KAVAN FS400AR - Instruction manual

Introduction

Important: Before attempting to operate your engine, please read through this instruction manual to familiarize yourself with the controls and other features of the engine. Also, pay careful attention to the recommendations contained in the “Safety notes and warnings” chapter of this instruction manual.

Specifications

Displacement	12.8 cc x5 (0.781 cu. in. ×5)
Bore	26.5 mm (1 043 in.)
Stroke	23.2 mm ( 0.913 in.)
Power	5.55 kW/7,250 r.p.m.
Practical R.P.M	1,800-9,000 r.p.m.
Weight (w/Muffler)	2800 g. (6.17 Ibs.) incl. motor mount

Dimensions (mm)

	A	B	C	D	E	F	G	H
AP06A	24	10	45	M4	38.5	33
AP09A	30	11	58	M5	43.5	41
S15AII	31.5	11	62	M5	49.8	42.8
S32AII	38	15	74.9	1/4”–28	56.7	53.2
S36AII	38	15	74.9	1/4”–28	56.7	53.2
S40AII	44	17.5	84.3	1/4”–28	70.2	60.3
S46AII	44	17.5	85	1/4”–28	70	60
S52AII	44	17.5	85.8	1/4”–28	70.9	60.7
S61AII	52	25	97.8	5/16”–24	80.3	68.5
S91A	52	25	97.5	5/16”–24	84.7	67
108A	58	25	105.3	3/8”–24	90	73.7
180AR	68	36.5	133.7	3/8”–24	108	96.6
FS-30AR	36	14	64.7	1/4”–28	71	46.8
FS-52AR	44	17.5	80.6	1/4”–28	82.4	59.2
FS-70AR	50	21	89	5/16”–24	97.4	65.3
FS-80AR	50	21	90	5/16”–24	98.3	65.3
FS-91AR	52	25	90	5/16”–24	100	65.3
FS-120AR	58	25	106	5/16”–24	116.3	78.3
FS-180AR	58	25	111.8	3/8”–24	120	80.8
FT-160AR	80	68	120	5/16”–24	195.3	69.5	56.5	56.5
FS-400AR		Ø122	160.5	3/8”–24	Ø227	78

Safety notes and warnings

Important:

Remember that your engine is not a „toy“, but a highly efficient internal-combustion machine whose power is capable of harming you, or others, if it is misused.
Before attempting to operate your engine, please read through these instructions to familiarize yourself with the operations and features of this technical, fully operational model engine. Please read through the entire manual before operating this engine. Pay particular attention to the Safety Instructions and Warnings section of the manual.
Your new KAVAN engine will give you dependable performance and will be a source of satisfaction and pleasure if you follow these instructions as to the engine‘s proper and safe use. Do not let pleasure turn into injury and/ or tragedy! You alone are responsible for the safe operation of your engine, so act sensibly and with care at all times. This engine is a precision built machine whose power is capable of causing harm to you and others if abused, misused, or if you fail to observe proper safety precautions. As owner, you, alone, are responsible for the safe operation of your engine, so act with discretion and care at all times.

Always Remember:

Keep spectators, especially small children, who can be hurt when the engine is running at least 5-6 metres (20 feet) away from the operating engine. NOBODY should (including yourself) should be found in the plane of the rotating propeller!
Mount the engine securely in the plane, or on a proper engine test stand using high quality steel hex cap screws, washers and locknuts. Follow the mounting recommendations on the airplane‘s plan and/or instruction manual, or in the test stand described in the directions. DO NOT clamp this engine into a vice!
Use the correct size propeller and follow the recommended mounting procedures. Follow this instruction manual, the building plan/kit instruction manual; ask an experienced modeller or skilled model shop personnel if in doubts.
Install your propeller properly (looking from the cockpit of your model, the propeller of an engine installed in the nose rotates clockwise, looking from the front of the model it rotates counter clockwise). Use a proper wrench to tighten the propeller nut. Do NOT use pliers. Four stroke engines and large two stroke ones should use special safety locking propeller nuts.
Never touch, or allow any object to come into contact with, the rotating propeller and do not crouch over the engine when it is running.
Beware of the prop, protect your fingers. When hand cranking your engine, always us the „chicken stick“ (available in model hobby shops) or strong leather glove. Preferably, use an electric starter.
After starting the engine, carry out any needle-valve readjustments from a safe position behind the rotating propeller.
To stop your engine, adjust the throttle linkage so that the engine stops when the throttle stick and trim lever on the transmitter are fully retarded. Alternatively, the engine may be stopped by cutting off the fuel supply. Never try to stop the engine physically.
Discard any propeller which has become split, cracked, nicked or otherwise rendered unsafe. Never attempt to repair such a propeller: destroy it. Do not modify a propeller in any way. Also, check the tightness of all the screws and nuts regularly and frequently
If you have to carry the model to the take-off point with the engine running, be especially cautious. Keep the propeller pointed away from you and walk well clear of spectators.
Do not fly your model near or under power lines.

Safety Tips

The wearing of safety glasses is strongly recommended.
Do not start your engine in an area containing loose gravel or sand. The propeller may throw such material in your face and eyes and cause injury.
Take care that loose clothing (ties, shirt sleeves, scarves, etc.) do not come into contact with the propeller. Do not carry loose objects (such as pencils, screwdrivers, etc.) in a shirt pocket from where they could fall through the propeller arc.
Take care that the glow plug clip or battery leads do not come into contact with the propeller.
If you install a spinner, make sure that the slots for the propeller blades do not touch the blade roots and weaken them.

Warnings

Model engine fuel is poisonous. Do not allow it to come into contact with the eyes or mouth. Always store it in a clearly marked container and out of the reach of children.
Model engine fuel is also highly flammable. Keep it away from open flame, excessive heat, sources of sparks, or anything else which might ignite it. Do not smoke or allow anyone else to smoke, near to it.
Model engines generate considerable heat. Do not touch any part of your engine until it has cooled.
Never operate your engine in an enclosed space. Model engines, like automobile engines, exhaust deadly carbon-monoxide. Run your engine only in an open area.
Remember: Operating any model requires experience and constant attention to safety rules. Model airplanes, boats or cars have a lot of energy that can cause serious personal injury or significant property damage.

Always proceed with caution!!
If you are a beginner, ask for help and advice from an experienced modeller!
Before trying to start the engine for the first time, carefully read the instructions and safety rules!

Features

The FS 400AR is a 5 cylinder radial overhead valve four-stroke engine of 4.00 cubic inch, 63.98 cc total displacement. The FS 400AR has been designed to meet the needs of the modellers who enjoy the larger airplanes, like 1/4 scale, who demand the high standards of refinements that are not available in larger displacement two-stroke engines.

Engine parts

FS 400 Accessories

Radial Motor Mount
10 Leads for wiring Glow Plugs
5 Four-stroke Glow Plugs
Display Stand
Tool Kit
Mounting Screws
Needle Valve Extension Cable
Choke Valve Rod
Ground Wire 16 Gauge

Installation

The FS 400AR includes a strong one piece CNC machined aluminium radial type mount for easy and secure installation to the firewall of your aircraft. When installing the FS 400AR to the firewall of your aircraft, it is imperative that the firewall is strong, at least 15 mm thick and secure, and firmly attached to the structure of your aircraft.

Installation Procedures

Locate the centre of the firewall.
Place the engine on a sheet of paper, mount down. Using a sharp pencil, outline the outside radius of the motor mount.
Then mark the exact location of the mounting holes.
Take engine off sheet of paper, and find centre of outlined motor mount.
Tape sheet of paper, matching centre of mount to centre of firewall.
Drill mounting holes for 5 mm screws (M5 x 25) in proper locations.
Secure the engine to the firewall, using the supplied screws, nuts and washers, making sure that the „KAVAN“ nameplate on the front housing is facing up.

Needle-valve extension

The needle-valve supplied with your FS 400AR is designed to use an extension so that the needle valve may be adjusted from outside the airplane once the engine is enclosed within the fuselage. A flexible cable with knob on 1 end, approximately 1.6 mm in diameter, should be inserted into the needle valve‘s centre hole. Secure cable by tightening the set screw in the needle valve with the small Hex key included with your engine. On the outside end of cable, secure the included know with the set screw using the small hex key.

Note: Do not use an excessively long extension cable that is unsupported, as this may cause a vibration which might affect the needle valve setting and/or damage the needle valve thread. If you need to have a longer extension cable so that the needle valve can be adjusted from outside of the airplane, always provide a suitable support at the outer end. Additionally, be sure not to position the support for the needle valve extension near the exhaust pipe.

Note: The carburettor cannot be reversed in order to reverse the needle valve location.

Choke Valve

The choke valve operating lever can be located either on the left or right side by reversing the hexagon nut and cap screw.
Unscrew the cap screw while holding the hexagon nut with the included wrench supplied, and refit the lever to your required location.
If the supplied rod is too long, cut it to required length. An unnecessarily long rod may tend to vibrate. The rod should be as short as possible or should have its outer end supported.

Exhaust Pipe Adjustment

The direction of the exhaust pipes may be altered in accordance with individual installation requirements. The angle is easily adjusted by loosening the nut that secures the exhaust pipe to the cylinder head. Use the supplied wrench.

Carburettor Cleanliness

It is vitally important for all engines, including the FS 400, that the fuel entering the carburettor is pure and clean. For this reason, it is recommended that the fuel is passed through a filter when the tank is filled and that a good in-line filter is installed between the fuel tank and the carburettor.
Additionally, occasionally remove the needle valve holder from the carburettor and rinse out the locations shown in Figures 5 & 6 with methanol or fuel. Be careful not to lose the gasket when removing the needle valve holder from the carburettor.