Zenoah G200pu User Manual

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  

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