Subaru Robin Power Products EY44-2, EY33-2 User Manual

Specifications and Main Features

  • Model: EY33-2, EY44-2
  • Type: Horizontal, Single Cylinder 4 cycles P.T.O. shaft air cooled.
  • Bore x Stroke: EY33-2: 78 mm x 68 mm (3.07 x 2.68); EY44-2: 90 mm x 68 mm (3.54 x 2.68).
  • Piston Displacement: EY33-2:325 cc (19.83) , EY44-2:433 cc (26.4)
  • Compression Ratio: 6.0
  • Output:
  • Continuous:
  • EY33-2: 6.5 HP/3,600 r.p.m and 6.5 HP/1,800 r.p.m.
  • EY44-2: 8 HP/3,600 r.p.m and 8 HP/1,800 r.p.m.
  • Maximum:
  • EY33-2: 8 HP/3,600 r.p.m and 8 HP/1,800 r.p.m.
  • EY44-2: 10.5 HP/3,600 r.p.m and 10 HP/1,800 r.p.m.
  • Max. Torque:
  • EY33-2: 1.7 kg-m/2800 r.p.m 3.4 kg-m/ 1400 r.p.m
  • EY44-2: 2.3 kg-m/2.6 kg-m/1300 r.p.m.
  • Direction of Rotation: Contrarotating, when viewed from the driver side looking at the r.p.m of the shaft.
  • Cooling System: Air forced system.
  • Valve Arrangement: Side Valve.
  • Lubrication: Type splash lubrication
  • Lubricant: Mobile Oil SAE #20, #30 or 10W-30.
  • Carburetor: Horizontal type Float.
  • Fuel: Automated Gasoline.
  • Fuel Consumption Ratio:290 g at ratio g/hp kWh sp test outputs
  • Fuel Feed System: Gravity Feed System.
  • Fuel Tank Capacity: Approximately 7.5 liters/1.98 US gallons.
  • Speed Reduction: 1/2 gear type.
  • Ignition System: Flywheel magneto
  • Bujía: NGK B-6HS
  • Capacidad de Iluminación: 12V ~ 16V, 15W (Se Disponible si Necesario)
  • Método de Arranque: Cuerda tipo / Arrancador Eléctrico
  • Peso Seco:
  • EY33-2: 38 kg (84 lbs.) y 43 kg (95 lbs.)
  • EY44-2: 41 kg (90 lbs) y 46 kg (101 lbs)
  • Dimensiones:
  • EY33-2: 378mm (Longitud) x 432mm (Ancho) x 533mm (Altura)
  • EY44-2: 386mm (Longitud) x 452mm (Ancho) x 544mm (Alto)

Frequently Asked Questions

P1: ¿Qué tipo de combustible utiliza el motor?

R1: Se trata de gasolina automotora.

P2: ¿Cuál es el sistema de lubricación que se utiliza en el motor?

R2: El sistema de lubricación es del tipo salpicado.

P3: ¿Cuál es la máxima potencia de salida del modelo EY44-2?

R3: La máxima potencia de salida de este modelo es 10.5 HP a 3600 r.p.m.

P4: ¿Cuál es el sistema de refrigeración de estos motores?

R4: Los motores utilizan sistema de refrigeración por aire forzado.

P5: ¿Qué método de arranque utilizan estos motores?

R5: Los motores son arrancados por medio de cuerda tipo o mediante un tipo de arranque eléctrico.

P6: ¿Cuál es el peso seco del modelo EY33-2?

R6: El peso seco es de 38 kg (84 lbs) para la versión base y de 43 kg (95 lbs) para la versión más grande.

Q7: What is the recommended lubricant for the engines?

A7: The oil to be used for this engine should be Mobile Oil SAE #20, #30 or 10W-30.

User Manual

ROBIN
AMERICA,
INC.
ROBIN
TO
WISCONSIN ROBIN
MODEL
CROSS
REFERENCE
LIST
ROBIN
EY
08
EY15 EY 15V EY20 EY20V EY23 EY28 EY3 5 EY40 EY45V EY2
1
EY44 EY 18-3 EY25 EY27
EH11 EH12 EH15
EH17
EH2 1 EH25 EH3
0
EH30V EH34 EH34V EH43V
EC13V
DY
23
DY27 DY30 DY35 DY4
1
WISCONSIN
ROBIN
SIDE
VALVE
W
1-080
WI-145 W1-145V W1-185 W1-185V W 1-230 W 1-280 Wl-340 W1-390 W 1 -450V EY21W EY44W
EY
18-3W EY25W EY27W
v
WO1-115 wo1-120 WO1-150 WO1-170 wo1-210 WO 1-250 WO
1
-300
WOI-3oov WO 1-340 WO1-340V WO 1-43 OV
TWO
CYCLE
WT1-125V
DIESEL
WRD
1-230
WRD
1-270
WRD1-300
WRD1-350
WRD1-410
CONTENTS
Section Title Page
1
.
SPECIFICATIONS
............................................
1
2
.
PERFORMANCE
............................................
2
2.1
.
Maximumoutput
.......................................
2
2.2
.
Continuous Rated Output ................................. 2
2.3
.
Maximum Torque and Fuel Consumption Ratio
at
Max . Output
........
2
3
.
FEATURES
...............................................
3
4
.
GENERAL DESCRIPTION
of
ENGINE CONSTRUCTION
...............
4
4.1
.
4.2
.
4.3
.
4.4
.
4.5
.
4.6
.
4.7
.
4.8
.
4.9
.
4.10
.
4.11
.
4.12
.
4-1
3
.
4- 14
.
4.15
.
4- 1 6
.
Sectional View
of
Engine
..................................
4
Crankcase
...........................................
6
Main Bearing Cover
.....................................
6
Crankshaft
...........................................
6
Connecting Rod and Piston
................................
6
Camshaft
...........................................
6
Cylinder and Cylinder Head
...............................
6
Valve Arrangement
.....................................
6
Balancer
.............................................
6
Governor
.............................................
7
Cooling
.............................................
7
Lubrication
...........................................
7
Ignition
.............................................
7
Carburetor
...........................................
7
Air Cleaner
...........................................
7
Selenium Rectifier
......................................
7
5.lNSTALLATlON
............................................
8
5.1
.
Mounting
............................................
8
5.2
.
Ventilation
...........................................
8
5.3.
Exhaust
Gas
Evacuation
..................................
8
5.4
.
Fuel System
..........................................
8
5.5
.
Power Transmission to Driven Machines
.......................
8
5.6
.
Wiring
..............................................
9
6
.
DISASSEMBLY
and
REASSEMBLY
..............................
10
81
.
Preparations and Suggestions
...............................
10
6-2 . SpecialTools
.........................................
10
6-3
.
Disassembly and Reassembly Procedures
.......................
11
7
.
MAGNETO
...............................................
18
7.1
.
Magneto
.............................................
18
7.2
.
Breaker Point Adjustment
.................................
18
7.3
.
Timing Adjustment
.....................................
18
7.4
.
Magneto Service Instructions
...............................
19
8
.
GOVERNOR
ADJUSTMENT
...................................
21
9.CARBURETOR
.............................................
22
9.1
.
Operation and Construction
................................
22
9.2
.
Disassembly and Reassembly
.................................
23
9.3
.
Adjustment
..........................................
23
10
.
RUN-IN OPERATION
OF
ENGINE
after
REASSEMBLY
...............
25
11
.
TROUBLE SHOOTING
.......................................
26
11.1 . Starting Difficultes
......................................
26
11.2 . Engine Misses
.........................................
27
11.3
.
Engine Stops
..........................................
27
11.4 . Engine Overheats
......................................
27
11.5 . Engine Knocks
........................................
28
11
.6
.
Engine Backfires Through Carburetor
.........................
28
12
.
CHECKS
and
CORRECTIONS
..................................
29
13 . MAINTENANCE
and
STORING
.................................
35
13.1
.
Daily Checks and Maintenance
..............................
35
13.2
.
Every 20 Hours Checks and Maintenance
.......................
35
13.4
.
Every 100-200 Hours (Monthly) Checks and Maintenance
...........
35
13.5
.
Every
500-600
Hours (Semianual) Checks and Maintenance
..........
36
13.6 . Every 1000 Hours (Yearly) Checks and Maintenance
...............
36
13.7 . Preparation for Long Abeyance
.............................
36
13.3 . Every
50
Hours (10 days) Checks and Maintenance
................
35
1. SPEC1
FICATIONS
-1-
2.
PERFORMANCE
2-1 MAXIMUM OUTPUT
The maximum output the moving parts properly worn-in, when operating with the fully open throttle valve. Therefore, it follows that engine may not develop this maximum output in the beginning, because moving parts are not in a properly condition.
2-2
CONTINUOUS RATED OUTPUT
The continuous rated output of an engine is such power as developed by that engine when running at an optimum speec most favorable from the point
driving system for any mechanism, with a model
of
requirement
2-3 MAXIMUM TORQUE AND FUEL CONSUMPTION RATIO AT MAX. OUTPUT
The maximum torque while the engine is developing its max. output. The fuel consumption ratio at max. output
an
engine while that engine is running at the max. output.
that mechanism must be kept below the continuous rated output specified.
a
of
an engine is such standard power as developed by that engine, after its initial run-in period with a1
of
view of engine life and fuel consumption ratio. Therefore, it follows that when designing
of
an engine is that driving torque
PERFORMANCE CURVE
EY33-2
RECOMMENDED OPERATING SPEED RANG
or
EY44-2
of
the driving shaft at which the engine is driving
Model
EY33-2
engine,
as
a
prime mover, the continuous powe
is
that fuel consumption ratio
(
)for B type
an
external load
a
nev
w0rn-h
i
o
I
HP
125112
124)12
I
ft"b
(23J11.5--
7
5
MAX.
5
-I
TORQUE
1.7(3.4)
--
~
1.6(3.2)
I
kg-rn
1.5
(3.0)
320
300
280
g/
P.h
2000
(1OOO)
2500
112501
rpm
-
-2-
3000 3500
115001
11750)
3.
FEATURES
1.
A
compact, lightweight, and highly durable 4cycle aircooled EYseries with high output, embodying ingenious design
and advanced machining techniques.
2.
Simple construction, good appearance, plus easy start-up.
3.
Smooth speed control functions range
of
applications.
4.
Economical advantage with minimized fuel consumption.
5.
Since power can be taken in any direction simply by pulling the belt, and the feed and drain oil work can also be done
of
easily in two directions
6.
The use
of
dynamic balancer reduces vibrations to such an extant as in a two-cylinder engine.
engine, the engine is easily coupled with operating machines.
of
governor guarantees stable operation under various load conditions over a wide
HP
(33)
(32)
(31)
tt-lb
11
10
9
0
7
6
16.5
16
15.5
PERFORMANCE
Model
RECOMMENDED OPERATING SPE
CURVE
EY44-2
(
)for
B
type
2.3(4.6)
2.2(4.4)
kg-m
2.1(4.2)
2000
(1000)
2500
(1250)
3000
(1500)
rpm-
-J-
3500
(1750)
/-
FLYWHEEL(COOLI~G
FAN)
LIGHTING
I
COIL
-4
\
CRANKCASE
-
SEl
-5-
4-2
CRANKCASE
The crankcase is made
of
aluminum die-cast and separable on driving shaft side with main bearing cover assembled.
Provided on blower side are two ball bearings, each supporting the crankshaft and camshaft.
4-3
MAIN BEARING COVER
The aluminum die-cast main bearing cover on the driving shaft side allows easy access
to
the engine interior
for
inspection simply by removing it. The’fange and boss permit direct coupling of operating machines such as generators, pumps, etc. The oil inlets which
also serve as oil gauges can be mounted on driving shaft side of Models
EY33-2B
and
EY44-2B.
The force-fit balancer shaft and balancer holder mounting boss assure easy mounting of the balancer mechanism.
44
CRANKSHAFT
The crankshaft is machined from carbon steel forging with an induction hardened crank pin. The breaker cam
is
provided on
blower side, while crankshaft gear and balancer gear are force-fit on driving side.
4-5
CONNECTING
The connecting rod (Model An
EY44-2 employs aluminum metal on the large end.)
oil
scraper is provided on the large end for the purpose of splashing lubricating oil. The piston is machined fron
ROD
and PISTON
is
machined from aluminum alloy forging, and forged alloy itself serves as bearing metal at both ends.
aluminum alloy casting and provided with grooves for two compression rings, one oil rings, and one skirt ring. The
EY44-2
piston has
an
offset structure at the piston pin center
so
as
to reduce striking sound of piston.
4-6
CAMSHAFT
The carbon steel forging camshaft incorporates integral intake and exhaust cams plus a force-fit cam gear.
also
serves
as
camshaft
4-7
CYLINDER and CYLINDER HEAD
The cylinder is made head is made
of
driving shaft and it
of
special cast iron and provided with many fins for assuring excellent cooling effects. The cylinda
aluminum alloy casting. The Ricardo type combusion chamber with a sufficient area assures hil
combusion efficiency. The spark plug
4-8
VALVE ARRANGEMENT
The exhaust valve durability
4-9
of
BALANCER
engine.
is
positioned in the upstream of the colling
is
driven at half the crankshaft speed.
is
tilted
to
facilitate fuel tank mounting.
air
so
that it is intensively cooled down for improv
An unbalanced inertia force produced due to crankshaft and piston connecting rod in the vertical and lateral direction: balanced by balancer which rotates at
ratio of
1:
1
in the direction opposite to crankshaft,
so
that vibrations due
a
unbalanced inertia force are reduced.
The
B-typ
-6-
4-10 GOVERNOR
The centrifugal flyweight type governor assures constant-speed operation at selected speed, irrespective
4-11
COOLING
The cooling fan which also serves as a flywheel forcily feeds cooling air to the cylinder head with the aid and head cover.
4-12
LUBRICATION
The rotating and sliding parts are lubricated by scooping and splashing oil in crankcase with oil scraper attached to
connecting rod.
4-13
IGNITION
The ignition system is
flywheel, an ignition coil, a breaker, and lighting (charging) coil. The flywheel (serving also as a fan) crankcase, while the other elements are directly assembled in crankcase (For details, refer to the MAGNETO section).
4-14 CARBURETOR
A
horizontal draft carburetor is employed. Its setting has been carefully after thorough tests to achieve best start-up,
acceleration, fuel consumption, output, and other performance. For other details, see the CARBURETOR section.
of
flywheel magneto type with ignition timing set at
23'
before TDC. The magneto
of
load fluctuations.
of
cylinder baffles
is
composed
is
mounted on
of
a
4-15 AIR CLEANER
An impinge type semi-wet air cleaner catches dust particles in the air by means of felt in dust case. The air
by passing through a filter element.
4-16 SELENIUM RECTIFIER
The selenium rectifier serves battery when a starting motor is combined.
to
rectify the
AC
current generated by AC charging coil
of
magneto into DC current to charge
is
then cleaned
-7-
5.
INSTALLATION
Since the installation method affects the service life, ease of maintenance, frequency of check and reapir, and operating
of
costs For details, refer to the separate “SALES MANUAL”-Engineering Information-.
5-1
engine, the following contents should be carefully examined before installing your engine.
MOUNTING
When installing the engine, its mounting position, coupling conditions with operating machines, and anchoring methods must be carefully examined. Particularly when determining its mounting position, due care should be taken to
of
assure the convenience of such routines as replenishment and checking
of
points, maintenance
5-2
VENTILATION
The engine must be supplied with .fresh air for cooling and fuel combustion. room, the engine room is heated, causing vapor lock, deterioration of oil, increase of oil consumption, power reduction,
loss
seizure,
It is therefore necessary of heated air after cooling engine and or temperature-rise of operating machines. The temperature
53
EXHAUST GAS EVACUATION
Since the exhaust gas from engine is toxic, it must be exhausted outside if engine is operated indoors.
As
the output power
proportion to its length.
of engine life, and thus proper engine operation can be expected
air cleaner, and oil drainage.
to
provied a cooling air duct and a baffle plate for the purpose
of
engine compartment should be kept below 4OoC even in mid-summer.
of
an engine is considerably influenced by the length of exhaust duct, its diameter must be increased in
fuel and oil, checking
If
engine is operated with a cover
no
longer.
of
preventing insufficient circulation
of
spark plug and breaker
or
supporting
or
in
a small
5-4
FUEL SYSTEM
When fuel tank is separated from engine, it must be located the fuel joint may overflow. For fuel piping, carefully examine it for heat conductivity, diameter, bending, and leakage through fittings air lock and vapor lock.
It
is recommended
5-5
POWER
5-5-1
Be
careful with the following items.
*Ilse a V-belt rather than a flat belt.
*Set the driving shaft of engine and the driven shaft
*Align the driving pulley
*Mount the driving pulley
of
TRANSMISSION
BELT
DRIVE
carburetor.
to
If
the fuel tank
minimize piping length. The standard
to
DRIVEN
of
engine and the driven pulley
as nearer to the engine as possible.
is
installed too low, fuel is not fed properly, and if it is too high, the carburetor
MACHINES
of
so
that its bottom surface lies within 5-50cm
ID
of
fuel pipe is 4-5mm
driven machine in paralled with each other.
of
driven machine correctly with each other.
-8-
(5,2”-13/64“).
(2”-20”)
so
as to eliminate
above
5-6
WIRING
a
-e
-@
-
"""
JIS
JIS
JIS
The
CB104
CA104
LA
104
dotted
female terminal
male terminal
or
LA1
08
plate terminal
parts are
not
supplied
with
the
engine.
5-6-1
5-6-2
ROPE STARTING ENGINE
SPARK PLUG
ENGINE with STARTING MOTOR
MAGNETO
MAGNETO
Fig.
5-6-1
_""""
LAMP
(12V.
15W)
'.-N
BUZZER
(6"-
8W)
/
LA
104
-
g
-:
6.
DISASSEMBLY
6-1
PREPARATIONS
1)
When disassembling engine, carefully note mounting positions and methods of respective parts in order
reassemble them correctly. Tag parts,
2)
Prepare several boxes to keep parts belonging to respective groups together.
3)
In order to prevent missing or misplacing, group related parts together, tentatively assembling them immediately after
and
REASSEMBLY
and
SUGGESTIONS
if
there is a possibility of confusion.
to
disassembling each sub-assembly.
4)
Carefully handle parts, and clean them with washing oil after disassembling.
5)
Use correct
6)
Standard tools to be prepared for disassembling.
tools
in correct ways.
a) Work Bench b)
'
Washing Pan c) Disassembling d) Washing
Tools
Oil
(Kerosene or Gasoline), Mobile Oil
e) Emery Paper, Cloth
7)
Drain fuel and
To
drain oil, unscrew the oil drain plug located on the side of crankcase on carburetor side by turning it
oil
without fail before disassembly.
counter-clockwise.
8)
Clamp cylinder head, cylinder main bearing cover, connecting rod, spark plug, and flywheel with specified torque when reassembling them.
9)
Replace all the packings and gaskets with new ones when reassembling.
IO)
Wash parts with new gasoline
1 1
)
Apply mobile
12)
Be careful not to contaminate parts with dust during reassembling.
13)
Tighten
oil
bolls,
nuts, and screws
to
the
or
washing oil, and blow them with compressed air before reassembling.
rotating and sliding parts.
to
correct torque readings specified.
If
small screws are tightened too strongly, they may
be broken.
14)
After reassembling, turn the moving parts by hand, and check them for signs of abnormal friction, noises,
or
be able
looseness.
to
6-2
SPECIAL TOOLS
..
.
~
""
c
"
"
-
."
-.
.
""
VALVE
SPRING
Fig.
6-2
-1
0-
"
3
-
COMPRESSOR
6-3
DISASSEMBLY
Flywheel
I
Bolt
Valve
Valve
Pilot Stem
and
REASSEMBLY PROCEDURES
Puller
Spring Compressor
Seat
Cutter
(45”)
209 9901
(Y790-350)
001
65085
209 9901
(Y790-282)
209
9901
(H640-118)
0
07
00
1
07
I1
2
07
1 1
6-3-1
1)
2)
3)
In reassembly;
CAUTION: REPLACE FULE PIPE WITH NEW ONE ONCE EVERY YEAR.
6-3-2
1)
2)
3)
.
6-3-3
1) Remove air cleaner cover and element.
2) Detach bottom plate
3)
In reassembly;
6-3-4
Remove muffler from cylinder part of crankcase (8mm nut X 2,
6-3-5
FUEL
TANK
Disconnect fuel pipe between fuel strainer and carburetor from carburetor. Detach fuel tank from its mounting bracket (8mm nut X
Detach bracket and head cover from cylinder head (8mm bolt X 2).
It is recommended to replace fuel pipe with new one before reassembly.
BLOWER HOUSING
Disconnect primary coil wire from stop button wire. Take
off
muffler cover and blower housing from crankcase. and baffle from cylinder head.
(6mm bolt X 36mm screw
Remove baffle from cylinder block. (6mm screw X
AIR CLEANER
(Also, detach the choke button from the carburetor chocke lever) Disconnect breather pipe.
Put air cleaner element
washing, dry the element thoroughly and apply mixture
reassembly.
MUFFLER
GOVERNOR LEVER
1) Detach governor lever from governor lever shaft (6mm nut
and
TANK BRACKET
4).
and
CYLINDER BAFFLE
-
X
4).
2).
of
air cleaner from carburetor by loosening two 6mm bolts.
in
gasoline and sufficiently wash it while shaking until dust is completely removed. After
oil
(gasoline and mobile
8mm bolt X
and
CARBURETOR
X
1
2) Detach governor rod and rod spring from carburetor.
3)
Remove carburetor from cylinder par‘t
In
reassembly:
“8.
Refer to
GOVERNOR
ADJUSTMENT” section.
of
crankcase
(EY33-2:
6mm nut
).
2).
X
2,
oil
mixed at a ratio of
EY44-2:
8mm nut
4:1),
before
X
2).
-1
1-
6-3-6
6-3-7
2) Detach cylinder head and gasket from cylinder by loosening lOmm nut.
In
2) Replace gasket with new
3)
NOTE:
6-3-8
CA
STARTING
Remove 3 pieces mounting bolts to detach starting pulley from flywheel. Remove flywheel from crankshaft. Insert a socket wrench nut, and give the wrench a sharp blow with a soft hammer. Remove nut and spring washer. Attach flywheel puller to flywheel as shown in Fig.
6-3-1,
and turn center bolt clockwise until flywheel becomes loose enough to be removed. Disconnect high tension cable spark plug, disconnect cable clip from crankcase, and then, remove ignition coil from crankcase
(6mm
X
25mm screw X 2). Remove cable clip from lighting coil cable, and detach lighting coil from crankcase (6mm Remove breaker cover, and then remove contact breaker and condenser from crankcase.
In reassembly
Refer to “7-2 BREAKER POINT ADJUSTMENT” and
CYLINDER HEAD
1)
Detach spark plug from cylinder head.
reassembly;
1)
Remove carbon from combustion chamber and also remove dirt from the vicinity
Check head face for distortion. Replace cylinder head, if needed.
;
PULLEY
and
FLYWHEEL
or
box wrench into an
of
ignition coil from
and
SPARK PLUG
(magneto)
18mm
“7-3
TIMING ADJUSTMENT”.
one.
Clamping torque
Leave spark plug detached temporarily to facilitate engine rotation during timing adjustment. When mounting
finally, tighten
INTAKE
Detach inner and outer tappet cover from cylinder
block
(6mm
Detach retainer locks and valves by Lifting valve spring
a
using both for intake valve and exhaust valve. Then, remove valve springs and spring retainers.
1
JTION:
TAPPET
TOOL .
valve spring retainer. Proceed in the same way
DO
of
cylinder head
it
250-300
and
EXHAUST VALVE
bolt x 2).
NOT DAMAGE GASKET SURFACE
CHAMBER
WITH
kg-cm
is
450-500
(18-21.7
THE
COMPRESSOR
ft-lbs).
(Fig. 6-3-2)
kg-cm (32.5-36 ft-lbs).
OF
Fig.
6-3-1
X
30mm screw
of
cooling fins of cylinder head.
x
2).
-
-1
2-
Fig.
6-3-2
In reassembly;
1) Clean carbon and gum deposits from the valves, seats, ports and valve stem holes.
2)
Replace valves, if badly burned, pitted or warped.
3)
Correct the valve seat by using
1.2-1 Smm
4)
Cylinder block should be replaced if valve stem clearance becomes excessive. 'Refer to Fig. ..-' 4 for
clearance specifications and proper assembly.
5)
After correcting valve seats, valve. Clean valves, and wash block thorough with with clean lint free rags and light engine oil.
CAUTION:
TAPPET CLEARANCE.
(.04-.05
DO
NOT ASSEMBLE VALVE SPRINGS AND SPRING RETAINERS
inch) in width.
45"
lap
seat cutter
valves in
tool
as illustrated in
place
until a uniform ring will show entirely around the face
a
hot solution
Fig.
6-3-3.
The seat should be
of
soap and water. Wipe cylinder walls
AFTER
finished
ADJUSTING
to
of
the
Fig.
VALVE
A - VALVE FACE ANGLE
I
B - SEAT ANGLE
I
C
D - VALVE STEM DIA.
MAXIMUM ALLOWABLE CLEARANCE BETWEEN
and
VALVE STEM HOLE CLEARANCE
-
GUIDE INSIDE DIA.
6-3-3
C
and
D
INTAKE
EXHAUST
INTAKE
EXHAUST
Fig.
6-3-4
I I
4
5"
45"
8
DIA.
8
DIA.
8
DIA.
0.030-0.09
0.090-0.146
+:.036
-0
-0:oss
1:::;;
(::!;::)
030
1
3168'
(
:313rr)
(
::fi::)
(.0012"-.0036")
(.0035"-,0057")
I
-1
3-
ADJUSTING
6)
*
Rotate crankshaft until tappet is in its lowest
TAPPET
CLEARANCE
position, hold valve down and insert feeler gauge between valve and tappet stem. The clearance for both intake and exhaust, with engine cold.
0.13-0.17mm (0.0051”to 0.0067“)
*
If clearance is less than specified, slightly grind valve
stem and measure it again.
*
If
clearance
is
larger than specified, sink valve seat
to adjust clearance.
*
After clearance adjustment, assemble valve springs and valve retainers, and secure them retainer locks. Check tappet clearance again for proper adjustment by turning crankshaft.
6-3-9
CYLINDER BLOCK
Detach cylinder by loosening one 8mm and five lOmm nuts.
In reassembly;
of
Remove from upper surface
cylinder, carbon deposit
which otherwise may damage piston when piston
moves. lnsert a doubling plate between piston skirt and crankcase, and set piston to the cylinder center
piston will not move easily. (Fig. 6-3-6). Stagger the piston ring gaps
Apply
oil
to piston ring and cylinder walls sufficiently.
NOTE:
5)
Use
new cylinder
Check if piston moves smoothly after reassembly.
Clamping torque of cylinder
8mm nut 170-190 kgcm
gasket.
90°
apart around piston.
is
as shown below.
(12.3-1
3.7
lOmm nut 350-400 kg-cm (25.3-29 ft-lbs.)
6-3-70.
I)
MAIN BEARING COVER
Unscrew 6mm bolt located
just
below crankshaft on driving shaft side of main bearing cover and bolts for mounting main bearing cover.
2) After setting crankshaft to the upper dead point piston, insert a
fix
crankshaft as shown in Fig. 6-3-7. Then, evenly tap
4mm
rod through 6mm screw
around the periphery of bearing cover with a soft hammer until cover breaks free from crankcase.
CAUTION:
SEA
1.
BE
CAREFUL NOT
TO
(Fig.
6-3-5)
in
place with
ft-lbs.)
DAMAGE
so
8
pieces
hole
that
of
to
OIL
HOLDER
\
MAIN
BEARING
Fig.
.
1;
Fig.
COVER
Fig.
6-3-5
:~
6-3-6
6-3-7
RING
GUIDE
d
”1
4-
In reassembly;
1) When reassembling main bearing cover, assemble governor lever shaft and governor arm before reinstalling them into crankcase.
NOTE: If replacement
of
oil seal is required, force-fit new oil seal before reassembly.
2)
When reassembling main bearing cover, apply oil to bearing surfaces, gear train, tappets, and
oil
seal lips, and form a
thin film
of
oil on main bearing cover face. Mount an oil seal guide onto .crankshaft
to
prevent damage to oil seal lips.
NOTE:
Turn crankshaft
to
TDC, and lock the balancer driven gear by inserting a
4mm
dia. rod thru the plug hole and Into a hole in
the balancer driven gear (Fig
6-38)
3) Check
if
side clearance
of
crankshaft
is
0"0.2mm,
and adjust it using adjusting collar, if needed.
4)
Clamping torque
of
mounting bolts for main bearing cover
is
170-1
90
kg-cm
(1
2.3-1 3.7 ft-lbs.).
\TJOWCl?.>nOnD*
TIMING
MARK
CAMSHAFT
Fig.
6-3-9
6-3-1 1 CAMSHAFT
and
TAPPET
1)
To
prevent tappets from falling out and being damaged when camshaft is removed, turn crankcase over on its side as
shown in
Fig.
6-3-9. Push tappets inward
to
clear cam lobes, and remove camshaft.
2)
Withdraw tappets.
NOTE: Mark them
so
that they can be reinstalled
in
the same holes.
In reassembly;
1) Put tappets back
in
their corresponding hole first and then mount camshaft.
CAUTION:
DON'T
FORGET TO MOUNT GOVERNOR SLEEVE
ON
CAMSHAFT.
2)
Timing marks
on
camshaft gear and crankshaft gear must be matched up.
If
valve timing is
off,
properly or may not run at all.
engine will not func
:tion
NOTE: Mount camshaft
so
that the marked tooth
on
crankshaft gear is between the two marked teeth of the camshaft
gear. (Fig.
6-3-9)
6-3-12 CONNECTING
ROD
and
PISTON
1)
Straighten out the bent tabs
of
rod lock washer and remove bolts from connecting rod.
2)
Remove
oil
scraper, lock washer and connecting rod cap from crankshaft.
3)
Remove piston from connecting rod by detaching two clips, and then removing piston pin.
4)
Remove piston rings from piston
by
widening open ends.
-1
5-
In reassembly;
PISTON RING
1) Use a ring expander tool becoming distorted
(See Fig.
6-3-10)
to
prevent ring from
or
broken when installing
piston.
is
If an expander tool placing the open end of the ring on first land Spread ring only far enough
not available, install rings by
of
to
slip over piston and into
correct groove, being careful not to district ring.
6-3-1
0)
NOTE:
With
or
ring first and
without expander tool, assemble bottom
work
upward, installing
top
ring last.
2) Assemble two pistons while facing maker’s
toward piston top.
CAUTION:
1.
BE CAREFUL NOT TO BROKEN THE RING.
2.
MOUNT SECOND RING
DOWN
EXCESSIVE RESUL T.
ment of rings.
PISTON
and
OTHERWISE
CONNECTING
OIL
Refer to Fig.
WITH
SCRAPER
OIL
PUMPING AND
CONSUMPTION MA
6-3-
11
for correct place-
ROD
Assemble piston and connecting rod using piston pin with clips mounted to both ends
NOTES:
7.
Measure the cfearance between cylinder and piston on thrust surface at skirt before assembly.
of
piston
pin.
onto
piston.
(Fig.
mark
EDGE
Y
Fig-
6-3-
10
TOP RING
.SECOND RING
,011
RING
If
worn out severer than specified, replace
2.
Since the piston pin center of piston for
is
offset from the center of piston by about 6 mm,
mark
set piston to the match
of
piston.
DF marks to the @ mark on the side of connecting
ASSEMBLY
I)
Assemble connecting rod
2)
Apply oil to large and
3)
Assemble the connecting rod cap matching the marks on connecting rod.
4)
Mount new lock washers and them without fail.
CAUTION: ASSEMBLE OIL SCRAPER WITHOUT FAIL,
(When engine
In
case
of
of
CONNECTING
small
is
operated while tilting
Models
so
ends
scribed at the top
B and D,
ROD
that the
@
of
connecting rod and crank pin sufficiently
it
it.
EY44-2
set
BF and
mark on its side faces flywheel side.
toward the
PTO
-1
Fig.
6-3-
11
rod
before reassembly.
So
THAT THE TAB FACES TOWARD FLYWHEEL.
shaft side, assemble oil scraper tab
on
main bearing cover side.)
6-
5)
Check
if
connecting rod moves smoothly after reassembly.
Clamping torque
of
connecting rod cap
is
250-300 kg-cm
(1
8-21.7
ft-lbs).
D
(crankshaft pin
Dia.)
W
(crankshaft
pin
Width)
PISTON TO CYLINDER AT PISTON SKIRT THRUST FACE (CLEALANCE) (.0059”L-.0074”L)
0.15OL-0.189L (.0061“L-.0070”L)
0.155L-0.177L
(.0020”L-.0098“L)
0.05L-0.25L (.0020”L-.0098”L)
0.05L-0.25L
TOP RING
SECOND RING OIL
RING
PISTON RING GAP (CLEARANCE)
SKIRT
RING
TOP RING
(.0079”L-.0157”L)
0.2L-0.4L (.0118”L-.0197”L)
0.3L-0.5L
(.0012”L-.0028”L)
0.031-0.07L
PISTON RING SIDE CLEARNACE IN GROOVES (CLEARANCE) (.0012”L-.0028”L)
0.03L-0.07 L
SKIRT RING
(.0031”L-.0044”L)
0.08OL-0.112L (.0016“L-.0042”)
0.04OL-0.107L
CONNECTING ROD TO CRANK PIN (CLEARANCE)
(.0079”L-.0197”L)
0.2L-0.5L (.0079”L-.0197”L)
0.2L-0.5L
(.001 1”L-.OO18“L)
0.027L-0.046L (.0010”L-.0019”L)
0.025L-0.047L
t
6-3-13
CRANKSHAFT
(Fig. 6-3-13)
CONNECTING ROD TO PISTON PIN (CLEARANCE)
PISTON PIN
TO
PISTON (CLEARANCE)
(.00035”T-.00039”L)
0.009T-0.010L (.0004”T--.0004”L)
0.01 1T-0.07
1
L
1)
Remove flywheel woodruf key.
2
)
Pull crankshaft out from open end
of
crankcase and
take care not to damage the
oil
seal. If necessary, loosen shaft by tapping lightly at flywheel end with
a
soft hammer.
Fig.
6-3-
72
Fig.
6-3-
7
3
-1
7-
7.
MAGNETO
7-1
MAGNETO
In Models EY33-2 and EY44-2, ignition spark is furnished by a magneto. The magneto is composed The flywheel is mounted crankcase.
7-2
BREAKER POINT ADJUSTMENT
The breaker points are mounted inside flywheel and directly assembled to crankcase. Check breaker points whenever ignition spark becomes weak. If there of
pitting or pyramidding, the breaker points must be
corrected and then, it becomes necessary to readjust the
gap to its proper clearance (0.35mm,
The normal breaker point opening is 0.35mm at full
separation. Since spark timing is regulated by point opening, use a timing light to obtain an accurate spark advance. starting pulley and flywheel from engine and observe following procedures. (see Fig.
To
adjust the breaker point opening, remove
of
the flywheel, ignition coil, lighting (charging) coil, breaker assembly (including condenser).
on
crankshaft, while ignition coil, lighting coil, and breaker assembly are directly assembled
is
evidence
0.014
inch).
7-2)
to
Remove point cover from crankcase.
in
Turn the crankshaft until breaker arm comes
of
opening Loosen contact support plate lock screw just enough to move bracket. Insert a 0.35mm feeler gauge between points. Apply and closing points. Clamp the setscrew Pull a strip After adjustment, assemble the point cover, flywheel, and starting pulley to engine.
7-3
TIMING ADJUSTMENT
The spark is timed to occur 23" before the piston reaches controlled by the breaker point opening and this advance is obtained when the breaker point opening is adjusted according to the BREAKER However, the advance timing
7-3-2.
Fig.
0.35mm).
a
screwdriver to adjusting tab, and move contact support plate just enough
of
contact support plate, and check the point gap again.
of
8
to lOmm wide white paper through closed points
POINT ADJUSTMENT
is
more accurately adjusted through the following procedures using a timing light as shown in
to
0.35mm
contact with the highest point
to
remove dust and oil.
TDC
on the compression stroke. This spark advance
(0.014
inch).
of
breaker cam (muximum point
to
obtain specified gap, while opening
of
23' is
-1
8-
For timing adjustment, the following alighment marks are provided:
D
B
type:
type:
D
mark at lower left crankcase (see
M
mark and slit on flywheel circumference
B
mark at upper left crankcase
M
mark and slit on flywheel circumference.
Fig.
7-3-1)
FLYWHEEL
Fig.
7-3-
I
For timing adjustment, the following procedures using a timing light: (See Fig-
Disconnect the stop button lead wires and the coil primary wire. Remove blower housing from engine. Connect one While the points are open, the light remains on and when the points are closed, the light is extinguished. Turn flywheel slowly counter-clockwise Then, turn flywheel very slowly clockwise the moment the light lights up. Check
the mark line is in alignment, the timing is correct. If the timing mark lines are not in alignment, then re-adjust the point opening according to the
ADJUSTMENT,
After completing the timing adjustment, re-mount the blower housing and connect the coil primary lead to the stop button.
7-4
MAGNETO
of
the timing light leads to the coil primary wire and ground the other lead
(D
type engines) or clockwise
(D
type engines) or counter-clockwise
if
the slit on the flywheel is in the time with the mark on the crankcase. When
by removing the flywheel and repeat the checking procedures
SERVICE
INSTRUCTIONS
(B
type engines) until the light extinguishes.
Fig.
7-3-2
7-32)
to
(B
type engines) and stop immediately
3)
through
5).
e-
crankcase. (see Fig.
BREAKER
7-3-1)
POINT
When engine does not start or starts with difficulty or when its operation is unstable, observe following tests to see
defect is caused by a defect in magneto.
1)
Check ignition coil for looseness, corrosion, breakage, or abrasion.
2)
Check sparking referring to “CHECKING
3)
Check if breaker points require cleaning or adjustment. (Condenser may have to be replaced in this case) See
4)
If
no spark takes place, replace ignition coil.
THE
IGNITION
“BREAKER
-19-
SPARK”,
If
they are contaminated, corroded, or pitted, replace them.
given below.
POINT ADJUSTMENT”.
if
such
a
*CHECKING
IGNITION
SPARK
Remove spark plug from cylinder head and place
it
on
cylinder head fin after connecting ignition cable to it. Crank engine
several times by starting pulley, and check if plug gap spark
is
strong
or
weak.
If
spark
is
weak, check it according to steps
1
)-3)
above. Correct plug
gap
is
0.6
to
0.7mm (.0236"".0276").
-20-
8.
GOVERNOR
ADJUSTMENT
EY33-2
and
EY44-2
employ a centrifugal flyweight type
governor which
is
mounted on a cam gear to automatically
regulate throttie valve
of
carburetor by mean
of
a lever,
so
that the engine speed is kept constant irrespective
of
load fluctuations. For adjustment, observe following procedures. (see Fig.
8-1
)
1)'
Connect carburetor throttle lever and governor lever with connecting rod, and mount them onto governor
shaft.
2) Connect governor lever and control lever with governor
Fig.
8-1
spring and install control lever to crankcase.
3)
Turn control lever counterclockwise until carburetor throttle valve
is
fully open. Lock control lever with butterfly nut.
4)
With a screwdriver inserted into groove
of
governor shaft, turn it fully clockwise or counter-clockwise until lever shaft
no
longer moves, and then lock governor lever to governor shaft by tightening clamp
nut.
-21
-
9.
CARBURETOR
9-1
OPERATION
and
CONSTRUCTION
(see
Figs.
9-1-1
and
9-1-2)
9-1-1
FLOAT
SYSTEM
The float chamber is located just below carburetor main body and serves to maint
joint action of float
valve, which is kept open while the fuel level the
float
to move
(F)
and needle valve
up.
[THROTTLE
VALVE
(NV)
incorporated. The fuel flows
is
low,
but closed when the fuel level reaches a predetermined level
from
r-BY.PASS
ain the fuel
I
.eve1 at a cons itant height by a
the fuel tank into float chamber via needle
cowing
rMAlN
NOZZLE
FLOAT
CHAMBER
Fig.
9-
,-NEEDLE
Fig.
9-
7-
1
1-2
1
VALVE
-22-
9-1-2
PILOT
SYSTEM
This pilot system feeds fuel to engine during idle and low speed operation. The fuel fed through main jet
(MI)
is measured by pilot jet
(PJ),
mixed with air measured by pilot air jet (PAJ), regulated by
pilot screw, and then fed
to
engine through pilot outlet (PO) and bypass (BP).
The fuel is mainly fed from pilot outlet
(PO)
during idling.
9-1-3
MAIN
SYSTEM
This system feeds fuel to engine during medium and high-speed operation. The air measured by main air jet
(MAJ)
is mixed into fuel through bleed holes
of
main nozzle
(MN)
and discharged to main
bore (MB) as atomized fuel where it
is
mixed with intake air through air cleaner to become an optimum air-fuel mixutre to
be supplied to engine.
9-1-4 CHOKE SYSTEM
The choke system serves to facilitate start-up in cold season. When engine is cranked with choke
(C)
closed, the negative
pressure to main nozzle
(MN)
increases to introduce fuel in large quantities to make start-up easy.
9-2
DISASSEMBLY
and
REASSEMBLY
Besides mechanical ,failures, most troubles are caused by
incorrect mixing ratio. The most common causes of such incorrect fuel-air mix­tures are clogged jets, restricted air and fuel passages, and variations in fuel level. In order to obtain the full performance
of
carburetor, it
is
necessary to keep air
cleaner and carburetor clean
so
that air and fuel flow without any restriction. Observe following disassembly and reassembly procedures.
(See
Fig.
9-2)
9-2-1 THROTTLE SYSTEM
1)
Remove Philipsscrew (1 1
),
remove throttle valve
(1
5),
and then pull out throttle shaft (1
6).
2)
Detach spring
(7)
by
unscrewing throttle stop screw
(8).
9-2-2 CHOKE SYSTEM
1)
Unscrew Philipsscrew (1 l), remove choke valve
(9),
pull out choke shaft
(IO),
and then remove choke ball
(1
2)
and choke spring
(1
3).
2)
When reassembiing choke
shaft,
place the notch of
choke valve on main air jet side.
5
7
6
1
7
8
25
24
-23-
Fig.
9-2
9-2-3 PILOT SYSTEM
1)
Remove pilot jet
2) Detach pilot screw
(5)
using a suitable tool while taking care not to damage it.
(6)
and spring (7).
In reassembly;
1)
Clamp pilot jet securely, otherwise fuel leaks, causing engine failures.
2)
If
the tapered portion of pilot screw
is
deformed, replace it with new one. Avoid clamping it
9-2-4 MAIN SYSTEM
1)
Detach main jet holder (23), and remove float chamber body
2) Detach main jet (22)
from
main jet holder
(23).
(20).
3) Remove main nozzle (2) from carburetor main body. In reassembly;
1) Clamp main jet to main jet holder securely, otherwise the fuel mixutre
2)
Tighten main jet holder to a clamping torque of 70-80 kg-cm (5.1-5.8 ft-lbs.).
9-2-5 FLOAT SYSTEM
After pulling out float pin (1 8), detach float
(1
7) and needle valve (4).
In reassembly;
When replacing needle valve, replace it together with valve seat without fail.
CAUTION: AVOID USING A DRILL
DAMAGED. CAUSING UNFAVORABLE EFFECTS TO FUEL FLOW.
OR
A WIRE WHEN CLEANING
too
tightly.
is
too
rich, and an engine disorder may result.
JETS,
OTHERWISE THE ORIFICE MAY
US€
COMPRESSED AIR WITHOUT FAIL.
h
BE
9-3
ADJUSTMENT
1)
Adjust pilot screw by turning it counter-clockwise
by
1-1/2 turn (EY33-2)
or
1-3/4 turn (EY44-2) after fully closing it
once. Avoid clamping pilot screw excessively, otherwise needle point may broken.
2) Turn throttle top screw clockwise until the specified idling speed
of
1,200rpm is obtained. If this speed exceeds
1,20Orpm, turn throttle top screw counter-clockwise.
3) Make final adjustments with air cleaner mounted and also engine at normal operating temperature.
-\
-24-
10.
RUN-IN
OPERATION
OF
ENGINE
after
REASSEMBLY
An
overhauled engine must be carefully run-in to get proper engine surface conditions on newly installed parts. A thorough
run-in operation is indispensable particularly when cylinder, piston, piston rings,
or
valves are replaced.
The recommended run-in schedule is as tabulated below.
LOAD
SPEED
EY33-2
EY44-2
TIME
I
I I
No
load
10
minutes
2500
r.p.m.
No
load
No
load
10
minutes 3000 r.p.m.
No
load
No
load
10
minutes 3600 r.p.m.
No
load
3.25
HP
30
minutes
3600
r.p.m.
4
HP
6.5
HP
60 minutes 3600 r.p.m.
8
HP
-25-
1.1.
TROUBLE
For
a satisfactory starting and running conditions
I.
The cylinder filled with a proper fuel-air mixture.
2.
An appropriate compression in the cylinder.
3.
Good spark at correct time to ignite the mixture.
If
all three requirements are not met simultaneously, an engine can not be started. There are also other factors such
as
heavy load at starting and too long exhaust pipe causing high back pressure, which contribute to hard starting.
The most common causes
11-1 STARTING DIFFICULTIES
11-1-1
FUEL SYSTEM
1)
No gasoline in fuel tank,
2)
Carburetor insufficiently choked, especially when engine is cold.
3)
Water, dirt
4) Inferior
5)
Needle valve in carburetor held open by dirt
SHOOTING
of
a
gasoling engine, the following three requirements
of
engine troubles are given below.
or
fuel cock closed.
or
gum in gasoline hindering flow of fuel to carburetor.
or
poor grade gasoline not vaporizing satisfactorily to produce correct fuel mixture.
or
gum. This condition is ascertained by c continuous fuel drip from
must
be met:
the carburetor during idling. Sometimes, this trouble is remedied by lightly tapping the float chamber with a screw driver handle
6)
Due to carburetor flooding, too much
rich
to
he ignited.
fuel
introduced
in
the cylinder through cranking, making the mixture too
When this happens, remove spark plug and turn the engine over several times with starting pulley to evac’uate over­rich mixture through the plug hole. Keep carburetor choke open during this operation. Dry spark plug thoroughly
to
and reinstall, and try
start again.
or
h
the like.
11-1-2 COMPRESSION SYSTEM
When the fuel system and the ignition system are eliminated as the cause
of
following are to be chccked for possible lack
1)
Cylinder dry after long interruption of operation.
2)
Loose
or
broken spark plug. In this case, a hissing noise
compression.
is
audible, during cranking, made by escaping mixture
of
starting difficulties and
loss
of
power, the
in compression stroke.
3)
Damaged head gasket or slack cylinder head tightening. A similar hissing noise is produced during compression
stroke.
4)
Tappet clearance incorrect. (See
If
the compression is not recovered after correcting the above faults, the engine must be partly dismantled and the following
“6-3-8,
6)
ADJUSTING TAPPET CLEARANCE”)
must he checked.
I)
Valve stuck open due to carbon or gum on valve stem.
‘7)
Piston rings stuck
in
piston
due
to
carbon accumulation. Remove piston and connecting rod from engine and
clean, correct or replace parts.
gas
-26-
11-1-3
ELECTRIC
SYSTEM
When there is no spark, the following must be checked.
3)
11-2
Disconnected cable leading to ignition coil, spark plug or contact breaker. Broken ignition coil winding, causing short circuit.
Wet
or
oil
soaked spark plug cable. Dirty or wet spark plug. Incorrect spark plug electrode gap. Short connection
of
spark plug electrodes.
Pitted
or
fused breaker points. Sticking breaker arm. Leaking
or
grounded condenser.
Incorrect ignition timing.
ENGINE
MISSES
Incorrect spark plug electrode gap. Worn and leaking ignition cable. Weak spark.
Loose connections in ignition wire.
Pitted
or
worn breaker points.
Gasoline containing water.
7)
Poor
compression.
11-3
ENGINE STOPS
1) Fuel tank empty. Gasoline contaminated with water, dirt or gum.
2) Gasoline vaporized in fuel lines due to excessive heating around engine. (Vapor lock)
3)
Vapor lock in fuel lines
or
carburetor due to the use of too volatile winter gas in the hot season
4)
Air
vent hole in fuel tank cap plugged,
5)
Seizure in rotating
or
sliding pairs in engine due to lack
of
oil.
6)
Ignition troubles.
114
ENGINE OVERHEATS
1) Crankcase
oil
supply low. Replenish immediately.
2)
Incorrect spark timing.
3)
Low
grade gasoline is used.
Engine overloaded.
4)
Restricked cooling air 5rculation.
*
5)
Cooling air partly misdirected causing loss
to
cooling efficiency.
6)
Cylinder head cooling fins blocked with dirt.
7)
Engine operated in closed space without fresh supply
of
cooling air.
-27-
8)
Restricked exhaust gas outlet.
Carbon deposit in combustion space.
9)
Engine detonating due
11-5
ENGINE KNOCKS
1)
Gasoline
2)
Engine operating under heavy load at low speed.
3)
Carbon or lead deposits in cylinder head.
4)
Incorrect spark timing.
5)
Losse
6)
Worn
7)
Engine overheated.
11-6
ENGINE
1)
Water
2)
Sticky intake valve.
3)
Overheated valves, or hot carbon particles
4)
Engine cold.
of
poor quality or low octane rating.
or
burnt out connecting rod bearing.
or
loose
piston pin.
BACKFIRES
or
dirt
in gasoline
to
low
octane gasoline with heavy load at low speed.
THROUGH
or
poor grade
CARBURETOR
of
gasoline.
in
engine.
-28-
12.
CHECKS
and
CORRECTIONS
After dismantling and cleaning the engine parts, check them, and if necessary, correct them, according to the correction table. The correction table applies whenever the engines are repaired. Its contents should be thoroughly understood by those who undertake the repairing. Its specifications must be abided by to effect correct maintenance.
Below, terms employed in the correction table are explained.
CORRECTION All operations performed
on the engine parts for the purpose
of
improving or recovering the engine performance,
consisting of repair, readjustment, and replacement.
STANDARD
SIZE
Design dimension of the part without the tolerance. CORRECTION TOLERANCE Tolerance
on
the re-finished part dimension or on the readjustment dimension.
CORRECTION LIMIT
Limit on the part and adjustment, beyond which any dimensional and functional change, due to wear, burn and other causes will adversely affect the normal engine performance.
USE
LIMIT
Limit, beyond which the part
is
no longer usable, due to defects m function or strength.
All dimensions in the CORRECTION
TABLE
are give
in
millimeter, except where otherwise specified.
-29
-
TABLE
REMARKS
USE
I
:ORRECTIOF
METHOD
STANDARD
SIZE
CORRECTION
TOLERANCE
"
"
-
"
"
-
-
-
-
"
-
-
-
-
ENGINE
MODEL
EY33-2
EY44-2
EY33-2
EY44-2
EY33-2
EY44-2
EY33-2
EY44-2
EY 33-2
EY44-2
EY33-2
EY44-2
EY33-2
EY44-2
EY33-2 EY44-2
EY33-2
EY44-2
EY33-2
EY44-2
EY33-2
EY 44-2
EY 33-2
EY44-2
EY33-2 EY44-2
EY 33-2 EY44-2
TOOL
LIMIT
1
0.05
Surface plate,
Feeler
Correct
Flatness
of
cylinder
head
0.1
5
78tJ
I
-0.010
+0.029
Bore
Roundness
Cylindricity
Valve seat contact width
Valve guide
I.D.
O.D.
at skirt, in
thrust direction
(inch. over size)
Width
of
ring
groove
Piston pin hole
Clearance between piston and
cylinder
Clearance between piston ring and ring groove
Fit between piston
&
piston pin
-
Ring gap
Ring width
0.1
5
1
-0.035
+0.057
I
0.01
Boring
t
0.01
5
Seat cutter
Cylinder
gauge
Correct
Replace
o.15
I
At middle portion
8@
1
0
+0.036
0.1 5
STD 77.87
I
0.251
,~
78.11
0.50
78.36
1
*
Mark
over size
Micro-
meter
-0.1
-0.1
Replace
-0.02
1
Vernier calipers
+0.04
+0.02
SKIRT
4.0
0.15
Replece
18@
1
+0,002
-0.009
0.035
0.035
Replace
204
1
-0.01
1
+0.002
der dia. and
Max. cylin-
at skirt in
piston dia. thrust direc.
tion
Cylinder
gauge.
Micro­meter
0.1
50-0.189
0.3
Replace
0.3
0.1
E
5-0.177
Feeler
gauge
Cylinder gauge
Micro­Meter
0.15
Replace
Replace
0.03-0.07
I0.009T-0.010L
0.06L
0.06L
I
0.01
1T-0.011 L
TOP
2nd
I
0.05-0.25
Micro-
meter
'ti-
Replace
1.5
-0.1
0.3-0.5
SKIRT
Micro­meter
-0.01
-0.03
SKIRT 4.0
Replace
-30-
ITEM
ENGINE
MODEL
STANDARD
SIZE
2ORRECTIOh
METHOD
TOOL
TOLERANCE
EY33-2
-0.008
0
Micro­meter
Piston
pin
O.D.
Replace
EY44-2
-0.009
0
E Y 33-2
EY44-2
EY
33-2
-0
+0.016
Cylinder gauge
Replace
Large end
I.D.
Clearance between rand large end
I.D.
and crankpin
Small end
I.D.
Clearance between small end
I.D.
and piston
pin
Large end side clearance
Parallelism between large end and
Distance between large end and
small end bores
Crankpin O.D.
Crankpin
O.D.
round ness
Crankpin O.D. cylindricity
Crankpin O.D. parallelism
Crankshaft journal O.D.
Cam lobe height
Journal O.D.
0.080-0.1 12 Replace
E Y 44-2
0.040-0.107
E
Y 33-2
+0.038 +0.027
Replace
EY 44-2
+0.038 +0.025
EY 33-2
Cylinder gauge.
Micro­meter
0.027-0.046 Replace
EY44-2
0.025-0.047
EY 33-2
EY44-2
Remachine or Replace
0.2-0.5
E Y 33-2
EY44-2
Test bar
&
Dial
indicator
Re-machine or Replace
0.06
EY33-2
123
EY44-2
132
-0.080
-0.096
EY 33-2
EY44-2
EY33-2
EY44-2
EY 33-2
EY44-2
EY 33-2
EY44-2
EY 33-2
EY44-2
EY33-2
E Y 44-2
EY 33-2
Micro meter
Re-machine
or Replace
35@
-0.080
-0.066
Micro­meter
0.005
Micro­meter
0.005
Dial
indicator
0.01
-0.003
-0.014
0
-0.01 1
Drive
S.
350
Mag.
S.
350
Micro-
meter
Micro­meter
Micro­meter
Replace
Replace
Replace
35
io.
1
)rive
S.
30cb
-0.003
-0.01 2
~
dag.
S.
25qj
-31
-
r
ITEM
ENGINE
MODEL
I
STAl:;RD
CORRECTION
1
TOLERANCE
,
USE
LIMIT
REMARKS
TOOL
:ORRECTIOF
METHOD
Journal O.D.
Free length
Squarences
Valve stem
Clearance between stem and guide
Tappet clearance
Clearance between
groove and retainer
Stem end length
O.D.
EY44-2
EY33-2
EY44-2
EU33--2
EY44-2
EY33-2 Intake
EY44-2
EY33-2
EY44-2
EY33-2
EY44-2
EY33-2
EY44-2
Mag.
Exhaust
S.
25@
46
-0.003
-0.01 2
I
-0.030
-0.055
-0.1 10
0.030-0.09 1
0.090-0.146
0.13-0.17
1
0.04-0.1 5
0.05
1
-1.5
-0.15
0.3
1
::E
1
-0.5
0.05
-1.5
.o
For total length
At middle
1
0.3
0.5
-0.5 Replace
Micro­meter
Vernier
calipers
Square
Micro-
meter
Feeler
Feeler Correct
Vernier calipers
Replace
Replace
Replace
Replace
Replace
Correct
Total length
Clearance between stem and guide
Mein jet unscrew
Pilot screw unscrew
plus
Spark
Spark gap
Spark timing
Point opening
-1
EY44-2
EY33-2 EY44-2
EY33-2
EY44-2
EY33-2
EY44-2 1%
E Y 33-2
EY44-2
EY33-2
EY44-2
EY33-2
EY44-2
E Y33-2
EY44-2
1
I
Fixed
1%
NG
1
B-6HS
23' before
T.D.C.
I
0'35
?0.05
I
0.025-0.062 0.2
I
f 114
K
1
-0.5
I
I
I
-0.5
0.2
#95
#125
Vernicr caliDers
Cylinder
gauge
&
Micro­meter
Replace
Replace
1 1
0.6-0.7
t0.05
1
1
1.0
+o.
1
Feeler
Timing tester
Contact breaker spanner
Adjust or
I
ace
Rep
Adjust
Adjust
-32-
ITEM
HP/rpm
MODEL
EY 33-2
8.013.600
Max. Output
EY44-2
lO.Ol3.600
EY33-2
613,600
Continuous Rated output
EY 44-2
813,600
I
I
CORRECTION
LIMIT
REMARKS
Below 11
0%
of
rated output
ITEM
REMARKS CORRECTION
LIMIT
literlhr
MODEL
EY33-2
3.1
Fuel Consumption
up 135% Standard Consumption
at Continuous Rated Output
EY 44-2 3.6
I
I
I
I
I
-
-
ITEM
REMARKS
USE
LIMIT
cclhr
cclhr
MODEL
I
I I I
Lubric~~t Consumption
EY33-2
60
30
EY 44-2 80 40
I
I
I
I I
Specified Lubricant Quality
1.4
L
I I
REMARKS
I
Use
the class SC
or
higher grade Mobile Oil
Below -10°C (14OF) SA€
1
OW-30
-10°C
(14°F)
-
2OoC
(68°F)
SA€ #20
2OoC
t68"F)
-40°C
(104°F)
SA€
#30
1
I
ITEM
I
MODEL
I
FREQUENCY
OF
OIL CHANGING
I
Oil Change
EY
33-2
First Time: Change oil after 20 hours operation
Second Time and Thereafter: Change oil every
50
hours operation
EY4.4-2
ITEM
TOOL
CORRECTION LIMIT
kglcm'lrpm
MODEL
Compression Pressure
I
EY33-2
I
5.01500
70%
of normal value
Pressure gauge
EY44-2
-33-
ITEM
MODEL
rpm
TOOL
REMARKS
Min. accelerating
revolution
ITEM
Cylinder head clamp nuts
Connecting
bolts
Magneto clamp nuts
Main bearing cover
bolts
rod
EY33-2
EY44-2
MODEL
EY33-2
EY 44-2
EY33-2
EY44-2
EY 33-2
EY44-2
EY 33-2
EY
44-2
1,150
kgcm
450-500
250-300
800-1
170-190
.OOO
Tachometer
ft-lb
32.5-36
18-2
57.9-72.3
12.3-13.7
1.7
TOOL
Torque wrench
Torque wrench
Toque wrench
Torque wrench
"
REMARKS
Spark plug
EY33-2
EY44-2
250-300
18-21.7
Torque wrench
-34-
-.
13.
MAINTENANCE
and
STORING
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
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,
re-tighten.
Check
oil
level in crankcase and add up as necessary
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 is operated without sufficient oil, it will
fail.
13-2 EVERY 20 HOURS CHECKS
and
MAINTENANCE
i
Checks and maintenance
To remove run-in wear particles.
Change crankcase
oil
Reasons for requiring them
13-3 EVERY
50
HOURS (10 DAY) CHECKS
and
MAINTENANCE
b
Checks and maintenance
Reasons for requirhg them
Change crankcase
oil
Output power
is
reduced and starting
Check spark plug. If contaminated, wash
in
Clogged air cleaner harms engine operation.
Clean air cleaner
Contaminated
oil
acceralates wear.
gasoline
or
polish with emery paper.
is made difficult.
~
.L
134 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.
The engine output drops.
~ ~~ ~ ~ ~~ ~~~
-35-
13-5
EVERY
500
-
600
HOURS (SEMIANUAL) CHECKS
and
MAINTENANCE
I
13-6
EVERY
I
13-7
PREPARATION
1)
Perform the above 13-1 and 13-2 maintenance jobs.
2) Drain fuel from the fuel tank and carburetor float chamber.
3)
To prevent rust in the cylinder hand. Re-install the plug.
4)
Turn the starting pulley
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.
Checks and maintenance Reasons for requiring them
Remove cylinder head and remove carbon deposit.
Disassemble and clean carburetor.
1000
HOURS
Checks and maintenance
Perform overhauls, clean correct or replace
parts. Change piston rings
(YEARLY) CHECKS
for
LONG
ABEYANCE
bore,
by
hand and leave it where the resistance
and
apply oil through the spark plug hole and turn the crankshaft several
The engine
MAINTENANCE
1
The engine output drops and become out
will
Reasons
is
the heaviest,
be out
for
of
order.
requiring them ~~ ~~
of
order.
turns
1
-\
-1
by
-36-
Industrial
Engines
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