Hudy Ultimate Break-In Bench User manual
BREAK-IN BENCH
FOR ALL 1/8 & 1/10 NITRO ENGINES
INSTRUCTION MANUAL
2
CONTENTS
INTRODUCTION............................................................2
SAFETY FIRST.............................................................3
EXPLODED VIEW.........................................................4
EQUIPMENT REQUIRED FOR OPERATION.......................5
FACTORY PRE-ASSEMBLED..........................................7
ASSEMBLY..................................................................8
PREPARATION............................................................11
STARTING THE ENGINE...............................................13
BREAK-IN PROCESS...................................................15
TROUBLESHOOTING...................................................17
WARRANTY................................................................18
HUDY Engine Break-In Bench
The HUDY Engine Break-In Bench is the ultimate tool for
easy, safe, and professional break-in of your .12/.15/.21ci
engine (with 5mm extended crankshaft). It allows for a
controlled break-in process that reduces wear & tear
on engine components, ensuring increased performance,
reliability, and longevity.
Constructed of top-quality components of tough aluminium
and spring steel, the Engine Break-In Bench comes partially
assembled from the factory to get you running sooner.
The heavy-duty aluminum base plate with integrated
clamps provides quick, solid mounting on any workbench,
and a large protective shroud safely covers the spinning
propeller. Other features include a large-capacity 125cc
fuel tank, pre-assembled throttle linkage, universal engine
mounts, and special propeller.
Break in your engine like the pros!
3
SAFETY FIRST
The HUDY Engine Break-In Bench is NOT A TOY, it is a
precision-manufactured hardware tool; if used improperly
it can injure you or others nearby and/or cause damage to
property or your nitro engine. It is very important to pay
attention as indicated in this manual. Improper use of the
tool can be very dangerous.
You alone are responsible for operating this tool and your
nitro engine safely; act with discretion and pay special
attention at all times.
• Carefully read and fully understand the safety instructions
and engine operation instructions before you operate this
tool or your engine.
• Keep these manuals in a place so you know where they
are at all times.
• Follow the instructions carefully.
• Wear safety glasses, ear protectors, and gloves.
• DO NOT wear a necktie, loose sleeves, or other loose
clothes while using the unit. In case of long hair, wear
your hair under a hat.
• Before starting the engine, always check that the engine
is securely mounted.
• Keep clear of the propeller safety cover; never stick your
ngers or anything else through the safety cover.
• Use the unit outside or in a well-ventilated room.
• When running the engine indoor, make sure the exhaust
gasses are directed to outdoors. Stay away from the
exhaust gasses at all times.
• Start the engine only using the spinner driver and an
electric starting device (such as an electric drill).
• Avoid making engine adjustments while the engine is
running.
• Stop the engine by pinching the fuel line.
• Avoid touching the cylinder head or the exhaust pipe as
this may cause serious burns.
4
EXPLODED VIEW
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5
EQUIPMENT REQUIRED FOR OPERATION
The HUDY Engine Break-In Bench
is designed for use with all
.12/.15/.21ci nitro engines with
a 5mm extended crankshaft. The
tapered crankshaft cone that
was included with the engine
must be used.
When breaking in your engine, we
strongly recommend using the
same fuel that you plan to run in
your engine after break-in.
Normally, you should always run
your engine with an air lter.
However, an air lter is not
used during the break-in
process on the HUDY Engine
Break-In Bench.
Use a compatible, high-quality
exhaust system when breaking
in your engine. Be sure to use
all gaskets, springs, and other
required mounting hardware.
A glowplug starter is required
to ignite the glowplug for
starting. We recommend
using a high-quality, battery-
operated glowplug starter from
a reputable manufacturer.
A glowplug wrench is required
for removing/installing the
engine glowplug. We recommend
using a high-quality glowplug
wrench such as the #107581
HUDY Wrench-Glowplug /
Clutchnut.
6
A high-quality screwdriver
is required for adjusting the
carburetor. We recommend
using high-quality tools such as
those offered by HUDY.
High-quality Allen wrenches
(2.0mm and 2.5mm) are
required for assembling and
adjusting the HUDY Engine
Break-In Bench. We recommend
using high-quality tools such as
those offered by HUDY.
A crankshaft or piston locking
tool is strongly recommended
for preventing the crankshaft
from turning while installing and
tightening the propeller and
spinner. We recommend using
a locking tool from a reputable
manufacturer.
A 17mm wrench is required for
tightening the spinner on the
crankshaft. We recommend
using tools from reputable
manufacturers.
An electric drill is required to
spin the crankshaft to start
the engine. We recommend
using tools from reputable
manufacturers.
A temperature gauge is
useful to check the engine
temperature during the break-in
period.
7
A hairdryer or heat gun is
recommended to pre-heat the
engine prior to initial starting.
Self-adhesive foil tape is
recommended to cover the
engine head ns to prevent
overcooling during break-in.
FACTORY PRE-ASSEMBLED
The HUDY Engine Break-in Bench is pre-assembled at the
factory with the exception of the fuel tank and stands,
which must be installed before use. Attach the two plastic
support stands to the base plate using the included
at-head screws, then attach the fuel tank to the stands
using the two button head screws and rubber grommets.
A pair of pliers is required to
connect the throttle control
rod ball-joint to the carburetor.
We recommend using a pair
of needle-nose pliers from a
reputable manufacturer.
8
ASSEMBLY
1. Use a crankshaft or piston locking tool to prevent the
crankshaft from rotating. This may require the removal
of the crankcase rear plate or glowplug, respectively.
2. Slide the tapered ywheel cone onto the crankshaft.
3. Slide the propeller support plate onto the crankshaft.
The small raised ridge on the support plate goes
TOWARD the engine.
NOTE
ORIENTATION
NOTE
ORIENTATION
4. Slide the propeller onto the crankshaft. The smooth
edge of the propeller goes AWAY from the engine.
1. Remove the engine mounts from the base plate.
2. Attach the engine mounts to the engine using the
supplied M3x12 screws.
9
5. Thread the spinner onto the crankshaft, and tighten
with a 17mm wrench until tight.
6. Remove the crankshaft or piston locking tool (if used),
and replace the crankcase rear cover or glowplug
as appropriate.
7. Rotate the propeller to ensure it does not touch hit
the carb. If it touches the carb, remove the propeller,
add a shim behind the tapered cone, then re-install the
propeller.
1. Re-attach the engine mounts to the base plate, and
align the engine so the spinner is centered in the safety
cover. Tighten the bottom engine mount screws.the
engine position if necessary.
2. Attach the throttle control ball-joint to the carburetor.
10
3. Attach the exhaust pipe header to the engine exhaust
outlet; remember to use the proper gasket and springs.
Attach the pipe to the exhaust mounting wire and
tighten the setscrew securely.
4. Use a length of silicone fuel tubing to connect the fuel
tank to the carburetor inlet.
5. Use a length of silicone fuel tubing to connect the
exhaust pipe pressure tting to the fuel tank cap
pressure tting.
11
1. Place the bench on a solid platform (such as a work
table).
2. Slide each clamp upward until the pad touches the
underside of the table.
3. Tighten each pad securely.
PREPARATION
This section describes steps to take to prepare for engine
break-in.
Cuts in the fuel tubing will cause fuel leaks and make the
engine run too lean.
Since an air lter is not used during break-in on the bench,
any swirling dirt that gets into the carb may cause internal
engine damage.
There will be a lot of vibration when the engine is running.
Loose parts may become undone and cause personal injury
or damage to the engine. The engine should be tightly
attached to the engine mounts, and the engine mounts
tightly attached to the bench.
Make sure the carburetor cinch bolt is tight. A loose
carburetor may twist during engine operation, possibly
coming into contact with the spinning propeller. This may
cause personal injury or severe engine damage.
12
Make sure the throttle control mechanism is not too loose;
it should remain in its set position and not move freely.
Cover most of the engine head lower ns with self-
adhesive foil tape to prevent over-cooling during break-in.
The propeller directs a lot of cooling air across the engine
head; if the head remains too cold during break-in, this will
cause premature engine wear (just like an overly rich carb
setting during break-in).
Before starting the engine for the rst time, pre-heat the
engine head with a hairdryer or heat gun. This expands
the sleeve slightly, allows for easier starting, and prevents
excessive wear that a cold engine is subject to.
If you use a heat gun, use the lower temperature setting;
DO NOT use the higher temperature range as this may be
too hot. Do not direct the hairdryer or heat gun at O-rings
or other rubber or plastic parts.
13
STARTING THE ENGINE
This section describes how to properly start the engine on
the bench, and some safety precautions to take.
Running an engine with a propeller represents great
hazards. Always follow these safety precautions:
• Wear safety glasses, ear protectors and gloves.
• Don’t wear a tie, loose sleeves or other loose textile
while using the unit. In case of long hair, wear your hair
under a hat.
• Before starting the engine, always check the mounting of
the unit to the platform.
• ONLY use the unit outside or in a well-ventilated room.
• When running the engine indoor, make sure the exhaust
gases are directed to outdoors. Stay away from exhaust
gases at all times.
• Start the engine only using the spinner driver and an
electric starting device.
• Keep clear of the safety guard. NEVER stick your ngers
or anything else through the safety guard.
• Only make engine adjustments when the engine is not
running. Stop the engine by fully closing the carburetor.
• Avoid touching the cylinder head or the exhaust pipe as
this may cause serious burns
1. Securely mount the spinner driver in an electric drill,
and then put the rubber insert in the end of the spinner
driver. Set the drill to “reverse” direction (counter-
clockwise). A minimum of 2000RPM is required to start
the engine.
14
2. Fill the fuel tank.
3.Open the carburetor to 2mm using the throttle linkage.
4. Apply the glowplug starter to the glowplug, press the
spinner driver rmly against the spinner, and turn on the
drill (running CCW or “reverse”).
5. If the engine does not re up within 5sec, try doing the
following:
a. Check the fuel line to see if fuel is reaching the
carburetor. If fuel is not reaching the carburetor,
remove the glowplug starter, cover the exhaust
tailpipe and “dry-start“ the engine for 2sec. This will
build up extra pressure in the pipe and in the pressure
line to the fuel tank, causing the fuel to be pushed to
the carburetor. Apply the glowplug starter and try to
start the engine again.
b. Unscrew the glowplug to check if the engine is getting
any fuel. The glowplug should be slightly wet. If it is
still dry, open the main needle another ½ turn richer
(CCW). Reinstall the glowplug and try to start the
engine again.
15
c. The glowplug may also be too wet. Start the engine
without the glowplug in place, for about 5sec, with
the throttle fully open. Fuel will escape through the
glowplug hole in the cylinder head; place a towel over
the cylinder head while doing this to avoid getting
fuel over everything. Close the main needle ¼ turn.
Reinstall the glowplug and try to start the engine
again.
6. Once the engine has started, apply a bit of throttle and
allow the engine to warm up to operating temperature
(approximately 1min). This is an important routine that
you should always follow. The internal parts need to
receive lubrication and reach operating temperature.
BREAK-IN PROCESS
A nitro-powered engine requires careful break-in the rst
time the engine is used to allow the internal parts to
achieve proper operating clearances. This is especially true
of the piston/cylinder, crankshaft, and conrod. Pay close
attention during the initial break-in period; this process is
very important to achieve the best engine performance,
reliability, and lifespan.
The proper way to break in this nitro engine is to “heat
cycle“ the engine with short periods of running followed
by cooling down periods. Heat cycling allows the engine
to heat up to its optimum operating temperature,
allowing the components to “wear in” to each other
properly. During the running time, the engines should
be run only SLIGHTLY rich; overly-rich mixtures and cold
temperature break-in will lead to premature wear and
failure of the piston & sleeve and other engine components.
After installing the engine in the HUDY Engine Break-In
Bench and performing the break-in preparation, then break
in the engine by performing the following steps:
1. Keep the carburetor factory settings; do not adjust.
2. Start the engine and allow it to reach operating
temperature.
16
3. For the rst tank of fuel, run the engine at 25%
throttle.
The engine should run very slightly rich. If not, stop the
engine by closing the throttle completely and pinching
the fuel line with needle-nose pliers… being careful
not to damage the fuel line or get the pliers near the
spinning propeller. Adjust the main needle and nish the
remainder of the rst 10min break-in period.
4. Stop the engine and allow it to cool down completely.
Make sure the piston does not get stuck at TDC (top
dead center – at the top of the cylinder); rotate the
propeller by hand to move the piston to the bottom of
its stroke (BDC – bottom dead center).
5. Run the engine through several more heat cycles:
a) more tanks of fuel at 50% throttle (the engine
should still be running slightly rich), with complete
cool-downs.
b) more tank of fuel at 70% throttle (the engine should
be running crisply now), then complete cool-down.
During the nal tank of fuel, vary the throttle and
check the crispness of the engine response.
Throughout the break-in process, regularly check the
engine temperature to ensure it stays within the range
of 200–250°F. This is only a guideline and may vary from
engine to engine. The engine temperature and RPM should
be steady and not vary signicantly; any signicant changes
indicate that the carb settings require attention.
17
TROUBLESHOOTING
• Make sure your glowplug starter is fully charged and
is properly connected to the glowplug. If the starter is
fully charged, replace the glowplug.
• Verify that fuel is getting to the carburetor. Remove the
fuel line from the carburetor and see if there is fuel in
it.
• Check your carb settings. It may be necessary to
adjust the carb settings if the weather has signicantly
changed since the last time you ran the engine.
• The engine’s compression may be low due to wear.
This will make the engine difcult to start when it is
warm, and may tend to stall when running and when the
throttle is closed suddenly.
• The engine may be ooded and hydraulically locked.
• Check for binding at the engine ywheel. If you are not
able to turn the engine by hand, the engine could be
ooded, the piston may be stuck at the top of the
cylinder (TDC), or there could be internal engine damage.
(Note: During engine break-in, it is normal for the engine
to be extremely tight and hard to turn when the piston
reaches the top of the cylinder.)
• The factory default break-in settings (on the carburetor)
may be too rich for your location, weather conditions,
or fuel brand. Extremes in temperature, humidity,
barometric pressure, and altitude cannot always be
accounted for by the factory default settings. These
symptoms may occur when air density is very low (such
as in high mountains or extremely cold temperatures.
Under these conditions, lean the main needle valve slightly
(1/8 turn CW), and check if there is any improvement in
starting and idling. Only lean the main needle until the
engine runs and idles reliably, then continue the break-in
process.
• Different fuel brands/types – in combination with extreme
weather conditions – can also make the factory default
break-in settings too rich and cause these symptoms.
Try leaning the fuel mixture slightly (1/8 turn CW),
and check if there is any improvement in starting and
idling.
18
• Engine performance depends on the carb settings and
how they compensate for the weather & atmospheric
conditions. Before suspecting other issues, richen the
main needle by at least ¼ turn CCW, then retune the
engine.
• Try installing a new glowplug.
• If carb settings are proper, ensure the fuel is fresh.
Old fuel, or fuel that has been left uncapped for a long
period, may cause sluggish performance.
• A brand new engine that has not had a lot of break-in
will typically have a very tight t between the piston
and the top of the cylinder (known as “pinch), since the
cylinder has a tapered t. The t should not be so tight
that then engine cannot be started. If the piston gets
stuck at TDC, use a pair of pliers to grasp the ywheel
from the bottom of the engine. Rotate the ywheel CCW
(viewed from the front of the engine) until the ywheel
turns; you should feel the piston become unstuck from
the top of the cylinder.
WARRANTY
This product is guaranteed to be free from defects in
materials and workmanship for a period of 1 year from the
date of purchase when returned for service accompanied
by proof of purchase (register receipt, credit card invoice,
etc.).
Damage caused by customer disassembly/assembly,
modication of components, improper use, or any use of
the product for other than its specic intended use will
automatically void this warranty.
19
NOTES
HUDY, Pred Polom 762, 91101 Trencin, Slovakia, EuropeHUDY, Pred Polom 762, 91101 Trencin, Slovakia, Europe
team@hudy.net
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