Zenoah G231PUM Owner'S Service Manual Download Page 13 | Manualshive

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12. Special Tools

Part Name

Part No.

External Appearance

Usage

1

Puller Assy

1490-96101

To remove rotor.

2

Piston Stopper

4810-96220

3

Rod Assy

1101-96220

To remove/install piston pin.

4

Hex Wrench

3304-97611

5

Snap Ring Pliers

5500-96110

To remove snap ring.

To hold crankshaft when

disassembling/assembling

the rotor.

For socket screw of

4mm, 5mm and 6mm.

13

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Summary of Contents for G231PUM

Page 1: ...s Purchaser has all responsibilities against any laws and regulations existing in the country Zenoah is exempt from such laws and regulations Read and completely understand this OWNER S SERVICE MANUAL before operating these engines MODEL G231PUM for radio control Boat G231PUH for radio control Helicopter G260PU for radio control Airplane G260PUM for radio control Boat G260PUH for radio control Hel...

Page 2: ...egulations in the countries Use genuine parts for replacement Check the propeller rotor and screw propeller every time If it is damaged replace it with a new one If 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 flywheeI Check the fIyw...

Page 3: ...Bolt 01252 30560 2 Muffler T2710 15110 3 Bolt T1565 72211 4 Spacer 1158 15420 5 Gasket 1140 13141 6 Spacer 1145 15412 7 Engine 8 Gasket T2075 13150 9 Carburetor T2077 81000 10 Air Cleaner 848EP18300 11 Air Cleaner Body 12 Filter 13 Air Cleaner Cover 14 Screw 0263 30555 15 Lock Knob 1 Engine 2 Gasket T2075 13150 3 Carburetor T2076 81000 4 Tube 1000 03030 5 Air funnel 848ES08300 6 Spacer 1142 83110 ...

Page 4: ... 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 5 Tighten the nut M8 with a torque of 80 120 kg cm by using a spark plug socket wrench which is 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 G231PUM G231...

Page 5: ... operation Make sure to use the rotor which is recommended by helicopter manufacturer Screw Propeller for boat The exhaust system e g 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 the muffler you select And then decide the appropriate the screw propeller that w...

Page 6: ...t Incorrect fuel filter use causes engine trouble like carburetor s fuel passage stuffing or piston surface scratching etc G260PU A HAND FLIP START Since the G260PU is equipped with the ultra compact C D I type flywheel magneto ignition system it should be started according to the following procedure The magneto system of G260PU is designed in such a way that when the exhaust port is closed by the...

Page 7: ...nd 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...

Page 8: ...lock position G260PUH G231PUH e Quickly pull the starter cord when the initial combustion noise is heard f When the initial combustion noise 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 6 2 For stopping the engine the black lead wire from the coil...

Page 9: ...e 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 ...

Page 10: ...formance The details for operation as complete product may be provided from complete product manufacturer Always keep well maintenance according to the Maintenance clause described in this owner s service manual 10 1 MAINTENANCE CHART Before Every Every Items Action Use 25 hours 100 hours Note Leakage Check Damage Crack Idling Speed Check Adjust Air cleaner PUH Check Cleaning Replace if necessary ...

Page 11: ...ndard Limit Standard Limit Standard Limit Measuring Device Remarks Bore mm ø32 Plating damaged ø34 Plating damaged ø36 Plating damaged Eye Checking Diameter mm ø31 97 ø31 87 ø33 97 ø33 87 ø35 97 ø35 87 Micro Meter Piston Ring 1 01 1 11 1 01 1 11 1 01 1 11 Thickness Gauge Groove width mm Piston Pin Hole mm ø8 01 ø8 05 ø8 01 ø8 05 ø8 01 ø8 05 Cylinder Gauge Clearance between Piston and 0 03 0 06 0 1...

Page 12: ...rth core 2 1 kΩ Sparkplug wire Earth core 6 TIGHTENING TORQUE Standard Limit Items Screw Size Remarks N m kg cm N m kg cm Carburetor M5 P 0 8 3 4 35 2 9 3 9 30 40 Insulator M5 P 0 8 4 4 45 3 9 4 9 40 50 Rotor M8 P 1 0 12 7 130 9 8 14 7 100 150 Cylinder M5 P 0 8 6 9 70 4 9 8 8 50 90 Crankcase M5 P 0 8 5 9 60 4 9 6 9 50 70 Spark Plug M10 P 1 0 10 8 110 8 8 12 8 90 130 Muffler M5 P 0 8 8 8 90 6 9 9 8...

Page 13: ...1490 96101 To remove rotor 2 Piston Stopper 4810 96220 3 Rod Assy 1101 96220 To remove install piston pin 4 Hex Wrench 3304 97611 5 Snap Ring Pliers 5500 96110 To remove snap ring To hold crankshaft when disassembling assembling the rotor For socket screw of 4mm 5mm and 6mm 13 ...

Page 14: ...m plate and confirm that the air gap is 0 3 0 4mm by thickness gage 3 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 4 INSTALLING PISTON Fig 10 1 Make sure to point the ar...

Page 15: ...rn out cylinder piston or piston ring Exchange poor compression 2 Gas leakage from cylinder and crank case gasket Apply liquid gasket and reassemble No fuel supply 1 Choked breather air hole Cleaning 2 Clogged carburetor Cleaning 3 Clogged fuel filter Exchange fuel filter 2 LACK OF POWER OR UNSTABLE RUNNING Description Cause Countermeasure 1 Air penetration from fuel pipe joints etc Secure connect...

Page 16: ...15 Parts list 16 ...

Page 17: ... RING 1 25 1 1600 41310 PISTON PIN 1 1 1 25 2 1101 41310 PISTON PIN 1 1 25 3 574 79 12 01 PISTON PIN 1 26 1260 41320 SNAP RING 2 2 2 2 2 2 27 5500 41410 BEARING 1 1 1 1 1 1 28 1101 41340 WASHER 2 2 2 2 2 2 29 T2075 42000 CRANKHAFT COMP 1 1 1 1 1 1 30 1155 74110 MOUNT 1 1 1 1 1 1 31 0262 10516 SCREW M5x16 3 3 3 3 3 3 32 1650 43230 NUT M8 1 33 1160 75210 PULLEY 1 1 1 1 34 1861 75101 RECOIL ASSY 1 1 ...

Page 18: ... English 1 1 1 1 1 1 72 2 T2075 93122 MANUAL Japanese 1 1 73 1490 96101 PULLER ASSY 1 1 1 1 1 1 OPTION 74 4810 96220 STOPPER 1 1 1 1 1 1 OPTION 75 1101 96220 ROD ASSY 1 1 1 1 1 1 OPTION 76 3699 91975 SPARK PLUG CMR6H 1 1 1 77 3699 91867 SPARK PLUG CMR7H 1 1 1 78 1148 08010 MUFFLER 1 1 1 1 1 1 OPTION 80 848ESZ7520 PULLEY ASSY 1 81 848ESZ75R0 RATCHET 2 82 1850 75230 SPRING 2 83 1034 72180 E RING 2 8...

Page 19: ...420 PLUG welch 1 15 3310 81230 LEVER 1 Q TY UNIT 16 3310 81240 SCREW 1 17 3310 81250 PIN 1 18 2630 81330 SCREW 1 19 3350 81380 SPRING 1 20 1172 81370 SHAFT throttle 1 21 2670 81410 SPRING 1 22 2880 81470 SCREW 2 23 3310 81340 VALVE throttle 1 24 1148 81390 RING 1 25 T2070 81460 SHAFT choke 1 26 T2075 81450 VALVE choke 1 27 3350 81350 SPRING 1 28 3350 81220 BALL 1 29 1148 81530 SCREW 4 30 1491 8116...

Page 20: ...shall not compensate any other accompanied or benefit losses caused to user and distributor manufacture by such faults and through repairing or replacing 4 Term of Warranty Three 3 months after purchased by end user subject to 12 months from produced month 5 Exempt from Warranty Zenoah shall not warrant this engine even if the fault has been caused during the period of terms of Warranty in case th...

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