Zenoah G200PU User manual

OWNER'S MANUAL
Thank you for purchasing a KOMATSU 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.
●Remodeling 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, ordinance and the like and
that KOMATSU ZENOAH shall bear no responsibility whatsoever.
Model: G200PU
Model code: X374320000
848EW093A0 (603)

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 Following Starting..........................................12
Trial Run.............................................................................13
Stopping the Engine...........................................................13
Engine Running Time.........................................................13
Inspection...........................................................................14
Tightening Torque Chart ....................................................15
Propeller Hub Removal ......................................................15
Other Information ...............................................................16
Parts List ............................................................................17
Warranty.............................................................................20
CONTENTS

3
NO. ITEM 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. Revolution direction Counterclockwise (from PTO side)
9. Starting method External motor
10. Sensor spacing 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

4
●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

5
•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 units.
SAFETY PRECAUTIONS

6
The carburetor, muffler, and air funnel
have not been attached. 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 linkage at a place
where it is easy to do so.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
Tightening
Torque (N-m)

7
1. Make sure to install the power switch.
2. Push the sparkplug cap all the way over the sparkplug.
3. Fixate the body within the fuselage, as shown in the diagram. Make sure
that the sponge, cloth or the like is not enclosed.
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)
Nic battery 4.8V
1500~2700mA
Use of anything
other than an 4.8V
battery is prohib-
ited.
Ground
wire surface D

8
●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 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 shift when the
engine is running.
1. Fuel tank Capacity of 300~400cc
2. Carburetor
3. Weight
4. Filter Mesh, 300 or more
5. Fuel pipe Gasoline-resistant rubber or plastic
type with inner diameter of 2.5~3mm
6. Fuel pipe Gasoline-resistant rubber type
7. Air vent pipe
8. Fuel head 100mm or less
(1) (2)
(3)
(4)
(5)
(5)
(6)
(7)
(8)

9
●Mount the throttle arm to
the carburetor’s throttle
shaft as shown in the
diagram.
THROTTLE LINKAGE AND ENGINE MOUNTING
Throttle arm
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 plate
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.

10
●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 lubrication 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)?
●Tighten the muffler additionally (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 unit and that the wiring and fuel pipe are not interferences.
ITEMS TO CONFIRM BEFORE STARTING THE ENGINE

11
●Close the choke lever and open the throttle valve 10% to 15%.
●Pressing the tip of the starter to the engine’s spinner, press the start switch for 1-2 sec and
let the engine rotate.
●If the engine makes an explosive sound, suspend the starting operation and start by
opening the choke lever and rotating the engine using the starter. (Opening or closing the
choke lever during engine operation is prohibited.)
●If the engine will not start, leave the choke lever in the open position and rotate the engine
by pressing the starter for 1-2 sec. --- If the engine will not start, repeat this operation 2 or 3
times.
(A) Points in starting
●During the first startup operation, does the fuel reach the carburetor?
●If the fuel reaches the carburetor, the choke will open.
●Is the ignition switch on?
●If there is absolutely no explosive sound, remove the sparkplug and check it.
●If leakage has occurred from the sparkplug being over choked, dry it out, open the choke, and
restart.
(B) Cautions in starting
●One person must restrain the fuselage during the startup operation. (Thus, solo startup is
prohibited.)
●With the sparkplug removed when using the starter for rotation or rotating the propeller by hand,
make sure the power has been turned off.
●Rotation should be to the left. Confirm the direction of motor rotation in advance.
STARTING THE ENGINE

12
(A) ADJUSTING THE IDLING
●Following startup, set the number of engine rotations for idling at about 2000rpm, rotate the
L needle to the right (to reduce fuel), and search for the position for the highest number of
rotations. From that position, turn the L needle about 1/4 (90°) to the left (to increase fuel)
and set the number of rotations for idling with the idle screw or the transmitter.
(B) ADJUSTING NUMBER OF ROTATIONS AT FULL THROTTLE
●Achieve full throttle slowly.
When the number of rotations stabilizes, turn the H needle to the left and right to locate the
position for the highest number of rotations.
●From the position of the highest number of rotations, open the H needle 1/8 (to increase fuel) to make the setting.
As a rule, consider 100rpm to be the difference between the highest number of rotations and the set number of rotations.
●After making the setting, return to idling. Accelerate rapidly and confirm that there are no problems with acceleration. If
acceleration is poor, open the L needle an additional 1/8th (45°) and confirm that acceleration is smooth. In this case, the
number of rotations for idling will be low, so use the idle screw or transmitter to adjust it.
●This engine has had the carburetor set at the standard position at time of factory manufacture. Thus, no calibration is
normally necessary.
In keeping, if poor acceleration or insufficient rotations at full throttle or the like result, make adjustments in conformance
with the main points of adjustment following startup.
However, the number of rotations for idling will change depending on the size of the propeller used, which will make
adjustment using the idle screw or transmitter necessary.
ADJUSTMENTS FOLLOWING STARTUP
118
112
Standard settings:
L: turns
H: turns
L needleH needle
Idle screw

●Different from a glow engine, this engine does not require any special trial run.
●After 5~10 tanks (2~3 hours), adjust the carburetor’s L and H needles if necessary.
●After about 5 hours’ running, the highest number of rotations will be slightly above the initial value,
owing to the engine having been conditioned.
STOPPING THE ENGINE
●To stop the engine, either use the transmitter to achieve full throttle or turn the battery switch off.
●When you have stopped the engine and when not operating the engine, make sure to keep the
battery switch off.
ENGINE RUNNING TIME
13
TRIAL RUN
120
60
0
Battery Capacity (mA)
1000
1500mA
2700mA
2000 3000
Condition: For new engines,
with the battery fully charged
Running time (min.)
40min.
70min.
Recommended battery: 4.8V / 1500~2700mA
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Because this engine uses a battery for power
supply, the engine’s continuous running time will
depend on battery capacity.
Please refer to the table on the right for guidelines.

14
To ensure safe use of the engine, make sure of the items specified in the table below.
INSPECTION
Cylinder, carburetor, muffler,
Leakage & breakage ✔✔✔
crankcase, Fuel pipe, etc.
Idling stability ✔✔✔Is it stable? Is acceleration okay?
Sparkplug –✔✔Remove sediment; adjust air gap
Cylinder –✔✔Check for wear & scratches
Piston/Ring –✔✔Check for wear & scratches
Muffler tightening bolt ✔✔✔Retighten
Ignition unit ✔✔✔Check for damage
Check for damage to screws
Propeller hub (Stud) ✔✔✔
& for deformation
Crankshaft ––✔Check alignment
Check for dislocation, cracks,
DC unit wiring ✔✔✔
wear, rattling, etc.
Stud/Nut ✔✔✔Is there any slack or screw damage?
Before
using
Every
25h
Every
100h
Item Inspection

PROPELLER HUB REMOVAL
●Remove the propeller hub as specified below.
15
TIGHTENING TORQUE CHART
Tightening Torque
Part Screw Size N-m Kg-cm Remarks
Cylinder M4 (P0.7) 3.9 40
Sparkplug M10 (P1.0) 7.8 80 Using the tool provided
Muffler M5 (P0.8) 8.5 90
Crankcase M4 (P0.7) 3.9 40
Insulator M4 (P0.7) 3.4 35
Carburetor M5 (P0.8) 3.4 35
Sensor M4 (P0.7) 1.7 20
Stud (hub) M6 (P1.0) 9.8 100 Using a piston stopper & LOCK TIGHT
Nut (propeller) M8 (P1.25) 9.8 100 Using the tool provided
Engine mount M4 (P0.7) 2.0 20
Piston stopper
P/N: 4810-96220
Spanner provided
P/N: 8488U3000
Turn
Nut (M8xP1.25) x 2
P/N: 8488608000
Stud bolt
P/N: 848EW052Y0
M6x1.0
L=about 45
Puller

OTHER INFORMATION
This information is to enable our customers to enjoy radio control airplanes more, but all
customers must take responsibility if they implement it.
●With this engine, the muffler side and the carburetor can be reversed by rearranging the
cylinder and piston.
●The crankcase is made of magnesium. During processing, allow for sufficient cooling to
avoid the risk of chips burning.
●In the event of even one crash, make sure to contact your service shop or dealer for
inspection and repairs.
16
CAUTION:
●Do not remove the sensor.
●Make sure that nuts turned with a lug wrench are nuts on the propeller hub side.
●Use a commercial puller of the appropriate size.
●When reassembling the start bolt, apply (LOCK TIGHT) to the M6 thread part.
CAUTION:
●When changing to (B), make sure to
also rearrange the piston or the
cylinder, piston, etc, will be damaged.
●Please use a new snap ring (1260-
41320) to prevent skipping of the piston
pin.
(B)
Standard (A)

KEY# PART NUMBER DESCRIPTION REMARKS
Q'TY/
UNIT
17
PARTS LIST
1848EW08100 CARBURETOR ASSY 1
23306-81380
• SCREEN 1
33080-81120
• COVER 1
43310-81130
• SCREW 1
53304-81140
• GASKET 1
61172-81150
• DIAPHRAGM 1
72850-81290
• GASKET 1
83310-81260
• DIAPHRAGM 1
10 3310-81280
• METERING COVER 1
12 2867-81270
• SPRING 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 848EW081T0
• SHAFT, throttle 1
21 2670-81410
• SPRING 1
22 2880-81470
• SCREW 2
23 1282-81340
• VALVE, throttle 1
24 1148-81390
• RING 1
25 T2070-81460
• SHAFT, choke 1
26 2841-81451
• VALVE, choke 1
27 3350-81350
• SPRING 1
28 3350-81220
• 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 2812-81520
• BALL 1
35 2810-81530
• SPRING 1
36 2812-81510
• PISTON 1

18
PARTS LIST

KEY# PART NUMBER DESCRIPTION REMARKS
Q'TY/
UNIT
KEY# PART NUMBER DESCRIPTION
REMARKS
Q'TY/
UNIT
19
25 1152-43290 WASHER 1
26 8488608000 NUT 1
27 848EW071N0 SENSOR 1
28 8488441400 BOLT 2
29 848EW071T0 SPARK PLUG 1 Y82
30 848EW053X0 MOUNT PLATE 1
31 3819-54780 SCREW 4
32 848EW07120 UNIT ASSY 1
33 01252-30410 B0LT 1
34 1641-20405 WASHER 1
35 848EW08100 CARBRETOR ASSY 1
36 T2070-82410 LEVER, choke 1
37 848H7014C1 GASKET 1
38 848ES08300 AIR,funnel 1
39 8488455000 BOLT 2
40 848EW015A0 MUFFLER 1
41 1140-13141 GASKET, muffler 1
42 01252-30540 BOLT 1
43 8488U30000 SPANNER 1
44 848EW093A0 OWNER'S MANUAL 1
45 4810-96220 STOPPER 1
OPTION
46 1101-96220 ROD ASSY 1 OPTION
1848EW012A1 CYLINDER 1
2848EW012B0 GASKET, cylinder 1
38488441800 BOLT 6
4848EW014A0 INSULATOR 1
5848EW014B1 GASKET, insulator 1
6848EW02110 CRANKCASE COMP. 1
7 848EW021D0 GASKET, case 1
81155-21240 BEARING 1
906034-06001 BEARING 1
10 T1600-21240 BEARING 1
11 04065-02812 SNAPRING 1
12 T1600-21210 SEAL 1
13 3310-72150 BOLT 4
14 848EW041A1 PISTON 1
15 T2071-41210 RING 1
16 1101-41310 PISTON PIN 1
17 1260-41320 SNAP RING 2
18 5500-41410 BEARING 1
19 1101-41340 WASHER 2
20 848EW04200 CRANKHAFT COMP. 1
21 1000-43240 KEY 1
22 1140-43250 SHIM 1
23 848EW05290 HUB COMP. 1
24 848EW052Y0 STUD 1
PARTS LIST

20
●Applicable Range
This warranty applies only to the engines and parts manufactured by K0MATSU ZENOAH and sold directly or through
distributors.
●Range of Warranty
This warranty shall apply only to trouble resulting from material defects and inferior assemblies that K0MATSU ZENOAH
acknowledges.
●Method and Extent of Compensation
1) Repair or replacement through the distributor, etc.
2) K0MATSU 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) Trouble resulting from not having read or from having ignored the essentials of engine operation
2) Dismantled or remodeled 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
WARRANTY
Head Office : 1-9 Minamidai, Kawagoe-city, Saitama, 350-1192 Japan
Phone: [phone] Fax: [phone]