848EW093A1 (901)
Model: G200PU
Model code: X374320000
OWNER'S MANUAL
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.
SPECIFICATIONS
NO.
ITEMS
SPECIFICATIONS
G200PU
1. Engine model
2. Displacement
3. Bore x stroke
4. Weight
3
20.1cm
ø32mm x 25mm
990g (not including DC Ignition Unit)
WT-811
5. Carburetor type
6. Ignition
Battery ignition; digital control
Champion Y82
7. Sparkplug
8. Rotating direction
9. Starting method
10. Sensor gap
Counterclockwise (from PTO side)
External motor
0.8 ~ 1.2mm (1.0mm 0.2mm)
1.0 / 9000rpm (at full throttle)
98dBA (APC 15x10)
11. Fuel consumption
12. Noise (at 2-meter points)
13. Battery capacity
4.8V / 1500 ~ 2700mA
3
SAFETY PRECAUTIONS
● 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.
• 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 fuel 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.
• 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.
4
SAFETY PRECAUTIONS
• 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.
5
ENGINE ASSEMBLY
The carburetor, muffler, and air funnel
have not been assembled. Please
assemble them correctly, following the
diagram shown below.
Tightening
No.
Part
Part no.
Quantity
(3)
Torque (N-m)
1. Bolt
01252-30540
848EW015A0
1140-13141
2
1
1
1
1
1
2
8.8
(1)
2. Muffler
3. Gasket
4. Gasket
(2)
848H7014C1
(6)
(7)
5. Carburetor set 848EW09710
(4)
6. Air funnel
7. Bolt
848ES08300
8488455000
(5)
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.
6
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
the unit by the sponge, cloth or the like.
4. The temperature of the bottom surface (D) of the unit, in particular, will
rise. Thus, when fixating surface (D), make sure to leave sufficient space
(a gap).
surface D
Gap: 5mm or more
surface D
The temperature of the unit may rise to as high as 70~80°C,
depending on the operating environment and conditions, but
this is not abnormal. However, make sure not to touch this part
or you could risk being burned.
surface
D
Switch
Bolt (4mm)
Sensor wire
Unit
surface
D
Capacity: 3A (or higher)
Battery wire
For charging
surface D
Battery 4.8V
1500~2700mA
Ground
wire
surface D
Use of anything
other than an 4.8V
battery is prohibited.
Sponge & cloth
Sparkplug wire
7
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.
(7)
(2)
(5)
(1)
(4)
(5)
(8)
(6)
Do not use a silicon tube.
Clip the weight so that it
does not come off when
the engine is running.
(3)
1. Fuel tank
2. Carburetor
3. Weight or weight with felt filter
Capacity of 300~400cc
•
•
4. Filter
Mesh, 300 or more
5. Fuel pipe
Gasoline-resistant rubber or vinyl tube
with inner diameter of 2.5~3mm
Gasoline-resistant rubber tube
6. Fuel pipe
7. Air vent pipe
8. Fuel head
100mm or less
8
THROTTLE LINKAGE AND ENGINE MOUNTING
● Mount the throttle arm to
the carburetor’s throttle
Stopper screw
shaft as shown in the
diagram or use the throttle
valve stopper plate located
at opposite side.
Throttle arm
(not supplied)
Shaft diameter: 4mm
Claw nut x4
M4 bolt x4
● Mount the engine as shown
in the diagram.
CG line
Gloves
CG line
Engine mount
10cm
Fuselage bulkhead (firewall):
8mm or more, with hard board
9kg
● For propeller mounting, use the
wrench provided and make sure
not to over-tighten the bolts.
Tightening torque:
90kg-cm
(8.8 N-m)
9
ITEMS TO 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 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?
● If 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.
● If 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.
11
ADJUSTMENTS AFTER ENGINE STARTUP
(A) ADJUSTING THE IDLING
● After engine startup, set the idling at about 2000rpm, turn the L needle to the right (to
Standard settings:
1
L: 1
turns
8
1
1
H:
turns
2
reduce fuel), and search for the position for the max. engine speed. From that position, turn
the L needle about 1/4 (90°) to the left (to increase fuel), set the idling speed with the idle H needle L needle
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
Idle screw
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
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 about 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
supply, the engine’s continuous running time will
depend on battery capacity.
120
60
Condition:
new and fully charged battery
70min.
Please refer to the table on the right for guidelines.
2700mA
40min.
1500mA
Recommended battery: 4.8V / 1500~2700mA
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.
Before
using
Every
25h
Every
100h
Item
Inspection
Cylinder, carburetor, muffler,
crankcase, Fuel pipe, etc.
Leakage & breakage
✔
✔
✔
Idling stability
Sparkplug
✔
–
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
✔
Is it stable? Is acceleration okay?
Remove deposit; adjust air gap
Check for wear & scratches
Check for wear & scratches
Retighten
Cylinder
–
Piston/Ring
–
Muffler tightening bolt
Ignition unit
✔
✔
Check for damage
Check for damage to screws
& for deformation
Propeller hub (Stud)
Crankshaft
✔
–
✔
–
✔
✔
✔
✔
Check alignment
Check for dislocation, cracks,
wear, rattling, etc.
DC unit wiring
Stud/Nut
✔
✔
✔
✔
Is there any slack or screw damage?
14
TIGHTENING TORQUE CHART
Tightening Torque
Part
Cylinder
Sparkplug
Muffler
Crankcase
Insulator
Carburetor
Sensor
Stud (hub)
Nut (propeller)
Engine mount
Screw Size
M4 (P0.7)
M10 (P1.0)
M5 (P0.8)
M4 (P0.7)
M4 (P0.7)
M5 (P0.8)
M4 (P0.7)
M6 (P1.0)
M8 (P1.25)
M4 (P0.7)
N-m
3.9
7.8
8.5
3.9
3.4
3.4
1.7
9.8
8.8
2.0
Kg-cm
40
80
90
40
35
35
20
100
90
Remarks
Using the tool provided
Using a piston stopper & LOCK TIGHT
Using the tool provided
20
PROPELLER HUB REMOVAL
● Remove the propeller hub as specified below.
Piston stopper
P/N: 4810-96220
M6x1.0
L=about 45
Turn
Spanner provided
P/N: 8488U3000
Stud bolt
P/N: 848EW052Y0
Nut (M8xP1.25) x 2
P/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 (1260-
41320) to prevent skipping of the piston
pin.
(B)
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
Q'TY/
UNIT
KEY# PART NUMBER
DESCRIPTION
REMARKS
1
2
3
4
5
6
7
8
848EW08100 CARBURETOR ASSY
1
1
1
1
1
1
1
1
3306-81380
3080-81120
3310-81130
3304-81140
1172-81150
2850-81290
3310-81260
•
•
•
•
•
•
•
SCREEN
COVER
SCREW
GASKET
DIAPHRAGM
GASKET
DIAPHRAGM
10
3310-81280
•
METERING COVER
1
12
13
14
15
16
17
18
19
2867-81270
3356-81310
1480-81420
3310-81230
3310-81240
3310-81250
2630-81330
3350-81380
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
SPRING
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
4
1
1
1
1
1
1
1
VALVE, inlet
PLUG, welch
LEVER
SCREW
PIN
SCREW
SPRING
20 848EW081T0
SHAFT, throttle
SPRING
SCREW
VALVE, throttle
RING
SHAFT, choke
VALVE, choke
SPRING
BALL
SCREW
SPRING
NEEDLE, low speed
SPRING
NEEDLE, high speed
BALL
SPRING
21
22
23
24
2670-81410
2880-81470
1282-81340
1148-81390
25 T2070-81460
26
27
28
29
30
31
32
2841-81451
3350-81350
3350-81220
3310-81351
1491-81160
1148-81171
3080-81320
33 T2070-81330
34
35
36
2812-81520
2810-81530
2812-81510
PISTON
17
PARTS LIST
18
PARTS LIST
KEY# PART NUMBER
Q'TY/
UNIT
Q'TY/
UNIT
DESCRIPTION
REMARKS
KEY# PART NUMBER
DESCRIPTION
REMARKS
1
2
3
4
5
6
7
8
9
848EW012A1 CYLINDER
1
1
6
1
1
1
1
1
1
1
1
1
4
1
1
1
2
1
2
1
1
1
1
1
25
26
1152-43290 WASHER
8488608000 NUT
1
1
1
2
1
1
4
1
1
1
1
1
1
1
2
1
1
2
1
1
1
1
1
848EW012B0 GASKET, cylinder
8488441800 BOLT
27 848EW071N0 SENSOR
848EW014A0 INSULATOR
848EW014B1 GASKET, insulator
848EW02110 CRANKCASE COMP.
848EW021D0 GASKET, case
1155-21240 BEARING
28
29
8488441400 BOLT
3699-92369 SPARK PLUG
Y82
30 848EW053X0 MOUNT PLATE
31 3819-54780 SCREW
32 848EW07120 UNIT ASSY
33 01252-30410 B0LT
06034-06001 BEARING
10 T1600-21240 BEARING
11 04065-02812 SNAP RING
12 T1600-21210 SEAL
34 01641-20405 WASHER
35 848EW08100 CARBURETOR ASSY
36 T2070-82410 LEVER, choke
37 848H7014C1 GASKET
13
3310-72150 BOLT
14 848EW041A1 PISTON
15 T2071-41210 RING
38 848ES08300 AIR FUNNEL
39
40 848EW015A0 MUFFLER
41 1140-13141 GASKET, muffler
8488455000 BOLT
16
17
18
19
1101-41310 PISTON PIN
1260-41320 SNAP RING
5500-41410 BEARING
1101-41340 WASHER
42 01252-30540 BOLT
43 8488U30000 SPANNER
44 848EW093A1 OWNER'S MANUAL
20 848EW04200 CRANKHAFT COMP.
21 848EW042D0 KEY
45
46
47
1101-96220 ROD ASSY
4810-96220 STOPPER
OPTION
OPTION
OPTION
22
1140-43250 SHIM
23 848EW05290 HUB COMP.
24 848EW052Y0 STUD
X374320099 CAP REPAIR KIT
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
Head Office : 1-9 Minamidai, Kawagoe-city, Saitama, 350-1165 Japan
Phone: (+81)49-243-1115 Fax: (+81)49-243-7197
20
|