Garmin 3006C GPS Receiver User Manual
Contents
1. ENGINE INSTRUCTION MANUAL G26 Air G26 23 I Marine G26 G2331 Heli G38 G62 8 Twin G45 0000000 Table of Contents nine m sagged dud ated DC sau dnc aa s hack sha 3 ATE y lt 5 y usu ace aura edt tzG d 27323 2 2 273 4 2 3 oedema 4o 19 379 309 V DR 3 Support Equipment 4 Mounting the Engine 5 ar cn a ee 5 IC d EE 5 SEELEN L ui a a DIOS RR RR awia auqa an mans 5 Starting the Engine Heli amp Boat 6 ANS ENJING aci ms pom ed Qa ma duse 6 Carburetor Adjustment 6 Engine Care ana VISITED BTOB EEN 7 Recommendations uso dd dei nn 7 Servicing the le TEEN 7 7 ASSEADIY uu uyawan aaa st eta hay Mu E ce 8 s a ag E E 9 Troubleshooting Guide for Gasoline Engines 11 Propeller CHE d ac aea aca a arua au aa era wae god ae 12 dor OR ge 13 Exploded MIUSNATIBI a icc die c Re CR RR CR RC ataca ataca dass ataca Ee e Ee ECCE2. No Description unit No Part No Description unit No Part No Description unit 1 ZEN44501 CYLINDER 2 22 ZEN44522 PISTON 2 43 ZEN44543 MOUNT 1 2 ZEN44502 MANIFOLD 1 23 ZEN44523 PIN RETAINER 4 44 7EN44544 3 3 ZEN44503 MANIFOLD GASKET 2 24 ZEN44524 BEARING 2 45 7EN44545 Boss 1 4 ZEN44504 MANIFOLD BOLT 4 25 ZEN44525 THRUST WASHER 4 46 ZEN44546 CLUTCH COMP 1 5 ZEN44505 CARBURETOR ASS Y 1 26 ZEN44526 CRANKSHAFT COMP 1 47 ZEN44547 SPRING 1 6 ZEN44506 CARBURETOR GASKET 1 27 ZEN6228 SHIM 0 2 48 ZEN44548 COLLAR 1 7 ZEN4547 CARB BOLT 2 28 ZEN6227 KEY 1 49 7EN44549 WASHER 1 8 ZEN44508 CYLINDER GASKET 2 29 ZEN6229 1 50 ZEN44550 1 9 ZEN44509 8 30 ZEN6235 ROTOR 1 51 ZEN44551 1 10 ZEN44510 CRANKCASE ASS Y 1 31 ZEN6236 SOURCE COIL 1 52 ZEN44552 HUB PROPELLER COMP 1 11 ZEN6213 4 32 ZEN6238 IGNITION COIL 2 53 ZEN44553 PIN 2 12 ZEN6215 BEARING 2 33 ZEN44533 CORD 1 54 ZEN6232 HUB BOLT 2 13 ZEN6214 SNAP RING 2 34 ZEN6238 PLUG CAP BLACK 2 55 7EN6233 HUB WASHER 1 14 ZEN44514 BEARING 1 35 ZEN6239 CAP SPRING 2 56 ZEN6234 PROP BOLT 1 15 ZEN6217 FRONT OIL SEAL 1 36 ZEN6242 SPARK PLUG C859 2 57 ZEN6247 TAP PROP BOLT 1 16 ZEN6276 FUEL NIPPLE ELBOW 1 37 ZEN44537 SCREW 4 58 ZEN44555 SOCKET 1 17 ZEN44517 PIPE 1 38 7EN44538 SCREW 2 59 7EN6251 PULLER ASSY OPTIONA
3. 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 throt tle 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 Zenoahe 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 approxi mately 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 chok
4. 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 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 pro duce 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 obser vance of safety precautions Support Equipment Disassembly The Zenoah engine
5. 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 pro peller 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 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 T Set the throttle valve at the idle position or at the position slightly open from idle
6. EE d 14 GeO koe ORAL UA E 14 G30 WC ee Oe ee oe ae ee re ee ee eee rrr rr ee ee ee eer DY 16 G45 m te tee eee te dela ee oe s 17 cp ee ee ee eT eee eee eee ee a e ee gg 18 MEER 19 Warranty Monai EREECHEN 20 Warranty Repairs 20 Non Warranty Repairs 20 Registration FOr z yaaa a A aa a ay 21 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 Safety Instructions 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 This manual describes the engine s features and func tions For specific information on mounting see the instruction manual included with the model airplane heli copter 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
7. can be disassembled or reassem bled 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 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 25 401 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 hea
8. 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 t 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
9. 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 Engine Care and Maintenance continued Maintenance Chart Items Action Before Use Every 25 hours Every 100 hours Note Leakage heck Damage Crack a Losing Speed Check Adjust Vv vV v Air cleaner PUH Check Cleaning v v Vv Replace if necessary Spark Plug gap Check Adjust V Cylinder barrel Check Cleaning 4 4 t Piston Ring Check Cleaning L vV t Muffler amp Bolt Check Cleaning e v v t Bearings Check Cleaning vV 4 t Crankshaft Check Alignment L t Rotor Check vV t Propeller Hub PU Check Alignment L t Water Jacket PUM Check Leakage v Z vV t Specifications amp Technical Data Items Unit G260PU G260PUM G260PUH G231PUM G231PUH Type Air Cooled Water Cooled Air Cooled Water Cooled Air Cooled Bore x Stroke mm 34 x 28 32 28 Displacement cm 25 4 lt 22 5 lt Effective Compression Ratio n 84 bs e Type Walbro WT 645 WT 644 WT 677 WT 644 WT 677 Ca
10. the spark Geen Turn on EE plug and dry it _Wiring is disconnected Repair The carburetor has L The spark plug is defective Replace del properly Readjust The ignition module is defective Replace J air gap is too large Adjust ES ISDOL Replace The spark plug gap is too large Adjust b The engine stops by itself It suddenly stops The crankshaft does not rotate See a or is abnormally heavy The crankshaft The plug cap has come off Put back rotates Wiring disconnection Repair _Spark plug bridge Use a standard plug Use clean fuel The Stop switch has been turned off Turn on It slows down and stops Out of fuel n Refuel out of fuel The fuel is not fed to the carburetor See Water is mixed in the fuel c Lower power output The carburetor has not beeen properly adjusttid Readjust Air suction from a carburetor joint or oil ssa gt Repair Abrasion of the piston ring Replace The fuel is not suitable Replace Overheating t Clogging of the muffler or exhaust port due to carbon Clean The spark plug heat range is not proper Replace d The engine does not stop Overheating See c The Stop switch is defective Repair Switch wiring is disconnected Repair 11 12 Troubleshooting Guide fo
11. 0 43240 ZEN6227 KEY 1 1 1 1 37 1140 43250 ZEN2337 SHIM 1 38 1 2629 71210 ZEN6236 COIL GREY 38 2 1160 71211 ZEN2339M COIL RED 1 39 1155 71110 ZEN2354 ROTOR 1 40 0260 30422 ZEN6241 SCREW M4 x 22 2 2121212 41 0263 30414 ZEN2341 SCREW M4 x 14 2 2121212 42 T2075 72210 ZEN2638 PLUG CAP 1 1 1 1 1 43 1400 72121 ZEN6239 SPRING 1 44 2629 71311 ZEN6237 COIL 1 45 3699 91809 ZEN26451 SPARK PLUG RZ7C 1 1 3699 91975 ZEN2667M SPARK PLUG MARINE ONLY 1 46 0263 30565 ZEN2648 SCREW M5 x 55 2 2121212 47 1142 83110 ZEN2647 SPACER 5 x 10 x 1 6 2 21 12 48 848ES08300 ZEN2649 AIR TUNNEL VENTURI 1 1 1 49 848EP18300 ZEN23150H CLEANER ASSEMBLY 1 50 1000 03030 ZEN2650 TUBE 1 _ _ 51 1 72075 81000 ZEN2651 CARBURETOR ASSY WT 645 EE 51 2 T2076 81000 ZEN23151 CARBURETOR ASSY WT 644 1 51 3 12077 81000 ZEN23152 CARBURETOR ASSY WT 643 1 1 52 1152 43260 ZEN2359 HUB 53 1152 43281 ZEN2360 STUD 54 1152 43290 ZEN2361 WASHER 55 3350 53410 ZEN2362 NUT M8 56 1140 13141 ZEN23156 GASKET MUFFLER 2 1 2 57 1 01252 30550 ZEN2357 BOLT M5 x 50 2 57 2 01252 30560 ZEN2357H BOLT M5 x 60 2 2 58 1 0263 30408 ZEN2358 SCREW M4 x 8 58 2 0263 90416 ZEN2358H RC SCREW x 16 1 1 59 1 12075 15110 ZEN2655 MUFFLER 59 2 1148 08010 ZEN2355 MUFFLER 1 1 60 1145 15412 ZEN2366 SP
12. 1 ZEN6227 KEY 1 50 ZEN6247 BOL 1 13 ZEN4513 CRANKCASE COMP 1 32 ZEN6229 FLYWHEEL NUT 1 51 ZEN6248 MOUNT 1 14 ZEN6213 CASE PIN 3 33 ZEN6230 PROP HUB 1 52 ZEN6249 BOL for GA50PU 4 15 ZEN6214 SNAP RING 1 34 ZEN6232 HUB BOLT 2 53 ZEN6250 WASHER 4 16 ZEN6215 BEARING 2 35 ZEN6233 WASHER 1 54 ZEN6251 PULLER ASSEMBLY 1 17 2 6216 REAR OIL SEAL 1 36 ZEN6234 PROP BOLT 1 55 ZEN6252 STOPPER OPTIONAL 1 18 7 6217 FRONT OIL SEAL 1 37 ZEN6257 MAGNETO ASSEMBLY 1 56 ZEN6253 GUIDE OPTIONAL 1 19 7 6276 ELBOW FUEL NIPPLE 1 38 ZEN6235 ROTOR 1 57 ZEN4557 WRENCH OPTIONAL 1 20 ZEN4520 CASE GASKET 1 39 ZEN6236 SOURCE COIL 1 17 Exploded Illustration G62 8 Accessory for G620PU 1 13 12 2 M 2 d HN j Index Q ty Index Q ty Index 0 ty No Part No Description unit No No Description unit No No Description unit 1 ZEN6201 CYLINDER 1 21 7 6221 PISTON RING 4 39 7 6239 PLUG CAP SPRING 2 ZEN6202 INSULATOR GASKET 1 22 ZEN6222 PISTON PIN 1 40 ZEN6240 JIGNITION COIL SCREW 2 3 ZEN6203 INSULATOR 1 23 ZEN6223 PIN RETAINER 1 41 7 6241 SOURCE COIL SCREW 2 4 ZEN6204 CARBURETOR GASKET 1 24 ZEN6224 NEEDLE BEARING 2 42 ZEN6242 SPARK PLUG C859 1 5 ZEN6205 CYLINDER BASE GASKET 1 25 ZEN6225 CONNECTING ROD SPACER 1 43 ZEN6243 CARBURETOR ASSEMBLY 1 6 ZEN2309 CYLIND
13. 12075 2111 ZEN23114 CRANKCASE COMPLETE 1 1 1 1 1 13 CRANKCASE REAR 1 1 1 1 1 14 CRANKCASE FRONT 1 1 1 1 1 15 2629 21130 ZEN6213 PIN 3 23131313 16 72075 21140 ZEN23116 GASKET 1 1 1 1 1 17 2169 21210 ZEN2317 SEAL 12 x 22x 7 1 1 1 1 1 18 1155 21240 ZEN2318 BEARING 2 2121212 19 04065 02812 7 2319 SNAPRING 1 1 1 1 1 20 06034 06001 ZEN2320 BEARING 1 1 1 21 1850 21220 ZEN2321M SEAL 12 x 28 x 7 1 11 Exploded Illustration G26 G231 continued Quantity per unit Key Zen Part HH Part Description G260 G260 G260 G231 6231 PU PUM PUH PUM PUH 22 01252 30530 ZEN2322 BOLT M5 x 30 4 4114414 23 1 T2088 41110 ZEN2623 PISTO 1 1 23 2 12070 41110 ZEN2320RC PISTO 24 1 T2088 41210 7 26224 RING 1 24 2 T2070 41210 ZEN2321RC RING 25 1 1600 41310 ZEN2625 PISTON PIN 1 25 2 1101 41310 ZEN2325 PISTON PIN 26 1260 41320 ZEN2326 SNAP RING 2 2121212 27 5500 41410 ZEN2327 BEARING 1 1 1 1 1 28 1101 41340 ZEN2328 WASHER 2 2 2 2 2 29 12075 42000 ZEN23129 CRANKSHAFT COMPLETE 1 1 1 1 1 30 1155 74110 ZEN2330 MOUNT PLATE 1 1 31 0262 10516 ZEN2331 SCREW M5 x 16 3 3 13 3 3 32 1650 43230 ZEN2332 NUT M8 1 33 1160 75210 ZEN2333M PULLEY 1 34 1861 75101 ZEN2634 RECOIL ASSEMBLY 1 1 35 0263 30414 ZEN2341 SCREW M4 x 14 4 4 4 4 36 100
14. 2 000 9 000 507138 645 152mm 130mm 185mm 2 000 10 000 BIS07145 G62 162 5mm 140mm 185mm 2 000 10 000 BIS07163 GT80 191 5mm 257mm 190mm 1800 10 000 BIS07445 6 SPECIFICATIONS Displacement Bore Stroke Weight K HP Carb cu in in in oz ISO H M Walbro G26A M H 1 55 1 41 1 1 54 57 M8x1 25 6x1 2 4 WT645 WT644 WT677 G231M H 14 1 3 1 1 54 M8x1 25 2 2 WT644 WT643 G38 2 3 1 5 1 3 67 M10x1 25 2 2 WT338 WTA 6A G45 2 74 1 69 1 22 74 8x1 3 3 HDA 48D G62 3 8 1 9 14 73 10x1 4 75 HDA 48D GT80 4 8 1 59x2 1 22x2 126 6 WJ 64 w spring starter 13 14 Exploded Illustration G26 G231 vi Quantity per unit Key Zen Part HH Description G260 G260 G260 G231 G231 PU PUM PUM PU 1 1 72075 12110 ZEN2601 CYLINDER 1 1 1 2 72077 12110 ZEN2301RC CYLINDER 1 2 1 T2076 12110 ZEN2601M CYLINDER 1 2 2 12078 12110 ZEN23102M CYLINDER 1 3 12076 12210 ZEN23103M JACKET 1 1 4 07851 00515 ZEN2304M JOINT 21 12 5 07000 13040 ZEN32105M O RING 3 x 40 1 1 6 12076 12320 ZEN23106M O RING 1 5 x 15 5 1 1 7 1160 12330 ZEN23107M BOLT 3 8 2 2 8 12075 13120 ZEN23108 GASKET CYLINDER 1 1 1 1 1 9 3310 12281 ZEN2309 BOLT M5X20 6 6 6 6 6 10 12075 13150 ZEN23110 GASKET INSULATOR 1 1 1 1 1 1 1148 13162 ZEN23111 INSULATOR 1 1 1 1 1 12 72075 14120 ZEN23112 GASKET CARBURETOR 1 1 2 11 2
15. ACER 1 1 61 1158 15420 ZEN2367 SPACER 1 1 62 13039 91310 ZEN23124RC SOCKET 1 1 1 1 1 12075 98110 ZEN23144 OPTION FOR G260PUM G231PUM ONLY 1 1 15 16 Exploded Illustration G38 Standard Accessory for G380PU Index Q ty Index Q ty Index Q ty No Part No Description unit No No Description unit No Part No Description unit 1 ZEN3801 CYLINDER 1 21 2 3821 PIN RETAINER 2 37 7 3837 MODULE 1 2 ZEN3802 INSULATOR 22 ZEN3822 CONROD SPACER 2 38 ZEN3838 ROTOR NEW 3 7 3803 CARB GASKET 23 ZEN3823 CONROD BEARING 1 39 ZEN3839 SPACER MODULE 3 4 ZEN3804 INSULATOR SCREW 2 24 ZEN3824 CRANKSHAFT 40 ZEN6238 PLUG CAP BLACK 1 5 ZEN3805 INSULATOR GASKET 1 25 ZEN3825 CRANKSHAFT BEARING 2 41 ZEN6239 CAP SPRING 6 7 3806 MUFFLER ASSEMBLY 26 ZEN3826 FRONT OIL SEAL 1 42 ZEN6242 SPARK PLUG C859 11 ZEN3811 MUFFLER GASKET 27 ZEN3827 SNAP RING 43 ZEN3843 MODULE BOLT 3 12 7 3812 MUFFLER BOLT 2 28 ZEN3828 REAR OIL SEAL 44 1 ZEN3844 CARB ASS Y HI 338 W CHOKE 1 13 7 3813 CRANKCASE 1 29 ZEN3829 KEY 44 2 ZEN3850 CARB ASSY WTA 6 W O CHOKE 14 7 3814 CASE BOLT 4 30 ZEN3830 ROTOR NUT 45 ZEN3845 CARB SCREW 2 15 ZEN3815 CASE WASHER 4 31 ZEN3831 LOCK WASHER 46 ZEN3846 MOUNT 1 16 ZEN3816 CASE PLUG 1 32 7EN3832 ROTOR WASHER 47 ZEN3847 MOUNT
16. ER BOLT 4 26 ZEN6226 CRANKSHAFT COMP 2 44 7 6244 CARB MOUNT SCREW 2 7 7 6207 MUFFLER 1 27 ZEN6227 KEY 1 45 ZEN6245 WASHER 2 8 ZEN6208 MUFFLER GASKET 1 28 ZEN6228 SHM 2 46 ZEN6246 WASHER 2 9 ZEN6209 MUFFLER BOLT 2 29 ZEN6229 FLYWHEEL NUT 1 47 ZEN6247 TAP PROP BOLT 1 10 7 6210 MUFFLER NUT 2 30 ZEN6230 HUB PROPELLER COMP 0 2 48 ZEN6248 MOUNT x 1 11 12 ZEN6211 CRANKCASE COMP 1 FOR 6620PU 1 1 49 ZEN6249 D SR 4 13 ZEN6213 CASE 3 31 ZEN6231 PIN FOR G620PU 1 1 50 ZEN6250 WASHER 4 14 ZEN6214 SNAP RING 1 32 ZEN6232 HUB BOLT 2 51 ZEN6251 PULLER ASSEMBLY 1 15 ZEN6215 BEARING 2 33 ZEN6233 PROP WASHER 1 52 ZEN6252 STOPPER OPTIONAL 1 16 7 6216 REAR OIL SEAL 1 34 ZEN6234 PROP BOLT 1 53 ZEN6253 PISTON PIN GUIDE OPTIONAL 1 17 ZEN6217 FRONT OIL SEAL 1 35 7EN6235 ROTOR 1 ZEN6200 SPRING STARTER 1 18 7 6218 CRANKCASE GASKET 1 36 ZEN6236 SOURCE COIL 1 ZEN6255 HIGH SPEED NEEDLE 1 19 ZEN6219 CASE ASSEMBLY BOLT 4 37 ZEN6237 IGNITION COIL 1 ZEN6256 LOW SPEED NEEDLE 1 20 ZEN6220 PISTON 1 38 ZEN6238 PLUG CAP BLACK 1 ZEN6257 MAGNETO ASSEMBLY 1 18 Exploded Illustration GT80 G69 9998 AOL SE Index Q ty Index Q ty Index Q ty No
17. ING for 6380 0 4 17 2 3817 PLUG GASKET 33 ZEN3833 PROP HUB NEW ZEN3870 GASKET SET 1 18 7 3818 PISTON 34 7EN3834 HUB BOLT 2 ZEN3871 SCREW NUT SET 19 7 3819 PISTON RING 35 ZEN3835 PROP WASHER NEW 1 20 7 3820 PISTON PIN 36 7 3836 PROP BOLT NEW 2 Exploded Illustration G45 Index Q ty Index Q ty Index 0 ty No Part No Description unit No Part No Description unit No No Description unit 1 ZEN4501 CYLINDER 1 21 ZEN4504 BOLT 4 40 ZEN6237 IGNITION COIL 1 2 ZEN4502 INSULATOR 1 22 ZEN4522 PIPE 1 41 ZEN6238 PLUG CAP BLACK 1 3 7 4503 INSULATOR GASKET 1 23 ZEN4523 PISTON 1 42 ZEN6239 CAP SPRING 1 4 ZEN4504 BOLT 2 24 ZEN4524 PISTON RING 2 43 ZEN4543 SOURCE COIL SCREW 2 5 ZEN6204 CARBURETOR GASKET 1 25 ZEN4525 PISTON PIN 1 44 ZEN6241 COIL SCREW 2 6 ZEN4506 CYLINDER GASKET 1 26 ZEN6223 PIN RETAINER 2 45 ZEN6242 SPARK PLUG 1 7 7 4504 BOLT 4 27 ZEN6224 CONROD BEARING 1 46 ZEN6243 CARBURETOR ASSEMBLY 1 8 ZEN6207 MUFFLER 1 28 ZEN4528 WASHER 2 47 ZEN4547 Bou 2 9 7 6208 MUFFLER GASKET 1 29 ZEN4529 CRANKSHAFT COMP 1 48 ZEN6245 WASHER 2 10 ZEN6209 MUFFLER BOLT 2 30 ZEN6228 SHIM 0 2 49 ZEN6246 WASHER 2 11 ZEN6210 MUFFLER NUT 2 3
18. L 1 18 7EN44518 CRANKCASE GASKET 1 39 7 44539 MUFFLER 2 60 7 44554 STOPPER OPTIONAL 1 19 ZEN44509 BOLT 4 40 ZEN44540 MUFFLER GASLET 2 ZEN44556 HIGH SPEED NEEDLE 1 20 ZEN44520 PISTON 2 41 ZEN6209 MUFFLER BOLT 4 ZEN44557 LOW SPEED NEEDLE 1 21 7 44521 PISTON RING 4 42 ZEN44542 NUT Index Q ty 680 No Part No Description unit 01 ZEN8001 CYLINDER 2 02 ZEN8002 INTAKE MANIFOLD BLACK 1 20 7 8020 PISTON 2 21 7 8021 PISTON RING 2 20 Warranty Information Zenoah engines are guaranteed against workmanship and manufacturing defects for a period of 3 years from the original date of purchase This warranty is limited to the original purchaser and is not transferable Warranty repairs will not cover Normal engine wear e Damage due to insufficient maintenance e Damage related to over revving of the engine due to small prop size or unreasonable use e Rusted bearings Crash damage e Damage due to use of improper fuel and or spark plug e Damage due to lean runs such as rusted bearings seized connecting rod or piston etc Damage caused by foreign objects e Damage caused by unreasonable mounting or running conditions dust insufficient cooling improper mount ing improper propeller size of lack of balancing etc Damage due to improper disassembly Modifications of any kind If your engine needs repair ship it in its original box f
19. ases 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 Operation continued High Speed Needle Turning this needle clockwise makes the gas mixture leaner and turning it counter clockwise 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 pro peller 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 nos
20. e 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 rotor pitch 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 Black Lead Engine E Body Ground Kill Switch 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 posi tions They may need minor adjustment depending upon the temperature humidity atmospheric pressure alti tude 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 1 s plus minus 1 4 b High Speed Needle 1 s plus minus 1 4 Idle Screw Turning this screw clockwise increases the idling rpm Turning it counterclockwise decre
21. e 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 e 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 dam age to the piston or connecting rod if the stopper is not screwed in to the bottom b Loosen and remove the rotor
22. nd mailed to Horizon Service Center Attn Zenoah Warranty 4105 Fieldstone Road Champaign IL 61822 Warranty Information continued Registration Form Fill in and mail this form along with your dated sales receipt Send a copy keep the original for your files within 10 days of purchase to Horizon Service Center Attn Zenoah Warranty Dept 4105 Fieldstone Road Champaign IL 61822 Engine Type Date of Purchase Owner s Name Street Address City State Zip Daytime Phone Number Purchased From Dealer s Name Street Address City State Zip Please cut on dotted line 21 22 23 Copyright 2003 Horizon Hobby Inc ox www horizonhobby com 6135
23. p 6 Fit the bearings snap ring and oil seal to the crank shaft 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 muf fler bolts and mount the muffler 14 Apply threadlock Blue Threadlock Z 42 to the igni tion 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 6 38 Place a thick ness 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
24. r mm 08 97 98 08 07 98 Micro Meter Connecting Rod small end mm gii 011 05 gii 011 05 Cylinder Gauge Crankshaft Dia at Main Bearing mm 012 011 98 012 011 98 Micro Meter Eccentricity mm 0 07 0 07 Dial Gauge Axial Play mm 0 5 0 5 Thickness Gauge Gritty or Gritty or 2 Main Bearing Has Flat Spot Has Flat Spot Troubleshooting Guide for Gasoline Engines Generally speaking there are very few things that will installed Should the engine fail to start after these items keep today s modern engines from starting Use good are verified refer to the charts on the following page quality fresh fuel and make sure that good plugs are a The engine does not start The crankshaft Seizure intrusion of a foreign substance Disassemble and repair does not rotate mu Clogging inside the The crankshaft The fuel has not been fed to carburetor Disassemble and clean rotates Clogging of the fuel Cian piping The fuel has been fed to the T No compression 7 Loosened Tighten further carburetor normally 7 kg cm spark plug 99 5 psi more Abrasion or damage of Replace Compression adequate the cylinder piston or piston ring The spark plug does not spark The spark plug does spark i Remove
25. r Gasoline Engines continued In the event that none of the above procedures result in the engine running properly contact our service department for suggestions at Propeller Chart Horizon Hobby Inc 4105 Fieldstone Road Champaign IL 61822 Phone 217 355 9511 M F 8 00 5 00 CST This chart enables you to select the best propeller for initial setup of your Zenoah engine Remember it s imperative to balance each propeller prior to installation onto your Zenoah engine Failure to do so may cause unwanted vibration in your aircraft ENGINE PROPELLER G26A 16x8 8 700 6231 Heli Adjust pitch of rotor to obtain G26 Heli 9 000 10 000 rpm of the engine at full throttle G26 Marine 0231 Marine Diameter 65 75mm Pitch ratio 1 9 1 4mm G38 Gas 18x10 7 300 G45 Gas 20x10 7 200 G62 Gas 22x10 7 200 GT80 Gas 22x12 7 200 24x10 7 200 Note All recommendations are based on engines using APC brand props Engine Specifications OUTSIDE DIMENSIONS MM Operating Optional Items Length Width Height RPM Mufflers G26A 139mm 105mm 181mm 2 000 10 000 507123 G26M 139mm 105mm 181mm 2 000 10 000 G26H 139mm 105mm 181mm 2 000 10 000 G231 HELI 142mm 105mm 181mm 3 000 11 000 G231 MARINE 142mm 105mm 181mm 3 500 15 000 G38 170mm 130mm 215mm
26. rburetor Venturi mm 127 lt e Air Cleaner Dry Type Dry Type Hand Flippi Starting SC 2 f Recoil Starter 4 m Type CDI lt nition BTDC rpm 28 7000 30 7000 amp STD RZ7C e amp Spark Plug Option CMR8H 7H CMR6H 7H 1800 Idle Speed rpm 18x 8 3500 3000 3500 3000 Max Power rpm 1 62 12000 2 16 12000 1 71 13000 2 09 12000 1 58 13000 Min Torque rpm 1 48 9000 1 94 9500 1 42 9500 1 79 10000 1 34 9000 Fuel Consumption CC 790 710 760 T20 700 Weight kg 1 69 1 52 1 54 1 77 1 57 1 55 1 78 1 58 Engine Care and Maintenance continued Maintenance Specifications Items Standard Limit Standard Limit Measuring Device Remarks Cylinder Bore mm 934 Plating damaged 932 Plating damaged Eye Checking At the skirt end and Diameter mm 933 97 933 87 931 97 931 87 Micro Meter the right angle to the piston pin Piston Rin Groove Width mm 101 111 101 111 Thickness Gauge Piston Piston Ring Hole mm 08 01 08 05 08 01 08 05 Cylinder Gauge Clearance between Piston Micro Meter 03 0 1 03 0 1 and Cylinder m 0 03 0 05 0 15 0 03 0 05 0 15 Cylinder Gauge Clearance between Groove f and Piston Ring mm 0 02 0 04 0 1 0 02 0 04 0 1 Thickness Gauge Piston End Gap mm 0 05 0 25 05 005 025 05 Thickness Gauge en medesima Ring Width mm 0 98 0 93 0 98 0 93 Micro Meter Piston Pin Diamete
27. reight prepaid to Horizon Service Center Attn Zenoah Service 4105 Fieldstone Road Champaign IL 61822 Phone 217 355 9511 Note Do not use the engine s original box as the shipping box Rather package this box inside a sturdy shipping box 1 Include complete name and address information inside the carton as well as clearly writing it on the outer label return address area 2 Include a note containing a brief summary of the difficulty and include the following information Propeller size and brand used Type of spark plug used Type of engine mount Approximately how much running time the engine had before difficulty 3 Date your correspondence and be sure your name and address appear on this enclosure 4 Include a phone number where you can be reached during the business day Warranty Repairs To receive warranty service you must include your origi nal dated sales receipt to verify your proof of purchase date Providing that warranty conditions have been met your engine will be repaired without charge Non Warranty Repairs Should your repair cost exceed 50 of the retail purchase cost you will be provided with an estimate advising you of your options Any return freight for non warranty repairs will be billed to the consumer We accept both Visa and MasterCard for payment Please include your card number and expiration date The Consumer Warranty Registration below must be completely filled out a
28. securing nut 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 con necting 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 circli
29. vily padded glove There are a variety of heavy duty electric starters on the market that can be used Zenoah Start Kit ZEN20002 Zenoah Oil ZEN20001 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 Operation 1 Be sure to set flat washers or a metal plate on the reverse side of the mount to prevent the bolts from sink ing into the mount Periodically check the engine mount for loose bolts 2 Since the engine is equipped with a floatless carbure tor 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 Break In No specific break in is required The engine is gradually broken in as it is used
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