the manifold Photo 4 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 a starting point refer to the props listed in the accompanying table 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 higher rpm or if a larger diameter lower pitch prop is used Choke valve 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 forget the WARNINGS and NOTES on propeller and spinner safety given on pages 2 3 and 4 Carburetor retaining screw Size DxP 16x8 18x6 8 20x6 Type Sport Scale NOTE Make a habit of always checking the tightness of the propeller before starting the engine Remember that especially with wooden propellers there is a tendenc
10. or about 13 15 minutes when some part throttle operation is included Fuel consumption also depends of course on the size of propeller used To be equal The ideal fuel tank location is with the top of the tank 5 10mm 1 4 3 8 above the needle valve However model design will usually require the tank to be located higher than this and there should be no trouble with such a tank location provided that you do not pursue spectacular aerobatic flight If the tank is located high fuel will flow into the carburetor when the tank is full Therefore pinch the fuel line with a clip when the engine is not running to prevent flooding and loss of fuel Ream to 12mm dia To be equal 11 GLOWPLUGS The FT 160 is supplied with an O S Type F glowplug specially designed forg s four stroke engines 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 When to replace 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 e Filament surface has roughened and turned white e Filament coil has become distorted e Foreign matter has adhered to filament or plug body has to keep the engine running Ignition timing is au
11. the engine carry out any needle valve readjustments from a safe position behind the rotating propeller Stop the engine before attempting to make other adjustments to the carburetor 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 fuel supply Never try to stop the engine physically e 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 e 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 e 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 e 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
12. the glowplugs except the one fitted to the cylinder that you want to check Note Each glowplug should be re fitted to the original cylinder You may start to check and adjust with any cylinder necessary with the aid of the O S Valve Adjusting Tool Kit 3 Turn the propeller counter clockwise until compression is first felt then turn it futher quarter turn At this point both valves should be closed If the prop driver drive hub of your engine is engraved with a letter T this mark should The kit comes in a plastic case and includes Hex key 1 5mm Feeler gauge 0 04mm Feeler gauge 0 1mm now be at the top Ai TA i pi 4 The standard valve clearance on both inlet and exhaust x valves is between 0 04mm and 0 1mm 0 0015 0 004 inch Wrench 5mm measured between valve stem and rocker arm Use the E 0 04mm and 0 1mm feeler gauges to check clearances F A See Fig 29 il a J 0 04mm Feeler Gauge Note Valve clearances of all O S four stroke cycle engines must be checked and reset ONLY WHEN THE ENGINE IS COLD Procedure is as follows Rocker Arm I 1 Remove the rocker cover from each cylinder head by unscrewing two socket head cap screws from the rocker box on top of the cylinder head with Allen key supplied 23 Note If the gap is found to be less than 0 04mn it is not necessary to readjust the clearance if the engine has good compression and starts easily Equally if the gap
13. too low or the idling mixture being too rich Throttle aN NOTE If an on board glowplug re heat system is fitted mixture adjustment at idling speed should be carried out with this in operation In the case of the idling speed being too low re set the idling position a little higher by means of the throttle trim on the transmitter In the case of the idling mixture being too rich turn the Mixture Control Screw in the reverse direction 21 3 Do not close the needle valve to too lean a setting This FLIGHT Checking before flight e Make sure that all two cylinders are firing e Make sure that engine runs steadily at idling speed e Make sure that engine is fully warmed up elt is necessary to warm up the engine as with a full size aircraft or automobile Do not attempt to take off immediately after the engine has been started Allow the engine to run at full throttle for at least 10 seconds before releasing the model will cause the engine to overheat and slow down and also will generate much nitromethane oxide due to extremely high temperature which will cause internal rusting of the engine Always adjust the needle valve very slightly to the rich side of the peak r p m setting 4 Clean the exterior of the engine with a clean cotton cloth If this is not done oil and dirt will burn onto the outside of the engine each time it is run and the engine will soon become blackened 5 If the engine is not in use
14. Breaking in 18 19 THROTTLE VALVE ADJUSTMENT 19 21 SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O S ENGINE WARNINGS in D y e Never touch or allow any object to come into Remember that your engine is not a toy but a highly contact with the rotating propeller and do not efficient internal combustion machine whose power is crouch over the engine when it is running capable of harming you or others if it is misused or abused As owner you alone are responsible for the safe A weakened or loose propeller may disintegrate or be thrown operation of your engine so act with discretion and care at off and since propeller tip speeds with powerful engines may all times exceed 600 feet 180 metres per second it will be understood if at zome future date your O S engine is acquired by that such a failure could result in serious injury see NOTES a section relating to propeller safety another person we would respectfully request that these anne y instructions are also passed on to its new owner e Model engine fuel is poisonous Do not allow it to come into contact with the eyes or mouth Always A store it in a clearly marked container and out of the reach of children W The advice which follows is grouped under two headings according to the degree of damage or danger which might arise through misuse or neglect e Model engine fuel is also highly flamm
15. able Keep it A N W AR N N G S away from an open flame excessive heat sources of sparks or anything else which might ignite it Do not smoke or allow anyone else to smoke near These cover events which might involve serious in to it extreme circumstances even fatal injury 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 e Model engines generate considerable heat Do _ not touch any part of your engine until it has These cover the many other possibilities generally less cooled Contact with the muffler silencer obvious sources of danger but which under certain cylinder head or exhaust header pipe in circumstances may also cause damage or injury particular may result in a serious burn e 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 If you remove the glowplug from the engine and check its condition by connecting the battery leads to it do not hold the plug with bare fingers Use an appropriate tool or a folded piece of cloth In
16. ankcase breather hole is located at the side of the engine and is fitted with a brass nipple See photo 3 on page 7 Fit a length of silicone tubing of approx 2 5 3mm I D to this nipple to conduct away the small amount of oil that escapes through the breather e Make a habit of draining out the excess oil in the crankcase at the end of each flying session Leaving contaminated oil in the crankcase for a long time will cause rust Also residual castoroil will tend to solidify and lock the engine Inject corrosion inhibiting oil into the crankcase to neutralize the effects of any remaining contaminants 15 e Do not start the engine with the throttle fully opened otherwise the model will tend to move forward suddently due to the strong thrust of the propeller Hold both wings of the model when starting the engine e Do not carry out carburetor adjustments except needle valve adjustment while engine is running e Use a high torque electric starter Starting procedure is as follows 1 Open the needle valve 3 to 3 5 turns from the fully closed position Fig 14 2 Make sure that glowplugs are not connected to the battery e If very strong compression is felt when trying to turn the Do not heat the glowplugs while priming Fig 15 propeller counter clockwise too much fuel has been drawn into the engine In this case do not use force but release the choke valve and turn the propeller clockwise slowly to a a eject excess f
17. at Under normal conditions the FT 160 will idle sufficiently slowly with the throttle closed to permit a safe landing approach However if conditions atmospheric fuel tank location etc are unfavourable there may be a tendency for one cylinder to cease firing if the engine is throttled down to a very low idling speed This can be prevented by installing a small on board Ni Cd battery which will automatically re heat the glowplugs when the engine is throttled down to idling speed Fig 12 A suitable switch should be installed so that it is actuated by the throttle servo only when the engine is throttled down Safe idling speeds of less than 1 800 rom may be obtained in this way and without undue drain on the battery STARTING Precautions For safety please observe the following instructions before starting the engine e Start the engine by turning the propeller counter clockwise i e normal running direction Reminder Model engine fuel is poisonous Do not allow it to A 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 A sparks or anything else which might ignite it Do not smoke or allow anyone else to smoke near to it Lubrication All parts of the FT 160 are automatically lubricated by the oil content of the fuel mixture e The cr
18. ium speed with reduced power Engine stops Yes Continue running at high speed Check mixture adjustment at idling for 5 seconds speed Make sure that all cylinders are firing Close the throttle e Adjustment should be carried out after stopping the engine e Do not move needle valve Run at idling speed for 5 seconds Lhe while adjusting other controls Does the engine stop Engine stops No Apply full throttle Does the engine regain full power immediately Yes Repeat the procedure while opening and closing the throttle until the best result is obtained Attention Do not leave the battery connected while adjusting the carburetor Adjusting the mixture control valve of the mark about 1 12 turn 30 Normal safe idling speeds are in the region of 2 000 r p m NOTE As this is two cylinder four stroke cycle engine firing strokes occur every half revolution 360 that is two firings take place every one complete revolution Therefore at first you may have an impression that the engine is idling at higher r p m than actual running r p m It is recommended to check the engine r p m with a tachometer Changing the make of glowplug or fuel may sometimes require re adjustment of carburetor throttle 1 If the engine hesitates puffing out a good deal of smoke before picking up to full speed it is probable that the idling mixture is too rich In this case
19. lt See notes below Lead acid 2 volt rechargeable cell A lead acid cell of 10 Ah preferably greater capacity is required However in this case it is necessary to reduce the applied voltage at the glowplugs to approximately 1 5 volt The recommended method is to insert a suitable resistor in each individual plug lead It is possible of course to use a rheostat attached to the 2 volt cell or to use extra long leads at least 2 metres to obtain the required voltage drop However the disadvantage of this method is that if one glowplug should fail or become disconnected voltage to the other three will be increased with the risk of burning out their elements Heavy duty dry batterie The two glowplug leads supplied with the engine should be brought together Fig 13 and connected to a conveniently located common external point on the fuselage This can either be a terminal with a separate terminal for the earth ground lead Fig 10 or a suitable socket or jack with connections for both glowplug and earth ground leads Fig 11 Note that the earth ground lead supplied is much heavier 2 0 mm multi strand copper core than the plug leads as this has to have the capacity to carry the current for all two plugs Similar wire should be used if a single lead is employed to extend the glowplug leads Fig 13 1 Fit terminals to the fuselage 2 Fit a jack to the fuselage e Heavy duty 1 5 volt dry battery Use at least four heavy d
20. n accordance with individual installation requirements The angle is easily adjusted by Unscrew the cap screw while holding the hexagon nut with 6mm wrench and re fit the lever to required location o f the rod is too long reduce it to required length loosening the nut that secures e A needlessly lengthy rod may vibrete The rod should be as the exhaust pipe to the cylinder short as possible or have its outer end supported head Use the 12mm wrench supplied Set screw Exhaust pipe Carburetor cleanliness t is recommended that the fuel is passed through a filter Cap screw when the tank is filled and that a good in line filter is installed between the fuel tank and carburetor Choke lever Hex nut Occasionally remove the needle valve holder from the Choke rubber pad carburetor and rinse out the locaions shown in Fig 6 and Fig 7 with methanol or fuel Be careful not to lose the Fuel inlet gasket when removing the needle valve holder from the The fuel inlet nipple on the carburetor can be adjusted to the carburetor most suitable position for connecting to the fuel delivery tube from the tank Slacken the needle valve holder with the 8mm Squeeze bottle wrench provided reset the inlet nipple at the required angle and re tighten Fuel inlet Dirt and fibrous matter mostly accumulate here Dirt and fibrous matter mostly accumulate here Needle valve holder Slacken with 8mm wrench Carburetor The
21. ng position If the engine does not start disconnect the battery from the glowplugs and re prime by closing the choke valve while rotating the propeller twice with the throttle open Initially the high temperature inside the combustion chambers may turn the liquid fuel into gas and emit it through the exhaust pipes Therefore repeat the priming procedure once or twice until the cylinders become cool enough for restarting 2 Running in in the air Start the engine Fly the model 18 Set the needle valve approx 40 open from optimum position approx 40 open from maximum r p m NOTE Avoid prolonged heavy load flight RUNNING IN Breaking in Obtain a 18x6 propeller for running in 1 Running in on the ground Start the engine 1 Set the needle valve at 500 1 000r p m lower than maximum r p m setting and run approx 10 seconds It is suggested to use a tachometer Open the needle valve at approx 1 000r p m lower than above setting and run approx 20 seconds Repeat above procedure while increasing the setting 1 r p m gradually for approx 10 minutes NOTE Keep the throttle fully open using only the needle valve to change r p m Prolonged running in on the ground is not suggested because the purpose is just initial running in to increace engine temperature gradually close to that of maximam r p m THROTTLE VALVE ADJUSTMENT Needle valve adjustment Adjust the needle valve following
22. risk of a painfully rapped knuckle 4 INTRODUCTION Description Quantity The O S FT 160 Gemini 160 is a horizontally Woodruff key opposed twin cylinder overhead valve four stroke Valve adjusting tool kit cycle engine of 26 5cc 1 62cu in displacement The horizontally opposed layout typical of modern light aircraft engine design provides very smooth running qualities and docile trouble free handling characteristics Hexagonal Allen Key 4mm Choke valve rod TOOLS AND ACCESSORIES The following tools and accessories are supplied with your engine Description Quantity Radial Motor Mount Set Radial Motor Mount Mount fixing screw M5X25 Lock washers 5 Blind nuts M5 Engine Fixing Screw M4X22 Set of leads for wiring glow plugs Leads for glow plug with clip Lead for earth ground Photo 1 ENGINE PARTS NAME Photo 2 Right No 2 Cylinder Crankcase 4 Left No 1 Cylinder Cylinder Head ih A Glow Plug 3 I Rocker Cover E I Aluminum tube Propeller Nut Lock Nut Propeller Washer Drive Hub Exhaust Pipe Carburetor x Aluminum tube is not supplied with the engine Choke Valve Photo 3 Intake Manifold Fuel Inlet Push Rod Cover OM Lat ee i T E iji oOo Rear Housing Intake Pipe Right Intake Pipe Left INSTALLATION It is essential that the firewall is strong and rigid e g at Needle valve e
23. stall 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 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 If a safety locknut assembly is provided with your engine always use it This will prevent the propeller from flying off in the event of a backfire even if it loosens Also check the tightness of all the screws and nuts before restarting the engine 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 e Use an electric starter for this engine The wearing of safety glasses is also strongly recommended e 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 After starting
24. the instructions given in STARTING section Photo 5 Mixture control screw With each successive flight close the needle valve slightly until at the end of 10 flight the needle valve is set for optimum position Finish running in The carburetor can now be adjusted for optimum throttle performance following the instructions given in the next section 19 Needle valve Fuel inlet Throttle stop screw Choke valve Mixture control valve adjustment After running is completed and the needle valve is set at optimum position approx 40 open from maximum r p m position check the idling running and adjust only when necessary Oc Start the engine open the throttle fully e Disconnect the glowplugs from the battery e Approx 40 open from maximum Adjust the neede valve r p m setting e Make sure that all 2 cylinders are firing Close the throttle gradually Find the idling position e The position where the lowest possible r p m with steady running is obtained Fix the idling position e Set the throttle opening by means of the throttle trim on Re set the idling position at a little higher r p m the transmitter so that the lowest practical speed without risk of the engine stopping is obtained Open the throttle fully e Make sure glowplug heat is switched The engine hesitates before picking Does the engine up to full speed or appears to run at regain full power med
25. tomatic under reduced load allowing higher rom the plug becomes hotter and appropriately fires the fuel air charge earlier conversely at reduced rom the plug becomes cooler and ignition is retarded corroded e Engine tends to cut out when idling e Starting qualities deteriorate 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 e Use fuel containing a moderate percentage of nitromethane unless more is essential for racing events e Do not run the engine too lean and do not leave the battery connected while adjusting the needle 12 e Ni Cd nickel cadmium 1 2 volt rechargeable battery Use a 10 Ah cell or 8 to 10 1 2 Ah cells as commonly used for electric powered R C cars wired in parallel and with short heavy leads to minimize voltage drop to the connection point on the fuselage GLOWPLUG HEATING Glowplug battery It is necessary to use a glowplug battery of fairly large capacity 10Ah or more as this is required to heat four glowolugs simultaneously A heavy duty 1 5 volt dry battery or preferably 1 2 volt Ni Cd battery may be used A 2 volt lead acid cell accumulator may also be used but only if porvision is made for reducing the voltage at the plugs since these are nominally rated at 1 5 vo
26. uel through exhaust pipes the glowplugs while priming Do not apply the starter with the choke closed 3 Open the throttle valve fully close the choke valve and turn e Warning Never close the choke valve when applying the the propeller counter clockwise through three revolutions starter Such an action will cause an excess quantity of fuel Fig 16 amp 17 to be drawn into the cylinder and result in hydraulic lock that may damage the engine Fig 18 Fig 16 e Excess fuel in the carburetor may drip into the engine compartment when the choke valve is reopened Therefore it is advisable to drill a drain hole in the bottom of the engine bay or cowling and to apply fuelproof paint to the surrounding surfaces to prevent fuel from penetrating the airframe structure Close the choke valve 4 Release the choke control and immediately turn the propeller counter clockwise several times so that fuel is drawn well into the cylinders Fig 19 Turn 3 revolutions 16 5 Set the throttle valve approximately 1 4 open from the fully closed position Fig 20 8 Make sure that all two cylinders are firing e The engine is running properly if white smoke is emitted through all four exhaust pipes A slight spray of fuel will be discharged through the exhaust pipe or any cylinder that is not firing Fully closed 6 Starting with an electric Fully open elf a cylinder ceases firing reduce the throttle setting to
27. uty cells wired in parallel Fig 9 and with short heavy leads to minimize voltage drop to the connection point on the fuselage The disadvantage of dry cells is that they cannot be recharged when their power diminishes and makes the engine difficult to start 13 Glowplug leads e The plug leads are fitted with special snap on connectors that ensure firm contact with O S plug They are a click fit and are not suitable for use with most other makes of glowplug e The earth ground lead is fitted with a plug terminal which should be connected to the engine by means of one of the mounting screws e Make sure that no part of the wiring touches the cylinder head or cooling fins e Keep wiring away from the fuel tank where it might cause a fire in the event of a short circuit Fig 12 Install Ni Cd battery in the fuselage and switch on or off by means of transmitter On board battery Switch should have sufficient capacity 1 2 volt Ni Cd battery with more than 6 Ah capacity 14 FUEL AND LUBRICATION Fuel The FT 160 should be operated on a methanol based fuel containing not less than 18 volumetric castor oil or a top quality synthetic lubricant or a mixture of both plus a small percentage 5 20 of nitromethane for improved flexibility and power If glowplug leads are extended together as a single cable use heavier wire e g 2 0 mm multi strand copper core as supplied for earth lead Glowplug re he
28. xtension least 15mm thick and firmly integrated with the structure of The needle valve with this engine is designed to incorporate the aircraft an extension so that when the engine is enclosed within the fuselage the needle valve may be adjusted from the installed with the carburetor below the crankcase so that ae An L shaped rod of 1 6 1 8mm_ dia and the exhaust pipes point downwards appfopriate length should be inserted into the needle s centre hole and secured by tightening the set screw in the needle valve knob with the small Allen key provided For longer extension it is recommended to use the extension cable with the engine together with the knob and support hook also For this purpose Needle Valve Extension Cable Set Code No 72200080 is available as an optional part e In the interests of scale appearance the engine should be Centre mark M5 Blind nut e Do not use an excessively long unsupported extension as this may vibrate and cause the needle valve setting to vary or even damage the needle valve thread Always provide a suitable support at the outer end Set screw Set screw Firewall 5 Lock washer r Ce At least 15mm 0 6 rigid hard wood Needle Fig 1 8 Choke valve Exhaust pipe adjustment Fig 5 The choke valve operating lever can be located rught or left e The direction of the exhaust 12mm wrench p by reversing the hexagon nut nd cap screw pipes may be altered in lt lt Tighte
29. y 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 licknut should be tightened firmly after retightening the propeller nut Intake manifold 10 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 Install this as follows Propeller n Locknut 5 Propeller washer Drive hub Back plate of spinner Drive h 1 Ream the propeller shaft hole to 12mm bore with an rive hub appropriate reamer checking that the hole is exactly centered The Safety Propeller Locknut can be used provided that the width is between 21 5mm and 26mm 2 Install the prop to the engine shaft followed by the retaining washer and prop nut and tighten firmly with a 17mm wrench not supplied Propeller nut 3 Add the special tapered and slotted locknut and secure with a 12mm wrench while holding the prop nut with the 14mm wrench not supplied FUEL TANK The suggested fuel tank size is 400cc or 14 oz This will give approximately 10 minutes running time at full power
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