OWNER'S SERVICE MANUAL
Contents
1. M8 BS yy aye 80120kg cm 10 15kg 10 15kg 80 120kg cm 1 De 3 4 4 Es D2. gt das This warranty is valid in Japan only
3. 1 1 G260PU EI 3
4. 6 7 14 2 Y 2 1 2 2 1 1 01252 30550 2 T2075 15110 3 1140 13141 4 0263 30408 5 6 T2075 13150 7 8 9 0 12075 81000 12070 82410
5. 8 23 Parts list 24 Parts list Q TY Key Part Number Description UNIT Remarks 1 848ES512A0 CYLINDER 1 2 T2075 13120 GASKET cylinder 1 3 3310 12281 BOLT M5x20 6 4 T2075 13150 GASKET insulator 1 5 1148 13162 INSULATOR 1 6 T2075 14120 GASKET carburetor 1 T2075 21100 CRANKCASE COMP 1 7 CRANKCASE R 1 8 CRANKCASE F 1 9 2629 21130 PIN 3 10 T2075 21140 GASKET 1 11 2169 21210 SEAL 12x22x7 1 12 1155 21240 BEARING 2 13 04065 02812 SNAPRING 1 14 06034 06001 BEARING 1 15 1850 21220 SEAL 12x28x7 1 16 01252 30530 BOLT M5x30 4 17 72088 41110 PISTON 1 18 72088 41210 RING 1 19 1600 41310 PI
6. 1 8 1 4 1 2 79 9 7L 2 47 HEC RY 71 3 ALES A lt 2 3 ELET
7. E 8 3 8 H L 13 8 1 4 1 3 8 1 4
8. 2 2 10 1 2 EE EE I 1 2 3 4 3 12 5
9. 1 2 3 300 1100
10. D 70 80C 16 0 O OO x 5mm D JU om EUCH am 7 3A 4 8V 4 8V 1500 2700mA 5 x 18x7 12 16x10 14 7500 8500rpm 17 2 25 1 Cc 40 1
11. mm 1 65 0 16 MPa 0 13 0 23 ENS kg cm aoe 2 N MPa 0 07 0 17 Lm kg cm2 0 7 1 7 4 TOT fa N m kg cm 5 P 0 8 3 4 35 5 P 0 8 4 4 45 8 P 1 0 12 7 130 5 P 0 8 6 9 70 5 P 0 8 5 9 60 M10 P 1 0 7 8 80 5 P 0 8 8 8 90 6 P 1 0 9 8 100 M8 P 1 25 9 8 100 21 12 a 8 Box 1 1490 96101 TH 2 4810 96220 3 1101 96220 4 6 3304 97611 M4 M5 M6 lt 5 5500 96110 EL 13 9 1 9 1
12. 11 f 1 Xj 25 100 v v v v v v v v v v t v v t FLO v v v 1 v v t BE v t v v t v v t 2 x mm 34x28 cm 25 4 8 4 2 WT 645 TIE UI m 012 7 3 Y82 rpm 1800 APC 18x8 kg 1 35 X OX 3
13. 848 ES0 8300 1142 83110 0263 30555 2 3 4 3 8mm 4 ra 1 2 3 100mm 4 inches
14. 1 13 3356 81310 VALVE inlet 1 14 1480 81420 PLUG welch 1 15 3310 81230 LEVER 1 16 3310 81240 SCREW 1 17 3310 81250 PIN 1 18 2630 81330 SCREW 1 19 3350 81380 SPRING 1 20 1172 81370 SHAFT throttle 1 21 2670 81410 SPRING 1 22 2880 81470 SCREW 2 23 3310 81340 VALVE throttle 1 24 1148 81390 RING 1 25 T2070 81460 SHAFT choke 1 26 T2075 81450 VALVE choke 1 27 3350 81350 SPRING 1 28 3350 81220 e BALL 1 29 3310 81351 SCREW 4 30 1491 81160 SPRING 1 31 1148 81171 NEEDLE low speed 1 32 3080 81320 SPRING 1 33 T2070 81330 NEEDLE high speed 1 34 3304 81450 SCREEN 1 35 3304 81441 RING 1 36 3360 81440 PLUG 1 26 Czenonn ZENOAH CO LTD Head Office 1 9 Minamidai Kawagoe city Saitama 350 1165 Japan Phone 81 49 243 1115 Fax 81 49 243 7197 T350 1165 1 9 G B 049 243 1110
15. 2 3 1 4 4 5 6 1 4 7 OFF
16. 5 Insulator M5 P 0 8 4 4 45 Rotor M8 P 1 0 12 7 130 Cylinder M5 P 0 8 6 9 70 Crankcase M5 P 0 8 5 9 60 Spark Plug M10 P 1 0 7 8 80 Muffler M5 P 0 8 8 8 90 Stud hub M6 P 1 0 9 8 100 with Locktight glue Nut Propeller M8 P 1 25 9 8 100 12 Special Tools Part Name Part No External Appearance Usage 1 Puller Assy 1490 96101 To remove rotor To hold crankshaft when 2 Piston Stopper 4810 96220 disassembling assembling the rotor 3 Rod Assy 1101 96220 To remove install piston pin For socket screw of 4 Hex Wrench 3304 97611 4mm 5mm and 6mm 5 Snap Ring Pliers 5500 96110 SOLE To remove snap ring d 13 Service Guide Fig 9 Plastic Hammer Rod Assy Arrow Mark 1 REMOVING PISTON PIN Fig 9 1 Remove snap rings from both sides of the piston pin 2 Engage the rod assy 1101 96220 to the piston pin and gently tap with a plastic hammer to push out the pin while holding piston firmly Hard hammering may damage the big end of the connecting rod 2 INSTALLING PISTON Fig 10 1 Make sure to point the arrow mark on the piston to the exhaust side 2 Fit the circlip in the groove so as to face the end gap below Deformed circlip may come off during engine operation and damage the engine 14 Warranty 1 SCOPE OF APPLICATION This engine manufactured by Zenoah Co Ltd hereinafter referred as ZENOAH and so
17. 848 ES5 93A0 704 Czenonn OWNER S SERVICE MANUAL MODEL G260PU El for radio control Airplane A WARNING A These engines are designed for radio controlled products When replacing parts use only parts which have been certified by Zenoah Zenoah assumes that no responsibility for these engines that are modified or used for any other applications Purchaser has all responsibility against any laws and regulations existing in the countries Zenoah is exempt from such laws and regulations Read and completely understand this OWNER S SERVICE MANUAL before operating these engines 1 Safety Precautions This manual describes the engine For its mounting and control see the instruction manual for the model airplane Engine is designed for use on model airplane If it is used for any other purpose we cannot be responsible for its reliability safety and any laws regulations in the countries Use genuine parts for replacement Check the propeller every time If it is damaged replace it with a new one If the propeller hit something while the engine is in operation immediately stop the engine and check it Start the engine on a flat surface without pebble stones When mixing the fuel or operating the engine carry it out in a well ventilated place 2 Engine Assembling The carburetor muffler air funnel and sensor are not assembled at factory Make sure that the assembling f
18. Maintenance 1 MAINTENANCE CHART Before Every Every Items Action Use 25 hours 100 hours Note Leakage Pci Check i d E ldling Speed Check Adjust v Spark Plug gap Check Adjust v v Replace if necessary Cylinder barrel Check Cleaning v v T Piston Ring Check Cleaning v v T Muffler amp Bolt Check Cleaning v v v T Bearings Check Cleaning v v T Crank Shaft Check Alignment v T Rotor Check v v T Propeller Hub Check Alignment v T Oo 2 SPECIFICATIONS amp TECHNICAL DATA Items unit Specifications Type Air Cooled Bore x Stroke mm 34x28 Displacement cm 25 4 Effective Compression Ratio 8 4 Carburetor Type Walbro WT 645 Venturi mm 012 7 Air Cleaner Starting Electric Motor Ignition Type Battery Ignition Spark Plug STD Y82 Idle Speed rpm 1800 APC 18x8 Max Power kW rpm NA Max Torque N m rpm NA Fuel Consumption g kW H NA Weight kg 1 35 Without Ignition System Specifications are subject to change without notice 3 CARBURETOR Items Unit Standard Measuring Device Metering Lever set mm 1 65 0 16 Vanier MPa 0 13 0 23 Inlet Valve Opening Pressure Leak Tester kg cm 1 3 2 3 MPa 0 07 0 17 Inlet Valve Closing Pressure Leak Tester kg cm 0 7 1 7 4 TIGHTENING TORQUE Standard Items Screw Size Remarks N m kg cm Carburetor M5 P 0 8 3 4 3
19. STON PIN 1 20 1260 41320 SNAP RING 2 21 5500 41410 BEARING 1 22 1101 41340 WASHER 2 23 72075 42000 CRANKHAFT COMP 1 24 848ES553X0 MOUNT 1 25 0262 10516 SCREW M5x16 3 26 1650 43230 NUT M8 1 27 848ES57110 ROTOR COMP 1 28 1000 43240 KEY 1 29 1140 43250 SHIM 0 3 30 848EW07120 UNIT ASSY 1 31 3699 92369 SPARK PLUG 1 Y82 32 0263 30555 SCREW M5x55 2 33 1142 83110 SPACER 5x10x1 6 2 34 848ES08300 AIR funnel 1 35 72070 82410 LEVER CHOKE 1 36 T2075 81000 CARBURETOR ASSY 1 WT 645 37 1152 43260 HUB 1 38 1152 43281 STUD 1 39 1152 43290 WASHER 1 40 3350 53410 NUT M8 1 41 1140 13141 GASKET muffler 1 42 01252 30550 BOLT M5x50 2 438 0263 30408 SCREW M4x8 2 44 T2075 15110 MUFFLER 1 45 8488441400 BOLT SENSOR 2 46 848EW071NO SENSOR 1 47 1490 96101 PULLER ASSY 1 OPTION 49 848ES596C0 GAUGE 1 50 4810 96220 STOPPER 1 OPTION 51 1101 96220 ROD ASSY 1 OPTION 52 8488U30000 SPANNER 1 53 1148 08010 MUFFLER 1 OPTION 54 848ES593A0 MANUAL 1 55 X374320099 REPAIR KIT PLUG CAP 1 OPTION KIT 25 Parts list CARBURETOR INNER PARTS Q TY Key Part Number Description UNIT 1 T2075 81000 CARBURETOR ASSY 1 2 3306 81380 SCREEN 1 3 3080 81120 COVER 1 4 3310 81130 SCREW 1 5 3304 81140 e GASKET 1 6 1172 81150 e DIAPHRAGM 1 7 2850 81290 e GASKET 1 8 3310 81260 e DIAPHRAGM 1 i 10 3310 81280 METERING COVER 1 12 2867 81270 SPRING
20. d position of fuel tank can be freely selected The Fuel head between carburetor and bottom of fuel tank must be less than 100 mm 4 inches If the rubber joint is placed between the engine and the body for anti vibration check if the rubber is too week and select the proper hardness of the rubber in order to avoid the unexpected vibration under operating engine RPM zone applying about 10 15 kg by hand as shown in the z Nut M8 figure NOTE Do not tighten the nut M8 with too large torque that may damage the stud 80 120kg cm 4 Ignition Unit Mounting Make sure to install the power switch switch is not supplied Push the sparkplug cap all the way over the sparkplug use gloves Fixate the unit within the fuselage as shown in the diagram Do not wrap the unit by the sponge cloth or the like 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 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 Fig 6 OOOO X Gap 5mm or more surface D surface surface D surface D Sponge amp cloth Fia 7 Switch 9 Sensor wire Capacity 3A or higher Bolt 4mm Unit not supplied For charging f surface D Ground w
21. ire Sensor Use of anything other than an 4 8V battery is prohibited Battery 4 8V 1500 2700mA not supplied Sparkplug wire 5 Propeller Rotor amp Screw Propeller The recommended prop sizes are as shown in the table bellow Diameter x Pitch in 18x7 12 16x10 14 Be sure to use a propeller which makes the engine speed approximately 7 500 8 500 rpm while the airplane is flying When mounting the spinner set a pin on the hub with more than 3mm of diameter thus preventing slipping Mix gasoline octane over 85 premium gasoline and high grade 2 cycle engine oil mixing use type F3C grade or ISO EGC grade at mixing ratio 25 40 1 The mixing ratio may be decided according to the oil recommendation NOTE 1 Never use any alcohol fuel or alcohol added fuel or the rubber parts in the carburetor Will be damaged 2 Gasoline is very flammable Avoid smoking bringing any fires near fuel 3 To prevent all possible problems on fueling system make sure to use the fuel filter which has more than 300 mesh or equivalent and gasoline proof rubber pipe or equivalent Incorrect fuel filter use causes engine trouble like carburetor s fuel passage stuffing or piston surface scratching etc 7 Starting Make sure to fix a spinner and make sure that the helpers hold the airplane firmly Also make sure that the electric motor has a power enough to run the engine at minimum 1 100 rpm How to s
22. ld to the user directly or through distributor manufacturer shall entitle to be covered by this warranty 2 LIMIT OF WARRANTY ZENOAH warrants that 1 The quality disclosed in the specifications 2 The engine which shall be considered defective by ZENOAH caused by material or production fault 3 LIMITS OF COMPENSATION 1 ZENOAH compensates such quality material and production faults by repairing or replacing through distributor manufacturer 2 ZENOAH shall not compensate any other accompanied or benefit losses caused to user and distributor manufacturer by such faults and through repairing or replacing 4 TERMS OF WARRANTY 3 months after purchased by user subject to 12 months from produced month 5 EXEMPT FROM WARRANTY ZENOAH shall not warrant this engine even if the fault has been caused during the period of terms of warranty in case of that 1 Any faults failures caused from neglect of this OWNER S SERVICE MANUAL for proper operation and maintenance Any modifications not approved by ZENOAH Normal abrasion and deterioration Consuming parts Using any parts which have not been certified by ZENOAH Add on or modified parts use oat co DY 11 12 Czenonn G260PU EI e
23. ling 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 Set this needle at a position which is 1 4 open from best mixture maximum R P M position 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 8 1 4 open from the maximum R P M position while the airplane is on ground 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 9 Engine Break In No specific break in is required The engine is gradually broken in as it is used and the output is also gradually increased For checking the whole conditions of the airplane it may be better to operate the engine at slow RPM for 1 3 tank and mid high RPM for 2 3 tank 10 Operation The engine is already tuned up to get high performance and needs correct maintenance to keep such high performance The details for operation as an airplane may be provided from the airplane manufacturer Always keep well maintenance according to the Maintenance clause described in this owner s service manual 11
24. or such parts are done according to the 2 1 and 2 2 Carburetor muffler and air funnel assembling Fig 1 Bolt 01252 30550 Muffler T2075 15110 Gasket 1140 13141 Screw 0263 30408 Engine Gasket T2075 13150 Carburetor T2075 81000 Lever choke T2070 82410 Air funnel 848ES08300 Spacer 1142 83110 Screw 0263 30555 gt Tightening torques see page 9 Sensor assembling Gauge Rotor Fig 2 Affix the gauge to magneto Fig 3 Turn the crankshaft until gauge position at top Fig 4 Fix the sensor on the mount while pushing the sensor Fig 4 Take away the gauge from the rotor Make sure that gasket and carburetor are mounted as the picture If carburetor is mounted upside down position the engine does not start as carburetor does not work correctly 3 3 Engine Mounting Make sure that the G260PU El is mounted on the aircraft grade plywood with more than 8mm of thickness or a mount of equivalent strength and is firmly fixed with 4 bolts If necessary please reinforce the firewall and the around NOTE 1 Tighten the nut M8 with a torque of 80 120 kg cm Fig 5 Be sure to set flat washers or metal plate on the reverse side of the mount to prevent bolts from sinking into the mount Before be sure to check for loose bolts Since the engine is equipped with a float less carburetor with a diaphragm pump the direction of cylinder an
25. tart a Fill the fuel tank with the fuel b Choke the carburetor c Set the throttle valve at idle position or at the position slightly open from the idle position Never open the throttle more than 1 4 of full throttle stroke d Turn the engine by electric motor until first combustion noise is heard e Open the choke and keep the throttle valve at slight open position from idle position f Turn the engine by electric motor then the engine will start Too much run by electric motor at choke condition may have a chance to wet spark plug In this case change the spark plug or dry it thoroughly and remove fuel rest in the cylinder by turning engine under full throttle open choke and without spark plug installing When engine is warm carburetor choking may not be necessary e Hand flip starting is prohibited to prevent the hazards 8 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 running High Speed needle Low Speed needle Fig 8 Idle Screw Standard opening of each needle as follows H L 13 8 1 4 1 3 8 1 4 Idle Screw Turning this screw clockwise increases the id
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