O.S. engine MaX-37SZ-HRING User manual

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 model, radio control equipment, etc., are

accessible for checking at the same time.

2-5

6-7

8-9

10-11

20-23

36-37

38-39

24-28

30-31

32-35

12-15

18-19

CONTENTS

SAFETY INSTRUCTIONS AND

WARNINGS ABOUT YOUR O.S. ENGINE

NOTES ON INSTALLING

COOLING-FAN AND CLUTCH

NOTES WHEN APPLYING AN ELECTRIC STARTER,

INSTALLATION OF THROTTLE SERVO

INTRODUCTION, ENGINE PARTS NAME 

BEFORE STARTING,

INSTALLATION OF THE ENGINE

INSTALLATION OF THE STANDARD ACCESSORIES

GLOWPLUGS

CARBURETOR CONTROLS

STARTING, RUNNING-IN ("Breakingin")

ADJUSTMENT

ADJUSTMENT CHART

CARE AND MAINTENANCE

TROUBLE SHOOTING

ENGINE EXPLODED VIEW & PARTS LIST

CARBURETOR EXPLODED VIEW & PARTS LIST

O.S. GENUINE PARTS & ACCESSORIES

THREE VIEW DRAWING

MEMO

!

!



Remember that your engine is not a "toy", but a highly efficient internal-

combustion machine whose power is capable of harming you, or others, if it is

misused.

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.

SAFETY INSTRUCTIONS AND WARNINGS ABOUT YOUR O.S. ENGINE

The advice which follows is grouped under two headings according to the

degree of damage or danger which might arise through misuse or neglect.

WARNINGS NOTES

These cover events which

might involve serious (in

extreme circumstances, even

fatal) injury.

These cover the many other

possibilities, generally less obvious

sources of danger, but which, under

certain circumstances, may also

cause damage or injury.

!

WARNINGS

••

•

Never touch, or allow any

object to come into contact

with, the rotating parts.

Model engine fuel is poison-

ous. Do not allow it to come

into contact with the eyes or

mouth. Always store it in a

clearly marked container and

out of the reach of children.

Model engine fuel is also

highly flammable. Keep it

away from open flame,

excessive heat, sources of

sparks,or anything else which

might ignite it. Do not smoke

or allow anyone else to smoke,

near to it.

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.

Never operate your engine in an en-

closed space. Model engines, like auto-

mobile engines, exhaust deadly carbon-

monoxide. Run your engine only in an

open area.

!



NOTES

•

This engine was designed for model

helicopters. Do not attempt to use it for any

other purpose.

Mount the engine in your model securely, fol-

lowing the manufacturers' recommendations,

using appropriate screws and locknuts.

Install an effective silencer (muffler). Frequent

close exposure to a noisy exhaust (especially

in the case of the more powerful high-speed

engines) may eventually impair your hearing

and such noise is also likely to cause

annoyance to others over a wide area.

Check the linkage to the throttle arm before

each flight.

Avoid sudden high r.p.m. immediately after the

engine is started, as the clutch will engage and

you may be struck by the rotor.

•

After starting the engine, carry out any needle-

valve readjustments after stopping the rotor by

closing the throttle to the lowest r.p.m..

Stop the engine before attempting to make

other adjustments to the carburetor.

Use an electric starter. The wearing of safety

glasses is also strongly recommended.

Press the rotor head down securely.

Take care that the glow plug clip or battery

leads do not come into contact with rotating

parts.

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.

•

!

NOTES

•

Take care that loose clothing (ties, shirt sleeves,

scarves etc.) do not come into contact with the

rotor. Do not carry loose objects (such as pen-

cils, screwdrivers, etc.) in a shirt pocket from

where they could fall through the rotor disc.

For their safety, keep all onlookers (especially

small children) well back (at least 20 feet or 6

metres) 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.

Hold the rotor securely and keep well clear of

spectators.

Warning! lmmediately after a glowplug-ignition

engine has been run and is still warm,

conditions sometimes exist whereby it is just

possible for the engine to restart when turned

over WITHOUT the glowplug battery being

reconnected. Remember this if you wish to

avoid the risk of accidents.

Notes on installing cooling fan and clutch

Do not use a tool which locks piston

when installing a cooling-fan and

clutch, or top of the piston may be

damaged. Also, do not insert a

screw driver or the similar into the

exhaust port.

It is recommended to use Crankshaft

Clamp 37 (Code No.71530600) available

as an optional tool.

Do not grip the engine mounting

beams with a vise, or the crankcase

will be distorted which will result in

engine breaking.

Vise

Beam Mount

Notes on installing cooling fan and clutch

NOTES WHEN APPLYING AN ELECTRIC STARTER

Because of this initial tightness, a

standard electric starter may have

difficulty in rotating the engine when

cold, before it has been adequately

run-in. In this case, use a high-torque

type 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 from

getting into your eyes.

90°

A=B

Linking the throttle servo to the carburetor

Link the throttle servo to the carburetor using the throttle lever supplied.

Throttle control rod A and B should be equal length. Set the linkage so that

the servo output lever and throttle lever are parallel when the throttle stick on

the transmitter is at middle position. Installing hole intervals on the F lever and

on the J lever are different. Decide the lever to use according to the servo used.

Be sure to cut off another lever to avoid any interference.

INTRODUCTION

Throttle lever is not installed on

the carburetor when the engine

leaves the factory.

Install it before using the engine.

NOTE

STANDARD ACCESSOIES

Glow Plug No.8

Throttle Lever Assembly

This is a high performance engine

designed for small-sized radio-

controlled helicopters.

Since the mounting bolt pattern of the

engine as well as silencer is the same as

those of the 32SX-H, it can be directly

replaced with the 32SX-H and most of

other 32-39 size engines. This powerful

engine is suitable for sport flight as well

as 3D flight.

With some models, needle interferes the

body and working on the body to avoid

this would be required.

Instruction manual

ENGINE PARTS NAME

Needle Valve

Fuel Inlet

Mixture Control Valve

Throttle Lever

Rotor Guide Screw

Carburetor Gasket

Heatsink Head

Carburetor

Type 20M

Crankshaft

Propeller nut

Crankcase

Glowplug

Beam Mount

Cover Plate

Thrust Washer

Items necessary for starting

Tools, accessories, etc.The following items are

necessary for operating the engine.

Battery leads

Glowplug battery

The power source for heating the glowplug may be

either a large heavy-duty 1.5volt dry cell, Ni-cd battery

or glowplug Igniter.

1.5 volt dry cell

These are used to conduct current

from the battery to the glowplug.

Basically, two leads, with clips, are

required, but, for greater conve-

nience, twin leads with special

glowplug connectors, as shown on

the right, are commercially available.

Battery leads

glowplug Igniter

Make sure glowplug element

glows bright red inside room

or shadow.

Battery leads

In case of 1.5volt dry cell

12V Battery

Starter

Electric starter and starter

battery

An electric starter is recom-

mended for starting.

Hexagon starting shaft

This shaft mounted on an

electric starting motor is driven

into the shaft cup to turn the

engine.

BEFORE STARTING

Select, by practical tests, the most suitable fuel from among

the best quality fuels available in your country for helicopter

use. For the best throttle response, a fuel containing 10% to

30% nitromethane is preferable. Lubricants may be either

castor-oil or a suitable synthetic oil (or a blend of both)

provided that they are always of top quality. For consistent

performance and long engine life, it is essential to use fuel

containing AT LEAST 18% lubricant by

volume. Some fuels containing coloring

additives tend to deterriorate and may

adversely affect running qualities. If in

doubt compare to a fuel known to be good.

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.

Reminder!

Fuel

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.

Alternatively, one of the purpose-made

manual or electric fuel pumps may be

used to transfer fuel directly from your

fuel container to the fuel tank.

Manual

Electric

Install a filter to the outlet tube of your

refueling container to prevent entry of

foreign matter into fuel tank. O.S. ‘Super

Filters’ (large and small) are available as

optional extras.

O.S. Super Filter (Fuel Can Filter)

It is recommended to install a good in-

line filter between the fuel tank and

carburetor to prevent entry of foreign

matter from getting into the carburetor.

Fuel Filter

Heatproof silicone tubing of approx.

5mm o.d. and 2.5mm i.d. is required

for the connection between the fuel

tank and engine.

Fuel Pump

Silicone Fuel Line

TOOLS

Screwdriver

Necessary for engine installation.

1.5mm, 2mm, 2.5mm, 3mm

Necessary for carburetor adjustments.

No.1, No.2, etc

Phillips Screwdriver

No.1, No.2, etc.

Socket Drivers

5mm, 5.5mm, 7mm

Hex Drivers

8mm

Recommended for easy removal and replacement of

the angled and recessed glowplug, the O.S.Long

Socket Wrench incorporates a special grip.

End Wrenches

8mm, 13mm, 14mm, etc.

Needle Nose Pliers

Long Socket Wrench With Plug Grip

The under-surfaces of all O.S. engine beam

mounting lugs are precision machined flat and

exactyly parallel to the engine's horizontal axis. It is

essential that the engine mounts in the model are

also accurately made and aligned. If they are not,

they will cause stress and distortion within the engine

itself, probably resulting in loss of performance and

internal damage.

The recommended screws for securing the engine to

the engine mounts in the model are 3mm or 4-40

steel Allen type. It is also advisable to use lock

washers or LOCTITE to prevent nuts from loosening.

Front view

CORRECT

Side view

Top surfaces are in the same plane.

Re-align the surfaces as necessary

INCORRECT

Top surfaces are not

in the same plane. Top surfaces are not in the

same plane.

Engine does not rest firmly.

Make sure that only the under-

surfaces of the engine’s mounting

lugs are in contact with the engine

mount.

INSTALLATION OF THE ENGINE

Make sure that only the under-surfaces of the engine’s

mounting lugs are in contact with the engine mount.

Please note that crankcase volume of the 37SZ-H is a

little larger than the 32SX-H’s. If the crankcase body

touches the mount, chamfer the edges of the mount.

INSTALLING THE GLOWPLUG

Install washer on glowplug and insert carefully into

Heatsink-head, making sure that it is not cross-

threaded before tightening firmly.

Glow plug

Washer

Throttle lever is not installed on the carburetor

when the engine leaves the factory.

Install it before using the engine referring to the

sketch below.

INSTALLATION OF THE THROTTLE LEVER

INSTALLATION OF THE STANDARD ACCESSORIES

Throttle Lever

Retaining Screw

Washer

GLOWPLUG

The role of the glowplug

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.:

Install a plug suitable for the engine.

Use fuel containing a moderate percentage of

nitromethane unless more is essential for racing events.

Do not run the engine too lean and do not leave the

battery connected while adjusting the needle.

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.

Apart from when actually burned out, a plug may

need to be replaced because it no longer delivers its

best performance, such as when:

When to replace the glowplug

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.

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. Recommended O.S. plugs are

No.8, No.7 and No.10 (Former A5) .

Carefully install plug finger-tight, before

final tightening with the correct size plug

wrench.

CARBURETOR CONTROLS

With a fixed-wing model, power failure is rarely a

serious threat to the safety of the aircraft since it can

usually glide down to a safe landing. In a helicopter,

on the other hand, it is vitally imporant that the engine

keeps running and that there is a quick and reliable

response to the throttle in order to ensure safe ascent

and descent of the model.

The Needle Valve:

When set to produce maximum power at full throttle,

this establishes the basic fuel/air mixture strength.

This is then maintained by the carburetor's

automatic mixture control system to cover the

engine's requirements at reduced throttle settings.

The Mixture Control Valve

For adjusting the mixture strength at part-throttle

and idling speeds, to obtain steady idling and

smooth acceleration to medium speeds. The Mixture

Control Valve has been factory set for the

approximate best result. First, run the engine as

received, and re-adjust the Mixture Control Valve

only when necessary.

Two adjustable controls are provided on this carburetor.

Needle Valve

MIxture Control Valve

REALIGNMENT OF MIXTURE CONTROL VALVE

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 setting can be reestablished as follows :

Mixture Control Valve

Carburetor Body

First rotate the Mixture

Control Valve until its

slotted head is flush with

the carburetor body.

Then screw the valve in

exactly 1 turn. This is the

standard position.

0.5mm

As shown in the sketch, the carburetor has graduation

marks. When the triangle mark on the carburetor rotor

meets the most right mark, throttle is fully closed.

When the triangle mark meets the top mark, throttle is

fully open. The range is approximately 80 degrees. You

may use other three marks as the reference marking of

throttle opening to your preference when hovering.

WARNING!

Never try to check the triangle mark position while

the engine is running and rotor is rotating, or you

may be hit by rotating rotor which results in serious

injury. Stop the engine and rotor before checking

the triangle mark position.

Carburetor Rotor

Carburetor Body

Fully closed position

Fully opened position Approx.

GRADUATIONS ON THE CARBURETOR BODY

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