321B Nitro Engine

Transcription

321B Nitro Engine

321B Nitro Engine
Instruction Manual
www.ProTekRC.com
Copyright © 2014
INSTRUCTION MANUAL
It is important that before attempting to operate your engine that you read, understand and
strictly follow the outlined guidelines in the “Safety Instructions, Warnings and Notes” section
on pages 1-3 of this manual.
• Study the information provided in this manual in order to become familiar with the controls
and features of the engine.
• Keep these instructions in a safe place so that you may refer to them when needed.
• It is recommended that you keep the instructions for the vehicle, radio/transmitter
equipment, etc. accessible at the same time so that you may refer to them when needed.
CONTENTS
1-3
Safety Instructions, Warnings & Notes
4-5
Engine Construction & Notes When Applying the Starter Box
6-7
About the Engine & Standard Included Accessories
8-10
Required Items & Basic Engine Parts
11-12 Carburetor Controls & Glow Plug
13-15 Installation of the Standard Accessories & Engine Installation
16-20 Starting & Breaking-In the Engine
21-23 Final Adjustment
24-25 Care & Maintenance
26-28 Troubleshooting
29-30 Engine Exploded View & Parts List
31-32 Carburetor Exploded View & Parts List
33
Engine Accessories
34
3D Drawing & Specifications
SAFETY INSTRUCTIONS,
WARNINGS & NOTES
3 D D R A W I N G & S P E C I F I C AT I O N S
Remember, this engine is not a “toy”! This is an internal combustion engine that has the
potential to damage property, as well as harm you or others if misused. As the owner, you
alone are responsible for the safe operation of this engine. Act with discretion and care at all
times. If the ownership of this engine is transferred to another person, it is the responsibility
of the original owner to provide this manual to the new owner.
Displacement
3.46cc (0.211cu.in.)
Practical R.P.M.
3,000 - 40,000 R.P.M.
Bore
16.6mm (0.654in.)
Power Output
2.5ps / 34,000 R.P.M.
Stroke
16.0mm (0.630in.)
Weight
355g (12.52oz)
The following warnings apply to ALL MODEL ENGINES and are grouped under two
headings according to the degree of danger and/or damage which could occur due to
misuse or neglect of this product.
WARNINGS
NOTES
These cover events which could
cause serious, and in extreme
circumstances, even fatal injury.
These cover the many other and generally less
obvious sources of danger, but which under certain
circumstances may also cause damage or injury.
WARNINGS
Near TDC
Model engine fuel is poisonous.
Do not allow it to come into contact with the
Near TDC
eyes or mouth. Always store fuel in a clearly marked container and out of the
reach of children.
Piston
4
Piston
Model engine
fuel is highly flammable.
Keep it away from open flames,
Cylinder Liner
Cylinder
Liner sources of sparks, or anything else that could ignite it. Do
excessive
heat,
Near TDC
not smoke or allow anyone else to smoke near it.
M2.6x7
Carburetor Restrictor (Venturi)
Crankshaft
7
7
8
Piston
Model engines
Cylinder Linergenerate considerable heat. Do not touch any part of your
Crankshaft
engine until
it has cooled. Contact with the exhaust system or cylinder head
Slight
may result
in ataper
serious burn.
When the engine is cold.
12
7
01
7
8
10
8
Near TDC
Crankshaft
Slight
taper
Model engine
exhaust, like automobile engine exhaust, contains deadly
Slight taper
Pistonyour engine in an enclosed space. Run
carbon-monoxide.
Never operate
8your engine
Cylinder only
Liner in an open, well ventilated area.
When the engine is hot.
O-Ring
Crankshaft
When the
engine is cold.
Rotate the retainer
Slight taper
nut gently
it stops
Rotate
the until
retainer
O-Ring
11
nut gently until it stops
Tighten a further
120º - 180º
Tighten
a further
O-Ring
O-Ring Retaining Screw
High Speed
Needle
High Speed
(Needle Valve)
Needle
Slide Boot
Slide Boot
(Needle
Valve)
Mid Needle
Idle Screw
(Mixture
Control Valve)
Carburetor Restrictor
(Venturi)
(Throttle
Mid
Needle
Idle ScrewStop Screw)
(Mixture Control Valve)
(Throttle Stop Screw)
High Speed
Needle
(Needle Valve)
High
Speed
Mid Needle
Needle
(Needle Valve)
Ball Link
Ball Link
Slide Boot
Idle Screw
(Throttle
Stop
Screw)
Low
Speed
Needle
Slide
Boot
(Metering Needle)
Dimensions (mm)
34
ENGINE ACCESSORIES
• This engine is intended for use in model cars. Do not attempt to use it for any
other purpose.
Part Number
Description
PTK-2542
P3 Turbo Glow Plug (Ultra Hot)
PTK-2060-1
PTK-2060 Tuned Pipe (No Manifold) (Welded Nipple)
PTK-2060
PTK-2060 Tuned Pipe w/Manifold (Welded Nipple)
PTK-2544
Off-Road Exhaust Manifold (for PTK-2060)
PTK-2090-1
PTK-2090 Tuned Pipe (No Manifold) (Welded Nipple)
PTK-2090
PTK-2090 Tuned Pipe w/Manifold (Welded Nipple)
PTK-2545
Off-Road Exhaust Manifold (for PTK-2090)
PTK-2516
6mm Aluminum Carburetor Restrictor
PTK-2518
6.5mm Aluminum Carburetor Restrictor
• Ensure that the linkage to the throttle arm is secure.
PTK-2519
PTK-2520
7.5mm Aluminum Carburetor Restrictor
• As a safety precaution, maintain a 20 foot (6 meters) distance between your model
and all bystanders (especially small children).
PTK-2521
PTK-2522
6mm Aluminum "Elliptical" Carburetor Restrictor
PTK-2523
6.5mm Aluminum "Elliptical" Carburetor Restrictor
PTK-2524
PTK-2525
7.5mm Aluminum "Elliptical" Carburetor Restrictor
PTk-2526
* Specifications are subject to change without notice.
33
NOTES
• Mount the engine in your model securely. Always follow the manufacturer
recommendations, using the appropriate screws and locknuts.
• Install an effective throttle return device. This will close the carburetor in the event
that battery power is lost during operation.
• Install an effective silencer (tuned pipe). Frequent close exposure to a noisy
exhaust (especially in the case of more powerful high speed engines) may eventually
impair your hearing and such noise is also likely to cause annoyance to others.
• Eye protection is highly recommended.
WARNING
WARNING: This product contains chemicals known to the State of California to
cause cancer, birth defects or other reproductive harm.
THIS PRODUCT IS NOT A TOY! NOT FOR CHILDREN UNDER 14 YEARS.
For proper opertation and to avoid risk of damage and injury, read and follow all
instructions before operating this product. Failure to comply may result in excessive
heat, fire, property damage and serious injury.
02
No.
Part Number
Description
1
PTK-2529
Ball Link
• Before starting the engine, verify that all fasteners, especially those at joints and
moving parts (such as the throttle arm) are tight and secure. Loose fasteners are
often the source of catastrophic problems and could lead to injury or property
damage.
1-1
PTK-H-4000
3x3mm Set Screw
2
PTK-2535
Carburetor Boot
3
PTK-2530
Low Speed Needle
• To stop the engine during normal operation, reduce the throttle to neutral, flip the
car over and push a blunt rubber object against the flywheel.
3-1
PTK-2531
Low Speed Needle O-Ring
4
PTK-2503
Slide Valve (Carburetor Complete)
• To stop the engine in the event of an emergency, use a blunt rubber object to
plug the exhaust and flood the engine (recommended), or cut off the fuel supply by
pinching the fuel delivery line from the fuel tank. In the event of an emergency DO
NOT attempt to stop the engine at the flywheel.
5
PTK-2524
Carburetor Restrictor – 7mm “Elliptical”
5
PTK-2526
Carburetor Restrictor – 8mm “Elliptical”
5-1
PTK-2517
Carburetor Restrictor O-Ring
• WARNING! Immediately after a glow type engine has been shut off, while the
engine is still warm, conditions exist that make it possible for the engine to abruptly
re-start if the piston is rotated through the compression point (top dead center:
TDC), WITHOUT the glow plug igniter being connected.
6
PTK-2540
High Speed Needle
6-1
PTK-2541
High Speed Needle O-Ring
7
PTK-2537
High Speed Needle Housing
7-1
PTK-2538
Fuel Inlet with Gasket
8
PTK-2543
Idle Screw
8-1
PTK-2536
Idle Screw O-Ring
9
PTK-2532
Mid Rangle Needle
9-1
PTK-2533
Mid Range Needle O-Ring Large (2)
9-2
PTK-2534
Mid Range Needle O-Ring Small (2)
10
PTK-2513
Carburetor Outer O-Ring
NOTES
03
32
6
M2.6x18
8
CARBURETOR EXPLODED VIEW
ENGINE CONSTRUCTION
This engine uses a chrome plated brass sleeve with a tapered cylinder wall. When the engine
is cold, the piston will feel tight when rotated through the top of its stroke, or Top Dead
Center (TDC). This is normal. The cylinder will expand and will achieve correct clearance once
normal operating temperature has been reached.
1
1-1
6-1
S.M3x3
2
5
3-1
4
6
NOTE: When this engine is new, DO NOT try to turn the crankshaft and rotate the piston
through TDC, as this will jam the piston in the cylinder.
7
5-1
Near TDC
7-1
8-1
3
8
Piston
9-2
Cylinder Liner
9-1
10
9
Crankshaft
Slight taper
7
8
31
Rotate the retainer
O-Ring
04
N O T E S W H E N A P P LY I N G
T H E S TA R T E R B O X
No.
Part
Number
Description
1
PTK-2501
Cooling Head
2
PTK-2508
Turbo Plug Button Head
DO NOT over prime the engine. This could cause a hydraulic lock and damage the engine
when the starter is applied.
3
PTK-2509
0.1mm & 0.2mm Head Gasket/Shim Set
4
PTK-2507
Complete Piston/Sleeve/Rod Assembly
• If over-primed, remove the glow plug, close the high speed needle valve, cover the head
with a rag and apply the starter to pump out excess fuel. The rag will help to prevent fuel
from coming into contact with your eyes.
5
PTK-2503
Complete Carburetor
6
PTK-2514
Carburetor Retainer Assembly
7
PTK-2504
7x19x6mm Front Engine Bearing
8
PTK-2502
Crankcase
9
PTK-2505
14x25.4x6mm Ceramic Rear Bearing
10
PTK-2506
Crankshaft
11
PTK-2512
Rear Cover Plate O-Ring
12
PTK-2511
Rear Cover Plate
13
PTK-2542
P3 Turbo Glow Plug (Ultra Hot)
DC
ston
* See additional option parts on Pg.33
High Speed
Needle
(Needle Valve)
Mid Needle
ngine is hot.
Slide Boot
Idle Screw
O-Ring
Ball Link
05
30
ENGINE EXPLODED VIEW
ABOUT THE ENGINE
M3x18
The ProTek R/C Samurai 321B is a 3.5cc high performance short-stroke nitro engine
produced and assembled in Japan by one of the most highly respected model engine
manufacturers in the industry. Designed for off-road radio-controlled competition racing, the
engine is ideal for 1/8 Scale Buggy and Truggy use while featuring a turbo glow plug and
slide carburetor. With its easy-to-tune and consistently stable operating characteristics, the
Samurai 321B is the ideal engine of choice for the racer seeking a reliable engine with a
smooth power band and great runtime.
13
1
NOTE: The carburetor is only lightly fit into the engine and is not fully installed. This
allows the user to adjust the angle and make necessary adjustments to suit their
specific application.
2
3
4
M2.6x7
5
12
11
10
9
M2.6x18
7
6
Dimensions (mm)
8
29
Part Number
Size
Pieces Used in an Engine
PTK-2515
2.6x7mm
Rear Cover Plate Screw - 4
PTK-2514
2.6x18mm
Carburetor Retainer Screw (Complete) - 1
PTK-H-1208
3x18mm
Cooling Head Retaining Screw - 4
1
1-1
06
6
Near TDC
Piston
Piston
Cylinder
CylinderLiner
Liner
S TA N D A R D I N C L U D E D
ACCESSORIES
Crankshaft
Crankshaft
TROUBLESHOOTING
Piston
SYMPTOM: NOT REACHING PEAK RPM
Cylinder Liner Slight
Slighttaper
taper
• ProTek P3 - Ultra Hot Turbo Glow Plug (PTK-2542) (1)
7 7
Cause
8 8
Crankshaft
Near TDC
Slight taper
• 0.1mm Cylinder Head Shim (PTK-2509) (1)
7
Near TDC
8
When
Whenthe
theengine
engineis iscold.
cold.
Cylinder Liner
• High Temp Exhaust Gasket (PTK-2528) (1)
When
Whenthe
theengine
engineis ishot.
hot.
Piston
Rotate
Rotatethe
theretainer
retainer
nut
nutgently
gentlyuntil
untilit itstops
stops
Piston
Cylinder Liner
Corrective Action
Insufficient warming up or break-in.
Set the needles only after warming up.
Complete the break-in process.
Silencer or manifold are not securely
connected or are disconnected.
Replace gasket.
Check and secure the system.
Fuel tubing from tank is split or broken.
Replace the tubing.
SYMPTOM: POOR THROTTLE RESPONSE
O-Ring
O-Ring
Cause
Corrective Action
Deteriorated glow plug.
Replace glow plug.
Incorrect carburetor settings.
Readjust low RPM range with Low Speed
Needle and Mid Needle.
O-Ring
O-Ring
Tighten
Tightena afurther
further
Incorrect Setting of transmitter Exponential
Check the transmitter setting.
O-Ring
Retaining
RetainingScrew
Screw
120º
180º
function.
120º - 180º
Hi
N
(N
M
(M
Crankshaft
Incorrect Linkage.
Make sure the throttle servo linkage does
Rotate the retainer
not bind and is connected correctly.
Slight taper
nut gently
until it stops
• 7mm “Elliptical” Carburetor Restrictor (PTK-2524)
(1) Crankshaft
Dirt
marked
Dirtand
anddust
dustmay
maylodge
lodgeinin
markedplaces
places
Exhaust
Exhaust
8mm “Elliptical” Carburetor Restrictor (PTK-2526) (1)
Close
Close
O-Ring
Gasket
Gasket
S
Y
M
P
T
O
M
:
P
O
O
R
R
P
M
D
R
O
P
Tighten
a
further
Slight taper
7
8
Turn
needle clockwise
Turnthe
thehigh
highspeed
speed
Retaining Screw
120ºneedle
- 180ºclockwise
Cause
Corrective Action
until
untilit itstops.
stops.This
Thisis isthe
thefully
fullyclosed
closed
High
Speed
High Speed
Glowplug
position.
position.DoDonot
notforce
forceit ittototurn
turnfurther.
further. Throttle position openNeedle
too far.
Close Low Speed Needle to adequate
7
8
Needle
Open
position to lower idle RPM.
Open
Dirt and dust may lodge in
marked places
• 3mm, 16mm & 17mm Dust CapExhaust
(PTK-2527) (1)
Carburetor not fully seated.
Install carburetor securely.
Close
Gasket
approx
0.5mm
approx
0.5mm
Low Speed Needle closed too far.
Open the Low Speed Needle a little.
Turn the high speed needle clockwise
Element
Elementglows
glowswhen
whenenergized
energized
Pliers
until
it stops. This
isApprox.
the
closed
When the engine
isPliers
cold.
When
thefully
engine
isopen
hot.
Approx.
0.5mm
0.5mm
open
O-Ring High Speed
position. Do not force
it tosetting
turn
further.
factory
with
factory
setting
withthe
the
Needle
Open
restrictor
removed.
restrictor
removed.
Rotate
retainer
When
the the
engine
is cold.
When
the engine is hot.
O-Ring
Carburetor
CarburetorBody
Body
07
28
Ball
BallLink
Link
approx 0.5mm
Replace the plug when the
Glowplug
Glowplug
TROUBLESHOOTING
REQUIRED ITEMS &
B A S I C E N G I N E PA R T S
S Y M P T O M : E N G I N E F I R E S I N T E R M I T T E N T LY
BUT DOES NOT RUN
Cause
Corrective Action
The following items are required to operate the engine.
FUEL
Insufficient fuel in the tank.
Fill the tank with fuel.
Deteriorated glow plug.
Replace glow plug.
Clogged fuel filter.
Air cleaner or internal silencer are dirty.
Clean or replace fuel filter.
Replace air cleaner element and clean
inside silencer.
Engine is over heated.
The user should only use high quality fuel for two stroke glow type
engines that contains 10-30% nitromethane. Fuel with 20% nitro
content is recommended for break in. Then, change to a fuel with a
higher nitro content later if desired. When the brand of fuel is changed,
or the nitro content is increased, it is advisable to repeat a short break
in procedure referred to in the BREAKING IN section. Please note that
high nitro content fuels produce more power at the expense of reduced
engine life. This will also shorten the life of the glow plug element.
Near TDC
Piston
Wait until engine is cool.
WARNING
Cylinder Liner
Incorrect clutch release.
Adjust the tension of the clutch spring.
Glow plug battery disconnected too soon.
Near TDC
Model engine fuel is poisonous.
Do not allow it to come into contact with
Near TDC
the eyes or mouth. Always store it in a clearly marked container and out of
the reach of children. Wash hands after use.
Wait until RPM becomes stable before
Near TDC
disconnecting plug battery.
Vibration causing air bubbles in fuel.
Install o-rings to the fuel tank screws to
Crankshaft
prevent bubbles.
Near TDC
Slight taper
Near TDC
Piston
S Y M P T O M : U N S TA B L E I D L E
7
8
Cause
Cylinder Liner
Incorrect glow plug.
Silencer or manifold are not securely
connected or are disconnected.
27
8
7
F U E L F I LT E R
Crankshaft
Crankshaft
Slight taper
Slight taper
Install the filter in the fuel line between the fuel tank and the
7
8
carburetor
to prevent
dust from entering the carburetor.
8
Piston 7
GLOW PLUG IGNITER
Do not use extremely high nitro or low oil
Crankshaft
Crankshaft
content fuel.
Crankshaft
Slight
taper
Add heavier
Slight taper
Slight
taper flywheel.
Extremely light flywheel.
7
Piston
Corrective
Action
Cylinder
Liner
Use the glow plug recommended inCylinder
the
Liner
instructions.
Unsuitable fuel.
Piston
Model engine fuel is highly flammable.
Keep away from open flames,
Piston
Cylinder Liner
excessive
heat,
Cylinder
Linersparks, or anything else that could ignite it. Do not smoke
or allow anyone else to smoke near it.
Replace seal ring.
8 secure
Check and
7 the system.
8
Commercially available, a glow plug igniter is a handy tool
When battery
the engine isto
cold.
the engine
is hot.
that uses an integrated
heat When
the glow
plug.
O-Ring
O-Ring
Recommended: PTK-7605 - ProTek R/C “SureStart” Rechargeable
Rotate the retainer
Glow Ignitor w/Charger (2100mAh
NiMH)
Rotate
the until
retainer
nut gently
it stops
O-Ring
S
TA
RTER BOX
Glowplug
O-Ring
O-Ring Retaining Screw
Retaining Screw
Tighten a further
Tighten
a further
120º - 180º
120º - 180º
Glowplug
Used
to start the engine.
Exhaust - ProTek R/C SureStart 1/8 Off-Road
Recommended: PTK-4500
Close
Exhaust
Gasket
Starter Box
Gasket
Turn the high speed needle clockwise Close
Rotate the retainer
Tighten a further
120º - 180º
When the
engine is hot.
Element glows when energized
Turn
high This
speed
until itthe
stops.
is needle
the fullyclockwise
closed
until it stops.
This
is the
position.
Do not
force
it tofully
turnclosed
further.
position. Do not force it to turn further. Open
Open
O-Ring
Retaining Screw
O-Ring
Pliers
approx 0.5mm
approx 0.5mm
High Speed
High
Speed
Needle
Needle
08
Hig
Nee
(Ne
ma
ma
Mid
(Mi
TROUBLESHOOTING
S TA R T E R B O X B AT T E R I E S
Use the battery type that is recommended by the starter box
manufacturer. Ensure that the battery is fully charged before use.
Recommended: ECP-LPH-5000-2S30 (x2) - EcoPower 2S Li-Poly
Battery Pack
S Y M P T O M : E N G I N E FA I L S T O S TA R T
Cause
FUEL BOTTLE
Use this to fill the fuel tank.
Recommended: PTK-7600 - ProTek R/C “Fast Fill” Fuel Bottle (500cc)
& PTK-7603 - ProTek R/C “Quick Pit” Fuel Gun
Fill the tank with fuel and repeat priming
procedure.
Glow plug element is burned out.
Replace glow plug.
Recharge or replace the battery.
Glow
plug battery discharged.
Carburetor Restrictor
(Venturi)
Clogged fuel filter.
SILICONE FUEL LINE
Heatproof silicone tubing suitable for nitro fuel with an approximate
5mm outer diameter and 2mm inner diameter is required to make the
connection between the fuel tank and the engine.
TOOLS
Air cleaner or internal silencer are dirty.
High Speed
Needle
(Needle Valve)
High Speed
Use for engine installation. 1.5mm, 2mm, 2.5mm, 3mm
Recommended: PTK-8227 - ProTek R/C “TruTorque”
O-Ring Metric Hex Driver Set
Remove glow plug and pump out excess
fuel.
Fuel tubing is disconnected.
Connect fuel tubing securely.
Check the tubing carefully and replace if
necessary.
Idle Screw
Incorrect servo linkage.
Connect correctly after setting servo at
neutral.
Slide Boot
Idle
Screw
Slide
Boot
Fuel
tubing
is kinked,(Venturi)
split or has a hole.
Carburetor
Restrictor
Mid Needle
High Speed
Needle
(Needle Valve)
SCREWDRIVER
Necessary for carburetor adjustments. No.1, No.2, etc.
Recommended:O-Ring
PTK-8219 - ProTek R/C “TruTorque” Flat
Retaining Screw
Blade Screwdriver (4mm)
Clean or replace fuel filter.
Replace air cleaner element and clean
inside silencer.
Engine is over primed (flooded).
Needle Mid Needle
(Needle Valve)
HEX SCREWDRIVER
Corrective Action
Fuel tank is empty.
Fuel not reaching the engine.
Reverse rotating direction of the
Ball Link
starter box.
Make sure the starter box rotates counter
clockwise as seen from crankshaft side.
Slide Boot
Mid Needle Ball LinkLow Speed Needle Idle Screw
(Metering Needle) (Throttle Stop Screw)
Thermo Insulator
O-Ring
LONG SOCKE
Wdust
R Emay
N Clodge
H in
DirtT and
W I TRetaining
H P L UScrew
G GRIP
marked
places Restrictor (Venturi)
Carburetor
Recommended for easy removal and replacement of the glow
Thermo Insulator
plug, this socket wrench incorporates a special internal grip.
High Speed PTK-8202 - ProTek R/C “TruTorque” 4-in-1 Carburetor Restrictor (Venturi)
Recommended:
High
Speed
marked places
Needle
Multi-Wrench
.5mm
Speed
dle
09
Low Speed Needle
(Metering Needle)
Do not allow
bottom of crankcase
to touch chassis
Needle
Slide Boot
(Needle Valve)
ProTek R/C offers a full line of batteries, chargers, servosCarburetor
and
Restrictor (Venturi)
accessories. Visit www.ProTekRC.com
forNeedle
more
information.
High
Speed
Mid
O-Ring
Do notofallow
Idle Screw
Chamfer
inside edges
bearers
Needle
Control Valve)
(Throttle Stop
Screw)
bottom
Retaining Screw (Mixture
Slide
Boot of crankcase
(Needle Valve)
High
Speed
Mid Needle
to touch chassis
Idle Screw
Thermo Insulator
Ball Link
Low Speed Needle
(Metering Needle)
26
O-Ring
Low Speed Needle
(Metering Needle)
Retaining Screw
Thermo Insulator
B A S I C E N G I N E PA R T S
marked places
Do not allow
Cooling Head
bottom of crankcase
to touch chassis
High Speed
Needle
Chamfer inside edges of bearers
I N S TA L L I N G D U S T C A PCarburetor
S
Body
Needle
EED
Carburetor
Ball Link
When storing the engine install the cap on the exhaust port, carburetor,
etc. to prevent dust
from entering the engine. This can cause permanent damage.
Exhaust
Rotate the low speed needle until the head
sticks out 0.5mm from the ball link body.
CHECKING THE ENGINE
This isparts
the as
standard
As the engine wears, performance will decrease. It is suggested to replace
needed position.
when the following symptoms are detected.
Back Plate
• Engine sound changes and easily overheats.
Slide Valve
• Power has dropped.
Low Speed Needle
5.5 turns out. Make adjustments with the slide in the open position.
Idle Screw
• Idling is unstable
and/or
engine cuts out when idling.
Low Speed
Needle
Crankshaft
First
mid needle until its slotted
In most cases, the bearings, piston & sleeve assembly, connecting
rodrotate
and/orthe
crankcase
LOWworn.
SPEED
NEEDLE
NEEDLE
have become
Check
the parts carefully and replace as needed.
head is flush with the carburetor body. This
Close
Open
is the
standard position.
Close
Mounting Lugs
Mid Needle
Less fuel
More fuel
Less fuel
Crankcase
2¾ turns out. Make adjustments with the slide in the open position!
Carburetor Body
Front Bearing
25
10
CARBURETOR CONTROLS
The following procedure is recommended for this engine when the ProTek R/C P3,
PTK-2060 or PTK-2090 tuned pipe and fuel containing up to 30% nitromethane are used.
H I G H S P E E D N E E D L E ( N E E D L E VA LV E )
Use to adjust the fuel mixture when the throttle is fully open. (*3½ Turns from fully closed)
1 The small particles of foreign matter that may be present in any fuel may obstruct fuel
flow, causing erratic engine performance, unreliable operation or permanent damage to
the engine. It is recommended that a high quality in-line fuel filter be installed between the
fuel tank and carburetor.
M I D N E E D L E ( M I X T U R E C O N T R O L VA LV E )
2 Do not forget to clean or replace filters regularly to remove the dirt and other material that
can accumulate. Additionally, the carburetor may require occasional maintenance.
LOW SPEED NEEDLE (METERING NEEDLE)
3 At the end of each operating session, drain out any remaining fuel from the fuel tank.
Then restart the engine to burn off any fuel that may remain inside the engine. Repeat
this procedure until the engine fails to start. This should be performed while the engine
is still warm.
For changing the fuel mixture at mid speed and acceleration. DO NOT rotate the screw more
than one turn. (*2¾ turns from fully closed)
For adjusting the fuel mixture at partial throttle and idle speed to obtain steady idling and
smooth acceleration to mid speed. (*5½ turns from fully closed)
IDLE SCREW (THROTTLE STOP SCREW)
For setting the minimum idle speed. This is adjusted at the factory.
High Speed
Needle
(Needle Valve)
Mid Needle
Slide Boot
Idle Screw
Ball Link
Thermo Insulator
11
CARE & MAINTENANCE
NOTE: We recommend
you double check
the needle settings
prior to beginning the
break in process. The
settings are set at
the factory, but slight
readjustment may be
necessary to allow
for changes in fuel
formula, gear ratio or
clutch engagement
point.
4 Remove the glow plug and inject a small amount of after-run oil into the engine from the
glow plug hole in the combustion chamber. Then turn over the engine with the starter box
for 4 to 5 seconds to distribute the oil to the working parts inside the engine.
NOTE: Do not inject after run oil in through the carburetor, as this may cause the
carburetor o-rings to deteriorate. These procedures will reduce the risk of starting
difficulties or corrosion after a period of storage.
5 Finally, when cleaning the exterior of the engine, use an approved nitro cleaner. Do not use
gasoline, kerosene, or any petroleum based chemical as this could damage engine seals
and other components.
NOTE: This engine uses a silicone ramped crankshaft. DO NOT use light oil, waterdisplacing oil, kerosene, or other petroleum based oils as an after run oil or to clean the
crank, as this will permanently damage the silicone. Use alcohol or nitro fuel to clean
the crank.
*Factory default settings.
When screwing the needles all
the way in, the slide must be in
the fully open position.
Low Speed Needle
(Metering Needle)
24
Thermo Insulator
irt and dust may lodge in
(Metering Needle)
marked places
• After the break in period, a leaner needle setting may be required to maintain maximum
performance.
Do not allow
CARBURETOR CLEANLINESS
bottom of crankcase
The small fuel orifices must be kept clear to ensure correct carburetor function.
to touch chassis
• REALIGNMENT OF THE LOW SPEED NEEDLE & MID NEEDLE
When making carburetor adjustments, it is possible that the low speed needle and mid
needle may be inadvertently screwed in or out too far and thereby moved beyond the
effective adjustment range. The basic positions can be found by rotating the low speed
needle until its slotted head is flush with the ball link body.
Carburetor Body
Ball Link
This is the standard position.
Slide Valve
Low Speed Needle
d Needle
First rotate the mid needle until its slotted
head is flush with the carburetor body. This is the
standard position.
D NEEDLE
Close
Mid Needle
Less fuel
2¾ turns out. Make adjustments with the slide in the open position!
Carburetor Body
GLOW PLUG
Since the chosen glow plug and fuel type will effect performance and reliability, it will
be worthwhile to test with different plugs to find the best plug for your application. We
recommend the ProTek R/C P3 plug. Carefully install the plug finger tight before final
tightening with the correct size plug wrench.
THE ROLE OF THE GLOW PLUG
With a glow plug engine, ignition is initiated when a 1.5 volt power source is connected to
the plug. When the engine is running and the power is disconnected, the heat retained within
the combustion chamber remains sufficient to keep the plug filament glowing. This keeps the
engine running. Ignition timing is automatic. This means under reduced load and higher RPM,
the plug gets hotter and fires the fuel/air charge earlier in the piston stroke; at reduced RPM
the plug becomes cooler and ignition is retarded firing the charge later in the stroke.
GLOW PLUG LIFE
In the case of high performance nitro engines, glow plugs must be regarded as expendable
items. However, plug life can be extended and engine performance maintained by careful
use, i.e.:
• Use 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 igniter battery connected while making
needle adjustments.
WHEN TO REPLACE THE GLOW PLUG
Apart from when actually burnt out, a plug may need to be replaced because it no longer
delivers its best performance, such as when:
• Filament surface is rough and has 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.
• Engine becomes more difficult to start.
23
12
Crankshaft
Slight taper
I N S TA L L AT I O7N O F8 T H E
S TA N D A R D A C C E S S O R I E S
• With the engine running, close the throttle and allow it to idle for about five seconds
and then open the throttle to the full throttle position. If, at this point, the engine puffs out
excessive smoke and the vehicle does not accelerate smoothly and rapidly, it is likely that
the idle mixture is too rich. In this case, turn the low speed needle clockwise 45-90°. If the
engine speeds up momentarily and then cuts out abruptly when the throttle is opened, the
idle mixture is too lean. Correct this by turning the low speed needle counter clockwise 45-90°.
I N S TA L L T H E G L O W P L U G
Insert the included plug into the heatsink head carefully making sure that it is not cross
threaded before tightening firmly.
INSTALL THE INCLUDED EXHAUST GASKET.
needle adjustments should be made in increments no more than
When the engine is hot. NOTE: Low speed
O-Ring
45-90°, carefully checking the effect on throttle response with each small adjustment.
Rotate the retainer
• Carry out adjustments patiently under actual running conditions, until the engine responds
quickly and positively to the throttle inputs.
O-Ring
Tighten a further
120º - 180º
Retaining Screw
WARNING!
Glowplug
Exhaust
Gasket
Mixture adjustments (whether via the low speed needle, or the high speed needle),
cannot be made accurately under ‘no load’ conditions. These adjustments are not
recommended and carry’s the risk of seriously damaging the engine through over
Close
revving
and overheating.
until it stops. This is the fully closed
High Speed
position. Do not force it to turn further.
• With the optimum mixture control
position, light smoke is visible during high speed running
Needle
Open
and the engine RPM increases steadily during acceleration. Remember, if the engine is
One 0.1mm cylinder head shim and one 0.2mm head shim are installed in the engine when it
leaves the factory. An additional 0.1mm head shim is supplied with the engine. You may add
it for break in, whenElement
you are trying
achieve
increased run time at the expense of a loss in
glowstowhen
energized
Pliers
power, or if the glow plug tends to burn out due to high temperature and/or high humidity.
Approx.
I N S TA L L I N G T H E C A R B U R E T O R R E D U C E R
Choose the reducer according to the track conditions.
marked plac
0.5mm open
factory setting with the
restrictor removed.
operated with a lean fuel/air mixture, it will overheat and run unevenly. It is advisable to set
both the high speed needle and low speed needle slightly on the rich side of the best RPM
approx 0.5mm
setting as a safety measure.
• If the engine runs too fast with the throttle closed, the idle screw should be
turned counter-clockwise to reduce the throttle opening.
Carburetor Body
• 7mm Installed from the factory.
approx 1mm
• 8mm Included inelement
package.does not glow or is
burnt out.
I N S TA L L AT I O N O F T H E D U S T C A P S E T
If the engine is going to be stored,Glow
installPlug
the included
Igniter exhaust and carburetor dust caps to
R
s
T
High Speed Needle
prevent debris or other foreign matter from getting inside the engine.
Slide Valve
13
Idle Screw
Ball
Low Spe
22
5.5 turns o
rce it to turn further.
bottom of crankcase
to touch chassis
Needle
Open
approx 0.5mm
mm open F I N A L A D J U S T M E N T
ng with the
moved. • Final adjustment should be performed only after the break-in has been completed.
7
Carburetor Body
High Speed Needle
Crankshaft
inside edges of bearers
I NChamfer
S TA
L AT I O N O F
SlightL
taper
THE CARBURETOR
8
Ball Link The carburetor is only lightly installed into the intake boss when it leaves the factory. Follow
Near TDC
below to
complete
Rotate the
thesteps
low speed
needle
untilthe
theinstallation.
head
sticks out
0.5mm
from
the
ball
link
body.
1 Loosen the retainer screw, rotate
the carburetor into the position that best suits your
This is theapplication
standardand
position.
make sure that it is fully seated into the intake boss, compressing the
rubber gasket.
Cylinder Liner
Idle Screw
when
se the high speed
dle approximately
as needed. This
cedure will be repeated
eral times throughout
break-in process.
Slide Valve
Rotate the retainer
head is flush with the carburetor body. This is the
standard position.
Low Speed Needle
HIGH SPEED NEEDLE
Open
Close
More fuel
Less fuel
LOW SPEED NEEDLE
Crankshaft
Close
Open
Slight taper
2 Gently turn the retainer screw until it stops, then tighten it an additional 120° - 180°. Do
When
the engine
is hot. body.
O-Ring
LowPiston
Speed Needle
not over tighten the screw as this will
damage
the carburetor
Glowplug
Mid Needle
7
8
More fuel
Less fuel
Exhaust
2¾ turns out. Make adjustments
with the slide in the open position!
Carburetor Body
• Run the vehicle down the longest straight away at full throttle to observe the speed. Bring
the car back to the starting point, close the high speed needle 30° and repeat the run,
taking note of the improvement in performance.
hot.
Pliers
element does not glow or is
burnt out.
Glowplug
Exhaust
Close
Gasket
the high
speed needle
clockwise
NOTE: Be careful not Turn
to damage
the o-rings
when removing
the carburetor retainer from
the engine. Do not push
theitpart
in orThis
it could
damage
the o-rings.
until
stops.
is the
fully closed
• Continue with additional runs, gradually reducing the high speed needle setting with a goal
to achieve the highest straight line speed. Remember that
if the the
highengine
speed needle
When
isElement
cold.is shut
When
theenergized
engine is
glows
when
too far the engine will run lean and overheat, accompanied by visibly diminished exhaust
smoke. At this point the model will begin to lose speed. If this happens, throttle down
immediately, stop the vehicle and open the high speed needle 45-90°. Rotate the retainer
21
Tighten a further
120º - 180º
Glow Plug Igniter
Tighten a further
120º - 180º
O-Ring
Open
High Spee
Needle
approx 0.5mm
Approx. 0.5mm open
restrictor removed.
O-Ring
approx 1mm
Retaining Screw
High Speed Needle
14
marked pla
Needle
(Needle Valve)
Slide Boot
Mid Needle
Idle Screw
E N G I N E I N S TA L L AT I O N
Make sure that the vehicles engine mount surfaces are level, and on the same plane.
Poor installation may cause distortion of the crankcase, bearings, etc, resulting in erratic
Fuel
performance and permanent damage.
Ball Link
The recommended screws for securing the engine are Allen head, hexagon socket type 3mm
or 4-40 steel screws.
If existing holes in the engine mount do not align perfectly
the engine
Lowwith
Speed
Needlemounting lugs in
the crankcase, enlarge the holes in the lugs slightly with a needle file so that the screws are
(Metering Needle)
perfectly aligned with the
engine
mount
holes.
Thermo Insulator
Glow Plug Igniter
Deliver fuel to the carburetor
Fuel Tank Side
High speed needle position when
starting the engine.
Close the high speed
30º needle approximately
Needle
30° as needed. This
procedure will be repeated
several times throughout
the break-in process.
Idle Screw
HIGH SPEED NEEDLE
Open
Close
More fuel
Less fuel
NOTE: In the event that you replace any of the major engine components (piston,
sleeve, con rod, crankshaft or bearings), a brief break-in should be performed. If you
change to a fuel with higher nitro content, the engine will need to be re-tuned.
arked places
HOW TO STOP THE ENGINE
Do not allow
bottom of crankcase
to touch chassis
To stop the engine during normal operation, reduce the throttle to neutral, flip the car over
and push a blunt rubber object against the flywheel. DO NOT use your fingers!
WARNING!
Do not touch rotating parts, the engine, or the tuned pipe; these components get
extremely hot and contact with them may result in a serious burn or other injury.
• Do not allow the bottom of the crankcase to touch the chassis.
Ball Link
• If needed, chamfer the inside edges of the engine mounts for clearance.
Low Speed Needle
15 is flush with the carburetor body. This is the
head
standard position.
20
Close the high speed
needle approximately
procedure will be repeated
BREAK
ING
-IN
several
times
throughout
30º
Fuel
NOTE: It is incredibly important to set the throttle to the neutral
position before starting the engine. If the engine is allowed to run
with the throttle open too far under “no load” conditions (i.e. with
the driving wheels not in contact with the ground), the engine may
overheat and could be damaged.
H E AT C Y C L E B R E A K - I N M E T H O D
The purpose of this break in method is to heat cycle the engine without subjecting the
components to the stress that comes from breaking-in an engine that is overly rich and cold.
You want the engine to reach temperatures in the low 200°F (93ºC) range to reduce stress
on the components.
Pre-heat the engine to approximately 150°-160°F (66º-71°C) using an engine heater or heat
gun before starting for the first time and pre-heat the engine each time you start it during the
break-in process. Additionally, if you have trouble keeping the temperature in the 200°F range
while the engine is running, it may be beneficial to wrap the cooling head with an insulator
of some type, such as tin foil, or an old sock. This will help the engine retain heat and reach
200°F while it is tuned with the rich needle settings.
After a brief warm up period, disconnect the glow plug igniter and run the car on the track
for approximately 3 minutes at low speed. If the engine stalls, increase the amount of throttle
being applied slightly. If the engine stalls because it is excessively rich, close the needle valve
30° and try again. When the 3 minutes are up, shut the engine down, verify that the piston
is at the bottom of the stroke (Bottom Dead Center - BDC) and let it cool completely. Once
the engine has cooled down, close the needle valve 30°, start it again and run the car for
another 3 minutes, let it cool off with the piston at BDC. Repeat 3 more times for a total of 15
minutes (five 3 minute cycles), keeping an eye on the temperature and making sure it is in the
low 200° range. Now increase the run time to 4 minute intervals and close the needle valve
as needed to prevent the engine from running overly rich. Vary the RPM, gradually increasing
speed, and make sure that the temperature is in the low 200° F range. Run at 4 minute
intervals, five cycles, for a total of 20 minutes. After this the engine is ready for race tuning.
Fuel Tank Side
Needle
S TA R T I N G &
THE ENGINE
HIGH SPEE
Open
More fuel
W H I L E O P E R AT I N G
• DO NOT drive the model on a public street! This can cause serious accidents, personal
injuries and/or property damage.
• DO NOT operate near pedestrians or small children.
• DO NOT operate in small or confined areas.
• DO NOT operate in areas where loud noises can disturb others, such as residential areas.
WARNING
Before starting the engine, make sure all fasteners are tight, especially those at joints and
moving parts, such as the throttle arm. Loose fasteners are often the source of damaged
components and could lead to injury and/or property damage.
BREAKING-IN
The break-in procedure is performed to prepare the engine for running conditions (fuel,
RPM, engine temperature, etc). Excessively rich and prolonged low speed running should be
avoided. Running at low speeds and low temperatures for prolonged periods of time will have
a negative effect on the performance and lifespan of your engine.
PRESSURIZED FUEL SYSTEM
• The constant changes in vehicle attitude that occur in off-road conditions, combined
with the distance between the fuel tank and carburetor can negatively affect performance.
Because of this, it is recommended that only a muffler with a pressurized fuel feed system
be used.
• Never run your vehicle without installing the air filter. The dust and dirt that will be drawn
into the engine will cause permanent damage to the components.
NOTE: During the first few cycles, it is important that you use smooth throttle inputs
and do not “spike” the throttle to protect the bearings.
19
16
nder Liner
der Liner
120º - 180º
Glowplug
Exhaust
The following procedure is recommended for this engine
when the ProTek R/C P3,
Gasket
Crankshaft
PTK-2060 or PTK-2090 tuned pipe and fuel containing up to 30% nitromethane
arehigh
used.
Turn the
speed
Rotate the retainer
Pliers
O-Ring
marked places
Carburetor
Restrictor
Close
• Low
speed needle (metering needle) and mid needle (mixture control
valve) are
set at the(Venturi)
Carburetor
Restrictor
(Venturi)
clockwisebasic position (refer to P23).
needle
Tighten
element
does moves
not glow
or isa further
• Switch the transmitter on and
make
sure that
the linkage
correctly.
High
Speed
120º - 180º
burnt out.
Needle
High (66º-71°C)
Speed using an engine heater or heat
Open the engine to approximately 150°-160°F
• Fill the tank completely with fuel.
• Pre-heat
High Speed
Glowplug
Needle
gun before starting.
Glow Plug Igniter
Needle
Slide Boot
• Check the glow plug and verify that the filament glows bright red when the igniter is attached.
(Needle Valve)
Slide Boot
approx
0.5mmon the exhaust and
(Needle Valve)
• Plug
the stinger
Exhaust
turn the engine over with the starter
Close Idle Screw
Mid Needle
Pliers
Gasket
Approx. 0.5mm open
Needle
box to draw fuel into the engine.
Idle Screw
Turn the highMid
speed
needle
clockwise
(Mixture
Control
Valve)
(Throttle Stop
High Scre
spee
Control
Valve)
Deliver
fuel to the carburetor
(Throttle Stop Screw
until ittostops.(Mixture
This is the
fully
closed
•
Now
connect
the
glow
plug
igniter
starting
th
restrictor removed.
High
heat the plug and start the engine.
Nee
Carburetor
Open Body
Ball
Lin
the engine is cold.
If the engine does not start, or
O-Ring
Needle
Replace
plugiswhen
he engine is cold.
When
the the
engine
hot. the
Fuel Tank Side
O-Ring
stalls out
after
started, try
Rota
approx 1mm
Fuel
Highright
Speed
Needle
element does not glow or is
approxBall
0.5mm
the following:
Link
stick
Rotate the retainer
Ball Link
This
Pliers
Rotate the retainerburnt out.
Set the high speed
needle approximately
2.50.5mm
turns open
from the fully closed position. Do
Approx.
open
not force the high speed needle to turn beyond a lightly closed position.
Glow Plug Igniter
O-Ring
Tighten a further
removed.
O-Ring
Set the throttle opening a little widerrestrictor
than the factory
setting by adjusting the idle Low
screwSpeed Needle
Tighten
a further
Retaining Screw
Speed
The carburetor is set at the factory
as shown
120º
- 180º in the images below. Double check theRetaining
Low SpeedLow
Needle
(throttle stop screw).
Screw
120º - 180º
settings before you start the engine.
Slide (Metering
Valve 5.5Needle)
turns out.
(Metering Needle)
Thermo Insulator
Idle Screw
High
speed
approx 1mmThermo Insulator
• The high speed needle (needle
valve)fuel
is set
3-turns
open
fromneedle
the fullyposition when
High Speed Needle
Deliver
to approximately
the carburetor
elementDirt
does
not
glow
or
is
Low Speed Needle
closed position.
starting
the
engine.
and dust may lodge in
marked places
haust
Close
the
high
speed
Dirt
and
dust
may
lodge
in
marked
places
burnt
out.
aust
First rota
Close
30º needle approximately
sket
Close
LOW SPEED NEEDLE
HIGH SPEED NEEDLE
ket
head is fl
Needle
Glow
Plug
Igniter
30°
as
needed.
This
Fuel Tank Side
standard
until it stops. This
Fuelis the fully closed
Do
not
allow
Close
High Speed
Open
Close
procedure will be repeated Open
Do not allow
High Speed
bottom
of
crankcase
Needle
position. Do not force it to turn further. Open
bottom of crankcase
Needle
to touch chassis
Mid Needl
Open
the break-in process.• When the engine starts, warm it up using smooth throttle inputs,
to touch
chassis
increasing
the rpm to
2¾ Idle
turns Sc
out
• Idle gap is set approximately 0.5mm open.
High
speed
needle
position
when
medium
speed and back to a fast idle in the neutral position with the mixture set rich.
Deliver fuel to the
carburetor
More
fuelof the car offCarburetor
Less the
fuelengine.
fuelplug
approx 0.5mm
starting
LeaveMore
the glow
igniter
connected,
and fuel
keep theLess
wheels
the ground.Body
approx 0.5mm
the
high
speed
inside
edges
bearers
The slightly rich mixture will provideChamfer
adequateClose
lubrication
andofcooling
indicated by profuse
Pliers
30º inside
Chamfer
of bearers
Approx. 0.5mm open
needleedges
approximately
exhaust smoke.
Pliers
HIGH SPEED NEEDLE
Approx. 0.5mm open
Needle
Fuel Tank Side
Fuel
restrictor removed.
Close
procedure will be repeated Open
restrictor removed.
Carburetor Body
Ball Link
Carburetor Body
Ball Link
approx
1mm
High
Speed
Needle
• Theapprox
opening1mm
should be approximately 0.5mm with the restrictor removed.
Rotate
the
low
speed
needle until the head
Less fuel
More fuel
High Speed Needle
17
18
Crankshaft
Slight taper
•
light taper
Identify and note the flywheel position when the piston is at Bottom Dead Center (BDC).

321B Nitro Engine

Transcription

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