Zenoah G200PU User's Manual
Contents
1. 18 PARTS LIST Q TY KEY PART NUMBER DESCRIPTION ae REMARKS KEY PART NUMBER DESCRIPTION ihe REMARKS 1 848EW012A1 CYLINDER 1 25 1152 43290 WASHER 1 2 848EW012B0 GASKET cylinder 1 26 8488608000 NUT 1 3 8488441800 BOLT 6 27 848EW071N0 SENSOR 1 4 848EW014A0 INSULATOR 1 28 8488441400 BOLT 2 5 848EW014B1 GASKET insulator 1 29 3699 92369 SPARK PLUG 1 v82 6 848EW02110 CRANKCASE COMP 1 30 848EW053X0 MOUNT PLATE 1 7 848EW021D0 GASKET case 1 31 3819 54780 SCREW 4 8 1155 21240 BEARING 1 32 848EW07120 UNIT ASSY 1 9 06034 06001 BEARING 1 33 01252 30410 BOLT 1 10 11600 21240 BEARING 1 34 01641 20405 WASHER 1 11 04065 02812 SNAP RING 1 35 848EW08100 CARBURETOR ASSY 1 12 71600 21210 SEAL 1 36 T2070 82410 LEVER choke 1 13 3310 72150 BOLT 4 37 848H7014C1 GASKET 1 14 848EW041A1 PISTON 1 38 848ES08300 AIR FUNNEL 1 15 T2071 41210 RING 1 39 8488455000 BOLT 2 16 1101 41310 PISTON PIN 1 40 848EW015A0 MUFFLER 1 17 1260 41320 SNAP RING 2 41 1140 13141 GASKET muffler 1 18 5500 41410 BEARING 1 42 01252 30540 BOLT 2 19 1101 41340 WASHER 2 43 8488U30000 SPANNER 1 20 848EW04200 CRANKHAFT COMP 1 44 848EWO93A1 OWNER S MANUAL 1 21 848EW042D0 KEY 1 45 1101 96220 ROD ASSY 1 OPTION 22 1140 43250 SHIM 1 46 4810 96220 STOPPER 1 OPTION 23 848EW05290 HUB COMP 1 47 X374320099 CAP REPAIR KI2. ENGINE ASSEMBLY The carburetor muffler and air funnel have not been assembled Please assemble them correctly following the diagram shown below 3 No SA o 5 NRA 6 Tightening Part Part no Quantity Torque N m 1 Bolt 01252 30540 2 8 8 2 Muffler 848EW015A0 1 3 Gasket 1140 13141 1 4 Gasket 848H7014C1 1 5 Carburetor set 848EW09710 1 6 Air funnel 848ES08300 1 7 Bolt 8488455000 2 3 4 The carburetor can be mounted anywhere 90 degrees apart on the top bottom left or right Mount the carburetor at a place where it is easy to do the linkage DC IGNITION UNIT MOUNTING 1 Make sure to install the power switch 2 Push the sparkplug cap all the way over the sparkplug use gloves 3 Fixate the unit within the fuselage as shown in the diagram Do not wrap RR D Battery 4 8V 1500 2700mA Use of anything other than an 4 8V battery is prohibited the unit by the sponge cloth or the like Gap OCE 4 The temperature of the bottom surface D of the unit in particular will surface D rise Thus when fixating surface D make sure to leave sufficient space a gap O r The temperature of the unit may rise to as high as 70 80 C depending on the operating environment and conditions but O ADB this is not abnormal However make sure not to touch this part or you could risk being burned Bolt N Sensor wire
3. a audi z a A i ada 14 Tightening Torque Chart a aaaaaaasanaasassasassasaasasanna 15 Propeller Hub Removal assess O A A O AAA 15 Other Information ay a A AO dO a 16 Parts LISt wa i A R GR O AAA GEE a ntti ai 17 Wartamy 111 sasanabnesunavnnnsvi aia naai punnabVns iraani aain 20 SPECIFICATIONS NO ITEMS SPECIFICATIONS 1 Engine model G200PU 2 Displacement 20 1cm 3 Bore x stroke 932mm x 25mm 4 Weight 990g not including DC Ignition Unit 5 Carburetor type WT 811 6 Ignition Battery ignition digital control 7 Sparkplug Champion Y82 8 Rotating direction Counterclockwise from PTO side 9 Starting method External motor 10 Sensor gap 0 8 1 2mm 1 0mm 0 2mm 11 Fuel consumption 1 02 9000rpm at full throttle 12 Noise at 2 meter points 98dBA APC 15x10 13 Battery capacity 4 8V 1500 2700mA A SAFETY PRECAUTIONS A These safety precautions are to prevent you and those in the vicinity from incurring harm or damage Make sure to observe these precautions and to constantly strive to ensure safety Safe use of the engine is your personal obligation and responsibility Constantly take care to act with good judgment as you enjoy your hobbies e Make sure never to touch the propeller when it is rotating Also make sure that the propeller does not come in contact with the ground or with anything in its surroundings Doing so could result in grave injury The f
4. the engine using the starter Opening or closing the choke lever during engine operation is prohibited If the engine will not start leave the choke lever in the open position and rotate the engine by pressing the starter for 1 2 sec If the engine will not start repeat this operation 2 or 3 times A Points in starting During the first startup operation does the fuel reach the carburetor f the fuel reaches the carburetor the choke should be open position Is the ignition switch on If there is absolutely no explosive sound remove the sparkplug and check it f the sparkplug became wet condition by over choking dry it out open the choke and restart B Cautions in starting One person must restrain the fuselage during the startup operation Thus solo startup is prohibited With the sparkplug removed when using the starter for rotation or rotating the propeller by hand make sure the ignition switch has been turned off Rotation should be to the left Confirm the direction of motor rotation in advance 17 ADJUSTMENTS AFTER ENGINE STARTUP A ADJUSTING THE IDLING Standard settings After engine startup set the idling at about 2000rpm turn the L needle to the right to E1 t turns 1 reduce fuel and search for the position for the max engine speed From that position turn H 14 turns the L needle about 1 4 90 to the left to increase fuel set the idling speed with t
5. 260 41320 to prevent skipping of the piston pin Standard A The crankcase is made of magnesium During processing allow for sufficient cooling to avoid the risk of chips burning In the event of even one crash make sure to contact your service shop or dealer for inspection and repairs 16 PARTS LIST 29 10 gt B KEY PART NUMBER DESCRIPTION mat REMARKS 1 848EW08100 CARBURETOR ASSY 1 2 3306 81380 SCREEN 1 3 3080 81120 COVER 1 4 3310 81130 SCREW 1 5 3304 81140 GASKET 1 6 1172 81150 DIAPHRAGM 1 7 2850 81290 GASKET 1 8 3310 81260 DIAPHRAGM ll 10 3310 81280 METERING COVER 1 12 2867 81270 SPRING 1 13 3356 81310 VALVE inlet 1 14 1480 81420 PLUG welch 1 15 3310 81230 LEVER 1 16 3310 81240 SCREW 1 17 3310 81250 PIN 1 18 2630 81330 SCREW 1 19 3350 81380 SPRING ll 20 848EW081T0 SHAFT throttle 1 21 2670 81410 SPRING 1 22 2880 81470 SCREW 2 23 1282 81340 VALVE throttle 1 24 1148 81390 RING 1 25 T2070 81460 SHAFT choke 1 26 2841 81451 VALVE choke 1 27 3350 81350 SPRING 1 28 3350 81220 BALL 1 29 3310 81351 SCREW 4 30 1491 81160 SPRING 1 31 1148 81171 NEEDLE low speed 1 32 3080 81320 SPRING 1 33 T2070 81330 NEEDLE high speed 1 34 2812 81520 BALL 1 35 2810 81530 SPRING 1 36 2812 81510 PISTON 1 17 PARTS LIST
6. 848EWO93A1 901 Model G200PU zenonH OWNER MANUAL Model code X374320000 Thank you for purchasing a ZENOAH engine Please read this Service Manual thoroughly and use the engine correctly For safety reasons please contact your sales dealer prior to using the engine if there is something about it that you do not understand This engine has been designed for radio control airplanes Please use it in conjunction with the manuals for the models or radio control equipment you will be using Modifications or use of the engine for other than its intended purpose is prohibited We ask that the product be used only after it has been understood that the purchaser user shall bear all obligations and responsibilities stipulated by law local ordinance and the like and that ZENOAH shall bear no responsibility whatsoever CONTENTS SP CIIICAtONS Hess ezai eta eia Ee a A JADE Ea ZE Ea Gi 3 Safety PreCaUtiOns a A SEA 4 Engine Assembly 11 111 a sna szara 0a A PAW A A AGS 6 DC Ignition Unit MOUNIIRO iw ewa O EE KE 7 Fuel and Pipin giin siaaa 8 Throttle Linkage and Engine Mounting a ai 9 Items to Confirm Before Starting the Engine 10 Starting the Engine sal dssavssnkavd kavanurn sald Adjustments After Engine Startup SIECIA OTEM Stopping the E GINE wa z O ea AE EA 13 Engine RUNNING NMO cio OE A WE O 13 Maintenance
7. CONFIRM BEFORE STARTING THE ENGINE Please determine the propeller to use in keeping with the airplane s size gross weight and flight characteristics If necessary consult with someone who has the proper experience Guidelines for an APC propeller about 8 300rpm 15x10 about 8 900rpm 15x8 Fuel pump for gasoline Electric starter device Make sure that during the fueling process the fuel does not come in contact with the battery or that fuel that has overflowed does not come in contact with the muffler Make sure there is no loosening of or abnormalities with the tightening etc of each part of the engine and model Are there any problems with the linkage in terms of its direction and actuation stroke Has the battery been sufficiently charged Are there any propeller abnormalities scratches deformation etc Re tighten the muffler for starting an engine from the second try on Make sure that the fuel pipe and the wiring of the DC ignition unit and the like do not pass through the engine s muffler body and that the wiring and fuel pipe are not interferences 10 STARTING THE ENGINE Close the choke lever and open the throttle valve 10 to 15 Pressing the tip of the starter to the engine s spinner press the start switch for 1 2 sec and let the engine rotate If the engine has made an explosive sound suspend the starting operation and start by opening the choke lever and rotating
8. S 3A or higher O rface a L _ c U G For charging x asc Sparkplug wire BEE amp cloth FUEL AND PIPING For gasoline please use either regular or high octane for cars The octane number should be 85 or higher For oil use a high performing mixed lubrication type of 2 cycle engine oil F3C grade or ISO EGC grade and make the fuel volume ratio 1 oil to 25 40 gasoline For fuel piping refer to the diagram shown below e Do not use a silicon tube e Clip the weight so that it does not come off when the engine is running 1 Fuel tank Capacity of 300 400cc 2 Carburetor 3 Weight or weight with felt filter 4 Filter Mesh 300 or more 5 Fuel pipe Gasoline resistant rubber or vinyl tube with inner diameter of 2 5 3mm 6 Fuel pipe Gasoline resistant rubber tube 7 Air vent pipe 8 Fuelhead 100mm or less THROTTLE LINKAGE AND ENGINE MOUNTING Mount the throttle arm to the carburetor s throttle shaft as shown in the Throttle arm diagram or use the throttle not supplied valve stopper plate located at opposite side Stopper screw 51am Claw nut x4 Mount the engine as shown ME polt in the diagram CG line Gloves 10cm Fuselage bulkhead firewall 8mm or more with hard board Tightening torque For propeller mounting use the 90kg cm wrench provided and make sure 8 8 N m not to over tighten the bolts ITEMS TO
9. T 1 OPTION 24 848EWOSZYO STUD 1 19 WARRANTY Scope of Application This warranty applies only to the engines and parts manufactured by ZENOAH and sold directly or through distributors Limit of Warranty This warranty shall apply only to trouble resulting from material defects and inferior assemblies that ZENOAH acknowledges Method and Limit of Compensation 1 Repair or replacement through the distributor etc 2 ZENOAH and its distributors shall not provide compensation for incidental loss to engine purchasers resulting from trouble Term of Warranty The term of warranty shall be three 3 months from the date of purchase within one year from the date of manufacture The warranty shall not cover the following even if occurring during the term of warranty 1 Any faults failures caused from neglect of this OWNER S MANUAL for proper operation and maintenance 2 Dismantled or modified engines and parts 3 Expendable parts 4 Trouble resulting from submersion in water from fire or from other natural disasters and calamities 5 Engines installed with parts that are not genuine Husqvarna Zenoah Co Ltd ZENORH Head Office 1 9 Minamidai Kawagoe city Saitama 350 1165 Japan Phone 81 49 243 1115 Fax 81 49 243 7197 20
10. bout 5 hours running the max engine speed will be slightly increased from initial max speed owing to the engine having been conditioned STOPPING THE ENGINE To stop the engine either use the transmitter to achieve full closed throttle or turn the battery switch off When you have stopped the engine and when not operating the engine make sure to keep the battery switch off ENGINE RUNNING TIME Because this engine uses a battery for power 120 Condition supply the engine s continuous running time will new and fully charged battery depend on battery capacity T Please refer to the table on the right for guidelines E E ENEA E ee ee ZURA T 2 Recommended battery 4 8V 1500 2700mA a re as a a L R A I 0 1000 2000 3000 Battery Capacity mA 13 MAINTENANCE To ensure safe use of the engine make sure of the items specified in the table below Item ang podj cp Inspection Leakage 8 breakage v v v Cylinder carburetor muffler crankcase Fuel pipe etc Idling stability V V V Is it stable Is acceleration okay Sparkplug V V Remove deposit adjust air gap Cylinder V V Check for wear amp scratches Piston Ring V V Check for wear amp scratches Muffler tightening bolt V V V Retighten Ignition unit V V V Check for damage Propeller hub Stud v v v Aaaa RE Crankshaft V Check alignment DC unit wiring v v Zo a Stud Nut V V V Is there any slack or screw
11. damage 14 TIGHTENING TORQUE CHART Tightening Torque Part Screw Size N m Kg cm Remarks Cylinder M4 PO 7 3 9 40 Sparkplug M10 P1 0 7 8 80 Using the tool provided Muffler M5 P0 8 8 5 90 Crankcase M4 PO 7 3 9 40 Insulator M4 PO 7 3 4 35 Carburetor M5 P0 8 3 4 35 Sensor M4 PO 7 1 7 20 Stud hub M6 P1 0 9 8 100 Using a piston stopper amp LOCK TIGHT Nut propeller M8 P1 25 8 8 90 Using the tool provided Engine mount M4 PO 7 2 0 20 PROPELLER HUB REMOVAL Remove the propeller hub as specified below Spanner provided P N 8488U3000 Stud bolt P N 848EW052Y0 TAS Nut M8xP1 25 x 2 P Piston stopper P N 4810 96220 MPO L about 45 N 8488608000 Puller Image picture 15 CAUTION Remove the sensor Make sure that nut turned with a spanner is nut on the propeller hub side Use a commercial puller of the appropriate size When reassembling the stud bolt apply LOCK TIGHT to the M6 thread part OTHER INFORMATION This information is to enable our customers to enjoy radio control airplanes more but all customers must take responsibility if they implement it With this engine the muffler side and the carburetor can be reversed by re assembling the cylinder and piston CAUTION When changing to B make sure to also re assemble the piston or the cylinder piston etc will be damaged Please use a new snap ring 1
12. he idle screw or the transmitter B ADJUSTING NUMBER OF ROTATIONS AT FULL THROTTLE Achieve full throttle slowly When the engine speed stabilizes turn the H needle to the left and right to locate the position for the max engine speed From the position of the max engine speed open the H needle 1 8 to increase fuel to make the setting In general consider 100rpm to be the difference between the max engine speed and the set engine speed After making the setting return to idling Accelerate rapidly and confirm that there are no problems with acceleration If acceleration is poor open the L needle an additional 1 8th 45 and confirm that acceleration is smooth In this case the idling will be low so use the idle screw or transmitter to adjust it This engine has had the carburetor set at the standard position at time of factory manufacture Thus no calibration is normally necessary In keeping if poor acceleration or insufficient speed at full throttle or the like result make adjustments in conformance with the main points of adjustment after engine startup However the idling will change depending on the size of the propeller used which will make adjustment using the idle screw or transmitter necessary 12 Idle screw BRAKE IN Different from a glow engine this engine does not require any special brake in After 5 10 tanks 2 3 hours adjust the carburetor s L and H needles if necessary After a
13. uel is toxic Do not let it get into your eyes or mouth Store it in a cool place out of the reach of infants and children Improperly handled it is a health hazard Use of open flames around the fuel is prohibited owing to the danger of fire occurring e To prevent burns make sure not to touch the engine while it is operating or immediately after it has stopped Do not run the motor in poorly ventilated places When running it outside do not breathe the exhaust as it is a health hazard A SAFETY PRECAUTIONS A Special caution must be taken with all propellers used Make sure to use them correctly in keeping with the manufacturers operating manuals etc Failure to do so could result in injury Please wear clothing that facilitates your safety Remove all scarves overly long sleeves neckties and the like Failure to do so could result in injury Please check to ensure that the direction in which the engine s throttle linkage operates and the amount it operates are correct Failure to do so could result in engine damage When starting the engine make sure to be wearing protective eyewear and gloves and to use the starter Failure to do so could result in injury Do not run the motor on sandy soil or where there is a lot of gravel Doing so could result in injury When mounting the engine to a model make sure to follow the model s operating manual If necessary reinforce the engine mounting unit and the peripheral parts
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