Zenoah G260PU-EI Guide d'application

OWNER’S SERVICE MANUAL

848-ES5-93A0 (812)

WARNING

•These engines are designed for radio

controlled products.

•When replacing parts, use only parts

which have been certified by Zenoah.

•Zenoah assumes that no responsibility for

these engines that are modified or used for

any other applications.

•Purchaser has all responsibility against

any laws and regulations existing in the

countries, Zenoah is exempt from such

laws and regulations.

•Read and completely understand this

OWNER'S SERVICE MANUAL before

operating these engines.

MODEL:

G260PU-EI – for radio control Airplane

1. Safety Precautions

•This manual describes the engine. For its mounting and control, see the

instruction manual for the model airplane.

•Engine is designed for use on model airplane. If it is used for any other

purpose, we cannot be responsible for its reliability, safety and any

laws/regulations in the countries.

•Use genuine parts for replacement.

•Check the propeller, every time. If it is damaged, replace it with a new one.

•If the 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.

•When mixing the fuel, or operating the engine, carry it out in a well-ventilated

place.

Gauge Rotor

Fig.2 Fig.3

Fig.4

2. Engine Assembling

The carburetor, muffler, air-funnel and sensor are not assembled at factory.

Make sure that the assembling for such parts are done according to the 2.1 and 2.2.

Tightening torques: see page 9

1. Bolt (01252-30550)

2. Muffler (T2075-15110)

3. Gasket (1140-13141)

4. Screw (0263-30408)

5. Engine

6. Gasket (T2075-13150)

7. Carburetor (T2075-81000)

8. Lever, choke (T2070-82410)

9. Air-funnel (848ES08300)

10. Spacer (1142-83110)

11. Screw (0263-30555)

Make sure that gasket and carburetor are mounted as the picture.

If carburetor is mounted upside down position, the engine does not start as

carburetor does not work correctly.

CAUTION

Fig.1

Fig.2: Affix the gauge to magneto.

Fig.3: Turn the crankshaft until gauge

position at top.

Fig.4: Fix the sensor on the mount while

pushing the sensor.

• Take away the gauge from the rotor.

Carburetor muffler and air-funnel assembling

2.1

Sensor assembling

2.2

3. Engine Mounting

4. Ignition Unit Mounting

Make sure that the G260PU-EI is mounted on the aircraft grade plywood with more

than 8mm of thickness or a mount of equivalent strength and is firmly fixed with 4 bolts.

If necessary, please reinforce the firewall and the around.

[ 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. The Fuel head between carburetor and bottom of fuel tank must be less than 100

mm (4 inches).

4. If 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.

5. Tighten the nut (M8) with a torque of 80~120 kg·cm

applying about 10~15 kg by hand as shown in the

figure.

(NOTE)

Do not tighten the nut (M8) with too large torque,

that may damage the stud.

Nut (M8)

8cm

10~15kg

(80~120kg·cm)

1. Make sure to install the power switch. (switch is not supplied)

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.

Fig.5

5. Propeller, Rotor & Screw Propeller

The recommended prop sizes are as shown in the table bellow.

Be sure to use a propeller which makes the engine speed approximately

7,500~8,500 rpm while the airplane is flying.

When mounting the spinner, set a pin on the hub with more than 3mm of

diameter, thus preventing slipping.

CAUTION

Diameter x Pitch ( in.)

18 x 7 ~ 12, 16 x 10 ~ 14

Bolt (4mm)

Sparkplug wire

Sensor wire

Sensor

Unit

Battery wire

For charging

Switch

Capacity: 3A (or higher)

(not supplied)

Battery 4.8V

1500~2700mA

(not supplied)

Use of anything

other than an 4.8V

battery is prohibited.

Ground wire

surface D

Sponge & cloth

Gap: 5mm or

more surface D

surface D

Fig.6

Fig.7

6. Fuel

7. Starting

•Mix gasoline (octane over 85 / premium gasoline) and high grade 2 cycle engine oil

(mixing use type; F3C grade or ISO EGC grade) at mixing ratio 25~40:1.

•The mixing ratio may be decided according to the oil recommendation.

[ NOTE ]

1) Never use any alcohol fuel or alcohol added fuel, or the rubber parts in the

carburetor. Will be damaged.

2) Gasoline is very flammable. Avoid smoking, bringing any fires near fuel.

3) To prevent all possible problems on fueling system, make sure to use the fuel filter

which has more than 300 mesh or equivalent and gasoline proof rubber pipe or

equivalent.

Incorrect fuel filter use causes engine trouble like carburetor's fuel passage stuffing

or piston surface scratching etc.

Make sure to fix a spinner and make sure that the helpers hold the airplane firmly. Also

make sure that the electric motor has a power enough to run the engine at minimum

1,100 rpm.

●How to start

a. Fill the fuel tank with the fuel.

b. Choke the carburetor.

c. Set the throttle valve at idle position or at the position slightly open from the idle

position (Never open the throttle more than 1/4 of full throttle stroke).

d. Turn the engine by electric motor until first combustion noise is heard.

e. Open the choke and keep the throttle valve at slight open position from idle position.

f. Turn the engine by electric motor, then the engine will start.

•Too much run by electric motor at choke condition may have a chance to wet

spark plug.

In this case, change the spark plug or dry it thoroughly and remove fuel rest in

the cylinder by turning engine under full throttle, open choke and without

spark plug installing.

•When engine is warm, carburetor choking may not be necessary.

•Hand flip starting is prohibited to prevent the hazards.

CAUTION

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-running.

Standard opening of each needle as follows;

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.

Set this needle at a position which is 1/4 open from best mixture (maximum R.P.M.)

position.

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 1/8~1/4 open from the

maximum R.P.M. position while the airplane is on ground.

1. Do not tighten the High and Low Speed needles too firmly.

2. When the unit has just started and the engine is not warm enough, there may

be insufficient acceleration and the engine may be stopped. Be sure to

perform idling before operation.

CAUTION

Low Speed needleHigh Speed needle

Idle Screw

8. Carburetor Adjustment

1 3/8±1/41 3/8±1/4

Fig.8

11. Maintenance

9. Engine Break-In

10. Operation

No specific break-in is required.

The engine is gradually broken-in as it is used and the output is also gradually

increased.

For checking the whole conditions of the airplane, it may be better to operate the

engine at slow RPM for 1/3 tank and mid-high RPM for 2/3 tank.

•The engine is already tuned up to get high performance, and needs correct

maintenance to keep such high performance.

•The details for operation as an airplane may be provided from the airplane

manufacturer.

•Always keep well maintenance according to the Maintenance clause described in

this owner's service manual.

1) MAINTENANCE CHART

Before Every Every

Items Action Use 25 hours 100 hours Note

Leakage, Check ✔✔✔

Damage/Crack

Idling Speed Check/Adjust ✔✔✔

Spark Plug(gap) Check/Adjust ✔✔Replace if necessary

Cylinder(barrel) Check/Cleaning ✔✔ ↑

Piston, Ring Check/Cleaning ✔✔ ↑

Muffler & Bolt Check/Cleaning ✔✔✔ ↑

Bearings Check/Cleaning ✔✔ ↑

Crank Shaft Check/Alignment ✔↑

Rotor Check ✔✔ ↑

Propeller Hub Check/Alignment ✔✔ ↑

2) SPECIFICATIONS & TECHNICAL DATA

Items unit Specifications

Type — Air Cooled

Bore x Stroke mm 34x28

Displacement cm325.4

Effective Compression Ratio 8.4

Type (Walbro) WT-645

Carburetor Venturi (mm) ø12.7

Air Cleaner —

Starting — Electric Motor

Ignition Type Battery Ignition

Spark Plug STD Y82

Idle Speed rpm 1800 (APC 18x8)

Max. Power kW/rpm NA

Max. Torque N·m/rpm NA

Fuel Consumption g/kW·H NA

Weight kg 1.35 (✽)

(✽): Without Ignition System Specifications are subject to change without notice.

3) CARBURETOR

Items Unit Standard Measuring Device

Metering Lever set mm 1.65 ± 0.16 Vanier

MPa 0.13~0.23

Inlet Valve Opening Pressure Leak Tester

kg/cm21.3~2.3

MPa 0.07~0.17

Inlet Valve Closing Pressure Leak Tester

kg/cm20.7~1.7

4) TIGHTENING TORQUE

Standard

Items Screw Size Remarks

N·m kg·cm

Carburetor M5 (P=0.8) 3.4 35

Insulator M5 (P=0.8) 4.4 45

Rotor M8 (P=1.0) 12.7 130

Cylinder M5 (P=0.8) 6.9 70

Crankcase M5 (P=0.8) 5.9 60

Spark Plug M10 (P=1.0) 7.8 80

Muffler M5 (P=0.8) 8.8 90

Stud (hub) M6 (P=1.0) 9.8 100 with Locktight glue

Nut, Propeller M8 (P=1.25) 9.8 100

13. Service Guide

1. REMOVING PISTON PIN (Fig.9)

1) Remove snap rings from both sides of the

piston pin.

2) Engage the rod assy(1101-96220) to the

piston pin and gently tap with a plastic

hammer to push out the pin while holding

piston firmly.

Hard hammering may damage the big end of

the connecting rod.

2. INSTALLING PISTON (Fig.10)

1) Make sure to point the arrow mark on the

piston to the exhaust side.

2) Fit the circlip in the groove so as to face the

end gap below.

Deformed circlip may come off during engine

operation and damage the engine.

CAUTION

Fig.9

Fig.10

12. Special Tools

Part Name Part No. External Appearance Usage

1Puller Assy 1490-96101 To remove rotor.

2Piston Stopper 4810-96220

3Rod Assy 1101-96220 To remove/install piston pin.

4Hex Wrench 3304-97611

5Snap Ring Pliers 5500-96110 To remove snap ring.

To hold crankshaft when

disassembling/assembling

the rotor.

For socket screw of

4mm, 5mm and 6mm.

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