DLE Engines DLEG0455 DLE-55RA Gas Rear Exhaust Owner's Manual

DLE-55RA
Operator’s Manual
Specifications
Displacement:
Performance:
Idle Speed:
Ignition Style:
Recommended Propellers:
Sparkplug Type:
Diameter × Stroke:
Compression Ratio:
Carburetor:
Weight:
™
1
© 2014 Hobbico®, Inc.
Fuel:
55.6 cc [3.4 cu. in.]
5.5 HP / 8,500 rpm
1,500 rpm
Electronic Ignition
22 u 8, 22 u 10, 23 u 8, 23 u 10
CM6
(Gap) 0.018 in.– 0.020 in. [0.45 mm – 0.51mm]
1.76 in. [45 mm] u1.37 in. [ 35 mm]
7.6:1
DLE with Manual Choke
Main Engine − 3.74 lb [1.33Kg]
Muffler − 5.04oz [143g]
Electronic Ignition − 5.39oz [153g]
Engine Mount Standoffs − 4.51oz [128g]
87− 93 Octane Gasoline with a 30:1
gas/2-stroke (2-cycle) oil mixture
DLEG0455 Mnl
Parts List
(1) DLE-55RA Gas Engine w/carb
(1) CM6 Spark Plug with spare ignition wire spring
(1) Muffler w/gasket
(2) 5x20mm SHCS (muffler mounting)
(1) Electronic Ignition Module w/ additional tachometer lead
(4) Engine Mounting Standoffs
(8) 5x20mm SHCS with 5mm washers (mounting engine to standoffs)
(4) 5x40mm SHCS with 5mm lock washers & flat washers (propeller mounting)
(1) Silicone Pick-up Wire Cover / Ignition Wire Cover
(1) Red Three Pin Connector Lead w/ Pig Tail (ignition switch)
(2) Three Pin Connector Securing Clips
(1) DLE Decal
(2) 25 x75mm White Exhaust Tubes with Clamps
Safety Tips and Warnings
2
● This engine is not a toy. Please place your safety and the
safety of others paramount while operating. DLE will not be
held responsible for any safety issues or accidents involving
this engine.
● Operate the engine in a properly ventilated area.
● Before starting the engine, please make sure all components
including the propeller and the engine mount are secure and tight. It
is strongly recommended that a screw sealant is used (Great Planes®
Threadlocker GPMR6060) during engine installation.
● During the break-in period, it is recommended that the engine be
installed on the aircraft or a test stand with an appropriate shock
absorber. Otherwise it is probable that vibration could rebound
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back to the engine and serious damages may occur during the
break-in period. Break-in should be considered about the first 3-5
gallons you run through the engine.
For your safety and the safety of others, please do not stand in
front of or in line with the propeller when the engine is running.
Keep onlookers away from the running engine, especially small
children.
Always use a balanced spinner and a balanced propeller. An
unbalanced spinner and propeller combination will cause high
levels of vibration and may cause the propeller shaft to break.
Always use a lightweight spinner on your engine. Lightweight
spinners are considered to be those with a cone wall of 1mm
or less. Heavy spinners could cause the propeller shaft to break.
Securely tighten the spinner and propeller on the engine to prevent
it from being thrown off the engine while running.
Never use a propeller that has hit the ground. Even though it may
look good from the outside, it may be cracked on the inside which
may cause it to disintegrate while in use. Do not use a nicked,
cracked or split propeller.
Keep foreign objects away from the propeller. Make sure that
nothing can be “sucked in” by the propeller.
Never start the engine on loose gravel or sand.
Do not attempt to stop the engine by throwing anything into the
path of the propeller.
Make sure the fuel line is well-secured to the engine and to the fuel
tank so that it won’t come off in flight.
Do not use silicone fuel line because it will be dissolved by the fuel.
Use gasoline approved vinyl or neoprene rubber fuel line. Always
secure the fuel line away from the cylinder head. The engine’s heat
can damage the fuel line.
Never touch the engine immediately after a run. The engine will
be hot.
Before transporting your model, remove all the fuel from the fuel
tank and fuel lines.
Always use high-quality oil intended for 2-stroke (2-cycle) engines.
It's a good idea to use a petroleum-based 2-cycle motor oil like
Lawn Boy All Season - Ashless oil for the break-in period.
Do not install your throttle servo inside the engine compartment.
Doing so could cause radio interference. Install all electronic radio
devices at least 305mm [12"] away from the engine.
The throttle and choke pushrods should be non-metallic.
In case the engine is not to be used for more than a month, drain
the fuel tank and remove any fuel from inside the carburetor. Do
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this by running the engine at idle until it quits by running out of fuel.
Keeping gasoline inside the carburetor over an extended period of
time will damage the diaphragm valve and clog passages inside
the carburetor. Because the carburetor is more complicated than
those used in glow engines, keep the fuel clean by using a fuel
filter. Use a filter intended to be used with gasoline engines. Metal
filters intended for glow engines are too coarse and will not screen
out finer particles.
Always filter your fuel by using an appropriate filter before putting
it into the airplane’s fuel tank.
Gasoline is extremely flammable. Keep it away from an open flame,
excessive heat or sources of sparks.
Do not smoke near the engine or the fuel tank.
This engine was designed for use in a model aircraft. Do not
attempt to use it for any other purpose.
Always install an ignition system on/off switch on the aircraft used.
Caution: Running the engine with a lean gas mixture will cause
the engine to overheat and burn the electrode of the spark plug.
Pay close attention to the High-Speed Needle adjustment. Running
the engine with the proper gas mixture will make the spark plugs
appear yellow at the ignition point.
For optimum performance please use fresh or recently purchased
87– 93 octane gasoline with a 30:1 gas /oil 2-stroke (2-cycle) mixture.
GAS/OIL Mixing Chart
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1 Gallon Gasoline (128 fl oz/3.78L) / 2-Cycle Oil
(4.26 fl oz /125.68ml) = 30:1 ratio
Excessive running of the engine at idle speed can result in a
seriously carbonized spark plug.
Keep the surface of the engine clean to ensure proper heat
dissipation.
To avoid permanent damage to the electronic ignition system,
NEVER rotate the propeller on your DLE engine with the
electronic ignition system switched on and the plug not installed
in the plug cap.
If you choose to use the optional TX activated gas engine kill switch
(DLEG9205) it is strongly recommended that you install the TX
activated kill switch between the with a manual on/off switch and
the ignition. The manual on/off switch provides an added safety
feature in the event the TX activated kill switch does not function
properly. This is especially important during the starting sequence
as it requires the manual on/off switch to be in the ON position
before ignition can occur.
Installation Instructions
Prepare the engine for installation
1. Check to see that all screws and bolts are tight. Check carefully
for any cracks, broken, or missing parts. Tighten or replace any
damaged or missing parts before proceeding.
2. Install the silicone wire cover over the pick up lead coming from
the motor (cut the excess silicone wire cover) and connect the lead
to the pick–up lead from the Electronic Ignition Module. Secure
the connection with the included three pin connector securing clip.
3. Connect the manual on/off switch lead to the red connector from
the electronic ignition system using the lead from the kill switch or
with the included three pin connector with pig tail. Use one of the
included three pin securing clips to secure the connection.
5
4. Connect the ignition module battery to the kill switch. Any
4.8-8.4V, 1000 mAh and above capacity battery will work well for
this. Use heat shrink tubing to secure this connection. Optional:
Install the TX activated gas engine kill switch (DLEG9205) between
the manual on/off switch and the ignition as shown above. This is
especially important during the starting sequence as it requires
the manual on/off switch to be in the ON position before ignition
can occur. The kill switch LED should be installed on the exterior of
the aircraft so that it’s visible from the front of the aircraft. This is to
ensure that the person starting the engine is aware that the ignition
is armed. If properly installed as shown above, an illuminated red
LED indicates that that the ignition is armed.
5. Install the ignition on/off switch on the aircraft so that it is easily
accessible through the cowling or the fuselage.
6. Install the ignition module
and battery securely in the
airplane forward area. It is
recommended that a thin
piece of foam rubber is
placed between the module
and the mounting surface
and that Velcro® strap is used
to hold the module in place.
7. Install the remaining silicone wire cover over the ignition wire.
8. Install the spark plug into the engine head (7– 8 lbs torque). Do
not overtighten.
6
Switch (Not included)
Charge Lead
Battery Lead
Ignition
Battery Lead
OPTO Gas Engine Kill Switch
LED
(DLEG9205, not included)
KILL
SWITCH
Rx
Ignition
Rx Batt
Lead
Ignition Control Switch Wire (To On/Off Switch)
Tachometer Lead/
RPM Signal Output
Ignition Wire
(To Spark Plug)
Pick-Up
Sensor Wire
(To Sensor
On Engine)
OPTIONAL
ELECTRONIC IGNITION
SYSTEM
Tachometer
(Not included) DLEG5525
Installing the DLE-55RA on Your Airplane
Note: The DLE-55RA must be installed on at least a 9.5mm [3/8"]
thick 5-ply plywood firewall. The firewall must be securely glued to
the airplane. Use triangle stock and pin the firewall with hardwood
dowels to reinforce the firewall glue joints. Never install the
DLE-55RA onto a firewall thinner than specified because it may fail
due to the power of the engine.
Note: The length of the engine from the back of the engine mount
stand offs to the propeller drive washer is 6.73" [171mm].
1. Use the supplied template (on the back cover of this manual) to
drill the engine mounting bolt holes.
7
2. Install the standoffs to the
firewall using (4) 5x20mm SHCS
with 5mm lock washers and 5mm
washers (not included) from
the back side and through the
firewall into the standoffs. Use
some threadlocking compound,
such as Great Planes® Pro™ Threadlocker (GPMR6060), on the
screws. Next install the DLE-55RA to the standoffs using the
included (4) 5x20mm SHCS with 5mm washers. Be sure to also
use threadlocker when mounting the engine to the standoffs.
3. Install the fuel tank in the airframe. Use only gasoline-safe fuel
lines and a gasoline safe fuel tank stopper. One line should go to
the carburetor and the other is to be used as a vent (a vent line is
simply an open ended fuel line from the fuel tank which exits the
engine compartment or the fuselage; most vent lines exit at the
bottom of the firewall).You can fill the tank by using the carburetor
line as fill line if you have access to it or install a third line to be
used as fill line. Installing a third line is the cleanest and easiest
way to add fuel. An alternative fueling set up is a 2-line system
with a T-fitting approved for gasoline use. Be sure to use a filler
plug with either a 2 line or 3 line set-up.
Supply Line
to T-Fitting
Fuel Tank
Carb
2-LINE
SET UP
Clunk Line
Make connection line
between T-Fitting and
Carburetor as short
as possible.
T-Fitting
Fuel fill line
Drain/Vent Pressure Relief Line
Route to top-front of fuel tank interior,
to prevent siphoning (2-Line Set-up)
Fuel Tank
3-LINE
SET UP
Filler Cap
or Plug
This line must be extended
to exit the bottom of the aircraft.
Drain/Vent Pressure Relief Line
Route to top-front of fuel tank
interior, to prevent siphoning.
Clunk Lines
Carb
Supply Line
to Carburetor
Fuel fill line
Plug
This line must be extended
to exit the bottom of the aircraft.
4. Install the manual on/off switch
on the aircraft so that it is easily
accessible from outside the plane.
5. Install the throttle servo at
least 305mm [12"] away from the
engine. Make sure that you get the
carburetor’s full range of rotation
with your servo travel. Be sure to
use a non-metallic linkage.
8
6. Install the choke servo
(optional) at least 305mm
[12"] away from the engine.
Be sure to use a non-metallic
linkage.
7. Install the ignition module
securely in the airplane forward area. It is recommended that a thin piece of foam
rubber is placed between
the module and the mounting surface and that Velcro™
strap is used to hold the
module in place.
8. Secure any unsecure connection with heat shrink tubing. (Not
included.)
9
9. Connect the ignition wire from ignition module to the spark plug.
10. Install the muffler onto the engine. Be sure to use threadlocker.
11. Cut all necessary clearance, carburetor adjustment, cooling, and
exhaust holes in the cowl.
12. Please ensure the sensor wire is supported as close to the sensor
pick-up as possible. Flight loads may cause stress and damage to
the wire where it enters the sensor body.
13. Make sure the cowl is secured to the airplane and that the
spinner to cowl clearance is at least 3.2mm [1/8"]. If starting the
engine the first time and during break-in it’s recommended that
you run the engine without the cowling.
Drill and Install the Propeller
The easiest way to drill the propeller to fit the hub is to use a drill
guide. (DLEQ0551) If you do not have a drill guide, you can use the
following method to drill your propellers.
1. Remove the cowling from the aircraft. Use the included propeller
washer to mark the centering hole in the propeller.
2. Once the location is established, use a drill press with a #5
(.2055” / 5.21mm) drill bit as a pilot hole. Once the pilot hole is
established, use a 13/32” (.406/10.31mm) drill bit to finish the hole.
In order to achieve a clean opening on both sides of the propeller,
drill only half way through the propeller with the finishing drill bit.
Then flip the propeller over and drill completely through the hole.
3. Next, set the engine
at the beginning of the
compression stroke. Note
the position of the ignition
magnet with engine inverted.
10
4. Place the propeller on
the crankshaft at the 1
o’clock position.
5. Mark the location of one
of the outer holes while
the propeller is in the
top of the compression
stroke position. Use a
Dead Center Hole Locator
(GPMR8130) to center
and start the hole.
6. Remove the propeller
from the engine and drill
the outer hole on the
drill press using a #35
drill bit as a pilot hole.
Next use a #5 (.2055” /5.21mm) drill bit to finish the hole. In order
to achieve a clean opening on both sides of the propeller, drill only
half way through the propeller with the finishing drill bit. Then flip
the propeller over and drill completely through the hole.
11
7. Use one of the 5x40mm SHCS with 5mm lock washers and 5mm
flat washers to align the propeller washer on the propeller and use
the Dead Center Hole Locator to mark position of the remaining holes.
8. Drill the remaining three holes in the propeller. In order to
achieve a clean opening on both sides of the propeller, drill only
half way through the propeller with the finishing drill bit. Then flip
the propeller over and drill completely through the hole.
9. Mount the propeller to the engine using the 5x40mm SHCS with
5mm lock washers and flat washers. Be sure to use threadlocker.
Starting Procedures
There are two recommended ways to start the DLE-55RA:
A. Manual Starting
Note: When hand starting the DLE-55RA, use a thick glove or heavy
duty starter stick to protect your hand.
1. The propeller should be installed on the drive washer so that it is
at the one o’clock position and at the beginning of the compression
stroke so that it is comfortable to flip it through compression.
2. Have someone help you hold the airplane while you start the
engine.
3. Close the choke on the carburetor and open the throttle slightly
from the idle position.
4. Switch on, or power your radio system and make sure you have
control of the throttle visually at the carburetor. Also make sure
that the reversing position of the servo is correct at the transmitter
and that the throttle is at the minimum position.
5. Switch the ignition to ON. If you installed the optionalTX activated
gas engine kill switch (DLEG9205) properly between the manual
on/off switch and the ignition make sure that the TX switch
assigned is in the on position. The LED should be illuminated
red to indicate that the ignition is armed.
6. Flip the propeller counter clockwise several times briskly.
7. After you hear some initial firing sounds, move the choke lever
to the OPEN position.
8. Set the throttle to a high idle. Set the propeller so that it’s at the
beginning of the compression stroke
9. Flip the propeller through compression rapidly. If this is done
properly, the engine will start after several brisk flips of the
propeller.
12
10. After starting, let the engine idle for 30 to 45 seconds. Open
and close the throttle slowly until the engine runs smoothly at
idle and at full throttle. Acceleration should also be smooth. If
acceleration is not smooth adjustments to the carburetor may
be necessary. (See Adjustment of the Engine on page 14.)
11. If your engine does not start, repeat steps 6 through 10.
B. Electric Starter Starting
1. A 24 volt electric starter is recommended to start the DLE-55RA.
Make sure you use a high quality, lightweight aluminum spinner.
2. Have someone help you hold the airplane while you start it.
3. Close the choke on the carburetor and open the throttle slightly
from the idle position.
4. Switch on, or power your radio system and make sure you have
control of the throttle visually at the carburetor. Also make sure
that the reversing position of the servo is correct at the transmitter
and that the throttle is at the minimum position.
5. Switch the ignition to ON. If you installed the TX activated gas
engine kill switch (DLEG9205) properly between the manual on/off
switch and the ignition make sure that the TX switch assigned is
in the on position. The LED should be illuminated red to indicate
that the ignition is armed.
6. Using the starter, turn over the engine till popping sound is
heard. Next, open the choke.
7. Use your electric starter to turn over the engine until it starts.
8. After starting, let the engine idle for one to two minutes. Open
and close the throttle slowly until the engine runs smoothly at
idle and at full throttle. Acceleration should also be smooth. If
acceleration is not smooth, adjustments to the carburetor may
be necessary. (See Adjustment of the Engine on pages 10–12.)
9. If your engine does not start, repeat steps 6 and 7.
13
Engine Troubleshooting
If your engine fails to start after the preceding starting procedures
please check the following.
Symptom
Engine
does not
fire
Engine
starts,
then rpm
increases
till engine
cuts out
14
Diagnosis
Fix
Ignition battery low
Charge or
replace battery
Battery wires faulty
Replace wires or
Re-connect/check
connections
Faulty spark plug
or not firing
Replace spark plug
or check for spark *
Engine flooded
Remove plug,
rotate prop to
remove fuel
Fuel not reaching
engine
Check for:
a) fuel in tank
b) fuel tubing
cut, blocked,
or kinked
c) carburetor
clogged
* This can be done by removing the spark plug from head of the
engine and contacting the plug on the outside of the crank case.
Have an assistant turn the engine over while checking this and be
sure to have the spark plug firmly plugged into the ignition wire.
Warning the high voltage from the ignition can cause bodily harm,
especially when checking for spark in this manner.
Adjustment of the Engine
Each DLE Engine has been factory preset. However, elevation
changes will influence the performance of the carburetor. To
obtain optimum output of the engine, slight adjustment of the
carburetor maybe necessary. Also, for safety reasons do not make
adjustments to the carburetor while the engine is running.
Engine Functions and Adjustments
1. Choke Control
(the choke should
be used when the
engine is cold)
2. Throttle Stop
3. Idle Adjustment
Screw (adjust the
idle speed)
4. (L) Low-Speed
Needle (adjusts the
fuel/air mixture at
low speeds)
5. (H) High-Speed
Needle (adjusts the
fuel/air mixture at
high speeds)
Idle Adjustment
Turning the Idle Adjustment Screw (No.3) clockwise will increase
the idle speed. Turning the Idle Screw counter-clockwise will
decrease the idle speed.
Low Speed Needle Adjustment
15
Turning the Low-Speed Needle (No.4) clockwise will lean the
fuel/air mixture at low speeds. Turning the Low-Speed Needle
(No.4) counter-clockwise will richen the fuel/air mixture at low
speeds. (The default or factory setting of the Low-Speed Needle
is as follows; turn the needle to the fully stop/closed position and
then open the needle 1.25 turns.)
High Speed Needle Adjustment
Turning the High-Speed Needle (No.5) clockwise will lean the
fuel/air mixture at high speeds. Turning the High-Speed Needle
(No.5) counter-clockwise will richen the fuel/air mixture at high
speeds. (The default or factory setting of the High-Speed Needle
is as follows; turn the needle to the fully stop/closed position and
then open the needle 1.5 turns). It is recommended that the HighSpeed Needle be adjusted by the use of a tachometer to obtain
maximum speed.
Smooth acceleration and deceleration is an indicator of proper
engine performance.
Ignition Timing Adjustment
The ignition timing is preset on the DLE-55RA at 44° beforeTop Dead
Center (TDC). The ignition timing can be advanced or retarded by
loosening the (2) ignition sensor phillips head screws and sliding
the sensor to the full extent clockwise (45° advancing the ignition)
or counter clockwise (43° retarding the ignition). Be sure to retighten
the Phillips head screws after adjusting the ignition timing.
Advancing the timing causes combustion to occur earlier resulting in
higher performance of the engine. However, advancing the timing
also causes higher engine temperatures and can cause premature
wear of internal engine components.
Carburetor Adjustment Troubleshooting
Problem
1. The engine hesitates when accelerated rapidly.
2. The rpm increases at idling.
3. The engine stops when the throttle is moved from high to low.
Solution
The low-speed needle “L” is too lean. Open it about 1/8 of a turn
and try again.
Problem
The idle is not steady.
Solution
The low-speed needle “L” valve is too rich. Close it 1/8 of a turn
and try again.
16
Problem
1. Engine stops at full throttle.
2. Engine hesitates when accelerated rapidly.
3. The engine will not come up to full rpm at full throttle.
Solution
The high-speed needle valve “H” is too lean. Open it 1/8 of a turn
and try again.
Problem
1. The engine does not reach full rpm.
2. Carbon build-ups appear consistently on your spark plug.
Solution
The high-speed needle valve “H” is too rich. Close it 1/8 turn and
try again.
17
Optional Mini Tachometer
An optional DigitalTachometer
(DLEG5525) is available that
can be directly connected to
the ignition and display the
RPMs of the engine.This unit
can be installed on the aircraft
or used to spot check the
Engine RPMs. Do not install
or uninstall the Digital Tachometer while the engine is running.
Many of the DLE Ignition modules have an addition lead to plug
into the optional tachometer. If your ignition module does not have
this additional lead, the digital tachometer can still be used. Simply
used the included Y-harness (included with the Digital Tachometer)
to connect to the pick-up lead from the engine. Be sure to secure
all connections and to secure the Digital Tachometer or leads on
the aircraft used.
Engine Maintenance
Please clean the fuel filter in the carburetor periodically. Failure to
do so may result in mis-calibration of the needle adjustments. In
order to do this it is necessary to remove the phillips head screw
which secures the carb filter cover and the carb filter gasket. Use
only carburetor cleaner to clean the opening around the filter.
18
19
Warranty Information
The DLE-55RA has a two year limited warranty through Hobby
Services beginning at date of purchase.
Contact Us
Hobby Services
3002 N. Apollo Drive Suite #1
Champaign, Il 61822
Ph: 217-398-0007
Fax: 217-398-7721
E-mail: [email protected]
Web address: www.hobbyservices.com
3.54 in. [90 mm]
2.60 in.
[66 mm]
2.76 in. [70 mm]
20
4.92 in.
[125 mm]
4.06 in. [103 mm]
21
2.68 in. [68 mm]
22
Replacement Parts
Key Stock
No. No.
1
2
3
4
5
6
7
8
9
10
12
16
24
30
11
13
14
15
17
18
19
20
21
22
23
25
26
27
28
29
31
32
33
34
Mfg
Stock
No.
Description
DLEG5701
DLEG5702
DLEG5703
DLEG5704
DLEG5705
DLEG5706
DLEG5707
DLEG5708
DLEG5709
55RA-N1
55RA-N2
55RA-N3
55RA-N4
55RA-N5
55RA-N6
55RA-N7
55RA-N8
55RA-N9
Propeller Drive Washer
Propeller Drive Nut
Propeller Drive Hub
Bearing Front
Crankcase
Crankshaft Spacer
Bearing Rear
Woodruff Key
Crankshaft
DLEG5710
55RA-N10
Gasket Set
DLEG5711
DLEG5713
DLEG5714
DLEG5715
DLEG5717
DLEG5718
DLEG5719
DLEG5720
DLEG5721
DLEG5722
DLEG5723
DLEG5725
DLEG5726
DLEG5727
DLEG5728
DLEG5729
DLEG5731
DLEG5732
DLEG5733
DLEG5734
55RA-N11
55RA-N13
55RA-N14
55RA-N15
55RA-N17
55RA-N18
55RA-N19
55RA-N20
55RA-N21
55RA-N22
55RA-N23
55RA-N25
55RA-N26
55RA-N27
55RA-N28
55RA-N29
55RA-N31
55RA-N32
55RA-N33
55RA-N34
Carburetor Heat Block
Reed Valve
Reed Valve Petal
Reed Valve Plate
Carburetor Complete
Engine Mount Standoff
Needle Bearing
Piston w/Pin
Piston Pin
Piston Pin Retainer
Piston Ring
Cylinder
Spark Plug
Spark Plug Cap
Electric Ignition
Ignition Sensor
Muffler
Exhaust Clamp
Exhaust Tube
Screw Set
Optional Parts (not shown)
DLEG5525
DLEG9205
DLEQ0551
23
Onboard Digital Tachometer
Gas Engine Kill Switch v2.0
Prop Drill Guide (55, 55RA, 60 Twin)
DLE-55RA Mounting Pattern
2.76 in. [ 70 mm]
2.60 in.
[66 mm]
3.54 in. [90 mm]