Zenoah G200PU User manual

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.
Model: G200PU
Model code: X374320000
848EW093A1 (901)

2
Specifications .......................................................................3
Safety Precautions ...............................................................4
Engine Assembly .................................................................6
DC Ignition Unit Mounting ....................................................7
Fuel and Piping ....................................................................8
Throttle Linkage and Engine Mounting ................................9
Items to Confirm Before Starting the Engine......................10
Starting the Engine.............................................................11
Adjustments After Engine Startup ......................................12
Brake in ..............................................................................13
Stopping the Engine...........................................................13
Engine Running Time.........................................................13
Maintenance.......................................................................14
Tightening Torque Chart ....................................................15
Propeller Hub Removal ......................................................15
Other Information ...............................................................16
Parts List ............................................................................17
Warranty.............................................................................20
CONTENTS

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NO. ITEMS SPECIFICATIONS
1. Engine model G200PU
2. Displacement 20.1cm3
3. Bore x stroke ø32mm x 25mm
4. Weight 990g (not including DC Ignition Unit)
5. Carburetor type WT-811
6. Ignition Battery ignition; digital control
7. Sparkplug Champion Y82
8. Rotating direction Counterclockwise (from PTO side)
9. Starting method External motor
10. Sensor gap 0.8 ~ 1.2mm (1.0mm ± 0.2mm)
11. Fuel consumption 1.0 / 9000rpm (at full throttle)
12. Noise (at 2-meter points) 98dBA (APC 15x10)
13. Battery capacity 4.8V / 1500 ~ 2700mA
SPECIFICATIONS

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●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.
SAFETY PRECAUTIONS

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•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.
SAFETY PRECAUTIONS

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The carburetor, muffler, and air funnel
have not been assembled. Please
assemble them correctly, following the
diagram shown below.
ENGINE ASSEMBLY
No. Part Part no. Quantity
1. Bolt 01252-30540 2 8.8
2. Muffler 848EW015A0 1
3. Gasket 1140-13141 1
4. Gasket 848H7014C1 1
5. Carburetor set 848EW09710 1
6. Air funnel 848ES08300 1
7. Bolt 8488455000 2 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.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Tightening
Torque (N-m)

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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).
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.
DC IGNITION UNIT MOUNTING
Sponge & cloth
Gap: 5mm or more
surface D
surface D
surface
D
surface
D
surface D
Bolt (4mm)
Sparkplug wire
Sensor wire
Unit
Battery wire
For charging
Switch
Capacity: 3A (or higher)
Battery 4.8V
1500~2700mA
Use of anything
other than an 4.8V
battery is prohibited.
Ground
wire surface D

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●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.
FUEL AND PIPING
•Do not use a silicon tube.
•Clip the weight so that it
does not come off when
the engine is running.
1. Fuel tank Capacity of 300~400cc
2. Carburetor
3. Weight or weight with felt filter
4. Filter Mesh, 300 or more
5. Fuel pipe Gasoline-resistant rubber or vinyl tube
with inner diameter of 2.5~3mm
6. Fuel pipe Gasoline-resistant rubber tube
7. Air vent pipe
8. Fuel head 100mm or less
(1) (2)
(3)
(4)
(5)
(5)
(6)
(7)
(8)

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●Mount the throttle arm to
the carburetor’s throttle
shaft as shown in the
diagram or use the throttle
valve stopper plate located
at opposite side.
THROTTLE LINKAGE AND ENGINE MOUNTING
Throttle arm
(not supplied)
Stopper screw
Shaft diameter: 4mm
CG line CG line
M4 bolt x4
Claw nut x4
Engine mount
Fuselage bulkhead (firewall):
8mm or more, with hard board
Tightening torque:
90kg-cm
(8.8 N-m)
Gloves
9kg
10cm
●For propeller mounting, use the
wrench provided and make sure
not to over-tighten the bolts.
●Mount the engine as shown
in the diagram.

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●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.
ITEMS TO CONFIRM BEFORE STARTING THE ENGINE