O.S. engine GT120THU Maintenance Manual Download

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2-stroke gasoline engine for UAV

GT120THU

Maintenance manual

Ver.1.03

2020.OCT.26

O.S. ENGINES MFG. CO., LTD.

Summary of Contents for GT120THU

Page 1: ...2 stroke gasoline engine for UAV GT120THU Maintenance manual Ver 1 03 2020 OCT 26 O S ENGINES MFG CO LTD ...

Page 2: ...INSPECTION AFTER EVERY 50 HOURS OF OPERATING TIME 10 2 Inspection of the regulate rectifier 1 Adjustment of the tension of the generator belt 3 Inspection of the generator 4 Ignitor inspection 7 INSPECTION AFTER EVERY 100 HOUR OF OPERATING TIME 11 1 Disassembling the engine for inspection and replacement Inspection and maintenance of the cylinder blocks Inspection and maintenance of the pistons In...

Page 3: ...2 20 3 Replacing the fuel filter 4 Replacing the fuel tubes 5 8 EXPLODED VIEW 17 9 PARTS LIST 18 ...

Page 4: ...might cause it to ignite Do not smoke or allow anyone else to smoke near to it Carry out mixing of gasoline and oil outdoors or in a well ventilated place away from any source of fire Refill the fuel tank only after the engine is well cooled down or there is a danger of fire The engine generates considerable heat Do not touch any part of the engine until it has cooled down Never operate your engin...

Page 5: ...containing loose gravel or sand The propeller may throw such material in your face and eyes and cause injury If you have to carry the aircraft to runway with the engine running make the engine on idling Keep the propeller pointed away from you and others with keeping an eye on it Turn off the ignition module when you stop the engine or fully close the carburetor via the transmitter to shut off the...

Page 6: ...e air blow or there is a possibility for it to rotate beyond the limited and cause damages 18 In case you check rotation of a ball bearing by feeling with fingers hold the inner race and turn the outer race to check or vice versa 19 When you remove a ball bearing pressing the steel balls check and confirm smooth rotation with feeling of fingers Replace it with new one if you feel it rough 20 Apply...

Page 7: ...enance of the pistons iii inspection and maintenance of the piston rings iv inspection and maintenance of the piston pins v inspection and maintenance of the crankshaft and the connecting rods vi inspection and maintenance of the ball bearings vii inspection and maintenance of the carburetors viii inspection and maintenance of the generator ix inspection and maintenance of the starter motor x insp...

Page 8: ... if there are 3 Inspection of the fuel filter Filter Body A of the fuel filter is transparent to check for the dust in the filter Wash the filter following the processes below 2 7 Remove the tube cramps at the both ends of the filter Take out the fuel filter putting a piece of rug under the filter to catch and absorb the fuel that will run out of the tubes when they are disconnected Disassemble th...

Page 9: ...ug cap holding its body tight Do not pull the high tension cord or use a screw driver to remove the plug cap from the spark plug It may ruin the plug cap Check for tear and worn on the surface of the high tension cord In case the outer metal mesh is worn more than 1 2 of its thickness replace the whole ignition system The high tension cord cannot be replaced itself alone In case it is worn less th...

Page 10: ...le servo and the choke servo Turn on the operation system and move up and down the throttle stick and check if the throttle servo moves smoothly without strange noise Replace it if you recognize strange noise from the servo or unsmooth movement of it Turn on the radio control system check if the throttle servo horn and the choke servo horn are fixed tight Turn on the operation system and shake the...

Page 11: ... pointed with the arrow in Fig 4 Turn the generator to adjust the deflection within 0 5 1 0mm Fix the M5 screw after adjustment with fastening torque 5 4N m 2 Inspection of the regulate rectifier Start the engine and move the throttle up until the generator can generate the set voltage 3 000rpm when the set voltage is 12V 6 000rpm when the set voltage is 24V Measure the voltage of the output when ...

Page 12: ... be a new one but a used one ii Cut off a part of the spark plug body as shown in the picture Detach the both plug caps and remove the spark plugs Attach the special spark plug mentioned in to the plug cap Turn on the starter and check if there is a spark between the center electrode and the spark plug body which is cut short as shown in Fig 6 Replace the ignitor if there is no spark Note The spar...

Page 13: ...nspection and maintenance of the pistons i Remove the piston pin retainers circlips the piston pin wrist pin and the piston ring from the piston Do not use the used piston pin retainers when you assemble the piston again ii Wash the piston with gasoline or kerosene WARNING When you wash the part with gasoline or kerosene carry out the work only outdoors or in well ventilated area away from any sou...

Page 14: ...on buildup and remove the carbon buildup Do not file off the ring itself but only remove the carbon buildup iii Check the outer surface of the ring for heat mark or any scratches Replace the ring if there are damages on it Check the inner wall of the cylinder block for damage as well It is likely to have damages on it when the outer surface of the ring is damaged iv Check the bottom side of the pi...

Page 15: ...r ring to confirm that it turns smoothly Replace the ball bearing if it does not turn smoothly Ball bearings are important parts in the engine so replace immediately when you find something abnormal Inspection and maintenance of the carburetor Some parts cannot be assembled upside down left side right or inside out even they look the same Follow the instructions 16 19 in 3 Notification on inspecti...

Page 16: ...engine Check the generator including connectors lead wires for any damages If there are any damages replace the part ii Remove the driven pulley 3G16 and the generator adapter from the generator Measure the diameter shown in Fig 16 at 12mm from the shaft end with a blade micrometer In case the diameter is φ7 960 or less replace the shaft iii The generator shaft and the ball bearings of the generat...

Page 17: ...rosene carry out the work only outdoors or in well ventilated area away from any source of fire to prevent a fire Inspection and maintenance of the generator belt and pulley Remove the generator belt and check the following i worn notches ii missing notches iii cracking on the outer surface iv cracking between the notches v fabric exposed on the side of the belt vi oil adhering to the surface of t...

Page 18: ...17 20 7 EXPLODED VIEW ...

Page 19: ...ﾄ一式 CRANKSHAFT ASSY 13 4AA07020 ﾄﾞﾘﾌﾞﾝﾌﾟｰﾘ 3G16 DRIVEN PULLEY 3G16 13 1 79820406 ｾｯﾄｽｸﾘｭｰ M4X6 10 ｲﾘ SET SCREW M4X6 10 SET 締付トルク Fastening Torque 1 5N m 14 4AA07050 ﾍﾞﾙﾄ 3GT 255 10 BELT 3GT 255 10 15 4AA32000 ﾎﾞｰﾙﾍﾞｱﾘﾝｸﾞｼﾞｪﾈﾚｰﾀ BALL BEARING GENERATOR 16 54059001 ｼﾞｪﾈﾚｰﾀｱﾀﾞﾌﾟﾀ GENERATOR ADAPTER 17 79871515 ｷｬｯﾌﾟｽｸﾘｭｰ M5X15 10 ｲﾘ CAP SCREW M5X15 10 SET 締付トルク Fastening Torque 5 4N m 18 4AA07040 ｼﾞｪ...

Page 20: ...2 79871140 ｷｬｯﾌﾟｽｸﾘｭｰ M3X12 10 ｲﾘ CAP SCREW M3X12 10 SET 締付トルク Fastening Torque 1 1N m 43 4AA07290 ｻｰﾎﾞﾏｳﾝﾄ L SERVO MOUNT L 44 4AA07280 ｻｰﾎﾞﾏｳﾝﾄ S SERVO MOUNT S 45 4AA07300 ｻｰﾎﾞ BLA1HF SERVO BLA1HF 46 79871030 ｷｬｯﾌﾟｽｸﾘｭｰ M2 6X10 10 ｲﾘ CAP SCREW M2 6X12 10 SET 締付トルク Fastening Torque 0 18N m LOCTITE 222 使用 47 79872026 平ﾜｯｼｬ 2 6 10 ｲﾘ WASHER 2 6 10 SET 48 4AA07060 ﾘﾝｹｰｼﾞﾎﾞｰﾙ LINKAGE BALL 49 79850020...

Page 21: ...締付トルク Torque 4 0N m 70 4AB81000 ｷｬﾌﾞﾚﾀｰ HS 324A CARBURETOR HS 324A 71 4AB81410 ｽﾛｯﾄﾙｱｰﾑ THROTTLE LEVER 72 4AA83000 ｴｱｸﾘｰﾅｰｱﾀﾞﾌﾟﾀ AIR CLEANER ADAPTER 73 79871555 ｷｬｯﾌﾟｽｸﾘｭｰ M5X55 10 ｲﾘ CAP SCREW M5X55 10 SET 締付トルク Torque 5 4N m 74 4AA84000 ｴｱｸﾘｰﾅ PK 7E AIR CLEANER PK 7E 付属品 ACCESSORIES 78300000 ｶﾞｿﾘﾝ用燃料フィルター S GASOLINE FUEL FILTER S 70000001 ﾎｰｽｸﾘｯﾌﾟ φ6 5 ｲﾘ HOSE CLIP 6 5PCS SET オプション OPTION 75 4AA...

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