EY28 Service Manual
EY28 Service Manual
EY28 Service Manual
SIDE VALVE
EY08
EY15 EY 15V EY20 EY2OV EY23 EY28 EY3 5 EY40 EY45V EY2 1 EY44 EY 18-3 EY25 EY27 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
EH11 EH12 WO1-115 wo1-120 WO1-150 WO1-170 wo1-210 WOl-250 WO 1-300 WO1-300V WO1-340 WO 1-340V WO 1-43V O TWO CYCLE EC13V WT1-125V
EH15
EH17 EH21 EH25 EH30 EH30V EH34 EH34V EH43V
DIESEL
DY23 DY27 DY30 DY35 DY4 1
CONTENTS
Section
Title
Page
. 2.
1 SPECIFICATIONS
PERFORMANCE
...........................................
2- 1 2-2 2-3
3. FEATURES
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- 13 4-14
............... Cylinder. Crankcase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Bearing Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Crankshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ConnectingRodandPiston ................................ Camshaft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Valve Arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CylinderHead . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Governor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sectional View of Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
5 6 6 7 7
8
8 8 9 9 10 18 18 18 20 27 37 37 37 38 39 39 40 42 42 43 45
5-3 5-4
6. MAGNETO
6-1 6-2 6-4 6-5
6-3 Timing Adjustment for EY15. EY20 Point Type Ignition System . . . . . . . .
Magneto Trouble Shooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Solid State Ignition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7 . GOVERNORADJUSTMENT 8. CARBURETOR
8-1 8-2
...................................
................
Section
Title
pese
(T.I.C. and P.I.T.)
............
46 46 46 46
10-1 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2 Basic Theory of T . I.C. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3 Basic Theory of P.I.T. 11 TROUBLE SHOOTING 11 .1 11 - 2 11- 3 11 - 4 11-5 11 -6
................................... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
StartingDifficulties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Misfires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Stops . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Overheats ....................................... Engine Knocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Engine Backfires through Carburetor . . . . . . . . . . . . . . . . . . . . . . . . . .
47 48 48 48 49 49 50
12 INSTALLATION
12-1 12-2 12-3 12-4 12-5
............................................
Installing Ventilation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exhaust Gas Discharge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Transmission to Driven Machines . . . . . . . . . . . . . . . . . . . . . . . . Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.............................................
50
50 50 50 51
53
53 53 54 54 55 57 57 58 59 65 65 65 65 65 66 66 66
RECOILSTARTERDISASSEMBLY
................ ..............................
...............................
...................................
...........................
Daily Checks and Every 20 Hours ChecksandMaintenance ....................... Every 50 Hours ChecksandMaintenance Every 100 200 Hours (Monthly) Checks and Maintenance . . . . . . . . . . . Every 500 600 Hours (Semiannual) Checksand Maintenance . . . . . . . . . Every 1000 Hours (Yearly) ChecksandMaintenance . . . . . . . . . . . . . . . . Preparation for Long Abeyance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
................................. Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
.......................
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 period with all in the moving parts properly worn in, when operating with a fully open throttle valve. Therefore, a new engine may not develop the maximum outputin the beginning because the moving parts are not in a properly worn-incondition.
23 MAXIMUM TORQUE
These mean the maximum torqueof the output shaft and fuel consumption ratio at the maximum output of an engine.
1 for B type
kg-m
4
Ma;. Torque
I
-7
~
07 .
0.6
HP
2000 (1000)
t i i
I \
3000 (1 500)
Revolution
r.p.m.
4000 (20001
-2-
for B t v m
Max. Toraue
1 .o
3
HP
. L
2000
3000
r.p.m.
4000
2000
( 1 000)
3000
( 15001
4000
I00 201
r.p.rn.
Revolution
Revolution
3. FEATURES
1. Compact, lightweight, durable, powerful 4-cycle air-cooled engine embodying ingenious design
t e c h q u e s and skilful
workmanship.
2. Simple construction, smart appearance, maximum easiness of start owing to automatic decompression device
3 . Pointless Solid State ignition system is newly adopted for preventing poor igniting as option.
4. Reliable prime mover for variety of purposes with smooth speed control by agovernor under varying load conditions.
5 . Economical because fuel consumption is very low.
6 . Great ve:satility in installation through a 360" belt extension possibihty and a two-side oil fill and drain arrangement.
-3-
4. GENERAL DESCRIPTION
4-1 CYLINDER, CRANKCASE
The cylinder and crankcase are
of ENGINECONSTRUCTION
casting. The c y h d e r liner, made of special castiron, is built into the alminum casting. The intake and exhaust ports are located on one into the casting. The crankcase is separable on the output shaft side, where the main bearing cover is attached to it. (See Fig. 1 .) side of the cyhder, and are also inserted
Fig. 1
The main bearing cover made of aluminum die casting is built onto the output shaftside of the crankcase so that the inside of the engine can readily be checked by simply removing the cover. It is provided with a flange and boss for directly mounting machmes, such as generators and pumps.
Two oil gauges also serving as oil filler caps can be mounted. (See Fig. 2 and Fig. 3.)
The EY 15B engine has 2 chain guides and a built-in shelter plate to prevent oil from being stirred by the governor gear (See F i g . 4.)
Ring for Centering
/
Oil Gauge
Fig. 2
Oil Gauge
Governor Gear
Fig. 3
Chain Guide
- Shelter Plate
1
Fig. 4 (E Y 15B)
-4-
4-3 CRANKSHAFT
The crankshaft is forged of carbon steel, and the crankpin is induction-hardened. It has a crank output end. (See Fig. 5 . ) . "he EY 15B type has a built-in drive sprocket. (See Fig. 6 . ) gear premred-fitted on the
Fig. 5
Fig. 6 (E Y 158)
and the
Oil Scraper
shape of the top ring is barrel face, that of second ring is taper under cut; and the oil ring has cutter expander.These rings are very much effective decreasing for engine consumption.
oil
Fig. 7
-5-
4-5 CAMSHAFT
In the D type, the camshaft is integrally built with a cam gear of special cast iron, and has intake and exhaust cams. Also
the camshaft has aluminum plain bearings attached to bothends. (No ball bearing is used.) (See Fig. 8.)
In the B type, the camshaft is made of carbon steel, and EYlSB type has a pressured-fitted cam gear and a driven sproket.
(See Fig. 9.) The camshaft functions also as an output shaft, and is driven by 1/2 rotation of the crankshaft, Ball bearings
J
Fig. 8
Cam Gear
Fig. 9 (E Y 156)
Exhaust Valve
Fig. 70
-6-
is tiltedforeasy
Fig. 1 1
4-8 GOVERNOR
The governor is a centrifugal flyweight type which permits constant operation at the selected speed against load variations. Governor gear is installed on the bearing cover without fail, and it engages with the cam gear afterreassembling. (See Fig. 12.)
Governor Sleeve
Fig. 12
-7-
4-9 COOLING
The cooling fan serving also as a flywheel cools t h e c y h d e r and cylinder head by forced air cooling. Cylinder baffles and head cover are provided for guiding the c o o h g air.
4-10 LUBRICATION
The rotating and sliding parts are being lubricated scoopby
ing and splashing the oil in the crankcase with the oil scraper attached to the connectingrod. (See Fjg. 13.)
Fig. 13
4-11 IGNITION
The ignition system is a flywheel magneto type with ignition timing set at 23" before TDC. The magneto is composed of a flywheel and ignition coil. The flywheel serving also as a fan is mounted directly on the crankshaft, and the ignition coil in the crankcase. (For further d e t d s , refer to Section on the Magneto.) (See
(BREAKER POINT IGNTION TYPE)
Ignition Coil
E a \ ?
Fig. 14
Fig. 15
-8-
4-12 CARBURETOR
fully set after thorough tests to assure satisfactory start up, acceleration, fuel consumption, output performance etc. For construction and order details, refer to the Section on Carburetor Construction, Disassembly and Reassembly. (See Fig. i6.)
Fig. 16
Fig. 17
-9-
MODEL EY15D
Cylinder Head
Blower Housing
Ignition Coil
Piston
Pin
Flywheel
(Cooling Fan)
Starting Pulley
Recoil Starter
Governor
- 10
\
Piston
/-Speed
Control Lever
Air Cleaner
Stop Button
'Carburetor
Connecting Rod
Oil Scraper-
1 Camshaft
MODEL EY15D
- 11 -
4-14-2
MODEL EY15B
Cvlinder Head
Blower Housing
Spark Plug
Piston Ring
Starting Pulley
Recoil Starter
--/
L Governor
- 12
Fuel Tank
Stop Button
Carburetor
Muff Ier
Chain
Oil Scraper
MODEL EY15B
- 13 -
Cover
Recoil Starter
Governor
MODEL EYPOD
(BREAKER POINT IGNITION TYPE)
- 14
Piston
Air Cleaner
Stop Button
Connecting Rod
Carburetor
Oil Scraper
.Muffler
Camshaft
\ -
\Tappet
MODEL EY20D
- 15 -
4-14-4
MODEL EY28
Spark Plug
Flywhe
Piston Ring
Crankcase
l g Cover
-Governor
MODEL EY28
(SOLID STATE IGNITION TYPE)
- 16 -
Fuel Tank
-0 I
MODEL EY28
- 17 -
To prevent missing and misplacing, temporarily assemble each group of disassembled parts.
Carefully handle disassembled parts, and clean them with washing oil. Use the correct tools in the correct way.
SPECIAL TOOLS
For your reference, the following shows special tools of Robin Enpne for Disassembiy, Measuring and Inspection Instruments.
Part No.
Tool
Use
Applicable Model
Shape
E YO8
EY10,13,14 EY 15,18,20 2099500407
Flywheel Puller (with bolt) For pulling off Flywheel
23095001 07
YO8
227 95003 07
For mounting and dismounting Valve Spring Retainer and Retainer Lock
230 95002 07
EY08
205 95001 07
EYlO
EY13, 14
- 18-
Part No.
Tool
Use
Applicable Model
2069500107
EY 18,23
2279500107
EY 15,20
2349500107
EY28
2079500107
EY25,27
226 9500 1 07
EY15B
EY33,35,40
timing
EY44
EC03,04,05 EC07,10,17 EC25,37
- 19 -
I :
Drain plug Recoil starter
Order
Item
Procedures
Remarks
Be careful not to lose the gasket.
Tool
14 mm spanner
(1) Drain engine oil. Drain plugs on both sides of the crankcase.
(1) Remove the recoil starter. 6@x 8 mm Flange bolt: 4 pcs.
10 mm box spanner
Gasket
- 20 -
Order
~~
Item
Blower housinl
Procedures
(1) Remove the Blower housing from the crankcase and head cover. EY15,20 . . . 64 x 12 mm bolt: 2 pcs. 6 5 x 14 mm bolt: 2 pcs. q EY28 . . . . . . 6q5 x 12 mm bolt: 4 pcs.
Remarks
Fastened together with the fuel tank
Tool
~
10 mm box spanner
(1) Close the fuel cock. (2) From the carburetor disconnect the fuel pipe between the fuel strainer and carburetor on the side of the fuel strainer. (3) Remove the fuel tank from the cylinder head. EY15,20 . . . 64 nut: 2 pcs. EY28 . . . . . . 84 nut: 4 pcs. (4) Remove the head cover from the cylinder head.
(1) Remove the air cleaner cover and element. Air cleaner is fasten(2) Remove the air cleaner case from the car- ed together with the buretor. carburetor. 6rp nut: 2 pcs. (3) Disconnect the breather pipe. (1) From the muffler remove muffler cover. EYl5,20 . . . 64 x 8 mm bolt: 3 pcs. EY 28 . . . . . 6q5 x 8 mm bolt: 4 pcs.
10 mm spanner or 12 mm spanner
Air cleaner
10 mm box spanner
Muffler cover
10 mm box spanner
Muffler
(1) Remove the muffler from the cylinder portion of the crankcase. 8 5 nut: 2 pcs. q
Brass nut
12 mmspanner
Muffler Cover
6.
/I
Muffler
- 21 -
Order 8
Item
Governor lever and the relative parts
Procedunx
(1) Remove the governor lever from the governor lever shaft. 6$1x 25 mm bolt: 1 pce. (2) Remove the governor rod and rod spring from the carburetor. (1) Remove the carburetor from the cylinder portion of thecrankcase.
Remarks
Just loosen the bolt, unnecessary to take out the bolt.
Tool
10 mm box spanner or 10 mm spanner
~~
Carburetor
Lever
Fig. 18
- 22 -
Order
10
Item
"
Rocedu~s
(1) Remove the starting pulley from the flywheel. 64 x 12 mm bolt: 3 pcs. Fit a box or socket wrench over the a flywheel nut, and strike it hard with hammer to remove the nut (EY15,20: 14 mrn, EY28: 18 mm) and spring washer.
"
Remarks
I
~
Tool
10 rnm box spanner 19 mm box spanner or 24 mm box spanner
Starting pulley
Be careful not to damage the blades of the flywheel with a driver and a like. Strike counterclockwise with a hammer. (See Fig. 19.)
11
Flywheel
Fit the flywheel pull- Flywheel puller er as shown in Fig.20, turn the center bolt clockwise and pull out the flywheel.
~
"
Ignition 12 coil
(1) Remove the ignition plug cap from the ignition plug; and remove the i p t i o n coil from the crankcase. 64 x 25 mm bolt: 2 pcs.
Sems bolt
1
10 mm box spanner
Flywheel
Order
13
Item
Procedures
(1) Remove the spark plug from the
Remarks
Tool
21 mm box spanner
~
, .
Spark plug
~~ ~~
cylinder head.
~~ ~~
14
Cylinder head
(1) Remove the 8 mm bolt and remove the cylinder head from the crankcase. 89 x 40 mm bolt: 8 pcs. (2) Remove the cylinder headgasket from the crankcase.
12 mm box spanner
15
(1) Remove the inner and outer tappet covers from the crankcase. 69 x I 2 mm bolt: 2 pcs. ( 2 ) Pull out the intake and exhaustvalve. (3) Remove the valve spring and the valve retainer .
Put the notch on the outer circumference of the spring retainer on this side. Hook the medium size (-) drive at the dent (lower side) of the spring retainer and pull out the valves, while pulling the spring retainer toward you. (See Fig. 2 1 .) Sems bolt
10 mm box spanner
16
fastening the main bearing cover. EY 1 5 , 2 0 . . . 6$ x 30 mm bolt: 8 pcs. EY28 . . . . . . 8$ x 28 mm bolt: 8 pcs. (2) Remove the cover, lightly tapping the cover evenly with a plastic hammer.
Spark Plug
Cvlinder Head
Cyclone Cleaner
Crankcase
I Drain Plug
- 24 -
Fig. 21
F&. 22
Procedules
(1) Remove the camshaft from the crankcase.
Remarks
Tool
To prevent the tappets from falling or damaging, place the crankcase on t h e side. (See Fig. 23.) Before removing put a mark of intake or exhaust on each tappet. I the EY 15B n type, remove the tappets after step 2 1 .
~~
~~~~
~~~~~
~~
18
Tappet
Intake Valve,
9 -1
Exhaust Valve
Valve Spring
Spring Retainer
Tappet
Camshaft
I
Fig. 23
Tappet
GoGernor Gear
- 25 -
Order
I
Item
I
Procedures
I
Remarks
i
Tool
10 mm box spanner or 10 mm spanner
19
posits from the upper parts of thecylinder and piston, and then straighten out the bent tabs of the lock washers on the connecting rod, and remove two pieces of the bolt. ( 2 ) Remove the oil scraper, lock washer and connecting rod cap from the crankshaft. (3) Turn the crankshaft until the piston is raised up to the highest position, push the connecting rod up, and remove the piston out of the top of the cylinder.
(1 j Remove the two clips, pull out the piston pin, and take the piston off from the small end of the connecting rod.
In the EYI 5B type, move the connecting rod to the position shown in Fig. 24.
20
(2) Spread the open ends of the piston rings and remove them frGm the piston.
Be careful not to damage the inside of the small end of the connecting rod. Be careful not to break the rings by spreading too much. Be careful not to damage the oil seal.
I
22
(1) Remove the woodruff key (for the magneto). (2) Lightly hammer the magneto end of the crankshaft, and pull it out of the crankcase.
Crankshaft (1) Remove the woodruff key (for the Camshaft Chain magneto). (2) Remove the crankshaft and the camshaft (for EY15B) at thesame time from the crankcase, tapping the crankshaft tipin the magneto side.
Be careful not to damage the oil seal. To prevent the tappets from failing or d a m aging, place the crankcase on the side.
j o o d r u f f Key
Connecting Rod
Crankshaft
Fig. 24 (E Y 15B)
- 26 -
Every and each part should be cleaned thoroughly. Especially, pay utmost care and attention to the cleanliness of the piston, cylinder, crankshaft, connecting rod and bearings. Scrape completely off carbons from the cylinder head and the upper part of the piston; especially the carbon adhered
in the groove of the piston ring should be carefully and completely taken out.
Carefully check the lip portion of every oil seal. If faulty one is found, replace it without any hesitation. Apply enough oil to thelip portion of the oilseal when reassembling. Replace all the gaskets with new ones. Replace the key, pin, bolt, nuts, etc. new one,if necessary. with Whenever tightening torque is specified, conform to thespecified figures. Apply oil to therevolutionary parts and friction surfaces, when reassembling. Check and adjust the clearances of variousportions and then reassemble. When some main portions are assembled in the course of reassembling, turn or move the gadgets by hand and pay attention to thefrictional noise and resistance.
5-4- 1 CRANKSHAFT
1)
Fit the oil seal guide onto the end of the crankshaft, and insert the crankshaft into the crankcase as shown
in Fig. 25.
NOTE: In case of not using the oil seal guide, be careful not to damage the oil seal lip.
I .
Fig. 25
- 27 -
PISTON RING GAP 0.090L PISTON RING SIDE CLEARANCE IN GROOVES OIL R I N G CONNECTING ROD TO CRANK PIN DIA. 0.01 OL
0.135L 0.050L
0.063L
0.095L 0.050L
- 0.09OL
0.01OL 0.020L
0.065L
- 0.065L
0.1 L
0.01OL
0.065L 0.01OL
S DE I
- 0.046L 0.037L
0.009T
Table 1
and
& A
so thatthewhite
link plate
of the crank-
2) Put thetappets
V
Timing Mark
, -
- 28
1)
If no ring expander is available, install the rings by placing the open ring ends over t h e first land of the piston and spreading the rings only far enoughto slip them over the correct k g grooves.
NOTE: Pay attention not to break the rings by twisting. Install the oil ring first followed by the second ring and then
top ring. Meantime, the surfaces of the second ring and the top ring with carved marks are t o be faced up.
Ring Piston
Fig. 28
EY15,20 Taper
I
Taper Under Cut
EY28
I
.-
Face
...
(with expander)
Fig.
29
2)
Reassemble the piston and connection rod by means of the piston pin.
NOTE: Apply enough oil t o the small top end of the connecting rod. Be sure to place the clipson both ends of the piston pin.
- 29 -
piston rings with the ring guide as shown in Fig. 30 (if no ring guide is available, keep pressing the piston rings with finger tips and gently strike the top of the piston with a wooden piece or the like to push it in),
Piston Ring Guide
@or and check that the symbol mark MA on the connecting rod is in the direction of the flywheel magneto.
NOTE: Apply enough oil to the piston rings, connect-
reassembling.
NOTE: The open ends of the piston rings must be 90"
Fig. 30
5 4 4 CONNECTING ROD
1)
Turn the crankshaft to the bottom dead center, lightly hammer the piston head
contacts the crankpin, andassemble. 2) When reassembhg the connecting rod cap, match the alignment projection markon the rod.
curely.
NOTE: After reassembly, confirm that theconnecting
Alignment Mark
Fig. 31
Oil Scraper
+-
. , . .... . . . . ... . . .. .
- 200
kg-cm
NOTE: For the piston, piston ring and rod clearance, see Fig. 26.
- 30 -
the camshaft.
NOTE: Align the timing mark a t the root of a tooth of the cam gear with the one on the crank gear. If thevalve timing is wrong, the engine cannot operateproperly or a t all. (See Fig. 32.) In the EY158, set the white link plate a t the
sprockets timing mark. (See Fig. 27.) NOT: If the intake tappet and exhaust tappet were clear-
Fig. 32
the clearance between the chain and the chain guidsi s from 0 to 0.5mm. (See Fig. 34.) NOTE: CHAIN GUIDE tightening torque 70 to 90 kgcm. Chain Guide
n
Fig. 33 (E Y 75B)
NOTE: As the governor gear is mounted on the main bearing cover side, install the main bearing cover while checking that it meshes with the teeth of the cam gear. {See Fig. 35.) Meantime, if the oil seal need be replaced, pressure-fit a new oil seal before installing the main bearing cover.
Fig. 34 (E Y 156)
I\
Pay attention t o the engagement of the governor gear and cam gear
- 31 -
NOTE: When installing main bearing cover, apply oil to the bearingand oil seal lip. Fit the oil seal guideover the crankshaft or camshaft lip from cover on. Check the crankshaft and camshaft their side clearanceare 0 damage. to protect the oil seal
the adjusting
Fig. 36
EY15, E Y 2 0 . EY28
8 0 - 100 kg-cm
170
Dial Indicator Ground Surface of Crankcase (The surface of the crankcase is t o be put together with the surface of the main bearing cover.)
190 kgcm
NOTE: Fig. 37 showsone of themethodsmeasuringthe crankshaft and camshaft side clearance between the machined face of the crankcase and adjusting collar.
11
II
11
Y=II
-32
5-4-7 I N T A K E a n d E X H A U S T V A L V E S
Remove carbon and gum depositefrom the valves, valve seats, intake and exhaust ports and valve guides.
NOTE: If the valve face is dinted or warped, replace t h e valves w i t h n e w ones. NOTE: If there is an excessive clearance between the valve guide and valve stem, replace the valve guide a spare. F o r rewith
placing, pull out the valve guide, using the valve guide pulling base and bolts as shown in Fig. 38, and pressure-fit a new valve guide into place. Valve Guide Puller
Crankcase
E
Valve Guide
Nut
Fig. 38
F&. 39
A-VALVE FACE ANGLE
EY15
EY20
45O 45O
EY28
B-SEAT ANGLE
C-GUIDE INSIDE DIA. D - V A L V E S T E M O U T S I D E DIA. INTAKE EXHAUST MAXIMUM ALLOWABLE C L E A R A N C E B E T W E E N C and D - V A L V E S T E M TILT ANGLE INTAKE EXHAUST
3"5 ' 3
;:::1
- 0.062L - 0.looL
3"30"
L: LOOSE
Table 2
- 33 -
and insert a feeler gauge between the valve and tappet stem to measure
Grinding Face
i
..
I
Fig. 40
Tappet
vT/
Fig. 41
Spring Retainer
NOTE: If the clearance is smaller than specified, slightly grind the top of the valve stem, and measure it again. On the contrary, if the ciearance is too large, replace the valve with new one, and polish its contact surface with a compound to obtain a good fit. Then adjust the clearance. NOTE: After the tappet clearance adjustment, install the valve spring retainers, and turn the crankshaft, and measure the
tappet clearance once again if it is correct. NOTE: INSTALLATION of SPRING RETAINERS Place the notch on the outer circumference of the retainer toward this side and insert the retainer, like pushing in, using a special tool. (This special tool is used for EY18 and other models.) If adriver isused, insertion may be easier. (See Fig. 42.)
Fig. 42
- 34
particularly its combustion chamber, and make clean the cooling f n .Also check is
Red mark
Green mark
EY28 -
Fig. 43
230 kg-cm
Embossed mark
As stated above, the pitch of the holes of cylinder head is common to both EY15 and EYZO. For enabling to discriminate the cylinder head of EY15 from that of EY20, anembossed mark 15 is given to the former, while no embossed mark is given t o
the latter.
For EY28, anembossed mark "EY28" is given on combustion the chamber side of the cylinder head.
Fig. 44
NOTE: Meantime, embossed mark forEY15 Kerosene engine is 15K. and EY20 Kerosene engine is 20K.
- 150 kg-cm
250 kg-cm
1)
Temporarily fasten the ignition coil to the crankcase, and install the flywheel to the crankshaft. Starting pulley is fastened together with the flywheel.
NOTE: Before installing, wipe out oil fromthe crankshaft and the tapered portion of the flywheel.
- 650
kg-cm
- 35
/"
Fig. 45
5 4 - 1 2 CARBURETOR
To the cylinder portion of the crankcase. install in the order of thegasket, insulator, gasket and carburetor, and then mount the air cleaner and fasten with two pieces of 6 mm nut.
54-13 GOVERNOR LEVER
, "
With two pieces of the brass nut fasten the muffler to thecrankcase and then install the muffler cover.
54-15 HEAD COVER, FUEL TANKand FAN COVER
Install i the order of the head cover, fuel tank and fan cover. n
NOTE: If these items are installed in the order of the head cover, fan cover and fuel be impossible. tank, removal of the fan cover would
- 36 -
6. MAGNETO
6-1 MAGNETO
The spark for ignition is furnished by a magneto assembly. The magneto consists of a flywheel, ignition coil and contact breaker assembly (including condenser), of which flywheel is mounted on crankshaft and ignition coil contact breaker are mounted in crankcase directly, The EYl5B type engine normally incorporates a solid state ignition system (T.1.C) described in 6-5.
The breaker points, whch are mounted in the crankcase inside the flywheel should be checked twice a season whenor ever the ignition spark becomes weak.If there is an evidence of pitting or pyramidding, the breaker points must be corrected, and then it becomes necessary t o readjust the gap t o its proper clearance. The normal breaker point opening (point by the point opening, use a timing light gap) is 0.35 mm to obtain an acat full separation. Since the spark timingof 23" is regulated curatesparkadvance.(Refer t o '6 -3 TIMING ADJUSTContact Breaker
MENT.")
Fig. 46
To adjust breaker point opening, remove starting pulley, blower housing and flywheel from the engine and proceed follows: (See Fig. 46.)
1) Remove breaker cover from contact breaker.
as
2) Turn crankshaft over until breaker arm comes in contact with the high point of the breaker cam. (Maximum point opening of 0.35 mm) 3) Loosen contact support plate lock screw just enough so that bracket can be moved. 4) Insert a 0.35 mm feeler gauge between the points.
CAUTION: Adjust breaker point gap without opening it more than 2 mm, otherwise rated heel-pressing force may not b e obtained due t o the bending of contact breaker arm.
5) Apply a screw driver t o adjusting tab and move the contact support plate justenough so that a slight drag is felt while
sliding the feeler gauge from between the points.
- 10 mm wide white paper through the closed points toremove oil and dust on the point surfaces.
CAUTION: When inserting a sheet of paper, never open the breaker point gap more than 2 mm.
8) Mount flywheel, blower housing and starting pulley on engine after adjustment.
.'
- 37 -
'
controlled by the breaker point opening and tius advance is obtained when the breaker point opening is adjusted according
to the BREAKER POINT ADJUSTMENT to its proper point gpening. However, the advance timing is more accurately ad-
justed through the following procedures using a timing tester as shown in Fig. 48.
NOTE: Refer t o section 4-11 IGNITION and 13. CHECKS and CORRECTIONS.
following alignment
the crankcase
Fig. 47
6 - 3 - 2 TIMING ADJUSTMENT with TIMING TESTER
/-
1)
Bsconnect the stop button lead wires and the coil primary wire.
While the points are open, the buzzer within tester remains ringing and when the points are closed, the tester remains silent. (See Fig. 48.)
4)
Turn the flywheel slowly until alignment mark on the flywheel is in the line with alignment mark on the carankcase.
Fig. 48
Fig. 49
- 38 -
By rotating the support plate of the breaker point, fmd the exact point ringmg from being silent. (SeeFigs. 48 and 49.)
tester starts
Put the flywheel back and check by rotating flywheel slowly. If the buzzer in timing tester starts ringing when line mark on the flywheel is in the line with line mark on the crankcase. When the line marks are in alignment, the timing is correct. If the timing mark lines are not in alignmnent, then readjust the point opening according t o the BREAKER POINT ADJUSTMENT, by removing the flywheel and repeat the checking procedure 3) through 5). After completing the timing adjustment remount the blower housing and connect the button. coil primary lead to the stop
MAGNETOTROUBLESHOOTING
When the engine does not,start or starts with difficulty, or when its operation is unstable, the following tests will clarify if they are caused by a defect in the magneto. 1) Check igntion cable for possible corrosion, broken, worn insulator or loose connection. 2) Check the sparking as described later in this section.
3) Check if the breaker points require cleaning, or adjusting o r not. If the points are badly corroded or pitted, condenser
may have t o be replaced too. Refer to BREAKER POINT ADJUSTMENT.
4) If no spark takes place, replace igntiion coil.
*SPARK TESTING
Remove spark plug from cylinder head and place iton blower housing, with the ignition cable connected to it. Crank the engine several times by starting pulley and observe the spark in the spark gap of spark plug. If the spark is strong, the ignition system can be eliminated the source of trouble. as If the spark is weak or there is no spark at all, repeat the checks accordingto theprocedures 1) through 3) above. The correct electrode gap 0.6 is
for
The following solid state ignition systems are available as optional or standard:
(EY15, EY20, EY28)
On the outside of the flywheel, an igntiion coil is installed, which is so-called outer coil type. This is equipped to the coil (primary-excitation) is available as an optional part. (The flywheel is for
2) P. I. T. (PULSER IGNITION TRANSISTOR) (EY 15, EY20) The ignition coil and lighting coil are installed inside the flywheeel. Thls built-in type ignition system is installed to the engine in w h c h lighting coil is requested. (P.I.T. unit is installed on the outside of the flywheel,)
- 39 -
7. GOVERNE
Models EY 15, EY20 and EY28 employ a centrifugal flyweight type governor. The governor is mounted on the governor gear and the throttle valve of the carburetor is automatically regulated by a lever which is connected to the governor in order to maintain constant engine speed against load variations. The adjustment procedure of the governor is as follows (See Figs. 50 and 5 1.):
1)
Connect the carburetor throt?le lever t o the governor lever with the connecting link,and mount them onto the govern
or shaft.
Fig. 50
Fig. 51
*The point where the governor spring i s to be hooked For EY15 and EY28 thegovernorspring point 2 for EY20.
is to be
4)
Turn rhe control lever towards high speed, and confirm that the carburetor throttle valve is fully opened.
I'
Governor Lever
-40 -
turn it 'clockwise" fully until the governor shaft no longer moves, and then lock thegovernor lever to the governor shaft with the governor lever tightening bolt. (See Fig. 53.) Governor Lever
Fig. 53
Both EY 15 and EY20 engines can be connected to the generators of both 50Hz and 60Hz; and the'dimensionsof the
governor spring t o be hooked are different each otheraccording to the hertz. Meantime, the dimensions of the governor spring for the standard engineis same as those of the spring for the engine t o be connected to the 60Hz generator. EY28 engine can be connected to the generators of both 50 Hz and 60 Hz; but it is necessary to select the right engine to the right generator. Meantime, standard type engineis for the 60 Hz generator.
Discrimination according to the dimensions: EY15/60Hz (Standard) EY 15/50Hz
-I(a)
I4Al-l
"
-: :--I (all"
(Longer Hook Side)
EY20/50Hz
"
EY28/60Hz( STD)
Fig. 54
*For EY15, EY20 and EY28 it is commonly said that the governor spring longer in the length of (A) is for 50 Hz. *Both ends of the spring for EYI 5 are bended to the same direction, while both ends of the spring for EY20 are bended to contrary directions.
-41 -
8. CARBURETOR
8-1 OPERATION and CONSTRUCTION (See Fig. 55 and Fig. 56.)
8-1-1
FLOAT SYSTEM
The float chamber is located just below the carburetor body and, with a float and a needle valve, maintains a constant fuel level during engine operation. The fuel flows from the fuel tank into the float chamber through the needle valve. When the fuel rises to a specific level, the float rises; and when its buoyancy and fuel pressure are balanced, the needle valve close to the shut off the fuel, thereby keeping the fuel at the reference level.
r By-Pass
Choke
I
Throttle Valve Pilot Outlet
,-
Pilot Jet
. Main
Nozzle
Float
Main Jet
Fig.
55
Needle
Float
- 42 -
8- 1 - 2 PILOT SYSTEM
The pilot system feeds the fuel the engine during idlingand low-speed operation. to The fuel is fed through the main jet to the pilot jet, where it is metered, and mixed with the air metered by.the pilot air jet. The fuel-air mixture is fed to the engine through the pilot outlet and the by-pass.
During engine idling, the fuel is mainly fedfrom the pilot outlet.
8-1- 3 MAIN SYSTEM
The main system feeds the fuel theengine during medium- and high-speedoperation. to
ih The fuel is metered by the main jet and fed to the main nozzle. The air metered by the main air jet is mixed w t the fuel
through the bleed holes in the main nozzle, and the mixture is atomized out of the main bore. It is mixed again with the air taken through the air cleaner into an optimum fuel-air mixture, which is supplied to the engine.
8-1-4 CHOKE
The choke is used for easy start in the cold season. When the recoil starter is pulled with a closed choke, the negative pressure applied to the main nozzle increases and draws much fuel accordingly; thus easily start up the engine.
8-2 DISASSEMBLY and REASSEMBLY Apart from mechanical failures, most of carburetor troubles are caused by an incorrect mixing ratio, which may arise mainly
due t o a clogged up air or fuel passage in jets, or fuellevel variations. In order t o assure proper flow of a i r and fuel, the carburetor must be kept clean at all times. The carburetor disassembly and reassembly procedures are as follows: (See Figs. 57 and 58.)
29 1 3
7
" i 4
-g 4J
I
* 8
12
A
-43
l1
12
"---@
4
Fig. 58 (EY28)
Fig. 57 ( E Y 15,201
8 - 2 - 1 THROTTLE SYSTEM
1)
Remove the Philips screw (27) and throttle valve (22), and pull out the throttle shaft (23).
2) The spring (24) can be taken out by removing the throttle stop screw (25).
and pull out the choke shaft (1 6 ) . spring(21), set these parts at the right
2)
When reassembling the choke shaft, make sure that the cutoutin the choke valve faces the main air jet. Meantime, when reassembling the moderation regulating ball (20) and the positions with the rings (1 8) and (19) and then reassemble.
8 - 2 - 3 PILOT SYSTEM
1)
Remove the pilot jet (26), using correct tool to avoid damage to it. Reassembly Tighten the pilot-jet securely. Otherwise, the fuel may leak, causing engine malfunction.
2)
8 - 2 - 4 MAIN SYSTEM
1)
Remove the bolt (1 2) and take out float chamber body (lo). Re-move the main jet (13) from the body (6). [In case of EY28, remove the main jet (13) from the pipe assy (29), and then remove the pipe assy (29) and the nozzle (28) from the carburetor body(6).] Reassembly
2)
3)
a) Fasten the main jet securely to the body.Otherwise, the fuel may become too rich and cause engine malfunction.
b) The bolt tightening torque is 70 kg-cm.
8 - 2 - 5 FLOAT SYSTEM
Ij
Pull out the float pin (9) and remove the float (8) and needle valve (1 7). If the needle valve need be replaced, replace
i t with rubber needle.
CAUTION: When cleaning the jets, use neither a drill nor a wire (because of possible damage of the orifice which will
adversely affect fuel flow). Be sure to use compressed air to blow them clean.
2 ) When removing the needle valve and floats, gently tap the reverse side using the rod more slender than the float pin
and remove because the float pin is calked to the carburetor body.
- 44 -
9. BREAK-IN OPERATION
An overhauled engine must be operated
of REASSEMBLED ENGINE
A thorough break-in is indispensable particularly
when the cylinder, piston,:piston rings or valves are replaced with new ones. The recommended break-in schedule is shown below.
LOAD
EY28 EY15 EY20
SPEED
CRANKSHAFTREV.)
TIME
NO LOAD
NO LOAD
2,500 rpm
10 minutes
3,000rpm
rpm 3,600
10 minutes
I I I
NO LOAD
1.35 HP 2.7 HP
1 I
1.75 HP
3.5 HP
I I
2.75 HP
5.5 HP
I I I
1 I I
10 minutes
30 minutes
60 minutes
-45
rough surface of breaker point and incorrecttiming resultant from worn mechanical parts.
10-2 BASIC THEORY of T.I.C. (See Fig. 59.)
T.I.C. (Transistor ignition type) consists ofthe flywheel and ignition with coil built-in its transistor; and basic theory is as
I
Resister
1
follows: Revolution of the flywheel generates electricity the on primary side of the ignition coil, and the electric current A runs. A makes the power transistor 'ON" and the electric current B passes. The flywheel goes round further, and at the time o f ignition the electric current
C runs, then the electric
Ignition Coil
1 1
&
.-
01 v)
current D runs to the signal transistor, by which the electric current B, passing through the power transistor, is abruptly cut; and as a result, the high voltage electricity is generated on the secondary side of the ignition coil and it sparks at the plug.
Fig. 59
I"
basic theory is
1) Revolution of the flywheelgenerateselectricity on the primary side of the ignition coil, and the electric current A runs. A makes the power transistor the electric current B passes.
"ON" and
2 ) Theflywheelgoesround
electric current
C
Then, the electric current D runs, by which the electric current B is cut abruptly, and as a result the high voltage electricity is generated on the secondary side
of the ignition coil and it sparksat theplug.
- 46
11. TRQU
The following three conditions must be satisfied for satisfactory engine start. 1. The cylinder filled with a proper fuel-air mixture.
of the
Th~s trouble may be remedied, depending on cases, by lightly tapping the float chamber with the grip of a screwdriver
of the like. If the carburetor overflows, excessive fuelruns into the c y h d e r when starting the engine,making the fuel-air mixture too rich to burn. If this happens, remove the spark plug, and turn the starting pulley a few turns in order rich fuel-air mixture out of the spark plug hole into the atmosphere. Keep the carburetor choke open during this operation. Dry the spark plug well, screw it into place, and try to start again. gasoline flow into the carburetor. 7 ) When the engine is cold, pull the carburetor knob to let the
11-1-2 COMPRESSION SYSTEM
to let the
If starting difficulties and loss of power are not due to the fuel system or ignition system, the following must checked for be possible lack of compression.
1) Engine inside is completely dried up because of a long periodof non-operation.
2) Loose or broken spark plug. This causes a hissing noise made by mixture gas running out of cylinder in compression
stroke during cranking.
3) Damaged head gasket or loose cylinder head.A similar hissing noise is produced during compression stroke.
4) IncorrectTappetClearance
If the correct compression is not obtained even after remedying the above, disassemble the engine and check further as follows: a) Valve stuck open due to carbon or gum on the valve stem. b) If the piston rings are stuck on the piston, remove the piston and connecting rod from the engine, and clean, remedy or replace the parts.
- 47 -
Check the following for lackof sparks. 1) Leads of the ignition coil, spark plug or contact breaker disconnected.
3) Sparks weak.
4) Ignition wire connections loose.
6) Water ingasoline.
7) Insufficient compression.
2 ) Vapor lock, i. e., gasoline evaporating in the fuel lines due to overheat around the engine.
3) Vapor lock in the fuel lines or carburetor due to theuse of too volatile winter gas in the hot season.
4)
A i r vent hole in the fuel tank cap plugged.
1 1 4 ENGINE OVERHEAT
Crankcase oil level low, Add oil immediately. Spark timing incorrect.
Low grade gasolineis used, or engine is overloaded.
Cooling air circulation restricted. Cooling air party misdirected causes loss of c o o h g efficiency. Cylinder head cooling fins clogged up with dirt. Engine operated in an enclosed space without fresh supply of cooling air. Exhaust gas discha'rge restricted, or carbon deposits in the combustion chamber. Engine running on low-octane gasoline detonates due to heavy load at low speed.
- 48 -
2) Engine operating under heavy load at low speed. 3) Carbon or lead deposits in the cylinder head.
4) Sparktimingincorrect.
4) Engine cold.
-49
12. INSTALLATION
Engine life, ease of maintenance and inspection, frequency of checks and repairs, and operating cost all depend on the way in whch the engine is installed. Carefully observethe following instructions for installing the engine.
, -
12-1 INSTALLING
When mouhting 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 be supplied andchecked, the easily spark plug and breaker can easily be checked, the air cleaner can easily be serviced, and that the oil can easily be discharged.
*
*
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 possib!e, span the belt horizontally. * Disengage the load when starting the engine.
If no clutch is used, use a belt tension pulley or the like.
12-4-2 FLEXIBLE COUPLING
be minimized.
- 50 -
12-5 WIRING
RECOIL STARTER OPERATION
Wire as shown in the wiring diagram below. Normally, those indicatedby dotted lines are not includedin engine wiring. Lighting coil for Models EY15,.EY20 and EY28 ( noptional, not standard accessory) permits installation of an AC buzzer with a
an intermediate tap.
[BREAKER POINT IGNITION TYPE]
Condenser Ignition C o i l
3 -
? m
v)
Magneto
Fig. 61
[SOLID STATE IGNITION TYPE for MODELS EY15 and EY201 1. T. I.C. (Standard)
2. P. I.T. (with
coil)' lighting
BlacklYellow
" "
Fig. 62
Fig. 63
- 51 -
1.
T. I.C. (Standard)
Stop Button Ignition Coil Connecter
l Black
Spark Plug
rrm
Flywheel
Fig. 64
Black
r-----
I " "
7 7 h
Starting Motor
/ "
Fig. 65
- 52 -
Bolt
0.6 kW
3.0 kg
DriveLever
Stop
Collar
Fig. 66
13-2 OPERATION
Connect the (t) side of battery to the 8 $ terminal of starting motor magnet switch. The state of starting motor ON is as shown in the following figure: When thekeyswitch closedand is putto
ON, the M+ circuit is
Battery
thecurrentflows
to thearrowheaddirection.
The magnet switch coil is excited, and the contact is drawn UP. Then the continuity is made to the starting motor, and the pinion gear is instantaneously pushed outby the drive lever. Thepiniongear is engaged withthe ring gear, andthe Magnet Switch
Fig. 67
engine cranking is made. This means that the lower current flows in the M + circuit,
(DType)
Starter
Rope
Pull the starting knob and pull out the starter rope for
30 to 40 cm.Firmly press the reel with a thumb as shown in Fig. 68 so that the reel should not make reverse turn ai the place where the reel notch comes to the outlet of starter rope. Pull out the starter rope the inside of recoil starterwith to
Notch %
a screwdriver. Then,
utilize the reel notch, and rewind it until the rotation stops in the arrowhead direction, braking the reel rotation with a thumb.
Starter Knob
'4
Fig. 68
of the
2
3
@-"
5 3
U typesnap ring
2. Thrust washer
3.
4.
5.
6.
Meantime, for removing the U type snap ring, nip the shaft with cuttingpliers and push it out.
Fig. 69
-54-
4)
Take out the reel from the starter case as shown in Fig. 70: In this case, slowly take out it turning the towardleftand right so thatthe from the reel hook section. If the reel is suddenly taken out, there is a fear that the spring jumps out in the form as it is hooked, w h c h is very dangerous,so be carefuly of it.
(If the spring jumped out, house itin the starter case as
reel lightly
spring is removed
instructed in Fig. 75.) Finally, release andtake outthestarterrope tied to both the reel side and the starting knob side. Thus, the disassembly work ends.
Starter Case
Fig. 70
Spring
No.2
No.1
pass throughthestarting
knob, and tie the rope as shown in Fig. 71 No.1. Then, have the opposite side of the rope pass through thestarter case andthe reel, and tie it as shown in Fig. 71 No.2. Then surelyhouse the end in the reel.
(In the Fig. 71 both the ropes are tied quite lightly, as
you see in figures No. 1 and No.2. Please note this is just for the purpose of easy understanding. Therefore,
Fig. 71
housing section, and have the spring to form so that its inner edge will be about 1 mm from the starter shaft and that ithooks surely the reel hook. Meantime, with the pliers about 10cm long spring from the inner edge can easily be formed.
Reel Hook
/
Starter Shaft
4 c m
Fig. 72
- 55 -
3) Before puttingthe
spring, notch. Set the reel hook to the inner end of the and put the reel in the startercase. (At this time, confirm that the reel hook is duly set to the spring.) Then, hold the starter rope as shown in Fig. 73, and turn the reel 4 times in the arrowhead direction, When wound up, firmly press the reel not to allow reverse turn, and pull the starting knob. Then, and slowly return khe starting knob.
4) When reassembling theparts,follow
up inthe reverse
order to Fig. 69. When putting the friction plate in the hole for it, set the return spring a little upward as shown in Fig. 74 so that the friction plate can easily be put in the hole for it. Next, turn the friction plate in the arrowhead direction till the position where its notch matches with the ratchet. Push firmly the friction plate to the snap ring. (Clamp the U shape snap ring with cutting pliers.)
Fig. 74
t With the above, the disassembly and reassembly works end, however, there is a case that theparts are not properly re-
assembled. Therefore, for caution's sake check the function of the recoil starter following the confirmation items described in the next page.
- 56 -
Pull the starting knob 2 or 3 times, and pull out the starter rope a little.
i)
If the starting knob is felt heavy t o pull and cannot be pulled, check whether the parts were reassembled correctly
as instructed.
n If the ratchet does not function, check whether the ) spring is hooked properly.
2) Pull the starting knob, and pull out the starter rope all the way long.
i)
If the starter rope remains left in the reel or the starter rope does not return atall, immoderate strain is imposed on
the spring. So rewind the starter rope 1 or 2 times as per instruction in Fig. 68. is weak or the starting knob is drooped on the way, inject a few drops of
mobile oil in the frictional portions.If it does not revive yet, wind it 1 or 2 times. (In this case, refer to the instructions explained in the paragraph i) above and confirm whether or not immoderate strainis imposed on the spring.)
i If the sound is heard that the spring is falling off, and the starter rope cannot.be wound in relay, reassemble once i i )
again from the biginning.
With thin wiremake a ring smaller than the case for spring, and hook the outer edge of spring on the part of the ring as shown in Fig. 75. House it in the spring housingsectionofthereel,andcalmlyremovethe ring, pressing the spring with fingers so as not to come out. The ring can easily be removed by gouging it with the tip of the screwdriver or the like. Meantime, refer to Fig. 72 for not to mistake the housing direction of the spring.
2 ) In case oflubricating
Lubricate the rotating parts, frictional parts and spring with heat resistant grease, if possible, or mobile oil at the time of disassembly or at the end of season for use.
Fig. 75
3)
In case thedirectionofrotation
is reverse (Type B)
As this manual is for right rotation recoil starter, perform reverse work for left rotation recoil starter.
- 57 -
- 58 -
I 1
EY20 EY28 EY 15 EY 20 EY28 EYl5 EY 20 EY 28 EY15 EY20 EY 28 EY 15
ENGINE MODEL
STANDARD SiZE
Less than 0.1
1
.
Dif. between
rnax. & rnin. 0 +0.019
REMARKS
7
0.65
TOOL
plate,
Bore
0.1 5
I
Boring
S.T.D. 75 dia.
Roundness
0.01
Cylindricity
1
6.5@
0.01 5
1.2 -1.5
2.5
Correct
Valveguide I.D.
I 1
EY15 EY20 EY 28 EY15 EY28
+0.022
0.1 5
0.1 5
A t middle portion
Cylinder gauge
Replace
- 0.02
-0.1
-0.1
Micrometer
Replace
I
Width of ring groove
EY15 EY2O
I
I
Oil
"*
I
+0.060
Top 1.5
t0.040
0.1 5
Replace
1
Piston pin hole Clearance between piston and cylinder EY15 EY20 EY 28
Oil 30
14 dia.
16 dia.
- 0.009
0.035
0.035
Max. cylin-
Micrometer
Replace
0.010-0.065
To P EY 0.050-0.095 0.010-0.055 0.010-0.065
0.1 5
0.1 5
Replace
- 59 -
TOLERANCE
USE
LIMIT 0.050-0.090
0.01 0-0.065 0.01 0-0.065 -0.009-0.010
LIMIT
0.1 5
REMARKS
TOOL
Feeler
CORRECTION METHOD
Replace
EY28
0.15
1 1
EY15 EY20 EY28
0.06L
0.06L
gauge. Micrometer
0.20
0.40
Ring gap
EYZO
0.05
0.25
1.5
1.5
Feeler
Replace
I 1
EY28
TEY15 width Ring
0.1
0.3
Oil 2nd
Oil
2;
2.8
~~~
-0.1
-0.1
Replace
0.030
I 1
EY28
EY15 Large end I.D. E Y 20 26 EY 28 Clearance between rad large end I.D. and crankpin EY15 EY20
I
dia.
I
I
I
-0.008
- 0.04
-0.04
Micrometer
Replace
+0.013
0.1
0.1
Cylinder
Replace
0.037-0.063
0.2
0.020-0.046
Cylinder
0.2
gauge,
EY28
Micrometer
Replace
14 dia. Small
EY 28
nd
0.08
16 dia.
0.08
Replace
10-0.029
Clearance between small end I.D. and pinstonpin Large end side clearance Parallelism between large end and small end bores
0.1 2
0.12
Replace
1 1
EY 15 EY28 EY20 EY 28
100
0.3
1 .o
1 .o
0.05
0.1
0.1
0.15
- 60
ITEM
lAODEL
24 die.
TOOL
CORRECTION METHOD
Crankpin O.D. EY28 Crankpin 0 . D roundness Crankpin O.D. cylindricity Crankpin O.D. parallelism Drive s. 25 die. EY15 Mag. 8 . 25 dia. Drive s. 25 die. EY 20 EYt5 EY20 EY 28
Micrometer
Re-machine
or Replace
28 dia.
-0.020 -0.033
Less than 0.005
Mag.s.
25 die.
- 0.012
- O.OO3
- 0.05 - 0.05
Micrometer
Replace
io.1
- 0.25
EY20
EY15
-t
Drive s. 15 dia. -0.01 6--0.027 Mag. s. 15 dia. -0.05 Drive s. 25 dia. -0.003--0.012 -0.016--0.027 -0.016--0.027 -0.020--0,033 -0.003--0.012 -0.020--0.033
EY 158 Mag. s. 15 die. Journal O.D. Drives. 15dia. EY 28D Mag. s. 25 dia Drive s. 30 dia. EY28B Mag. s. 25 dia. EY15 EY 20 EY 28 EY15 EY 20 EY 28
I-0.05
- 0.25
Micrometer
Replace
Micrometer
Replace
Free length
37
-1.5
Vernier calipers
Replace
Squareness
,,o
-61
Square
Replace
ITEM
TOLERANCE SIZE
LIMIT
-0.15
USE LIMIT
REMARKS
Micrometer
I
Cylinder gauge
CORRECTION METHOD
Replace
0.025
0.056
0.025 0.056
"
03 .
blow
03 .
At middle
Replace
I I
EY15
Correct
0.1
0.3
0.5
Replace
I
Stem end length
I
I
EY,5
EY2O
I
I
I
Intake Exhaust 5.9 Intake 6'2 Exhaust 6.4 Tntake Exhaust 4.45
I
I
-1
.o
-1 .o
Vernier calipers
Replace
EY15
35.6
- 0.5
EY28
- 0.5
Vernier calipers
Replace
43.7
1
stem and guide Spark plug
0.013
0.037
0.2
0.2
1 I
EY28
NGKBBHS
1
I
0.013-0.043
EY28 EY15
NGK BPBHS
Spark gap
I :: I ;
I I
EY15 EY 28 EY20 23'before T.D.C.
0.6
0.7
Feeler
Adjust or replace
1
t 5"
Spark timing
Timing tester
Adjust
Point opening
0.05
0.1
breaker spanner
Adjust
- 62 -
tTEM
MODEL
EYISD EYl5B EY2OD EY28D EY 288 EY15D EYl58 EY2OD EY 28D EY28B
HP/rpm
3.514000 3.512000 5.0/4000 7.514000 7.512000 2.713600 2.711 800 3.513600 5.513600 5.511 800
CORRECTION LIMIT
REMARKS
Max. output
Continuous Rated
O t u up t
MODELCORRECTION PRECISENESS
CORRECTION PROCEDURE
Fuel Consumption
ITEM
MODEL EY15
cc/hr
REMARKS
10
15
50
Lubricant Consumption
EY20 EY28
60
ITEM
c
Q
0.6
0.85
REMARKS
ITEM
MODEL
REMARKS When the peripheral temparature is below -2OoC, use the oil of viscosity and quality fitted tothe local conditions.
Single grade
?,I, !,
#30
I I II
Multigrade
1
#40.
II
When the peripheral temparature i s more than 4OoC. use the oil of vismsitv and quality to fitied t h e local conditibns. The oil consumption i s apt t o increase, when used under high peripheral temparature, so it i s necessary t o check every day.
II
~~.
I
-20
I
1OW-30
I
0
I
10
I
20
30 4OoC
-10
If quality and quantity of the engine oil become lower or less, burning might be caused
- 63 -
ITEM
FREOUEMCYOFOILCHANGE
Oil C h a w
EY15 EY 20 EY 28
First time: Change oil after 2 houn operation. 0 Second Time and Thereafter: Change oil every 50 hours operation.
ITEM
MODEL EY15
kglcm'lrpm 514 00
CORRECTION LIMIT
TOOL
REMARKS
Pressure gauge
ITEM
rpm
1200
600
1200 1200
600
kgem 190
- 230 260
115
I I
TOOL
REMARKS
ft-lb
TOOL
REMARKS
-_
Torque wrench
Connectin0 rod
SO170
ti wn
Magneto clamp nuts
I Ff;: 1
I
EY28
Torque wrench
200
600- 650
I
1
wrench
Toraue wrench
. . WlfS
150
Torque
230
- 270
-64-
m e following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated maintenance intervals are byno means guarantees for maintenance free operations during these intervals.
For example, if the engine is operated in extremely dusty conditions, theair cleaner should be cleaned every day instead of every 50 hours. 17-1DAILY CHECKS and MAINTENANCE
Checks and maintenance Remove dust from whatever parts which accumulated dust. Check external fuelleakage. If any, retighten or replace. Check screw tightening.If any loose one is found, re-tighten. Check ol level in crankcase and add upas necessary. i Not only wasteful but also dangerous
I I
Reasons for requiring them The governor linkage is especially susceptible to dust.
17-2EVERY
I
17-3EVERY
50 HOURS(10DAYS)
Checks and maintenance
Change crankcase oil. Clean air cleaner. Check spark plug.I f contaminated, wash in gasoline or polish with emery paper.
is made difficult.
17-4EVERY100
I
Clean fuel filter
I 1
I
~~
~~~
- 65 -
17-5 EVERY
Remove cylinder head andremove carbon deposit. Disassemble and clean carburetor.
parts.
Change piston rings. Replace fuel pipe once year. aTo prevent from danger caused the by fuel leakage.
2) Drain fuel from the fuel tankand carburetor float chamber. 3) To prevent rust in the cylinder bore, apply oil through the spark plug hole and turn the crankshaft several turns by
h d . Reinstall the plug.
4)
Turn the starting pulley by hand and leave it where the resistance is the heaviest.
6 ) Put a vinyl or other cover over the engine and store the engine in dry place.
- 66 -
Industrial Engines
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