Zenoah G45, G26-231, G26, GT80, G26 AIR User Manual

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Zenoah G45, G26-231, G26, GT80, G26 AIR User Manual

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INSTRUCTION MANUAL

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G26/231Marine

G26/G231 Heli

G38

G62

GT80 Twin

G45

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Table of Contents

 

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Support Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Mounting the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Break-In . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Starting the Engine-Aircraft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

Starting the Engine-Heli & Boat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Carburetor Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine Care and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Recommendations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Servicing the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7

Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Troubleshooting Guide for Gasoline Engines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Propeller Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Exploded Illustration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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G26/G231 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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G38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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G45 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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G62 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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GT80 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Warranty Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Non-Warranty Repairs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Registration Form . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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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 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.

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.

3.Use the correct size and pitch of propeller for your engine; refer to the propeller chart in this manual.

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.

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.

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.

11.Make sure your fuel is kept in a safe place well away from sparks, heat or anything that could ignite the fuel.

Recommendations

1.Use safety glasses or goggles when starting and running your engine.

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.

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.

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Safety Instructions (continued)

Caution

1.Model engines get very hot while running. Do not attempt to handle them until they have cooled.

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.

Disassembly

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:

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.

Zenoah Oil

Zenoah Start Kit

ZEN20001

ZEN20002

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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-vibra- tion, 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

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.

Coil

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.

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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.

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

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

body, or the throttle valve should be closed completely. Installation of a “stop” or “kill” switch is recommended.

Red Lead

Black Lead

 

Engine

Kill Switch

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

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.

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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.

Note: Do not tighten the high and low speed needles too tightly.

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.

Engine Care and Maintenance

Recommendations

To extend the life of your Zenoah® engine, the following is recommended:

1.Use a Zenoah quality 2-stroke oil mixed at 32 to 1.

2.Use the recommended spark plugs.

3.Use the proper propeller size and balance the propeller prior to use.

4.Always adjust the engine to a slightly rich setting.

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

Regular screwdriver

Phillips screwdriver

Hexagonal wrench (4mm/5/32")

Open wrench (19mm/3/4")

Plastic hammer

Thickness gauge

Tapered round rod

Liquid gasket (Permatex or equivalent)

Threadlock (Blue Threadlock Z-42 or equivalent)

Lithium grease

Engine oil

Washing gasoline

Brush

Scraper

Cloth

The engine can be disassembled or reassembled without any specific difficulties, but note the following:

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.

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.

2.Remove the carburetor and insulator carefully without damaging the gasket.

3.Remove the muffler.

4.Remove the spark plug and ignition module.

5.Remove the propeller hub.

6.Remove the rotor (flywheel). If it cannot be detached, use a plastic hammer and tap the part lightly.

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.

b.Loosen and remove the rotor securing nut.

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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.

11.Remove the Woodruff key from the crankshaft.

12.Remove the oil seal, snap ring and bearings.

13.Remove the circlip and pull out the piston pin.

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.

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.

2.Fit the piston ring to the piston.

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).

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.

5.Fit the circlip.

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.)

7.Wipe the contact surfaces of the cylinder block and crankcase, and apply liquid gasket (Permatex or equivalent).

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.

10.Check that the crankshaft can be smoothly turned by hand.

11.Put back the Woodruff key.

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.

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.

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.

16.Using a new gasket, fix the insulator with screws

to which threadlock (Blue Threadlock Z-42) has been applied.

17.Using a new gasket, mount the carburetor with screws, paying attention to its mounting direction.

18.Tighten the mounting plate, using screws with threadlock (Blue Threadlock Z-42) applied.

19.Install the spark plug.

Note: Disassembly and assembly steps were written using a G38 engine as an example, but they apply to all engines.

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