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SKY 100-3 eng97
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1. SKY 100 User s Manual INDEX e 1 1 General warnings 1 2 Recommendations for the prevention of accidents e 2 1 Fuel 2 2 Running in e 2 3 Starting the engine e 3 1 Engine illustration e 3 2 Technical specifications e 3 3 Assembly of secondary components e 3 3 1 Special assembly instructions 3 3 2 Radiator 3 3 3 Muffler 3 3 4 Clutch 3 3 5 Starter 3 3 6 Rods and silent block 3 3 Silencer 3 3 8 Laminar bundle 3 3 9 Carburetor Cleaning Topping up liquids Adjustment Schedules and general recommendations e Requirements e Warranty Certificate 1 0 INTRODUCTION Thank you for purchasing a SKY100 engine developed and manufactured by SKY ENGINES WE ADVISE YOU TO CAREFULLY READ THIS MANUAL AND FOLLOW ALL THE MAINTENANCE INSTRUCTIONS GIVEN BELOW BEFORE USING THE ENGINE IN ORDER TO AVOID SEVERELY DAMAGING IT lf you require more information have queries or need to purchase spare parts please contact us byphone or e mail using the contact details printed on the cover We thank you for the attention wish you the best of fun and hope you are satisfied with yourpurchase Best regards Sky Engines s r l 1 1 GENERAL WARNINGS e SKY ENGINES shall not be directly or indirectly liable for the use of the engine especially if it is altered or tampered with by third parties e MAINTENANCE IS ESSENTIAL to avoid severely damaging the engine Therefore we advise you to CAREFULLY read Chapter 4 0 o
2. 1 REGULARLY INSPECT THE OIL LEVEL IN THE REDUCTION GEAR USING THE BUSHING ON THE FRONT SIDE 2 REPLACE THE WHOLE AMOUNT OF OIL AFTER APPROXIMATELY 100 HOURS OR IF YOU NOTICE THAT THE BUSHING IS PLACED INPERFECT VERTICAL POSITION 3 OPEN THE BUSHING AND INSERT 30 ml OF SYNTHETIC OIL OF GEARS Our technician recommend Bardahl SAE 75W 90 synthetic oil 4 3 ADJUSTMENTS The only adjustment that may enhance the operation of the engine is the regulation of the maximum and minimum level of the carburetor STANDARD ADJUSTMENT OPEN INDICATED SCREW BY A QUARTER OF REVOLUTION 3 4 4 SCHEDULES AND GENERAL RECOMMENDATIONS This paragraph lists a few recommendations that have been defined as a result of the tests carried out by our mechanics and on the basis of the feedback provided by customers We kindly ask you to report anomalies or maintenance procedures that are not described in this manual using the space provided in chapter 7 0 You can also use this space for feedback or queries to which we will be glad to answer some components of SKY100 are subject to wear Therefore to avoid damaging engine or affecting its operation we recommend you perform the operations described below at the specified intervals Before flying always check the safety devices of the muffler silencer and filter box verify that the steel cables are in place and correctly connected Replace the sparking plug after approximately 80
3. TO MAKE UNAUTHORIZED CHANGES THAT COULD DAMAGE THE ENGINES NOT COVERED BY WARRANTY e Unauthorized changes could make the engine highly unstable e Replace the components of the engine with original SKY ENGINES spare parts to guarantee a reliable operation 3 3 2 RADIATOR Assemble the silent blocks on the radiator then fit the whole assembly on the radiator rods gt gt Threads tubes 1 2 and 3 in the corresponding inlets a b c of the Carefully check the position of the fittings radiators on the tube clamps straps and make sure that they have been applied as shown in the photo 3 3 3 MUFFLER Apply sealant glue to the manifold of the muffler then position the muffler on the manifold close to the glue layer firmly pushing the pipe union on the manifold a Firmly tighten the fittings of the muffler with the silent blocks of the engine frame using two M8 TCCE screws and washers Insert the springs between the hooks of the muffler and those of the manifold Thread the steel cable between the hooks that keep the springs in place insert it between the springs and fix them on the side of the manifold as shown in the photo 3 3 4 CLUTCH After reduction s unmounting unscrew the center nut by a pneumatic or manual wrench in the second case block crankshaft rotation Remove the washer Unscrew the nut of pad s pin by an 8 mm wrench Remove the pin Squeeze
4. VOLUME 102 CC MAX MAX POWER MAXPOWER 18 18HP 10200RPM 18HP 10200RPM 10200 RPM BORE 2 BORE 5 00000000000 mm CARBURETOR WALBRO WG8 amp TOTAL WEIGHT WITH LIQUIDS 13 Kg CHT 170 MAX TEMPERATURE MAXIMUM MAXIMUM WEIGHT OF USER 90 100 Kg CLUTCH DRY CENTRIFUGAL WARNINGS The general recommendations included in the Technical Specifications sections are very important to prevent severe damage to the engine and for the safety of users ALWAYS FOLLOW THE INSTRUCTIONS GIVEN ABOVE AND DO NOT EXCEED THE MAXIMUM VALUES SPECIFIED SKY ENGINES SHALL NOT BE LIABLE FOR INJURIES TO PEOPLE OR DAMAGES TO PROPERTY ARISING FROM THE FAILURE TO FOLLOW THE AFOREMENTIONED TECHNICAL SPECIFICATIONS 3 3 ASSEMBLY OF SECONDARY COMPONENTS 3 3 1 SPECIAL ASSEMBLY INSTRUCTIONS Engine SKY100 is more complex than other models and a greater experience is therefore required to assemble its components and specifically its internal ones As the engine is liquid cooled the assembly of the components that use the radiator s coolant requires the implementation of specific tasks that only a skilled mechanics is able to carry out Therefore all users who are not specifically skilled or trained to perform these operations SHOULD NOT TOUCH THE ENGINE EXCEPT FOR ORDINARY MAINTENANCE OPERATIONS WHICH SHOULD BE PERFORMED FOLLOWING THE DETAILED INSTRUCTIONS SPECIFIED BELOW DO NOT IMPROVISE OR ATTEMPT
5. pads to better extract it In the new pad unscrew completely the dowel and put the spring in his site greater diameter into body clutch Squeeze the pad as in unmounting case to center holes could be useful to use a little tube and put in the pin Use a medium force screw blocker replace the washer and tighten the nut it is normal that washer could move a little Put some medium force screw blocker on the registration dowel and tighten it Adjust dowel to have a little between pad and clutch when you try to open it the same for the other Mount clutch on crankshaft without forcing a lot Reassemble washer and nut lf you need to tune up clutch it is possible to adjust dowels by a wrench in holes without unmounting clutch NOTE Tightening dowels you have a smaller opening of pads releasing them you have a faster contact of pads on bell housing 3 3 5 STARTER Remove the cover from the manual starter loosening the screws a crossed pattern fi Loosen the wire reel and remove it from the cover Then loosen the handle and remove the wire reel from the spring Remove the worn wire from the side hole of the wire reel and replace it with a new one Knot the end of the wire and firmly insert the knot into the hole To replace the spring insert the end side into the cover duct as shown in the photo Attention When inserting the s
6. that it may accidentally switch off e For detailed information on the warranty terms see Chapter 6 0 in this manual WARNING This is not a certified engine lt is intended to be used for experimental and not certified engines 1 2 RECOMMENDATIONS FOR THE PREVENTION OF ACCIDENTS As the use of this engine can be very dangerous it is important to adopt all the necessary precautions both during before and after the flight in order to avoid severe accidents We advise you to follow the general precautions illustrated below in order to avoid damages or accidents e As the engine does not solve all flying problems it is important to avoid risky moves One of the most common mistakes 15 flying above areas that do not allow you to land at very low heights It is always important not to underestimate the possibility of faults and the need of having to make an emergency landing e Always take into account that the lack of thrust of the engine may affect the flight Stability Pay particular attention to swinging movements caused by the change of trimming that cause falls of 4 5 meters As the engine could switch off at any time it is important to make sure you are able to perform an emergency landing if required e ALWAYS avoid flying above water for your own safety and in order not to damage the engine 2 0 DIRECTIONS FOR USE The directions for use provided in this manual refer to models available a
7. R FURTHER INFORMATION PLEASE CONTACT US DIRECTLY BY PHONE OR E MAIL OR VISIT www skyengines com ALWAYS REMEMBER TO RETURN THE COMPLETED AND SIGNED WARRANTY CERTIFICATE TO ACTIVATE THE WARRANTY DATE SIGNATURE OF DISTRIBUTOR 28 C da San Rustico snc 63038 Ripatransone AP enGmnNnNes www skyengines com SHP 6 2 WARRANTY CERTIFICATE ENGINE MODE CAND GOLOR DISTRIBUTOR NAME OF PW RG AS Brera ne OF THIS CERTIFICATE GUARANTEES THE ENGINE FOR ONE YEAR STARTING FROM THE DATE OF PURCHASE FOR DETAILED INFORMATION ON THE TERMS CAREFULLY READ THE MANUAL FOR FURTHER INFORMATION PLEASE CONTACT US DIRECTLY BY PHONE OR E MAIL OR VISIT www skyengines com ALWAYS REMEMBER TO RETURN THE COMPLETED AND SIGNED WARRANTY CERTIFICATE TO ACTIVATE THE WARRANTY DATE SIGNATURE OF DISTRIBUTOR 28 C da San Rustico snc 63038 Ripatransone AP enGmnNnNes www skyengines com SHP 6 2 WARRANTY CERTIFICATE ENGINE MODE CAND GOLOR DISTRIBUTOR NAME OF PW RG AS Brera ne OF THIS CERTIFICATE GUARANTEES THE ENGINE FOR ONE YEAR STARTING FROM THE DATE OF PURCHASE FOR DETAILED INFORMATION ON THE TERMS CAREFULLY READ THE MANUAL FOR FU
8. RTHER INFORMATION PLEASE CONTACT US DIRECTLY BY PHONE OR E MAIL OR VISIT www skyengines com ALWAYS REMEMBER TO RETURN THE COMPLETED AND SIGNED WARRANTY CERTIFICATE TO ACTIVATE THE WARRANTY DATE SIGNATURE OF DISTRIBUTOR C da San Rustico snc 63038 Ripatransone AP 2 www skyengines com
9. escribed in the chapter above with a frequency of at least 50 hours of flight for an optimum operation of the muffler 4 2 TOPPING UP LIQUIDS The only liquids that need replacing are RADIATOR COOLAN THE LEVEL OF THE RADIATOR COOLANT MUST BE INSPECTED APPROXIMATELY AFTER 10 HOURS OF FLIGHT BY PERFORMING THE FOLLOWING OPERATIONS 1 Loosen the RADIATOR CAP 2 Verify that the liquid inside the radiator reaches the side nut next to the cap If the liquid level is below the indicator top up the radiator coolant as specified above 4 When replacing the whole amount of coolant always remember not to exceed the amount of 700 600 ml directly in the radiator 100 ml in the recovery tank ATTENTION COOLANT MUST ALWAYS BE TOPPED UP WHEN THE ENGINE IS COLD WHEN PERFORMING THIS OPERATION ALWAYS REMEMBER TO POUR THE LIQUID INTO THE RADIATOR AND NOT INTO THE SMALL CONTAINER AS THE LATTER IS DESIGNED TO BE USED TO COLLECT THE COOLANT IN EXCESS NOT TO FILL THE RADIATOR THE LIQUID IN EXCESS MAY EXIT FROM THE SMALL TANK IF LEAKS ARE VISIBLE ALWAYS THOROUGHLY CHECK THE SMALL TANK AND VERIFY THAT THE COOLANT DOES NOT EXCEED THE RECOMMENDED LEVEL THE SMALL TANK MUST BE FILLED UP TO THE INDICATOR WITH THE BLACK MAX WORD SITUATED ON THE EXTERNAL SIDE AS SHOWN IN THE PHOTO ALWAYS REMEMBER NOT TO FILL THE SMALL TANK ABOVE THE MAXIMUM LEVEL AS THIS COULD CAUSE LEAKS REDUCTION GEAR OIL
10. f this manual and thoroughly follow all the instructions For information on damaged spare parts see paragraph 3 3 which illustrates the assembly procedures for all the secondary components that tend to deteriorate in time e SKY ENGINES shall not be liable for damages caused by an inaccurate maintenance or incorrect assembly except for the replacement of components covered by the warranty e The engine has a maximum capacity of 90 100 Kg which means that it is able to transport a person with a maximum body weight within these parameters The use of the engine to transport heavier weights may cause problems to the trimming e It is advisable to perform all the inspections required in order to verify that the engine is safe and in good working order before flying e Technical alterations made by the user though permitted are full responsibility of the user Spare parts used for said alterations shall not be covered by warranty e Alterations carried out by the user or the removal of original spare parts jeopardize the safety of the engine e SKY ENGINES reserves the right to change models and or catalogues without warning and without any whatsoever obligation Further information is provided on Web site www skyengines com e Aircraft driven by this engine must be used in open spaces only and in areas reserved for these activities The user must be aware of all the hazards connected with the use of this engine and be aware of the fact
11. ges seizure caused by the use of gasoline without added lubricant Damages caused by the use of parts not specifically designed by Sky Engines Damages caused by the use of the engine at speeds above those recommended by Sky Engines S r l Damages caused by the loss of components during a flight originating from the improper tightening of assembly disassembly parts which is responsibility of the owner Accidents injuries abuse or negligence caused by the owner or by any other person using the engine in his name Damages caused by the suction of foreign material Damages caused by maintenance carried out by incompetent mechanics or unskilled personnel 4 SPECIFIC INFORMATION This is not a certified engine Alterations carried out by the user or the removal of original spare parts may jeopardize the safety of the engine The user agrees to accept full liability and acknowledges that the engine may switch off during use FOR ADDITIONAL INFORMATION ON THE USE OF THIS ENGINE PLEASE CONTACT SKY ENGINES SRL DIRECTLY SHP 6 2 WARRANTY CERTIFICATE ENGINE MODE CAND GOLOR DISTRIBUTOR NAME OF PW RG AS Brera ne OF THIS CERTIFICATE GUARANTEES THE ENGINE FOR ONE YEAR STARTING FROM THE DATE OF PURCHASE FOR DETAILED INFORMATION ON THE TERMS CAREFULLY READ THE MANUAL FO
12. hours of flight Inspect the silent blocks that support the radiator every 50 hours and replace them after approximately 100 hours of flight The same applies to the silent blocks of the crosspiece and muffler which have to be replaced after 100 hours of flight Inspect the blocks of the clutch after approximately 50 hours of EFFECTIVE flight For information on how to disassemble them see the section on the disassembly of secondary components in Chapter 3 0 e the increase the wearing out of the blocks of the clutch an exagerated number of departures decrease the effective hours of flight in this case we recommend especially to the beginner who are making exercises of departures to check constantly the wear of the different component of the clutch Replace the membranes of the carburetor after approximately 100 hours of flight Inspect the laminar bundle under the radiator every 50 hours of flight Carefully inspect the conditions of the blades because they could damage or break the engine if damaged Inspect the bank bearings approximately every 150 hours Regularly inspect the teeth of the flywheel CHECK THE LEVEL OF COOLANT INSIDE THE RADIATOR EVERY 10 HOURS OF FLIGHT USING THE CAP SITUATED ON THE TOP OF THE RADIATOR NOT THE ONE IN THE DISCHARGE CONTAINER Y Our technicians recommend the use of Arexons Glitech 4100 Coolant 5 0 SPARE PARTS The manufacturer always recommends the use of original SKY ENGINES part
13. pring always make sure that the tip of the spring is facing the channel from which the wire projects Delicately tighten the spring on the cover holding it with one hand 9 Thoroughly lubricate the area in contact with the spring Insert the wire reel and turn the spring by one revolution Loosen the worn teeth of the flywheel Install the new teeth following the procedure described in points 1 2 and 3 3 3 6 RODS AND SILENT BLOCK Install the silent blocks with the Teflon plate on the rod supports Install the silent blocks on the rods Install the tank as shown in the photo slightly tightening the nut until the tip of the screw is visible Install the rods on the silent blocks Install the radiator on the silent blocks 3 3 7 SILENCER Loosen small bolts that join the manifold to the base of the maffler remove the pipe while maintaining in place the manifold muffler remove the old glass wool couple the new glass wool fold the glass wool in its original configuration reinsert the pipe and tighten the manifold as described above 3 3 8 LAMINAR BUNDLE Apply a minimum amount of Sili Motoron the 44 mouth of the laminar bundle distribute it 4 consistently with a finger and verify that there are no traces of material inside the bundle Insert the Teflon plate and the laminar bundle Repeat thi
14. rvals of time Do not keep the accelerator in the same position for several seconds in this case it is preferable to open and close the accelerator without increasing the elevation in order not to force the engine Use the engine for 10 minutes at a time then allow it to cool Repeat the same operations every time you check the engine THE BREAK IN PERIOD CAN BE CONSIDERED COMPLETED AFTER 3 HOURS OF FLIGHT OR THE USE OF 10 LITERS OF FUEL 2 3 STARTING THE ENGINE SKY100 engine 15 started by a manual starter It must strongly pull the rope and avoid to flooding the engine WARNINGS The exhaust gases of the engine contain carbon monoxide which can cause death DO NOT START THE ENGINE INDOORS ALWAYS VERIFY THAT THIS OPERATION IS PERFORMED OUTDOORS IN ADEQUATELY VENTILATED AREAS If the engine is cold always wait Always start the engine after it has a few minutes after start up to been completely assembled as the lack of heat the engine and accelerate some components could cause severe at regular intervals to avoid damage damaging it e Always handle the propeller with utmost care at it may reach very high speeds to the point of becoming hardly visible Always maintain a safety distance 3 1 FIGURE OF THE ENGINE 4 LAMINAR BUNDLE 5 014 5 MUFFLER SEAL 5 017 8 MUFFLER MAINFOLD SK036 9 REDUCTION GEAR 5 015 016 3 2 TECHNICAL SPECIFICATION TYPE SINGLE CYLINDER 2 STAGE ENGINE WITH LIQUID COOLING SWEPT
15. s only The catalog of spare parts is available on Web site www skyengines it Spare parts can be ordered by contacting us directly by phone or e mail or through local distributors For information on how to replace components covered by warranty see the following chapter 6 0 WARRANTY 6 1 REQUIREMENTS The warranty is valid for 12 months from the date of sale or from the date in which the product has been sold by the distributor Specific requirements are listed below 2 THE WARRANTY APPLIES TO All spare parts and labor except transportation charges that shall have to be paid by the customer provided that the product has been used and serviced according to instructions To order spare parts Send the order by e mail or fax remembering to quote the serial number printed on the side of the engine guard Always attach a photo of the faulty spare part clearly highlighting the damage and describing in detail the problem If the product has not been purchased directly from us please contact your distributor first 3 THE WARRANTY SHALL NOT APPLY TO Failures faults caused by an improper use or negligence Engine modifications not specifically authorized and approved by Sky Engines S r l Ordinary wear of components parts and spare parts Damages caused by the failure to perform to perform a regular maintenance Damages caused by the use of the engine without a propeller Damages caused by corrosion Dama
16. s operation for all surfaces Install the Walbro plate above the laminar bundle Install the ring and the Walbro carburettor on the small plate using M 6 x 50 screws 3 3 9 CARBURETOR Loosen the Walbro and replace membranes 1 and 2 screws 4 0 MAINTENANCE THIS CHAPTER CONTAINS VERY IMPORTANT INFORMATION INORDER ENHANCE THE LIFE OF YOUR ENGINE AND PREVENTING PROBLEMS CAUSED BY WEAR IT IS ESSENTIAL TO CAREFULLY READ ALL THE WARNINGS AND DATA ON SCHEDULES AND FOLLOW ALL THE INSTRUCTIONS PROVIDED IT IS USEFUL TO REMEMBER THAT DAMAGE ORIGINATING FROM AN INSUFFICIENT MAINTENANCE ARE NOT COVERED BY THE WARRANTY 4 1 CLEANING SKY100 engines do not require specific cleaning operations However when performing this operation always remember not to use corrosive solvents on the external or internal parts of the engine ALWAYS KEEP THE INTERNAL PART OF THE ENGINE CLEAN TO PREVENT RESIDUALS FROM ENTERING THE INTERIOR OF THE CYLINDER OR WORST STILL THE GUARD AND CAUSING THE SEIZURE OF THE ENGINE When using a filter box always remember to disassemble it and wash the internal filter with water and a degreasing detergent after approximately 100 hours of flight Cleaning the muffler does not improve the performance of the engine but only the quality and quantity of exhaust emissions Customers who prefer not to hear so much noise while flying should carry out the maintenance operations d
17. t the time of print Although the manufacturer is not obliged to provide updates on changes users may request specific information on the upgrade of single products For more information visit Web site www skyengines com 2 1 FUEL WARNINGS FUEL IS EXTREMELY FLAMMABLE AND EXPLOSIVE ALWAYS PERFORM REFUELING OPERATIONS OUTDOORS IN AN ADEQUATELY VENTILATED AREA AND WHEN THE ENGINE IS NOT RUNNING DO NOT SMOKE CLOSE TO FUEL AND DO NOT STORE IT INAREAS WHERE COULD BE EXPOSED TO SPARKS OR FREE FLAMES KEEP THE FUEL OUT OF THE REACH OF CHILDREN SKY100 is a 2 stage engine that employs a mixture of fuel and oil Always remember that a correct carburetion and fuel mixing are essential to prevent the seizure of pistons fitted on 2 stage engines which are not covered by warranty ATTENTION MIX FUEL AND OIL WITH A 3 RATIO USING PREMIUM QUALITY SYNTHETIC OIL FOR 2 STAGE ENGINES ATTENTION Always check the amount and presence of NEVER MIX DIFFERENT TYPES OF ol OILS as THE LACK OR EXCESSIVE Only use100 BARDAHL KTS syntheti COULD DAMAGE THE ENGINE a synthetic INTERVAL OF OIL PERCENTAGE TIME BREAK IN 3 SUBSEQUENT PERIOD 2 5 2 2 RUNNING IN A good breaking in ensures a long life of the engine and enhances the performance of its components Use the engine very carefully during the first 3 hours of flight Do not use the engine at maximum power for extended inte
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