Robin EY45V Service Manual

ROBIN AMERICA,

INC.

ENGINE

MODEL

CROSS

REFERENCE

LIST

ROSIN

TO

WISCONSIN ROBIN

I

ROBIN

EY08 EYl5 EY 15V EY20 EY20V EY23 EY28 EY3

5

EY40 EY45V EY2

I

EY44

EY

18-3 EY25 EY27

EHl1 EH12 EHl5 EH17 EH2 1 EH25 EH3

0

EH30V EH34 EH34V EH43V

EC13V

DY

23

DY27 DY30

DY3

5

DY4

1

WISCONSIN

ROBIN

SIDE

VALVE

W 1-080 w1-145 W1-145V W1-185 W1-185V W 1-230 W 1-280 W 1-340 W 1-390 W 1 -450V EY2 1 W EY44W EY 18-3 W EY25W EY27W

OVERHEAD

VALVE

WO1-115 wo1-120 WO1-150 WO1-170 wo1-210 WO1-250 WO1-300

WO

1

-300v

WO1-340 WO 1 -340V

WO

1-43

OV

TWO

CYCLE

WTI-125V

DIESEL

WRD

1-230

WRD

1-270

WRD

1-300 WRD1-350 WRDI-410

CONTENTS

Section Title Page

1 . SPECIFICATIONS

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

1

2

.

PERFORMANCE

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

2

2-1 Maximum Output

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

2

2-2 Continuous Rated Output

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

2

2-3

Maximum Torque

at

Maximum Output

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

2

3

.

FEATURES

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

3

4 . GENERAL DESCRIPTION

of

ENGINE CONSTRUCTION

..........

3

4-1 Cylinder. Crankcase

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

3

4-2 Main Bearing Cover

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

4

4-3 Crankshaft

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

4

4-4 Connecting Rod and Piston

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

4

4-5 Camshaft

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

5

4-6

Valve Arrangement

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

5

4-7 Cylinder Head

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

5

4-8 Governor

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

6

4-9 Cooling

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

6

4-

10

Lubrication

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

6

4-11 Ignition

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

6

4-12 Carburetor

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

7

4-

13

Air Cleaner

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

7

4-14 Balancer

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

7

4-15 Sectional View

of

Engine

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

8

5

.

DISASSEMBLY

and

REASSEMBLY

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

10

5-

1

Preparation and Suggestion

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

10

5-2 Special

Tool

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

10

5-3 HowTo Disassemble

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

11

5-4

How To Reassemble

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

20

6

.

ENGINE SPEED SETTING

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

29

7 .

MAGNETO

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

30

7-1 Features

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

30

7-2

Basic

Theoryof T

.

I.C.

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

30

7-3 Wiring Diagram

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

30

7-4 Checking Procedures

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

31

Section

Title

Page

8

.

CARBURETOR

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

32

8-

1 Operation and Construction

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

32

8-2

Disassemblyand Reassembly

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

33

9

.

STARTING MOTOR

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

35

9-1 Disassembly

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

35

9-2

Inspection and Repair

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

38

9-3 Reassembly

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

41

10

.

BREAK-IN OPERATION

Of

REASSEMBLED ENGINE

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

42

11

.

TROUBLESHOOTING

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

43

11 -1 Starting Difficulties

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

43

11

-2

Engine Misfires

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

44

11-3 Enginestops

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

44

11 -4 Engine Overheats

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

44

11 -6 Engine Backfires through Carburetor

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

45

12 .

INSTALLATION

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

46

11 -5 Engine Knocks

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

45

12-1 Installing

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

46

12-2 Ventilation

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

46

12-3 Exhaust

Gas

Discharge

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

46

12-4 Power Transmission to Driven Machines

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

46

13

.

CHECKS

and

CORRECTIONS

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

47

14

.

TABLE

of

CORRECTION STANDARDS

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

48

15

MAINTENANCE

and

STORING

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

.

53

15-

1

Daily Checks and Maintenance

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

53

15-2 Initial 20 Hours Check

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

53

15-3

Every

50

Hours

(10

days) Checks and Maintenance

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

53

15-4 Every 100

-

200

Hours (Monthly) Checks and Maintenance

.....

53

15-5 Every

500

-

600 Hours (Semiannual) Checks and Maintenance

...

54

15-6 Every

1000

Hours (Yearly) Checks and Maintenance

...........

54

15-7 Preparation for Long Storage

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

54

.

1

SPEC1

F

ICATIONS

Model

TY

Pe

Bore

x

Stroke

~~

Piston Displacement Maximum Maximum Torque Direction of Rotation

Lubrication Lubricant

Carburetor

Fuel Fuel Feed

Horse

Power

I

Air-Cooled, 4-Cycle, Vertical Shaft, Single Cylinder Gasoline Engine

90

mm x 70 mm (3.54" x 2.75")

445 cc (27.15 cu. in)

12 HP/3600 r.p.m. (SAE Code-J607a)

2.5

kg-m/2600 r.p.m. (18.08 ft-lbs./2600 r.p.m.)

Counter-clockwise

Automobile Oil SAE

Horizontal Draft, Float Type

Automobile Gasoline

EY45V

as

viewed from

Forced Air Cooling Cooling System

Oil Pump

Gravity Type

#20

P.T.

-

30, Class

0.

shaft side

SC

Governor Centrifugal Flyweight Type

Ignition System

Spark Plug

Charging (Lighting) Capacity

Starting System

Dry Weight

Length

Dimensions

1

Width

I

Height

I

Flywheel Magneto Type (Solid

NGK BPMGA

DC 12V-1.5A Battery Charge

AC12V-15W or 1OOW Lighting Coil (Optional)

Electric Starter (Recoil Starter: Optional)

Approx. 35 kg (77.1

(1

41 5.5 mm

373.5 mm (14.7")

312 mm (12.28") excluding

6.35")

State

lbs.)

P.T.

Ignition)

0.

Shaft

-1-

2.

PERFORMANCE

2-7 MAXIMUM OUTPUT

The maximum output

fully opened after its initial break-in period when all the engine may not produce the maximum output in the beginning because the moving parts are not in a properly worn-in condition.

2-2

CONTINUOUS RATED OUTPUT

The continuous rated output of an engine is such a power as produced by the engine when running continuously at an optimum speed, and most favorable from the viewpoint of engine life and fuel consumption ratio, with the governor in operation. anism, with this engine as prime mover, the continous power requirement of that mechanism the continuous rated output specified.

2-3

MAXIMUM TORQUE AT MAXIMUM OUTPUT

These mean the maximum torque of the output shaft at the maximum output of an engine.

of

an engine is such a standard power as produced by the engine with its throttle valve

moving

It

is suggested, therefore, that when designing a driving system

PERFORMANCE CURVES

parts are properly worn in. Therefore, a new

for

any

be

kept below

Kg-m

mech-

12

6

2.5

2.3

f

5

Revolution

-

r.p.m.

3.

FEATU

I.

The cylinder and crankcase is a light weight one-piece aluminum diecasting. The dimensions are as those of a 10-horsepower engine.

2.

The engine is powerful with a wide torque range from low speed to high.

3.

The vibration-free design with twin balancer shafts.

4.

A pointless electronic ignition system is adopted as standard, which makes the ignition system mainte-

nance-free.' timing.

5.

The engine employs a special cast iron cylinder liner, a forged steel crankshaft, main ball bearings at both sides and forced spray lubrication by oil pump for prolonged durability. All this adds up to improved durability.

RES

You

will no longer be troubled by worn contact points or faulty sparking from wrong ignition

as

small

4.

GENERAL

4-1

CYLINDER. CRANKCASE

The cylinder and crankcase

diecasting. The cylinder liner, made iron,

is

molded into the aluminum casting. The intake and exhaust ports are located on one side of the cylinder. The crankcase has a fitting surface on the output shaft side, where the main bearing cover is attached. (See Fig.

1

.)

DESCRIPTION

is

single piece aluminum

of

special cast

ENG

-3-

NE CONSTRUCTIO

Fig.

1

4-2

MAIN BEARING COVER

The main bearing cover is an aluminum diecasting, which is mounted on the output shaft side of the crank-

case. Remove the main bearing cover to expose the inside

of

the engine for inspection.

n

The main bearing cover also serves

as

an oil pan, with a trochoid oil pump, oil filler and oil drain plug. (See

Figs.

2

and

3.)

Fig.

2

4-3

CRANKSHAFT

The crankshaft is forged carbon steel, and the crank pin

is

induction-hardened. The output end of the shaft has a crankshaft gear and balancer gear that are pressed into position. (See Fig.

4.)

4-4

CONNECTING

ROD

and

PISTON

The connecting rod is forged aluminum alloy, and its large and small ends serve as bearings. The piston is

an

aluminum alloy casting, and carries two

com-

pression rings and one oil ring. The piston pin hole

is

offset from the center

of

the piston to reduce hit-

ting noise and improve durability.

(See

Fig.

5.)

Fig,

3

Induction Hardening (Portion

of

Crankpin)

Crank Gear (Press-fit)

Fig.

4

Fig.

5

-4-

The camshaft is a hollow special cast iron integrally molded with the camshaft gear. The governor plate is riveted to it, and one end of.the camshaft has a pin

for

driving the oil pump. (See Fig.

6

.)

4-6

VALVE ARRANGEMENT

The intake valve is located at flywheel side of the crankcase. Hard alloy valve seats are molded in the cylinder block for added durability. (See

Fig.

7.)

4-7

CYLINDER HEAD

Fig.

6

Exhaust

intake

Valve

Fig.

7

The cylinder head is an aluminum die casting, and forms a Ricardo type combustion chamber with ample area for high combustion efficiency.

Fig.

8

-5-

The governor is a centrifugal flyweight type

which

permits constant operation at the selected speed against load variations. Governor gear

is

installed on

the bearing cover, and it engages with the cam gear after reassembling. (See Fig.

9.)

4-8

GOVERNOR

-

Fig.

9

4-9

COOLING

The cooling fans on the flywheel cool the cylinder and cylinder head by forced air cooling. Cylinder baffles is provided

for

guiding the cooling air.

4-

10

LUBRICATION

The trochoid

oil

pump is mounted inside of the

main bearing cover.

Oil

pump

is

driven by the camshaft to supply

oil

for

the

rotating

or

sliding parts. (See Fig.

10.)

4-11

IGNITION

The ignition system is a flywheel magneto type with ignition timing set at

23"

before TDC. The magneto

is

composed

of

a

flywheel and ignition

coil.

The flywheel is mounted directly on the crankshaft, and ignition coil

on

the crankcase. (See

Fig. 1 1

.)

(For further details, refer

to

page

30,

Section

"7.

MAGNETO".)

&

Camshaft

/

Oil Filter

Holder

(Camshaft

Oil Pump (Inner)

Oil

Pump (Outer)

Fig.

10

I

Ignition Coil

-6-

4-12

A

been carefullyset after thorough tests

CARBURETOR

horizontal draft carburetor

is

employed. It has

to

assure satisfactory start up, acceleration, fuel consumption, output performance, etc. (See Fig.

For construction and other details, refer to page Section

"8.

CARBURETOR".

12.)

32

Fig.

12

4-13

AIR CLEANER

The air cleaner is a semicyclone type with double

Fig.

elements. (See

4-14

BALANCERS

Unbalanced moments

13.)

of

inertia that are generated in the vertical and horizontal directions are balanced by the two balancers that rotate

1

to

1

with the crankshaft to effectively reduce vibration. (See

Fig.

14.)

'leaner

Case

Cleaner Element

~

Fig.

Cleaner Cover

13

-7-

Fig.

14

4-15

SECTIONAL VIEW

of

ENGINE

Flywheel

/-(Cooling Fan)

f

Ignition

Coil

Housing

-8-

'

Head

r

Tappet Air Cleaner

Intake

and

Exhaust Valve

Muffler

rSpark

“Spark

Plug

Cap

1

Oil Filler Starting Motor

-9-

5.

DISASSEMBLY

5-1

PREPARATIONS

1)

When disassembling the engine, memorize well the locations of individual parts

sembed correctly.

and

If

you are uncertain of identifying some parts,

REASSEMBLY

SUGGESTIONS

so

that they can be reas-

it

is

suggested that tags be attached to

them.

2)

Have

boxes

ready to keep disassembed parts by group.

3)

To

prevent missing and misplacing, temporarily assemble each group

4)

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

5)

Use the correct tools in the correct way.

5-2

SPECIAL

TOOLS

of

disassembed parts.

For your reference, the following table shows special tools for disassembling Robin Engines.

Part

No.

209 95004

207

95003

Flywheel Puller

07

Valve Spring

Tool

(with bolt)

Retainer

Use

For

pulling

Flywheel

For mounting and dismounting Valvc Spring Retainer and Retainer

off

Lock

Applicalbe

Model

EY10,13,14 EY15,18,20 EY25,27,28 EY33,35,40

EY44.45 EC05.07,lO EC17,25,37

EY10, 13,14 EY15,18,20 EY25,27,28 EY33,35,40 EY44.45

Shape

-

10-

5-3

HOW

TO

DISASSEMBLE

*Bolt

length

is

the length from bolt end to the bottom surface of bolt head.

Order

item

Engine

(Oil

drain plug)

Muffler and bracket

E

Remove

(1)

(2)

oil

drain plug and discharge

Remove muffler bracket.

Turn

up heat deflector tabs,

nuts.

Procedure

and

oil.

remove

Remarks

Be

careful

gasket.

not

to

lose

Tool

17

mm box wrench

10

mm box wrench

12

mm box wrench

Muffler

-

11

-

Order

I

item

Governor lever

Procedure

(1)

Remove governor lever from shaft.

(2)

Remove governor spring from governor lever.

and

governor rod

I

Remarks

~ ~~~

Memorize or

the

governor spring

hooking

mark

position.

I

10

mm

Tool

box

wrench

I

’

+

(1)

(2)

Remove speed control assembly from crankcase.

Remove choke rod from speed control assembly.

10

mm box wrench

Control

,”-

Rod

Go

V

I

Ylarburetor Governor Lever

Spring Choke

Fig.

-

12

Rod15

15

-

\

Governor

Choke Lever

ltrol

Spring

Order

Item

Air

cleaner

Carburetor and intake manifold

Procedure

I

(1)

Remove wing nuts, cleaner cover, and element.

(2)

Remove cleaner case.

(1)

Remove support (elbow) bolt on crankcase side.

(2)

Remove intake manifold nuts, and assembly of intake manifold, carburetor and elbow from engine.

(3)

Separate carburetor and elbow from intake manifold if necessary.

Remarks

I

Disconnect breather pipe at elbow side end.

Tool

10

mm wrench

10

mm box wrench

12

mm box wrench

12

mm box wrench

Oil

filler

(1)

(2)

L

Clamp

(Oil

Filler)

Oil

Filler

Remove clamp Pull out

oil

filler from main bearing cover.

(oil

filler).

/Crankcase

Be careful not to

O-ring.

lose

10

.I#"-

%=.

mm box wrench

Wing

Nut

Washer

Grommet

-Cleaner Cover

Intake Manifold

-

13

-

1

Order

I

8

I

9/

I

Item

I

Starting motor Rotating

screen

I

Remove starting motor. Remove rotating screeen and spacer.

Procedure

I

Remarks

Tool

1

12

mm

box

wrench

12 mm box wrench

I I

/

I

lo

Blower

and

I

housing

head cover

(1 j Remove blower housing.

(2 j Remove cylinder baffle.

(3

j

Remove head cover.

1

10

mm box wrench

I

1

-

14

-

Order

11

12

Item

Igntion coil

Flywheel and

lighting

coil

Procedure Remarks

Remove ignition coil from crankcase.

(1)

Remove nut from tip of crankshaft.

(2)

Remove flywheel (See Fig.

(3)

Remove charge coil. (See Fig.

16.)

using

flywheel puller.

17.)

I

Be

sure

to

remove

ignition coil (Ring gear

inward coil,

is

pulled out first,

is

of

ignition

so,

if flywheel

case may become broken.)

fist.

located

Tool

I

10

mm box wrench

24

mm box wrench

Phillips screwdriver

Fig.

16

Flywheel

Puller

Fig.

17

-

15

-

Order

Item

Procedure Remarks

Tool

13

14

15

16

Cylinder head

Breather

Intake and ex-

haust valves

Main bearing cover

(1)

Remove spark plug. 19 mm plug wrench

(2) Remove cylinder head.

(1)

Remove breather cover.

(2)

Remove breather plate.

(1) Remove tappet cover.

..

(2)

Using a valve spring retainer, remove retainer lock from valve stem.

(3) Remove intake and exhaust valves. in case of reusing

(See

(4)

Remove spring retainers and valve springs.

(1)

Remove bolts.

(2)

Remove main bearing cover by lightly tapping its side with a plastic hammer. (See Fig. 19.)

Fig.

"

18.)

Be careful

I

Intake and exhaust valves use the same valve spring, retainer, and retainer lock, but

them, reassemble them exactly as be-

fore.

.Be

damage Oil with keyway.

.Be careful

lose crankshaft and camshaft

adjusting spacers.

careful

PTO

of

gaskets.

not

shaft

not

to

14

mm box wrench

10

mm

box wrench

10

mm

box wrench

Valve spring retainer

12

mm

box

wrench

/"-

I

Fig.

18

I

Fig.

19

Main Bearing Cover

,'

-

16-

Head Gasket

Spark

Plug

Valve

Guide

iappet

Exhaust

Valve

(Outer)

Main

Bearing Cove;

Q

-

17

-

Order

Item

-

Balancers

Camshaft and tappets

1

I

(1)

Turn crankshaft

(2)

Remove balancers. (See

(1)

Remove camshaft. (See

(2)

Remove tappets.

Procedure

to

top dead center.

Fig.

20.)

2 1 .)

Remarks

The tappets for take and exhaust

valves are inter-

changeable, but case

of

reusing, re-

assemble exactly

before.

in-

in

as

Tool

12

mm box wrench

-

Cran

Balancer

Blancer

/

1

Fig.

20

\

Balancer

Add

2

11

-

18

-

Fig.

21

\

Camshaft

I"

Order

19

I

Item

~~ ~~~~ ~ ~

Connecting rod

I

(1)

Turn

up

(2)

Remove connecting rod large end cap, push

up

piston

Procedure

lock washer tabs and remove bolts.

out

of

cylinder.

I

Remarks

I

Tool

12

mm box wrench

20

Crankshaft

Remove crankshaft

wheel end.

by

lightly tapping its

fly-

Be careful not damge crankcase seal.

a-

@-

to

Spring

Washer

oil

Washer

Connecting

Rod

Connecting

Rod

Lock

Connecting

Rod

Bolt

Washer

-

19-

5-4

HOW

TO

REASSEMBLE

5-4-1

PRECAUTIONS

IN

REASSEMBLY

Every and each part should be cleaned thoroughly. Especially, pay utmost care and attention to the clean-

/"

liness of the piston, cylinder, crankshaft, connecting rod and bearings. Scrape off carbons completely from the cylinder head and the piston top; especially the carbon adhered in the groove

of

the piston ring should be careflly 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 sea1 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 rotating 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 attention 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 reassembl-

ing.

1

I

W

(Crankshaft Pin Width)

29;O.l

rnrn

I

Bore

90

dia.

-o:o16

rnrn

+O

006

Piston Outside Diameter (In Skirt Thrust Direction)

89.973

dia.

-o.02

mrn

0

I

Piston to Cylinder

at

Piston Skirt Thrust Face

I

0.01

1

L

-

0.053

L

I

Piston Ring Gap (To Ring - Second Ring)

I

0.1

L

-

0.3

L

TOP

0.11

L-0.15

L

Piston Ring Side Clearance in Grooves

0.01

L

-

0.05

L

Oi

I

0.06

L

-

0.10

L

Second

Clearance between Connecting Rod

Large End and Crankshaft Pin

and

Outside

Diameter

Clearance between Inside

Side Clearance

0.1

L

-

0.3

L

0.050

-

0.082

L

Clearance between Connecting Rod

~~ ~~~ ~~

1

Small End and Piston Pin

0.010

L

-

0.032

L

Clearanc between Piston Pin and Piston Pin Hole

0.011

T

-

0.01

1

L

L:

LOOSE

T:

TlGH

Table

1

-

20

-

5-4-3

ASSEMBLING

ORDER

and

PRECAUTIONS

-

1) Place the tappets into the crankcase.

NO,TE: The intake and exhaust tappets are the

same, but mark them differently when

disassembling because of different valve clearances; and fit them into their original place. Apply oil

to

the tappets before-

hand.

-

2)

Assemble the crankshaft and camshaft at the same time.

NOTE: The timing marks are punched on the

crankshaft gear and the camshaft gear. Match these timing marks when assembl-

ing. (See Fig.

22.)

3)

Assemble the connecting rod and the piston.

NOTE: The piston

is

offset. Assemble

it

so

that

the square

(0)

on

the piston top matches

the

@

MAG mark on the connecting.rod.

(See Fig.

23.)

CAUTION: When inserting the piston pin and

fitting the clip on, be careful not to

damage the piston surface.

I

Fig.

22

Fig.

23

4) Fit the piston rings on

the

piston.

NOTE: Each piston ring has a punched mark

on

its

open end. These marks have to face upward when

assembled.

NOTE: When

the

piston rings are fitted in place, make sure that their ends

are

staggered as shown

in

Fig.

24.

Be careful not to install them in the wrong groove. (See Figs.

24

and

25.)

Thrust

Side

Top

Ring

(Chrome-plated)

Second

Ring

(Undercut)

Oil

Ring

(Chrome-plated)

(Assembly Type)

Fig.

24

-

21

-

Fig.

25

5)

Install the piston and connecting rod assembly. When installing the connecting rod into place, hold piston

rings

with the ring guide as shown

in

Fig.

26

(if

no

ring guide

is

available, keep press-

ing the piston

ring,

with finger tips and gently

tap the top of the piston with a wooden piece

or

the like to push it in), and check that the

sym-

bol 8 or

the mark

“MAG”

on

the connecting rod

is in the direction

of

the flywheel magneto.

NOTE: Apply enough oil to the piston rings, con-

necting rod plain bearings, and cylinder wall before reassembling.

NOTE: The open ends of the piston rings must

be

90”

apart from one another on the

piston periphery.

NOTE: The clearance between the piston and

cylinder must be measured at the piston skirt thrust surface.

iston

Ring Guide

(Magneto Side)

Fig.

26

6)

Connecting

rod

tightening

Match the mark on the large end cap with that

of

the connecting rod large end, and install the large end

cap.

Bolts:

8

x

46

mm

Tightening torque:

250

-

300

kg-cm

Use

a

new lock washer and be sure to bend the tabs.

7)

Main

bearing cover subassembly

Assemble the governor shaft, governor yoke,

oil

pump, holder (camshaft), and oil filter with the main

bearing cover.

NOTE: Be careful not to damage the oil

seal

when installing the governor shaft.

NOTE: Remove dust, chips, etc. from the inside

of

the pump housing and apply engine oil to

it

before

installing the oil pump.

Holder (camshaft) bolts:

6

x

25

mm

with washer and spring washer

Holder (camshaft) tightening torque:

70

-

90

kg-cm

-

22

-

8)

Side clearance measuring

Adjust the side clearances of the crankshaft and camshaft with the adjusting collars. Measure

and E shown in and camshaft will be

Fig.

27,

and select adjusting collars

0

to

0.25

mm.

so

that the side clearances

of

both

the crankshaft

A,

B,

D,

NOTE:

C

indicates gasket thickness. Calculate

Three kinds

the crankshaft and camshaft.

of

adjusting collars-

1.05

it

as

mm,

0.25

1.2

mrn.

rnrn,

and

1.35

T:

Thickness

T

=

E - D

mrn

thick-are available

of

the

adjusting

+

(0

-

0.25)

collar

for

both

Fig.

-

27

23

T = B

-

A

+

(0

-

0.25)

-

9)

Balancer mounting Move the piston to the top dead center. Engage balancer

1

with the crankshaft, and balancer 2 with balancer

1.

(See Fig.

28.)

Match the match marks as shown in Fig.

28.

/-

As

viewed

from

drive

shaft

side.

Balancer Gear

Match Marks

Balancer

1

Fig.

28

10) Main bearing cover mounting .Fit the governor sleeve on the camshaft; install the adjusting collars selected in Step

8),

and install

the

main bearing cover assembly that was readied in Step

7).

.Move the piston to the top dead center, align the groove

of

the

oil

pump shaft that

is

installed in

the

main bearing cover with the camshaft holder groove as shown in Fig.

29,

and mount the main bearing

cover.

,"--

Align the direction of

oil

pump

shaft groove

with the groove on the holder (camshaft).

NOTE: Replace the

gasket

(main bearing cover) with a new one.

NOTE:

Be

careful

not

to

damage the oil seal.

Bolts:

8

x

45

mm with washer and spring washer

Tightening torque:

170

-

190

kg-cm

-

24

-

*Intake and exhaust valve specifications are as

follows:

VALVE

A-VALVE FACE ANGLE

and

VALVE GUIDE CLEARANCE

~~ ~~

Guide

45O

B-SEAT ANGLE

C-GUIDE INSIDE

D-VALVE STEM OUTSIDE DIA

MAXIMUM ALLOWABLE CLEARANCE BETWEEN

DIA.

Cand

D

INTAKE

E

XH UAST

INTAKE

.TAPPET CLEARANCE ADJUSTMENT

Turn

the crankshaft

check the tappet clearance

Clearance:

If

the clearance

of

end

valve stem.

0.08

is

to

compression

as

follows.

-

0.12

mm

too

small, slightly grind the

TDC,

when cold

and

Table

2

8dia.

8

0.030

0.070

dia.

L L

45O

+0.036

-0

030

-o:055

-0.070

-o.090

-

0.091

-

0.126

mrn

mm

mrn

L L EXHAUST

L: Loose

Fig.

30

-

25

-

"Intake and exhaust valve installation

Apply oil to the valve stems, and install the valves securely by using the valve spring retain-

er and pliers. (See Fig. After their installation, check the tappet clearance again.

12)

Install the gasket and tappet cover.

13)

Install breather plate and breather plate with gaskets.

3

1

.)

Fig.

31

Intake/Exhaust

Valve

NOTE:

14) Cylinder head Replace the head gasket with a new one.

NOTE:

15) Spark plug

16)

Electrical parts a) Lighting coil

b) Flywheel

Make sure

The

edge- folded side

Head nuts: Tightening torque:

Tightening torque:

NOTE:

Clean the dust or wheel.

Be sure to clamp the wire

6 x 20

to

use the correct gaskets.

10

mm

screw and washer assembly

of

flange nuts

350

-

120 - 150

oil

from the tapered portion

the gasket must face the cylinder head.

400

kg-cm

to

prevent it con tact with the flywheel.

of

the crankshaft and flywheel, and install the fly-

NOTE:

c> Ignition coil

Adjust the clearance (air gap) between the ignition coil and flywheel, and then tighten the ignition

coil.

d) Starter motor

Install the flywheel before the ignition coif.

Tightening torque:

Air

gap:

0.5

mm

8

x

30

rnm

reamer bolts with washer and spring washer

Tightening torque:

800 - 1000

160

-

200

kg-cm

-

26

-

17) Blower housing and head cover

Install head cover, blower housing and cylinder baffle.

18)

Rotating screen

Mount the rotating screeen with spacer.

8

x

50

mm bolts with washer and spring washer

Tightening torque:

19)

Oil filler Insert the oil filler into the main bearing cover, exercising care not to damage the O-ring at the bottom of the oil filler. Fasten the top of the oil filler with the oil filler clamp.

20)

Intake manifold, carburetor, elbow, and air-cleaner .Temporarily fasten the intake manifold, carburetor, elbow, air-cleaner, etc. and make sure that these

parts

are

properly positioned relative

@Be sure to use the correct gasket on each flange. (See Fig.

160

-

200

I

TYPES

kg-cm

to

of

one another. Then tighten the

32.)

GASKETS

and

MOUNTING

POSITIONS

bolts

and nuts.

I

Intake

Insulator

Carburetor

Fig.

-

27

Elbow

32

-

a) Intake manifold

b)

Insulator Be careful of its mounting direction.

Intake Manifold Side Carburetor Side

Intake manifold side

Carburetor side

c) Carburetor

*Pay attention to the types

of

gaskets on

the front and back.

.Install the governor rod, rod spring, and

choke rod.

d)

Elbow and support (elbow)

Install the breather pipe between the crank-

case and elbow.

e) Air-cleaner case

Place the air-cleaner case on the elbow and intake manifold, check that it

is

properly

positioned relative to them, and tighten it.

f) Cleaner element, cleaner cover

Fig.

33

2

1)

Governor lever and speed control

a)

Governor lever

Hook the governor rod and rod spring to the end

of

the governor lever, and install the lever

on

the

governor shaft.

b) Speed control, governor spring

Hook the choke rod

to

the choke lever. Install the governor spring

on

the governor lever and speed

control.

22)

Governor set

Pull the speed control lever

in

the high speed directim, fully open the carburetor throttle valve, turn

the governor shaft clockwise all the way, and tighten the governor lever bolt.

NOTE: The engine speed setting procedure

is

described in a separate section.

23)

Muffler

Replace the muffler gasket with a new one, and install the muffler and muffler bracket.

Muffler nuts:

M8

flange nuts (stainless steel)

Tightening torque:

180

-

220

kg-cm

After tightening the flange nuts, bend the tabs

of

the lock washers for the heat deflector to prevent the

nuts from turning loose.

-

28

-

6.

ENGINE

S

6-1

CHOKE

and

SPEED ADJUSTMENT

Operate the engine at no-load. Then, turn speed control lever toward “CHOKE” position until it just contacts the choke/R.P.

M.

adjusting screw on choke lever (do not move choke lever.).

To

adjust the “CHOKE” start position and

HIGH

speed operating

R.P.M.,

use a tachometer or revolution

counter. Turn the adjusting

screw

in or out against the speed control lever until

the

desired no load operating

speed

is

obtained. This same position will be the start

of

the ‘CHOKE’ operation.

6-2

TO

INSTALL REMOTE CONTROL

WIRE

1.

Use

a control wire suitable for

a

.098“

(2.5

mm) diameter wire hole

and

.236“ (6

mm) diameter casing

hole.

2.

Install control wire to engine

by

control wire bracket. Use pliers and pinch bracket around casing

to

secure in place.

3.

Insert the end

of

control wire into the speed control lever.

4.

Place speed control lever in

“LOW

SPEED”

position and tighten control wire lockscrew.

Governor

Lever

Fig.

34

-

29

-

7.

MAGNETO

The pointless electronic ignition magneto consists of a flywheel and an ignition coil.

7-1

FEATURES

This system is outer coil type without pulser and is called T.I.C. (Transistor igntion circuit type).

To

the

EY45V

engine this T.

I.

C. is equipped as standard parts.

Being different from the breaker point type ignition system this brand-new system

is

completely free from such troubles as starting-up failure owing to dirty, burnt or corroded point surface, reduction of ignition efficiency being caused

by

moisture, rough surface

of

breaker point and incorrect timing resulted from

worn

mechanical parts.

7-2

BASIC THEORY

of

T.I.C.

(See

Fig.

35.)

Resister

Ignition

Coil

T.I.C.

(Transistor igntion type) consists of the

fly-

L

\I)

wheel and ignition coiI with built-in transistor; and

’5

its basic

theory

is

as follows:

U

E

1) Revolution of the flywheel generates electricity

2

on

the primary side of the ignition coil, and the

E

electric current

A

flows. A turns the power tran-

3

sistor

“ON”

and the electric current B flows.

a

2)

The flywheel goes round further, and at the time

of ignition, the electric current

C

flows to turn

Fig.

35

the signal transistor

“ON”

to allow current

D.

At

this moment the electric current

B,

passing through the power transistor, is abruptly shut; and as a result, the high voltage electricity is generated on the secondary side of the ignition coil and it produces sparks at the plug.

c.l

v)

m

3

L

(D

Q

m

In

.-

/

.-

7-3

WIRING

DIAGRAM

The following parts are not supplied with eingine as standard equipments.

STOP SWITCH STARTER MAGNETIC SWITCH SWITCH spARKpLuG?JlB‘*c5

12V

BATTE

R

Y

COIL

AC

12V

LAMP

STARTER

IGNITION

STOP

SWITCH

.+

-

““67”

L”I

1

77)77.

12v

BATTERY

NOTE:

RED

(AC SOURCE)

SWITCH

GREEN/

AC

source

is

for

12V,

lOOW

load.

WHITE

The

lighting

coil

is

optional.

Rated and maximum loads

for

the

AC

I

source are

80W

and

1OOW

respectively.

Wires indicated

by

dotted lines are not

supplied with engine.

I

0

LAMP

7/3m

Fig.

36

.I

(AC12V-1

OOW)

-

30

-

7-4

CHECKING PROCEDURES

MEASURING RESISTANCES

1)

Primary Side

-

7-4-1

IGNITION

COIL

-

2)

Secondary Side

n

Tester

7-4-2

LAMP COIL and CHARGE COIL

1)

Charge Coil

Tester

Note:

The

following resistance

values are measured

at

20°C.

Between stop lead and core

i"GZZd

Between high tension cord and core

Between GreedWhite cord and GreedWhite cord

10.9 - 1.3a

1

\

GreedWhite

2)

Lamp Coil (Optional)

Tester

Between red cord and core

-1

-

31

-

8.

CARBURETOR

8-1

OPERATION

8-

1

-

1

FLOAT

and

CONSTRUCTION

SYSTEM

(See

Fig.

37

and

38.)

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 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 closes to shut

off

the fuel, thereby keeping the fuel at the predetermined level.

Throttle Valve

I

Nozzle

Pilot Outlet

Fig.

37

Air

Jet

FI

Needle Valve

Fig.

-

32

38

-

D

8-

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 outlet and the by-pass.

At idling speed, the fuel is mainly fed from the pilot outlet.

b

8-1-3

The main system feeds the fuel to the engine at 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

with the fuel through the bleed holes It is mixed again with the air taken through the air cleaner into an optimum fuel-air mixture, which is supplied to the engine.

8-1

The choke is used for easy start in the cold season. When the starter negative pressure applied to the main nozzle increases and draws much fuel accordingly; thus easily start up the engine.

8-2

Apart from mechanical failures, most of carburetor troubles are caused by an incorrect mixing ratio, which

may arise mainly due to a clogged up per flow of assembly procedures are

8-2-1 THROTTLE SYSTEM

1)

2)

MAIN

-4

CHOKE

DISASSEMBLY

Remove the Philips screw

(4),

and pull out the throttle shaft The spring the throttle stop screw

*Exercise care not to damage throttle valve ends.

SYSTEM

in

the main nozzle, and the mixture is atomized out

and

REASSEMBLY

air

or

fuel passage

air

and fuel, the carburetor must be kept clean at all times. The carburetor disassembly and re-

as

(1

2)

can be taken out

follows: (See Fig.

(5)

and throttle valve

(9).

(1

3).

by

removing

39.)

is

operated with a closed choke, the

in

jets, or fuel level variations.

is

of

the main bore.

In

order to assure pro-

mixed

8-2-2 CHOKE SYSTEM

1)

Remove the Philips screw

(3),

and pull out the choke shaft

2)

When reassembling the choke shaft, make sure

that the cutout in the choke valve faces the main

air jet.

Meantime, when reassembling set the rings and

(1

4)

at

the

right position.

8-2-3 PILOT SYSTEM

1)

Remove the pilot jet avoid damage to it.

2)

Reassembly Tighten the pilot jet securely. Otherwise, the fuel may leak, causing engine malfunction.

(6),

(2)

and choke 'valve

(7).

using correct tool to

(8)

-

33

Fig.

39

-

8-2-4

1)

2)

3)

MAIN SYSTEM

Remove the bolt From the body

nozzle

(1

8).

Reassembly

(21)

(1)

remove the main nozzle

a) Fasten the main jet securely

malfunction.

b)

The bolt tightening torque

and take out float chamber body

(1

8),

and then remove the main jet

to

the body. Otherwise, the fuel may become too rich and cause engine

is

70

kg-cm.

(23).

(20)

from the main

/"-

8-2-5

1)

FLOAT SYSTEM

Pull out the float

(1

6)

and remove the float

(1

7)

and needle valve

(24).

If the needle valve need be re-

placed, replace it with rubber needle.

Caution: 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

2)

When removing the needle valve and flots, gently tap the reverse side using the rod more slender than the

float pin and remove because the float

is

calked to the carburetor body.

air

to

blow

them clean.

/"

-

34

-

9.

STARTING

9- 1 DISASSEMBLY

1)

Remove 5 mm terminal

2)

Remove 5 mm

3)

Remove terminal

through

MOTOR

nuts.

bolts.

bush.

(2

pcs.)

Fig.

40

4)

Remove rear cover.

3

Fig.

y'

41

4

Fig.

42

-

35

-

Remove 4 mm Screws. Remove Brush Holder.

The brush holder

4

mm screws.

(2

Remove the Terminal

8)

Yoke Assembly

Remove yoke assembly.

(2

pcs.)

is

disassembed by removing the

pcs.)

Bush

No.

2.

I

Fig.

43

9)

The

pinion stopper clip

is

removed with a standard screwdriver while the pinion stopper pushed toward the pinion.

is

Fig.

44

A

"\

1

Fig.

45

\"I

-

36

-

10)

Disassemble pinion stopper spring

11)

Disassemble armature front cover

1

and pinion assembly

1

5.

10,

13,

thrust washer

12.

pinion

return

14

and

10

Fig.

12

46

1)

The 5 mm Terminal Nuts

2)

"M"

Terminal Bush

3)

The

5

mm

Through Bolts

4)

The Rear Cover

5)

The

4

mm

Screws

6)

The Brush Holder

7)

"M"

Terminal Bush No.2

8)

Yoke

Assembly

9)

The Pinion Stopper Clip

IO)

Pinion Stopper

11)

Pinion Return Spring

12)

Pinion Assembly

13)

Armature

14)

Thrust Washers

15)

Front Cover

(4

No.

(2

pcs.)

1

(2

pcs.)

(2

pcs.)

a

5

Fig.

6

Fig.

47

4

48

-

37

-

9-2

INSPECTION

and

REPAIR

9-2-1

1)

2)

ARMATURE

Check the diameter

If

the outside diameter smaller than the limit, then replace armature with a new one.

Standard (New)

30

mm

Continuity Test for the Armature

Use a tester allel points on the commutator. nuity, the armature is good.

No

continuity: (broken coil)

to

of

the commutator.

of

check

for

continuity between par-

Replace the armature unit.

the commutator is

Limit

(Used)

29

mm

Coil

If

there is conti-

Tester

Fig.

49

3)

Insulation Test for the Armature Coil Use a tester to check for continuity between a

point

core.

good.

Continuity Exists: (Short circuited coil)

on

the commutator and the shaft or the

If

there

is

no continuity, the armature

Replace the armature.

is

-

38

I

-

Tester

Fig.

50

51

4)

Check for Surface Distortion on the Armature

and the Commutator

Use

a dial gauge outside surfaces commutator. If it is above the limit, then repair

or

replace it.

5)

Check the Surface

If the commutator surface with fine sandpaper

to

measure the distortion of the

of

the armature core and the

of

the Commutator

is

rough, polish

(#

500

-

600).

(mm)

it

I

Fig.

Core

52

6)

Check the Depth the Commutator Surface If the depth of the insulating material from the

commutator segments pair it

by

Standard

filing

(New)

0.5 - 0.8

of

the Insulating Material from

is less than the limit, re-

it

down.

Limit

0.2

(Min.)

(mm)

(Used)

Insulator

Fig.

53

Correct

Incorrect

Fig.

54

0.5

-

0.8

Commutator Segments

mm

-

39

-

Measure the length of the brushes and if they are shorter than the limit, replace them.

Standard

I

9-2-3

1)

BRUSH

Insulation Test for the Brush Holder Check for continuity between the brush holder's top (positive side) and its base (negative side). If

there is

Continuity Exists: (Insulation failure)

(New)

12.5

mm

HOLDER

no

continuity, then

Limit

I

Replace brush holder.

it

9

is

good.

(Used)

mm

1

I

Brush

Fig,

55

2)

Inspection Check the return force

of

the Brush Springs

r

Normal

1.4

of

the brush springs.

force

(kg)

-

1.8

Fig.

56

4k

Fig.

57

-

40

-

9-2-4

PINION

CLUTCH

Inspection of the Pinion Clutch Rotate the pinion manually. While rotating

it

in

the direction of normal operation, smoothly reverse the direction

of

rotation to confirm that

it

locks.

In

the event

of

any irregularity, replace it.

9-3

REASSEMBLY

Fig.

58

Reassembly

is

in

the

reverse order of disassembly, however, please note the following points.

The Places to Apply Grease:

The sliding surfaces of the pinion

and

the shaft’s spline.

The metals holding the shaft at the front

and

rear covers.

-

41

-

IO.

BREAK-IN OPERATION

of

REASSEMBLED ENGINE

*

An overhauled engine must be operated at low speed to break-in the parts. A thorough break-in is indispensa-

or

ble particularly when the cylinder, piston, piston rings The recommended break-in schedule

LOAD

EY45V

NO

4.5HP

9.OHP

LOAD LOAD

LOAD

is

shown below.

valves are replaced with new ones.

SPEED TIME

2,500

3,000

3,600

rpm rpm rpm rpm rpm

10

minutes

10

minutes

10

minutes

30

minutes

60

minutes

-

42

-

B

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

1. The cylinder filled with

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

engine start difficult, e.g., a heavy load on the engine when it

to

pressure due

The

most common causes

a long exhaust pipe, just

a

proper fuel-air mixture.

to

say a few.

of

engine troubles are given below:

is

about

also

to

start at low speed, and a high back

other factors which make

111-1

11-1-1 FUEL SYSTEM

11

If

be checked for possible lack

1) Engine inside

2)

3)

4) Incorrect Tappet Clearance

STARTING

No

gasoline in the fuel tank; or the fuel cock is closed. The carburetor Water, dust

Inferior grade gasoline mixture.

The carburetor needle valve is held open

out of the carburetor when the engone is idling. (Overflow)

This trouble may be remedied, depending on cases, by lightly tapping the float chamber with the grip

a screwdriver or the like. If the carburetor overflows, excessive fuel runs into the cylinder when starting the engine, making the fuel-air mixture too few turns in order to let the rich fuel-air mixture out the carburetor choke open during this operation. start again.

-

1-2

COMPRESSION SYSTEM

starting difficultes and loss of power are not due to the fuel system or ignition system, the followings must

Loose or broken spark plug. This causes a hissing noise made

compression stroke during cranking. Damaged head gasket or loose cylinder head. A similar hissing noise stroke.

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

check further as follows:

a)

Valve

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.

DIFFICULTIES

is

not choked enough, particularly when the engine is cold.

or

gum in the gasoline blocks the fuel flow to the carburetor.

or

poor

quality gasoline is not vaporized enough to produce the correct fuel-air

by

dirt or gum. This trouble can be detected as the fuel flows

rich

to burn. If this happens, remove the spark plug,

of

the spark pulg hole into the atmosphere. Keep

Dry

the spark plug well, screw it into place, and

of

compression.

is

completely dried

stuck

open due to carbon

up

because

or

gum

of

a long period of non-operation.

on

the valve stem.

and

turn the starting pulley a

by

mixture gas running out

is

produced during compression

of

cylinder in

try

of

to

-

43

-

11-1-3

ELECTRICAL

SYSTEM

Check the followings for lack of sparks.

1)

Leads

of

the ignition coil, spark plug or contact breaker disconnected.

2)

Ignition coil damaged and shorted.

3)

Spark plug cable wet or soaked with oil.

4) Spark plug dirty

or

wet.

5)

Spark plug electrode gap incorrect.

6)

Spark plug electrodes are connected or bridged.

7) Incorrect spark timing.

11

-2

ENGINGE

MI

FIRES.

1)

Incorrect spark plug electrodge gap. Adjust it to anywhere between

0.6

and

0.7

mm.

2)

Ignition cable worn and leaking.

3)

Sparks weak.

4)

Ignition wire connections loose.

5)

Water

in

gasoline.

6)

Insufficient compression.

11-3

ENGINE

STOPS.

1)

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

in

gasoline.

2)

Vapor lock,

i.

e.,

gasoline evaporating in the fuel lines due to overheat around the engine.

3)

Vapor lock

in

the fuel lines

or

carburetor due

to

the use

of

too volatile winter gas in the hot season.

4)

Air

vent

hole

in

the fuel tank cap plugged.

5)

Bearing parts seized due to lack of

oil.

6)

Magneto or ignition coil faulty.

11

-4

ENGINE

OVERHEATS.

1)

Crankcase oil level

low.

Add oil immediately.

2)

Spark timing incorrect.

3)

Low grade gasoline is used, or engine is overloaded.

4)

Cooling air circulation restricted.

5)

Cooling air path misdirected causes loss of cooling efficiency.

6)

Cylinder head cooling

fins

clogged up with dirt.

7)

Engine operated in an enclosed space without fresh supply of cooling air.

8)

Exhaust gas discharge restricted, or carbon deposits

in

the combustion chamber.

9)

Engine running

on

low-octane gaoline detonates due to heavy load at low speed.

,"-

-

44

-

11-5

ENGINE KNOCKS.

1) Low-quality gasoline.

-

2)

Engine operating under heavy load at

low

speed,

-

3)

Carbon or lead deposits in the cylinder head.

4) Spark timing incorrect.

5)

Loose connecting rod bearing due

to

wear.

6)

Loose piston pin due to wear.

7)

Cuases

of

engine overheat.

11

-6

ENGINE BACKFIRES

through

CARBURETOR.

1)

Water or dirt in gasoline,

or

low-grade gasoline.

2)

Intake valve stuck.

3)

Valves overheated, or red-hot carbon particles in the combustion chamber.

4)

Engine cold.

c

-

45

-

12.

INSTALLATION

Engine life, ease

of

maintenance and inspection, frequency of checks and repairs,

and

operating

cost

all

de-

pend on the way

in

which the engine is installed. Carefully observe the following instructions for installing

,"-

the engine.

12-1 INSTALLING

When mounting the engine, carefully examine its position, the method of connecting it to a load (machine), the foundation, and the mehtod 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 can easily be checked, the air cleaner can easily be serviced, and that the

oil

can

easily be discharged.

12-2 VENT1 LATION

Fresh air is necessary for cooling the engine and burning the fuel. In case 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

oil

consumption,

loss

of power, piston seizure, shorter

engine life, etc., making it impossible to operate the engine properly. It is necessary, therefore,

to

provide a

duct or baffle to guide cooling

air

to

the engine to prevent recirculation of he

hot

air used for engine cooling,

and temperature rise of the load (machine).

Take steps as necessary

to

keep the engine room temperature below 50°C even in the hottest period of the

year.

12-3 EXHAUST

GAS

DISCHARGE

Exhaust gas is noxious. When operating the engine indoors,

be

sure

to

discharge the exhaust gas outdoors.

If

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

Exhaust pipe: Less than

3

m long, pipe inside diameter

25

mm,

Less than

5

m long, pipe inside diameter

30

mm.

,"-

12-4

POWER

TRANSMISSION

to

DRIVEN MACHINES

12-4-1

BELT

DRIVE

Take the following notes into consideration.

*

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 in line with the driven pulley of the load.

*

Install the engine pulley

as

close

to

the engine

as

possible.

*

If

possible, span the belt horizontally.

*

Disengage the

load

when starting the engine.

If

no

clutch

is

used, use a belt tension pulley

or

the like.

12-4-2

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.

-

46

-

13.

CHECKS

and

CORRECTIONS

After disassembling and cleaning the engine, check and repair,

if

necessary, according to the correction table.

The correction table apolies whenever the engines are repaired. It is important for the servicemen to

be

familier with the contents

of

this table. Correct maintenance is recommended by observing the correction standards specified. The meanings

of

the terms used in the correction table are as follows:

1)

Correction

2)

Correction Limit

Repair, adjustment or replacement

of

any engine parts.

The limit on wear, damage or functional deterioration

of

engine parts beyond which normal engine per-

formance cannot be expected without repairing such parts.

The

limit beyond which

parts

can

no

longer be used

in

respect

of

performance

or

strength.

The design dimensions

of

new parts minus tolerance.

Tolerance on the dimensions of engine parts refinished or adjusted.

3)

Use Limit

4)

Standard Dimensions

5)

Correction Tolerance

. . ..

..

-

47

-

14.

TABLE

of

CORRECTION STANDARDS

lTEM

Flatness

head

of

cylinder

Bore

Roundness

Cylindricity

Valve seat contact width

Valve guide

O.D. at skirt, thrust direction

(incl. over size)

B

0.25

C

0.5

I

.D.

in

STANDARD

SIZE

90

dia.

8

dia.

STD

89.973

B

90.223

C

90.473

dia.

dia. dia.

1

CORRECT1

TOLERANCE

Dif. between max.

+0.006

0.01

1

.2

+0.036

-0.02

0.05

&

0.01

-1.

0

min.

-0.016

5

.5

-

0.1

2.5

0.1

-0.1

T

US

E

LIMIT

+

0.65

5

Surface plate, Feeler

ZORRECTIOfl

METHOD

Correct

Boring

I

Correct

5

0.1

-0.1

5

portion

1

gauge

I

Micro-

meter

Replace

Width

of

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

Top,

Oil:

20

2nd:

4

dia.

2.5

Top

+0.06 - +0.04

2nd

+0.04

Oil

+0.04

+0.002

-

0.01

0.053

-

Top

0.1

2nd

0.10

Oil

0.05

0.01 1 T

0.011

:.q0..

Oil

-

0.01

5

+0.02

1

-

0.1

-

0.06

-

0.01

L

-

1

0.1

1

0.1

5

0.035

-

0.1

5

-

1.5

-

0.1

5

0.035

0.25

0.1

5

1.5

Vernier

calipers

dia.

'

gauge.

Feeler

gauge

Cylinder gauge.

Micrometer

Max. cylin-

der

dia. and Cylinder

piston

at skert in Micro-

thrust direc- meter

tion

Replace

Ring width

Top, 2nd: 2.5

4

Oil:

Top 2nd Oil

-0.07

-0.04

+0.01

-

-0.0s

-

-0.OE

-

-0.01

-

48

0.1

-0.1

-

Mircrometer

-

ITEM

1

STYFtRD

1

CoRRECTlyN

TOLERANCE

'

USE

1

REMARKS I TOOL

I

METHOD

CORRECTION

LIMIT

-0.03

t

Piston

O.D.

20

dia.

0

-

-0.009

-0.03

I I

I

0.1

I

Cylinder gauge

Replace

0.1

Large end

I.

D.

38 dia.

+0.016

-

0

Cylinder

Micrometer

gauge, Replace

Clearance between rod large end

I.D.

and crankpin

0.2

0.050

-

0.082

0.08

1

Small end

I.D.

20

dia.

+0.023

-

+0.010

0.08

0.1

2

1

.o

0.1

5

0.05

Cylinder

meter

Micro-

0.1

2

gauge,

Replace

Feeler

Re-machine

1

.o

gauge or Replace

Clearance between small end

I.D.

0.01

0

-

0.032

Large end side

clearance

0.1

-

0.3

0.1

1

Parallelism between large end and

0.06

small end bores

Distance between large end and

120

*0.1

small end bores

Crankpin O.D. 38 dia. -0.050

-

-0.066

and Dial

or Replace

0.15

I

Test bar

0.5

1

Micro- Re-machine

or

Replace

Crankpin O.D. roundness

Micro-

Re-machine

meter

or Replace

Micro-

Re-machine

meter

or Replace

Dial Re-machine gauge or Replace

Less

than

0.005

Crankpin O.D. cylindricity

Less

than

0.005

I

Crankpin

O.D.

parallelism

I

Less than

0.01

Crankshaft

journal

O.D.

PTO

Side

Magneto Side

35

dia.

-0.003

-0.014

0.05

I

Intake

36

Exhaust

35.5

Cam lobe height

AO.1

PTO Side

Journal

O.D.

Magneto Side

-0.020

-

-0.033

-0.25

1 1

Micro-

1

~~~l~~~

meter

-0.25

0.05

1

Micrometer

Replace

0.05

20

&a.

-

49

-

ITEM

Free length

Squareness

Valve stem O.D.

Clearance between

stem and guide

STANDARD

SIZE

46

8

Intake

Exhaust

dia.

Intake

Exhaust

111

CORRECTION

TOLERANCE LIMIT

-0.030

-

0.055

-0.070

-0.096

0.030-0.091

0.070

-

0.1

26

I

-1.5

-0.15

0.3

LIMIT

,

.o

0.3

I

REMARKS

For total

length

At middle

Vernier calipers

Square feeler

WJge

Micro-

meter

CORRECTION

1

METHOD

Replace

,-

Tappet clearance

Clearance between groove and retainer

Stem end length

Total length

Clearance between stem and guide

Pilot screw unscrew

Spark plug

I I

0

.-

L

c

u

1

Spark timing

w

1

5.3

BPMGA

I

NGK

23"

before T.D.C.

57

Feeler gauge

I

0.04

-0.1

5

-0.5

-

0.5

I

0.025-0.062

0.2

I

I1

i

114

Vernier calipers

Cylinder

gauge

&

Micro-

meter

I

Correct

Replace

/"-

I

0.6

*

3"

0.7

1

1.0

Feeler gauge

Timing tester

Adjust or replace

Adjust

Clearance

Flywheel

Ignition Coil

between

and

I

0.5

i0.2

Feeler gauge

-

50

-

Adjust

r

Max. Output

HPlrpm

12.013600

Below

USE

LIMIT

1

10%

of rated output

REMARKS

Continuous Rated output

I

ITEM

Fuel Consumption

ITEM

Lubricant

Consumption

I

ITEM

Fixed quantity

of

Lubricant

9.0/3600

liter/hr

4.0

cc/hr

10-

15

liter

1.3

CORRECTION PRECISENESS

of

standard consumption

USE

LIMIT

cdhr

40

REMARKS

At continuous ratad output Above 135%

-

REMARKS

Single grade oil

1

*Use the

*If

SC

or

Specified Lubricant

Qualitv

quality and quantity

higher grade engine oil.

Comparison between oil viscosity and ternparature

Single grade

-

Multigrade

1

2(

-4

of

the engine oil become lower or less, burning

-10

1

14

ow

20w

#20

1OW-30

I I

0

32

I

10

50

-51

I

#30

I

20

68

-

I

#40

I

30

86

4OoC

104OF

REMARKS

When the peripheral temparature below

-20°C,

and quality fitted to the local conditions.

When the peripheral temperature 40"C,

use

fitted to the local conditions.

The oil consumption when used under high peripheral tempa-

rature,

day.

might

be caused.

use the oil

the oil

of

so

it

is

necessary to check every

of

viscosity

viscosityand quality

is

apt

to

increase,

is

above

*

ITEM

FREQUENCY

OF

OIL CHANGE

First time: Change oil after

20

hours operation.

Second Time and Thereafter: Change

oil

every

50

hours operation.

Oil Change

Cylinder pressure 7.0

-

7.5/800

CORRECTION

LIMIT

REMARKS

TOOL

70%

of

normal value

and down

Pressure gauge

ITEM

Min. accelerating revolution

r

ITEM

Cylinder head clamp

nuts

Connecting rod

bo1

ts

Magneto clamp

nuts

Main bearing cover

bolts

2000

TOOL

Tachometer

r

kg-cm

340- 390

250

-

300

800-1000

170- 190

120-160

ft-lb

24.6-28.3

18-21.7

57.9-72.3

12.3-13.7

8.7

-

11.6

REMARKS

Crankshaft

TOOL

R

€MAR

KS

Torque wrench

-

52

-

15.

MAINTENANCE

and

STORING

The following maintenance 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

15-1

DAILY CHECKS

Remove dust which accumulated or clogged.

Check external fuel leakage. If any, retighten

or

replace.

Check screw tightening.

found, re-tighten.

Check oil level in crankcase and add up as

necessary.

50

Checks and maintenance

or

grass from whatever parts

jobs

apply when the engine

hours.

and

MAINTENANCE

If

any loose one is

is

operated correctly under normal conditions. The

Reasons for requiring them

The governor linkage is especially susceptible to

dust.

Not only wasteful but also dangerous

Loose screws and nuts will result in vibration accidents.

If the engine

it

will fail.

is

operated without sufficient oil,

D

15-2

15-3

INITIAL

I

Change crankcase oil.

EVERY

Change crankcase oil.

I

Clean air cleaner. Check spark plug.

gasoline

20

Checks and maintenance Reasons for requiring them

50

Checks and maintenance

or

polish with emery

HOURS

If

CHECK

(10

contaminated, wash

DAYS) CHECKS

in

paper.

I

TO

remove run-in wear particles

and

MAINTENANCE

Contaminated

1

Clogged Output power

difficult.

Reasons for requiring them

oil

accelerates wear.

air cleaner harms engine operation.

is

reduced and starting is made

I

-

53

-

15-4

EVERY

100 - 200

HOURS (MONTHLY) CHECKS

and

MAINTENANCE

Checks and maintenance

Reasons

for

requiring them

Clean fuel filter and fuel tank.

The engine will

be

out

of

order.

Clean contact breaker points.

I

The engine output drops.

I

Remove grass, chaff

or

dirt clogged the air

and clean it.

cooling system. Remove the blower housing

The engine overheats.

15-5

EVERY

500 - 600

HOURS (SEMIANNUAL) CHECKS and MAINTENANCE

Checks and maintenance

Reasons for requiring them

Remove cylinder head and remove carbon deposit.

The

engine

will be out of order.

~~~ ~~ ~~~~~~

Disassemble and clean carburetor,

15-6

EVERY

1000

HOURS (YEARLY) CHECKS

and

MAINTENANCE

I

Checks and maintenance

I

Reasons

for

requiring them

I

Perform overhauls, clean, correct or replace parts. 1 The engine output drops and become out of order.

I

Change piston rings.

I

Replace fuel pipe once a year.

To

prevent from danger caused by the fuel

leakage.

,

15-7

PREPARATION

for

LONG STORAGE

Perform the above 15-1 and 15-2 maintenance

jobs.

Drain fuel from the fuel tank and carburetor float chamber.

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.

Turn the starting pulley by hand and leave

it

where the resistance

is

the heaviest.

Clean the engine outside with oiled cloth.

Put

a

vinyl or other cover over the engine and store the engine

in

dry place.

-

54

-

Industrial

Engines