Zenoah G230PU User manual

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@1 155-931 10(9705)
OWNER'S MANUAL
MODEL : G230PU - for Airplane
G230PUH - for Helicopter
G230PUM - for Boat
G23OPU
G23OPUH
G2SOPUM

1. SAFETY PRECAUTIONS
. This manua! describes the engine. For its mounting and
control, see the instruction manual for the model
airplane, helicopter and boat.
. Each engine is designed for use on each model
airplane, helicopter and boat. !f it is used for any other
purpose, we cannot be responsible for its reliability or
safety.
. Use genuine parts for replacement.
. Check the propeller, rotor and screw propeller every
time. lf it is damaged, replace it with a new one.
. lf the propeller (or the rotor or the screw 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.
. Never modify the flywheel.
. Check the flywheel. lf it is damaged, replace it with a
new one.
. When mixing the fuel, or operating the engine, carry it
out in a well-ventilated place.
2. MOUNTING G23OPU
Make sure that the G230PU is mounted on the aircraft grade
plywood with more than 6mm of thickness or a mount of
equivalent strength and is firmly fixed with 4 bolts.
I NOTE ]
1. 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.
2. Since the engine is equipped with a float-less carburetor
with a diaphragm pump, the direction of cylinder and
position of fuel tank can be freely selected .
3. lf 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.
Note carefully that if the engine is vibrated at idling, then
the idling RPM is likely to get unstable due to overflow at
carburetor by the vibration.
4. Coat the bolts for muffler with anti-looser (e.9., Locktite or
equivalent).when assembling.
3. PROPELLER, ROTOR & SCREW PROPELLER
l. Propeller for airplane
The recommended prop sizes are as shown in the table bellow.
DiameterxPitch(in.)
18x6, 16x8- 10
This engine with a standard muffler produces the maximum
output when the engine is running at about 10,000rpm. Be
sure to use a propeller which makes the engine speed
approximately 7,000-9,500rpm while the airplane is flying.
I NOrE ]
When mounting the spinner, set a pin on the hub with more
than 3mm of diameter, thus preventing slipping.
2. Rotor for helicopter
Adjust the rotor-pitch to obtain 9,000-10,000 rpm of the
engine at full throttle operation.
3. Screw Propeller for boat
The exhaust system (e.9., muffler) is not equipped with as
standard. When you select the exhaust system for the
engine, check how many the engine speed (rpm) is
required when the maximum output is generated by using
I"iTJl"l#1"'?,l""loo,ooriatethescrewpropererthat
would meet such engine speed (rpm) that the muftler
required.
In general, standard size of the screw propeller (Surface
prop type) are as follows:
Diameter ( mm )
65-75 Pich ratio ( mm )
1.9 - 1.4
4. FUEL
Mix gasoline and 2-stroke oil at a mixing ratio ol 25 - 40 :1 .
I NOTE ] 1. Be sure to use a gasoline-resistant fuel piping. (Do not use any silicon rubber tube).
2. Never use any alcohol fuel or alcohol added fuel, or the rubber part in the carburetor will be damaged.
5. OPERATION
Hand llip start
Since the G230PU is equipped with the ultra compact C.D.l.
type flywheel magneto ignition system, it should be started
according to the following procedure;
* The magneto system of G230PU is designed in such a way
that when the exhaust port is closed by the piston, that is,
when the compression stroke starts (Refer to Fig. l-A),
sparks are never produced on spark plug no matter how
fast the propeller may be flipped. Be sure to quickly flip the
propeller when the edge of magnet on the rotor is
approaching the coil (Fig. 1-B). lt means that the propeller
should be quickly flipped about 90 degrees in crank angle
before the compression is about to start.
How to Start the Engine
1. For Airplane
a. Fill the fuel tank with the fuel .
b. Choke the engine and turn the propeller a few tinieS until
the fuel appears at the carburetor.
c. Set the throttle valve at the idle position or at the position
@il
Fig.1-A Fig.1-B
slightly open from the idle position. Quickly flip the
propeller in the counterclockwise direction according to
the procedure described above. Flip the propeller a few
times. Then the engine starts.
2. For Helicopter & Boat
a. Fill the fuel tank with the fuel.
b. Push the priming bulb upper the carburetor until fuel
appears in the priming bulb.(for Helicopter)
c. Choke the engine and open the throttle valve
approximately 113-112 of the full open position.

d. Quickly pull the starter cord when the initial explosion is
heard.
e. When the initial explosion is heard, open the choke, 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. Then the engine starts.
I NOTE ]
. Be sure to open the choke when the initial explosion is heard.
. When the choke is opened, be sure to close the throttle
valve to a position near the idle position before starting the
next flipping (lf the engine is started while the throttle is wide
open, a great thrusting force is produced, which is very
dangerous).
. Be sure to wear a thick glove when flipping the propeller.
Use all fingers, except thumb, for the flipping operation.
How to Stop the Engine
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.
RED LEAD
BLACK LEAD
I -. .- ENGINE
'- - - do- - - - - - - - - - -V aoav
(ItQtAflT^U r -
K|LL SWTTCH t EARTH
6. CARBURETOR ADJUSTMENT
7. ENGINE BREAK.IN
No specific break-in is required. The engine is gradually broken-in as it is used and the output is also increased gradually.
8. SERVICING
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-f unctioning.
High Speed needle Low Speed needle
'l . Standard opening of each needle as follows;
Low speed needle '. 11,/s tl/q
High speed needle: 13/s t 1/q
The engine can be disassembled or reassembled without any
specific difficulties, but be careful of the following matters;
a. For disassembling, the special tools shown in the parts list
are required in addition to the general tools. Be sure to use
a new gasket when the crankcase and cylinder have been
disassembled.
b. Removing rotor
1. Screw in the stopper (P/N 3350-96220) in place of the
spark plug. Then turn the rotor counterclockwise until
the piston touches the stopper. Take care it can cause
damage to the piston or connecting rod if the stopper is
not screwed in to the bottom.
2. Loosen and remove the rotor securing nut.
3. Remove the rotor by using the puller (P/N 1490-96101). .
Do not hit on the crankshaft by a hammer, that can
increase the runout of the shaft.
c. Assembling crankcase
1. Apply grease on the oil seal lips and oil on the be€irihg.
2. Assemble the crankshaft with a new gasket.
3. When both front and rear crankcases are tightened, the
Idle Screw: Turning this screw clockwise increases the idling
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.
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 1/4 open from the maximum
R.P.M. position while the airplane is on ground.
I NOrE ]
1. Do not tighten the High and Low Speed needles too firmly.
--Z-U/hEn th'e-Un rfhas ju$SterGttand theGngl-nc is-noT wErm
enough, there may be insufficient acceleration and the
engine may be stopped. Be sure to pedorm idling before
operation.
portion of gasket protruding on the cylinder mounted
surface should be cut off with a knife until the gasket
becomes flush with the cylinder mounted sudace.
d. Assembling piston
Before assembling the piston, apply the oil on the small
end bearing and piston, and set the piston ensuring that
the arrow mark on the top of piston is directed toward the
direction of exhaust port.
e. Assembling cylinder
'l . Coat the oil on the inner surface of cylinder.
2. The piston is provided with a knock pin which stops the
piston ring from turning. Set the splitted section of piston
ring at the knock pin and assemble the cylinder ensuring
not to break the piston ring.
f. Adjusting air gap of coil.
' Tfre air gap of coil should be adjusted to 0.3 mm (0.01").
g. Adjusting ignition time.
This engine with the point-less C.D.l. type requires no
adjustments of ignition time.

9. SPECIFICATIONS
Specifications are subject to change without notice
MODEL ZENOAH G23OPU ZENOAH G23OPUH ZENOAH G23OPUM
PURPOSE Airolane Helicopter Boat
TYPE Air.cooled Water cooled
DISPLACEMENT 22.scc
BORE x STROKE 32mm x 28mm
COMPRESSION RATIO 8.6: 1
MAXIMUM OUTPUT 1.95PS/10500rom t 1.80Ps/10500rom I2.25PS/t 1000rpm
OPERATING ENGINE SPEED 2000-10000rpm 3000-1 1000rpm 3500-15000rpm
IGNITION SYSTEM CDI tvpe Flvwheel maqneto
CARBURETOR WALBRO WA197A WALBRO WA167A WALBRO WA167A
AIR CLEANEB Drv tvpe
STARTING Hand llip Recoil starter
FUEL 2-cycle oil pre-mixed qasoline ( Mix ratio 25-40:1
SPARK PLUG NGK BMRTA or CHAMPION RCJ4
DRY WEIGHT [* with standard muffler ]1.42Kq l*1.58Kq I1.49Ks [ *1 .6sKs I1.45K9
10. PARTS LIST
62
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7-1 57-2
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5
2
38
39
45
I NOTE ] The parts indicated " {< " in the part number column are supplied as an assembly. No individual part available.
lndex
No. lndex
No.
lndex
No. 2
1
2
1
2
1
'I
3
1
0
0
0
,l
0-2
1
0
1
2
1
0
1
2
1
2
2
1
2
1
2
1
1
3
0
1
1
4
1
o-2
0
'I
1
2
0
1
1
2
1
0
BING PISTON
PIN PISTON
RING SNAP
BEARING
WASHER THRUST
CRANKSHAFT C
PLATE MOUNT
SCREW CMsx16
NUT
PULLEY
RECOIL ASSY
SCREW M4x14
KEY
SHIM
corL so (GRAY)
corL so (RED)
COIL IG
SCREW M4x14
CAP PLUG (BLACK)
CAP PLUG (RED)
SPRING
SCREW M4x22
SPABKPLUG tsMR7A
SCREW M5x50 '
0263-30555
'I 142-831 10
1751-82002
'I 1 45-81002
1 1 48-81002
0263-90520
1155-71110
1 148-0801 0
1 140-1 3140
0263-30408
0263-9041 6
1152-43260
'1152-43281
't'152-43290
3350-5341 0
3350-96220
1490-96101
1 1 1 0-91320
1145-15412
1 I 58-15420
SCREW M5x55
SPACER 5x10x1.6
AIBCREANEB
CARBURETOR 197A
CABBUBETOR 167A
SCREW M5X2O
ROTOR
MUFFLEB
GASKET MUFF
BOLT M5x50
BOLT M5x60
SCREW M4x8
SCREW M4x16
HUB
STUO
WASHER HUB
NUT
STOPPER (OPT)
PUTLEB ASSY (OPT)
SOCKET
SPACER
SPACER
2
0
1
0
1
2
1
'I
2
0
2
U
1
0
0
0
1
1
1
1
1
0
2
0
0
1
2
1
0
0
0
0
0
0
0
0
0
0
1
1
'I
0
0
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
1 148-1 21 1 1
1160-121 t0
1160-12210
0785 1 -0051
'I 160-1 2320
1 160-12330
1 140-13121
331 0-1 2281
1 140-131 51
1 148-l 3161
3330-1412t
1155-21101
{<
*
2629-21130
1140-2'1141
2169-21210
1155-21240
04065-02812
06034-06001
1850-21220
01252-30530
5600-41 1 1 1
1 100-41 21 0
't 101-41310
1260-41320
'I t40-41330
'1101-41340
1 1 55-42000
1155-74110
0262-10516
1 650-43230
1 160-75210
1 861 -75100
0263-30414
1 000-43240
1 140-43250
2629-71210
1160-7'1210
2629-71311
0263-304 t 4
2629-72210
2850-72110
1400-72121
0260-30422
1148t73120
0263-30550
CYLINDER
CYLINDER
JACKET
JOINT
O RING 3x38
O R|NG.l.5x19.5
BOLT M3x8
GASKET CYL
BOLT M5x20
GASKET INSU
INSULATOR
GASKET CARB
CRANKCASE COMP
CHANKCASE (R)
CRANKCASE (F)
PIN
GASKET CASE
SEAL 12x22x7
BEARING
RING SNAP
BEARING
SEAL OIL
BOLT M5x30
PISTON
1
2
3
4
5
6
7
I
9
10
11
12
't3
14
15
16
'17
18
19
20
21
22
23
'I
0
0
0
0
0
0
1
4
'I
0
0
0
0
0
0
1
4
1
1
2
1
1
1
3
,l
1
2
1
1
0
4
1
KOMATSU ZENOAH trO. Head Office'. 2-1 42-1 Sakuragaoka, Higashiyamato,
Tokyo, 207 Japan
Phone : [phone] Fax : [phone]
Printed in Japan