Robin EY35, EY40 Service Manual

ROBIN AMERICA,

INC.

ROBIN

TO

WISCONSIN

ROBIN

ENGINE

MODEL

CROSS

REFERENCE

LIST

ROBIN

EY08

EY15 EY 15V EY20 EY20V EY23 EY28 EY35 EY40

EY45V

EY2 1 EY44 EY 1 8-3 EY25 EY 27

EHll EH12

EH15

EH17

EH21

EH25

EH3

0

EH3 OV

EH34

EH3 4V

EH43V

EC13V

DY23

DY27

DY30

DY3

5

DY4

1

WISCONSIN

ROBIN

-

Wf-080 W1-145 W1-145V W1-185

W1-185V

W 1-230

W

1-280 W 1-340 W1-390

W

1

-450V

EY21W EY44W

EY25W EY27W

EY 18-3 W

-

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

WO

1-300

WO 1 -300v

WO

1

-340

WO 1 -340V

WQ 1

-430V

TWO

CYCLE

WT1-125V

DlESEL

WRD1-230

WRD

1

-270

WRD

1-300 WRD1-350 WRD1-410

1

.

See

tion

1

.

SPECIFICATIONS

2

.

PERFORMANCE

CONTENTS

Title

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

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

Page

1

2

2-1 2-2 2-3

3

.

FEATURES

4

.

GENERAL DESCRIPTION

44-2 4-3 4-4 4-5 4-6 4-7

4-8

4 4-10

4-1

4-12

4-13 4-14

4 4-16

4-17

Maximum Output Continuous Rated Output Maximum Torque and Fuel Consumption Ratio

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

1

Cylinder. Crankcase Main Bearing Cover Crankshaft Connecting Rod and Piston Camshaft Cylinder Head Valve Arrangement Governor

Balancer

-9

Decompression Device Cooling Device

1

Lubrication

Ignition Device

Carburetor

Air Cleaner

.

1.5

Diode Rectifier Sectional View of Engine

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

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

at

of

ENGINE CONSTRUCTION

Max . Output

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

.......

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

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

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

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

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

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

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

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

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

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

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

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

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

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

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

2

2 2

4

5 5 5

6

7

8

9

9 9

10

5 .

DISASSEMBLY

5-1 5-2

5-3

5-4

Preparations and Suggestion Special

How

Tappet Clearance Adjustment

Ignition Timing Adjustment

Governor Setting Method

and

Tools

to Disassemble

to Reassemble

REASSEMBLY

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

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

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

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

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

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

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

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

12

12 12 13

18

22 23

25

See rion Title

6

.

CARBURETOR

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

Page

26

6-1 Operation and Construction 6-2 Disassembly and Reassembly

7

.

BREAK-IN OPERATION

8

.

ROBIN SOLID STATE IGNITION ENGINE (OPTION)

8-1 Features 8-2 Basic Circuit and Operating Theory 8-3 Checking 8-4 Measuring Resistances

9

.

TROUBLE SHOOTING.

9-1 Starting Difficulties 9-2 Engine Misfires 9-3 Enginestops 9-4 Engine Overheat 9-5 Engine Knocks 9-6 Engine Backfires through Carburetor

10

.

INSTALLATION

10-1 Installing 10-2 Ventilation 10-3 Exhaust Gas Discharge

10-4

10-5 Power Transmission to Driven Machines 10-6 Wiring

Fuelsystem

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

S.S.I.

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

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

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

of

REASSEMBLED ENGINE

Unit with Tester

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

..................................... 30

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

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

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

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

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

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

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

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

of

Exciter Coil and Pulser Coil

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

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

of

S.S.

I . System

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

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

:

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

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

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

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

26 27

28

29

29 29 29 29

30

31 31 31

32

33

33 33 34 34

11

.

CHECKS

12

.

TABLE

13

.

MAINTENANCE

13-1 Daily and Maintenance 13-2 Every 20 Hours Checks and Maintenance 13-3 Every 13-4 Every 100

13-5 Everv 13-6 Every 1000 Hours (Yearly) Checks and Maintenance

13-7 Preparation for Long Abeyance

and

CORRECTIONS

of

CORRECTION STANDARDS

and

STORING

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

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

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

50

Hours (10 days) Checks and Maintenance

-

200 Hours (Monthly) Checks and Maintenance

500-

600

Hours (Semiannual) Checks and Maintenance

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

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

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

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

..........

........

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

37

38

43

43 43 43 43 44 44 44

1.

SPECIFICATIONS

w

i

-1-

2.

PERFORMANCE

2-1

MAXIMUM

OUTPUT

The maximum ouput

of

an engine

is

such

standard power

as

developed by the engine, after its initial break in period with

all

the m,oving parts properly worn in, when operating with a fully open throttle valve. Therefore, a new engine may not develop the maximum output

in

the

beginning because the moving

parts

are not in a properly worn-in condition.

-

rpm

-2-

PERFORMANCE

CURVE

MODEL EY40D

kg-m

2.2

(4.4)

2.1

(4.2)

t

10

9

8

7

HP

I

6

5

4

3

2

1

0

-3-

3.

FEATURES

Small

in

size, light in weight

The cylinder and crankcase are reduced as much as possible

Quiet

operation with

low

Intake and exhaust noises are reduced by use chine noise is reduced by selection up

to

a quiet engine. Vibration

of

a timing balancer and optimum balance factor.

Easy

to start

of

for

easy mounting.

level

of

vibration

is

a one-piece aluminum diecast structure, which

of

a newly designed muffler having glass wool and a cyclone cleaner. Ma-

of

a suitable cam shaft profile and optimum clearances

also reduced

to

a low level by weight reduction

is

light in weight. The dimensions are

for

inner parts.

of

reciprocating parts, and selection

These engines can easily be started because they employ an automatic decompression device and a newly designed recoil starter.

of

Wide range

These models are available in various types

for

application to various kinds of machines. The engines have two

in any desired direction. Various optional parts are

adaptability

of

output shafts and also a type (Type

oil

drain ports, and their recoil starter can be pulled

also

available. All these combine

B)

with a built-in

to

increase adaptability to machines.

1

/2

reduction gear

Durable, reliable and safe

A

liner

of

special cast iron, hard-chrome-plate piston rings, forged rod, etc. are used to make these engines as reliable

and durable as the preceding models

of

the

EY

Series. Safety devices are also incorporated to assured added safety.

All

ths

adds

4.

GENERAL DESCRIPTION

4-1

CYLINDER,

CRANKCASE

of

ENGINE CONSTRUCTION

The cylinder and crankcase are single piece aluminum die casting. The cylinder liner, made

of

special cast iron, is built into the aluminum casting. The intake and exhaust ports are located on one side

to

the casing. The crankcase is separable the main bearing cover is attached to it. (See Fig.

of

the cylinder, and are also inserted in-

on

the output shaft side, where

1

.)

-4-

Fig.

1

4-2

MAIN

BEARING COVER

B

The main bearing cover made of aluminum die casting is built onto the output shaft side of the crankcase

so

that the inside

of the engine can readily be checked by simply removing the cover. It is provided with a flange and boss for directly mount-

ing machines, such as generators and pumps. Two

oil

gauges also serving as oil filler caps can be mounted. . (See Fig. 2 and Fig.

3

.)

RING

for

CENTERING

OIL

GAUGE

Fig.

2

Fig.

3

4-3

CRANKSHAFT

INDUCTION HARDENING

(PORTION

of

CRANKPIN)

The crankshaft

is

forged

of

carbon steel, and the crankpin

is

induction-hardened. It has a crank gear pressure-fitted on

the output end.

-

(See Fig.

4.)

CRANK GEAR (PRESSURE-FIT)

Fig.

4

4-4

CONNECTING

ROD

and

PISTON

The

connecting

rod

is

forged

of

aluminum alloy, which it-

self serves as bearings at both the large and small ends. The

large end has

a

built-in

oil

scraper

for

splashng the

lubri-

cating

oil.

The

piston

is cast

of

aluminum alloy, and has grooves

for

receiving two compression rings and one

oil

ring.

(See

Fig.

5.)

SECOND

RING

Fig.

5

-5-

4-5

CAMSHAFT

Models

EY3S-B,

3S-BS,

EY40-B

and

40-BS

have intake

and

exhaust cams

of

forged carbon steel, which are fitted with

a

cam gear under pressure. The assembly serves as output shaft that

is

driven at one

half

the speed of the crankshaft.

The

cam gear has a governor fitted

to

it.

Model EY35-D,

35-DS,

EY40-D

and

40-DS

have a camshaft

of

special cast iron, which is integrally assembled with a cam

gear. The two ends of the shaft serve as plain bearings

so

no

ball bearings are used. (See

Fig.

6.)

4-6

CYLINDER HEAD

The cylinder head

is

an

aluminum

die

casting,

and

forms a

Ricardo type combustion chamber with ample area

for

high combustion effeciency. The spark plug is tilted for easy mounting of the fuel tank.

(See

Fig.

7.)

0

Fig.

6

Fig.

7

4-7

VALVE ARRANGEMENT

.

"

. ".

.._

_.

The exhaust valve is located upstream of the cooling air with

the

result that the exhaust valve is intensively cooled

for

improved engine durability. The inner side

of

the valve head

is reinforced with hard alloy fused

to

it

for

added durability.

(See

Fig.

8.)

Fig.

8

-6-

4-8

GOVERNOR

The governor is a centrifugal flyweight type which permits constant operation

at

the selected speed against load varia-

tions. (See

Fig.

9.)

4-9

BALANCER

The balancer is assembled with the main bearing cover. Unbalanced moments

of

inertia generated in vertical and horizontal directions by the crankshaft, piston and connecting rod are balanced by the balancer whxh rotates at the same rate as the crankshaft in opposite direction thereto, thus reducing vibration

due

to unbalanced moments

of

inertia.

(See

Fig.

10.)

4-10

DECOMPRESSION DEVICE

The intake cam has a special profile and the intake valve is sligh

of

compressed air out to make starting easy. (See

Fig.

11

.)

EXHAUST TAPPET

IN

TAPPET

'.O.

EXHAUST-CAM

DECOMP

LIFT

SHAFT

SIDE

Fig.

9

Fig.

10

.tly raised during the compression stroke to let a slight amou

IN

TAPPET

IN

CAM

Fig.

I

1

-7-

4-11

COOLING

DEVICE

The cooling fan serving also

as

flywheel cools the cylinder and cylinder head by forced air cooling.

An

air guide plate and

head cover are used to let the cooling air

go

through.

The cooling fan employs curved blades

so

Types B and D have cooling

fan

parts special to their own.

".

.

4-12

LUBRICATION

The rotating and sliding parts are being lubricated

by

scoop-

ing and splashing the oil in the crankcase with the

oil

scraper

attached to the connecting rod.

(See

Fig.

12.)

OIL

SCRAPER

Fig.

72

4-13 IGNITION

DEVICE

Models EY35 and

EY40

have a flywheel magneto type ignition system

(Fig.

13) with

an

ignition timing of 23" before TDC

(Top

Dead Center). The flywheel

(also

serving

as

fan) is fitted onto the crankshaft; and the ignition coil, contact breaker,

and

charging coil are directly assembled with the crankcase.

An

S.S.I.

electronic system (Fig.

14)

is

also

available in types,

including

a

1

SO-watt load type.

The

S.S.I.

system, except the 150-watt type, electrically advances the ignition timing. The ignition timing after this advance

is 23" before

TDC.

(See Figs.

13

and

14.)

POINT

COVER

Fig.

13

FLYWHEEL

IGNITI~N

COIL

Fig.

14

4-14

CARBURETOR

A

horizontal draft carburetor is employed.

It

has been care-

fully set after

thorough

tests to assure satisfactory start up, acceleration, fuel consumption, output performance etc. For construction and other details, refer

to

the Section

6.

CARBURETOR (Construction, Disassembly

and

Reassem-

blY

1.

(See Fig.

15.)

4-15

AIR

CLEANER

Cyclone type semi-wet double element air cleaner is used. (See Fig.

16.)

4-16

DIODE

RECTIFIER

The engines with an electric starter have a diode rectifier which converts the alternating current generated

by

the

charging coil into

a

direct current and charges the battery.

(See

Fig.

17.)

L,

Fig.

15

Fig.

16

Fig.

17

-9-

4-17

SECTIONAL VIEW

OF

ENGINE

/

RECOIL

STARTER

(OPTION)

-

I

MODEL

EY35D.

-

10

-

CRANKCASE

40D

BALANCER

FUEL TANK CAP

INTAKE

&

EXHAUST VALVE

FUEL

COCK

BALANCER

MODEL EY35D,

40D

-

11

-

5.

DISASSEMBLY

5-1

PREPARATIONS

1)

When disassembling the engine, remember well the locations correctly.

2)

Have boxes ready to keep disassembled parts by group.

3)

To

prevent missing and misplacing, temporarily assemble each group

4)

Carefully handle disassembled parts, and clean them with washing oil.

5)

Use the correct

5-2

SPECIAL

For

your

reference, the following shows special tools

and

REASSEMBLY

and

SUGGESTIONS

If

you are uncertain

tools

in

the correct way,

TOOLS

of

identifying some parts, it

of

Robin Engine

of

individual parts

is

suggested that tags be attached to them.

of

disassembled parts.

for

Disassembly, Measuring and Inspection Instruments.

so

that they can be reassembled

Part

No.

2099500407

2079500307

Tool

Flywheel Puller

(with

bolt)

Valve

Spring

Retainer

~

Wse

For pulling Flywheel

For mounting and dismounting Valve Spring Retainer and Retainer

off

Lock

Applicable

Model

EY10,13,14

EY15,18,20

EY25,27,33

EY35,40,44

EC05,07,

ECf

EYIQ, 13.14

EY15,18,20

EY25,27,33

EY35,40,44

10

7,25,37

Shape

"20248

riming Tester

For adjusting timing

EYlO, 13,14

EY15,18,20

EY25,27,33

EY35,40,44

EC03,04,05

EC07,10,17

EC25,37

-

12

-

,"-

5-3

HOW

TO

DISASSEMBLE

*Length of the bolt indicates the length from the bolt head bottom surface to the threaded end.

Order

1

2

3

4

5

6

Item

Engine

Fuel tank

Tank bracket

Air cleaner

Muffler cover

Muffler

Procedures

Drain engine oil. Drain plugs on both sides of the case

(1) Close the strainer cock. (2)

Move the fuel pipe clamp (on

strainer side) downward.

(3)

Remove the tank from tank

bracket.

Remove tank bracket.

(1)

Remove

element.

(2)

Remove choke knob.

(3)

Remove the bottom plate of

air cleaner.

Remove muffler cover.

(1)

Remove the flange portion of the muffler.

(2)

Remove the muffler bracket.

air

cleaner cover and

Remarks

Be careful not to lose the the gasket.

Bolts, nuts, etc. used

Flange bolt

8

mm

(No.2)

SpI-ing washer

10

mm flange nut (tightened together with cylinder head)

Swivel

6

x

12 mm flange bolt

. .

.

6

x

8

(5T) Flange bolt

*

.

8

mm brass nut

8

x

16

.

. .

nut

. .

.4

pcs.

.

.4

pcs.

.

.4

2

pcs.

4

pcs.

. . .

2

pcs.

(ST) Bolt & washer 2

pcs., Washer

. . .

pcs.

1

pce

Carburetor

7

Governor

8

lever

Remove the carburetor.

Remove the governor lever.

Be careful etc. Joint sheet, insulator, and then paper packing, in ths order from the engine side

Be careful of the governor spring.

of

the packing

of

the position

6

mm nut

Spring washer Washer

6

mm special nut.

Washer

6

x

25

.

. .

. . .

(7T)

. .

.2

2 pcs.

1 pce.

bolt

pcs.

.

2

.

. . .

pcs.

,

1

pce.

Fig.

-

13

18

-

I

Order

Speed control

9

Bolts,

nuts,

etc.

used

Remarks

Procedures

Item

Circle clip

. .

.

1

pce.

Remember the assembling Disassemble. order

of

component parts.

(See Fig.

19.)

8

mm butterfly nut.

. .

1

pce.

-

Order

10

11

Item

Operation case

Electric starter

h

Fig.

19

(1)

Disconnect the high voltage wire connecting the electric starter to the magnetic switch on the side

of

the switch.

(2)

Remove the bolts.

(3

pcs.)

Remove electric starter.

Remarks

Bolts, nuts, etc. used

(See Fig.

20.)

Two

of

the three

6 x 8

(5T)

flange bolts tighten the cylinder buffle and fan cover together.

8

x

30

reamer bolt

. . .

2

pcs.

Spring washer

.

. .

2

pcs.

Washer

.

.2

pcs.

Fig.

20

-

14-

Order

-

12

-

13

Starting pulley Flywheel

14

-

Item

Fan cover

I

(1)

(2)

(3)

Remove starting pulley.

I

Remove flywheel. Be sure

Procedures

Remove the fan cover. Remove the head cover.

Remove the cylinder buffle.

I

Removable by loosening bolts

wheel puller. crankshaft.

Fig.

to

Remarks

21

.)

use the fly-

Do

I

Bolts,

nuts,

6 x 8

flange bolt

6

x

8

flange bolt

8

x

12

(ST)

18

mm nut

not Spring washer

bolt

. . .

etc.

1

.

. .

. . .

pce.

.

1

used

.

6

pcs.

1

pce.

3

pcs. (See

pce.

Fig.

21

Fig.

22

b

--

15

-

Order

15

-

16

Item

Electric devices

Cylinder head

Procedures

(1)

Remove point cover.

(2)

Remove contact breaker.

(3)

Remove ignition coil and condenser.

(1)

Remove spark plug.

(2) Remove cylinder head.

Remarks

Be careful lead connecting direction.

before disassembly.

of

the primary

Bolts,

nuts,

etc. used

4

x

12

screw

and

. .

.

2

pcs.

4

x

8

screw and washer

. . .

1

pce.

6

x

25

screw and washer Remove the lighting coil

. .

.

2

pcs.

10 mm flange nut

washer

. .

.8

pcs.

I

1

17

Tappet cover (breather

plate)

Intake and

exhaust valves

Remove Tappet cover.

(1)

Remove intake valve.

(2)

Remove exhaust valve.

Be

valve mounting position and the order

ing

(See

Intake and exhaust valve springs, retainers and retainer locks are common; but be sure to set up them

on

the original valves.

(See Fig. 24.)

Of

packings.

Fig.

23.)

the

breather

of

assembl-

I

6

x

14 flange

bolt

. . .

I

Use valve spring retainers.

2

pcs.

I

Fig.

23

Fig.

24

-

16-

Irder

I

Item

19

Main bearing cover

~

20

Camshaft

I

Procedures

~~~ ~ ~ ~~~~~

(1)

Set the piston to the TDC, re-

move blind plug

in

the lower

part

of

the front side of bear-

ing cover, and insert the

4

mm

stick.

(2)

Remove bolts.

(3)

Strike the side of main bearing cover with a plastic hammer or the like to remove the

cover from crankcase.

Remove camshaft.

r

Order

Intake/ex-

2

1

Item

haust tappets

22

Connecting rod and piston

23

Crankshaft

Remarks

I

Bolts, nuts, etc. used

(See Fig.

25.)

In case of Type

B,

be careful not to remove camshaft together. *Crankshaft and camshaft

have adjusting

shims.

(TY

Pe

B)

6

x

8

flange bolt

. .

.

1

pce.

Gasket (aluminium)

.

1

pce.

8

x

35

(7T)

set bolt

. .

.

8

pcs.

Camshaft can easily be pulled by hand. Be careful not to let the tappets drop.

1

Fig.

25

Fig.

26

Procedures

Bolts, nuts, etc. used

Remarks

~ ~~

Remove intake/exhaust tappets. Intake and exhaust tap-

pets are the same, but be sure to intall them in their original positions because

1

of

the valve clearance.

~~

(1)

Return the lock washer.

(2)

Remove bolts.

(3)

Push

the piston up out

of

the top of cylinder.

8 x 46

reamer bolt

.

~

.2

pcs.

I

Hold crankshaft with hand. and

I

Be careful of

oil

seal on

I

gently tap the flywheel end. the crankcase magneto

side.

-

17

-

5-4

HOW

TO

REASSEMBLE

5-4-1

PRECAUTION IN REASSEMBLY

Every and each part should be cleaned thoroughly. Especially, pay utmost care and attention to the cleanliness of the piston, cylinder, crankshaft, connecting rod and bearings. Scrape completely off carbons from the cylinder head and the upper part of the piston; especially the carbon adhered in the groove of the piston ring should be carefully and completely taken out. Carefully check the lip portion

of

every oil seal.

If

faulty one is found, replace it without any hesitation.

Apply enough

oil

to the lip portion

of

the

oil

seal when reassembling.

Replace all the gaskets with new ones.

Replace the key, pin, bolt, nuts, etc. with new one, if necessary.

Whenever tightening torque is specified, conform

to

the specified figures.

Apply oil

to

the revolutionary parts and friction surfaces, when reassembling.

Check and adjust the clearances

of

various portions and then reassemble.

When some main portions are assembled in the course

of

reassembling, turn or move the gadgets by hand and pay at-

tention to the frictional noise and resistance.

5-4-2

MEASURING CRANKCASE and CRANKSHAFT

Bore the cylinder or take other steps as necessary

to

meet

the following specifications before reassembling.

EY35

E

Y40

I

W

(Crankshaft

Width)

I

29

+0.1

0

Bore

Piston Outside Diameter (In Skirt Thrust Direction)

78

dia.

40.019

I

84

dia.

,,

+0.022

I

Piston

to

Cylinder

at

Piston Skirt

Thrust

Face

I

0.049L

-

0.1

08L

1

0.049L - 0.1

11

L

Piston Ring Gap (Top Ring - Second Ring)

I

Piston Ring Side Clearance in Grooves

(Top Ring

-

Second Ring)

Clearance between Connecting

Rod Large End and Piston Pin

and

Outside

Diameter

Clearance between Inside

Side

Clearance

0.1

L

-

0.3L

0.05

-

0.09

Clearance between Connection

Rod Small End and Piston Pin

Clearance between Piston Pin and Pinston Pin Hole

0.070

-

0.102L

0.020L - 0.042L

0.1

L

-

0.4L

0.1

1T - 0.01 1 L

r'

L:

LOOSE

Fig.

27

-

18

-

5-4-3

ASSEMBLING

1)

Place the tappets into the crankcase.

NOTE:

The intake and exhaust tappets are the same, but mark them differently when disassembling because of different

fit

the tappets beforehand.

ORDER

them into their origianl place. Apply oil to

Assemble the crankshaft time.

NOTE:

3)

Assemble the connecting

NOTE:

CAUTION:

4)

Fit

NOTE:

The same timing mark side

is

punched on the crankshaft gear inward

of the balancer gear

match these timing marks on the crankshaft and camshaft sides before installing these shafts in the crankcase.

The piston

must be marked with

direction indicated.

When inserting the piston pin and fitting the clip on, be careful not to damage the piston surface.

the

piston rings on the piston.

Each

that The oil ring consists spacer, lower rail, and upper rail.

in this order. The open ends of each ring must

be

as

is

not offset

piston ring must be installed upside

is,

the puched mark

shown in Fig.

and

PRECAUTIONS

..

valve

clearances; and

and

camshaft at the same

as

on the crankshaft

as

shown in Fig.

rod

with

the piston.

so

a

new piston does not require to

a

sign indicating its direction when disassembling

28.

So,

up,

at

the open ends up.

of

three parts, that is,

Fit

them on

a

UPPER RAIL LOWER

29.

TIMING MARK ON CAMSHAFT SIDE

(Punch

2

pcskl

TIMING

(Punch

be

MARK ON

1

pce.)

installed in a specific direction, but a used piston

CRANKSHA??

Fig.

28

so

that

it

can be assembled again in the

THRUST SIDE

RAIL

Fig.

30

-

19-

Fig.

29

ASSEMBLY TYPE

Fig.

3

1

OIL

RING

5)

Assemble the piston

and

connecting

rod

that were

readied in Steps

3)

and

4).

NOTE:

The symbol @FAN mark on the connecting

rod must be on the magneto side.

NOTE:

Be careful

of

the match mark on the cap. If

the match mark

is

at

the correct position, the

oil scraper should be on the main bearing

cov-

er side.

NOTE:

Tightening bolt

. . .

. . . .

8

x

46

(special)

Tightening torque

. . .

250

-

300

kg-cm

Use new lock washers, and bend their edges

securely.

Install

the

main

bearing

cover.

NOTE:

If

the oil

seal

is

damaged when the governor

yoke

is

installed, replace

it

with a new one.

NOTE:

Adjust the side clearance to anywhere be-

tween

0.05

and

0.2

mm. The side clearance

can be measured by measuring sizes

A

and

B

as

shown in

Fig.

33,

and assume that the thick-

ness

of

packing

C

is

0.25

mm when tightened.

*

The side clearance can

also

be measured

as

shown in photos below. (Figs.

34

and

35)

~

MATCH

u__

Fig.

32

CRANKSHAFT SPACER

\

MAIN BEARING

BALANCER

Fig.

33

Fig.

34

-

20

-

Fig.

35

NOTE:

7)

Install the intake

*

Intake

Check the main bearing cover joint for flaw, and correct

Fit the governor with new packing.

*

Move the piston up to TDC, insert the 4 mm stick into the main bearing cover, and fasten the balancer Tightening bolt Tightening torque

*

Insert the blind plug the balancer fixing hole with the aluminum gasket, and check if the crankshaft srnooth-

ly

and

if

necessary.

sleeve

into

the

as

runs.

and

exhaust valves.

shown in Fig.

. . .

. . . .

.

.170

(6

x

8

x

-

190

flange

36.

35

bolt)

exhaust valve specifications are as

cam gear

(7T)

kg-cm

into

follows:

A.4

IF

Fig.

4O

36

VALVE

A-VALVE FACE ANGLE 6-SEAT ANGLE

C-GUIDE INSIDE DIA.

~~~~ ~ ~

D-VALVE STEM OUTSIDE DIA.

MAXIMUM ALLOWABLE

CLEARANCE 8ETWEEN

and

VALVE

GUIDE

C

and

CLEARANCE

INTAKE

D

Fig.

-21

37

-

EY35

+0.036

8dia.

dia.

-0.070

-0.090

0.030L

-

0.091

0.070L - 0.1

26L

GUIDE

E

Y40

L

.TAPPET CLEARANCE ADJUSTMENT

Move the piston up to compression the tappet clearance as

follows,

TDC,

and adjust

using a grinder or the like. Clearance (Models

EY35,

EY40

intake and exhaust):

0.13 - 0.1 7 mm when cold

*

Intake and exhaust valve installation Apply oil to the valve stems, and install the valves securely by using the special tool, valve spring re-

tainer and pliers. (See Fig.

39.)

After their installation, check the tappet clearance

again.

Fig.

38

8)

Install the breather plate and tappet cover.

NOTE:

9)

Install the cylinder head.

NOTE:

Be careful of the gasket installing order (See Fig.

40.)

and breather valve position. The breather side.

6

x

14

Replace the head gasket with a new

10

mm flange nut

Tightening torque

valve

flange bolt

must be on the intake

..........

...........

...

340 - 390

Fig.

39

valve

2

pcs.

Fig.

40

one,

and tighten the nuts uniformly with the specified torque.

8

pa.

kg-cm

-

22

-

10)

Electrical installation

*

Install the ignition coil Screws:

*

Temporarily install the contact breaker. Screw:

CAUTION:

*IGNITION TIMING ADJUSTMENT

Ignition timing

Point gap

Adjusting method

If

the point surfaces are rough, smoothen them. Hold the top of the point cam on the crankshaft in contact with the heel contact breaker itself until the correct point gap is tained. The ignition timing of the engine depends on the point gap. tion timing

.IGNITION TIMING

Use a timing tester, Part Checking method

As

shown in Fig. other lead to the crankcase, switch the timing tester on, and hold the earphone close to the ear. Slowly turn the flywheel matches the agree, repeat the above mentioned adjustment.

6

x

25

screw and washer

4

x

8

screw and washer

Be

careful

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

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

of

the contact breaker, and move the

If

the gap is correctly adjusted, the igni-

will

be

43,

in

normal direction (clockwise for Type

M

mark on the case when the buzzer sounds, it

and

capacitor.

. .

2

...

1

of

the

location

of

23"

before TDC

.0.35

23"

before

CHECK

connect one of the leads

TDC.

N0.M-20248

pcs. each

pce. each

the

cord.

k0.05

mm

Fig. 4 1

ob-

Fig.

42

of

the timing tester to the primary wire of the ignition coil, and the

D,

or counterclockwise for Type

is

the correct ignition timing. If the two marks do not

B),

and if the mark on the flywheel

rKER

---"

FLYWHEEL

Fig.

43

-

23

-

Fig.

44

*SPARK CHECK

*

Clean the point surfaces of

oil

with paper or the like, and temporarily install the flywheel.

*

Hold the high-voltage wire with hand

so

its end

is

about 5 mm away from the case,

and

turn the flywheel in normal

direction.

*

Check that a spark

is

generated when the M mark

on

the flywheel passes the M mark on the case.

*

Install the

point

cover.

4

x

12

screw and washer

......

2

PCS.

11) Install the flywheel.

NOTE:

Before installing the flywheef, clean the crankshaft and the tapered part of the flywheel of oil.

16mmnut

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

1 pce.

Spring washer

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

1

pce.

Washer.

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

1 pce.

Tightening torque

..

.800

-

1000

kg-cm

12) Install the starter pulley.

8 x 12

bolt

(ST)

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

3

pcs.

13) Install

the

fan

cover and head cover cylinder buffle.

NOTE:

Before installing the fan cover, first install

the

head cover

on

the cylinder head.

Also

install

the

muffler brack-

et

in

place

at

the same time.

6

x

8

flange bolt

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

7

pcs.'

14)

Install the recoil starter

NOTE:

Pulling direction may vary with machine make.

6

x

8

flange bolt

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

4

pcs.

15)

Install the carburetor.

NOTE:

Install

the carburetor with the joint sheet, insulator, and paper packing in this order.

6

mm nut

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

2

pcs.

Spring washer

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

2

pcs.

Washer.

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

2

pcs.

16) Install the speed control

and

governor lever according

to the arrangement

of

parts

shown

in

Fig.

47.

Hook

the governor spring at the proper hole.

8

mm wing nut

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

1

pce.

Clip..

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

1

pce.

0

Fig.

45

-

24

-

.GOVERNOR

*

Set the speed control lever to the high-speed position, and fasten it there with the wing nut. (The governor spring

*

Check that the carburetor and throttle valve are

fully open.

*

Turn the governor shaft counterclockwise,

fasten the governor lever. (See Fig. 46.)

Install the starter motor.

8 x 30

Spring washer

Washer.

Install the operation case. (with the electric starter)

6 x 8

*

Two of the three flange bolts tighten the case together with the cylinder buffle and fan cover.

*

Properly wire as shown in the wiring diagrams (Pages

Install the muffler.

NOTE:

Install the muffler cover.

Install the

NOTE:

After mounting the cleaner bottom plate, install the choke knob, element retainer, element and cover Install the tank bracket.

Install the fuel tank.

Connect the fuel pipe. Clamp the pipe securely. Supply 1.2 liter engine

The muffler gasket must be placed

8m brass nut

8

Washer.

6

Make sure that the tip of the breather pipe

SETTING METHOD

is

in.)

reamer bolt

...........

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

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

flange bolt (5T)

.........

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

x

16

bolt (for bracket)

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

x

8

flange bolt (5T)

air

cleaner.

6

x

12 flange bolt

10

mm flange nut

(also for cylinder head)

8

mm

No.2

nut

Spring washer

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

oil.

.........

...........

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

in

.......

and

2

pcs.

2

PcS.

2

pes.

3

pcs.

34

and

35).

'the correct direction.

2 pcs. 2

pcs.

1

pce.

4

pcs.

out

of the tappet cover

2

pcs.

4

pcs.

4

pcs.

4

pcs.

Fig.

46

(Non-symmetric direction)

is

clear off the element retainer.

in

ths order.

-25

-

6,

CARBURETOR

SPECIFICATION

I

Model

Main

Pilot Throttle Valve Pilot Screw

1

(Return)

OPERATION and CONSTRUCTION

6

-1

No.

Jet Air

Jet

I

EY35

#107.5

1

turn

E

I

Y40

BV26-20 BV26-19

2246230100 2236230100 Part

#112.5 $1.2 $1.5

#57.5 #55 #135 #150

PI

LOT

NEEDLE VALVE

FLOAT CHAMBER

A

FUEL

FLOAT

Fig.

-

W

26

48

-

6-1

-1

FLOAT SYSTEM

The float chamber

is

located just below the carburetor body and, with a float and a needle valve, maintains a constant fuel level during engine operation. The fuel

flows

from the fuel tank into the float chamber through the needle valve. When the fuel rises to a specific level, the

float rises; and when its buoyancy and fuel pressure are balanced, the needle valve close to the shut off the fuel, thereby

keeping the fuel at the reference level.

6-1

-2

PI

LOT SYSTEM

The pilot system feeds the fuel

to

the engine during idling and low-speed operation. The fuel is fed through the main jet to the pilot jet, where it is metered, and mixed with the air metered by the pilot air jet. The fuel-air mixture

is

fed to the engine through the pilot outllet and the by-pass. During engine idling, the fuel is mainly fed from the pilot outlet. 6-1-3

MAIN SYSTEM

The main system feeds the fuel to the engine during medium- and high-speed operation. The fuel is metered by the main jet and fed to the main nozzle. The air metered by the main air jet is mixed with the fuel through the bleed holes in the main nozzle, and the mixture is atomized out of the main bore. It is mixed again with the

air

taken through the air cleaner into an optimum fuel-air mixture, which is supplied to the engine. 6-1

-4

CHOKE

The choke is used for easy start in the cold season. When the recoil starter

is

pulled with a closed choke, the negative pres-

sure applied to the main nozzle increases and draws much fuel accordingly; thus easily start up the engine.

6-2

DISASSEMBLY

and

REASSEMBLY

Apart from mechanical failures, most of carburetor troubles are caused by an incorrect mixing ratio, which may arise mainly due to a clogged up ah or fuel passage in jets, or fuel level variations. In order to assure proper flow of air and fuel, the car; buretor must be kept clean at all times. The carburetor disassembly and reassembly procedures are as follows: (See Fig.

6-2-1

THROTTLE SYSTEM

1) Remove the Phdlips screw

2)

The spring

(5)

can be taken out by removing the throttle stop screw

*Be careful of the direction

(I)

and throttle valve

of

the throttle valve.

(2),

and pull

The circumference of the throttle valve is aslant. Install the valve

out

the throttle shaft

(4).

so

the punched mark on the valve can be seen on the

(3).

left.

''

6-2-2

6-2-3

CHOKE

I)

Remove the Phillips screw

2)

When reassembling the choke shaft, make sure that the cutout in the choke valve faces the main air jet.

PILOT SYSTEM

I)

Remove the pilot jet

2)

Remove pilot screw

3)

Reassembly

SYSTEM

(6)

and choke valve

(1

0),

using correct tool to avoid damage to it.

(1

1)

and spring

(1

2).

(7),

and pull out the choke shaft

(8).

Stop ring

(9)

can not be removed.

*Tighten the pilot jet securely. Otherwise, the fuel may leak, causing engine malfunction. *If the tapered part of the pilot screw is out

of

shape, replace it with a new one.

49.)

-

27

-

6-2-4

MAIN

SYSTEM

1)

Remove the bolt

(1

3)

and take out float chamber

body

(15).

2)

Remove the main jet

(1

7)

and

main

nozzle

(1

8),

using

correct tool to avoid damage to it,

3)

Reassembly Fasten the main jet securely to the body. Otherwise, the fuel may become

too

rich and cause engine mal-

function.

6-2

-5

FLOAT

SYSTEM

When removing the needle valve

(21)

and float

(20),

gently tap the reverse side using the rod more slender than the float pin

(19)

and remove because the float pin

is

calked to

the carburetor body.

*When cleaning the jets, use neither

a

drill

nor

a wire

(because of possible damage of the orifice which will adversely affect fuel

flow).

Be sure to use compressed air to blow them clean. Fully tighten the pilot screw and then loosen

it

coun-

terclockwise by one turn for Model

EY35,

or one

turn and a

half

for Model

EY40.

When fully closing the pilot screw, do not tighten it too hard. Otherwise, the needle at the tip might become damaged. Turn the throttle stop screw clockwise

to

a

normal

idling speed

of

1200

rpm.

Make a final adjustment when the engine is in normal

I

A

‘17

19

-18

Fig.

49

operating condition at normal temperature with the correct air cleaner mounted.

7.

BREAK-IN OPERATION

of

REASSEMBLED ENGINE

An

overhauled engine must be operated

at

low speed break-in the parts. A thorough break-in is indispensable particularly when the cylinder, piston, piston rings or valves are replaced with new ones. Thl

e

recommended break-in schedule is shown below.

LOAD

SPEED

TIME

EY35

EY

40

NO

LOAD

10

minutes

2,500

rprn

~

NO

LOAD

30

minutes

3,600

rpm

4.0

HP

3.5

HP

10

minutes

3,600

rprn

NO

LOAD

10

minutes

3,000

rpm

7.0

HP

I

8.0

HP

~

1

3,600

rpm

I

60

minutes

1

-

28

-

8.

ROBIN

SOLID

STATE IGNITION ENGINE (OPTION)

8-1 FEATURES

The

S.S.I.

system is free

of

the weak points of the conventional point type ignition system, that is, ignition failure due to a

dirty or burnt contact point, oxidation during long storage,and mechanical wear,and

featuresmaintenance-free

performance,

proper sparking, and freedom from the

ill

effects of water,

oil

dust, and moisture.

8-2

BASIC CIRCUIT

and

OPERATING THEORY

of

S.S.

I.

SYSTEM

1)

As the flywheel and magneto rotate, a voltage is induced

in

the exciter coil, and flows through the pri-

mary wire to the transistor base.

A

2)

At the same time, the transistor is energized to form a

circuit between the exciter coil and the transistor.

B

3)

At the ignition time, electric power flows from the pulser coil to the

SCR

gate to energize the

SCR.

C

Thus the current flowing to the transistor is cut off,

and the exciter current suddenly rushes to the primary side of the ignition coil.

D

Thus, a high voltage is

generated

on

the secondary side

of

the ignition coil to

produce a spark in the spark plug.

E

8-3 CHECKING IGNITION UNIT

with

TESTER

The ignition unit can be checked with an ordinary circuit tester.

Checkit as shown in the table at right, and if the test results are

as

specified, the ignition unit

is

in normal condition. If

any

of

the

test results

is

not satisfactory, replace the whole

ignition unit.

NOTE:

Use

a

circuit tester, not a megger

or

other

tester

that

requires

high

ovltage.

ON

in

the

table indicates the forward characteristic

of

the diode, and

if

the tester pointer moves to

a

certain extent,

it

is good.

OFF

in

the table indicates

ma.

IGNITION UNIT

"-1

IGNITION

COIL

L

Fig.

50

Connect

(+)

terminal

of

tester.

I

8-4

MEASURING RESISTANCES

of

EXCITER COIL

and

PULSER COIL

Exciter

Coil

A-tB A+B

Pulser Coil

STD

t

4.5R

*

20%

150W

66Q

*

20%

0.97Q

*

20%

Fig.

51

*

Values

in

the table above apply where ambient temperature is 20°C.

-

29

-

9.

TROUBLE

SHOOTING

The following three conditions must be satisfied for satisfactory engine start.

1.

The cylinder filled with a proper fuel-air mixture.

2.

An appropriate compression in the cylinder.

3.

Good sparks at the correct time to ignite the mixture. The engine cannot be started unless these three conditions are met. There are also other factors which make engine start difficult, e. g., a heavy load on the engine when it pipe,

just

to say a few.

is

about to start at low speed, and a

high

back pressure due

to

a long exhaust

The most common causes of engine troubles are given below:

9-1

STARTING DIFFICULTIES

9-1

-1

FUEL SYSTEM

NO

gasoline in th fuel tank; or the fuel cock is closed. The carburetor is not choked enough, particularly when the engine is cold. Water, dust Inferior grade gasoline The carburetor needle valve is held open by dirt carburetor when the engine

or

gum in the gasoline block flow of the fuel to the carburetor.

or

poor quality gasoline is not gasfied enough to produce the correct fuel-air mixture.

or

gum. This trouble can be detected as the fuel flows out

is

idling. (Overflow)

of

the

This trouble may be remedied, depending on cases, by lightly tapping the float chamber with the grip of a screwdriver of the like. If the carburetor overflows, excessive fuel runs into the cylinder when starting the engine, making the fuel-air mixture too rich to burn. rich fuel-air mixture out operation. Dry the spark plug well, screw it into place, and try

If

this happens, remove the spark plug, and turn the starting pulley a few turns in order to let the

of

the spark plug hole into the atmosphere. Keep the carburetor choke open during this

to

start again.

9-1-2

If

COMPRESSION

starting difficulties and

SYSTEM

loss

of power are not due to the fuel system

or

ignition system, the following must be checked for

possible lack of compression.

1)

Engine inside

2)

Loose

is

completely dried up because of a long period of non-operation.

or

broken spark plug. This causes a hissing noise made by mixture

gas

running out

of

cylinder in compression

stroke during cranking.

3)

Damaged head gasket or loose cylinder head. A similar hissing noise

4)

Incorrect Tappet Clearance

If

the correct compression is not obtained even after remedying the above, disassemble the engine and check further

as

follows:

a)

Valve stuck open due to carbon

or

gum

on

the valve stem.

is

produced during compression stroke.

b) If the piston rings are stuck on the piston, remove the piston and connecting rod from the engine, and clean, remedy

or

replace the parts.

-

30

-

9-1-3

ELECTRICAL SYSTEM

Check the following

Leads of the ignition coil, spark plug Ignition coil damaged and shorted. Spark plug cable wet Spark plug dirty Spark plug electrode gap incorrect. Spark plug electrodes in contact with each other. Contact breaker points pitted or fused.

Breaker arm stuck.

Condenser leaking

Incorrect spark timing.

ENGINE MISFIRES

Incorrect spark plug electrode gap. Adjust it to anywhere between Ignition cable worn and leaking. Sparks weak. Ignition wire connections loose. Pitted or worn breaker points. Water in gasoline.

Insufficient compression.

for

lack

or

wet.

or

of

sparks.

or

soaked with oil.

grounded.

or

contact breaker disconnected.

0.6

and

0.7

mm.

0

ENGINE

9-3

Fuel tank empty. Water, dirt, gum, etc. in gasoline.

1)

Vapor lock, i. e., gasoline evaporating in the fuel lines due to overheat around the engine. Vapor lock in the fuel lines

Air

Bearing p.arts seized due to lack

Magneto

ENGINE OVERHEAT

9-4

Crankcase

Spark timing incorrect. Low grade gasoline is used, Cooling air circulation restricted. Cooling air party misdirected causes loss of cooling efficiency.

Cylinder head cooling fins clogged

Engine operated in an enclosed space without fresh supply of cooling air. Exhaust gas discharge restricted, Engine running on low-octane gasoline detonates due to heavy load at low speed.

STOPS

or

carburetor due to the use

vent hole in the fuel tank cap plugged.

of

oil.

or

ignition coil faulty.

oil

level low. Add

oil

immediately.

or

engine

up

or

is

overloaded.

with dirt.

carbon deposits in the combustion chamber.

of

too volatile winter

gas

in the hot season.

-

31

-

ENGINE

KNOCKS

Low-quality gasoline. Engine operating under heavy load at low speed. Carbon

Spark

or

lead deposits in the cylinder head.

timing incorrect. Loose connecting rod bearing due to wear. Loose piston Causes

due to wear.

of

engine overheat.

ENGINE BACKFIRES

1)

Water or dirt in gasoline, or low-grade gasoline.

2)

Intake valve stuck.

3)

Valves overheated,

4)

Engine cold.

through

or

red-hot carbon particles

CARBURETOR

in

the combustion chamber.

-

32

-

10.

INSTALLATION

Engine life, ease in whlch the engine is installed. Carefully observe the following instructions for installing the engine.

10-1

INSTALLING

When mounting the engine, carefully examine its position, the method and the method of supporting the engine.

When determining its mounting position, in particular, make sure that gasoline and oil can easily be supplied and checked, the spark plug and breaker can easily be checked, the air cleaner can easily be serviced, and that the oil can easily be discharged.

10-2

VENTILATION

Fresh air is necessary for cooling the engine and burning the fuel. In cases where the engine is operated under a hood or in a small room, temperature rise in the engine room can cause vapor lock,

oil

deterioration, increased to operate the engine properly. prevent recirculation of the hot

Take steps as necessary to keep the engine room temperature below 50°C even in the hottest period of the year.

10-3

EXHAUST GAS DISCHARGE

Exhaust gas is pipe is used in such a case, the internal resistance increases causing loss of engine power. Thus pipe inside diameter must crease in proportion to exhaust pipe length.

of

maintenance and inspection, frequency of checks and repairs, and operating cost all depend on the way

of

connecting it to a load (machine), the foundation,

oil

consumption,loss,of power, piston seizure, shorter engine life, etc., making it impossible

It

is necessary, therefore, to provide a duct or baffle to guide cooling air to the engine to

air

used for engine cooling, and temperature rise of the load (machine).

noxious.

When

operating the engine indoors, be sure to discharge the exhaust gas outdoors. If a

long

exhaust

in-

*

Exhaust pipe:

*

Put safety covers over the exhaust pipe, muffler, etc.

10-4

FUEL

STSTEM

If the fuel tank

5

cm to

50

cm above the fuel joint of the carburetor. the fuel tank is too Be careful of heat conduction, pipe size, bends, and leaks from the joints in piping and make the fuel pipe as short as possible to prevent air and vapor from being trapped. The standard fuel pipe diameter is

10-5

POWER

10-5-1

Take the following notes into consideration.

If

BELT

*

V-belts are preferable to flat belts.

*

The driving shaft of the engine must be parallel to the driven shaft of the load.

*

The driving pulley of the engine must be

*

Install the engine pulley as close to the engine as possible.

*

If

possible, span the belt horizontally.

*

Disengage the load when starting the engine.

no

clutch is used, use a belt tension pulley or the like.

Less

than 3 m long, pipe inside diameter

Less

than

5

m

is

removed from the engine

high,

on

the other hand, it can cause the carburetor to overflow.

TRANSMISSION

DRIVE

to

long, pipe inside diameter

in

mounting the engine in a machine, install the fuel tank back

If

the fuel

DRIVEN

MACHINES

in

line with the driven pulley

30 33

mm,

mm.

tank

is installed

4

to 5 mm.

of

the load.

too

low, the fuel will not

so

its bottom is

be

supplied. If

-

33

-

10-5-2

FLEXIBLE

COUPLING When using a flexible coupling, runout and misalignment between the driven shaft and engine shaft must be minimized. Runout and misalignment tolerance are specified by the coupling manufacturer.

10-6

WIRING

Models

EY35

and

EY40

are available

in

types that have the ignition and starting systems shown

below.

The parts indicated by dotted lines in the diagram are

[RECOIL

Note:

[ELECTRIC STARTER TYPE]

STARTER TYPE

and

LIGHTING

Standard type is not equipped

with the

lighting

SPARK PLUG

coil.

MAGNETO

COIL]

MAGNETO

Green/Yellow

not

normally supplied with the engine.

STOP BUTTON

-

- - -

-

1

BUZZER

Fig.

52

KEY SWITCH

E

in

the

wiring diagrams

ELECTRIC STARTER MAGNETIC SWITCH

[S.S.I.

with

RECOIL STARTER

and

BUZZER

6V8W

LIGHTING COIL]

MAGNETO

@

*

QLAMP 12V15W

Fig.

53

1

SPARK PL .UG

STOP

BUTTON

I

J,

Fig.

54

-

34

-

[S.S.I.

with

ELECTRIC STARTER]

KEY SWITCH

BATTERY

12W24AH

[S.S.I.

*

15OW

with

CHARGING

The

symbols

"""-

ELECTRIC STARTER]

COIL

shown

EXCITER

in

Not mounted

COIL

-

""_

the wiring diagrams above signify the following.

on

RedIWhite

""-I

[

Black/White

the engine

A

Red

Fig.

56

12V24AH

ELZRIC STARTER

--

--D

*

In the wiring diagram showing the circuit with a the standard

models.

@

JIS

CB104 jack

JIS

CA104 plug

JIS

LA104

or

LA108 plate terminal

recoil,

the ignition

-

35

coil

is

optional, and therefore is not supplied

on

-

10-7

VINYL-INSULATED

WIRE

Recent engine sets become complex, and an increasing number of them are remote-controlled.

When designing or repairing such machines, special care must be taken

in

selecting their wire. Select the correct wire from

the table below by considering the following.

FACTORS

TO

BE

CONSIDERED

*

Amperage

*

Current flowing time (continuous, intermittent)

*

Wire length

*

Mechanical strength

of

wire against vibration

*

Wire size versus resistance

Size

(mm2

I

0.50

0.85

1.25

2.0

3

.O

5

.O

8.0

15.0

20.0

30

.O

No.

of

conductors/

conductor diameter (mml

7r0.32 11r0.32 1

6r0.3 2

2610.32

41 10.32

6510.32

5010.45

8410.45 4

1

10.80

70f0.80

Resistor

(Wml

2OoC

Albwable curre1

(I

0.03250

9

0.02050

120

0.00051

84

0.00087

59

0.00136

47

0.00228

37

0.00374

27

0.00550

20 0.00867

1.5 0.01410

12

*

Electrical resistance increases with wire length, and decreases as conductor diameter increases. Resistance also varies with material even if size and length are the same.

*

Nominal size means the nominal area

of

steel wire expressed by

00

square

(SQ).

-

36

-

11.

CHECKS

After disassembling and cleaning the engine, check and repair, if necessary, according to the correction table. The correction table applies whenever the engines are repaired. It is important for the servicemen to be familiar with the contents of

table. Correct maintenance The meanings

1) Correction Repair, adjustment or replacement of any engine parts.

2)

Correction Limit The limit on wear, damage or functional deterioration of engine parts beyond which normal engine performance cannot be expected without repairing such parts.

3)

Use Limit The limit beyond which parts can no longer be used in respect of performance.or strength.

4)

Standard Dimensions The design dimensions of new parts minus tolerance.

5)

Correction Tolerance Tolerance on the dimensions of engine parts refinished or adjusted.

and

CORRECTIONS

is

recommended by observing the correction standards specified.

of

the terms used in the correction table are

as

follows:

tlus

-

37

-

12.

TABLES

OF

CORRECTION STANDARDS

T

-

USE

LIMIT

TOOL

CORRECTION

METHOD

ENGINE

MODEL

EY35 EY40

EY 35 EY40

EY35 EY40

EY 35 EY40

EY35

EY40

EY35

EY40

EY35 EY40

EY35

EY40

EY35

EY40

EY35 EY40

EY35

EY40

EY35 EY40

STANDARD

SIZE

ITEM

REMARKS

TOLERANCE LIMIT

Surface

plate, Feeler

Flatness

of

cylinder

head

Bore

Roundness

Cylindricity

Valve seat contact

width

Valve guide

I.D.

O.D. at skirt, in thrust direction (incl. over size)

B

0.25

C

0.5

Width

of

ring

groove

Piston pin hole

Clearance between piston and cylinder

Clearance between pisition ring and ring groove

Fit between piston

and piston pin

Ring gap

Ring width

0.05

0.1

5

Correct

Dif. between max.

&

min.

+0.019

0

S.T.D.

78 dia.

84 dia.

0.1

5

0.65

0.01

Boring

0.01

5

-

2.5

1.2-1.5

Correct

Replace

+0.036

0

At middle portion

8

dia.

0.1

5

0.1 5

-0.1

0.1

5

S.T.D. 77.951 dia.

B

78.201 dia.

C

73.451 dia.

S.T.D.83.951 dia.

B

84.201 dia.

C 84.451 dia.

Top,

2nd

2

0

-0.04

Micrometer

-

0.1

-

0.1 5

Replace

Top

+0.04

+0.06

-

oil

+0.055

-

+0.2

Vernier

caliwrs

Replace

Oil

4

+0.002

-0.01

1

20

dia.

0.035

0.048

-

0.108

Cylinder gauge,

Micro-

meter

Max. cylin-

der

dia. and piston dia. at skert in thrust direc-

tion

Replace

0.025

0.048

-

0.1

11

Top

0.05

-

2nd 0.09

0.1 5 0.1 5

Replace

Cylinder Micro-

meter

gauge,

0.011

T

0.011

L

TOP

2nd

0.1

-

0.3

1.5

-

0.1

-

Replace

1.5

-0.1

Oil

0.2

-

0.9

Top.2nd 2

Oil

4

TOP

-0.01

2nd

-0.03

Mircrometer

-

38

-

ITEM

Piston pin

0.

D.

1

ENGINE1

MODEL

STANDARD

t

SIZE

1

CORRECTION

USE

1

LIMIT TOLERANCE

LIMIT

-0.03

REMARKS

I

Micro-

meter

CORRECTION

1

METHOD

Replace

Large end

rod large end and crankpin

Small end

a

:L."--

V

Large end side

clearance

Parallelism between large end and

Distance between large end and small end bores

Crankpin O.D.

I.

D

I.D.

EY35

1

34 dia. +0.016

I

20

I

I.D.

EY40

EY35

EY40

EY15 +0.033

EY15

EY20

1

EY35

1

EY40

dia.

I

0.02

-0.070

I

-

+o.02

-

0.042 0.12

0.1 - 0.4

-

-0.080

0

0.1

1

0.08

0.1

5

I

+

Oql

I

0.2

1

0.08

0.12

I

1.0

1

0.1

0'15

I

0.5

I

Cylinder gauge

Cylinder gauge,

Micro-

meter

Cylinder gauge

Cylinder gauge, Micro-

meter

Feeler

gauge

Test

bar

gauge

Test bar and Micrometer

Micro-

meter

Replace

Re-machine

or Replace

Re-machine or

Replace

Re-machine

or

Replace

Crankpin

roundness

cylindricity Crankpin O.D.

E

b

Crankpin parallelism

1

Crankshaft

O.D.

journal

I

Cam lobe height

O.D.

EY15 EY20

EY15

EY20

EY 20

EY15

EY40

EY35B

EY35D

1 I

Drive

Mag. Drive,s. 25 dia. -0.014

Mag.

Intake 36

Exhaust 35.5 Drive

Mag.

Drive Mag.

5.

s.

S.

25

dia.

25 dia.

25

dia.

35 dia.

25 dia.

17 dia. 17 dia.

Less than

Less

0.005

than 0.005

than 0.01

~~~~ ~

-0.003

to.1 -0.25

-0.003

-0.014

-0.003

-0.012

,.

n.

P

-0.01 6

I."&,

-0.027

-0.01

6

-0.01

7

-

I

-0.25

0.05

Micro-

meter

Micrometer

Dial Re-machine

gauge or Replace

Micrometer

Micro-

meter

Re-machine

or Replace

Re-machine

or Replace

Replace

-

39

-

LIMIT

1

REMARKS

1

TOOL

ITEM

1

CORRECTIOP

METHOD

i

Drive

S.

35 dia.

Mag.

S.

25

dia.

-0.003

-0.014

-0.003

-0.01

2

EY4OB

.4-

4-

5

Journal

OD.

MicroMeter

0.05

Replace

0.05

Drive

S.

17 dia.

-0.016

EY40D

-0.027

EY35 EY40

1

-1.5

Vernier calipers

46

Replace

EY35

1

EY40

!Square feeler

Qawe

Micro. meter

Replace

I

-

0.030

-0.055

-0.070

-0.15

Exhaust

8

dia.

Replace

Valve stem

O.D.

0.3 At middle

EY35 Intake

0.030-0.091

EY40

Exhaust

0.070-0.126

0.3

Clearance between

Replace

Correct

w

4

I

Clearance between

Replace

0.04-0.1

5

=

I

groove and retainer

EY35

1

5.3

EY40

1

-0.5

-L

Vernier

calipers

Stem end length

Total length

Replace

Vernier calipers

-0.5

I

E

1-

Clearance between

EY35

1

EY40

Cylinder

gauge

&

Micrometer

Replace

0.025-0.062

0.2

I

stem and guide

EY35

I

1

I I

I(

+1/4

I

Pilot screw

unscrew

EY40

I

1%

7

Spark plug

EY35 EY40

1

B-6HS

EY40

EY35

I

0.6

-

0.7

I

1.0

Adjust or replace

Timing tester

EY35

i

3O

f

5"

EY40

EY35 0.35

f

0.05

f

0.1

23'before

T.D.C.

.

Adjust

I

Point opening

EY40

-40

-

ITEM

Max. Output

Continuous Rated

output

MODEL

~~~

EY35

EY40

EY35

EY40

8.514000

1

0.0/3,600

Below

1

10%

of

rated

output

7.013600

8.013600

I

ITEM

REMARKS

CORRECTION PRECISENESS

literlhr

MODEL

Fuel Consumption

EY35

EY40

2.9

3.5

Up

135%

of standard consumption

At continuous rated output

1

I

1

ITEM

REMARKS

USE

LIMIT

cc/hr

MODEL

EY35

60

25

- 30

Consumption

Lubricant

EY40

80

30

-

40

ITEM

REMARKS

liter

MODEL

-

Fixed quantity

of

Lubricant

EY35

EY40

1.2

ITEM

REMARKS

liter

MODEL

Use

the class SC

or

higher grade Engine Oil

Winter (lower than

0°C)

SAE 1 OW-30

Spring and Autumn SAE

#20

Summer

SAE

#30

I

1

ITEM FREQUENCY

OF

OIL CHANGE MODEL

Oil Change

EY35

EY40

First time: Change oil after

20

hours operation.

Second Time and Thereafter: Change oil every 50 hours operation.

ITEM

REMARKS

TOOL

CORRECTION LIMIT

kg/cm'/rpm

MODEL

I

1

I

EY35

-

41

-

ITEM

MODEL

rpm

TOOL

REMARKS

,-

Min. accelerating revolution

-

r

Cylinder head clamp nuts

Connecting rod

bolts

Magneto clamp EY35 nuts

Main bearing cover bolts

Spark plug

ITEM

I

MODEL

EY35

EY40

EY35 EY40

1

EY40

EY

EY40

35

I

340- 390

250

1

800-1000

170-190

260

kgcm

-

300

-

290

T

24.6-28.3

18-21.7

57.9-72.3

12.3-13.7

18.8-21

ft-lb

TOOL

Crankshaft

REMARKS

Torque wrench

-42

-

13.

MAINTENANCE

The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated maintenance intervals are by no means guarantees for maintenance free operations during these intervals.

For example, if the engine is operated in extremely dusty conditions, the air cleaner should be cleaned every day instead of

every

50

hours.

13-1

DAILY CHECKS and MAINTENANCE

and

STORING

13-2

13-3

Checks and maintenance

Remove dust from whatever parts which

accumulated dust. Check external fuel leakage. If any, retighten or

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

I

re-tighten. Check oil level in crankcase and add up as necessary.

EVERY

I

EVERY

20

HOURS CHECKS and MAINTENANCE

Checks and maintenance Reasons for requiring them

Change crankcase

50

HOURS

oil.

(10

DAYS) CHECK and MAINTENANCE

I

The governor linkage is especially susceptible to dust.

Not only wasteful but also dangerous

Loose screws and nuts will result

1

accidents.

If

the engine

I

fail.

1

TO

remove run-in wear particles

Reasons for requiring them

in

vibration

is

operated without sufficient oil,

it

will

1

I

13-4

Checks and maintenance Reasons for requiring them

Change crankcase

1

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

EVERY

100-

I

Clean fuel filter and fuel tank. Clean contact breaker points.

oil.

200

HOURS (MONTHLY) CHECKS and MAINTENANCE

Checks and maintenance

-43

Contaminated

I

Clogged air cleaner harms engine operation.

1

Output power is reduced and starting

is made difficult.

The engine will be out The engine output drops.

-

oil

accelerates wear.

Reasons for requiring them

of

order.

~____

1

13-5

EVER'.'

502 - 600

HOURS

(SEMIANNUAL) CHECKS

and

MAINTENANCE

Remove cylinder head and remove carbon deposit.

Disassemble and clean carburetor.

13-6

EVERY

1000

I

Perform overhauls, clean, correct or replace parts.

Change piston rings.

I

Replace fuel pipe once a year.

13-7

PREPARATION

1) Perform the above

Checks and maintenance

The engine will be out of order.

HOURS (YEARLY) CHECKSand MAINTENANCE

Checks and maintenance

for

LONG ABEYANCE

13-

1

and

13-2

maintenance jobs.

I

The engine output drops and become out of order.

1

To

prevent from danger caused by the fuel leakage.

Reasons for requiring them

2)

Drain fuel from the fuel tank and carburetor float chamber.

3)

To

prevent rust in the cylinder bore, apply oil through the spark plug hole and turn the crankshaft several turns by

hand. Reinstall the plug.

4)

Turn the starting pulley by hand and leave it where the resistance is the heaviest.

5)

Clean the engine outside with oiled cloth.

6)

Put

a vinyl or other cover over the engine and store the engine

in

dry place.

-

44"

Industrial

Engines