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ENGINE INSTRUCTION MANUAL
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3
5
2
7
1
6
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G26 Air
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G26/231Marine
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G26/G231 Heli
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G38
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G62
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GT80 Twin
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G45
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Table of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Mounting the Engine . . . . . . . . . .
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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 This instruction manual has been developed to ensure for properly, these high-quality, finely crafted engines will optimum performance from the Zenoah engine you have offer many years of reliability. purchased. It’s important that the instructions are read thoroughly prior to mounting and
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Safety Instructions (continued) Caution Disassembly ® 1. Model engines get very hot while running. Do not The Zenoah engine can be disassembled or reassem- attempt to handle them until they have cooled. bled without any specific difficulties. Refer to the Engine Maintenance Section for specific instructions on these 2. Always run your model engines in a well-ventilated procedures. If you need service to your Zenoah engine, area. Similar to automotive engines, model engines pro- please send it to
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Mounting the Engine Make sure the engine is mounted on the aircraft using 1. Be sure to set flat washers or a metal plate on the aircraft grade plywood that’s at least 6mm in thickness reverse side of the mount to prevent the bolts from sink- for the G26 engine, and 10mm in thickness for the G38 ing into the mount. Periodically check the engine mount through GT80 twin, or a mount of equivalent strength. for loose bolts. Make sure it’s firmly mounted with 4 bolts. 2. Since the engine is equipped
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Operation (continued) 8. Quickly flip the propeller in a counterclockwise body, or the throttle valve should be closed completely. direction according to the procedure described in Installation of a “stop” or “kill” switch is recommended. the note above. Red Lead 9. The engine should start after a few flips of the propeller. 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
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Operation (continued) High-Speed Needle: Turning this needle clockwise When the engine has just started and is not warm makes the gas mixture leaner, and turning it counter- enough, there may be insufficient acceleration clockwise makes it richer. Set this needle at a position and the engine may die. Be sure to allow the which is 1/4 open from the maximum rpm position while engine to warm up at idle for a few minutes the aircraft is on the ground. before conducting normal operation. Note: Do not
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Engine Care and Maintenance (continued) c. Remove the rotor by using the puller. Do not hit 7. Wipe the contact surfaces of the cylinder block the crankshaft with the plastic hammer, as this can and crankcase, and apply liquid gasket (Permatex increase the runout of the shaft. or equivalent). 7. Remove the mounting plate. 8. Put the piston in the cylinder, with the piston’s arrow facing in the exhaust port direction. Set the crankshaft 8. Remove the four bolts from the crankcase. to the cylinde
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Engine Care and Maintenance (continued) Maintenance Chart Items Action Before Use Every 25 hours Every 100 hours Note Leakage, ; Check ; ; Damage/Crack Losing Speed Check/Adjust ; ; ; Air-cleaner (PUH) Check/Cleaning ; ; ; Replace if necessary Spark Plug (gap) Check/Adjust ; ; G Cylinder (barrel) Check/Cleaning ; ; G Piston, Ring Check/Cleaning ; ; G Muffler & Bolt Check/Cleaning ; ; ; G Bearings Check/Cleaning ; ; G Crankshaft Check/Alignment ; G Rotor Check ; ; G Propeller Hub (PU) Check/Align
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Engine Care and Maintenance (continued) Maintenance Specifications Standard Limit Standard Limit Items Measuring Device Remarks Cylinder ø34 Plating damaged ø32 Plating damaged Bore (mm) Eye Checking At the skirt end and ø33.97 ø33.87 ø31.97 ø31.87 Micro Meter the right angle to the Diameter (mm) piston pin Piston Ring 1.01 1.11 1.01 1.11 Thickness Gauge Groove Width (mm) Piston ø8.01 ø8.05 ø8.01 ø8.05 Piston Ring Hole (mm) Cylinder Gauge Micro Meter Clearance between Piston 0.03–0.05 0.15 0.0
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Troubleshooting Guide for Gasoline Engines Generally speaking, there are very few things that will installed. Should the engine fail to start after these items keep today’s modern engines from starting. Use good are verified, refer to the charts on the following page. quality “fresh” fuel and make sure that good plugs are a) The engine does not start. The crankshaft Seizure, intrusion of a foreign substance Disassemble and repair does not rotate Clogging inside the Disassemble and clean The fuel
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Troubleshooting Guide for Gasoline Engines (continued) In the event that none of the above procedures result Horizon Hobby, Inc. in the engine running properly, contact our service 4105 Fieldstone Road department for suggestions at: 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 Note: All recommendations are based on engines using ® initial setup of your Zenoah engine. APC brand props. Remember, it’s imperativ
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Engine Specifications OUTSIDE DIMENSIONS (MM) Optional Operating Items Length Width Height Mufflers RPM 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 SPEC
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Exploded Illustration G26/G231 14 Quantity per unit Key # Zen Part # HH Part # Description G260 G260 G260 G231 G231 PU PUM PUH PUM PUH 1-1 T2075-12110 ZEN2601 CYLINDER 1 – 1 – – 1- 2 T2077-12110 ZEN2301RC CYLINDER – – – – 1 2-1 T2076-12110 ZEN2601M CYLINDER – 1 – – – 2-2 T2078-12110 ZEN23102M CYLINDER – – – 1 – 3 T2076-12210 ZEN23103M JACKET – 1 – 1 – 4 07851-00515 ZEN2304M JOINT – 2 – 2 – 5 07000-13040 ZEN32105M 0-RING 3 x 40 – 1 – 1 – 6 T2076-12320 ZEN23106M O-RING 1.5 x 15.5 – 1 – 1 – 7 116
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Exploded Illustration G26/G231 continued Quantity per unit Key # Zen Part # HH Part # Description G260 G260 G260 G231 G231 PU PUM PUH PUM PUH 22 01252-30530 ZEN2322 BOLT, M5 x 30 4 4 4 4 4 23-1 T2088-41110 ZEN2623 PISTON 1 1 1 – – 23-2 T2070-41110 ZEN2320RC PISTON – – – 1 1 24-1 T2088-41210 ZEN26224 RING 1 1 1 – – 24-2 T2070-41210 ZEN2321RC RING – – – 1 1 25-1 1600-41310 ZEN2625 PISTON PIN 1 1 1 – – 25-2 1101-41310 ZEN2325 PISTON PIN – – – 1 1 26 1260-41320 ZEN2326 SNAP RING 2 2 2 2 2 27 5500-41
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Exploded Illustration G38 (Standard Accessory for G380PU) Q’ty/ Q’ty/ Q’ty/ Index Index Index unit unit unit Part No. Description Part No. Description No. Part No. Description No. No. MODULE 1 1 ZEN3801 CYLINDER 1 21 ZEN3821 PIN RETAINER 2 37 ZEN3837 ROTOR (NEW) 1 22 ZEN3822 CONROD SPACER 2 38 ZEN3838 2 ZEN3802 INSULATOR 1 SPACER (MODULE) 3 23 ZEN3823 CONROD BEARING 1 39 ZEN3839 3 ZEN3803 CARB GASKET 1 PLUG CAP (BLACK) 1 24 ZEN3824 CRANKSHAFT 1 40 ZEN6238 4 ZEN3804 INSULATOR SCREW 2 CAP SPRING 1
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Exploded Illustration G45 Index Q’ty/ Index Q’ty/ Index Q’ty/ No. Part No. Description unit No. Part No. Description unit No. Part No. Description unit 1 ZEN4501 CYLINDER 1 21 ZEN4504 BOLT 4 40 ZEN6237 IGNITION COIL 1 2 ZEN4502 INSULATOR 1 22 ZEN4522 PIPE 1 41 ZEN6238 PLUG CAP (BLACK) 1 3 ZEN4503 INSULATOR GASKET 1 23 ZEN4523 PISTON 1 42 ZEN6239 CAP SPRING 1 4 ZEN4504 BOLT 2 24 ZEN4524 PISTON RING 2 43 ZEN4543 SOURCE COIL SCREW 2 5 ZEN6204 CARBURETOR GASKET 1 25 ZEN4525 PISTON PIN 1 44 ZEN6241 C
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Exploded Illustration G62 (Accessory for G620PU-1) * Index Q’ty/ Index Index Q’ty/ Q’ty/ Part No. No. Description unit No. Part No. Description unit No. Part No. Description unit PLUG CAP SPRING ZEN6201 ZEN6221 PISTON RING 4 ZEN6239 1 CYLINDER 1 21 39 ZEN6202 ZEN6222 PISTON PIN 1 ZEN6240 IGNITION COIL SCREW 2 2 INSULATOR GASKET 1 22 40 PIN RETAINER 1 SOURCE COIL SCREW 2 3 ZEN6203 INSULATOR 1 23 ZEN6223 41 ZEN6241 NEEDLE BEARING 2 SPARK PLUG, C859 1 4 ZEN6204 CARBURETOR GASKET 1 24 ZEN6224 42 ZEN
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Exploded Illustration GT80 Index Index Index Q’ty/ Q’ty/ Q’ty/ No. Description Description unit Part No. Description unit No. Part No. unit No. Part No. 1 ZEN44501 CYLINDER 2 22 ZEN44522 PISTON PIN 2 43 ZEN44543 MOUNT 1 2 ZEN44502 MANIFOLD 1 23 ZEN44523 PIN RETAINER 4 44 ZEN44544 BOLT 3 3 ZEN44503 MANIFOLD GASKET 2 24 ZEN44524 BEARING 2 45 ZEN44545 BOSS 1 4 ZEN44504 MANIFOLD BOLT 4 25 ZEN44525 THRUST WASHER 4 46 ZEN44546 CLUTCH COMP 1 5 ZEN44505 CARBURETOR ASS’Y 1 26 ZEN44526 CRANKSHAFT COMP 1
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Warranty Information ® Zenoah engines are guaranteed against workmanship 1. Include complete name and address information and manufacturing defects for a period of 3 years from inside the carton, as well as clearly writing it on the the original date of purchase. This warranty is limited to outer label/return address area. the original purchaser and is not transferable. 2. Include a note containing a brief summary of the difficulty and include the following information: Warranty repairs will not
