Beruflich Dokumente
Kultur Dokumente
-
ROBIN TO WISCONSIN ROBIN
ENGINE MODEL CROSS REFERENCE LIST
EY08 Wf-080
EY15 W1-145
EY 15V W1-145V
EY20 W1-185
EY20V W1-185V
EY23 W 1-230
EY28 W 1-280
EY35 W 1-340
EY40 W1-390
EY45V W 1-450V
EY2 1 EY21W
-
EY44 EY44W
EY 1 8-3 EY 18-3 W
EY25 EY25W
EY 27 EY27W
EHll wo1-115
EH12 wo1-120
EH15 WO1-150
EH17 WO1-170
EH21 wo1-210
EH25 wo1-250
EH30 WO 1-300
EH3 OV WO 1-300v
EH34 WO 1 -340
EH3 4V WO 1-340V
EH43V WQ 1-430V
TWO CYCLE
EC13V WT1-125V
DlESEL
DY23 WRD1-230
DY27 WRD 1-270
DY30 WRD 1-300 1
DY3 5 WRD1-350
DY4 1 WRD1-410
CONTENTS
.
See tion Title Page
1. SPECIFICATIONS .......................................... 1
2. PERFORMANCE ........................................... 2
3. FEATURES .............................................. 4
5-1 Preparations
and
Suggestion ............................... 12
5-2 Special Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5-3 How to Disassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5-4 How to Reassemble . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Tappet Clearance Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Ignition Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Governor Setting Method . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
See rion Title Page
6. CARBURETOR ............................................ 26
6-1 Operation
and Construction ............................... 26
6-2 Disassembly
and
Reassembly .............................. 27
8. ROBINSOLIDSTATEIGNITIONENGINE(OPTION) ................. 29
8-1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
8-2 Basic Circuit andOperatingTheory of S.S. I . System . . . . . . . . . . . . . . . 29
8-3 Checking S.S.I. Unitwith Tester . . . . . . . . . . . . : . . . . . . . . . . . . . . . 29
8-4 MeasuringResistances of Exciter Coil andPulser Coil . . . . . . . . . . . . . . 29
9. TROUBLESHOOTING. ...................................... 30
10 . INSTALLATION ........................................... 33
10-1 Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-2 Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-3 Exhaust Gas Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-4 Fuelsystem . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
10-5 PowerTransmission to Driven Machines . . . . . . . . . . . . . . . . . . . . . . . 34
10-6 Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
i
-1-
2. PERFORMANCE
2-1 MAXIMUM OUTPUT
The maximum ouput of an engine is such standard power as developed by the engine, after its initial break in period with all
the m,oving parts properly worn in,when operating with a fully open throttle valve. Therefore, a new engine may not develop
the maximum output in the beginning because the moving parts are not in a properly worn-in condition.
-2-
- rpm
PERFORMANCE CURVE
MODEL EY40D
kg-m
t
2.2 (4.4)
2.1 (4.2)
10
HP
I
6
-3-
3. FEATURES
Small in size, light in weight
The cylinder and crankcase are of a one-piece aluminum diecast structure, which is light in weight. The dimensions are
reduced as much as possible for easy mounting.
Quiet operation with low level of vibration
Intake and exhaust noises are reduced by use of a newly designed muffler having glass wool and a cyclone cleaner. Ma-
chine noise is reduced by selectionof a suitable cam shaft profile and optimumclearances for inner parts. All t h s adds
up to a quiet engine. Vibration is also reduced to a low level by weight reduction of reciprocating parts, and selection
of a timing balancer and optimum balance factor.
Easy to start
These engines can easily be started because they employ an automatic decompression device and a newly designed re-
coil starter.
Wide range of adaptability
These models are available in various types of output shafts and also a type (Type B) with a built-in 1/2 reduction gear
for application to various kinds ofmachines. The engines have two oil drain ports, and theirrecoil starter can be pulled
in any desired direction. Various optional parts are also available. All these combine to increase adaptabilityto machines.
Durable, reliable and safe
A liner of special cast iron, hard-chrome-plate piston rings, forged rod, etc. are used to make these engines as reliable
and durable as the preceding models of the EY Series. Safety devices are also incorporated to assured added safety.
Fig. 1
-4-
4-2 MAIN BEARINGCOVER
The main bearing cover made of aluminum die casting is built onto the output shaft side of the crankcase so that the inside
of the engine can readily be checked by simplyremoving the cover. It is provided with a flange and boss for directly mount-
B ing machines, such as generators and pumps.
Two oil gauges also serving as oil filler caps can be mounted. . (See Fig. 2 and Fig. 3 .)
R I N G for CENTERING
O I L GAUGE
Fig. 2 Fig. 3
4-3 CRANKSHAFT
INDUCTION HARDENING
(PORTION of C R A N K P I N )
The crankshaftis forged of carbon steel, and the crankpin is
induction-hardened. It has a crank gear pressure-fitted on
-
the output end.
- (See Fig. 4.)
Fig. 4
Fig. 5
-5-
4-5 CAMSHAFT
4-6 CYLINDERHEAD
Fig. 7
. " . ". _.
.._
4-7 VALVEARRANGEMENT
Fig. 8
-6-
4-8 GOVERNOR
Fig. 9
4-9 BALANCER
Fig. 10
4-10 DECOMPRESSIONDEVICE
The intake cam has aspecial profile and the intakevalve is sligh.tly raised during the compression stroke to let a slight amou
of compressed air out tomake startingeasy. (See Fig. 11.)
TAPPET
EXHAUST IN TAPPET IN TAPPET
'.O.
SHAFT
SIDE
EXHAUST-CAM IN C A M
DECOMP L I F T
Fig. I 1
-7-
4-11 COOLING DEVICE
The cooling fan serving also as flywheel cools the cylinder and cylinder head by forced air cooling. An air guide plate and
head cover are used to let the coolingair go through.
The cooling fan employs curved bladesso Types B and D have cooling fan parts special to their own.
" . .
4-12 LUBRICATION
OIL SCRAPER
Fig. 72
Models EY35 and EY40 have a flywheel magneto type ignition system (Fig. 13) with an ignition timing of 23" before TDC
(Top Dead Center). The flywheel (also serving as fan) is fitted onto the crankshaft; and the ignition coil, contact breaker,
and charging coil are directly assembled with the crankcase. An S.S.I. electronic system (Fig. 14) is also available in types,
including a 1SO-watt load type.
The S.S.I. system, except the 150-watt type, electrically advances the ignition timing. The ignition timing after this
advance
is 23" before TDC. (See Figs. 13 and 14.)
FLYWHEEL
Fig. 13 Fig. 14
4-14 CARBURETOR
L ,
Fig. 15
Fig. 16
Fig. 17
-9-
4-17 SECTIONALVIEW OF ENGINE
/
I
RECOIL STARTER - CRANKCASE BALANCER
(OPTION)
- 10 -
FUEL TANK CAP
F U E L COCK
BALANCER
- 11 -
5. DISASSEMBLY and REASSEMBLY
5-1 PREPARATIONS and SUGGESTIONS
For your reference, the following shows special tools of Robin Engine for Disassembly, Measuring and Inspection Instruments.
~
EY10,13,14
EY15,18,20
EC05,07,10
ECf 7,25,37
EYIQ, 13.14
For mounting and
Valve Spring dismounting Valve EY15,18,20
2079500307
Retainer Spring Retainer
and Retainer Lock EY25,27,33
EY35,40,44
EYlO, 13,14
EY15,18,20
EY25,27,33
EC07,10,17
,"-
EC25,37
- 12 -
5-3 HOW TO DISASSEMBLE
*Length of the bolt indicates the length from the bolt head bottom
surface t o the threaded end.
1 Engine Drain engine oil. Be careful not tolose the Flange bolt
Drain plugs on bothsides of the the gasket.
case
2 Fuel tank (1) Close the strainer cock.
(2) Move the fuel pipe clamp (on
strainer side) downward.
(3) Remove the tank from tank 8 mm (No.2) nut . . . 4 pcs.
bracket. SpI-ing washer . . . 4 pcs.
3 Tank bracket Remove tank bracket. 10 mm flange nut . . . 4 pcs.
(tightened together with
cylinder head)
4 Air cleaner (1) Remove air cleaner cover and
element.
(2) Remove choke knob. Swivel
(3) Remove the bottom plate of 6 x 12 mm flange bolt
air cleaner. . . . 2 pcs.
5 Muffler cover Remove muffler cover. 6 x 8 (5T) Flange bolt
* . . 4 pcs.
Fig. 18
- 13 -
I I I I I
Order Item Procedures Remarks Bolts, nuts, etc. used
Fig. 19
-
Order Item Remarks Bolts, nuts, etc. used
Fig. 20
- 14-
Order Item I Procedures I Remarks I Bolts, nuts, etc. used
-
12 Fan cover (1) Remove the fan cover. Removable by loosening 6 x 8 flange bolt . . . 6 pcs.
bolts
(2) Remove the head cover.
(3) Remove the cylinder buffle. 6 x 8 flange bolt . . . 1 pce.
-
13 Starting pulley Remove starting pulley. (See Fig. 21 .) 8 x 12 (ST)bolt . . . 3 pcs.
14 Flywheel I Remove
flywheel. Be sure to use thefly-
wheelpuller. Do not
18 mm nut . . . 1 pce.
Springwasher . . . 1 pce.
crankshaft.
-
Fig. 21 Fig. 22
b
-- 15 -
Order Item Procedures Remarks Bolts, nuts, etc. used
I
15 Electric (1) Remove point cover. 4 x 12 screw and washer
devices . . . 2 pcs.
4 x 8 screw and washer
(2) Remove contact breaker. Be careful of the primary . . . 1 pce.
lead connecting direction.
(3) Remove ignition coil and con- Remove the lighting coil 6 x 25 screw and washer
- denser. before disassembly. . . . 2 pcs.
16 Cylinder head (1) Remove spark plug.
(2) Remove cylinder head. 10 mm flange nut . . . 8 pcs. 1
17 Tappet cover
(breather
plate)
Remove Tappet cover.
Be mounting
valve Of the breather
position
and the order of assembl-
I
I
6 x 14 flange bolt . . . 2 pcs.
I
ing packings.
(See Fig. 23.)
Intake and (1) Remove intake valve. Intake and exhaust valve Use valve spring retainers.
exhaust valves (2) Remove exhaust valve. springs, retainers and re-
tainer locks are common;
but be sure to set up them
on the original valves.
(See Fig. 24.)
Fig. 23 Fig. 24
- 16-
Irder I Item
19 Main bearing
~~~ ~ ~ ~~~~~
Procedures
Fig. 25 Fig. 26
- 17 -
5-4 HOW TO REASSEMBLE
EY35 E Y40
I Piston to Cylinder a t Piston Skirt Thrust Face I 0.049L - 0.108L 1 0.049L - 0.11 1 L
Piston Ring Gap (Top Ring - Second Ring) 0.1 L - 0.3L
I
-
Piston Ring Side Clearance in Grooves
(Top Ring Second Ring)
0.05 - 0.09
L: LOOSE
Fig. 27
- 18 -
5-4-3 ASSEMBLING ORDER and PRECAUTIONS
. .
1) Place the tappets into the crankcase.
TIMING MARK ON CAMSHAFT SIDE
NOTE: The intake and exhaust tappets are the same,
(Punch 2 pcskl
but mark them differently whendisassembl-
ing because of different valve clearances; and
fit them into their origianl place. Apply oil t o
the tappets beforehand.
Assemble thecrankshaft and camshaftatthesame
time.
NOTE: The same timing mark as on the crankshaft
side is punched on the crankshaft gear inward TIMING MARK ON CRANKSHA??
of the
balancer gear as shown in Fig. 28. So, (Punch 1 pce.)
Fig. 29
- 19-
5 ) Assemble thepiston and connecting rod that were
readied in Steps 3) and 4).
NOTE: The symbol @FAN mark on the connecting ~ MATCH
Fig. 32
MAIN BEARING
Fig. 33
Fig. 34 Fig. 35
- 20 -
NOTE: Check the main bearing cover joint for flaw,
and correct if necessary.
Fit the governor sleeve into the camgear
with new packing.
* Move the piston upto TDC, insertthe 4 mm
stick into the main bearing cover, and fast-
en the balancer as shown in Fig. 36.
Tightening bolt . . . . .. . 8 x 35 (7T)
Tightening torque . . .170 - 190 kg-cm
* Insert the blind plug (6 x 8 flange bolt) into
the balancer fixing hole with the aluminum
gasket, and check if the crankshaft srnooth-
Fig. 36
ly runs.
GUIDE
6-SEAT ANGLE
+0.036
C-GUIDE INSIDE DIA. 8dia.
~~~~ ~ ~
INTAKE
D-VALVE STEM OUTSIDE DIA. dia. -0.070
-0.090
MAXIMUM ALLOWABLE
INTAKE 0.030L - 0.091 L
Fig. 37
-21 -
.TAPPET CLEARANCE ADJUSTMENT
Move the piston up to compression TDC, and adjust
the tappet clearance as follows, using a grinder or the
like.
Clearance (Models EY35,EY40 intake and exhaust):
0.13 - 0.17 mm when cold
Fig. 38
Fig. 39
Fig. 40
- 22 -
10) Electrical installation
* Install the ignition coil and capacitor. rKER
Screws: 6 x 25 screw and washer . . 2 pcs. each
* Temporarily install the contact breaker.
Screw: 4 x 8 screw and washer . . . 1 pce. each
CAUTION: Be careful of the location of the cord.
---"
FLYWHEEL
Fig. 43 Fig. 44
- 23 -
*SPARK CHECK
* Clean the point surfaces of oil with paper or the like, and temporarilyinstall the flywheel.
* Hold the high-voltage wire with hand so its end is about 5 mm away from the case, and turn the flywheel in normal
direction.
* Check that a sparkis generated when the M mark on the flywheel passes the M mark on the case.
* Install the point cover.
4 x 12 screw and washer . . . . . . 2 PCS.
11)Installtheflywheel.
NOTE: Before installing the flywheef, clean the crankshaft andthe tapered part of the flywheel of oil.
16mmnut . . . . . . . . . . . . . . . . 1pce.
Spring washer . . . . . . . . . . . . . . 1 pce.
Washer. . . . . . . . . . . . . . . . . . . 1 pce.
-
Tightening torque . . .800 1000 kg-cm
12) Install the starter pulley.
8 x 12 bolt (ST) . . . . . . . . . . . . 3 pcs.
13) Install the fan cover and head cover cylinder buffle.
NOTE: Before installing the fan cover, first install the head cover on the cylinder head. Also install the muffler brack-
e t in place a t the same time.
6 x 8 flange bolt ............ 7 pcs.'
14) Install the recoil starter
NOTE: Pulling directionmay vary with machine make.
6 x 8 flange bolt . . . . . . . . . . . . 4 pcs.
15) Install thecarburetor.
NOTE: Install the carburetor with the joint sheet, insulator, and paper packing in this order.
6 mm nut . . . . . . . . . . . . . . . . . 2 pcs.
Spring washer . . . . . . . . . . . . . . 2 pcs.
Washer. . . . . . . . . . . . . . . . . . . 2 pcs.
16) Install the speed control and governor lever according
t o the arrangement of parts shown in Fig. 47. Hook
the governor spring at the proper hole.
8 mm wing nut . . . . . . . . . . . . . 1 pce.
Clip.. . . . . . . . . . . . . . . . . . . . 1 pce.
Fig. 45
- 24 -
.GOVERNOR SETTING METHOD
* Set the speed control lever to the high-speed posi-
tion, and fasten it there with the wing nut. (The
governor spring is in.)
* Checkthatthecarburetorandthrottle valve are
fully open.
* Turnthe governorshaftcounterclockwise, and
fasten the governor lever. (See Fig. 46.)
-25 -
6, CARBURETOR
SPECIFICATION
I EY35 I E Y40
BV26-20 BV26-19
Model
Part No. 2246230100 2236230100
Main Jet #107.5 #112.5
Main Air Jet $1.2 $1.5
Pilot Jet #57.5 #55
Throttle Valve #135 #150
1 Pilot Screw
(Return)
I 1 turn
PI LOT
FUEL
NEEDLE VALVE
FLOAT
FLOAT CHAMBER
Fig. 48
- 26 -
6-1 -1 FLOAT SYSTEM
The float chamber is located just below the carburetor body and, with a float and a needle valve, maintains a constant fuel
level during engine operation.
The fuel flows from the fuel tank into the float chamber through the
needle valve. When the fuel rises to a specific level, the
float rises; and when its buoyancy and fuel pressure are balanced, the needle valve close to the shut off the fuel, thereby
keeping the fuel at thereference level.
6-1 - 2 PI LOT SYSTEM
The pilot system feeds the fuelto the engine during idling and low-speed operation.
The fuel is fed through the main jet to thepilot jet, where it is metered, and mixed with the air metered by the pilotair jet.
The fuel-air mixtureis fed to the engine through the pilot outllet and the by-pass.
During engine idling, the fuel is mainly fed from the pilot outlet.
6-1-3 MAIN SYSTEM
The main system feeds the fuelto theengine during medium- and high-speed operation.
The fuel is metered by the main jet and fed to the main nozzle. The air metered by the main air jet is mixed with the fuel
through the bleed holes in the main nozzle, and the mixtureis atomized out of themain bore. It is mixed again with the air
taken through the air cleaner into an optimum fuel-air mixture, which
is supplied to the engine.
6-1 -4 CHOKE
The choke is used for easy start in the cold season. When the recoil starter is pulled with a closed choke, the negative pres-
sure applied to themain nozzle increases and drawsmuch fuel accordingly; thuseasily start up theengine.
- 27 -
6 - 2 - 4 MAIN SYSTEM
1) Remove thebolt (1 3) andtakeoutfloat chamber
body (15).
2) Remove the main jet (17) and main nozzle (1 8), using
correct tool toavoid damage t o i t ,
3) Reassembly
Fasten the main jet securely to the body. Otherwise,
the fuel may become too rich and cause engine mal-
function.
6 - 2 -5 FLOAT SYSTEM
When removing the needle valve (21) and float (20), gently
tap the reverse side using therodmore slender thanthe
float pin (19) and remove because the float pin is calked to IA 17
the carburetor body. -18
*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 19
air to blow them clean.
Fully tighten the pilot screw and then loosen it coun-
terclockwise byoneturnfor Model EY35, orone
turn and a half for Model EY40. When fully closing
the pilot screw, do not tighten it too hard. Otherwise,
the needle at the tipmight become damaged.
Turn the throttle stop screwclockwise to a normal
idling speed of 1200 rpm.
Make a final adjustment when the engineis in normal Fig. 49
operating condition at normal temperature with the correct air cleaner mounted.
LOAD
SPEED TIME
EY35 EY40
- 29 -
9. TROUBLE SHOOTING
The following three conditions must besatisfied for satisfactory engine start.
1. The cylinder filled with a proper fuel-air mixture.
2 . An appropriate compression in the cylinder.
3. Good sparks at the correct time to ignite the mixture.
The engine cannot be started unless these three conditions are met. There are also other factors which make engine start dif-
ficult, e. g., aheavy load on the engine when it is about to start at low speed, and high
a back pressure due to a long exhaust
pipe, just to say a few.
The most common causes of engine troubles
are given below:
9-1 STARTINGDIFFICULTIES
- 30 -
9-1-3 ELECTRICAL SYSTEM
Incorrect spark plug electrode gap. Adjust it to anywhere between 0.6 and 0.7 mm.
Ignition cable worn and leaking.
Sparks weak.
Ignition wire connections loose.
Pitted or worn breaker points.
Water in gasoline.
Insufficient compression.
9 - 4 ENGINE OVERHEAT
- 31 -
ENGINE KNOCKS
Low-quality gasoline.
Engine operating under heavy load at low speed.
Carbon or lead deposits in the cylinder head.
Spark timing incorrect.
Loose connecting rod bearing due to wear.
Loose piston pin due to wear.
Causes of engine overheat.
ENGINE BACKFIRES through CARBURETOR
- 32 -
10. INSTALLATION
Engine life, ease of maintenance and inspection, frequency of checks and repairs, and operating cost all depend on the way
in whlch the engine is installed. Carefully observe the following instructions for
installing the engine.
10-1 INSTALLING
When mounting the engine, carefully examine its position, the methodof connecting it to a load (machine), the foundation,
and the methodof supporting the engine.
When determining its mounting position,in particular, make sure that gasoline and
oil can easily be supplied and checked,the
spark plug and breaker can easily be checked, the air cleaner can easily be serviced, and that the oilcan easily be discharged.
10-2 VENTILATION
Fresh air is necessary for cooling the engine and burning the fuel.
In cases where the engine is operated under a hood or in a small room, temperature rise in the engine room can cause vapor
lock, oil deterioration, increased oil consumption,loss,of power, pistonseizure, 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 thehot air used for engine cooling, and temperaturerise of the load (machine).
Take steps as necessary to keep the engine room temperature below 50Ceven in the hottest period of the year.
Exhaust gas is noxious. When operating the engine indoors, be sureto 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 in-
crease in proportion to exhaust pipe length.
* Exhaust pipe: Less than 3 m long, pipeinside diameter 30 mm,
Less than 5 m long, pipe inside diameter 33 mm.
* Put safety covers over the exhaust pipe, muffler, etc.
10-5-1 BELT D R I V E
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.
- 33 -
10-5-2 F L E X I B L E COUPLING
When using a flexible coupling, runout and misalignment between the driven shaft and engine shaft must be minimized.
Runout and misalignment tolerance are specified by the coupling manufacturer.
10-6 WIRING
Models EY35 and EY40 are available in types that have the ignition and starting systems shown in the wiring diagrams
below.
lines in the diagram arenot normally supplied with the engine.
The parts indicated by dotted
- - - - - - - --1
E
Green/Yellow
SPARK PLUG
BUZZER
Fig. 52
[ELECTRIC STARTER TYPE]
MAGNETO
KEY SWITCH
ELECTRIC
STARTER
MAGNETIC
SWITCH
Fig. 53
[S.S.I. with RECOIL STARTER and LIGHTING COIL]
MAGNETO
SPARK PL.UG
STOP BUTTON
I
J,
BUZZER
6V8W @
* QLAMP 12V15W
Fig. 54
- 34 -
[S.S.I. with ELECTRIC STARTER]
KEY SWITCH
BATTERY
12W24AH
CHARGING COIL
12V24AH
""_
-
[
""-I
Black/White
A Red
E L Z R I C STARTER
Fig. 56
* The symbols shown in the wiring diagrams above signify the following.
"""- Not mounted on the engine
- -
JIS CB104 jack
D
-- JIS CA104 plug
@ JIS LA104 or LA108 plate terminal
* In the wiring diagram showing the circuit with a recoil, the ignition coil is optional, and therefore is not supplied on
the standard models.
- 35 -
10-7 VINYL-INSULATED WIRE
Recent engine sets become complex,and anincreasing number ofthem are remote-controlled.
When designing or repairing such machines, special care must be taken in selecting their wire. Select the correct wire from
the table below by considering the following.
FACTORS TO BE CONSIDERED
* Amperage
* Current flowing time (continuous, intermittent)
* Wire length
* Mechanical strength of wire against vibration
* Wire size versus resistance
* Electrical resistance increases with wire length, and decreases as conductor diameter increases. Resistance also varies
with material even if size and length are the same.
* Nominal size means the nominal area of steel wire expressedby 00 square (SQ).
- 36 -
11. CHECKS and CORRECTIONS
After disassembling and cleaningthe engine, check and repair,
if necessary, according to the correction table. The correction
table applies whenever the engines are repaired. It is important for the servicemen to be familiar with the contents of tlus
table. Correct maintenance is recommended by observing the correction standardsspecified.
The meanings of the terms usedin the correction table are as follows:
Correction
1)
Repair, adjustment orreplacement of any engine parts.
2) CorrectionLimit
The limit on wear, damage or functional deterioration of engine parts beyond which normal engine performance can-
not be expected without repairing such parts.
3) Use Limit
The limit beyond which parts can no longer be used in respect
of performance.or strength.
4) StandardDimensions
The design dimensionsof new parts minus tolerance.
5) CorrectionTolerance
Tolerance on thedimensions of engine parts refinished or adjusted.
- 37 -
12. TABLES OF CORRECTIONSTANDARDS
-
ITEM
ENGINE STANDARD T CORRECTION T USE
REMARKS TOOL
CORRECTION
MODEL SIZE TOLERANCE LIMIT LIMIT METHOD
Surface
Flatness of cylinder EY35 0.05 0.1 5 plate, Correct
head EY40 Feeler
Cylindricity EY 35 0.01 5
EY40
-
Valve seat contact EY35
width EY40 1.2-1.5 2.5 Correct
EY 35 +0.036 At middle
Valve guide I.D. 8 dia. 0.1 5 0.1 5 Replace
EY40 0 portion
EY35 0.048
0.108
- Max. cylin-
der dia. and Cylinder
Clearance between piston dia. gauge,
piston and cylinder
EY40 0.048
0.1 11
- 0.025 0.025 at skert in
thrust direc-
tion
Micro-
meter
Replace
EY35
Top
2nd
0.05
0.09
-
Clearance between
pisition ring and 0.1 5 0.1 5 Replace
ring groove
EY40
Cylinder
F i t between piston EY35 0.011 T gauge,
and piston pin EY40 0.011 L Micro-
meter
EY35
TOP
2nd
0.1 - 0.3 1.5 1.5
Ring gap Replace
EY40
Oil 0.2 - 0.9
-
- 38 -
ITEM
1 ENGINE1
MODEL
t
STANDARD
SIZE
1 CORRECTION
LIMIT
USE
TLO
IM
1 REMARKS
L IETR A N C E 1 CORRECTION
METHOD
I
+
Micro-
Piston p i n 0.D. -0.03 Replace
meter
33
Small end I.D.
EY15
20 dia. I +o.02 1 0.08 0.08
Cylinder
gauge
Replace
:L."--
a
EY15
EY20
I 0.02 - 0.042
0.12 0.12 I Cylinder
gauge,
Micro-
Replace
1
meter
V
Large end side
clearance
0.1 - 0.4 1.0 1 Feeler
gauge
Re-machine
or Replace
1
small end bores
0'15
Crankpin O.D.
EY35
EY40
I -0.070 - -0.080 I 0.1 5
I
Micro-
meter
Re-machine
or Replace
Crankpin O.D.
roundness
EY15
EY20
1 Less than 0.005
0.5
Micro-
meter
Re-machine
or Replace
1
EY15 Micro- Re-machine
Eb cylindricity
Crankpin O.D.
EY20
Less than 0.005
meter or Replace
Crankpin O . D .
parallelism EY 20
EY15 I Drive 5. 25 dia.
Less than 0.01
~~~~ ~
Re-machine Dial
gauge or Replace
I Cam lobeheight
EY35B
Intake
36
Exhaust 35.5
Drive S. 35 dia.
to.1
-0.003
-0.014
-0.003
-0.25
I
-0.25
Micro-
meter
Replace
Drive S. 17 dia.
,.
-0.012
n.
-0.01 6 P
- 0.05
0.05 0.05 meter
Replace
EY35D -0.027
I."&,
Mag. S . 17
dia. -0.01 6
-0.01 7
- 39 -
1
ITEM
LIMIT 1 REMARKS 1 TOOL CORRECTIOP
METHOD
i
-0.003
Drive S. 35 dia.
-0.014
EY4OB
4- -0.003
.4-
Mag. S. 25 dia. -0.01 2 Micro-
5 Journal OD. 0.05 0.05 Meter
Replace
-0.016
Drive S. 17 dia.
-0.027
EY40D
-0.027
EY35
EY40
46 1 -1.5 -1.5
Vernier
calipers
Replace
EY35
EY40
1 !Square
feeler
Qawe
Replace
Correct
w
4= II
I Clearance between
grooveandretainer
0.04-0.1 5 Replace
1 1
E - 1I
Stem end length
Total length
EY35
EY40
5.3 -0.5
-L
-0.5 I
Vernier
calipers
Vernier
calipers
Replace
Replace
Clearance between
stemandguide
EY35
EY40
1 0.025-0.062 0.2
Cylinder
gauge &
Micro-
Replace
meter
I
I I
EY35I
( 1
+1/4
Pilot screw I
unscrew EY40 I 1%
71 Spark plug
EY35
EY40 B-6HS
EY40
EY35 I 0.6 - 0.7 I 1.0
Adjust or
replace
EY35 i 3O f 5"
Timing
23'before T.D.C. . tester
Adjust
EY40
I Point opening
EY40
Adjust
-40 -
ITEM MODEL
~~~
EY35 8.514000
Max. Output Below 1 10% of rated output
EY40 10.0/3,600
EY35 7.013600
Continuous Rated
output
EY40 8.013600
I
EY35 2.9
Fuel Consumption Up 135% of standard consumption At continuous rated output
EY40 3.5
1 I I 1
Lubricant
EY35 25 - 30 60
Consumption
EY40 30 - 40 80
EY35
Fixed quantity
1.2
of Lubricant
EY40
EY35
First time: Change oil after 20 hours operation.
Oil Change
Second Time and Thereafter: Change oil every 50 hours operation.
EY40
ITEM
I
MODEL
EY35
I
I
kg/cm'/rpm
I
CORRECTION LIMIT
I
TOOL
I
REMARKS
1
- 41 -
- ITEM MODEL rpm TOOL REMARKS
,-
Min. accelerating
Crankshaft
revolution
EY35
Cylinder head
340- 390 24.6-28.3 Torque wrench
clamp nuts
EY40
EY35
Connecting rod
bolts EY40
250 - 300 18-21.7 Torque wrench
Magneto
clamp
nuts 1 EY35
EY40 1 800-1000
57.9-72.3 Torque wrench
Spark plug
EY 35
EY40
260 - 290 18.8-21 Torque wrench
-42 -
13. MAINTENANCE and STORING
The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated main-
tenance intervals are by no means guarantees for maintenance free operations during theseintervals.
For example, if the engine is operated in extremely dusty conditions, the air cleaner should be cleaned every day instead of
every 50 hours.
Remove dust from whatever parts which The governor linkageis especially susceptible to dust.
accumulated dust.
Check external fuel leakage. If any, retighten or Not only wasteful butalso dangerous
replace.
Check screw tightening.If any loose one is found, Loose screws and nuts will result in vibration
I re-tighten. 1 accidents.
maintenance
Reasons and Checks for
themrequiring 1
I Change crankcase oil. 1 TO remove run-in wear particles I
13-3 EVERY 50 HOURS (10 DAYS) CHECK and MAINTENANCE
I maintenance
and
Checks Reasons for requiring them 1
Clean fuel filter and fuel tank. The engine will be out of order.
Clean contact breaker points. The engine output drops.
-43 -
13-5 EVER'.' 502 - 600 HOURS (SEMIANNUAL) CHECKS and MAINTENANCE
Remove cylinder head and remove carbon The engine will be out of order.
deposit.
Disassemble and clean carburetor.
Perform overhauls, clean, corrector replace The engine output drops and become out of order.
parts.
Change piston rings.
- 44"
Industrial
Engines