USER MANUAL rex-HR91-ENG-reva09-03-09x
Contents
1. WHEN RICH idle will be lower loosing RPM without throttle valve movement sound will be inconstant also when disconnecting the glow plug driver the engine will loose RPM and eventually stop In this condition close turn clockwise the Low Speed Needle by a turn and retest To practice and understand clearly the effects of Low Speed needle adjustments we advise with a running engine to carefully turn the Low Speed Needle in both directions and listen to the different engine sounds Hover Mixture check and set while Heli is hovering The Low Speed Needle Valve also manage the Hover position and the transit of the throttle valve from Idle to Max opening i e full throttle then if the Idle Mixture is set up according to the above stated method the Hovering Mixture will very close to optimum if not we recommend for a perfect mixture to check the hover mixture before pass to Max Speed Mixture set If the engine sound is inconsistent and crackly while hovering and smoke will reduce during the hovering flight which means that the Hover Mixture is lean please land and carefully open turn counter clockwise the Low Speed Needle by 1 8 turn and retest If the engine sound is inconsistent cuffing and smoke will increase during the hovering flight that means that the Hover Mixture is rich please land and carefully close turn clockwise the Low Speed Needle by 1 8 turn and retest To check the Hover mixture before passing to high speed2. in period 5 full tanks will be enough during break in fly pay attention not to run at max RPM but set it to 80 90 of target RPM Do not use special break in fuel mixtures or mix with Castor oil standard Heli fuel mix will be perfect Set the high speed needle to a rich setting respect its optimum setting and fly gently maneuvers without loading the engine The gentler the first flight is the more powerful the engine will become After break in period is possible set RPM at desired target point and start to lean the high speed needle setting to get the engine towards max performance amp NOVAROSSI WORLD S R L Via Europa 20 a 25040 Monticelli Brusati BS Italy Tel 39 030 6850316 Fax 39 030 6850314 Web www novarossi com E mail info novarossi it eesti Codice fiscale Partite IVA 02812810980 5 2 FUEL MIXTURE SET Rich Lean Practical advises for ease fuel mixture set Low Speed Needle set wile Heli in landing position With an running engine and a correct mechanical idle set up and mixture settings then the idle RPM and the engine stroke rhythm will be regular and will not affected by disconnecting the glow plug driver WHEN LEAN idle will be higher taking RPM without throttle valve movement sound will be constant but in case of auto engine stop it will be difficult to restart the engine immediately In this condition open turn counter clockwise the Low Speed Needle by a 1 4 turn and retest
3. mixture settings we suggest holding the hover position for few minutes then land and use a digital thermometer check crankcase rear cover and engine head temperature without giving your engine time to cool down Crankcase rear cover advised temperatures are 40 45 C 104 113 F and the engine cooling head 100 120 C 212 248F High Speed Needle set while Heli is flying With the Low and Hover Mixture set up correct you can set up the High Speed Mixture Testing engine max speed can be dangerous we recommend doing the two test typology according the experience of the pilot During a standard flight add progressively pitch to maximum then reduce suddenly pitch to avoid that the Heli is losing control or if you are comfortable practice fast vertical climb If the High speed needle mixture is correct the climb will be progressive and engine sound consistent without stroke interruption and smoke will stay constant WHEN LEAN Climb will fast but the engine sound s inconstant and crackly and smoke will reduce progressively during the climb In this condition land and open turn counter clockwise the High Speed Needle by 2 two clicks and retest WHEN RICH Climb will slow the engine sounds like it is 4 stroking with smoke increase during climb In this condition land and close turn clockwise the High Speed Needle by 2 two clicks and retest 5 3 3D FLY FUEL MIXTURE SET To define fuel mixture to use during 3D maneuvers we recomm
4. Heli use New 2 needle carburetor Low Speed High Speed Low Speed needle valve designed to manage hovering status Double O Ring seal between carburetor and crankcase 2 0 MAIN GEAR RATIO TRANSMISSION CAUTION REX Heli engines are designed to be used in high quality RC Heli mechanics and with correct class size correspondence REX Heli engine should be used with a main rotor gear ratio of approx 8 4 2 1 MAIN ROTOR RPM SETTING In order to optimize the REX Heli engine we recommend using a RPM limiter or better Governor We advise to set Head speed target point as value equal or just higher to the rapport between Max Torque Engine RPM Heli Main rotor gear ratio 3 0 ENGINE SET UP REX engines are designed to run with Heli glow fuel mix with min Nitro percentage of 10 and a max of 30 For the heavy duty flyer we recommend to use 30 Nitro which will optimize power and efficiency The fuel oil must be of low viscosity and have a percentage between 18 and 22 USER MANUAL MOTORE REX R91HR 3D HELI Doc User Manual REX91 Rev01 ENG Pag 1of 2 Tested and advised Heli Mix Fuel Novarossi HRK Cool Power Wild Cat Power Master Rapicon Power Mix Jet Different Nitro percentages will affect the engine timing therefore the amount of compression rings MUST set according to the Nitro percentage The Factory setting is 0 3 mm set for approx 15 20 Nitro percentage For a Nitro percentage of 10 we recommend to set t
5. NOVAROSSI WORLD S R L Via Europa 20 a 25040 Monticelli Brusati BS Italy Tel 39 030 6850316 Fax 39 030 6850314 Web www novarossi com E mail info novarossi it Codice fiscale Partite IVA 02812810980 Specifiche Tecniche R91HR 3D Bore 2 7 0 mm Stroke 24 80 mm Displacement 15 0 cmq Weight 586g RPM Min 800 RPM Max 19000 RPM Max Torque 16000 Iller RI SY aint ly High Speed Needle Radiator Low Speed Needle Fig 2 3 1 0 FEATURES The R91HR 3D engine is a brand new REX engine produced by NOVAROSSI WORLD S r l specially designed for 3D Heli use Power Torque curve fast RPM recover ease of mixture tuning and fatigue resistance are some of NOVAROSSI goals for the R9Q1HR 3D NOVAROSSI s Micro engine experience in cooperation with 3D Heli pilots developed a new Heli engine platform which pilots will enjoy at all skill levels 1 1 TECHNICAL SPECIFICATIONS New Piston design with an L shaped piston ring Piston Rod and Crankshaft with special mechanical features will reduce vibration and improve power Engine Head is CNC machined of two separate Aluminum alloy parts to improve thermal exchange Built in cavities for Carb Smart thermal sensor assembly New Crankcase design with special heat sink to improve thermal exchange New sleeve with eight 8 transfer ports and an exhaust with booster ports designed for 3D
6. ad 243 blue to assure the mechanical assembly 6 Check that carburetor barrel will operate for all 90 degree rotation and assure that throttle servo don t bind eventually ADJ it from radio travel ADJ 7 If the carburetor is removed pay attention during re assembly to insert it completely into the crankcase before lock the special screw After the first few flights please re check the carburetor screw lock 8 Install the glow plug according of the outside temperature Hot Medium Cold We recommend to use NOVAROSSTI s heli type glow plug don t use plane car or turbo glow plugs Advised Glow plugs are NOVAROSSI HR3 or HR4 4 0 STANDARD NEEDLE VALVE ADJUSTMENT Before start REX engines we recommend to read the information below to understand the carburetor needle settings REX engine carburetors come with factory set up so that this engine will start up easily then according the following variables ambient temperature and fuel will be probably necessary to re adjust the needle settings To help the needle adjustment head needles has a 2 5 mm HEX socket insert than using a STD Heli Hex tip screwdriver Fig 2 and 3 show the position of needles valve Low speed and High speed R57HR 3D Standard Carburetor setting Low Speed Needle Valve Open turn counter clockwise completely and then close it 4 turns High Speed Needle Valve Close turn clockwise it completely and then open it 2 turns NOTE NOVAROSSI carburetors a
7. end adjusting the mixture as stated above then check engine responsiveness when making fast stop and go s eventually ADJ the Low Speed needles carefully this procedure is similar to the set up of the mixture during hovering We advise to check the engine temperature often to avoid possible overheating The 3D series REX Engines have dedicated carb smart temperature sensor mounting hole To ease this mixture temperature management there is an in flight adjustable High Speed needle available NOVAROSSI p n 11900 6 0 FIRST FLY RECOMMENDED CHECK UP After the first flight we recommend to check the assembly of the following mechanical components 1 Tuned Pipe and header 2 Engine mount 3 Carburetor and throttle actuator 4 Glow Plug This procedure is advised only after the first flight and after component replacement or re assembly After first 10 flights we recommend to check the engine compression color condition of glow plug coil and the surface color around the coil When the compression is correct the coil will be silver as a new glow plug and the surface around the coil will have a brown copper color IF the compression is too high the glow plug coil will be silver but deformed and the surface around the coil will have silver color also IF the compression is low the glow plug coil will have a brown copper color and surface color around the coil will also have a dark brown color In case of wrong compr
8. ession settings we advise to check and adjust the amount of compression rings as explained in point 3 0 USER MANUAL HELI ENGINE REX R91HR 3D Doc User Manual REX91 Rev01 ENG Pag 2 of 2 7 0 TROUBLE SHOOTING If engine does not start or while running it stops suddenly please follow the advice below Following information at point 4 0 adjust needle valve as factory standard set Check if the glow plug driver is working replace it if necessary Check if fuel reaches the carburetor Check muffler pressure line holes can reduce pressure in the tank Adjust carburetor throttle lever position with transmitter stick in idle position the carburetor throttle valve is marked and should be positioned between fully closed and half open positions Switch on the radio system TX and RX don t connect the glow plug at this moment adjust the throttle position to full throttle and without glow plug driver connected using the starter run the engine for 5 10 second Than reduce the throttle position to idle connect the glow plug driver and your engine now is ready to start If the engine starts but stops suddenly increase the idle position operating from Tx throttle trim than retest If the engine is unable to start try to start it while closing fuel line near the carburetor If engine will starts with closed fuel line that means that the Low speed mixture is to rich in this condition close turn counter clockwise Low Speed Need
9. he compression rings to 0 2 mm and 0 4 mm total for 30 Nitro In need of changing the amount of compression rings use calibrated tools to check sizes work in a well light and clean environment and use the appropriate tools for this job When removing mounting the cooling head amp combustion chamber use the X order to loosen tighten the head screws Max torque to tighten the head screws is 2 5Nm do NOT over tight 3 1 ENGINE ASSEMBLY 1 Remove the crankcase rear back plate and using the special crankshaft holder tool NOVAROSSI part nr 70000 and hold crankshaft than per instruction of your heli kit install all parts such as clutch engine support and eventually start shaft Re assembly crankcase rear back plate and install your prepared engine into you heli frame 2 Make a right fuel line connection between tank and carburetor and between muffler and tank See example showed at Fig 4 Use specific Heli glow fuel line Advised NOVAROSSI part nr 35000 3 Carburetor and engine internals are sensitive to dirt in the fuel a fuel filter strongly advised 4 In order to reduce exhaust pressure gas temperature it is recommend installing a special radiator between muffler and tank Advised NOVAROSSI part nr 36000 5 Install throttle links and ADJ the throttle lever according to your heli needs to ease the mechanical adjustment we advise to use double HEX key to operate directly over the two barrel s nuts We recommend adding Lock thre
10. le by 1 4 turn and retest If the engine continues to be unable to start also with a closed fuel line then the Low speed mixture is too lean then open turn clockwise the Low Speed Needle by 1 4 turn and retest For further support you can visit the heli section of the Novarossi forums 8 0 SAFETY Many indications referring the right and safe use of the engine have been supplied in this workbook In this chapter we resume and complete them with other ones pointing out that the user is the only responsible for a safe conduct towards him self third parties animals and locations Being the engine part of a complex model which can potentially be dangerous it must be started up after having checked the model responses to the most important safety requirements 8 1 Everybody who can be injured by the model above all children must be kept away from the operator and from the model Spectators must always respect safety distances 8 2 The engine must be carefully fixed on the Heli Attention to the heat developed and the noise must be reduced using an appropriate tuned pipe You cannot start the engine a tuned pipe 8 3 The pipe and size of the blades must be suitable to the engine and to the model and must be of high quality Ask to the manufacturer of the models for detailed information and for installation ways 8 4 When you start the engine you must keep your body away from moving parts propellers gears wheels Touch the engine
11. only when Heli is landed holding firmly main rotor head and pay attention to parts with high temperatures such as the tuned pipe or the engine cooling head 8 5 All adjustments must be made using instruments screw drivers of correct dimensions 8 6 You must use a radio control and components of high quality this allows a perfect control of the engine acceleration and stop 8 7 Main rotor can be dangerous for many reasons such as on dusty soil propeller can blow dust and other objects in the eyes ties pens and other hanging objects can be attracted by the main rotor Even when the engine is stopped the helicopter rotor blades will turn for some time be careful 8 8 Keep fuel in a suitable and secure place 8 9 Carefully follow the safety rules given by different federations basing on category and use of model 9 0 CONCLUSION AND WARRANTY INFORMATION Novarossi World S r l will always try to use the best materials available to maintain the high quality and reliability of products We reserve the right to make changes without prior notice No warranty is given for Ball bearings Rod Sleeve piston and piston ring Crankshaft These components are moving engine parts and are exposed to wear Novarossi advise to maintain the engine internal parts in good condition replace if required In any case Novarossi cannot replace under warranty any engines or spare parts which after examination present manipulation of one of
12. re different from other available carburetors please follow upper instruction for ease setting and run in Carburetor setting advises Low Speed Needle Valve Rotate of turn a time during first adjustment than reduce the amount of needle rotation when coming closer to the correct setting High Speed Needle Valve Needle as a knurl head with clicks use it for reference operate of 3 or 5 clicks during first adjustment than reduce to one click coming closer the correct setting NOTE Low Speed and High Speed needle valves all work the same way Turning the needles clockwise closing will lean the fuel mixture and counter clockwise opening will richen the fuel mixture 5 0 FIRST ENGINE START UP AND SETTING Full up the heli tank closing line connection to the carburetor when done open fuel line connection to the carburetor Switch on radio system TX and RX don t connect the glow plug at this moment open from transmitter the throttle to the max speed position and without glow plug connection using the starter run the engine for 5 10 second Then close the throttle to the idle position connect the glow plug driver The engine now is ready to start This operation is recommend each time that engine will start up because the engine will start better and is lubricated Wile the engine starts adjust the throttle idle position operating with throttle trim or sub trim 5 1 ENGINE BREAK IN REX engines don t require a long break
13. the defaults above listed
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