G62PU
Contents
1. 0263 30416 Screw 2 41 0260 30422 Screw 2 42 3699 90032 Spark plug RCJ 7Y 1 43 2629 81004 Carburetor assy HDA 48D 1 44 Body assembly 1 45 3306 81380 Screen inlet 1 46 3350 81130 Cover pump 1 47 3350 81140 Cover diaphragm 1 48 2629 81150 Shaft assy throttle 1 12 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 zenoar ZENOAH C2. above When flipped several times the sound popping sound of initial explosion is heard 4 When the initial explosion is heard open the choke valve set the throttle valve at the idle position or at the position slightly open from the idle position and flip the propeller a few more times Then the engine starts NOTE Be sure to open the choke when the initial explosion is heard When the choke is opened be sure to close the throttle valve to a position near the idle position before starting the next flipping If the engine is started while the throttle is wide 3 open a great thrusting force is produced which is very dangerous Be sure to wear a thick glove when flipping the propeller Use all fingers except thumb for the flipping operation How to Stop the Engine For stopping the engine the black lead wire from the coil should be grounded to the E7731 engine body or the throttle valve should be PASK closed completely KILL SWITCH oe ENGINE BODY EARTH 6 Carburetor Adjustment The carburetor is provided with 3 adjust screws which are set to the best approximately positions by our company but they may need a little adjustment depending on the temperature atmospheric pressure altitude etc of the area where the engine is used Start the engine without making any adjustments Make readjustments only when the engine shows any mal functioning Low Speed Needle 1 Hd High Speed JP Needle Standa
3. c dr pit des Gasoline oil mixture 25 40 1 Spark pUJ ses tire CHAMPION RCJ 7Y Recommended prop sizes inch 22x6 8 20x7 10 18x8 12 Specifications are subject to change without notice 11 Parts List G620PU G620PU 1 G620PU G620PU 1 Index Parts No Description aty inde Parts No Description ra 1 3366 12116 Cylinder 1 49 3366 81340 e Valve throttle 1 2 848C9014B3 Gasket insulator 1 50 3356 81170 Shaft assy choke 1 3 2618 14120 Insulator 1 51 2629 81180 Valve choke 1 4 848C9014C2 Gasket carburetor 1 52 3350 81190 e Stop throttle 1 5 2616 14211 Gasket cylinder base 1 53 3356 81310 e Valve inlet 1 6 3310 12281 Bolt 4 54 3350 81220 Ball friction 1 7 2629 15111 Muffler 1 55 3350 81230 e Gasket pump 1 8 3356 15210 Gasket muffler 1 56 3350 81240 e Gasket diaphragm 1 9 T2100 15220 Bolt 2 57 3350 81250 Lever metering 1 10 2850 15230 Nut 2 58 2618 81260 Diaphragm pump 1 11 12 2629 21100 Crankcase comp 1 59 3350 81270 Diaphragm assy 1 13 2629 21130 e Pin 3 60 2880 81470 Screw valve 3 14 04065 03515 Snap ring 1 61 3310 81240 e Screw metering lever 1 15 06030 06202 Bearing 2 62 1491 81130 Screw pump cover 1 16 1520 21220 Oil seal 1 63 3310 81250 e Pin metering lever 1 17 1400 21220 Oil seal 1 64 2630 81330 Screw idle speed 1 18 2629 21311 Gasket cr
4. zenonv OWNER S MANUAL MODEL G620PU G620PU 1 848H4893A3 704 A WARNING A Do not modify any parts of the engine This engine is designed to be used to Radio controlled products In case any modification by customer ZENOAH shall not bear any responsibility from the damage caused by such modification Keep ignition system well maintained CORMSIYVAIY a RITRARRE ENTHE O A4BA2EnTHHEN ERASI O81 EA Eho ORICBRmtRlomR Biel TOMAS ESL April 2007 1 Safety Precautions This manual describes the engine For its mounting and control see the instruction manual for a model plane This engine is designed for use on the model plane If it is used for any other purpose we cannot be responsible for its reliability or safety Use genuine parts for replacement Check the propeller every time If it is damaged replace it with a new one If the propeller hits something while the engine is in operation immediately stop the engine and check it Start the engine on flat surface without pebble stones Never modify the flywheel Check the flywheel If it is damaged replace it with a new one When mixing the fuel or operating the engine carry it out in a well ventilated place Make sure that the engine is mounted on the aircraft grade plywood with more than 10mm of thickness or a mount of equivalent strength and is firmly fixed with 4 bolts NOTE 1 Be sure to s
5. 51410 or 2629 91510 3544 11510 and 1100 43231 Rotor transformation play airgap 2 Every 25 hours check Spark plug gap cleaning Oylinder abrasion Piston Ring abrasion Bearing Gritty According to the checks replace any part if necessary The engine can be disassembled or reassembled without any specific difficulties but be careful of the following matters a For disassembling the special tools shown in the parts list are required in addition to the general tools Be sure to use a new gasket when the crankcase and cylinder have been disassembled b Removing rotor 1 Screw in the stopper P N 3350 96220 in place of the spark plug Then turn the rotor counterclockwise until the piston touches the stopper Take care it can cause damage to the piston or connecting rod if the stopper is not screwed in to the bottom 2 Loosen and remove the rotor securing nut 3 Remove the rotor by using the puller P N 1490 96101 Do not hit on the crankshaft by a hammer that can increase the runout of the shaft c Assembling crankcase 1 Apply grease on the oil seal lips and oil on the bearing 2 Assemble the crankshaft with a new gasket 3 When both front and rear crankcases are tightened the portion of gasket protruding on the cylinder mounted surface should be cut off with a knife until the gasket becomes flush with the cylinder mounted surface d Assembling piston Before assembling the piston apply the oil on the s
6. O LTD Head Office 1 9 Minamidai Kawagoe city Saitama 350 1165 Japan Phone 81 49 243 1115 Fax 81 49 243 7197 Printed in Japan
7. alcohol added fuel or the rubber part in the carburetor will be damaged Hand flip start Since the engine is equipped with the ultra compact C D I type flywheel magneto ignition system it should be started according to the following procedure The magneto system of the engine is designed in such a way that when the exhaust port is closed by the piston that is when the compression stroke starts Refer to Fig 1 A sparks are never produced on spark plug no matter how fast the propeller may be flipped Be sure to quickly flip the propeller when the edge of magnet on the rotor is approaching the coil Fig 1 B It means that the propeller should be quickly flipped about 90 degrees in crank angle before the compression is about to start Coil s Because of the above conditions the propeller should be mounted to the hub as shown in Fig 2 and quickly flipped within the range of about 180 from the horizontal position Fig 2 mo The cut portions of propeller mount and the propeller should aK be set in the same direction Cut portion NOTE When the engine is mounted so the cylinder is kept horizontal the propeller should be set at a different angle of 90 How to Start the Engine 1 Fill the fuel tank with the fuel 2 Close the choke valve and open the throttle valve approximately 1 3 1 2 of the full open position 3 Quickly flip the propeller in the counterclockwise direction according to the procedure described
8. ankcase 1 65 3310 81351 Screw assy 4 19 3350 21320 Bolt 4 66 3350 81350 Spring friction 1 20 2618 41112 Piston 1 67 1491 81160 Spring needle adjust 2 21 2618 41210 Ring piston 2 68 3350 81370 Spring metering lever 1 22 3366 41310 Pin piston 1 69 3350 81380 Spring idle speed 1 23 3350 41320 Snap ring 2 70 2629 81390 e Spring throttle return 1 24 1400 41410 Needle bearing 1 71 2629 81411 needle high speed 1 25 2616 41510 Thrust washer 2 72 2629 81420 needle idle 1 26 2629 42002 Crankshaft comp 1 73 1480 81420 plug welch 1 27 1000 43240 Key 1 74 2629 82210 Bolt 2 28 1300 42410 Shim 0 2 75 01641 20508 Washer 2 29 1100 43231 Nut 1 76 01601 20513 Washer 2 30 1 2628 51101 Hub propeller comp for G620PU 1 1 77 2629 91510 Bolt L50 1 30 2 04025 00312 Pin for G620PU 1 2 78 01641 21016 Washer 1 31 2629 51111 Hub propeller comp for G620PU 1 79 0290 21025 Washer 1 32 3544 11510 Bolt 2 80 262891110 Mount 1 33 2629 51310 Washer hub 1 81 01252 30614 Bolt fs G620PU 1 4 34 2629 51410 Bolt L45 1 82 0290 20615 Washer 4 35 1490 71110 Rotor 1 83 1490 96101 Puller assy Optional 1 36 2629 71210 Source coil 1 84 3350 96220 Stopper Optional 1 37 2629 71311 Ignition coil 1 85 3356 96230 Guide piston pin Optional 1 38 2850 72110 Cap plug 1 39 1400 72121 Spring plug cap 1 40
9. et flat washers or metal plate on the reverse side of the mount to prevent bolts from sinking into the mount Before flying the air plane be sure to check for loose bolts The mounting bolts should be screwed into the crankcase within 8 12 mm of depth Since this engine is equipped with a float less carburetor with a diaphragm pump the direction of cylinder and position of fuel tank can be freely selected 3 Propeller 1 Recommended prop size The recommended prop sizes are as shown in the table bellow Diameter x Pitch in 22 x6 8 20x7 10 18x8 12 This engine produces the maximum output when the engine is running at about 8 500rpm Be sure to use a propeller which makes the engine speed approximately 7 000 9 000rpm while the airplane is flying When using a propeller of small diameter a light weight propeller is not suitable There are two types of propeller mounting bolts L 45 and L 50 Select the proper type of bolt depending on the thickness of propeller used and the use of the spinner NOTE 1 2 When mounting a thin propeller cut off the end of bolt or add a flat washer When mounting the spinner set a pin on the hub with more than 3 mm of diameter thus preventing slipping Mix gasoline and 2 stroke oil at a mixing ratio of 25 40 1 2 NOTE 1 Be sure to use a gasoline resistant fuel piping Do not use any silicon rubber tube 2 Never use any alcohol fuel or
10. mall end bearing and piston and set the piston ensuring that the arrow mark on the top of piston is directed toward the direction of exhaust port e Assembling cylinder 1 Coat the oil on the inner surface of cylinder 2 The piston is provided with a knock pin which stops the piston ring from turning Set the splitted section of piston ring at the knock pin and assemble the cylinder ensuring not to break the piston ring f Assembling rotor Make sure to put lock tight Medium strength type TreeBond 1322N LOCTITE 242 243 PACER ZAP Z 42 on the rotor fixing nut P N 1100 43231 g Adjusting air gap of coil The air gap of coil should be adjusted to 0 3 mm 0 01 h Adjusting ignition time This engine with the point less C D I type requires no adjustments of ignition time 10 Specifications Model eere G620PU G620PU 1 Type cick San eter Air cooled two stroke cycle gasoline engine Displacement esses 62 0cc 3 78cu in Bore x Stroke sssssssssss 47 5mm x 35mm 1 87 in x 1 38 in Compression ratio esssess 8 2 1 Maximum Output sassen 5 7 PS 9500rpm 4 9 PS 9500rpm with Muffler Operating engine speed 2000 10000rpm Weight siian nette iets 2 0kg 4 4lbs 2 3kg 5 1lbs with muffler Ignition system eeeeese CDI type Flywheel magneto Carburetor wii WALBRO HDA 48D FUGI 5o tions ee
11. rd Opening Position LOW SPEED NEEDLE 1 2 4 Idle Screw C Mr 1 Z HIGH SPEED NEEDLE 1 4 4 NOTE Be sure to stop the engine before starting the adjustment thus ensuring safety Idle Screw Turning this screw clockwise increases the idling R P M Turning it counterclockwise decreases the idling R P M Low Speed Needle This is the fuel adjust screw not the air screw Turning this needle clockwise makes the mixture gas leaner and turning it counterclockwise makes it richer High Speed Needle Turning this needle clockwise makes the mixture gas leaner and turning it counterclockwise richer Set this needle at a position which is 1 4 open from the maximum R P M position while the airplane is on ground NOTE 1 Do not tighten the High and Low Speed needles too firmly 2 When the unit has just started and the engine is not warm enough there may be insufficient acceleration and the engine may be stopped Be sure to perform idling before operation 7 Engine Break in No specific break in is required The engine is gradually getting break in as it is used and the output is also increased gradually 8 Maintenance This engine is used for power source for radio controlled airplane so you are strictly requested to check engine and relative parts of airplane 4 1 Daily check before starting Leakage damage crack Muffler fixing bolts torque crack Propeller hub transformation fixing bolts nut P N 2629
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