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Zenoah GT80 TWIN manual

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Table of contents for the manual

  • Page 1

    ENGINE INSTRUCTION MANU AL G26 Air G26/231Marine G26/G231 Heli G38 G62 GT80 T win G45 ® 1 1 2 3 4 5 6 7 2 3 4 5 6 7[...]

  • Page 2

    2 T able of Contents Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Support Equipment . . . . . . [...]

  • Page 3

    3 Introduction Safety Instructions Ve ry Important This manual describes the engine’ s features and func- tions. For specific information on mounting, see the instruction manual included with the model airplane, heli- copter or boat in which you intend to install the engine. This model engine will give you considerable pleasure, satisfaction and [...]

  • Page 4

    4 Safety Instructions (continued) Support Equipment Caution 1. Model engines get very hot while running. Do not attempt to handle them until they have cooled. 2. Always run your model engines in a well-ventilated area. Similar to automotive engines, model engines pro- duce harmful carbon monoxide fumes. 3. Never modify the flywheel. 4. Check the fl[...]

  • Page 5

    5 Mounting the Engine Make sure the engine is mounted on the aircraft using aircraft grade plywood that’ s at least 6mm in thickness for the G26 engine, and 10mm in thickness for the G38 through GT80 twin, or a mount of equivalent strength. Make sure it’ s firmly mounted with 4 bolts. 1. Be sure to set flat washers or a metal plate on the rever[...]

  • Page 6

    6 Operation (continued) 8. Quickly flip the propeller in a counterclockwise direction according to the procedure described in the note above. 9. The engine should start after a few flips of the propeller . 10. Be sure to open the choke when the initial firing of the engine is heard. 11. When the choke is opened, be sure to close the throttle valve [...]

  • Page 7

    7 Operation (continued) High-Speed Needle: T urning this needle clockwise makes the gas mixture leaner , and turning it counter- clockwise makes it richer . Set this needle at a position which is 1/4 open from the maximum rpm position while the aircraft is on the ground. Note: Do not tighten the high and low speed needles too tightly . When the eng[...]

  • Page 8

    8 c. Remove the rotor by using the puller . Do not hit the crankshaft with the plastic hammer , as this can increase the runout of the shaft. 7. Remove the mounting plate. 8. Remove the four bolts from the crankcase. 9. T ap around the case fitting side gently with the plastic hammer and slowly separate the crankcase from the cylinder block. 10. Pu[...]

  • Page 9

    9 Engine Care and Maintenance (continued) Items Leakage, Damage/Crack Losing Speed Air -cleaner (PUH) Spark Plug (gap) Cylinder (barrel) Piston, Ring Muffler & Bolt Bearings Crankshaft Rotor Propeller Hub (PU) W ater Jacket (PUM) Action Check Check/Adjust Check/Cleaning Check/Adjust Check/Cleaning Check/Cleaning Check/Cleaning Check/Cleaning Ch[...]

  • Page 10

    10 Items Bore (mm) Diameter (mm) Piston Ring Groove Width (mm) Piston Ring Hole (mm) Clearance between Piston and Cylinder (mm) Clearance between Groove and Piston Ring (mm) End Gap (mm) Width (mm) Eccentricity (mm) Axial Play (mm) Main Bearing Measuring Device Eye Checking Micro Meter Thickness Gauge Cylinder Gauge Micro Meter Cylinder Gauge Thick[...]

  • Page 11

    11 T roubleshooting Guide for Gasoline Engines a) The engine does not start. The crankshaft does not rotate Seizure, intrusion of a foreign substance The fuel has not been fed to the carburetor The fuel has been fed to the carburetor The Stop switch has been turned off Wiring is disconnected Disassemble and repair Disassemble and clean Clean Loosen[...]

  • Page 12

    12 Propeller Chart T roubleshooting Guide for Gasoline Engines (continued) In the event that none of the above procedures result in the engine running properly , contact our ser vice department for suggestions at: Horizon Hobby , Inc. 4105 Fieldstone Road Champaign, IL 61822 Phone: 217-355-9511 (M–F 8:00–5:00 CST) This chart enables you to sele[...]

  • Page 13

    13 Engine Specifications Items G26A G26M G231 HELI G231 MARINE G38 G45 G62 GT80 G26H 139mm 139mm 139mm 142mm 142mm 170mm 152mm 162.5mm 191.5mm 105mm 105mm 105mm 105mm 105mm 130mm 130mm 140mm 257mm 181mm 181mm 181mm 181mm 181mm 215mm 185mm 185mm 190mm 2,000 – 10,000 2,000 – 10,000 2,000 – 10,000 3,000 – 11,000 3,500 – 15,000 2,000 – 9,00[...]

  • Page 14

    14 14 Exploded Illustration G26/G231 Key # Zen Part # HH Part # Description G260 G260 G260 G231 G231 PU PUM PUH PUM PUH 1-1 T2075-12110 ZEN2601 CYLINDER 1 – 1 – – 1- 2 T2077-12110 ZEN2301RC CYLINDER – – – – 1 2-1 T2076-12110 ZEN2601M CYLINDER – 1 – – – 2-2 T2078-12110 ZEN23102M CYLINDER – – – 1 – 3 T2076-12210 ZEN23103[...]

  • Page 15

    15 Exploded Illustration G26/G231 continued Quantity per unit Key # Zen Part # HH Part # Description G260 G260 G260 G231 G231 PU PUM PUH PUM PUH 22 01252-30530 ZEN2322 BOL T , M5 x 30 4 4 4 4 4 23-1 T2088-41110 ZEN2623 PISTON 1 1 1 – – 23-2 T2070-41110 ZEN2320RC PISTON – – – 1 1 24-1 T2088-41210 ZEN26224 RING 1 1 1 – – 24-2 T2070-4121[...]

  • Page 16

    16 Exploded Illustration Index No. Part No. Description 1 2 3 4 5 6 11 12 13 14 15 16 17 18 19 20 ZEN3801 ZEN3802 ZEN3803 ZEN3804 ZEN3805 ZEN3806 ZEN3811 ZEN3812 ZEN3813 ZEN3814 ZEN3815 ZEN3816 ZEN3817 ZEN3818 ZEN3819 ZEN3820 CYLINDER INSULA TOR CARB GASKET INSULA TOR SCREW INSULA TOR GASKET MUFFLER ASSEMBL Y MUFFLER GASKET MUFFLER BOL T CRANKCASE [...]

  • Page 17

    17 Exploded Illustration Index No. Part No. Description 1 2 3 4 5 6 7 8 9 10 11 13 14 15 16 17 18 19 20 ZEN4501 ZEN4502 ZEN4503 ZEN4504 ZEN6204 ZEN4506 ZEN4504 ZEN6207 ZEN6208 ZEN6209 ZEN6210 ZEN4513 ZEN6213 ZEN6214 ZEN6215 ZEN6216 ZEN6217 ZEN6276 ZEN4520 CYLINDER INSULA TOR INSULA TOR GASKET BOL T CARBURETOR GASKET CYLINDER GASKET BOL T MUFFLER MU[...]

  • Page 18

    18 Exploded Illustration Index No. Part No. Description 1 2 3 4 5 6 7 8 9 10 11,12 13 14 15 16 17 18 19 20 ZEN6201 ZEN6202 ZEN6203 ZEN6204 ZEN6205 ZEN2309 ZEN6207 ZEN6208 ZEN6209 ZEN6210 ZEN6211 ZEN6213 ZEN6214 ZEN6215 ZEN6216 ZEN6217 ZEN6218 ZEN6219 ZEN6220 CYLINDER INSULA TOR GASKET INSULA TOR CARBURETOR GASKET CYLINDER BASE GASKET CYLINDER BOL T[...]

  • Page 19

    19 Exploded Illustration Index No. Part No. Description 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 ZEN44501 ZEN44502 ZEN44503 ZEN44504 ZEN44505 ZEN44506 ZEN4547 ZEN44508 ZEN44509 ZEN44510 ZEN6213 ZEN6215 ZEN6214 ZEN44514 ZEN6217 ZEN6276 ZEN44517 ZEN44518 ZEN44509 ZEN44520 ZEN44521 CYLINDER MANIFOLD MANIFOLD GASKET MANIFOLD BOL T CARBURET[...]

  • Page 20

    20 W arranty Information Zenoah ® engines are guaranteed against workmanship and manufacturing defects for a period of 3 years from the original date of purchase. This warranty is limited to the original purchaser and is not transferable. W arranty repairs will not cover: • Normal engine wear • Damage due to insufficient maintenance • Damage[...]

  • Page 21

    21 W arranty Information (continued) Engine T ype: ________________________________________________________________________________ Date of Purchase: ______________________________________________________________________________ Owner’ s Name: ______________________________________________________________________________ Street Address: _________[...]

  • Page 22

    22[...]

  • Page 23

    23[...]

  • Page 24

    © Copyright 2003, Horizon Hobby , Inc. www .horizonhobby .com ZZPZ200 6135[...]