ENGINE INSTRUCTION MANUAL - Horizon Hobby

1 ENGINE INSTRUCTION MANUALG26 AirG26/231 MarineG26/G231 HeliG38G62GT80 TwinG45 112345672345672 Table of ContentsIntroduction .. 3 Safety Instructions .. 3 Support Equipment .. 4 Mounting the ENGINE .. 5 Operation .. 5 Break-In .. 5 Starting the ENGINE -Aircraft ..5 Starting the ENGINE -Heli & Boat ..6 Stopping the ENGINE ..6 Carburetor Adjustment ..6 ENGINE Care and Maintenance .. 7 Recommendations ..7 Servicing the ENGINE .. 7 Disassembly ..7 Assembly .. 8 Charts .. 9 Troubleshooting Guide for Gasoline Engines ..11 Propeller Chart .. 12 ENGINE Specifications .. 13 Exploded Illustration .. 14G26/G231 .. 14G38 .. 16G45 ..17G62 ..18GT80 ..19 Warranty Information ..20 Warranty Repairs ..20 Non-Warranty Repairs .. 20 Registration Form ..213 IntroductionSafety InstructionsVery ImportantThis MANUAL describes the ENGINE s features and func-tions. For specific information on mounting, see theinstruction MANUAL included with the model airplane, heli-copter or boat in which you intend to install the ENGINE .

2 This model ENGINE will give you considerable pleasure,satisfaction and performance if you strictly follow thesesafety instructions and take heed of the warnings as tothe ENGINE s safe and proper use. This ENGINE has morethan enough power to cause harm if misused or if thesafety precautions are not Use genuine parts for Check the propeller, rotor (helicopter) or screwpropeller (boat) prior to each time the ENGINE is nicked, scratched, cracked or damaged in any way,replace it with a new Use the correct size and pitch of propeller for yourengine; refer to the propeller chart in this It is extremely important to balance the propellerprior to installation of the ENGINE . Failure to do so maycause damage to the Zenoah ENGINE and/or the tighten the propeller nut against the washerand Inspect the tightness of the propeller nut prior toeach Keep your face and body away from the path of thepropeller blades when starting or running your Use a thickly padded glove when hand startingthe Make all carburetor adjustments from behindthe To stop the ENGINE , the black lead wire from thecoil should be grounded to the ENGINE body, or use thethrottle linkage to shut off the air by closing the throttlevalve NOT USE HANDS, FINGERS OR ANY OTHER PARTOF THE BODY TO STOP THE PROPELLER.

3 DO NOTTHROW ANY OBJECT INTO A PROPELLER TO STOP IT!10. Ensure that all spectators, especially children, are atleast 20 feet away when you start running the Make sure your fuel is kept in a safe place well awayfrom sparks, heat or anything that could ignite the Use safety glasses or goggles when starting andrunning your Do not run the ENGINE in the vicinity of loose gravelor sand. The propeller may throw such materials intoyour eyes. The ENGINE could also ingest these Avoid loose clothing when operating your modelengine, 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 theydo not fall into the on purchasing a Zenoah ENGINE . Caredfor properly, these high-quality, finely crafted engines willoffer many years of INSTRUCTION MANUAL has been developed to ensureoptimum performance from the Zenoah ENGINE you havepurchased.

4 It s important that the instructions are readthoroughly prior to mounting and running the TO READ AND FOLLOW THESE INSTRUCTIONS BEFORE YOU PROCEED MAY RESULT IN ENGINEDAMAGE AND THE VOIDING OF YOUR WARRANTY!4 Safety Instructions (continued)Support EquipmentCaution1. Model engines get very hot while running. Do notattempt to handle them until they have Always run your model engines in a well-ventilatedarea. Similar to automotive engines, model engines pro-duce harmful carbon monoxide Never modify the Check the flywheel. If it s damaged, replace it with anew When mixing the fuel or operating the ENGINE , do soin a well-ventilated area6. Remember that model engines produce a substantialamount of power, more than enough to seriously injurepeople and/or do considerable damage to use common sense, skill and constant obser-vance of safety Zenoah ENGINE can be disassembled or reassem-bled without any specific difficulties. Refer to the EngineMaintenance Section for specific instructions on theseprocedures.

5 If you need service to your Zenoah ENGINE ,please send it to the authorized service center at the following address: Horizon Hobby , : Zenoah Service4105 Fieldstone RoadChampaign, IL 61822 Phone: (217) 355-9511 ENGINE Parts IdentificationIt s important to be able to identify the parts of yourZenoah engines. Attached you will find an exploded viewof Zenoah engines, as well as a chart including partnumbers and descriptions. This will assist you in easilyand rapidly identifying the respective parts of yourZenoah following items are not included with your Zenoahengine but are necessary for Mix gasoline and 2-stroke oil at a mixing ratio of25-40:1. Note:Be sure to use a gasoline-resistant fueltubing (do not use any silicone rubber tube).Never use any alcohol fuel or alcohol-addedfuel as this will damage the rubber part ofthe carburetor. Propeller Refer to the Propeller Selection Chart locatedon Page 8 to determine the best initial propeller for yourparticular or Electric Starter For MANUAL starts, achicken stick is highly recommended.

6 Neveruse yourfingers to start any model ENGINE as you could beinjured. If you must hand-start a gasoline ENGINE , besure to protect your hand with a heavily padded are a variety of heavy-duty electric starters on themarket that can be OilZEN20001 Zenoah Start KitZEN200025 Mounting the EngineMake sure the ENGINE is mounted on the aircraft usingaircraft grade plywood that s at least 6mm in thicknessfor the G26 ENGINE , and 10mm in thickness for the G38through GT80 twin, or a mount of equivalent sure it s firmly mounted with 4 Be sure to set flat washers or a metal plate on thereverse side of the mount to prevent the bolts from sink-ing into the mount. Periodically check the ENGINE mountfor loose Since the ENGINE is equipped with a floatless carbure-tor with a diaphragm pump, the direction of the cylinderand position of the fuel tank can be freely If the ENGINE is mounted on a shock (rubber) mountplaced between the ENGINE and the firewall for anti-vibra-tion, check the hardness of the rubber, making sure it snot too soft, in order to avoid excessive vibration duringengine operating rpms.

7 Note carefully if the ENGINE isvibrating at idle, as excessive vibration can result in erratic ENGINE operation due to overflow at the It is suggested that the bolts for the muffler be coatedwith threadlock when mounting the muffler to the specific break-in is required. The ENGINE is graduallybroken-in as it is used, and the output power increasesgradually as the ENGINE breaks the ENGINE AircraftBefore attempting to start the ENGINE , be sure to readthrough all the steps for starting the ENGINE as outlinedbelow:Zenoah engines are equipped with the ultra type flywheel magneto ignition system and shouldbe started according to the following procedure:Note:The magneto system is timed in such away that when the compression stroke starts(refer to Figure 1-A) sparks are never producedon the spark plug, no matter how fast the pro-peller is flipped. The correct starting procedureis to quickly flip the propeller when the edge ofthe magnet on the rotor is approaching the coil(Figure 1-B).

8 This means that the propellershould be quickly flipped at about 90 degreesin crank angle before the compression stroke isabout to Make sure the spark (glow) plug(s) are installed andtightened. Check the condition of the plug cap for cracksor Be sure the propeller is properly Make sure the fuel tank line(s) are properly main line should be connected to the carburetorspray Be certain the mufflers are installed Fill the fuel Choke the ENGINE and turn the propeller through afew times until the fuel appears at the Set the throttle valve at the idle position or at theposition slightly open from 1-ACoilMagnetFig 1-BOperation6 Operation (continued)8. Quickly flip the propeller in a counterclockwisedirection according to the procedure described inthe note The ENGINE should start after a few flips of Be sure to open the choke when the initial firingof the ENGINE is When the choke is opened, be sure to close thethrottle valve to a position near the idle position beforethe next flipping of the propeller is :If the ENGINE is started when the throt-tle is wide open, a great thrusting force will begenerated, which can be very If you do not use a chicken stick to start the ENGINE ,be sure to wear a thick glove when flipping the propellerand use all fingers, except the thumb, for the Do not over-rev the ENGINE .

9 These engines aredesigned to develop maximum output with the standardmuffler and the recommended propeller size. Pleaserefer to the propeller chart on page 10 to confirm theproper propeller for the applicable Zenoah the ENGINE Helicopter andBoat1. Fill the tank with Push the priming bulb located on the carburetor untilfuel 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 Quickly pull the starter cord until the initial firing ofthe ENGINE is When the initial firing is heard, open the choke, setthe throttle valve at the idle position or at the positionslightly open from the idle position and quickly pull thestarter cord a few more times until the ENGINE For helicopter operation, you should adjust the rotor-pitch to obtain a 9,000 to 10,000 rpm of the ENGINE atfull throttle the EngineThe ability to shut down the ENGINE in an emergency isextremely important. For stopping the ENGINE , the blacklead wire from the coil should be grounded to the enginebody, or the throttle valve should be closed of a stop or kill switch is to the example shown in the following AdjustmentThe carburetor is provided with three adjustment screws,which are factory set to the best (approximate) posi-tions.

10 They may need minor adjustment, depending uponthe temperature, humidity, atmospheric pressure (alti-tude), etc., of the area where the ENGINE is being Start the ENGINE without making any Make adjustments only when the ENGINE shows signsof inefficient Standard settings of each needle is as follows:a. Low-Speed Needle: 11/8plus/minus 1/4b. High-Speed Needle: 13/8plus/minus 1/4 Idle Screw:Turning this screw clockwise increases theidling rpm. Turning it counterclockwise decreases theidling Needle:This is the fuel adjust screw (notthe air screw). Turning this needle clockwise makes thegas mixture leaner, and turning it counterclockwisemakes it LeadBlack LeadKill SwitchEngineBodyGroundHigh-Speed NeedleLow-Speed NeedleIdle Screw7 Operation (continued)High-Speed Needle:Turning this needle clockwisemakes the gas mixture leaner, and turning it counter-clockwise makes it richer. Set this needle at a positionwhich is 1/4 open from the maximum rpm position whilethe aircraft is on the :Do not tighten the high and low speedneedles too the ENGINE has just started and is not warmenough, there may be insufficient accelerationand the ENGINE may die.