Zenoah G26 Air Users Manual 6135_Zenoah Engine
Zenoah Zenoah_Engine_Manual
G26231MARINE to the manual 85e12101-a0e6-4b7e-ad07-3744c2c0ac40
2015-02-03
: Zenoah Zenoah-G26-Air-Users-Manual-474621 zenoah-g26-air-users-manual-474621 zenoah pdf
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® ENGINE INSTRUCTION MANUAL 4 3 5 2 7 1 6 G26 Air G26/231Marine G26/G231 Heli G38 G62 GT80 Twin G45 1 2 3 4 5 6 7 Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Mounting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Starting the Engine-Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 Starting the Engine-Heli & Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6 Engine Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Servicing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Troubleshooting Guide for Gasoline Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 Propeller Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Exploded Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 G26/G231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 G38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 G45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17 G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18 GT80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19 Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20 Non-Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Registration Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21 2 Very Important FAILURE TO READ AND FOLLOW THESE INSTRUCTIONS BEFORE YOU PROCEED MAY RESULT IN ENGINE DAMAGE AND THE VOIDING OF YOUR WARRANTY! Introduction Congratulations on purchasing a Zenoah® engine. Cared for properly, these high-quality, finely crafted engines will offer many years of reliability. This instruction manual has been developed to ensure optimum performance from the Zenoah engine you have purchased. It’s important that the instructions are read thoroughly prior to mounting and running the engine. Safety Instructions This manual describes the engine’s features and functions. For specific information on mounting, see the instruction manual included with the model airplane, helicopter or boat in which you intend to install the engine. This model engine will give you considerable pleasure, satisfaction and performance if you strictly follow these safety instructions and take heed of the warnings as to the engine’s safe and proper use. This engine has more than enough power to cause harm if misused or if the safety precautions are not observed. Always 1. Use genuine parts for replacement. 7. Use a thickly padded glove when hand starting the engine. 8. Make all carburetor adjustments from behind the propeller. 9. To stop the engine, the black lead wire from the coil should be grounded to the engine body, or use the throttle linkage to shut off the air by closing the throttle valve completely. DO NOT USE HANDS, FINGERS OR ANY OTHER PART OF THE BODY TO STOP THE PROPELLER. DO NOT THROW ANY OBJECT INTO A PROPELLER TO STOP IT! 10. Ensure that all spectators, especially children, are at least 20 feet away when you start running the engine. 2. Check the propeller, rotor (helicopter) or screw propeller (boat) prior to each time the engine is used. If nicked, scratched, cracked or damaged in any way, replace it with a new one. 11. Make sure your fuel is kept in a safe place well away from sparks, heat or anything that could ignite the fuel. 3. Use the correct size and pitch of propeller for your engine; refer to the propeller chart in this manual. 1. Use safety glasses or goggles when starting and running your engine. 4. It is extremely important to balance the propeller prior to installation of the engine. Failure to do so may cause damage to the Zenoah engine and/or the airframe. Securely tighten the propeller nut against the washer and propeller. 2. Do not run the engine in the vicinity of loose gravel or sand. The propeller may throw such materials into your eyes. The engine could also ingest these harmful materials. 5. Inspect the tightness of the propeller nut prior to each flight. 6. Keep your face and body away from the path of the propeller blades when starting or running your engine. Recommendations 3. Avoid loose clothing when operating your model engine, as it could become entangled in the propeller, creating the possibility of bodily harm. All loose objects (screwdrivers, pencils, nickel cadmium glow drivers, etc.) should be removed from your pockets so that they do not fall into the propeller. 3 Safety Instructions (continued) Caution Disassembly 1. Model engines get very hot while running. Do not attempt to handle them until they have cooled. The Zenoah engine can be disassembled or reassembled without any specific difficulties. Refer to the Engine Maintenance Section for specific instructions on these procedures. If you need service to your Zenoah engine, please send it to the authorized service center at the following address: 2. Always run your model engines in a well-ventilated area. Similar to automotive engines, model engines produce harmful carbon monoxide fumes. 3. Never modify the flywheel. 4. Check the flywheel. If it’s damaged, replace it with a new one. 5. When mixing the fuel or operating the engine, do so in a well-ventilated area 6. Remember that model engines produce a substantial amount of power, more than enough to seriously injure people and/or do considerable damage to property. Always use common sense, skill and constant observance of safety precautions. ® Horizon Hobby, Inc. Attention: Zenoah Service 4105 Fieldstone Road Champaign, IL 61822 Phone: (217) 355-9511 Engine Parts Identification It’s important to be able to identify the parts of your Zenoah engines. Attached you will find an exploded view of Zenoah engines, as well as a chart including part numbers and descriptions. This will assist you in easily and rapidly identifying the respective parts of your Zenoah engine. Support Equipment The following items are not included with your Zenoah engine but are necessary for operation. Fuel—Mix gasoline and 2-stroke oil at a mixing ratio of 25-40:1. Note: Be sure to use a gasoline-resistant fuel tubing (do not use any silicone rubber tube). Never use any alcohol fuel or alcohol-added fuel as this will damage the rubber part of the carburetor. Propeller—Refer to the Propeller Selection Chart located on Page 8 to determine the best initial propeller for your particular application. Manual or Electric Starter—For manual starts, a chicken stick is highly recommended. Never use your fingers to start any model engine as you could be injured. If you must hand-start a gasoline engine, be sure to protect your hand with a heavily padded glove. There are a variety of heavy-duty electric starters on the market that can be used. 4 Zenoah Oil ZEN20001 Zenoah Start Kit ZEN20002 Mounting the Engine Make sure the engine is mounted on the aircraft using aircraft grade plywood that’s at least 6mm in thickness for the G26 engine, and 10mm in thickness for the G38 through GT80 twin, or a mount of equivalent strength. Make sure it’s firmly mounted with 4 bolts. 1. Be sure to set flat washers or a metal plate on the reverse side of the mount to prevent the bolts from sinking into the mount. Periodically check the engine mount for loose bolts. 2. Since the engine is equipped with a floatless carburetor with a diaphragm pump, the direction of the cylinder and position of the fuel tank can be freely selected. 3. If the engine is mounted on a shock (rubber) mount placed between the engine and the firewall for anti-vibration, check the hardness of the rubber, making sure it’s not too soft, in order to avoid excessive vibration during engine operating rpms. Note carefully if the engine is vibrating at idle, as excessive vibration can result in erratic engine operation due to overflow at the carburetor. 4. It is suggested that the bolts for the muffler be coated with threadlock when mounting the muffler to the engine. Operation Break-In Coil No specific break-in is required. The engine is gradually broken-in as it is used, and the output power increases gradually as the engine breaks in. Starting the Engine—Aircraft Before attempting to start the engine, be sure to read through all the steps for starting the engine as outlined below: Zenoah engines are equipped with the ultra compact C.D.I. type flywheel magneto ignition system and should be started according to the following procedure: Note: The magneto system is timed in such a way that when the compression stroke starts (refer to Figure 1-A) sparks are never produced on the spark plug, no matter how fast the propeller is flipped. The correct starting procedure is to quickly flip the propeller when the edge of the magnet on the rotor is approaching the coil (Figure 1-B). This means that the propeller should be quickly flipped at about 90 degrees in crank angle before the compression stroke is about to start. Magnet Fig 1-A Fig 1-B 1. Make sure the spark (glow) plug(s) are installed and tightened. Check the condition of the plug cap for cracks or breaks. 2. Be sure the propeller is properly secured. 3. Make sure the fuel tank line(s) are properly connected. The main line should be connected to the carburetor spray bar. 4. Be certain the mufflers are installed properly. 5. Fill the fuel tank. 6. Choke the engine and turn the propeller through a few times until the fuel appears at the carburetor. 7. Set the throttle valve at the idle position or at the position slightly open from idle. 5 Operation (continued) 8. Quickly flip the propeller in a counterclockwise direction according to the procedure described in the note above. 9. The engine should start after a few flips of the propeller. body, or the throttle valve should be closed completely. Installation of a “stop” or “kill” switch is recommended. Red Lead Black Lead 10. Be sure to open the choke when the initial firing of the engine is heard. 11. When the choke is opened, be sure to close the throttle valve to a position near the idle position before the next flipping of the propeller is attempted. CAUTION: If the engine is started when the throttle is wide open, a great thrusting force will be generated, which can be very dangerous. 12. If you do not use a chicken stick to start the engine, be sure to wear a thick glove when flipping the propeller and use all fingers, except the thumb, for the flipping operation. 13. Do not over-rev the engine. These engines are designed to develop maximum output with the standard muffler and the recommended propeller size. Please refer to the propeller chart on page 10 to confirm the proper propeller for the applicable Zenoah engine. ® Starting the Engine— Helicopter and Boat Kill Switch Engine Body Ground Refer to the example shown in the following diagram. Carburetor Adjustment The carburetor is provided with three adjustment screws, which are factory set to the best (approximate) positions. They may need minor adjustment, depending upon the temperature, humidity, atmospheric pressure (altitude), etc., of the area where the engine is being used. High-Speed Needle Low-Speed Needle 1. Fill the tank with fuel. 2. Push the priming bulb located on the carburetor until fuel appears in the priming bulb (for helicopter). 3. Choke the engine and open the throttle valve approximately 1/3–1/2 of the full open position. 4. Quickly pull the starter cord until the initial firing of the engine is heard. 5. When the initial firing is heard, open the choke, set the throttle valve at the idle position or at the position slightly open from the idle position and quickly pull the starter cord a few more times until the engine starts. 6. For helicopter operation, you should adjust the rotorpitch to obtain a 9,000 to 10,000 rpm of the engine at full throttle operation. Stopping the Engine The ability to shut down the engine in an emergency is extremely important. For stopping the engine, the black lead wire from the coil should be grounded to the engine 6 Idle Screw 1. Start the engine without making any adjustments. 2. Make adjustments only when the engine shows signs of inefficient operation. 3. Standard settings of each needle is as follows: a. Low-Speed Needle: 11/8 plus/minus 1/4 b. High-Speed Needle: 13/8 plus/minus 1/4 Idle Screw: Turning this screw clockwise increases the idling rpm. Turning it counterclockwise decreases the idling rpm. Low-Speed Needle: This is the fuel adjust screw (not the air screw). Turning this needle clockwise makes the gas mixture leaner, and turning it counterclockwise makes it richer. Operation (continued) High-Speed Needle: Turning this needle clockwise makes the gas mixture leaner, and turning it counterclockwise makes it richer. Set this needle at a position which is 1/4 open from the maximum rpm position while the aircraft is on the ground. When the engine has just started and is not warm enough, there may be insufficient acceleration and the engine may die. Be sure to allow the engine to warm up at idle for a few minutes before conducting normal operation. Note: Do not tighten the high and low speed needles too tightly. Engine Care and Maintenance Recommendations • Engine oil To extend the life of your Zenoah® engine, the following is recommended: • Washing gasoline 1. Use a Zenoah quality 2-stroke oil mixed at 32 to 1. • Scraper 2. Use the recommended spark plugs. • Cloth 3. Use the proper propeller size and balance the propeller prior to use. The engine can be disassembled or reassembled without any specific difficulties, but note the following: 4. Always adjust the engine to a slightly rich setting. For disassembling, the special tools shown in the parts list are required (stopper, puller assembly), in addition to general tools. Be sure to use a new gasket when the crankcase and cylinder have been disassembled. 5. For long-term storage, make sure there is no fuel left in the tank or the engine. Remove the spark plug(s) and apply several drops of high-quality oil (e.g., Marvel Air Tool Oil) to the top of the engine and into the spark plug hole. Rotate the crankshaft several times. Store the engine in the box it came in or on the airplane with the nose down in order to keep oil in the bearings. Servicing the Engine Required Tools • Brush Note: Because the crankshaft is of the assembly type, do not disassemble, hit or twist its end. Disassembly 1. Dismount the engine from the model. • Regular screwdriver 2. Remove the carburetor and insulator carefully without damaging the gasket. • Phillips screwdriver 3. Remove the muffler. • Hexagonal wrench (4mm/5/32") 4. Remove the spark plug and ignition module. • Open wrench (19mm/3/4") 5. Remove the propeller hub. • Plastic hammer 6. Remove the rotor (flywheel). If it cannot be detached, use a plastic hammer and tap the part lightly. • Thickness gauge • Threadlock (Blue Threadlock Z-42 or equivalent) a. Screw the stopper in place of the spark plug, then turn the rotor counterclockwise until the piston touches the stopper. Take care, as it can cause damage to the piston or connecting rod if the stopper is not screwed in to the bottom. • Lithium grease b. Loosen and remove the rotor securing nut. • Tapered round rod • Liquid gasket (Permatex or equivalent) 7 Engine Care and Maintenance (continued) c. Remove the rotor by using the puller. Do not hit the crankshaft with the plastic hammer, as this can increase the runout of the shaft. 7. Remove the mounting plate. 8. Remove the four bolts from the crankcase. 9. Tap around the case fitting side gently with the plastic hammer and slowly separate the crankcase from the cylinder block. 10. Pull out the crankshaft with the piston, bearings, and other parts attached. 8. Put the piston in the cylinder, with the piston’s arrow facing in the exhaust port direction. Set the crankshaft to the cylinder block. Then, fit the oil seal to the cylinder block. The snap ring joint should be set vertically to the cylinder. 9. Fit the crankcase to the cylinder block and tighten the bolts. 11. Remove the Woodruff key from the crankshaft. 10. Check that the crankshaft can be smoothly turned by hand. 12. Remove the oil seal, snap ring and bearings. 11. Put back the Woodruff key. 13. Remove the circlip and pull out the piston pin. 12. Replace the rotor (flywheel), fitting it to the Woodruff key. Tighten the hub nut after having applied threadlock (Blue Threadlock Z-42 or equivalent) to the threads. 14. Remove the thrust washers and needle bearing from the smaller end of the connecting rod (G38). 15. Remove the piston ring. 16. Wash each part. Check for abrasion and damage, and replace any part that is defective. 13. Apply threadlock (Blue Threadlock Z-42) to the muffler bolts and mount the muffler. 14. Apply threadlock (Blue Threadlock Z-42) to the ignition module set screws and fix the coil temporarily. 2. Fit the piston ring to the piston. 15. Set the rotor (flywheel) so that the magnet is located on the opposite side of the module (G-38). Place a thickness gauge between the core of the module and rotor (flywheel) and adjust the clearance to 0.25 ^ 0.35 mm (0.01 ^ 0.014 in). Then tighten the set screws after having applied threadlock (Blue Threadlock Z-42) to them. 3. Mount the needle bearing and thrust washer (with its oil slot facing inside) to the smaller end of the connecting rod and apply engine oil (SAE #30). 16. Using a new gasket, fix the insulator with screws to which threadlock (Blue Threadlock Z-42) has been applied. 4. With the arrow on the top of the piston facing the straight side (opposite side to the propeller) of the crankshaft, fit the piston to the top of the connecting rod and insert the piston pin with its blank end to the exhaust port side. 17. Using a new gasket, mount the carburetor with screws, paying attention to its mounting direction. 5. Fit the circlip. 19. Install the spark plug. Assembly (G38) 1. Apply engine oil (SAE #30) to the inside of the cylinder and to the needle bearings on the larger end of the connecting rod. 6. Fit the bearings, snap ring and oil seal to the crankshaft. (Apply lithium grease to the lip area of the oil seal and fit it, paying attention to its direction.) 8 7. Wipe the contact surfaces of the cylinder block and crankcase, and apply liquid gasket (Permatex or equivalent). 18. Tighten the mounting plate, using screws with threadlock (Blue Threadlock Z-42) applied. Note: Disassembly and assembly steps were written using a G38 engine as an example, but they apply to all engines. Engine Care and Maintenance (continued) Maintenance Chart Items Action Before Use Every 25 hours Every 100 hours Leakage, Damage/Crack Check ; ; ; Losing Speed Check/Adjust Air-cleaner (PUH) Check/Cleaning ; ; Spark Plug (gap) Check/Adjust Cylinder (barrel) Check/Cleaning Piston, Ring Check/Cleaning Muffler & Bolt Check/Cleaning Bearings Check/Cleaning ; ; ; ; ; ; ; Crankshaft Check/Alignment Rotor Check Propeller Hub (PU) Check/Alignment Water Jacket (PUM) Check/Leakage ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; ; Note Replace if necessary G G G G G G G G G Specifications & Technical Data Items Unit G260PU G260PUM G260PUH G231PUM G231PUH Type –– Air Cooled Water Cooled Air Cooled Water Cooled Air Cooled Bore x Stroke mm 34 x 28 3 cm 25.4 A A A A 32 x 28 Displacement 22.5 A A Effective Compression Ratio –– 8.4 A A A A Type (Walbro) WT-645 WT-644 WT-677 WT-644 WT-677 Venturi (mm) 12.7 A A A A –– –– Dry Type –– Dry Type –– Hand Flipping or Electric Motor Recoil Starter A A A Type CDI A BTDC/rpm 28/7000 30/7000 STD RZ7C A A A A A A A A A A Option –– CMR8H/7H –– CMR6H/7H –– Idle Speed rpm 1800 APC 18 x 8 3500 3000 3500 3000 Max. Power rpm 1.62/12000 2.16/12000 1.71/13000 2.09/12000 1.58/13000 Min. Torque 1.94/9500 1.42/9500 1.79/10000 1.34/9000 Carburetor Air Cleaner Starting Ignition Spark Plug rpm 1.48/9000 Fuel Consumption cc 790 710 760 720 700 Weight kg 1.69 (* 1.52) 1.54 1.77 (*1.57) 1.55 1.78 (*1.58) 9 Engine Care and Maintenance (continued) Maintenance Specifications Items Standard Limit Standard Limit Measuring Device Bore (mm) ø34 Plating damaged ø32 Plating damaged Eye Checking Diameter (mm) ø33.97 ø33.87 ø31.97 ø31.87 Micro Meter Piston Ring Groove Width (mm) 1.01 1.11 1.01 1.11 Thickness Gauge Piston Ring Hole (mm) ø8.01 ø8.05 ø8.01 ø8.05 Cylinder Gauge Clearance between Piston and Cylinder (mm) 0.03–0.05 0.15 0.03–0.05 0.15 Micro Meter Cylinder Gauge Clearance between Groove and Piston Ring (mm) 0.02–0.04 0.1 0.02–0.04 0.1 Thickness Gauge End Gap (mm) 0.05–0.25 0.5 0.05–0.25 0.5 Thickness Gauge Width (mm) 0.98 0.93 0.98 0.93 Micro Meter Piston Pin Diameter (mm) ø8 ø7.98 ø8 ø7.98 Micro Meter Connecting Rod small end (mm) ø11 ø11.05 ø11 ø11.05 Cylinder Gauge Crankshaft Dia. at Main Bearing (mm) ø12 ø11.98 ø12 ø11.98 Micro Meter Eccentricity (mm) –– 0.07 –– 0.07 Dial Gauge Axial Play (mm) –– 0.5 –– 0.5 Thickness Gauge Main Bearing –– Gritty or Has Flat Spot –– Gritty or Has Flat Spot –– Cylinder Piston Piston Ring 10 Remarks At the skirt end and the right angle to the piston pin When inserted in a new cylinder Troubleshooting Guide for Gasoline Engines Generally speaking, there are very few things that will keep today’s modern engines from starting. Use good quality “fresh” fuel and make sure that good plugs are installed. Should the engine fail to start after these items are verified, refer to the charts on the following page. a) The engine does not start. The crankshaft does not rotate Seizure, intrusion of a foreign substance The crankshaft rotates The fuel has not been fed to the carburetor Disassemble and repair Clogging inside the carburetor Disassemble and clean Clogging of the fuel piping Clean The fuel has been fed to the carburetor No compression (normally 7 kg/cm2 99.5 psi or more) Compression adequate The spark plug does not spark Loosened Tighten further spark plug Replace Abrasion or damage of the cylinder, piston, or piston ring The spark plug does spark Remove the spark plug and dry it The carburetor has not been properly Readjust adjusted The fuel is not Replace suitable The Stop switch has Turn on been turned off Wiring is disconnected Repair The spark plug is defective Replace The ignition module is defective Replace The air gap is too large Adjust The spark plug gap is too large Adjust Wet plug b) The engine stops by itself It suddenly stops The crankshaft does not rotate or is abnormally heavy The crankshaft rotates See a) The plug cap has come off Wiring disconnection Put back Spark plug bridge Use a standard plug Use clean fuel The Stop switch has been turned off It slows down and stops Out of fuel Not out of fuel Repair Turn on Refuel The fuel is not fed to the carburetor Water is mixed in the fuel See a) Replace c) Lower power output Overheating The carburetor has not beeen properly adjusted Air suction from a carburetor joint or oil seal Abrasion of the piston ring The fuel is not suitable Clogging of the muffler or exhaust port due to carbon The spark plug heat range is not proper Readjust Repair Replace Replace Clean Replace d) The engine does not stop Overheating The Stop switch is defective Switch wiring is disconnected See c) Repair Repair 11 Troubleshooting Guide for Gasoline Engines (continued) In the event that none of the above procedures result in the engine running properly, contact our service department for suggestions at: Horizon Hobby, Inc. 4105 Fieldstone Road Champaign, IL 61822 Phone: 217-355-9511 (M–F 8:00–5:00 CST) Propeller Chart This chart enables you to select the best propeller for initial setup of your Zenoah® engine. Remember, it’s imperative to balance each propeller prior to installation onto your Zenoah engine. Failure to do so may cause unwanted vibration in your aircraft. ENGINE PROPELLER G26A 16x8 @ 8,700 G231 Heli G26 Heli Adjust pitch of rotor to obtain 9,000–10,000 rpm of the engine at full throttle G26 Marine G231 Marine Diameter=65–75mm Pitch ratio 1.9–1.4mm G38 Gas 18x10 @ 7,300 G45 Gas 20x10 @ 7,200 G62 Gas 22x10 @ 7,200 GT80 Gas 22x12 @ 7,200 24x10 @ 7,200 12 Note: All recommendations are based on engines using APC brand props. Engine Specifications OUTSIDE DIMENSIONS (MM) Items Length Width Height Operating RPM Optional Mufflers G26A 139mm 105mm 181mm 2,000–10,000 BIS07123 G26M 139mm 105mm 181mm 2,000–10,000 G26H 139mm 105mm 181mm 2,000–10,000 — — G231 HELI 142mm 105mm 181mm 3,000–11,000 G231 MARINE 142mm 105mm 181mm 3,500–15,000 — — G38 170mm 130mm 215mm 2,000–9,000 BIS07138 G45 152mm 130mm 185mm 2,000–10,000 BIS07145 G62 162.5mm 140mm 185mm 2,000–10,000 BIS07163 GT80 191.5mm 257mm 190mm 1800–10,000 BIS07445/6 SPECIFICATIONS Displacement (cu in) Bore (in) Stroke (in) Weight (oz) K (ISO) HP (H/M) Carb (Walbro) G26A/M/H 1.55 1.41 1.1 54/57 M8x1.25/6x1 2.4 WT645/WT644/WT677 G231M/H 1.4 1.3 1.1 54 M8x1.25 2.2 WT644/WT643 G38 2.3 1.5 1.3 67 M10x1.25 2.2 WT338/WTA-6A G45 2.74 1.69 1.22 74 8x1 3.3 HDA-48D G62 3.8 1.9 1.4 73 10x1 4.75 HDA-48D GT80 4.8 1.59x2 1.22x2 126 — 6 WJ-64 * w/spring starter 13 Exploded Illustration G26/G231 14 Key # Zen Part # HH Part # 1-1 1- 2 2-1 2-2 3 4 5 6 7 8 9 10 11 12 T2075-12110 T2077-12110 T2076-12110 T2078-12110 T2076-12210 07851-00515 07000-13040 T2076-12320 1160-12330 T2075-13120 3310-12281 T2075-13150 1148-13162 T2075-14120 T2075-2111 ZEN2601 ZEN2301RC ZEN2601M ZEN23102M ZEN23103M ZEN2304M ZEN32105M ZEN23106M ZEN23107M ZEN23108 ZEN2309 ZEN23110 ZEN23111 ZEN23112 ZEN23114 2629-21130 T2075-21140 2169-21210 1155-21240 04065-02812 06034-06001 1850-21220 ZEN6213 ZEN23116 ZEN2317 ZEN2318 ZEN2319 ZEN2320 ZEN2321M 13 14 15 16 17 18 19 20 21 14 Description CYLINDER CYLINDER CYLINDER CYLINDER JACKET JOINT 0-RING 3 x 40 O-RING 1.5 x 15.5 BOLT M3 x 8 GASKET, CYLINDER BOLT M5X20 GASKET, INSULATOR INSULATOR GASKET, CARBURETOR CRANKCASE, COMPLETE CRANKCASE, REAR CRANKCASE, FRONT PIN GASKET SEAL, 12 x 22 x 7 BEARING SNAPRING BEARING SEAL, 12 x 28 x 7 Quantity per unit G260 G260 G260 G231 G231 PU PUM PUH PUM PUH 1 – 1 – – – – – – 1 – 1 – – – – – – 1 – – 1 – 1 – – 2 – 2 – – 1 – 1 – – 1 – 1 – – 2 – 2 – 1 1 1 1 1 6 6 6 6 6 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 3 3 3 3 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 1 1 1 1 1 – 1 – 1 – 1 – 1 – Exploded Illustration G26/G231 continued Key # Zen Part # HH Part # 22 23-1 23-2 24-1 24-2 25-1 25-2 26 27 28 29 30 31 32 33 34 35 36 37 38-1 38-2 39 40 41 42 43 44 45 01252-30530 T2088-41110 T2070-41110 T2088-41210 T2070-41210 1600-41310 1101-41310 1260-41320 5500-41410 1101-41340 T2075-42000 1155-74110 0262-10516 1650-43230 1160-75210 1861-75101 0263-30414 1000-43240 1140-43250 2629-71210 1160-71211 1155-71110 0260-30422 0263-30414 T2075-72210 1400-72121 2629-71311 3699-91809 3699-91975 0263-30565 1142-83110 848ES08300 848EP18300 1000-03030 T2075-81000 T2076-81000 T2077-81000 1152-43260 1152-43281 1152-43290 3350-53410 1140-13141 01252-30550 01252-30560 0263-30408 0263-90416 T2075-15110 1148-08010 1145-15412 1158-15420 T3039-91310 T2075-98110 ZEN2322 ZEN2623 ZEN2320RC ZEN26224 ZEN2321RC ZEN2625 ZEN2325 ZEN2326 ZEN2327 ZEN2328 ZEN23129 ZEN2330 ZEN2331 ZEN2332 ZEN2333M ZEN2634 ZEN2341 ZEN6227 ZEN2337 ZEN6236 ZEN2339M ZEN2354 ZEN6241 ZEN2341 ZEN2638 ZEN6239 ZEN6237 ZEN26451 ZEN2667M ZEN2648 ZEN2647 ZEN2649 ZEN23150H ZEN2650 ZEN2651 ZEN23151 ZEN23152 ZEN2359 ZEN2360 ZEN2361 ZEN2362 ZEN23156 ZEN2357 ZEN2357H ZEN2358 ZEN2358H/RC ZEN2655 ZEN2355 ZEN2366 ZEN2367 ZEN23124RC ZEN23144 46 47 48 49 50 51-1 51-2 51- 3 52 53 54 55 56 57-1 57-2 58-1 58-2 59-1 59-2 60 61 62 Description BOLT, M5 x 30 PISTON PISTON RING RING PISTON PIN PISTON PIN SNAP RING BEARING WASHER CRANKSHAFT, COMPLETE MOUNT, PLATE SCREW, M5 x 16 NUT, M8 PULLEY RECOIL ASSEMBLY SCREW, M4 x 14 KEY SHIM COIL, (GREY) COIL, (RED) ROTOR SCREW M4 x 22 SCREW M4 x 14 PLUG CAP SPRING COIL SPARK PLUG RZ7C SPARK PLUG MARINE ONLY SCREW, M5 x 55 SPACER, 5 x 10 x 1.6 AIR TUNNEL (VENTURI) CLEANER ASSEMBLY TUBE CARBURETOR ASSY WT-645 CARBURETOR ASSY WT-644 CARBURETOR ASSY WT-643 HUB STUD WASHER NUT, M8 GASKET, MUFFLER BOLT, M5 x 50 BOLT, M5 x 60 SCREW, M4 x 8 SCREW, M4 x 16 MUFFLER MUFFLER SPACER SPACER SOCKET OPTION FOR G260PUM/ G231PUM ONLY Quantity per unit G260 G260 G260 G231 PU PUM PUH PUM 4 4 4 4 1 1 1 – – – – 1 1 1 1 – – – – 1 1 1 1 – – – – 1 2 2 2 2 1 1 1 1 2 2 2 2 1 1 1 1 1 1 1 1 3 3 3 3 1 – – – – 1 1 1 – 1 1 1 – 4 4 4 1 1 1 1 1 1 1 1 1 – – – – 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 – 1 – 1 2 2 2 2 2 2 – 2 1 1 – 1 – – 1 – 1 1 – 1 1 – – – – 1 – 1 – – 1 – 1 – – – 1 – – – 1 – – – 1 – – – 1 – 2 – 2 – – – – – 2 – 1 – – – – – 1 – 1 – – – – – 1 – – – 1 – – – 1 – 1 1 1 1 – 1 – G231 PUH 4 – 1 – 1 – 1 2 1 2 1 1 3 – 1 1 4 1 1 – 1 1 2 2 1 1 1 1 – 2 – – 1 – – – 1 – – – – 2 – 2 – 1 – 1 1 1 1 1 15 Exploded Illustration G38 (Standard Accessory for G380PU) Index No. 1 2 3 4 5 6 11 12 13 14 15 16 17 18 19 20 16 Part No. Description ZEN3801 CYLINDER ZEN3802 INSULATOR ZEN3803 CARB GASKET ZEN3804 INSULATOR SCREW ZEN3805 INSULATOR GASKET ZEN3806 MUFFLER ASSEMBLY ZEN3811 MUFFLER GASKET ZEN3812 MUFFLER BOLT ZEN3813 CRANKCASE ZEN3814 CASE BOLT ZEN3815 CASE WASHER ZEN3816 CASE PLUG ZEN3817 PLUG GASKET ZEN3818 PISTON ZEN3819 PISTON RING ZEN3820 PISTON PIN Q’ty/ unit 1 1 1 2 1 1 1 2 1 4 4 1 1 1 1 1 Index No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Part No. Description ZEN3821 PIN RETAINER ZEN3822 CONROD SPACER ZEN3823 CONROD BEARING ZEN3824 CRANKSHAFT ZEN3825 CRANKSHAFT BEARING ZEN3826 FRONT OIL SEAL ZEN3827 SNAP RING ZEN3828 REAR OIL SEAL ZEN3829 KEY ZEN3830 ROTOR NUT ZEN3831 LOCK WASHER ZEN3832 ROTOR WASHER ZEN3833 PROP HUB (NEW) ZEN3834 HUB BOLT ZEN3835 PROP WASHER (NEW) ZEN3836 PROP BOLT (NEW) Q’ty/ unit 2 2 1 1 2 1 1 1 1 1 1 1 1 2 1 2 Q’ty/ Index unit No. Part No. Description 1 37 ZEN3837 MODULE 1 38 ZEN3838 ROTOR (NEW) 3 39 ZEN3839 SPACER (MODULE) 1 40 ZEN6238 PLUG CAP (BLACK) 1 41 ZEN6239 CAP SPRING 1 42 ZEN6242 SPARK PLUG, C859 3 43 ZEN3843 MODULE BOLT 44-1 ZEN3844 CARB ASS’Y (HT-338) W/CHOKE 1 44-2 ZEN3850 CARB ASS’Y (WTA-6) W/O CHOKE 1 2 45 ZEN3845 CARB SCREW 1 46 ZEN3846 MOUNT for G380PU 4 47 ZEN3847 MOUNTING BOLT 1 ZEN3870 GASKET SET 1 ZEN3871 SCREW/NUT SET } Exploded Illustration G45 Index No. 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 Part No. ZEN4501 ZEN4502 ZEN4503 ZEN4504 ZEN6204 ZEN4506 ZEN4504 ZEN6207 ZEN6208 ZEN6209 ZEN6210 ZEN4513 ZEN6213 ZEN6214 ZEN6215 ZEN6216 ZEN6217 ZEN6276 ZEN4520 Description CYLINDER INSULATOR INSULATOR GASKET BOLT CARBURETOR GASKET CYLINDER GASKET BOLT MUFFLER MUFFLER GASKET MUFFLER BOLT MUFFLER NUT CRANKCASE COMP. CASE PIN SNAP RING BEARING REAR OIL SEAL FRONT OIL SEAL ELBOW FUEL NIPPLE CASE GASKET Q’ty/ unit 1 1 1 2 1 1 4 1 1 2 2 1 3 1 2 1 1 1 1 Index No. 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 Part No. Description ZEN4504 BOLT ZEN4522 PIPE ZEN4523 PISTON ZEN4524 PISTON RING ZEN4525 PISTON PIN ZEN6223 PIN RETAINER ZEN6224 CONROD BEARING ZEN4528 WASHER ZEN4529 CRANKSHAFT COMP. ZEN6228 SHIM ZEN6227 KEY ZEN6229 FLYWHEEL NUT ZEN6230 PROP HUB ZEN6232 HUB BOLT ZEN6233 WASHER ZEN6234 PROP BOLT ZEN6257 MAGNETO ASSEMBLY ZEN6235 ROTOR ZEN6236 SOURCE COIL Q’ty/ unit 4 1 1 2 1 2 1 2 1 0-2 1 1 1 2 1 1 1 1 1 Index No. 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 Part No. Description ZEN6237 IGNITION COIL ZEN6238 PLUG CAP (BLACK) ZEN6239 CAP SPRING ZEN4543 SOURCE COIL SCREW ZEN6241 COIL SCREW ZEN6242 SPARK PLUG ZEN6243 CARBURETOR ASSEMBLY ZEN4547 BOLT ZEN6245 WASHER ZEN6246 WASHER ZEN6247 BOLT ZEN6248 MOUNT *for G450PU ZEN6249 BOLT ZEN6250 WASHER ZEN6251 PULLER ASSEMBLY ZEN6252 STOPPER (OPTIONAL) ZEN6253 GUIDE (OPTIONAL) ZEN4557 WRENCH (OPTIONAL) } Q’ty/ unit 1 1 1 2 2 1 1 2 2 2 1 1 4 4 1 1 1 1 17 Exploded Illustration G62 * (Accessory for G620PU-1) Index No. Part No. Description 1 ZEN6201 CYLINDER 2 ZEN6202 INSULATOR GASKET 3 ZEN6203 INSULATOR 4 ZEN6204 CARBURETOR GASKET 5 ZEN6205 CYLINDER BASE GASKET 6 ZEN2309 CYLINDER BOLT 7 ZEN6207 MUFFLER 8 ZEN6208 MUFFLER GASKET 9 ZEN6209 MUFFLER BOLT 10 ZEN6210 MUFFLER NUT 11,12 ZEN6211 CRANKCASE COMP. 13 ZEN6213 CASE PIN 14 ZEN6214 SNAP RING 15 ZEN6215 BEARING 16 ZEN6216 REAR OIL SEAL 17 ZEN6217 FRONT OIL SEAL 18 ZEN6218 CRANKCASE GASKET 19 ZEN6219 CASE ASSEMBLY BOLT 20 ZEN6220 PISTON 18 Q’ty/ Index unit No. Part No. Description 1 21 ZEN6221 PISTON RING 1 22 ZEN6222 PISTON PIN 1 23 ZEN6223 PIN RETAINER 1 24 ZEN6224 NEEDLE BEARING 1 25 ZEN6225 CONNECTING ROD SPACER 4 26 ZEN6226 CRANKSHAFT COMP. 1 27 ZEN6227 KEY 1 28 ZEN6228 SHIM 2 29 ZEN6229 FLYWHEEL NUT 2 30 ZEN6230 HUB,PROPELLER COMP. FOR G620PU-1 1 3 31 ZEN6231 PIN FOR G620PU-1 1 32 ZEN6232 HUB BOLT 2 33 ZEN6233 PROP WASHER 1 34 ZEN6234 PROP BOLT 1 35 ZEN6235 ROTOR 1 36 ZEN6236 SOURCE COIL 4 37 ZEN6237 IGNITION COIL 1 38 ZEN6238 PLUG CAP (BLACK) Q’ty/ unit 4 1 1 2 1 2 1 2 1 0-2 1 1 2 1 1 1 1 1 1 Index No. 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 Part No. Description ZEN6239 PLUG CAP SPRING ZEN6240 IGNITION COIL SCREW ZEN6241 SOURCE COIL SCREW ZEN6242 SPARK PLUG, C859 ZEN6243 CARBURETOR ASSEMBLY ZEN6244 CARB MOUNT SCREW ZEN6245 CARB WASHER ZEN6246 WASHER ZEN6247 TAP PROP BOLT ZEN6248 MOUNT * for G62PU ZEN6249 BOLT ZEN6250 WASHER ZEN6251 PULLER ASSEMBLY ZEN6252 STOPPER (OPTIONAL) ZEN6253 PISTON PIN GUIDE (OPTIONAL) ZEN6200 SPRING STARTER ZEN6255 HIGH-SPEED NEEDLE ZEN6256 LOW-SPEED NEEDLE ZEN6257 MAGNETO ASSEMBLY } Q’ty/ unit 2 2 1 1 2 2 2 1 1 4 4 1 1 1 1 1 1 1 Exploded Illustration GT80 Index No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 Part No. ZEN44501 ZEN44502 ZEN44503 ZEN44504 ZEN44505 ZEN44506 ZEN4547 ZEN44508 ZEN44509 ZEN44510 ZEN6213 ZEN6215 ZEN6214 ZEN44514 ZEN6217 ZEN6276 ZEN44517 ZEN44518 ZEN44509 ZEN44520 ZEN44521 Description CYLINDER MANIFOLD MANIFOLD GASKET MANIFOLD BOLT CARBURETOR ASS’Y CARBURETOR GASKET CARB BOLT CYLINDER GASKET BOLT CRANKCASE ASS’Y PIN BEARING SNAP RING BEARING FRONT OIL SEAL FUEL NIPPLE ELBOW PIPE CRANKCASE GASKET BOLT PISTON PISTON RING Q’ty/ unit 2 1 2 4 1 1 2 2 8 1 4 2 2 1 1 1 1 1 4 2 4 Index No. 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 Part No. ZEN44522 ZEN44523 ZEN44524 ZEN44525 ZEN44526 ZEN6228 ZEN6227 ZEN6229 ZEN6235 ZEN6236 ZEN6238 ZEN44533 ZEN6238 ZEN6239 ZEN6242 ZEN44537 ZEN44538 ZEN44539 ZEN44540 ZEN6209 ZEN44542 Description PISTON PIN PIN RETAINER BEARING THRUST WASHER CRANKSHAFT COMP SHIM KEY NUT ROTOR SOURCE COIL IGNITION COIL CORD PLUG CAP (BLACK) CAP SPRING SPARK PLUG, C859 SCREW SCREW MUFFLER MUFFLER GASLET MUFFLER BOLT NUT Q’ty/ unit 2 4 2 4 1 0-2 1 1 1 1 2 1 2 2 2 4 2 2 2 4 Q’ty/ Index unit No. Part No. Description 1 43 ZEN44543 MOUNT 3 44 ZEN44544 BOLT 1 45 ZEN44545 BOSS 1 46 ZEN44546 CLUTCH COMP 1 47 ZEN44547 SPRING 1 48 ZEN44548 COLLAR 1 49 ZEN44549 WASHER 1 50 ZEN44550 BOLT 1 51 ZEN44551 PAD 1 52 ZEN44552 HUB. PROPELLER COMP 2 53 ZEN44553 PIN 2 54 ZEN6232 HUB BOLT 1 55 ZEN6233 HUB WASHER 1 56 ZEN6234 PROP BOLT 1 57 ZEN6247 TAP PROP BOLT 1 58 ZEN44555 SOCKET 59 ZEN6251 PULLER ASS’Y (OPTIONAL) 1 1 60 ZEN44554 STOPPER (OPTIONAL) 1 ZEN44556 HIGH-SPEED NEEDLE 1 ZEN44557 LOW-SPEED NEEDLE G80A Index No. 01 02 20 21 Part No. ZEN8001 ZEN8002 ZEN8020 ZEN8021 Description CYLINDER INTAKE MANIFOLD (BLACK) PISTON PISTON RING Q’ty/ unit 2 1 2 2 19 Warranty Information Zenoah® engines are guaranteed against workmanship and manufacturing defects for a period of 3 years from the original date of purchase. This warranty is limited to the original purchaser and is not transferable. Warranty repairs will not cover: • Normal engine wear • Damage due to insufficient maintenance • Damage related to over-revving of the engine due to small prop size or unreasonable use • Rusted bearings • Crash damage • Damage due to use of improper fuel and/or spark plug • Damage due to lean runs, such as rusted bearings, seized connecting rod or piston, etc. • Damage caused by foreign objects 2. Include a note containing a brief summary of the difficulty and include the following information: • Propeller size and brand used • Type of spark plug used • Type of engine mount • Approximately how much running time the engine had before difficulty 3. Date your correspondence and be sure your name and address appear on this enclosure. 4. Include a phone number where you can be reached during the business day. Warranty Repairs • Damage caused by unreasonable mounting or running conditions (dust, insufficient cooling, improper mounting, improper propeller size of lack of balancing, etc.) To receive warranty service you must include your original dated sales receipt to verify your proof-of-purchase date. Providing that warranty conditions have been met, your engine will be repaired without charge. • Damage due to improper disassembly Non-Warranty Repairs • Modifications of any kind If your engine needs repair, ship it in its original box, freight prepaid to: Horizon Service Center Attn: Zenoah Service 4105 Fieldstone Road Champaign, IL 61822 Phone: (217) 355-9511 Note: Do not use the engine’s original box as the shipping box. Rather, package this box inside a sturdy shipping box. 20 1. Include complete name and address information inside the carton, as well as clearly writing it on the outer label/return address area. Should your repair cost exceed 50% of the retail purchase cost, you will be provided with an estimate advising you of your options. Any return freight for non-warranty repairs will be billed to the consumer. We accept both Visa and MasterCard for payment. Please include your card number and expiration date. The Consumer Warranty Registration below must be completely filled out and mailed to: Horizon Service Center Attn: Zenoah Warranty 4105 Fieldstone Road Champaign, IL 61822 Warranty Information (continued) Registration Form Fill in and mail this form along with your dated sales receipt (send a copy, keep the original for your files) within 10 days of purchase to: Horizon Service Center Attn: Zenoah Warranty Dept. 4105 Fieldstone Road Champaign, IL 61822 Engine Type: ________________________________________________________________________________ Date of Purchase: ______________________________________________________________________________ Owner’s Name: ______________________________________________________________________________ Street Address: ______________________________________________________________________________ City/State/Zip: ________________________________________________________________________________ Daytime Phone Number: ________________________________________________________________________ Purchased From: ______________________________________________________________________________ Dealer’s Name: ________________________________________________________________________________ Street Address: ______________________________________________________________________________ City/State/Zip: ________________________________________________________________________________ Please cut on dotted line. 21 22 23 © Copyright 2003, Horizon Hobby, Inc. www.horizonhobby.com ZZPZ200 6135
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