Robin ECO2 Service Manual

ROBIN

ENGINE

ROBIN

MODEL CROSS

AMERICA,

TO WISCONSIN

INC.

ROBIN

REFERENCE

LIST

ROBTN

EY 08 EY15 EY

15V EY20 EY20V EY23 EY28 EY35 EY40 EY45V EY2

I

EY44 EY 18-3 EY25 EY27

-

v

WISCONSIN

W 1-080 W1-145 W1-145V W1-185 W1-185V W1-230 Wl-280 W 1-340 W 1-390 W1-450V

EY2

1

EY44W EY18-3W EY25W EY27W

ROBIN

W

EH11 EH12 EH15

EH17

EH21 EH25 EH3

0

EH30V EH34 EH34V EH43V

EC13V

DY23

DY27

DY30

DY35

DY4 1

TWO CYCLE

DIESEL

WOI-115 wo1-120 WO1-150 WO1-170 wo1-210 WO1-250

WO

1

-300 WO1-300V WO1-340

WO

1

-340V

WO 1-43

WT1-125V

WRD

-1-300

WRD1-350

WRD1-410

OV

1-230 1-270

CONTENTS

Section

1

.

SPECIFICATIONS ........................................... 1

2

.

PERFORMANCE ............................................ 2

2.1

.

Maximum Output

2.2 . Continuous Rated Output

2.3

.

Maximum Torque and Fuel Consumption Ratio and

3

.

FEATURES

4

.

DISASSEMBLY and REASSEMBLY ...............................

4.1

. Preparation and Suggestions ...............................

4.2

.

Special

4.3.

4.4

5

.

. BREAKER POINT ADJUSTMENT PROCEDURES

6

.

CARBURETOR ADJUSTMENT

7

. OPERATION

Disassembly Procedures

. Reassembly Procedures

Title

......................................

................................

Max

. Output

......

...............................................

Tools

.........................................

..................................

.....................

..................................

OF

FLOAT DIAPHRAGM CARBURETOR

................

Page

2 2 2

3

4

5

6

9

10

11

8

.

TROUBLE SHOOTING

9

.

CHECKS and CORRECTIONS

10

.

MAINTENANCE and STORING

10-

1 . Daily Checks and Maintenance

10.2

. Every 50 Hours Checks and Maintenance

10.3

. Every 150 Hours Checks and Maintenance

10.4 . Yearly Checks and Maintenance

. Preparation for Long Abeyance ............................. 19

10.5

........................................

...................................

.............................

......................

............................

13

16

19

SPARK PLUG

CARBURETOR

\

AIR CLEANER

\

\-

\

/

TICKL

STARTER KNOB (Recoil

Starter)

MUFFLER.COVER

/

FUEL

TANK

CAP

,FUEL

TANK

FUEL COCK

.

MUFFLER COVER

1.

SPEC1

FlCATlONS

-1-

2.

PERFORMANCE

2-1

MAXIMUM OUTPUT

The maximum output of the EC02-A and ECOZ-R is such standard power as developed by the engine, after its run-in period

with all the moving parts properly worn-in, when operating with the fully open throttle valve. Therefore, it follows that a new

engine may not develop this maximum output in the beginning, because moving parts are not

in

a properly worn-in condi-

tion.

2-2 CONTINUOUS RATED OUTPUT

,"

The continuous rated output mum speed most favorable in view ing system

for

any mechanism, with the engine, as a prime mover, the continuous power requirement of that mechanism must

of

the EC02-A and EC02-R

of

engine

life

and fuel consumption ratio. Therefore,

be kept below the continuous rated output specified.

2-3

MAXIMUM

The maximum torque external load, while the engine tion ratio

of

TORQUE

and

FUEL CONSUMPTION RATIO at MAX. OUTPUT

of

the EC02-Aand EC02-R

is

pulling its rnax. output. The fuel consumption ratio at max. output

is

the engine while the engine is running at the max. output.

MODEL ECO2-A

HP

and

is

such power as developed by the engine when running at

that driving torque

ECOP-R PERFORMANCE CURVE

of

the driving shaft at which the engine is driving an

an

it

follows that when designing a driv-

is

that fuel consump-

opti-

ft-LbS

-2-

3.

FEATURES

1.

COMPACT, LIGHT WEIGHT, HIGH PERFORMANCE and LOW FUEL CONSUMPTION

2.

TROUBLE FREE because of simple design and easy

to

handle

3.

HIGH DURABILITY engine withstand long severe operation

4.

TILTED OPERATION AVAILABLE

Be

able to operate at any position due to diaphragm carburetor.

5.

EASY STARTING with recoil starter

6.

Forged steel Crankshaft

7.

Ball main bearings at both ends

8.

Forged steel connecting

rod.

9.

With CHROME PLATED CYLINDER, HEAT CONDUCTIVITY and WEAR

PROOF

are quite excellent.

-3-

4.

DISASSEMBLY

and

REASSEMBLY

4-1

PREPARATION

and

SUGGESTIONS

1) When disassembling the engine, memorize the locations

of

individual parts

so

as

to

be able to reassemble them correct-

ly. Tag parts if there

is

a possibility

of

confusion.

2)

Prepare several boxes

to

keep parts belonging to certain groups together.

3)

Group those parts related each other, tentatively assembling where they belong, immediately after removing, in order

to prevent missing and misplacing.

4) Handle the disassembled parts carefully and wash them in kerosene.

5)

Use the correct tools in the correct way.

6)

Standard tools required for disassembling and reassembling: a) Work table b) Washing pan c) Disassembling tools d) Washing oil (kerosene or gasoline),

2

cycle-oil

e) Emery paper, cloth

7)

Before starting

to

disassemble the engine, drain fuel.

8)

Tighten the screws of the cylinder, crankcase, connecting rod, spark plug, and flywheel

to

the specified torque values.

9) Use new packings and gaskets in reassembly.

10)

Immediately before assembling parts, wash them in fresh gasoline or kerosene and blow them dry.

1 1) Apply

2

cycle-oil on rotating and sliding

parts.

12)

Take care not

to

contaminate the parts by dust during assembling.

13)

Tighten bolts, nuts and screws with proper torque according

to

the

their sizes.

If

small screws are tightened too tight,

they may get broken.

14) After completely assembling the engine; turn it by hand and check if there

is

any abnormality or loose members.

,-

4-2

SPECIAL

TOOLS

(Fig.

1)

Fig.

1

-4-

-

4-3

DISASSEMBLY

PROCEDURES

-

4-3-1 FUEL DRAIN

Drain fuel from the fuel tank,

4-3-2 THROTTLE

Wl

RE

(See

Fig.

2)

Remove throttle wire from carburetor together with piston valve.

.-

Fig.

2

4-3-3 FUEL TANK

and

RUBBER

TUBE

L

1)

Disconnect fuel pipe between fuel tank and carbure-

I

tor at carburetor side.

2)

Remove fuel tank by unscrewing bolts.

3)

Only for

EC02-R

After removing fuel pump, push the head of rubber tube toward arrow mark

in

Fig.

3

with a screwdriver

of

minus top (preferably not sharpened) and remove

rubber tube.

CA

U

TION:

NEVER REMOVE RUBBER

TUBE

EXCEPT AT RE-

P

LACEMENT.

BE SURE

TO

REPLACE

WITH

MEW ONE WHEN

RE-

MOVED.

BE

CAREFUL NOT TO DAMAGE THE HOLE

IN

WHICH

RUBBER TUBE WILL BE IMSERTED.

4-3-4 KILL SWITCH WIRE

Disconnect stop button wire terminal.

4-3-5 RECOl L STARTER

Remove starter case from crankcase by unscrewing bolts.

4-3-6 MAGNETO FLYWHEEL

(See

Fig.

4)

After removing nut, pull out flywheel from crankshaft,

Turn

cenler

bolt

clockwiw

FLYWHEEL'

~LYWHEEL

PULLER

.

*...

-

I.

Fig.

4

4-3-7

BREAKER,

C'ONDENSER,

and

COIL

(See

Fig.

5)

Remove breaker cover, condenser, breaker, and ignition coil from crankcase by unscrewing bolts.

IGNITION

COIL

.*

Fig.

3

Fig.

5

4-3-8 CARBURETOR and CARBURETOR BRACKET

(EC02-A), CARBURETOR and HEAT BLOCK (EC02-R)

(See

Fig.

6)

Remove carburetor and carburetor bracket by unscrewing

bolts

(EC02-A),

and remove carburetor and heat block by

unscrewing bolts

(EC02-R).

HEAT

BLOCK

Fig.

6

4-3-9

MUFFLER

Remove muffler from cylinder by unscrewing bolts.

4-3-10 CYLINDER (See

Fig.

7)

Remove cylinder quietly

so

as not

to

damage sliding sur-

faces of cylinder and

piston.

CRP

Fig.

7

4-3-11

DIVISION

of

CRANKCASE

(See

Fig.

8)

After unscrewing bolts, disassemble front and rear crankcases from crankshaft by tapping with

a

soft

hammer.

Washing crankcase with gasoline, apply the film

of

oil

to

crankcase ball bearing bore and grease

to

oil

seal bore,

KCASE

FRONT

C~ANKCASE

I

CRANKSHAFT

Fig.

8

44

REASSEMBLY

PROCEDURES

4-4-

1

CRANKCASE

(See

Fig.

9)

1)

Insert crankshaft into front crankcase bearing.

2)

Assemble the crankcase.

3)

Use new gasket.

4)

Tighten bolts to

40-50

kg-cm

(2.9-36

ft-lbs) torque.

5)

Cut

off

crankcase gaskets stuck

out

to the mating sur-

face of cylinder.

CRANKSHAFT

Fig.

9

-6-

4-4-2

CYLINDER

(See

Fig.

10)

1) Replace cylinder gasket with new one. At the same

time,

try

to mate the tapper hole with the groove

the contact surface

CAUTION:

TAKE CARE THAT GASKET

SITION

2)

3)

AND

ON

In assembling cylinder,

piston rings and cylinder.

Tighten bolts to 40-50 kg-cm (2.9-3.6 ft-lbs).

of

crankcase.

RIGHTSIDE.

take care

IS

PLACED

IN

RIGHTPO-

of

the position

4-4-6

IGNITION COIL

Tighten ignition

on

4-4-7 BREAKER

Insert knock pin Tightening torque: 25 kg-cm

the right side.

coil

tentatively, putting high tension

of

breaker into the hole of crankcase.

(1.8

ft-lbs).

Regarding the adjustment of spark timing, refer to

of

Breaker Point adjustment Procedure.

4-4-8 CONDENSER

Assemble it, running stop wire through the bottom of condenser. Tightening torque: 25

k2

kgcm

Tool: Plus driver, Torque wrench

wire

Section

5.

"A

Fig.

10

4-4-3 SPARK

PLUG

Tighten spark plug to 220-300 kgcm (1 5.9-21.7 ft-lbs).

4-4-4 CARBURETOR BRACKET

1)

Use

new

gasket.

OR

HEAT BLOCK

2) Tighten bolts to 50-70kg-cm (3.6- 5.1 ft-lbs) torque for EC02-A and to 40-5Okgcm (2.9-3.6 ft-lbs) torque

for

ECO2-R.

4-4-5 CARBURETOR

(See

Fig.

11)

Tighten nuts to 50-7Okgcm (3.6-5.1 ft-lbs) torque for ECO2-A and to 40-50kgcm (2.9-3.6 ft-lbs) torque for EC02

-R

.

II

4-4-9 POINT

After inserting stop

COVER

wire

and primary wire into the groove of crankcase, assemble point cover, Tightening torque: 25 kgcm (1.8 ft-lbs).

4-4-10 FLYWHEEL

Mount flywheel on crankshaft and tighten flywheel nut. Flywheel tightening torque

is

150-180 kgcm (10.8-13.0

ft-lbs).

4-4-1.1 IGNITION

COIL

(See

Fig.

12)

Tighten ignition coil, keeping' a clearance of 0.4-0.6 mm

from

flywheel.

Tightening torque: 25 kg-cm

(1.8

ft-Lbs).

/

,NIT1

-YWI

ON

HEEL

COIL

Fig,

1

-7-

Fig,

12

4-4-1'2

MUFFLER

Tighten muffler to

90-

1

lOkgzm

(6.5-8.3

ft-lbs).

Use new gaskets.

4-4-13

TENTATIVELY TIGHTENING OF CYLINDER COVER

Mount the both ends of cylinder covers on the mating portions of the crankcase and tentatively tighten with screws. In Type A,

also

mount fuel tank stay together on the cylinder head with flat washers. Tool: Plus Driver

4-4-14

RECOIL STARTER, STOP BUTTON

AND

GROMMET

Install stop button to starter case with toothed washer on

its

reverse side. Run high tension cord through the grommet and assemble plug cap spring and plug cap. Run the grommet through the groove

of

starter case and tighten starter

case to crankcase with three screws.

Tightening torque: Stop button

25

+-2

kgcm

Starter case

45

+3 kg-cm

Tool: Plus driver, Torque wench

A-

.

,?

4-4-16

RUBBER TUBE

IN

FUEL TANK (EC02-R)

Insert the rubber tube in the hole of fuel tank from the end of felt side

of

rubber tube. Use spacer or backing plate to

gently put in with vice or

squill

vice as shown in the figures. Completely put in theridge of rubber tube. After inserting, pinch the outer side

of

rubber tube and turn it to assure that

the ridge has been completely inserted.

Fig.

14

CA

U

TI0

N:

AFTER INSERTING,

BE

SURE TO CONFIRM THE

IN-

SERTION OF THE RIDGE

OF

RUBBER

TUBE.

4-4-15

TIGHTENING

OF

CYLINDER COVER

Tighten the cylinder cover. Tightening torque:

45

*3

kg-cm

Tool: Plus driver, Torque wrench

Fig.

15

4-4-17

FUEL

TANK

Put spacer into fuel tank and install with screws. (Use a large type flat washer.) Connect fuel line to carburetor. Tightening torque:

45

*

3kg-cm

(3.3

*

0.2

ft-lbs)

Tightening torque:

45

k3

kg-cm

Tool: Plus driver, Torque wrench

-

8-

5.

BREAKER POINT

1)

Remove starter case.

2)

Remove flywheel from crankshaft. (Flywheel nut is left-hand threads).

3)

Take off woodruff key from crankshaft and point cover.

4)

Remove carbon deposits on breaker point and clean mating surface by cloth or paper.

5)

Fit woodruff key to crankshaft,

6)

Tack flywheel, and set again.

(See

Fig.

7)

Adjust as per the

a)

Loosen breaker fitting screw.

b) Confirm open/close condition of point by pushing breaker in the direction of arrow. Adjust breaker

to

be about Notice that ignition timing will be over

8)

Point cover, magneto, starter case shall be assembled in order after point has been adjusted.

open. (Normal ignition timing will be

ADJUSTMENT

“F”

16)

Fig.

17

(under the condition stated

IGNITION

COIL

PROCEDURES

on flywheel to the mark on cfankcase. Then gently remove flywheel from crankshaft

in

item

6).

23O-27O)

30’

if point is opening under the condition shown in

\n

Fig.

so

that point may

17.

CRANKCASE

Fig.

16

Point

cover

Fig.

Breaker-installing screw

17

-9-

6.

CARBURETOR

ADJUSTMENT

Since the carburetor has carefully been adjusted at shop before shipment, avoid adjusting it unless absolutely necessary.

If

adjustment are needed, refer to the following.

1)

Idle adjustment

Adjust idling revolution with throttle stop screw,

(See

Fig.

?8)

EC02-A, EC02-R

If

turn throttle stop screw clockwise, revolution will increase. If turn

it counter-clockwise, revolution will reduce.

CUATION: DO NOT IDLE UNDER

2)

Fuel

flow

adjustment

a)

At low speed (at the small opening of the throttle)

is

When fuel

too

adjusting screw

b)

At high speed (at the large opening

When fuel

ing

screw

to

is

the

too

(See

RICH,

to

the

RICH,

LEFT.

CAUTION: LOW SPEED FUEL ADJUSTING SCREW

THAT THE DIRECTION

2,800r.p.m.

Fig.

18)

EC02-R

turn the low speed fuel adjusting screw to the

RIGHT.

of

the throttle)

turn high fuel adjusting screw

OF

TURNING SCREW

to

the

RIGHT.

IS

FOR ADJUSTMENT

IS

REVERSE

LEFT.

When it is too

OF

TO

THAT OF HIGH SPEED FUEL ADJUST-

LEAN,

turn high speed fuel adjust-

AIR AMOUNT,

turn low speed fuel

SO

IT

IS

NOTED

ING SCREW.

r

THROTTLE STOP SCREW LOW SPEED FUEL ADJUSTING SCREW

HIGH SPEED

Fig.

18

FUEL

ADJUSTING SCREW

i

/"

-

10

-

PRESSI

7.

OPERATION OF FLOAT AND DIAPHRAGM CARBURETORS

DIAPHRAGM CARBURETOR FLOATCARBURETOR

JRE

CHANGE

IN

CRANKCA

PRIMER PUMP

LOW SPEED FUEL ADJUSTING SCREW

HIGH SPEED FUEL ADJUSTING SCREW FROM

FUEL TANK

IDLE ADJUSTING SCREW

CARB VENTURI TICKLER BUTTON

OVERFLOW

ATMOSPHERIC PRESSURE

7-1

OPERATION

VALVE

JET NEEDLE

OF

FLOAT

-

"".-

\

'

PRESSURE COMPENSATING DIAPHRAGM CHAMBER

CARBURETOR

fig.

STEEL BALL

19

1) Fuel from the fuel tank enters the float chamber through the needle valve, which is kept open while the fuel level is low.

2)

When the fuel level rises, the float is allowed to move up and lift the arm connected to the needle valve.

3)

The arm lifted

4)

When the fuel

by

the main je't and the jet needle the fuel level falls low, causing the float to move down.

5)

The falling of the float lowers the arm connected to the needle valve, which admits the fuel to enter the float chamber. After this, the same operations in 1)

by

the float raises the needle valve, which shuts off the supply of fuel.

in

the float chamber

is

suctioned into the engine through the carb venturi, the fuel amount

-

5)

are repeated.

is

measured

-

11

-

7-2 OPERATION OF DIAPHRAGM CARBURETOR

1)

When the engine runs, positive pressure and negative pressure will alternately occur in the crankcase. This alternation in pressure

2)

The fuel drawn up by fuel pump enters pressure compensating diaphragm chamber through the felt, rubber tube in fuel tank, fuel pipe and needle valve.

3)

The fuel than atmospheric pressure and pushes down the pressure compensating diaphragm.

4)

When the pressure Compensating diaphragm is pushed downwards, the arm connected to needle valve turns clockwise

by

the strength

5)

The fuel in pressure compensating diaphragm chamber

entering the engine through the carb venturi. Then, the pressure in pressure compensating diaphragm chamber becomes

lower than atmospheric pressure and the diaphragm is pushed up against the strength

6)

When the pressure compensating diaphragm needle valve, which admits fuel to enter. After this, the same operations in

NOTE:

I.

OPERATION

When the opening of the throttle

and jet needle. Therefore, even by low speed fuel adjusting screw, fuel

density of fuel. Accordingly, in high and low speed fuel adjusting screws, the direction of turning the screw each other. For instance, when the opening of the throttle ing screw TO THE RIGHT to make the fuel lean, but when the opening of the throttle turn low speed fuel adjusting screw TO THE LEFT to make the fuel lean.

2.

OPERATlON

1)

When tickler button lowering needle valve, which allows fuel to enter. At the same time, when the tickler button

2)

In

pensating diaphragm chamber chamber

3)

Further, when primer pump overflow valve and, at the same time, a

justing screw and jet needle.

4)

A little amount of fuel sent to carb venturi by the operation of

engine, and becomes somewhat rich and suitable fuel for easy starting of the engine.

is

led to the reverse side of fuel pump diaphragm

in

pressure compensating diaphragm chamber

of

spring and pushes

OF

LOW

OF

TICKLER BUTTON

a condition of

is

filled with fuel.

SPEED

1/,

if

FUEL

is

small,

is

pushed up, the lever connected to needle valve turns left against the strength of spring,

primer pump

is

exhausted throught the overflow valve,

is

operated continuously, fuel

so

that the top side will work as fuel pump.

is

sent by pressure,

up

the needle valve, which shuts out the supply of fuel.

is

measured by high speed fuel adjusting screw and jet needle,

is

pushed up, the arm turns counterclockwise against the spring and lowers

ADJUSTING

it

is

not sufficient to measure the fuel only by high speed fuel adjusting screw

is

repeatedly pushed, fuel

little

SCREW

is

LARGE and the fuel

is

pushes up, overflow valve

is

pumped up from

is

forced to flow into the overflow pipe through the

amount of fuel

is

sent to carb venturi through the high speed fuel ad-

31,

so

that the fuel pressure becomes higher

1)

-

6)

are repeated.

is

measured and sent to the venturi to adjust the

is

also held open through the lever.

so

that the pressure compensating diaphragm

if recoil starter

of

spring.

RICH,

turn high speed fuel adjust-

is

SMALL and the fuel

the

tank and air in pressure com-

is

pulled,

it

is

taken into the

is

reverse to

is

RICH,

f-

/"

-

12

-

8.

TROUBLE

SHOOTING

For a gasoline engine to start and run satisfactorily, the following three requirements must be met:

1) The cylinder filled with a proper fuel-air mixture.

2)

An appropriate compression in the cylinder.

3)

Good spark at correct time

to

ignite the mixture. If all the three requirements are not met simultaneously, an engine can not be started. There are also other factors heavy load at starting and

most

common causes

8-1

STARTING

DIFFICULTIES

too

long an exhaust pipe causing a high back pressure, which contribute to hard starting. The

of

engine troubles are given below.

such

as

Cause

Defects

in

spark

plug

Defects in contact cable

Defects in contact breaker

Defects in magneto

Other defects in electric system

Remedy

1)

If

contaminated, wash in gasoline, remove

foreign material and dry.

2)

If spark plug replace plug.

3) Adjust spark gap to 0.6-0.7mm

is

broken and lost insulation,

(.024-

,027").

If cable is burnt, replace cable along with coil.

1)

If breaker points are rough, smooth out

surface with emery paper

2)

If breaker point gap specified 0.35t0.05mm by loosening contact support plate lock screws.

3)

If

spark timing is incorrect, adjust

23"

-

27'

before TDC.

4)

If breaker is defective in insulation, replace breaker.

5)

If

condenser

1)

If wire or insulation

magneto.

2)

If

magnetism

magneto maker)

1)

If kill switch

replace or repair.

2)

If primary wire body, insulate tape.

is

defective, replace.

is

weak, re-magnetize (at the

or

is

it

(#400).

is

incorrect,

is

replace.

faulty, (short circuiting)

grounded

with insulating adhesive

adjust

it

broken, replace

to

the engine

to

Preventive measure

1)

Use spark plugs not

use

poor grade oil. Clean air cleaner and

avoid dust entry.

2)

When spark gap is adjusted, if center elec-

is

trode

damaged.

of

specified heat range. Do

hit or bent, insulator may

get

1)

Gas leak from combustion chamber

Defects in piston

assembly

Defects in fuel tank

system

If spark plugs are

2)

If

1)

If

2)

If

31

If piston rings are stuck, clean or replace

rings.

1)

Clean clogged tank outlet.

2)

Clean clogged fuel strainer.

3)

If incorrect fuel water is mixed, drain tank completely and fill

4)

When fuel pipe is locked with

5)

If

rubber components of fuel line system,

due

loose,

tighten.

spark plugs are defective, replace.

piston

is

worn, replace.

piston rings are worn, replace.

is

poured into tank or

it

with correct fuel.

there

is

any crack or damage in the

to

their deteroriation, replace.

air,

-

13

-

expel1 air.

1 ) Keep air cleaner always clean.

2)

Do

not use poor grade oil. Change oil

regularly.

1)

Be sure

to

2)

Use mixture (gasoline

use a filter when adding fuel.

20 - 25

:

oil

1

I

as fuel

/"

8-2

OVERHEATING

CaUSe

Defects in carburetor

Piston or Connecting

Rod

seized

Remedy

1)

If

clogged

2)

If

defective. replace.

Clean

with

dust, clean.

jets

and other orifices.

if

they are

clogged.

1)

Start engine with fully open choke valve and fully open throttle valve.

2)

Remove spark plug and disconnect fuel pipe, repeat starting operation several times to evacuate excess fuel.

If

fuel overflows, check needle valve seat for

wear. Replace. if necessary.

1)

If piston seizes, correct or replace.

2)

If connecting rod large end or small end seize, replace.

Preventive measure

1)

Never close choke valve when engine warm.

2)

When stopping the engine,

speed

Tor a while. This practice not only favourably affects next starting, improves engine life.

3)

Clogged aircleaner results fuel mixture. Clean

it

thoroughly.

Be careful clogged carburetor.

1)

Do

not use poor grade oil.

2)

Use

fuel of proper mixing ratio.

run

in

~ ~~ ~~ ~

it

at

but

too rich air-

is

slow

also

1)

If the ignition timing is

2)

If

too much carbon deposits

3)

If the heat range of the spark plug

4)

If the air-fuel mixture is too lean, clean jets and other holes

5)

If the load is in excess, reduce it below the specified continuous load.

POWER

If

DROP

the cylinder, piston or piston rings are worn, replace them.

too

far advanced, correct to

in

the combustion chamber, remove it.

is

too cool, replace it with correct one

23' - 27'

If the carburetor is out of order, re-adjust or clean it.

If

the

spark

plug

is

faulty (contamination, gas leakage

If

the magneto or the contact breaker

If

the aircleaner

is

clogged, clean it.

is

faulty, replace them

or

If the fuel system is clogged, clean it.

If

the

oil

seals at the crankshaft are

8-4

EXCESSIVE FUEL

1)

If too rich air-fuel mixture, clean jets and small holes

2)

If

fuel leakage, re-tighten screws or replace.

3)

If

beside these causes,

CONSUMPTION

also

worn

and let the compressed gas through, replace them.

in

caused by power drop, perform remedies for power drop, according to

DROP.

(NGK

BM7A).

in

the carburetor. Clean the aircleaner also.

faulty insulation), clean it or replace it.

or

re-adjust them.

carburetor.

7-3.

POWER

-

14

-

8-5

ENGINE HUNTING

-

If the fuel-air mixture is too lean. Clean the carburetor.

8-6

OTHER

1) Fuel overflow from carburetor If the fuel flows towards the aircleaner or much fuel flows into the crankcase while the engine flowing), the needle valve or the float is faulty. Correct

2)

If the engine suddenly stops with abnormal noise, the piston or the crankshaft and connecting rod assembly is seized. Correct them or replace them.

3)

If the engine produces abnormal noise during operation, be sure to stop the engine and do not start it again before the cause If the cause for the trouble is not found, contact our distributor and entrust the engine in the hand engineer.

COMPLAINTS

is

found.

or

replace them.

is

standing still (over-

of

our service

-

15

-

9.

CHECKS

After disassembling and cleaning the engine parts, check them, and if necessary, correct them according to the correction

table. The correction table applies whenever engine are repaired. Its contents should be thoroughly understood by those who undertake the repairing. Its specifications must be abided by to effect correct maintenance.

Below, terms employed in the correcrion table as explained.

1)

CORRECTION All operations performed on the engine parts for the purpose consisting

2)

STANDARD The design dimensions of the part without the tolerance.

3)

CORRECTION TOLERANCE The tolerance on the re-finished part dimension or

4)

CORRECTION LIMIT

The limit on the part and adjustment, beyond which any dimensional and functional changes, due other causes will adversely affect the normal engine performance.

5)

USE

The limit, beyond which the part is no longer usable, due to defects in function or strength.

NOT€:

and

CORRECTIONS

of

repairs, readjustments, and replacements.

SIZE

LIMIT

ALL

DlMENSlONS IN

THE

'%ORRECTION

of

improving or recovering the engine performance,

on

the readjusted dimension.

to

wear, burn, and

TABL€"are given in millimeter, except where otherwise specified.

/"

ITEM

Breaker, condenser point cover, & ignition coil

0.

Carburetor

g

c-

.-

Tank, starter

E

c

r

2

Heat

I-

2

.-

'c

0

Flywheel

g

v)

Spark plug

case

Block

kg-crn

23 - 27 42

-

42 - 48 Crankcase 42

-

42

-

42 - 48 Cylinder & muffler

150

-

220

-

48

180

300

ft-lbS

1.7

-

1.9

3.0

-

3.5

3.0

-

3.5

3.0

-

3.5

3.0

-

3.5

3.0

-

3.5

10.8 - 12

15.9

-

21.7

TOOL

Torque

Wrench

,"--

-

16-

CORRECTION

TABLE

iTEM

Clearance between cylinder

Cylinder bore Piston Side clearance

piston ring Width of ring

groove Ring width Ring gap

Clearance between piston

Piston pin hole Piston Side clearance

connecting rod large end

Run-out shaft

Axial clearance crankshaft iournal

Tightness of main bearing

Housing inner dia.

Clearance of main bearing

Bearing inner dia. Crankshaft

dia. Connecting rod

small end

Ignition timing

&

O.D.

&

piston

of

outer

O.D.

I.D.

piston

of

O.D.

of

crank-

of

dia.

O.D.

I.D.

STANDARD

SIZE

0.020L

-

0.057L

I

32.01 dia

31.99 dia.

1

o,ol

-

o,08L

1.6

I

1.6

0.1

-

0.3

I

0.007T

-

0.008L

8

dia.

8

dia.

0.1

L-0.5L

1

0.05

I I

0.05 - 0.6

0.014T - 0.036T

28

dia.

28

dia.

I

0.008T

-

0.008L

12 dia.

11

I

dia.

25'

before top

dead center

CORRECTION

LIMIT

0.12L

1

32.01 dia.

31.99 dia.

I

0.13L

1.6

+0.08

1.64.05

0.6

0.03L

8

dia

+0.02

8

dia. -0.01

0.7L

0.1

0.8

0

28 dia.

28

dia. -0.01 Bearing

0.014L

12 dia.

12

dia. -0.01

11 dia

+0.04

-0.05

-0.01

+0.003

+0.02

R

EMAR

KS

I

at middle portion at middle portion

Max. width groove

1

"in.

Max. inner dia.

Min.

Supporting assembled crankshaft between centers, measure journal where

1

from

of

ring width

outer dia.

crankcase

ring

is

5mm

I

TOOL

Cylinder gauge Micrometer

Feeler gauge Replace

Block gauge

Micrometer Feeler gauge

Micrometer

Feeler gauge

Dial gauge

Cylinder gauge Micrometer

I

Cylinder gauge

1

CORRECTION

METHOD

Replace

1

Replace Replace

Replace

I

Replace Replace

Replace

Replace Cylinder gauge Replace

Replace

Correct

I

Replace

I

Replace

rReplace

Replace

Replace Dial gauge

1

I

Timing tester

Adjust

Point gap

Air gap

Spark plug gap

1

0.35

0.2

0.6-0.7

I

-0.05

+0.05

+o.

0

kO.1

Feeler gauge

1

-

17

-

Feeler gauge

Thickness gauge

1

Adjust

Adjust Feeler gauge

10.

MAINTENANCE

and

STORING

The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated maintenance intervals are by engine is operated in extremely dusty conditions, the air cleaner should be cleaned every

10-1

DAILY CHECKS

1)

Remove dust from whatever which accumulated dust.

2)

Check external fuel leakage. If any, retighten or replace.

3)

Check screw tightening. If any loose one is found, retighten.

10-2

EVERY

1)

Check spark plug. If contaminated, wash in gasoline or polish with emery paper.

2)

Clean air cleaner.

10-3

EVERY

1)

Clean fuel strainer and fuel tank.

2)

Clean contact breaker points.

3)

Clean exhaust port

50

HOURS CHECKS

150

no

means guarantees for maintenance free operations during these intervals. For example,

and

MAINTENANCE

HOURS CHECKS

of

cylinder and both inlet and outlet

and

MAINTENANCE

and

MAINTENANCE

of

muffler.

day,

instead

of

every

50

if

hours.

/"

the

10-4

YEARLY CHECKS

1)

Remove carbon from cylinder head and piston head.

2)

Clean fuel tank inside.

3)

Clean carburetor diaphragm chamber inside. (In type

4)

Clean contact breaker and adjust point gap.

5)

Replace fuel line once a year.

10-5

PREPARATION

1)

Perform the above

2)

Drain fuel from the fuel tank and carburetor float chamber. (In case type R with diaphragm carburetor, run the engine

until

it

stops from lack

3)

Remove spark plug, and apply times

by

pulling the recoil starter handle slowly. Re-install the spark plug.

4)

Clean the engine outside with oiled cloth.

5)

Put a vinyl or other cover over the engine and store the engine in dry place.

and

MAINTENANCE

for

LONG ABEYANCE

9-1

and

9-2

maintenance jobs.

of

fuel.)

5

to lOcc

A,

float chamber inside)

of

lubricating oil through the spark plug hole. Perform idle operation several

-

18

-

Industrial

Engines