CONTENTS - O.S. Engines

CONTENTS - O.S. Engines
It is of vital importance, before attempting to
operate your engine, to read the general
'SAFETY INSTRUCTIONS AND WARNINGS'
section on pages 2-5 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.
It is suggested that any instructions supplied
with the vehicle, radio control equipment, etc.,
are accessible for checking at the same time.
CONTENTS
SAFETY INSTRUCTIONS AND
WARNINGS ABOUT YOUR O.S. ENGINE
2-5
FINAL ADJUSTMENT
23-24
ENGINE CONSTRUCTION, NOTES WHEN
APPLYING AN ELECTRIC STARTER
6-7
CARBURETOR CLEANLINESS,
CARE AND MAINTENANCE
25-27
CHECKING THE ENGINE,
TROUBLE SHOOTING
27-31
EXPLODED ENGINES VIEWS &
PARTS LIST
32-37
CARBURETOR EXPLODED VIEW &
PARTS LIST
38-41
O.S. GENUINE PARTS & ACCESSORIES
42
INSTRUCTIONS,
TOOLS, ACCESSORIES, etc.
BASIC ENGINE PARTS,
CARBURETOR CONTROLS (11G), (11J)
8-10
11-12
INSTALLATION
NOTES CONCERNING THE RECOIL STARTER
13-14
SUPER AIR CLEANER 202, 203
15-17
GLOWPLUG,
PRESSURIZED FUEL SYSTEM
18-19
STARTING THE ENGINE &
RUNNING-IN ('Breaking-in)
20-23
THREE VIEW DRAWING,
MEMO
1
43-45
46
SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O.S. ENGINE
Remember that your engine is not a "toy", but a highly efficient internalcombustion machine whose power is capable of harming you, or others, if it is
misused.
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 applies basically to ALL MODEL ENGINES and is
grouped under two headings according to the degree of damage or danger
which might arise through misuse or neglect.
!
!
WARNINGS
NOTES
These cover the many other
possibilities, generally less obvious
sources of danger, but which, under
certain circumstances, may also
cause damage or injury.
These cover events which
might involve serious (in
extreme circumstances, even
fatal) injury.
2
!
WARNINGS
• Never 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 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 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.
• Model engine fuel is also
highly flammable. Keep it
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 to it.
3
NOTES
This engine is intended for model cars.
Do not attempt to use it for any other
purpose.
Take care that the glowplug clip or
battery leads do not come into contact
with rotating parts. Also check that the
linkage to the throttle arm is secure.
Mount the engine in your model
securely, following the manufacturer's
recommendations, using appropriate
screws and locknuts.
For their safety, keep all onlookers
(especially small children) well back (at
least 20 feet or 6 meters) when
preparing your model for running.
Install an effective silencer (muffler).
Frequent close exposure to a noisy
exhaust (especially in the case of the
more powerful highspeed engines) may
eventually impair your hearing and such
noise is also likely to cause annoyance
to others over a wide area.
Before starting the engine, always check
the tightness of all the screws and nuts
especially those of joint and movable
parts such as throttle arm. Missing
retightening the loose screws and nuts
often causes the parts breakage that is
capable of harming you.
The wearing of safety glasses is also
strongly recommended.
4
NOTES
To stop the engine, fully retard the
throttle stick and trim lever on the transmitter, or, in an emergency, cut off the
fuel supply by pinching the fuel delivery
line from the tank.
Pull the operating handle straight out
when starting the engine, so that the cord
does not rub against the vehicle body or
engine. This will help prevent the cord
from being damaged by abrasion or
engine heat.
Do not attempt to disassemble the recoil
starter of the 18CV-RX. If you do so, the
very strong spring inside will be suddenly
ejected. This can be very dangerous.
Warning! Immediately after a glowplugignition engine has been run and is still
warm, conditions sometimes exist
whereby it is just possible for the engine to
abruptly restart if it is rotated over
compression WITHOUT the glowplug
battery being reconnected.
Do not extend the starter cord more than
45cm (18"). Do not abruptly release the
operating handle. Allow the cord to
rewind smoothly while still holding the
handle.
5
Near TDC
ENGINE CONSTRUCTION
With this engine, the piston will
feel tight at the top of its stroke
Piston
(TDC) when the engine is cold.
Cylinder Liner
This is normal.
The cylinder bore has a slight
taper.
Crankshaft
The piston and cylinder are
Slight taper
designed to achieve a perfect
running clearance when they
reach operating temperature.
When the engine is cold.
When the engine is hot.
6
NOTES WHEN APPLYING
AN ELECTRIC STARTER
Do not over-prime. This could
cause a hydraulic lock and damage
the engine on application of the
electric starter.
If over-primed, remove glowplug,
close needle-valve and apply
starter to pump out surplus fuel.
Cover the head with a rag to
prevent pumped out fuel getting
into your eyes.
NOTE
As delivered, the engine has the
carburetor lightly fit into its intake.
Secure it changing its angle
according to the car chassis.
7
MAX-18CV-R
BLUE HEAD SERIES
INSTRUCTIONS
About the Head Gasket
These engines are equipped with two head
gaskets of 0.1mm thick and 0.2mm thick. It is
suggested to adjust the total thickness
according to atmospheric temperature,
humidity and glowplug used.
This manual handles the following three versions.
MAX-18CV-R (P) with 11G carburetor
MAX-18CV-R with 11J carburetor
MAX-18CV-RX with 11J carburetor
At early stage of running-in, when a glowplug
tends to burn out early or when high
nitromethane content fuel is used, try to run
the engine with both gaskets.
When low nitromethane content fuel is used,
try to run the engine removing the 0.1mm
gasket.
The MAX-18CV-R and MAX-18CV-RX are
high-perfomance engines for 1/10 class
stadium trucks, off-road vehicles and sport
cars.There are two verions, the one with
11G carburetor and the other with 11J
carburetor.
Standard accessories
Glow Plug No.8
Super Air Cleaner 203 Assembly
Super Air Cleaner 202 Assembly(for 18CV-R(P))
Engine Mount Spacer (for 18CV-RX)
Instruction manual
8
REMINDER!
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.
TOOLS, ACCESSORIES, etc.
The following items are necessary for operating the
engine.
Items necessary for starting
FUEL
Generally, it is suggested that the user selects a fuel
that is commercially available for model two-stroke
engines and contains 10-30% nitromethane. As a
starting point, we recommend a fuel containing 20%
nitromethane, changing to a fuel containing more
nitro if necessary. When the brand of fuel is
changed, or the nitro content increased, it is
advisable to repeat the running-in procedure
referred to in the RUNNING-IN paragraphs. Please
note that with high-nitro fuels,
although power may be increased
for competition purposes,
glowplug elements do not last as
long and engine life will be
shortened.
!
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.
FUEL FILTER
Shouls be installed in the fuel line
between fuel tank and carburetor to
prevent foreign matter from entering
the carburetor.
GLOWPLUG IGNITER
Commercialy available handy
glowplug heater in which the
glowplug battery and battery
leads are integrated.
9
TOOLS
STARTER BOX
HEX SCREWDRIVER
Necessary for engine installation.
1.5mm, 2mm, 2.5mm, 3mm
For starting the engine.
It is not necessary for
the recoil starter version-i.e. 18CV-RX.
7.2V BATTERIES FOR STARTER BOX
Batteries for starter box.
Select according to the
starter box used. Be sure to
full charge before using.
SCREWDRIVER
Necessary for carburetor adjustments.
No.1, No.2, etc
FUEL PUMP
LONG SOCKET WRENCH WITH PLUG GRIP
Recommended for easy removal and
replacement of the angled and recessed
glowplug, the O.S.Long Socket Wrench
incorporates a special grip.
For filling the fuel tank, a simple,
polyethylene "squeeze" bottle,
with a suitable spout, is required.
SILICONE FUEL LINE
Heatproof silicone tubing of
approx. 5mm o.d. and 2mm i.d.
is required for the connection
between the fuel tank and
engine.
10
BASIC ENGINE PARTS
Heatsink Head
Heatsink Head
Carburetor
Type 11J
Starter Handle
Carburetor
Type 11G
Cover Plate
Mounting Lugs
Crankcase
Crankshaft Ball Bearing
Crankshaft
MAX-18CV-R(P)
Recoil Starter
Assembly No.5
Mounting Lugs
Rear Adaptor
Crankcase
Drive Hub
Crankshaft
MAX-18CV-RX
11
CARBURETOR CONTROLS (11G)
CARBURETOR CONTROLS (11J)
Three adjustable controls are provided on this
carburetor.
Three adjustable controls are provided on this
carburetor.
The Needle-Valve:
The Needle-Valve:
For adjusting the mixture strength when the throttle
is fully open.
For adjusting the mixture strength when the throttle
is fully open.
The Mixture Control Valve:
The Mixture Control Screw:
For adjusting the mixture strength at partthrottle and idle speed, to obtain steady idling
and smooth acceleration to mid speeds.
For adjusting the mixture strength at partthrottle and idle speed, to obtain steady idling
and smooth acceleration to mid speeds.
The Throttle Stop Screw:
The Throttle Stop Screw:
For setting the minimum idle speed.
NOTE:
Readjustment may
be necessary, occasionally to allow for
changes in fuel formula, gear ratio or
clutch engagement
point.
For setting the minimum idle speed:
NOTE:
Mixture Control Valve
Needle Valve Readjustment
may
be necessary, occasionally to allow for
changes in fuel, gear
ratio or clutch engagement point.
Throttle
Stop Screw
Needle Valve
Throttle Stop Screw
Mixture Control Screw
12
INSTALLATION OF THE CARBURETOR
ENGINE INSTALLATION
As delivered, the engine has its carburetor
lightly installed into the intake boss. Secure it
as follows.
Make sure that the vehicle's engine mounting
surfaces are level and in the same plane. Poor
installation may cause distortion of the
crankcase, bearings, etc., resulting in erratic
running and loss of performance.
The recommended screws for securing the
engine are 3mm or 4-40 steel Allen hexagon
socket type.
If existing holes in the engine mount do not align
perfectly with engine mounting lugs, enlarge
them slightly with a needle-file so that screws
enter vertically.
1. Loosen the retainer screw, rotate the
carburetor to its correct position and make
sure that it is pressed well down into the
intake boss, compressing the rubber gasket,
before retightening screw.
2. Rotate the retainer screw gently until it
stops, then tighten a further 60-90˚.
Do not overtighten the screw as this will
damage the carburetor body.
Rotate the retainer nut
gently until it stops.
Tighten a further 60-90˚
Chassis
Chamfer inside edges of bearers.
13
Avoid forcing the screws. Secure with locknuts.
If the bottom of the recoil starter housing would
otherwise touch the car chassis, install the
engine mount spacers (supplied) between the
engine's mounting lugs and the engine mount.
Use the M3x15 screws provided. With some
vehicles, it may be necessary to make minor
trimming modifications to chassis or body
when installing the engine.
NOTES CONCERNING THE RECOIL STARTER
REMINDER!
Do not attempt to disassemble the recoil starter.
If you do so, the very strong spring inside will be
suddenly ejected. This can be very dangerous.
Do not extend the starter cord more than 45cm
(18"). Do not abruptly release the operating
handle. Allow the cord to rewind smoothly while
still holding the handle.
NOTE:
When spacers are supplied joined in pairs
(see sketch) separate them as shown.
Either face may be placed downwards.
Pull the operating handle straight out when
starting the engine, so that the cord does not
rub against the vehicle body or engine.
This will help prevent the cord from being
damaged by abrasion or engine heat.
Mount Spacer
Separate
Engine Mount
( 18CV-RX ONLY)
Try to avoid spilling fuel over the starter unit and
its cord. Some fuels have a detrimental effect on
these parts.
The starter prevents the engine from being rotated in the wrong direction.The unit will be
damaged if you attempt to force the flywheel in
the opposite direction (i.e. clockwise when
viewed from the crankshaft end).
Engine Mount Spacer
14
AIR CLEANER TYPE 202
INSTALLING THE FILTER ELEMENT
It has a single filter element and is intended
primarily for circuit racing.
The lower height of the Super Air-Cleaner 202 also
facilitates easier installation in cars where available
space may be restricted.
The element is already
impregnated with a special filter
oil. As this oil is very sticky, take
care, when handling it, to
prevent dust or dirt from
adhering to the element. If your
fingers become contaminated,
wash them with soap and
water.
INSTALLATION OF AIR CLEANER
Carefully clean the carburetor, removing any old
adhesive or sealant that may have been previously
used on the outside of the air intake.
Insert beneath flange
During storage, the oil may have become unevenly
dispersed through the element. This will be indicated
if the blue colour of the element material appears
patchy. In this case, place the element in a small
plastic bag and gently rub it between finger and thumb
to redistribute the oil.
Press the air cleaner body firmly over the carburetor
air intake. Make sure that the outer rim of the air
intake engages the internal annular groove in the air
cleaner: failure to do so may result in the air cleaner
falling off.
Position the air cleaner
correctly, so that it does
not interfere with the
cylinder-head or obstruct
the needle-valve.
REPLACEMENT OF ELEMENT
It is advisable to replace the filter element with a new
one after not more than one hour of running time.
Always remove contaminated elements carefully, to
ensure that dirt cannot enter the carburetor.
15
AIR CLEANER TYPE 203
ASSEMBLY
This is a heavy-duty wet type air cleaner that has
been developed specifically for 3.5cc 'off-road'
model car engines. It is more compact than the
former O.S. SUPER AIR CLEANER 202 and this
makes it easier to install within a car body.
Insert the filter element on the element base.
Install the end plate with retaining screw, making
sure that the element fits correctly between the end
plate and base.
Insert the joint pipe on the element base and
secure it with "O" ring.
203 Intake Elbow
Element Base
Filter Element
End Plate
Install the end plate, retaining screw, making sure
that the element fits correctly between the end plate
and base.
"O" Ring
Retaining Screw
NOTE:
The element is already impregnated with a special
filter oil. As this oil is very sticky, take care, when
handling it, to prevent dust or dirt from adhering to
the element. If your fingers become contaminated,
wash them with soap and water.
Element misaligned
16
REPLACMENT OF ELEMENT
FURTHER PRECAUTIONS
NOTE:
During storage, the oil may have become unevenly
dispersed through the element. This will be
indicated if the blue color of the element material
appears patchy. In this case, place the element in a
small plastic bag and gently rub the element
between finger and thumb to redistribute oil.
When removing the air cleaner, check the inside of the
element base and carburetor venturi. If any dirt is
detected, this indicates that the filter element was
incorrectly installed or should have been replaced
earlier. In this event, it is vitally important to wash out
the inside of the engine thoroughly, with alcohol or fuel,
before it is used again, otherwise rapid wear of the
piston/cylinder assenbly, bearings, connecting-rod,
etc., will occur. Obviously, it will be necessary to carry
out the same procedure with the air cleaner and to
replace the filter element.
It is advisable to replace the filter element after each
hour of running time. Be careful not to allow dirt and
dust to enter the carburetor.
INSTALLATION
NOTE:
Be careful not to splash alcohol or fuel over the
filter element, or the filter oil will be washed away,
and the filter capacity will be lowered.
Carefully clean the carburetor, removing any old
adhesive or sealant that may have been previously
used on the outside of the air intake.
"O" Ring
17
GLOWPLUG
Glowplug life
Since the glowplug and fuel combination used may
have a marked effect on performance and reliability, it
would be worthwhile to experiment with different plug
types. An O.S. No.8 glowplug is supplied with the
engine. Other Recommended O.S. plugs are A5 and
R5. Carefully install plug finger-tight, before final tightening with the correct size plug wrench.
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.:
Install a plug suitable for the engine.
Use fuel containing a moderate percentage of
nitromethane unless more is essential for racing
events.
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 rpm, the plug becomes
hotter and, appropriately, fires the fuel/air charge
earlier; conversely, at reduced rpm, the plug become
cooler and ignition is retarded.
Do not run the engine too lean and do not leave the
battery connected while adjusting the needle.
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:
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.
18
PRESSURIZED FUEL SYSTEM
The somewhat violent changes of vehicle attitude
that occur in off-road running, combined with the
fact that, in buggy type cars, the fuel tank is often
located some distance from the carburetor, means
that fuel 'head' at the carburettor can vary and upset
running.Therefore,it is recommended that a muffler
pressurized fuel feed system be used.
!
Never run your vehicle without installing the air
cleaner. Dust and dirt that may otherwise be drawn
into the engine will rapidly shorten its life.
Connect suitable length of
Silicone tubing between fuel
tank and silencer.
Fuel Tank
Silicone tubing
Silencer
19
Before starting the engine, always check
the tightness of all the screws and nuts
especially those of joint and movable parts
such as throttle arm. Missing retightening
the loose screws and nuts often causes
the parts breakage that is capable of
harming you.
STARTING THE ENGINE & RUNNING-IN ('Breaking-in)
The following procedure is suitable for these engines when the O.S. T-1040 tuned silencer and a
fuel containing up to 30% nitromethane are used.
Turn the needle-valve clockwise slowly until it
stops. This is the fully closed position.
Do not force to turn further.
Needle Valve
Open the Needle-Valve 2
turns from the fully closed Close
position.
Fill the tank completely with fuel.
Temporarily remove the glowplug to check that it
glows bright red when energized.
Open
Element glows when energized.
In case of the 11G carburetor
Pliers
approx 0.3-0.5mm
Set the throttle-stop screw
so that the minimum
throttle opening (idle
setting) is approximately
0.3-0.5mm.
Replace the plug when the
element does not glow or is
burnt out.
In case of the 11J carburetor
approx 1mm
Set the throttle-stop screw
so that the minimum
throttle opening (idle
setting) is approximately
1.0mm.
Glow Plug Igniter
Throttle Stop Screw
20
Swith on the transmitter and make sure that each
linkage moves correctly.
Pull the starter handle
briskly straight out several
times to start the engine.
Turn the engine with starter box to draw fuel into
the engine.
Starter Handle
Deliver fuel into the carburetor.
When the engine starts, first allow it to operate in
short runs at the very rich starting settings, with
the glowplug battery still connected and the driving
wheels clear of the ground. The rich mixture will,
under these conditions, provide adequate
lubrication and cooling, indicated by profuse
smoke from the exhaust.
Fuel
Fuel tank side
Now connect glowplug battery lead to heat the
plug filament and start the engine.
Start the engine using a starter box, making sure
the engine rotation direction is correct (counterclockwise seen from the crankshaft end). Be sure
to install an air cleaner when starting.
In case of the 18CV-RX
Push the choke button on the fuel tank several
times to deliver the fuel to the carburetor. (Do not
over-prime or the recoil starter cannot be pulled.)
21
Remember!
It is vitally important to set the
throttle at the correct position
before attempting to start the
engine. If the engine is allowed to
run with the throttle too far open
under "no load" conditions, it will
rapidly overheat and may be
seriously damaged.
The position of the needle-valve
when starting the engine.
Needle
Close the needle-valve approx.
30˚ after running the vehicle for
one full tank of fuel.
Repeat this procedure several
times.
Next, disconnect the glowplug battery and try
running the car on the track. If the engine stalls,
open the throttle fractionally, but try to keep the
engine running as rich as possible: if it stops
because of being excessively over-rich, close the
Needle-Valve 30˚ and try again.
To stop the engine, close the throttle to idling
speed, then shut it off completely with the trim
lever on the transmitter. To cut off the fuel supply,
pinch the fuel delivery line to the carburetor.
Remember!
If the engine should need to be disassembled
(e.g. for cleaning or minor parts replacement) it
is advisable to return the Needle-Valve to the
original rich, starting setting and check whether
further running-in time is required before the car
is raced again. In the event of any major working
parts(e,g, piston/cylinder liner assembly) being
replaced, the complete running-in should be
repeated.
Run the car on the track until one tank of fuel has been
consumed, then close the Needle-Valve 30˚ and run
the car for another full tank of fuel.
Repeat this procedure until 5 more tanks of fuel have
been consumed, during which time the throttle may
be opened for brief bursts of increased power.
If the engine stops at medium speeds, close the
Mixture Screw 45-90˚.
22
To stop the engine, close the throttle to idle speed,
then shut it off completely with the trim lever on the
transmitter. To cut off the fuel supply, pinch the fuel
delivery tube to the carburetor.
FINAL ADJUSTMENT
Run the vehicle (with throttle fully open) over the
longest available straight course, in order to
observe the model's speed. Next return the car to
the starting point, close the Needle-Valve 30˚ and
repeat the run, taking note of the improvement in
performance. Continue with further runs, gradually
reducing the Needle-Valve setting and aiming to
achieve the highest straight-line speed.
Remember, however, that, if the Needle-Valve is
shut down too far, the engine will overheat and,
accompanied by visibly diminished exhaust smoke,
the model will lose speed. At this point, throttle
down immediately, stop the vehicle and reopen the
Needle-Valve 30˚.
Warning!
Do not touch rotating parts,
engine and silencer when
stopping the engine as they
become very hot, and contact with them may result in
a serious burn.
Fuel
Having established the optimum Needle-Valve
setting, check the Mixture Control Valve setting as
follows.
With the engine running, close the throttle and
allow it to idle for about five seconds, then reopen
the throttle fully. If, at this point, the engine puffs
out an excessive amount of smoke and the vehicle
does not accelerate smoothly and rapidly, it is
probable that the idle mixture is too rich.
23
With the optimum mixture control position, light
smoke is visible during high speed running,and the
engine rpm increases smoothly during acceleration.
Remember that, if the engine is operated with the
fuel/air mixture slightly too lean, it will overheat and
run unevenly. As with all engines, it is advisable to
set both needle-valve and mixture control screw
very slightly on the rich side of the best rpm setting,
as a safety measure.
In this case, turn the Mixture Control Valve
clockwise 45-90˚. If, on the other hand, the engine
tends to speed up momentarily and then cut out
abruptly when the throttle is opened,the idle
mixture is too lean. Correct this by turning the
Mixture Control Valve counter-clockwise 45-90˚.
NOTE:
Mixture Control Valve adjustment should be made
in steps of not more than 45-90˚, carefully
checking the effect,on throttle response, of each
small adjustment.
If the engine runs too fast with the throttle closed,
the throttle stop screw should be turned counterclockwise to allow the throttle opening to be
reduced.
Carry out adjustments patiently, under actual
running conditions, until the engine responds
quickly and positively to the throttle control.
Finally, beyond the nominal break-in period, a
slight readjustment toward a leaner needle setting
may be required to maintain performance.
Warning!
Mixture adjustments (whether via the Mixture
Control Valve, or the Needle-Valve) cannot be
made accurately under 'no-load' conditions,
which, in any case, are not advised, since such
operation carries the risk of seriously damaging
the engine through over-revving and overheating.
24
CARBURETOR CLEANLINESS
The correct functioning of the carburetor depends on its small fuel orifices remaining clear.
BALL LINK AND SLIDE VALVE EXTENSION
In case of the 11G carburetor
(In case of the 11G carburetor)
It is seldom necessary to separate the slide-valve
extension from the slide-valve itself. For cleaning,
withdraw this complete sub-assembly from the
carburetor body after removing the slide-valve guide
screw. Then wash with methanol or glow-fuel.
(Note: take care not to lose the guide screw;it is a
special one.) When it is necessary to adjust the balllink position, loosen the ball-link retaining screw
with a 3mm hexagon key, re-align the ball-link and
re-tughten the screw firmly.
First rotate the Mixture Control
Valve until its slotted head is
flush with the carburetor body.
Then screw the valve in exactly
1.5 turns (0.8mm).
This is the standard position.
Mixture Control Valve
Carburetor Body
In case of the 11J carburetor
REALIGNMENT OF MIXTURE CONTROL VALVE
Throttle Lever
In the course of making carburetor adjustments, it is
just possible that the Mixture Control Valve may be
inadvertently screwed in or out too far and thereby
moved beyond its effective adjustment range. Its
basic position can be found by first rotating the
Mixture Control Valve until its slotted head is flush
with the carburetor body. The valve is then screwed
in exactly 1.5 turns to re-establish its neutral
position.
First rotate the Mixture Control
Screw until its slotted head is
flush with the carburetor body.
Then screw the valve in
exactly 0.5 turn.
This is the standard position.
Mixture Control Screw
Carburetor Body
25
CARE AND MAINTENANCE
4. Then, inject some after-run oil into the engine, and
rotate the engine with an electric starter for 4 to 5
seconds to distribute the oil to all the working
parts.
1. The minute particles of foreign matter, that are
present in any fuel may, by accumulating and
partially obstructing fuel flow, cause engine
performance to become erratic and unreliable.
O.S. 'Super-Filters' (large and small) are available,
as optional extras, to deal with this problem.
One of these filters, installed on the outlet tube
inside your refueling container, will prevent the entry
of foreign material into the fuel tank. It is also
recommended that a good in-line filter be installed
between the tank and carburetor.
Note:
Do not inject after-run oil into the carburetor as
this may cause the O-rings inside the carburetor
to deteriorate. These procedures will reduce the
risks of starting difficulties or corrosion after a
period of storage.
5. Finally, when cleaning the exterior of the engine,
use methanol or kerosene. Do not use gasoline or
any solvent that might damage the silicone fuel
tubing.
2. Do not forget to clean the filters regularly to remove
dirt and lint that accumulate on the filter screens.
Also, clean the carburetor itself occasionally.
3. At the end of each operating session, drain out any
fuel that may remain in the fuel tank.
Afterwards,energize the glow-plug and try to restart
the engine, to burn off any fuel that may remain
inside the engine. Repeat this procedure until the
engine fails to fire. Do this while the engine is still
warm.
Caution:
The rear crankshaft bearing of this engine uses a
special plastic retainer. If the front housing needs
to be heated to remove or replace the bearing, do
not allow the bearing to exceed 120˚C (248˚F),
otherwise it may be damaged and rendered
unserviceable.
26
Installing Dust Caps
CHECKING THE ENGINE
When storing the engine, install the cap on the
exhaust port, carburetor, etc. to prevent dust from
entering the engine.
Dirt and dust may lodge in
If the engine will not develop normal performance
after a long period of running it may be due to the
wearing of parts. It is suggested that the worn parts
be replaced when the following symptoms are detected.
marked places.
Engine sound changes and easily overheats.
Power has dropped considerably.
Idle is unstable and/or engine tends to stop at idle.
In most cases, ball bearings, cylinder & piston assembly,
connecting rod and/or crankcase have become worn
out or abnormal. Check the parts carefully and replace
them if necessary.
27
Symptom
TROUBLE SHOOTING
Engine fails to fire.
Corrective action
Cause
Fuel tank is empty.
Fuel not reaching the engine.
Fill the tank with fuel and repeat
Priming procedure.
Glowplug element is burnt out.
Glowplug battery discharged
Replace glowplug.
Recharge or replace the battery.
Clogged fuel filter
Air cleaner and silencer inside is dirty.
Clean or replace fuel filter.
Replace cleaner element and clean inside silencer.
Over priming
Remove glowplug and pump excess fuel.
Fuel tubing is disconnected.
Fuel tubing is kinked, split or has a hole.
Connect fuel tubing securely.
Check the tubing carefully and replace if necessary.
Incorrect servo linkage
Connect correctly after setting servo at neutral.
Mare sure it rotates counter clockwise seen
from crankshaft side.
Inject cleaner spray into starter cord crevis
on the body.
Reverse rotating direction of starter box.
Recoil starter slips.
28
Symptom
Engine fires intermittently but does not run.
Corrective action
Cause
Insufficient fuel in the tank.
Fill the tank with fuel.
Deteriorated glowplug
Replace glowplug.
Clogged fuel filter
Air cleaner and silencer inside is dirty.
Clean or replace fuel filter.
Replace cleaner element and clean inside silencer.
Engine overheated
Wait until engine cools.
Incorrect clutch release
Adjust the tension of clutch spring.
Glowplug battery disconnected too soon.
Do not disconnect plug battery and wait until
r.p.m. become stable.
Air bubbles in fuel
Install O rings to the tank screws to
prevent bubbles.
29
Symptom
Unstable idle
Corrective action
Cause
Unsuitable glowplug
Use suggested glowplug in the instructions.
Unsuitable fuel
Do not use extremely high nitro or
low oil content fuel.
Extremely light flywheel
Add suitable load.
Silencer is disconnected or has play
Install silencer securely.
Symptom
Not reaching expected peak r.p.m.
Corrective action
Cause
Insufficient warming up or running-in.
Set the needle only after warming up.
Complete running-in.
Silencer or manifold is not securely connected
or disconnected.
Replace seal ring.
Check the connections and secure them.
Fuel tubing from tank is split or broken.
Replace the tubing.
30
Symptom
Poor response
Corrective action
Cause
Deteriorated glowplug
Replace glowplug.
Incorrect carburetor settings
Readjust low r.p.m. range with metering
needle and mixture control valve.
Incorrect setting of transmitter Exponential function. Check the transmitter setting.
Symptom
Poor r.p.m. drop
Corrective action
Cause
Throttle position open too far.
Close metering needle to adequate position
to lower idle r.p.m.
Incorrect carburetor installation
Install carburetor properly.
31
33
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Description
Heatsink Head
Gasket Set
Cylinder & Piston Assembly
Piston Pin
Piston Pin Retainer (2pcs.)
Connecting Rod
Carburetor Complete (Type 11G)
Carburetor Retainer Assembly
Crankshaft Ball Bearing (Front)
Crankcase
Crankshaft Ball Bearing (Rear)
Crankshaft
Cover Plate
Screw Set
Glow Plug No.8
Super Air Cleaner 202 Assembly (W/2 filter elements)
202 Cleaner Body
202 Filter Elements (4pcs.)
The specifications are subject to alteration for improvement without notice.
Code No.
21804010
21824000
21823000
21816000
21817000
21815000
21883000
21818000
21833000
21811000
21832000
21812020
21807100
21213000
71608001
72412000
72412100
72412200
No.
18CV-R(P) W/11G ENGINE PARTS LIST
32
7
9
8
5
C.M2.6x12
4
10
6
2
12
13
C.M2.6x7
14
C...Cap Screw M...Oval Fillister-Head Screw
F...Flat Head Screw N...Round Head Screw S...Set Screw
Type of screw
11
3
1
18CV-R(P) W/11G EXPLODED VIEW
35
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Description
Heatsink Head
Gasket Set
Cylinder & Piston Assembly
Piston Pin
Piston Pin Retainer (2pcs.)
Connecting Rod
Carburetor Complete (Type 11J)
Carburetor Retainer Assembly
Propeller Nut
Drive Hub
Crankshaft Ball Bearing (Front)
Crankcase
Crankshaft Ball Bearing (Rear)
Crankshaft
Cover Plate
Screw Set
Glow Plug No.8
Super Air Cleaner 203 Assembly (W/2 filter elements)
203 Filter Elements (4pcs.)
The specifications are subject to alteration for improvement without notice.
Code No.
21804010
21824000
21823000
21816000
21817000
21815000
21884000
21818000
20810007
21408000
21833000
21811000
21832000
21812000
21807100
21213000
71608001
72413000
72413200
No.
18CV-R W/11J ENGINE PARTS LIST
34
9
7
10
11
8
5
C.M2.6x12
4
12
13
2
14
15
C.M2.6x7
16
C...Cap Screw M...Oval Fillister-Head Screw
F...Flat Head Screw N...Round Head Screw S...Set Screw
Type of screw
6
3
1
18CV-R W/11J EXPLODED VIEW
37
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
18-1
18-2
Description
Heatsink Head
Gasket Set
Cylinder & Piston Assembly
Piston Pin
Piston Pin Retainer (2pcs.)
Connecting Rod
Carburetor Complete (Type 11J)
Carburetor Retainer Assembly
Propeller Nut
Drive Hub
Crankshaft Ball Bearing (Front)
Crankcase
Crankshaft Ball Bearing (Rear)
Crankshaft
Starting Shaft
Rear Adaptor
Screw Set
No.5 Recoil Starter Assembly
No.5 Recoil Starter Body
No.5 One-way Clutch
Glow Plug No.8
Super Air Cleaner 203 Assembly (W/2 filter elements)
203 Filter Elements (4pcs.)
Engine Mount Spacer
The specifications are subject to alteration for improvement without notice.
Code No.
21804010
21824000
21823000
21816000
21817000
21815000
21884000
21818000
20810007
21408000
21833000
21811000
21832000
21812100
21812200
21801800
21313030
73003000
73003100
73003200
71608001
72413000
72413200
72404000
No.
18CV-RX W/11J ENGINE PARTS LIST
36
9
7
10
11
8
5
4
15
C.M2.6x12
16
12
6
14
M.+M2.6x7
18-2
2
18
17
18-1
M.+M2.6x7
C...Cap Screw M...Oval Fillister-Head Screw
F...Flat Head Screw N...Round Head Screw S...Set Screw
Type of screw
13
3
1
18CV-RX W/11J EXPLODED VIEW
11G CARBURETOR EXPLODED VIEW
2-1
2
2-2
3
1-1
1-2
4
5
6
1
7
8
9
Type of screw
C. M 3.5x8
C...Cap Screw M...Oval Fillister-Head Screw
F...Flat Head Screw N...Round Head Screw S...Set Screw
38
11G CARBURETOR PARTS LIST
No.
Code No.
1
1-1
1-2
2
2-1
2-2
3
4
5
6
7
8
9
21285600
46066319
22781800
21285901
27881820
21881950
23818500
21883100
21483200
21483600
21881320
23818420
22615000
Description
Mixture Control Valve Assembly
"O" Ring(L) (2pcs.)
"O" Ring(S) (2pcs.)
Needle Valve Assembly
"O" Ring (2pcs.)
No.14 Universal Nipple Assembly
Throttle Stop Screw
Carburetor Body
Slide Valve
Metering Needle Assembly
Dust Cover
Ball Link No.4
Carburetor Rubber Gasket
The specifications are subject to alteration for improvement without notice.
39
11J CARBURETOR EXPLODED VIEW
1-1
1
1-2
3
4
5
2
6
7
9
10
9-1
Type of screw
8
C...Cap Screw M...Oval Fillister-Head Screw
F...Flat Head Screw N...Round Head Screw S...Set Screw
40
11J CARBURETOR PARTS LIST
No.
Code No.
1
1-1
1-2
2
3
4
5
6
7
8
9
9-1
10
21285901
27881820
21881950
22681310
21884100
22481506
21884200
21283210
22681419
21481420
21484600
27881820
22615000
Description
Needle Valve Assembly
"O" Ring (2pcs.)
No.14 Universal Nipple Assembly
Throttle Stop Screw
Carburetor Body
Rotor Spring
Carburetor Rotor
Dust Cover
Throttle Lever
Throttle Lever Fixing Nut
Mixture Control Screw
"O" Ring (2pcs.)
Carburetor Rubber Gasket
The specifications are subject to alteration for improvement without notice.
41
O.S. GENUINE PARTS & ACCESSORIES
RACING ENGINE PARTS
O.S. Glow Plug
A3
(71605300)
Tuned Silencer
Exhaust Header Pipes
For Kyosho Super10
(72103110)
For Tamiya TGX
(72103120)
A5
(71605100)
For Kyosho Spider & HPI Nitro
(72103140)
For MUGEN MTX
(72103150)
T-1040 L52
For Kyosho
V-ONE R,S
(72103160)
T-1040 R52
(72103051)
(72103056)
T-1040 L70
For Tamiya TG10
(72103130)
(72103071)
T-1040 R70
(72103076)
Super Joint Tube 15
(72103310)
■ Dust Cap Set
Long Socket Wrench
With Plug Grip
Cap Screw Set
3 (5 pcs. set) (73300305)
For Carburetor Nipple
(71521000)
7 (3 pcs. set) (73300712)
For Tuned Silencer
16 (3 pcs. set) (73301612)
For Carburetor
(10pcs. set)
M2.6x7 (79871020)
M2.6x12 (79871040)
M3.5x8 (79871060)
42
18CV-R(P) W/11G THREE VIEW DRAWING
11
SPECIFICATIONS
3.0 cc (0.183 cu.in.)
16.0mm (0.629 in.)
15.0mm (0.590 in.)
3,000-32,000 r.p.m.
1.35 ps / 1.37 hp / 28,000 r.p.m.
235g (8.30oz.)
31.4
Displacement
Bore
Stroke
Practical R.P.M.
Power output
Weight
UNF1/4-28
25
27.5
Dimensions(mm)
25
39
34.9
79.4
43
15
18CV-R W/11J THREE VIEW DRAWING
11
SPECIFICATIONS
3.0 cc (0.183 cu.in.)
16.0mm (0.629 in.)
15.0mm (0.590 in.)
3,000-32,000 r.p.m.
1.35 ps / 1.37 hp / 28,000 r.p.m.
237g (8.37oz.)
31.4
Displacement
Bore
Stroke
Practical R.P.M.
Power output
Weight
M5x0.8
25
27.5
25
39
Dimensions(mm)
15
41
69
44
18CV-RX W/11J THREE VIEW DRAWING
SPECIFICATIONS
11
3.0 cc (0.183 cu.in.)
16.0mm (0.629 in.)
15.0mm (0.590 in.)
3,000-32,000 r.p.m.
1.35 ps / 1.37 hp / 28,000 r.p.m.
295g (10.41oz.)
M5x0.8
31.4
Displacement
Bore
Stroke
Practical R.P.M.
Power output
Weight
20
25
80.9
100.9
27.5
Dimensions(mm)
41
40
45
87.8
33.8
MEMO
L I TY PRECISION & P
ERF
QUA
ED
OR
L
L
M
E
ANC
E
ES
TA
BL
ISH
ING
NC
UNEQ
UA
46
L
CEL
THE STAN ARDS OF EX
D
E
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
C Copyright 2004 by O.S.Engines Mfg. Co., Ltd. All rights reserved. Printed in Japan.
60091560
061102
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