DLE-111 - Atlanta Hobby

DLE-111 - Atlanta Hobby
DLE-111
Operator’s Manual
Specifications
Displacement:
Performance:
Idle speed:
Ignition Style:
Recommended Propellers:
Spark Plug Type:
Diameter x Stroke:
Compression Ratio:
Carburetor:
Weight:
™
1
© 2010 Hobbico®, Inc.
Fuel:
111cc [6.8cu. in.]
11.2HP/ 7,500RPM
1,400 RPM
Electronic Ignition
27 u 10, 26 u 12, 28 u 10
CM6
(Gap) 0.018 in.– 0.020in. [0.5mm]
1.77in. [45 mm] u1.38in. [35mm]
7.6:1
DLE with Manual Choke
Main Engine − 5.51lbs [2,500 g]
Mufflers (2) − 3.6oz [100 g]
Electronic Ignition − 5.1oz [160 g]
Standoffs − 1.16oz [40 g]
87− 93 Octane Gasoline with a 30:1
gas/2-stroke (2-cycle) oil mixture
DLEG0111 Mnl
Parts List
(1) DLE-111cc Gas Engine w/carburetor
(2) CM6 Spark Plugs
(2) Mufflers w/gasket
(4) 5x20mm SHCS (muffler mounting)
(1) Electronic Ignition Module with additional tachometer lead
(4) Engine Mounting Standoffs
(6) 5x40mm SHCS with 5mm flat and 5mm lock washers (propeller mounting)
(2) Silicone Ignition Wire/Pick-up Wire Cover
(1) Red Three Pin Connector with Pig Tail
(2) Three Pin Connector Securing Clips
(1) DLE Decal Set
Safety Tips and Warnings
● 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.
2
● 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
back to the engine and serious damages may occur during the
break-in period.
● For your safety and the safety of others, please do not stand
in front of the propeller or inline 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
them 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.
● Do not use silicone fuel line because it will be dissolved by the
fuel. Use gasoline approved 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, Generation II oil for the break-in
period. Break-in should be considered about the first 3-5 gallons
you run in the engine. A high quality synthetic 2-cycle oil is
recommended for optimum performance and a longer engine
life. Synthetic 2-cycle oils leave fewer combustion byproducts
than natural oils, which can foul the engine and exhaust ports,
resulting in reduced performance. Synthetic oils also better
reduce friction and provide more fluidity at low temperatures.
3
● Do not install your throttle servo or kill switch servo inside the
engine compartment. Doing so could cause radio interference.
Install all electronic radio devices at least 12" [305mm] away
from the engine.
● The throttle and choke pushrods should be non-metallic.
● If 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 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 engine 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 kill switch on the aircraft used.
● Caution: Running the engine with a lean fuel mixture will cause
the engine to overheat and burn the electrode of the spark plugs.
Pay close attention to the High-speed Needle adjustment. Running
the engine with the proper fuel 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 fuel/oil mixture.
Fuel/Oil Mixing Chart
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
carbonized spark plugs.
● Keep the surface of the engine clean to ensure proper heat
dissipation. Ensure proper cooling/ventilation around both
cylinders with adequate air exhaust.
4
● 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.
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 engine (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 connection securing clips.
5
3. Connect the kill switch lead to the red connector from the Electronic
Ignition Module using the lead from the kill switch or with the
included three pin connector with pigtail. Use one of the included
three pin securing clips to secure the connection.
Switch
Charge Lead
(Not included)
Battery Lead
Ignition Control
Switch Wire
(To On/Off Switch)
ELECTRONIC IGNITION
SYSTEM
Ignition Wires
(To Spark Plugs)
Pick-Up
Sensor Wire
(To Sensor On Engine)
Tachometer
Lead/
RPM
Signal
Out-Put
Optional
Tachometer
(Not included)
4. Connect the ignition module battery to the kill switch. Any 4.86.0V, 1000mAh and above capacity battery will work well for this.
Use heat shrink tubing to secure this connection.
5. Install the ignition kill 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® is used to
hold the module in place.
6
7. Secure all connections with heat shrink tubing. (not supplied)
8. Install the remaining
silicone wire covers over
the ignition wires.
9. Install the spark plugs
into the cylinders (7-8lbs
torque)
Installing the DLE-111 on Your Airplane
Note: The DLE-111 must be installed on a minimum 3/8" [9.5mm]
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-111 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 on the engine mount
to the face of the propeller washer is 7-13/32" [186 mm].
1. Use the supplied template (on the back cover of this manual) to
drill the engine mounting bolt holes.
2. Install (4) 6mm blind nuts (not
included) into the back side (nonengine side) of the firewall. Install
the engine to the firewall using
(4) 6x45mm SHCS with 6mm
lock washers and flat washers
(not included) with the included
standoffs. Use threadlocking
compound, such as Great Planes® Pro™ Threadlocker (GPMR6060),
on the screws where they thread into the blind nuts.
7
3 Install the fuel tank in the airframe. Use only gasoline approved
fuel tank and 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. It is a good idea to
add an extension to the vent line as shown, that goes up and to
the rear of the tank. This helps to avoid draining fuel from the tank
when the model is pointed down.
Fuel Tank
Clunk Line
Supply Line
to T-Fitting
Carb
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)
Filler Cap
or Plug
This line must be extended
to exit the bottom of the aircraft.
4. Install the throttle servo
at least 12" [305mm] 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. A
high torque metal gear
servo is recommended
to operate the throttle.
5. Connect the ignition wires from ignition module to the spark plugs.
6. Install the mufflers onto the engine. Be sure to use threadlocker,
and that the ignition wires do not contact the mufflers.
7. Cut all necessary clearance, cooling, carburetor adjustment, and
exhaust holes in the cowl.
8. Make sure the cowl is secured to the airplane and that the spinner
back plate to cowl clearance is at least 1/8" [3.2mm].
Drilling the Propeller
8
The easiest way to drill the propeller to fit the hub is to use a drill guide.
If you do not have a drill guide, you can use the following method to
drill your propellers. Most propellers within the recommended size
range have a 0.393" [10mm] center hole pre-drilled. If your propeller
has this predrilled hole, move on to step 3. If not, start with step 1.
1. Remove the cowling from the aircraft. Use the included propeller
washer to mark the centering hole on 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.
4. Place the propeller on the crankshaft at the one o’clock position.
9
5. Mark the location
of one of the outer
holes. Use a GPM Dead
Center Hole Locator
(GPMR8130) to center
and start the hole.
6. Remove the propeller
from the engine and
drill the outer hole
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.
7. Use one of the 5x50mm SHCS with 5mm lock washers and flat
washers to align the propeller washer on the propeller and use the
Dead Center Hole Locator to mark the position of the remaining
five holes.
8. Drill the remaining five holes in the propeller.
9. Securely mount the propeller to the engine using the
5x50mm SHCS with 5mm lock washers and flat washers. Be
sure to use threadlocker.
Adjustment of the Engine
10
Each DLE has been factory preset. However, higher elevations will
influence the performance of the carburetor. To obtain optimum
output of the engine, slight adjustment of the carburetor may
be necessary.
Functions and Adjustments
1. Choke Control (the choke control is used under the circumstance
of cold start-up)
2. Throttle Control
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
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 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 closed position and then open the needle 1.5
turns). It is recommended that the High-speed Needle be adjusted
by the use of a tachometer to obtain maximum speed.
Smooth acceleration and deceleration is an indicator of proper
engine performance.
11
Ignition Timing Adjustment
For most applications mount the sensor with the mounting screw
centered in the slot. The ignition timing is preset on the DLE-111 at 44°
before Top Dead Center (TDC). The ignition timing can be advanced
or retarded slightly 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:
If The engine hesitates when accelerated rapidly.
or The rpm increases at idling.
or The engine stops when the throttle is moved from high to low.
Solution:
The low-speed needle “L” is too lean. Open it up about 1/8 of a
turn and try again.
Problem:
If 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.
Problem:
If Engine stops at full throttle.
or Engine hesitates when accelerated rapidly.
or The engine will not come up to full rpm at full throttle.
Solution:
The high-speed needle valve “H” is too lean. Open it up 1/8 of
a turn and try again.
Problem:
If Your engine does not reach full rpm.
or Carbon build-ups appear consistently on your spark plug.
Solution:
The high-speed needle valve “H” is too rich. Close it up 1/8 turn
and try again.
12
Starting Procedures
When starting the engine for the first time and during break-in,
it’s recommended that you run the engine with out the cowling.
Also, for safety reasons do not make adjustments to the carburetor
during operation.
There are two recommended ways to start the DLE-111:
A. Manual Starting
Note: When hand starting the DLE-111, 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 the ignition to ON.
5. Flip the propeller counter clockwise several times briskly.
6. After you hear some initial firing sounds, move the choke lever
to the OPEN position.
7. Set the throttle to a high idle. Set the propeller so that it’s at the
beginning of the compression stroke
8. Flip the propeller through compression rapidly. If this is done
properly, the engine will start after several brisk flips of the propeller.
9. 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 11.)
10. If your engine does not start, repeat steps 1 through 10.
B. Electric Starter Starting
1. A 24 volt electric starter is recommended to start the DLE-111.
Make sure you use a good quality, lightweight aluminum spinner.
2. Have someone help you hold the airplane while you start it.
13
3. Close the choke on the carburetor and open the throttle slightly
from the idle position.
4. Switch the ignition to ON.
5. Turn over till popping sound are heard. Next, open the choke.
6. Use your electric starter to turn over the engine until it starts.
7. 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.)
8. If your engine does not start, repeat steps 1 though 7.
Engine Troubleshooting
Symptom
Engine
does not
fire
Engine
starts,
then rpm
increases
till engine
cuts out
14
Diagnosis
Fix
Ignition battery
voltage low
Charge or
replace battery
Battery wires faulty
or loose
Replace wires or
Re-connect/check
connections
Faulty spark plug
or not firing
Replace spark plug
or check for spark *
Engine flooded
Remove plug,
disconnect fuel
line, 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 the cylinder
of the engine, inserting the plug into the plug cap and contacting
the plug to the outside of the crankcase. 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.
Optional Digital Tachometer
An optional Digital Tachometer
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 additional 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
use the 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.
15
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 four phillips head
screws which secure the carb filter cover and the carburetor filter
gasket. Use only carburetor cleaner to spray around the opening
of the filter.
16
Warranty Information
The DLE-111 has a two year limited warranty through Hobby Services
beginning at date of purchase. Please retain your receipt as your
proof of purchase.
Contact Us
Hobby Services
3002 N. Apollo Drive Suite #1
Champaign, Il 61822
Tel: 217-398-8970
Fax: 217-398-7721
E-mail: www.enginesupport@Hobbico.com
4.84 in.
[123 mm]
3.15 in.
[80 mm]
2.76 in. [70 mm]
6.53 in. [166 mm]
0.78 in.
[20 mm]
10.04 in. [255 mm]
17
18
30
29
17
18
10
6
20
19
13
7R
1
3
23
8
28
16
27
11
26
15
26
21
25
12
24
5
22
4
23
2
24
5
25
14
7L
4
3
9
1
Stock Number/Key Numbers
Stock
No.
Key
No.
DLEG5501
DLEG1102
DLEG1103
DLEG5504
1
2
3
4
23
24
5
6
7L
7R
8
9
10
11
12
13
14
15
17
18
19
20
21
22
16
25
26
27
28
30
29
24
22
DLEG5505
DLEG1106
DLEG1107
DLEG1117
DLEG1108
DLEG1109
DLEG5510
DLEG1111
DLEG1112
DLEG1118
DLEG1116
DLEG1119
DLEG1114
DLEG1115
DLEG1113
DLEG5517
DLEG1120
Description
Cylinder
Crankshaft w/Connecting Rods
Crankcase front and rear w/Screws
Piston
Piston Pin w/ Piston Pin Retainers
Needle Bearing
Piston Ring
Electronic Ignition System
Left Front Muffler w/(2) 5X20MM SHCS and Gasket
Right Muffler w/(2) 5X20MM SHCS and Gasket
Carburetor Complete
Engine Mount
Spark Plug CM-6
Reed Valve Assembly
Inner Bearing
Front Bearing
Rear Bearing
Carburetor Heat Block
Propeller Washer
Crankshaft Extension
Propeller Hub
Drive Nut
Crankshaft Sleeve
Woodruff Key
Carburetor Base
(2) Cylinder Gaskets
(2) Carburetor Heat Block Gasket
Reed Valve Gasket
Carburetor Gasket, Muffler Gaskets
Screw Set
Ignition Sensor w/Phillips Head Mounting Screws
Needle Bearing
Woodruff Key
Optional Parts (not shown)
DLEG5525
19
Onboard Digital Tachometer
DLE 111 Mounting Pattern
3.15 in.
80 mm
2.75 in.
[70 mm]
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