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Page Count: 35

SERVICE
MANUAL
Model
EC13V
1193S122
ROBIN
AMERICA, INC.
ROBIN
TO
WISCONSIN
ROBIN
ENGINE
MODEL
CROSS REFERENCE
LIST
ROBIN
EY08
EY15
EY 15V
EY20
EY2OV
EY23
EY28
EY3
5
EY40
-
EY45V
EY2
1
EY44
EY 18-3
EY25
EY27
EH11
EH12
EH15
EH17
EH21
EH25
EH30
EH30V
EH34
EH34V
EH43V
EC13V
DY23
DY27
DY30
DY3
5
DY4 1
WISCONSIN
ROBIN
SIDE
VALVE
W
1-080
W1-145
W1-145V
W1-185
W1-185V
W1-230
W 1-280
W
1-340
W 1-390
Wl-45OV
EY21W
EY44W
EY18-3W
EY25W
EY27W
OVERHEAD
VALVE
WO1-115
wo1-120
WO1-150
WO1-170
wo1-210
WOl-250
WO 1-300
WO1-300V
WO1-340
WO
1
-340V
WO 1-43 OV
TWO CYCLE
WT1-125V
DIESEL
WRD
1-230
WRD
1-270
-1-300
WRD1-350
WRD1-410
0
0
0
FOREWORD
This manual covers the construction, function and sevicing procedures of the
Robin
I
engine
model
EC13V.
Good operation and a planned maintenance program as outlined in this manual are
of
vital importance in obtaining maximum engine performance, and long engine life.
Careful observance of the instructions will result in better, safer service work,
IMPORTANT:
All information, illustrations, directions and. specifications in this
book are
on
the basis
of
information available at the time it was written.
Fuji Heavy Industries Ltd. reserves the right to make changes without incurring any
obligation whatever.
No
part
of
this publication may be reproduced without written permission.
Recoil
Starter
\
Fuel
Tank
Carburetor
I:
P.T.O.
Shaft
Lever
Section
Title
Page
1
.
SPECIFICATIONS
...........................................
1
2
.
PERFORMANCE
...........................................
2
2-1
Maximum Output
......................................
2
2-2 Continuous Rated Output
...............................
2
.
2.3 Maximum Torque and Fuel Consumption Ratio
at
Continuous Rated Output
...............................
2
3
.
FEATURES
...............................................
3
4
.
SECTIONAL VIEW
of
ENGIN€
...............................
4
5
DISASSEMBLY and REASSEMBLY
6
.
............................
5-
1
Preparations and Suggestions
.............................
6
5-3 Disassembly and Reassembly Procedures
....................
8
5-2
Special
Tools
.........................................
7
6
.
MAGNETO
...............................................
17
6-1
Operation
of
the
Ignition System
..........................
17
6-2 Ignition System Check
..................................
18
6-3
Ignition Unit Installation
................................
18
7
.
GOVERNOR
..............................................
19
7-
1
Construction and Operation
..............................
19
7
-2 Governor Adjustment
...................................
20
7-3 High Speed Adjustment
.................................
21
8
.
BREAK
IN
OPERATION
of
REASSEMBLED ENGINE
.............
22
9
TROUBLE SHOOTING
.....................................
23
9-1 Starting Difficulties
.......
:
............................
23
9-2 Slow-speed
out
of order
.................................
24
9-3 Overheating and Knockjng
...............................
24
9-4
PowerDrop
..........................................
24
9-5 Excessive Fuel Consumption
.............................
24
9-6 Engine Hunting
.......................................
25
9-7 Other Complaints
......................................
25
10
.
CHECKS and CORRECTIONS
.................................
26
11
.
CLEARANCE DATA
and
LIMITS/TORQUE SPECIFICATIONS
......
27
12
.
MAINTENANCE
and
STORING
...............................
29
12-
1
Daily Checks and Maintenance
............................
29
12-2 Every 50 Hours
(10
days) Checks and Maintenance
............
29
12-3
Every 100
-
200
Hours (Monthly) Checks and Maintenance
..... 29
12-4
Every
500
-
600
Hours
(Semiannual) Checks and Maintenance
...
29
12-5 Every 1000 Hours (Yearly) Checks and Maintenance
...........
30
12-6 Preparation
for
Long Storage
.............................
30
1
SPECIFICATIONS
Model
EC
13V
Type
.
Air-cooled, 2-Cycle, Vertical Shaft, Single Cylinder Gasoline Engine
Bore x Stroke
Piston Displacement
56
mm x
50
mm.(2.20
in
x
1.97
in)
3.2 HP/3600 rpm
(2.4
KW/3600 min"
)
Continuous Rated Output
Fuel Consumption Ratio
Automobile Gasoline (mixed with oil)
Fuel
Horizontal Draft, Float Type
Carburetor
2-Cycle Engine
Oil
Lubricant
Gasoline Oil Mixing Type (Mixing Ratio
50
:
1)
Lubrication
Forced Air Cooling
Cooling System
Counter-clockwise facing to P.T.O. shaft
Rotation
0.8
kg-m/3000 rpm
Max. Torque
4.2
HP/4000
rpm
(3.1
KW/4000
min"
)
Max. Output
.,
123
cc
(7.49
cu. in)
(gr/HP-h)
1
360
at
continuous rated output operation
I
Fuel Feed
Approx.
2.0
liter
(0.53
U.S.
gal.)
Fuel Tank Capacity
Gravity Type
Speed Governor
I
Centrifugal Flyweight Type
I
Ignition System
.
11.2 kg
(24.7
Ibs)
Dry Weight
Recoil Starter
Starting System
NGK BMGA or CHAMPION CJ8 Spark Plug
Flywheel Magneto Type
(Solid
State
Igntion)
Length
400
mm (1
5.7
in)
Dimensions Width
334
mm (13.1 in)
Height 331 mm (13.0 in)
-1-
2.
PERFORMANCE
r\
2-1
MAXIMUM OUTPUT
\
The maximum output
of
the engine
is
the power delivered by the engine running with full throttle opening
after the engine is throughly broken in.
A
brand new engine may not produce this maximum output until it has been sufficiently broken in.
2-2
CONTINUOUS RATED OUTPUT
The continuous rated output
of
the engine is the power delivered by the engine running at
an
optimum speed
most favorable
for
engine life and fuel consumption. When designing an equipment driven by an engine, it is
most important to keep the power requirement less than continuous rated output of the engine.
2-3
MAXIMUM TORQUE.and FUEL CONSUMPTION
RATIO
AT CONTINUOUS RATED OUTPUT
The maximum torque curve
of
the engine
is
the output torque curve at
P.T.O.
shaft when the engine is run-
ning with full throttle opening.
Fuel consumption ratio at continuous rated output is the one while the engine is delivering continuous rated
output.
HP
PERFORMANCE CURVE
kg-m
"
2400
2800 3200 3600
4000
Revolution
____)
r.p.m.
-2-
0
3.
FEATURES
"
1.
CRANKSHAFT: Forged steel crankshaft assembled with induction hardened crankpin, precision bal-
anced for low engine vibration, durability, greater shock loading resistance and longer life.
2.
BEARINGS: Ball bearings at both ends of crankshaft and needle roller bearings
at
small end and large
end of connecting rod give less friction, better radial support, maximum side loading capability and
longer life.
3.
ALUMINUM 'CYLINDER and CRANKCASE: Aluminum die-cast cylinder with molded-in cast iron
liner makes the engine light in weight with extra strength, durability, lower oil consumption and longer
life.
4.
AIR CLEANER: Rugged dual stage. air cleaner with high efficiency, ease of service and longer engine
life.
5.
SOLID STATE IGNITION: Solid state, high energy electronic ignition gives more precise ignition tim-
ing, hotter spark for easy starting, no breaker points
to
service, ease
of
maintenance and longer spark
plug life.
6.
ALL-SPEED GOVERNOR: Rapid response mechanical flyweight type governor system is fully lubri-
cated with oil mixed .fuel for long life and which enables more precision speed regulation and better reli-
ability.
.
This all-speed governor system enables the setting for any desired speed by simply moving the control
lever.
7.
CARBURETOR: Precision modern design with butterfly throttle and choke. Removable fixed jet and
float type design gives maximum fuel economy and ease
of
starting.
8.
PISTON: High strength aluminum alloy piston--is specially designed
for
durability and longer life.
9.
PISTON RINGS: Two ring design. Chrominum plated top ring and perkarized second ring give smooth
running and durability.
10.
FUEL TANK: Large, no rust'resin tank gives.trouble-free long operation.
-3-
4.
SECTIONAL VIEW
of
ENGINE
Flywheel
\
/
Recoil Starter
P.T.O.
Shaft
-4-
Connecting
Rod
\
-5-
5-
1
-4
REASSEMBLY
1)
Before reassembly, wash parts in kerosene and blow them with compressed air.
2)
Apply mobile oil on the rotating and sliding surface.
3)
Take care not ‘to contaminate the parts with dust during reassembly.
4)
Be sure to assemble those parts.provided with alignment marks by bringing the marks in alignment.
5)
Tighten bolts, nuts and screws to the correct torque specified. When there is no torque specification,
tighten them to torque readings appropriate to the size.
Standard Tightening Torque
for
screws are as follows:
6
mm
.............
90
kg-cm
(6.5
ft-lbs)
8
mm
..............
250
kg-cm
(1
8
ft-lbs)
10
mm
.............
370
kg-cm
(26.7
ft-lbs)
If small screws are tightened too hard, they may get broken. Tighten the large size nuts such as ones for
the magneto flywheel, enough by giving hammer blows on the socket wrench handle.
When tightening the several screws fastening the single part, tighten them all evenly, by alternately tight-
ening diagonally located pairs.
6)
Do not apply oil to the part to which packings or sealing agent to be applied.
7)
When engine is completely reassembled, make sure that there
is
no parts remained.
8)
During the assembly, turn the moving part by hand
to
check for friction and noise.
9)
After the completion
of
reassembly, turn the engine by hand, and check if there is any disorder
or
loose
members.
0
5-2
SPECIAL
TOOLS
Part
No.
2099500407
Tool
Flywheel Puller
(without bolt).
Use
For
pulling
off
Flywheel
Applicable
Model
All Robin
gasoline engines
Shape
-7-
5-3
DISASSEMBLY
and
REASSEMBLY PROCEDURE
5-3-1
FUEL
TANK
and
FUEL
TANK
BRACKET
1)
Disconnect fuel pipe from carburetor.
2)
Remove mounting bolts, and detach fuel tank and fuel tank bracket from crankcase and blower housing.
CAUTION: Rep face fuel pipe once a year in order to prevent
from
the
danger of fuel leakage caused by
the
cracks.
Tank
Band
Fuel
Tank
Bracket
n
I
Fuel
Pipe
Fig.
1
-8-
5-3-2
AIR
CLEANER
0
1)
Remove air cleaner cover and element.
2)
Unscrew two nuts and bolts which clamped air cleaner base plate to carburetor and remove base plate.
In reassembly, wash element based on the following procedure before reassembly:
1)
Wash outer and inner elements with detergent and dry them thoroughly.
2)
Soak them in the mixture of
2
-
4
kerosene and
1
engine oil, and squeeze the outer element to remove
excess oil.
5-3-3
CARBURETOR
1) Remove governor rod and rod spring from carburetor.
2)
Remove carburetor from cylinder block.
’
In reassembly:
Refer
to
section
“7.
GOVERNOR.”
..
5-3-4
GOVERNOR
LEVER
1
1) Remove governor lever from governor shaft.
2)
Remove governor spring from control lever.
In reassembly:
Refer to section
“7.
GOVERNOR.”.Assembly shall be made correctly including engine speed adjustment.
Screw
Cleaner Element
\
Fig.
2
Cleaner Cover
-9-
5-3-5
MUFFLER
Unscrew nuts and remove it from cylinder.
5-3-6
BLOWER
HOUSING
Unscrew bolts and remove blower housing from crankcase and cylinder head.
,
Nut
”-%
5-3-7
RECOIL STARTER
1)
Remove recoil starter from blower
housing
by
unscrew
4
x
M6
bolts.
2)
Remove starting pulley from flywheel by loosing bolts clamped.
NOTE:
Unless
it
is necessary,
do
not disassemble recoil starter
as
special tools are required
for
reassembly.,
Muffler
Bolt
Recoil Starter
Starting Pulley
Cylinder
Baffle
Bolt
Fig.
3
-
10-
5-3-8
MAGNETO
and
FLYWHEEL (Fig.
4)
1)
Remove flywheel from crankshaft.
Apply a socket wrenchover the nut at the end
of
crankshaft and give the wrench handle a sharp
blow with
a
hammer.
Remove nut and spring washer. Attach flywheel
puller. to. flywheel as illustrated in Fig.
4,
turn
the center bolt clockwise until flywheel comes
loose enough to be removed.
2)
Remove spark plug cap from high tension cable
of
ignition coil. Then, remove ignition coil from
crankcase.
In reassembly:
Refer to section
“6.
MAGNETO.”
Ignition
Coil
Bolt
=u
Flywheel Puller
Fig.
4
Flywheel
/
I
Crankshaft
Spark
Plu’g
Cap
Fig.
5
-
11
-
Washer
Spring
Washer
Nut
Fig.
6
-
13-
In reassembly
:
.PISTON
RINGS
(Fig.
7
and
8)
If an expander
is
unavailable, install the ring by placing the open ends of the ring on first land of piston, then
spread the ring only far enough
to
slip over the piston and carry it into the correct groove.
CA
U
TI0 NS:
I)
Be extremely careful not to distort and break the ring.
2)
Put the open ends of piston rings to the knock pins in the grooves. (This
is
to prevent the rings from
3)
Assemble the rings in the order of the 2nd ring and then top ring. (Fig.
8)
rotation while operating the engine.)
Top
ring
.....................
Chromium plated surface (looks white silver in colour)
2nd ring
......................
Perkarized surface (looks dark in colour)
r”\
\’
Fig.
7
Fig.
8
Top
Ring
Second
Ring
.PISTON
1)
Position the
“F”
mark of piston top
to
flywheel side and reassemble the piston and connecting rod with
the needle bearing by gently striking the piston pin.
CAUTION: Apply oil
to
the needle bearing before reassembling
it
to piston pin.
2)
Assemble piston pin clip.
CAUTION: Replace piston pin clip
if
there
is
any looseness after reassembling
it.
3)
Be sure that piston and connecting rod
move
smoothly after reassembled.
-
14
-
5-3-12
CRANKCASE
Unscrew
5
bolts which fasten upper and lower parts of the crankcase, and divide the crankcase into two parts
by tapping with soft hammer, and detach crankshaft connecting
rod
assy.
In reassmbly:
1)
Before reassembling upper and 'lower parts
of
the crankcase, check bearing and oil seals if there is any
2)
Apply
oil
to
the bearings
of
crankcase and ascertain that there
is
no warp on the lip
of
oil seal.
damage, and in case
of
any damage being found, replace them with new ones.
Tightening torque
is
90
-
100
kg-cm
(6.5
-
7.0
ft-lbs).
Clean the joint
of
both crankcases and apply sealing agent to the fitting surfaces of both crankcases.
As-
semble the crankshaft and join both crankcases with press (or tap them with a soft hammer) having extra
care not to damage the oil seal.
CAUTION:
When reassembling the crankcase, tighten the diagonally located pairs
of
bolts according to
the specified tightening torque.
NOTE:
After reassembling the crankshaft to the crankcase, check
if
the crankshaft rotates smoothly,
5-3-13
CRANKSHAFT
and
CONNECTING ROD ASSY
Do
not take apart the crankshaft and connecting
rod.
Crankshaft and connecting rod assembly is supplied as a spare part.
Crankshaft
-
15-
5-3-14 GOVERNOR’PLATE
’
Pull out governor plate, governor sleeve from crankshaft.
In reassembly:
Reassembly
is
just reverse
of
disassembly sequence.
5-3-15 GOVERNOR SHAFT
1)
Unscrew
2
screws
and
remove governor yoke.
2)
Pull out governor shaft
from
crankcase.
NOTE:
Do
not
disassemble
unless
it
is
required.
In reassembly:
Refer to
section
“7.
GOVERNOR.”
5-3-16 CONTROL LEVER
Unless it is required,
do
not remove control lever from crankcase.
For disassembly and reassembly procedures, refer to section
“7.
GOVERNOR.”
Choke Rod
Governor Yoke
Governor Plate
Governor Shaft
Choke Rod
Governor Yoke
Governor Plate
Governor Shaft
’I
Flange Bolt
.
Choke Lever
Fig.
10
-
16-
a
6.
MAGNETO
-
EC13V
engine is equipped with a pointless Solid State Ignition system. This is a circuit breaker type ignition
device which utilizes the power transist,or as an element for controlling electric current.
This system is free from start-up failure due to dirty, burnt
or
oxidized point surfaces, low ignition efficiency
because of moisture, rough' breaker point surface and incorrect timing resulting from worn mechanical parts.
6-1
OPERATION
of
the
IGNITION SYSTEM
This system is referred to as T.C.I. (Transistor Con-
trolled Ignition) system.
As illustrated in Fig.
1 1,
this is a simple system, con-
sisting
of
a flywheel with magnetic fields, an ignition
coil with built-in transistor, and lead wires to spark
plug and stop switch.
Rotation
of
the flywheel generates
a
voltage on the
primary side of the ignition coil.
By
this voltage, electric current (11
)
flows
through
the resistor (RI) to the base
of
the power transistor.
This current actuates the transistor to permits the
amplified flow of current
(IC).
With further rotation of the flywheel, the voltage at
IGNITION
COIL
WITH
BUILT-IN TRANSISTOR
*
BLACK
a
0
Fig.
11
WIRING DIAGRAM
SOLID STATE IGNITION
the point
@
reaches up to the trigger voltage of the
thyrister (SCR) and the current
(13)
flows eliminat-
ing current (11). At this moment, current (IC) is cut
off abruptly resulting in high voltage on the second-
ary side of the ignition coil, which in turn fires the
spark plug.
RESISTOR
IGNITION
COIL
Fig.
12
.
T.C.
IGNITION CIRCUIT
-
17
-
6-2
IGNITION SYSTEM
CHECK
In the event of malfunction of the ignition system, check the followings at first:
0
Broken, frayed, loose
or
disconnected ignition wires.
0
Faulty spark plug-wet, dirty, insulation broken
or
incorrect plug gap.
'
If difficulty
is
experienced in starting the engine or if engine misses firing, the strength of the ignition spark
should be checked:
Remove spark plug-then with the ignition cable connected to it, lay the spark plug on a convenient metal
part of the engine
so
that the gap can be observed as
you
rotate the crankshaft several times by means of the
recoil starter. If a good strong spark occurs, the ignition system can be eliminated as the source
of
trouble. If
there is a weak spark
or
no
spark at all, check the ignition system as follows':
1)
Check to make sure that the external magnet, mounted on the flywheel is in a good condition.
2)
Since the solid state ignition unit is self-contained, the only testing which can
be
performed is
on
the
secondary coil resistance.
Using a good quality ohm-meter, check the secondary coil resistance between the plug terminal of the igni-
tion cord and the core
of
the ignition coil.
This resistance reading should be approximately 13,000
ohms
f
10%.
If the resistance reading is infinite, this
indicates open winding in the ignition unit, a loose or broken spark plug connector or a failed high tension
lead.
If a very low reading is taken, the secondary coil
is
probably shorted. If, after testing, the ignition unit itself
is determined to be faulty, then it will have to be replaced.
6-3
IGNITION UNIT INSTALLATION
When installing the ignition unit on the crankcase,
use a non-metallic feeler gauge
to
measure the air-
gap between the ignition coil and flywheel. The igni-
tion coil can be moved to adjust the air-gap by loos-
ening its holddown screws.
Adjust the air-gap between
0.4
-
0.5
mm
(0.0
16"
-
0.02").
NOTE:
Fig.
13
If the flywheel
is
removed,
wipe
off
oil
and grease thoroughly from the tapered portion
of
the crank-
shaft
and
flywheel before reassembly.
Tightening Torque for flywheel nut
390
-
420
kg-cm
(28
-
30
ft-lbs)
n
'\..
I
J
-
18
-
7.
GOVERNOR
7-1
CONSTRUCTION
and
OPERATION
A
centrifugal flyweight type governor is used. The governor plate, governor sleeve and governor yoke are in-
stalled in the crankcase, and lubricated by the oil mixed -fuel.
As
the engine speed fluctuates, flyweights on the governor plate, rotating together with the crankshaft,
changes its opening angle and moves the governor sleeve, which in turn rotates the governor shaft through
the governor yoke. The governor lever
is
connected to the extending part
of
the governor shaft and this
governor lever is connected to the carburetor throttle lever through the governor rod
at
the other end; thus
the throttle valve is opened
or
closed and engine speed and output are controlled.
When the crankshaft speed increases, all the relevant members move in the direction indicated by
+a-
marks
and the carburetor throttle valve closes, reducing the fuel supply and consequently reducing the speed and
output. When the crankshaft speed decreases, the same members move in the direction indicated by
-e
marks and the carburetor throttle valve open, increasing the fuel supply and consequently recovering the fail-
ing speed and output.
Throttle Valve
Choke Valve
Fig.
14
-
19-
7-2
GOVERNOR ADJUSTMENT
The governor system should be adjusted at reassembly
by
the following procedures.
f-7
\
1)
Connect governor rod and rod spring to carburetor throttle
lever
and governor lever, then install governor
lever to governor shaft.
NOTE:
Never tighten the set screw for the adjusting plate at this time, and
do
not fix adjusting plate,
governor lever and
governor
shaft.
2)
Connect governor lever and control lever with governor spring, and install control lever to crankcase.
And the governor adjustment is to be made in the following sequence:
a) Attach the governor lever on the governor
b)
To
the governor shaft, fasten temporarily the
adjusting plate with nut and spring washer.
c)
To
the governor lever, fasten temporarily the
adjusting plate with screw and washer assy.
At this moment, the adjusting plate is free to
move. (See
Fig.
15.)
d)
Push down the adjusting plate downward
and tighten the screw. (See
Fig.
16.)
e,) Set the speed control lever at the position
“High,” and tighten the nut. (See
Fig.
17.)
shaft.
Fig.
16
I
Nut
Screw
and
Washer
Assy
Fig.
15
Fig.
17
fl
\,
”
-
20
-
7-3
HIGH
SPEED ADJUSTMENT
(Fig.
16)
7-3-1
WHEN
NO
TACHOMETER
Is
AVAILABLE
Unless required in the process
of
disassembling, do not remove control lever and/or other related parts from
crankcase. If it
is
necessary to remove them, never turn high speed stopper bolt on control lever (Fig.
18).
7-3-2
WHEN
A
TACHOMETER
IS
AVAILABLE
1)
Install control lever and other related parts.
2)
By turriing control lever with governor spring on it, increase gradually the engine speed up to specified
3)
Locate high speed stopper bolt
on
the control lever and lock it
so
that it will work as stopper
of
control
Make sure that the governor spring is hooked
in
the same hole
on
the governor lever as original. There are
5
holes on the governor lever.
Normally, hook governor spring in the center hole.
engine speed.
lever against the stopper plate.
Speed Control Lever
\
Choke Lever
Governor
\
Fig.
18
-
21
-
8.
BREAK IN OPERATION
of
REASSEMBLED ENGINE
f-l
>\
i
An overhauled engine must be carefully broken in
to
get proper surface condition on newly installed parts.
Especially when cylinder, piston or piston rings are replaced,
a
thorough break in operation
is
indispensable,
The recommended break
in
schedule
is
as follows:
I"
LOAD
1
SPEED
1
TIME
I
I
NO
LOAD
1
2,000
rpm
1
IO
minutes
I
I
NO
LOAD
I
3,000
rpm
I
10
minutes
I
NO
LOAD
.
,_
3,600
rpm
1.6
HP
3,600 rpm
I
3.2
HP
~~
I
3,600 rpm
I
60
minutes
I
NOTE:
Use
25:
I
oil
mixed
fuel
for
break
in
period.
-
22
-
a
9:
TROUBLE
SHOOTING
For a gasoline engine to start and run satisfactorily, the following three requirements must be met:
1)
A
proper fuel-air mixture is supplied to the combustion chamber.
2)
An appropriate compression in the cylinder.
3)
Good
spark at correct time to ignite the mixture.
If
all the three requirements are not met simultaneously, an engine cannot be started. There are also other
factors such as heavy load at'starting or too long an exhaust pipe causing a high back pressure, which contri-
bute
to
hard starting.
The most common causes
of
engine troubles are given below.
9-1
STARTING
DIFFICULTIES
Cause
Defects in spark plug
Defects in high-tension
cord
Defects in magneto
Other defects in
electric system
Gas leak through head
gasket or other parts
Defects in piston
assembly
Defects in fuel tank
system
Defects in carburetor
Remedy
1
)
If contaminated, wash in gasoline, re-
2)
If
spark plug
is
broken
or
lost insula-
3)
Adjust spark gap to
0.6
-
0.7
mm.
move foreign matters and dry.
tion, replace plug.
If cord
is
burnt or damaged, replace the
ignition coil unit.
1)
If wire or insulation
is
broken, replace
2)
If
magnetism
is
weak, re-magnetize
(at
magneto.
the magneto maker) or replace flywheel.
1
)
If switch
is
faulty (short circuit),
2)
If primary wire
is
grounded to the
replace or repair.
engine body, insulate
it
with insulating
tape.
1)
If head gasket
is
defective, replace.
2)
If head bolts are loose, tighten.
3)
If spark plug
is
loose, tighten.
.
4)
If spark plug
is
defective, replace.
1)
If piston
is
worn, replace.
2)
If
cylinder
is
worn, re-bore and use over.
3)
If piston rings are worn, replace.
4)
If piston rings are stuck, clean or
size
piston and piston ring.
replace rings.
1
)
Clean clogged tank outlet.
2)
Clean clogged fuel strainer.
3)
If incorrect fuel
is
poured into tank or
water
is
mixed, drain tank completely
and fill
it
with correct fuel.
discharge air.
4)
When fuel pipe
is
locked with air,
1)
If clogged with dust, clean.
2)
If defective, replace.
Clean
jets
and other orifices, if they are
clogged.
-
23
-
Preventive measure
1
)
Use spark plugs
of
specified heat range.
Do not use poor grade.oil. Clean air
cleaner and avoid dust entry.
2) DO
not hit or bend the center electrode of
the spark plug
at
adjusting or the insulator
may
get
damaged.
1)
Keep air cleaner always clean.
2)
Do
not use poor grade oil.
1)
Be
sure to use
a
filter when adding fuel.
2)
Use mixture (gasoline
50
:
1
)
as
fuel.
Cause
Defects in fuel supply
Remedy
1
)
Start engine with fully open choke
valve
and half open throttle valve.
2)
Remove drain plug from crankcase, and
close fuel cock, repeat starting opera-
tion several times to discharge excess
fuel.
Preventive measure
1)
Never close choke
valve
when engine
is
warm.
2)
When stopping the engine, run
it
at
slow
speed for
a
while. This practice not only
favorably affects next starting, but also
improves engine life.
fuel mixture.
Clean
it
throughly.
3)
Clogged air cleaner results in too rich air
I
Defects in carburetor
1
If
fuel overflows, check needle
valve
seat
Be
careful clogged carburetor.
for wear. Replace, if necessary.
1)
If tension of transmission belt
is
too
2)
If
load
is
still
too heavy, install
a
clutch.
Excess load tight, reduce tension.
Ir
1)
If piston
seizes,
repair or replace.
1)
Do
not use poor grade oil.
2)
If connecting rod large end or small end
2)
Use fuel
of
proper mixing ratio.
Piston
Or
Connecting
Rod
seized
seize,
replace.
..
~ ~~ ~ ~~ ~~
9-2
SLOW-SPEED
out
of
order
Most defects listed as causes for starting difficulty are also causes for faulty slow-speed operating.
9-3
OVERHEATING
and
KNOCKING
1)
If
too much carbon deposits are accumulated in the combustion chamber, remove it.
2)
If the heat range of the spark plug is too cool, replace it with a correct one, i. e.
NGK
BM6A or CHAMPI-
r\
3)
If the air-fuel mixture is too lean, clean jets and other passages in the carburetor.
4)
If the load is in excess, reduce it below the specified continuous load.
ON
CJ8.
Clean the air cleaner also.
~
.I
9-4
POWER DROP
1)
If the cylinder, piston
or
piston rings are worn, replace them
or
re-bore the cylinder and fit oversize pis-
2)
If the carburetor is out of order, re-adjust or clean it.
3)
If the spark plug is faulty (contamination, gas leakage or faulty insulation), clean it or replace it.
4)
If combustion gas leaks through the head gasket, re-tighten the clamping screws.
If the gasket is faulty, replace it.
5)
If the magneto is faulty, replace them.
6)
If
the air cleaner
is
clogged, clean.it.
7)
If the fuel system is clogged, clean it.
8)
If
the oil seals at the crankshaft are worn and the compressed gas are leaking, replace them.
ton and piston rings. Replace
or
clean piston rings if they are stuck in the grooves.
9-5
EXCESSIVE FUEL CONSUMPTION
1)
If air-fuel mixture is
too
rich, clean jets and passages in carburetor.
2)
If the throttle shaft of carburetor
is
worn, replace throttle shaft. (carburetor)
rl
3)
If fuel
is
leaking, re-tighten screws or replace faulty part.
4)
If the engine suffers power drop accompanied with excessive fuel consumption, trouble-shoot by follow-
‘j
1
ing step
9-4.
-
24
-
9-6
ENGINE
HUNTING
1)
If the governor lever, governor shaft, governor spring or other members are incorrectly adjusted, re-adjust
2)
If the fuel-air mixture is too lean, clean and adjust the carburetor.
3)
If the governor spring is distorted permanently, replace it.
4)
If the governor sleeve
is
not functioning correctly, correct it.
5)
If the flyweight or the governor sleeve
is
worn, replace it.
6)
If
the governor shaft does not move smoothly, correct it.
or
correct them.
9-7
OTHER
COMPLAINTS
1)
Fuel overflows from carburetor.
If
the fuel
flows
into the air cleaner or much fuel flows'into the crankcase while the engine is standing
still (over-flowing), the needle valve or the float
is
fauity. Correct or replace them.
,2)
If
the engine suddenly stops with abnormal noise, the piston or the crankshaft
or
the connecting rod is
seized. Repair
or
replace them.
3)
If the engine produces abnormal noise during operation, be sure
to
stop the engine and do not start it
again before the cause
is
removed.
If the cause of the trouble cannot be found, contact your dealer and ask them for service.
-
25
.-
IO.
CHECKS
and
CORRECTIONS
After disassembling and cleaning the engine parts, check them, and
if
necessary, correct them according to
the correction table.
The correction table applies whenever 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.
Followings are the terms employed in the correction table.
CORRECTION
All operations performed on the engine parts for the purpose of improving or recovering the engine per-
formance, consisting of repairs, readjustments, and replacements.
STANDARD SIZE
The design dimension of the part without the tolerance.
CORRECTION TOLERANCE
The tolerance on the re-finished part dimension or on the readjusted dimension.
CORRECTION LIMIT
The limit
on
the part and adjustment, beyond which any dimensional and functional changes, due to
wear, burn, and other causes will adversely affect the normal engine performance.
USE
LIMIT
,
The limit, beyond which the part
is
no longer usable, due to defects in function
or
strength.
NOTE: All dimentions in the "CLEARANCE DATA AND LIMITS/7ORQUE SPECIF1CATIONS"are given
in
millimeter, except where otherwise specified.
-
26
-
11.
CLEARANCE DATA
and
LIMITS/TORQUE
SPECIFICATIONS
I
REMARKS CORRECTION
METHOD
LIMIT
USE
0.65
-0.1
-0.035
0.1 5
0.15
0.25
0.06 L
1.5
-0.1
-0.03
t0.020
t0.055
+0.020
0.055
0.7
0.1
0.3
-LIMIT
0.2
0.1 5
-0.1
-0.035
0.1
5
0.1 5
0.25
0.06L
1.5
-0:
1
-0.03
+0.020
+0.055
+0.020
0.055
0.7
0.1
0.3
TOOL
Surface
date,
Feeler
Cylinder
gauge
Micrometer
Cylinder
gauge
Vernier
caliper
Feeler
gauge
gauge.
Cylinder
Micrometer
Cylinder
Micrometer
Feeler-
gauge.
gauge
Micrometer
Micrometer
Cylinder
Cylinder
Micrometer
gauge.
Cylinder
gauge
Cylinder
Micrometer
Feeler
gauge,
gauge
Test bar,
Dial-
indicator
Correct
S
.T.D
.
$156
O.S.
056.25
O.S.
056.50
Bore
Boring
Roundness
,
0.01
Cylindricity
0.01
5
Diameter
from
bottom,
in
traverse
to piston
pin
3
-
20.5
(max. dia.)
S.T.D.
G55.96
Outside Diameter
0,s.
056.21
O.S.
056.46
0
-0.01 5
Replace
Piston
pin
hole
1
G12 Replace
I
,
J.011
+0.060
+0.040
+0.040
+0.020
Top
2.0
2nd
2.0
Width of
ring groove Replace
Clearance between
piston ring and
I
TOP
piston aroove
2nd
0.05
-
0.09
0.03
-
0.07
Replace
e
a
Max. cylinder
dia. and min.
piston dia.
Clearance between
piston and cylinder
I
0.04
-
0.74
I
Replace
and piston
pin
Fit between piston
0.008L-0.008T
Replace
Ring gap
I
TOP
2nd
I
0.1
-
0.25
Replace
Ring width
1
TOP
2nd
2.35
I
io.1
Replace
r-
Piston
pin
O.D.
I
@12
I
-0.008
-0.003
Replace
I
Large end
I.D.
@24
I
+:'009
I
Replace
Clearance
in
tion
radial direc-
Clearance between
and crank
pin
rod large end
I.D.
0.004
-
0.022
Obtain correct
clearance
by
replacing parts
Replace
needle bearing
Small end
I.D.
@16
+0.011
0
1
Clearance between
I I
I
Clearance
in
radial direc-
tion
Obtain correct
clearance
by
replacing parts
I
small end
I.D.
and piston
pin
I
I
0.003
-
0.027
I
needle bearing
I
I
Replace
I
Large end side or
small end side
I I
0.5
-
0.1
I
Holding large
end
as
refer-
ence, measure
test bar,
(L
=
100)
inserted
in
small and
large end
Parallelism and
Twist between large
end and small end
Parallelism
0.08
Replace
bores Twist
0.08
-
27
-
ITEM
'
1
STANDARD
I
TOLERANCE
SIZE
REMARKS
I
'
TOOL CORRECTION
METHOD
t
i0.25
Large and small end
I.D.
roundness
&
cylindricity
Roundness
Cylindricity
Max.
0.004
Max.
0.004
Distance between
large end &small
end bores
Crankpin
O.D.
t
0.05
-0.005
P
Mandrels,
Micrometer
Micrometer
Micrometer
Replace
-7"
-0.020
-0.020
Replace
Crankpin
O.D.
Roundness Roundness Max.
0.005
Cylindricity Mzx.
0.005
Replace
'
Crankshaft journal
1
Q.D.
$J~~
I
-0.006
+0.003
Micrometer
Feeler
gauge
Replace
at
I
I
I
I
Measure
between
bearing
&
crankshaft
Replace
between crankshaft
0
-
0.2
Supporting
assembled
crankshaft
between
centers,
Dial-
indicator crankshaft
Runout of Correct
0.05
measure
journal.
I
rl
Dia. of small end
needles
needle bearing
Io
-0.004
I
Micrometer Replace
unscrew Fixed
.
Spark plug CHAMPION CJ8 NGK BM6A
18" (fixed)
1.0
1
Adjust
~~ ~
.-
2
Spark plug gap
0.6
+0.1
0)
u1
0
-
Spark gap Min.
5
Magnet
revolution:
400
rpm
TORQUE
SPECIFICATIONS
ITEM REMARKS TOOL
ft-lbs
kg-ern
m
.E
250
-
300
Spark plug
6
9
28
-
30
390
-
420
Flywheel nut
18
-
22
+F,
z?
Cylinder nuts 13
-
16 180
-
220
?L
Crankcase bolts
90
-
100
6.5
-
7.3
0).
Torque
wrench
z.
v)
1
r)
\.,
I
-
28
-
12.
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.
12-1 DAILY CHECKS and MAINTENANCE
I
Checks and Maintenance
I
Reasons for requiring them
1
Remove dust from whatever parts which accumu-
lated dust. The governor linkage is especially susceptible to dust.
Check external fuel leakage. If any, retighten the
loose part
or
replace faulty part. Danger of causing fire
Check screw tightening. If any loose one is reasulting in the engine damage.
found, re-tighten:
Loose screws and nuts will cause vibration
I
12-2 EVERY
50
HOURS
(10
DAYS) CHECK and MAINTENANCE
Checks and Maintenance Reasons
for
requiring them
Clean air cleaner Clogged air cleaner affects engine operation.
Check spark plug. If contaminated, wash in
gasoline
or
polish with emery paper.
Output power is reduced and starting is made
difficult.
12-3 EVERY 100
-
200 HOURS (MONTHLY) CHECKS and MAINTENANCE
Checks and Maintenance
I
'.
Reasons for requiring them
Clean fuel strainer and fuel tank. The carburetor will be clogged with
dirt
or dust
causing bad starting
or
poor
operation.
12-4 EVERY
500
-
600
HOUUS (SEMIANNUAL) CHECKS and MAINTENANCE
I
Checks and Maintenance
I
Reasons for requiring them
I
I
Remove cylinder head and remove carbon
I
I
deposit.
Remove carbon deposit
from
exhaust port and
I
The engine output power drops.
muffler.
The carburetor will be dogged causing bad starting
or poor operation.
Disassemble and clean carburetor.
-
-
29
-
12-5
EVERY
1000
HOURS (YEARLY) CHECKS
and
MAINTENANCE
Checks and Maintenance Reasons for requiring them
Perform overhaul, clean, correcfor replace parts.
Change piston rings.
The engine output drops and becomes out
of
order.
Replace fuel pipe once a year. Rubber pipes may be hardened and cracked by the
ozone in the air.
I
12-6
PREPARATION
for
LONG STORAGE
1) Perform the above 12-1 and 12-2 maintenance jobs.
2)
Drain fuel from the fuel tank, carburetor float chamber and fuel lines.
3)
To
prevent rust in the cylinder bore, apply oil through the spark plug hole and turn the crankshaft for
several turns by hand. Re-install the spark plug.
Turn
the starting pulley by hand and leave it where the resistance
is
the heaviest.
4)
Clean the engine outside with oiled cloth.
5)
Put a vinyl or other cover over the engine and store the engine in dry place.
-
30
-
n
',
Industrial
Engines

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