Zenoah G380PU User manual

OWNER’S MANUAL
2609-93112 (811)
November 2008
•Do not modify any parts of the engine.
•This engine is designed to be used to Radio
controlled products.
•In case any modification by customer,
ZENOAH shall not bear any responsibility from
the damage caused by such modification.
•Keep ignition system well maintained.
WARNING
●この製品はラジオコントロール
飛行機用に設計されています。
●改造、組み替えされて使用され
た場合当社は一切の責任を負い
ません。
●特に電装品は常に点検、整備し
てご使用ください。
警 告
MODEL: G380PU
G380PU-1

•This engine is designed for the model aircraft use.
ZENOAH assumes no responsibility for those engines that are modified or used for
any other applications.
•This Manual describes the engine part only. For its mounting to the aircraft and its
control, see instructions described in the manual of the aircraft.
•Check the propeller every time before starting the engine, and replace it with a new
one if it is damaged.
•When the propeller hits something in operation, immediately stop the engine and
check it.
•Check the flywheel, and replace it with a new one if it is damaged.
•Never modify the flywheel.
•Use the ZENOAH genuine parts for replacement.
•When the vibration is abnormal, stop the engine and check the entire unit for
possible damage or loose fasteners.
•Mixing the gas and 2-cycle engine oil and filling it up are to be done in a well-
ventilated place.
•Never run the engine in a place of poor ventilation, as exhaust fumes contain
harmful carbon monoxide.
Mix unleaded gasoline and 2-stroke oil in the ratio of 25 ~ 40:1.
[ 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.
Starting Engine
1. Fill the fuel and fix to the aircraft body firmly.
2. Close the choke and set the throttle to one third open.
[ NOTE ]
If the choke is closed too much, it may dampen the spark
plug and it may cause starting failure.
3. Turn the propeller slowly counterclockwise until it is
resisted, and then powerfully. When turning it
manually,use all the fingers except the thumb.Turn it
at proper intervals.
3. Operation
2. Fuel
1. Safety Precautions
2
BLACK LEAD
KILL
SWITCH
ENGINE
BODY
EARTH

4. When engine first fires, open the choke and turn the propeller again in the same manner.
5. When the engine is started,warm it up for 2 to 3 minutes at low speed.
Stopping Engine
Ground the black wire from the source coil to the engine, and the engine will stop.
The carburetor comes with a standard setting.
This setting is for optimum performance under the barometric pressure and climactic
conditions at the factory.
Therefore, the carburetor should be readjusted wIth a load applied (with the propeller
mounted) after the engine having been warmed up.
[ NOTE ]
1. Adjustment standards :
2. IDLE SCREW - Turn clockwise to increase the idling rpm.
3. LOW SPEED NEEDLE - This needle controls fuel flow in the low rpm range.Turning
clockwise makes the fuel lean. Turning counterclockwise makes the fuel rich.
4. HIGH SPEED NEEDLE - This needle controls fuel flow in the high rpm range. Turning
clockwise makes the fuel lean and the reverse makes it rich. Set the needle 1/4 turns
open from a position where the peak rpm is obtained on the ground.
5. Do not overtighten the needles.
6. Warm up the engine before adjusting the carburetor.
7. Make sure to stop the engine while adjusting the carburetor.
4. Carburetor Adjustment
3
LOW SPEED NEEDLE : 1 ± 1/4turns open
HIGH SPEED NEEDLE : 11/2±1/4turns open

4
•Check if screws and bolts are firmly tightened.
•Check if there is any fuel leakage.
•Check if there is any damage (crack or deformation).
•Check if the fuel line is clogged.
•Check if the spark plug and the muffler are contaminated.
WARNING !
When the engine is not in use, take great care in casually flipping the prop as you might do
in checking compression or for adequate lubrication in engine. These ignition engines will fire
and start with just one weak flip. Broken arms have already resulted from just such an
unexpected experience.
5. Daily Inspection
1. Crankcase fixing bolt 14 50 ~ 80 kg-cm, 3.6 ~ 5.8 ft-lbs.
2. Flywheel fixing hub nut 30 150 ~ 190 kg-cm, 10.8 ~ 13.7 ft-lbs.
3. Muffler fixing bolt 12 40 ~ 50 kg-cm, 2.9 ~ 3.6 ft-lbs.
4. Ignition module fixing screw 43 20 ~ 25 kg-cm, 1.4 ~ 1.8 ft-lbs.
5. Insulator fixing screw 4 30 ~ 40 kg-cm, 2.2 ~ 2.9 ft-lbs.
6. Carburetor fixing screw 45 30 ~ 40 kg-cm, 2.2 ~ 2.9 ft-lbs.
7. Mount plate fixing screw 47 30 ~ 40 kg-cm, 2.2 ~ 2.9 ft-lbs.
8. Spark plug 42 150 ~ 180 kg-cm, 10.8 ~ 13.0 ft-lbs.
Applicable positions
and Part Names Tightening Torque
Illustration
index No.
Table of Tightening Torque

5
6. Specifications
Model .......................................................G380PU · G380PU-1
Type .........................................................Single cylinder gasoline engine, 2-stroke air cooled
Displacement............................................37.4cc (2.28cu. in.)
Bore x Stroke............................................38mm x 33mm (1.496 in. x 1.299 in.)
Compression ratio ....................................6.8 : 1
Fuel...........................................................Gasoline mix
(mixture ratio gasoline to 2-stroke oil : 25 ~ 40 : 1)
Carburetor ................................................WALBRO WT338
Ignition .....................................................Flywheel magneto (contact-less type)
Spark plug ................................................CHAMPION RCJ7Y
Service engine speed...............................7000 ~ 9000rpm
Allowable engine speed (instantaneous) ........12000rpm
sizes (L x W x H) ......................................170 x 130 x 215mm (6.30 x 5.12 x 8.46 in.)
(Length covers as far as the end of the hub nut.)
Weight ......................................................2.0kg (4.4 lbs)
Specifications are subject to change without notice.

6
7. Parts List G380PU, G380PU-1

46 2630-81120 • Cover 1
47 3310-81130 • Screw 1
48 3304-81140 • Gasket 1
49 1172-81150 • Diaphragm 1
50 3356-81310 • Valve 1
51 2850-81290 • Gasket 1
52 3310-81260 • Diaphragm 1
53 3310-81280 • Cover 1
54 2670-81270 • Spring 1
55 3310-81240 • Screw 1
56 3310-81250 • Pin 1
57 3310-81230 • Lever 1
58 1480-81420 • Plug 1
59 3350-81380 • Spring 1
60 2630-81330 • Screw 1
61 2670-81410 • Spring 1
62 2609-81370 • Shaft 1
63 2880-81470 • Screw 2
64 3356-81340 • Valve 1
65 1148-81390 • Ring 1
66 1491-81160 • Spring 1
67 2609-81170 • Needle 1
68 3080-81320 • Spring 1
69 2609-81330 • Needle 1
70 3310-81351 • Screw 4
71 2813-81460 • Shaft 1
72 2670-81450 • Valve 1
73 3350-81220 • Ball 1
74 3350-81350 • Spring 1
75 T2100-06020 • Gasket kit 1
76 0260-10540 Screw 2
77 3378-85111 Mount 1
78 3310-31720 Screw 4
Q' ty
/unit
DescriptionParts No.
Index
No.
7
13378-12111 Cylinder 1
23330-14111 Insulator 1
33330-14121 Gasket 1
40260-20520 Screw 2
53330-14132 Gasket 1
62609-15001 Muffler assy 1
11 2841-15210 Gasket 1
12 3330-15220 Bolt 2
13 3378-21110 Crankcase 1
14 01252-30540 Bolt 4
15 0292-20510 Washer 4
16 3120-13510 Plug 1
17 3130-13520 Gasket 1
18 3340-41113 Piston 1
19 3340-41211 Ring 1
20 3304-41310 Pin 1
21 3310-41320 Ring (Circlip) 2
22 1650-41510 Washer 2
23 3310-41410 Bearing 1
24 3378-42000 Crankshaft comp. 1
25 06030-06201 Bearing 2
26 1650-21220 Seal 1
27 04065-03212 Ring 1
28 2169-21210 Seal 1
29 1260-43240 Key 1
30 1140-43231 Nut 1
31 0290-20820 Washer 1
32 01641-20812 Washer 1
33 2609-51110 Hub 1
34 3544-11510 Bolt 2
35 1145-43290 Washer 1
36 2609-51411 Bolt 1
37 3378-71110 Module 1
38 2609-71210 Rotor 1
39 1260-71261 Spacer 3
40 1400-72111 Cap 1
41 1400-72121 Spring 1
42 3699-90032-10 Spark plug 1
43 3310-72150 Bolt 3
44 2609-81000 Carburetor assy (WT338) 1
45 3306-81380 • Screen 1
Q' ty
/unit
DescriptionParts No.
Index
No.

for G380PU

G380PU, G380PU-1

●Scope of Application
This warranty applies only to the engines and parts manufactured by ZENOAH and sold
directly or through distributors.
●Limit of Warranty
This warranty shall apply only to trouble resulting from material defects and inferior
assemblies that ZENOAH acknowledges.
●Method and Limit of Compensation
1) Repair or replacement through the distributor, etc.
2) 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) Any faults, failures caused from neglect of this OWNER'S MANUAL for proper
operation and maintenance.
2) Dismantled or modified 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.
8. Warranty
Printed in Japan
Head Office : 1-9 Minamidai, Kawagoe-city, Saitama, 350-1165 Japan
Phone: [phone] Fax: [phone]