128450734119317500
TRANSCRIPT
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Section Title Page7.AUTOMATIC DECOMPRESSION SYSTEM........................................................... 468.CARBURETOR ........................................................................................................ 47
8-1 OPERATION AND CONSTRUCTION........................................................................... 478-2 DISASSEMBLY AND REASSEMBLY............................................................................ 48
9.STARTING SYSTEM................................................................................................ 509-1 RECOIL STARTER ........................................................................................................ 509-2 ELECTRIC STARTER .................................................................................................... 54
10.TROUBLESHOOTING ........................................................................................... 5610-1 STARTING DIFFICULTIES .......................................................................................... 5610-2 ENGINE MISFIRE ........................................................................................................ 5710-3 ENGINE STOPS .......................................................................................................... 5710-4 ENGINE OVERHEAT................................................................................................... 5810-5 ENGINE KNOCKS ....................................................................................................... 5810-6 ENGINE BACKFIRES THROUGH CARBURETOR.................................................... 58
11. INSTALLATION ..................................................................................................... 5911-1 INSTALLING ................................................................................................................. 5911-2 VENTILATION .............................................................................................................. 5911 -3 EXHAUST GAS DISCHARGE ..................................................................................... 5911 -4 POWER TRANSMISSION TO DRIVEN MACHINES.................................................. 59
12 SERVICE DATA....................................................................................................... 6012-1 CLEARANCE DATAAND LIMITS ................................................................................012-2 TORQUE SPECIFICATIONS ....................................................................................... 6612-3 OIL GRADE CHART .................................................................................................... 66
13.MAINTENANCE AND STORAGE.......................................................................... 6713-1 DAILY MAINTENANCE ................................................................................................ 6713-2 INITIAL 20 HRS MAINTENANCE............................................................................... 6713-3 EVERY 50 HRS (10 DAYS) MAINTENANCE ............................................................. 6713-4 EVERY 100-200 HRS (MONTHLY) MAINTENANCE ................................................ 6813-5 EVERY 500-600 HRS MAINTENANCE ...................................................................... 6813-6 EVERY 100 HRS. (YEARLY) MAINTENANCE ........................................................... 6813-7 ENGINE STORAGE .......................................... : ........................................................ 68
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I EH36 1MODEL ~~~ ~ ~EH36B EH36DS EH3H36BSI
Type Air-Cooled, 4-Cycle, Single-Cylinder,Horizontal P.T.O. Shaft, OHV Gasoline EngineBore x Stroke
8.3ompression Ratio404 cm3 (24.65 cu.in.)iston Displacement
89 x 65 mm (3.50x 2.56 in.)
Continuous 6.3 kW (8.5 HP) /3600 .p.m. 6.3 kWP) /I800 .p.m.output Max. 8.5 kW (1 1.5HP) /3600 r.p.m..5 kW (11.5 HP) /1800 r.p.m.~
Max. Torque 54.9 N m 5.60 gf m)/1250 r.p.m. 27.4 N m (2.80 kgf m)/2500 .p.m.I
Directionof Rotation 1 Counterclockwisesiewedrom.T.O. Shaft Side I_ _ _ _ ~Cooling systemValve Arrangement
Forced Air Cooling
Automobile Oil SAE#20, 30 or 1OW-30 ; Class SE or higherubricantSplash Type Lubrication
Overhead Valve
~ _ _ _ _ _Capacity of Lubricant 1.2 liters (0.32U.S. gal.)Carburetor I Horizontalraft,loatypeFuel
Fuel Tank CapacityGravity Typeuel Feed System
310 g/kW h (230 g/HP h ) At Continuous Rated Output Fuel ConsuAutomobile Unleaded Gasoline
7.0 liters (1.85 U.S. gal.)Ignition I FlywheelagnetoSolidtate) ISpark Plug NGK BP6ESCharging Capacity -
-/2 Camshaft Drivepeed ReductionStarting System12V-1.3AV- 1.3A
Governor System Centrifugal Flyweight TypeAir Cleaner Double Element Type
Recoil tarter & Recoil Stafler Recoil Starterecoil Starter Electric Starterlectric Starter
Dry Weight I 32.0 kg (70.6 Ib.) I 35.0 kg (77:2 Ib.) I 31.Okg (68.4 Ib.) I 34.0 kg(75.0b.) ]~ _ _ _ _ _Dimensions L x W x H) 389 mm x 431 mm x 433 mm (15.31 in. x 16.97 in. x 17.05 in.) ISpecifications are subject to change without notice.
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EH41 IMODEL EH41B EH41DSH41DH41 BSAir-Cooled, 4-Cycle, Single-Cylinder,Horizontal P.T.O. Shaft, OHV Gasoline EngineIBore x Stroke 89 x 65 mm (3.50 x 2.56 in.)
btonbisplacement 404 cm3 (24.65 cu.in.)Empression Ratio~~ 8.3 I
Continuous 7.0 kW (9.5 HP) 13600 r.p.m..0 kW (9.5 HP) /1800 r.p.m.Output Max. 9.9 kW (13.5 HP) /3600 r.p.m..9 kW (13.5 HP) /1800 r.p.m. ,Max. Torque 56.8 N m (5.80 kgf m) I 28.4 N m (2.90 kgf m)/1250.p.m. /2500 r.p.m.Directionof RotationCooling system
Counterclockwise As Viewed From P.T.O. Shaft Side
Splash TypeubricationOverhead Valvealve Arrangement
Forced Air Cooling
(Lubricant I AutomobileOil SAE #20,#30or low-30 ; Class SE or higher ICapacity of Lubricant
310 g/kW h (230 g/HP h) At Continuous Rated Outputuel Consumption RatioAutomobile Unleaded Gasolineuel
Horizontal Draft, Float Typearburetor1.2 liters (0.32 U.S. gal.)
I Fuel Feed System T~ - Gravityype1 7.0iters1.85 US. gal.)Ignition SystemSpark Plug
Flywheel Magneto (Solid State)
12V-1.3A 12Vharging CapacityNGK BPGES
Starting SystemSpeed Reduction 1/2 Camshaft Drive -Governor System Centrifugal Flyweight TypeAir Cleaner Double Element Type
Electric Starter& Recoil Starterecoiltarter& Recoil Starterecoil tarter Electric Starter
Dry WeightDimensions (L x W x H) 389 mm x 431 mm x 433 mm (1 5.31 in. x 16.97 in. x 17.05 in.)
~ ~~ 32.0 kg (70.6 Ib.) 34.0 kg (75.0 Ib.)1.0 kg (68.4 Ib.)5.0 kg (77.2 Ib.)
Specificationsare subject to changeithout notice.
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2. PERFORMANCE2-1 MAXIMUM OUTPUT
The maximum output is the output ofn engine with its throttle valve fully opened under the conditioall the moving parts are properly brokenn after the nitial break-in period.A new engine may not produce full maximum output whilets moving parts are still not broken-in.
NOTE :Power curves shown n the following charts are maden conformity withSAE internal combustion enginestandard test code 1349.
2-2 CONTINUOUS RATED OUTPUTThe continuous rated outputs the output of an engine at optimum governed speed which s most favor-able from the view point f engine's life and fuel consumption.When the engine is installed on a certain equipment, it is recommended that the continuous outputrequired from the engine e kept below this continuous rated output.
2-3 MAXIMUM TORQUEThe maximum torque s the torque at the output shaft when the engine is producing maximum outpucertain revolution.
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2-4 PERFORMANCE CURVES
EH36
( ) for type B
t kgf-m(5.6) 2.8(5.4) 2.7(5.2) 2.6j (5.0) 2.5(4.8) 2.4(4.6) 2.3(4.4) 2.2
HP12
11
10
9
8
7
6
5
4
3
Nom:54) 27:52) 26:50) 25:48) 24:46)23(44) 22
kW9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.0 24(12) 28(14) 3216) 36(18)REVOLUTION r.p.m.
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EH41
kgfom(5.8) 2.9w (5.6) 2.8-
(5.2) 2.6I- HP14
13
12
11
10
9
8
7654
3
( for tvpe BNom
(56) 2854) 27
(52) 26kW
10.0
9.0
8.0
7.0
6.0
5.0
4.0
3.0
2.020 24 28 326 x10 (10) (12)14) (16) (18)REVOLUTION r.p.m.
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1. The overhead valve design offers a compactness,ight weight and ideal combustion characteristicsresulting in more power from lessuel and prolonged engine life.
2. The adoption of an inclined cylinder offers low heightf engine, making he arrangements for installingthe engine much easier for various powered equipments.
3. The vibration, free design with a balancer system and lighter reciprocating parts.4. Combustion and mechanical noises have been analized acoustically and improved or better tonal
quality and lower engine noise.5. The automatic decompression system lightenshe recoil pull forceby 50% comparing to the conven-
tionalSV engine.
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The ntakevalve s ocated on flywheelside of thecylinder head.Hard alloy valve seats are moldedn the cylinderhead and stellite is fused to the exhaust valve face.The cylinder baffle leads cooling air to the exhaustvalve area or the optimum cooling.
EXHAUST VALVENTAKEALVE
Fig. 4-7
4-8 CYLINDER HEADThe cylinder head is an aluminum die-castingwhich utilizes semi-spherical type combustionchamber for the high combustion efficiency.
Fig. 4-8
4-9 GOVERNOR SYSTEMThe governor s a centrifugal flyweight type whichensures constant operation athe selected speedagainst load variations.The governor gear with governor weights is in-stalled on the main bearing cover.
~
GOVERNOR GEAR/
Fig. 4-9
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4-10 COOLING SYSTEMThe large fins on the flywheel provide sufficientcooling air capacity for the inlet and exhaust areaand cylinder.The cylinder baffle helps the coolingir flow effi-ciently.
4-11 LUBRICATION SYSTEMAll the rotating and sliding parts are splash- lubri-cated by theoil splasher on the connecting rod.
OIL SPLASHER
4-12 IGNITION SYSTEMThe ignition system is transistor controlled rnag-net0 system which consistsof a flywheel and anignition coil with a built-in transistor mounted onthe crankcase.This system has an automatic ignition timing ad-vance characteristic for asy starting.
Fig. 4- 10
FLYWHEEL I
Fig . 4- 11
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4-13 CARBURETORThe engine s equipped with a horizontal draft car-buretor that has a float controlled fuel system anda fixed main jet.The carburetors are calibrated carefully for surestarting, good acceleration, less fuel consumptionand sufficient output.For details, refer o page 47, section 8 CARBU-RETOR''.
Fig. 4-72
4-14 AIR CLEANER KNOBAir-cleaner is a heavy-duty type with a dual ele-ment system he primary ones an urethane foamper element.
URETHANEsemi-wet) and secondary one is a dry type pa-&
FOAM
CLEANERCASE ELEMENT
Fig. 4- 13
4-15 BALANCERUnbalanced inertia force s cancelled by the bal-ancer which rotates in the same speed as thecrankshaft to effectively reduce vibration.
Fig. 4-14
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4-16 DECOMPRESSION SYSTEM AUTOMATIC DECOMPRESSION SYSTEMAn automatic decompression mechanismwhichopens exhaust valve before the piston reachescompression top is assembled on he camshaftfor easy starting.
RETURN SPRING
Fig. 4- 15
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4-17 SECTIONAL VIEW OF ENGINE
MUFF
P.T.O.
MAIN BEARING COVER
Fig. 4-16
FLYWHEEL
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FUEL TANK
BALANCER SHAFT \CRANKSHAFTRANKCASEFig. 4-17
CAMSHAFT
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5. DISASSEMBLY AND REASSEMBLY5-1 PREPARATIONS AND SUGGESTIONS
1) When disassembling the engine, memorizehe locations of individual parts so that they canreassembled correctly.f you are uncertain f identifying someparts, it is suggested that tagattached to them.
2) Have boxes ready o keep disassembledparts by group.3) To prevent losingand mispfacing, temporarily assemble each group f disassembled parts.4) Carefully handle disassembled parts, and clean them with washingil if necessary.5 ) Use the correct tools in the correct way.
5-2 SPECIAL TOOLSTool No. Useool
209-95004-07 For pulling ff the flywheel Flith bolt
FLYWHEEL PULLER
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5-3 DISASSEMBLY PROCEDURESStep Fastenersemarks and proceduresarts to remove
Engine oil drain
(2) To discharge oil quickly, remove(1) Remove oil drain plug and drain
1 oil.oil gauge.
OIL LEVEL
GASKETOIL DRAIN PLUG
GAUGE
Fig. 5-2
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Step Fastenersemarks and proceduresarts to removecap nut2 Air cleaner cover and elements
Remove breather pipe from cylinder M6 flange nut :3 2 pcs.ead.ir cleaner base and gasket
M6 x 28 : 1 pce.
CAP NUT
fig.5-3
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Step
4
Parts to removeFuel tank.rtop switch
M8 BOLT ANDWASHER ASSY :
Remarks and procedures(1) Close fuel cock.(2) Loosen the nut of fuel strainer
and remove it.(3) Disconnect fuel pipe from fuel
strainer.* Wipe off spilt fuel thoroughly.Disconnect wire complete.
FastenersM8 x 20 ; 4 pcs.
Remove stopwitch. I screw ; 2 pcs.
RUBBER PIPE
Fig. 5-4
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Parts to removeControl box, Diode rectifier,Magnetic switch and Electricstarter (Option)
Remarks and procedures(1) Disconnect wiresand remove(2) Remove black wires from electric(3) Loosen two bolts and remove
control box.starter.electric starter.
Fasteners
M8 ; 2 pcs.
WIRE 2
M6 NU1
M6 FLANGE BOLT : 1 me.M6 SCREW(PANHEAD) :1 pce.
Fig. 5-5
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Step Fastenersemarks and proceduresarts to remove
7 Muffler and muffler bracket Be careful not o lose muffler gasket. M8 nut ; 2 pes.M8 x 16 ; 2 pcs.Remove carburetor carefullyspring from governor lever.
8 unhooking governor od and rodarburetor
M6 TAPPINGS C R E W :5 CS.
M8 FLANGE FFLER UNIT
Fig 5-6
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Parts to remove I Remarks and procedures(1 Unhook governor spring rom
governor lever.Mark the holeon which thegovernor spring s hooked.governor lever.
~~~~~
(2) Loosen the bol t and remove
GOVERNOR LEVERGOVERNOR ROD
GOVERNOR SPRINGROD SPRING
M6 BOLT ANDWASHER AY : pce. j
FastenersM6 bolt
Fig. 5-7
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Step Fastenersemarks and proceduresarts to removeRecoil starter
10 M6 x 8 ; 4 pcs.Pulley cover ; type DS andtype BS)
11 M6 x 12 ; 5 pcs..lower housing
M6 FLANGE BOLT: 4 pcs.\M6 FLANGE BOLT
BLOWER HOUSING CP /
PULLEY COVER CP(type W B S )
Fig. 5-8
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Step.
12
Parts toemove I Remarks and procedures I FastenersIgnitionoil I (1) Removeparklugaprom I M6 x 25 ; 2 pcs.
spark plug.crankcase.
(2) Remove ignition coil rom
13
M8 BOLT : pes.(Except type DS,BS)\
Flywheel (1) Remove the starting pulley.(2) Remove nut from crankshaft.
M8 x 12 ; 3 pcs.
(See Fig. 5-11 )(4) Remove the key from crankshaft.
flywheel puller. (See Fig. 5-10.)(3) Remove flywheel using the
spring washerSee Fig. 5-9.)M18 nut, washer,
SPARK PLUG CAP1\ STARTINGULLEY I
WOODRUFF KE
M6 BOLT ANDWASHER A Y :2 pcs./ IIGNITION COIL CPFig. 5-12
fig. 5-10 - 23- Fig. 5- 7
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Step astenersemarks and proceduresarts to remove14 M6 x 20 ; 2 pcs. Remharge coil (Option)15 Cylinderaffle M6 x 8 ; 4 pcs.16 I Spark plug NGK ;BPGES
CYLINDER BAFFLE 1with SPEED CONTROLa&) M6 FLANGE BOLT:2 pcs.
M6 SCREW (PANHEAD) :1 pce.
M6 FLANGE BOLT :2 pcs.
Fig. 5-13
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Step
20
Parts to removeintake and exhaust valves
Remarks and procedures(1) Press down spring retainer, ake
out collet valve, and then removespring retainer and valve spring.
(2) Remove intake and exhaustvalves from cylinder head..
Clean carbon and um deposit fromthe valves, valve seats,ports andguides.Inspect valves, valve seatsandguides.
Fasteners
INTAKE VALEXHAUST VAL COLLETALVE
VALVE SPRING
VALVE GUIDE
uFig. 5-15
I
Fig. 5- 6
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Step Fastenersarts to remove Remarks and proceduresI22 Camshaft and tappets Be careful not to damage camshaftand tappets.
Position piston at top dead centerand remove balancer.23 Balancer
IFig 5-79
Fig. 5-20
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Step
24
25
Parts to removeConnecting rod and piston
Piston and piston pin
Remarks and procedures(1 Remove connecting od bolts and(2) Turn crankshaft until piston
connecting rod cap.comes to top dead center, pushout connecting rod and pistonassembly through top of cylinder.
*Scrape off all carbon deposits thatmight interfere with removal ofpiston from upperend of cylinder.
(1 Remove clips andpiston pin toremove connecting rod frompiston.
(2) Remove piston rings from piston.*Be areful not to give damagesopiston and connecting rod.
Be careful not to break rings byspreading too much or twisting.
FastenersM8 x 40 ; 2 pcs
CLIPPISTON PIN \
\ PISYON RINGSPISTON
Fig 5-21
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Step
26
Parts to remove
Crankshaft
Remarks and procedures.Tap lightly on flywheel end ofcrankshaft to remove fromcrankcase.
I
Fig. 5-22
__1Fasteners
CRANKSHAFT-ig. 5-23
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5-4 REASSEMBLY PROCEDURESPRECAUTIONS FOR REASSEMBLY
1) Clean parts thoroughly before reassembly.Pay most attention o cleanlinessof piston, cylinder, crankshaft, connecting rod and bearings.
2) Scrape off all carbon deposits from cylinder head, iston top and piston ring grooves.3) Check lip of oil seals. Replaceoil seal if the lip is damaged. Apply oil to the lip before reassembl4) Replace all the gaskets with new ones.5 ) Replace keys, pins, bolts, nuts, etc., f necessary.6) Torque bolts and nuts to specification referring o the TORQUE SPECIFICATIONS .7) Apply oil to rotating and sliding portions.8 ) Check and adjust clearancesand end plays where specified in his manual.
5-4-1 CRANKSHAFT(1) Install crankshaft on crankcase wrapping the
key-way with polyvinyl tapeo avoid damageto oil seal.
(2) Installwoodruff key for flywheeln crankshaft.
Fig. 5-24
5-4-2 PtSTONAND PISTON RINGS(1) Install oil ring first, then second ring and top
ring.Spread ring only ar enough to slip over pis-ton and into correct groove. Use care not todistort ring.Install second ring with punched mark besidethe gap face upward. (See Fig.5-27)
OPEN ENDS OF PISTON RING
IFig. 5-25
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(2) Install piston and connecting rod assemblyinto cylinder.Use a piston ring compressor to hold pistonrings.The FAN mark of the connecting rod is toface flywheel side when assembled.
Note:(1) Apply enough oilo piston rings, con-
necting rod bearings and cylinderbore beforeassembly.
(2) Set gaps of the piston rings90 de-grees apart fromeach other beforeassembly.
5-4-4 CONNECTING ROD(1) Turn crankshaft to bottom dead center, lightly
tap topof the piston until large endf the rodmeet crank pin.
(2) Install connecting rod cap to connecting rodmatching alignment marks.Torque connecting rod bolts to specification.M8 40 mm connecting rod bolt : 2 pcs.
Tightening torque:22.1 - 27.0 N .m(225 275 kgmcm)(16.3 19.9 ftmlb.)
Fig. 5-29
i / - SECOND RING
Fig. 5-30
ALIGNMENT GARKSFig. 5-31
(3) Check for free movement of connecting rodby turning crankshaft slowly.
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Install balancer shaft to crankcase aligning match-ing mark of balancer gear and crank gear asshown in the illustration.
CAUTION :Incorrect timing of the gears wi l l causemalfunc tion of the engine and may re-sults in damage due to interference ofthe parts.
~~~
CRANKSHFT GEAR
~~
5-4-6 TAPPETS AND CAMSHAFT(1) Oil the tappets and nstall them.
Push in fully to avoid damage during camshaft installation.(2) Lubricate bearing surfaces f camshaft.
TIMING MARKSFig. 5-32
Align the timing mark on crankshaft gear with the timing mark on camshaft and install camshaftcrankcase. (See Fig. 5-32)
Incorrect valve t iming wi l l cause mal-function of the engine.
5-4-7 ADJUST CRANKSHAFTAND CAMSHAFT ENDPLAY(1) Adjust end play to the specified valuesusing the proper spacer.
The proper spacer may e determined following manner.
DEPTH GAUGE
MAIN BEARING COVER
I0 0t
I RANKCASE
Fig. 5-33- 34-
Fig. 5-34
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5-4-7-1 CRANKSHAFT END PLAY (For ype D and type B)1) Measure the depth Al (From the mating surface o the inner raceof the ball bearing.)2) Measure the height B l (From the mating surface to the crank gear.)
(A1+0.35)-81= SIDE CLEARANCE (mm)(SIDE CLEARANCE)-0.2 mm =THICKNESS OF CRANKSHAFT SHIM(mm)(A1 +O.O14)-Bl= SIDE CLEARANCE (in.)(SIDE CLEARANCE)-0.008 in.= THICKNESS OF CRANKSHAFT SHIM (in.)
Following are available spacer hims.CRANKSHAFT
T= 0.6mm (0.024 in.)SPACER SHIMS T= 0.8mrn (0.031n.)T= 1.0 rnrn (0.039 in.). Table.5-1
5-4-7-2 CAMSHAFT END PLAY (For type D and type B)1) Measure the depth A From the mating surface o the inner raceof the ball bearing.)2) Measure the height 82 (From the mating urface to the cam gear inner boss.)
(A2+0.35)-62=SIDE CLEARANCE (mm)(SIDE CLEARANCE)-0.2 mm = THICKNESS OF CAMSHAFT SHIM (mm)(A2+0.014)-B2= SIDE CLEARANCE (in.)(SIDE CLEARANCE)-0.008 in.= THICKNESS OF CAMSHAFT SHIM (in.)
Following are available spacer shims.CAMSHAFT
For type D For type BT= 0.6mm (0.024 in.)
T= 1.0 mrn (0.039n.)= 0.8 mm (0.031n.) T= 0.8 mm (0.031n.)= 0.7 mm (0.028n.)PACER SHIMST= 0.6 mm (0.024n.)
Table.5 2
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2) Lubricate the oil seal and bearing surfaces. Add a light filmfoil on main bearing cover face o holdtheasket in place.Placepacershosen at procedure (1) onrankshaftndamshaft.Use an oil seal guide when installing main earing cover to avoid damaging the seal.Tap the cover into place with asoft hammer.
NOTE ;Be sure to use two M8 12T)'BOLTS andWASHERS in two locations ust-the root of cylinder to asten themain bearing cover o crankcase. For other five locations,use M8 TT ) BOLT 8, WASHER ASSY.
\ M i BOLT (7T) ND WASHER AY : 5 pcs.M8 BOLT (12T) :2 pcs.Fig. 5-35
5-4-8 CYLINDER HEAD(1) Clean carbon and gum deposits from the valves, seats, ports and guides. Inspect valves, valve s
and valve guides.(2) Replace valves that are badly burned, itted or warped.(3) When installing valves in cylinder head, oil the valve stems and insert them into valve guide.
Then place cylinder headon fiat table, install valve spring and spring retainer.
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4) Valve guides shouldbe replaced when valve stem clearance exceeds specifications (See SERDATA).Draw valve guides out and press new guides in.Refer to SERVICE DATA for clearance specifications.After replacing valves and guides,ap valves in place until a uniform ring shows around the facthe valve. Clean valves and wash cylinder head thoroughly.
5 ) Install cylinder head to cylinder with new head gasket.Tighten four flange bolts evenlyn three steps by the following tightening torque:Cylinder headMI0 x 65 mm bolt : 4 pcs.I~ightening torqueI 1 st step I 2 nd step I Finaltepr ~~9.8N - m (24.6-30.4t . b.)1 4.5 ? Ib.)7.2t -Ib.) (340-420g cm)200 g scrn)100 g mcm) 33.3-41.2 m9.6 - m I
5-4-9 ROCKER ARMS AND PUSH RODS(1) Insert push rods into crankcase. Put ush rod tip in the hollow f tappet top.(2)Apply oil to rocker arms and assemble them to cylinder head using pivotnd nut.
pcs.
Fig 5-36
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5-4-10 VALVE CLEARANCE ADJUSTMENTNote:Temporally fit thelywheel in position foreasy operation.
(1) Position pistonat top dead center of compres-sion stroke by matching the mark T of fly-wheel with the thread hole @) of crankcase.
(2) Loosen the nutn rocker arm and turn the pivotto adjust the clearance between rocker armand valve stem end.Tighten the nut on rocker arm.
-
Valve clearance:0.085 - 0.115 m m(0.0034 0.0045 in.)
r Note:Check and adjust alve clearance whileengine is cold.Check operation of valves by turningcrankshaft. Then recheck the valve clear-ance.
(3) Install rocker cover nd gasket.Rocker coverM6 x 25 mm bolt : 4 pcs.
5-4-11 SPARK PLUGInstall spark plugo cylinder head.Spark plug :NGK BPGESI Tighteningorque 1
New spark plug 1 Retightening 111.8 - 14.7 N m (230 270 g .cm)120 150 kg cm) 22.6 26.5N m(8.7 - 10.9 ft . b.) (16.6 - 19.5 ft Ib.)
I 1 THREAD HOLE (01Fig. 5-37
AFig. 5-38
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5-4-12 CYLlNDER BAFFLEInstall cylinder baffle to cylinder head.M6 x 8 mm flange bolt 4 pcs.
5-4-13 FLYWHEELMAGNETO(1) Install chargecoil to crankcase. (Option)
Clamp coil wire to crankcase.Note:Be carefulnot to pinch coil wire betweencharge coiland crankcase.
(2) Put woodruff keyn keyway f crankshaft. Wipeoff oil and grease thoroughly from tapered por-tion of crankshaft and flywheel center hole.
(3) Installflywheel to crankshaft.Tighten flywheel nut with spring washer andwasher.
Tightening torque:78.4 98.0 N -m(800 - 1000 kg cm)(58.0 - 72.5 ft.lb.1
(4) Install starting pulley o flywheel.M8 x 12 mm bolt : 3 pcs.
Tightening torque:6.9 - 8.8 N m(70 - 90 kg -cm)(5.1 - 6.5 ft'lb.)
5-4-14 IGNITION COILInstall ignitioncoil to crankcase.Adjust air gap between ignition coil and flywheelusing a thickness gaugeand tighten bolts.M6 x 25 mm bolt : 2 pcs.
I Ai r gap :0.3 - 0.5 mrn(0.012 - 0.020 in.)
Fig. 5-39~~
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5-4-15 BLOWER HOUSING AND RECOIL STARTER(1) Attach blower housing to crankcase. Tighten
five flange bolts.M6 x 12 mm flange bolt :5 pcs.Insert the high tension cord from the ignitioncoil into the notch of the blower housing sothat not to pinch the cord.
(2) Install recoil startero blower housing.M6 x 8 rnm flange bolt : 4 pcs.
Note:Be careful of pulling direction of starterrope.
5-4-16 GOVERNOR, SPEED CONTROLSYSTEM AND CARBURETORInstall governor lever o governor shaft.Tighten locking bolt temporarily.Install speed control lever to cylinder baffle,friction washer, self lock nut, etc. s shown inillustration.Hook governor spring to proper holes of gov-ernor lever and speed control lever.(See Fig. 5-42 and below.)
I Hooking position Fig.5-42I Rated 3000 rprn (50 Hz) applications ]- 5-C~
GOVERNOREVEROVERNOR ROD
STOP PLATE
WASHER
CYLINDERBAFFLE1I Rated 3600 rpm 60 Hz)applications I 4-C I'(4) Install insulator and gaskets for carburetor to
cylinder head.Fig. 5-41
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(7) Adjust governor system.(a) Turn the speed control lever all the way
toward the high speed position and fix it bytightening self lock nut.
(b) Check that governor lever is pulled by gov-ernor spring and carburetor throttle valveis fully open.
(c) Turn governor shaft counterclockwise allthe way using a screw driver,and tightenlock bolt to secure the lever n the shaft.
(d) Loosen the self ock nut to allowhe speedcontrol lever o move freely.
5-4-17 MUFFLER
GOVERNOR
Fig. 5-43
(1) Install muffler bracket o cylinder head. M8 x 16 mm bolt: 2 pcs.(2) Install muffler-to muffler bracket. M8 flange nut :2 pcs.(3) Install muffler cover. M6 tapping screw: 5 pcs.
5-4-18 STOP SWITCH(1) Install stop switch o blower housing.(2) Connect wires referring o the wiring diagram.
5-4-19 ELECTRIC STARTER AND CONTROL BOX CP (Optional equipment)(1) Install electric starter to crankcase.(2) Install control box cp (include magnetic switch, diode rectifier and key switch)o crankcase.(3) Connect wires referring to the wiring diagram.
5-4-20 FUEL TANK(1) Install fuel tank to crankcase.
M8 x 20 mm bolt : 4 pcs.(2) Connect fuel strainer and fuel nlet of carburetor with the fuel hose. Be sureo clamp securely.
5-4-21 AIR CLEANERInstall air cleaner element and cleaner cover
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5-5 BREAK-IN OPERATIONAn engine that has been completely overhauled by being fitted with a new piston, rings, valves anconnecting rod should be thoroughly UN-IN before being put back nto service.Good bearing surfaces and running clearances between the various parts can only be establishedoperating the engine under reduced speed andoads for a short period of time.While the engine is being tested, check for oil leaks.Make final carburetor adjustment and regulate the engineperating speed.
Step
10 min.,600pmo Loadtep 310 min.,000 rpmo Loadtep 210 min.,500pmo Loadtep 1Timengine Speedoad
Step 4 3,600 rpm 30min.EH36
7.0 W (9.5 HP)H416.3kW (8.5 HP) EH363.5 kW (4.8 HP)H413.2 W (4.3 HP)
* Step 5 60min.,600 rpmTable.5-2
6. MAGNETO6-1 FLYWHEEL MAGNETO
The ignition system of the EH36/EH41 is a pointless flywheel magneto with automatic advancing cacteristic.Being different from the breaker point type ignition system, this system is completely free from sutroubles as starting-up failure dueo dirty, burnt or corroded point surface.The electronic automatic advancing ensures extremely easy starts and stable high performanating speed by advancing the ignition timing o the most suitable point.
6-2 BASIC THEORY(1) Revolution of the flywheel generates electricity on the primary sideof the ignition coil, and the b
current 11 flows to the power transistor.Current 11 turns the power transistorONnd the electric currentI2 flows.
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(2) At lower engine revolution, when the flywheel reached the ignition point the low speed ignition timingcontrol circuit operates to runhe base current I3 to turn he signal transistor A ON allowing thecurrent 11 to bypass as current 14.At this moment the power transistor turns OFFnd the currenth s abruptly shut resulting in thehigh voltage generated inhe secondary coil which produces sparks t the spark plug.
(3) At higher engine revoluti.on, he advancing control circuit operates at the ignition timing to run thebase current I5 to turn the signal transistorE3 ON allowing the current 11 to bypass as currents.At this moment the power transistor turns OFF and the current h s abruptly shut resulting in thehigh voltage generated n the secondary coil which produces sparks t the spark plug.The operating timing of the advancing control circuit advances in accordance with the increase ofengine speed resulting in the advancingof ignition timing as shown in Fig. 6-l(b ).
Fig 6-7 a)ELECTRONIC ADVANCING FLYWHEEL
(B.T.D.c.) MAGNETOSYSTEMf TEP ADVANCINGI I I500 1000 2000 3000 (r.p.m.)
ENGINE REVOLUTIONFig. 6-1 (b)
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6-3WIRING DIAGRAMSTANDARD
IgnitionCoil Connectortopwitch
Spark plug
/ / /
FlywheelFig. 6-2
ENGINEWITH ELECTRIC STARTER
Electrictarteragneticwitch
Fig. 6-3
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.AUTOMATIC DECOMPRESSION SYSTEMEH36, 41 engines are employinghe automatic decompression system s a standard feature.This enables easy and light startf the engine.The automatic decompression system releases the compressionf the engine by lifting up the exhaustvalve at the cranking. Following are the explanation usingype D engine as a sample how the systemworks. The components of the systems are different for the type D and B engines, however, thepinciple of the function is same.At the end of the compression process, he release lever ifts up the tappet which n turns opensup theexhaust valve slightly to release the compression. The release lever has a flyweight on its end andanother end of the lever is a crescent cam.When the engine is cranked, the cresent cam projects he camshaft cam profileand lifts up the tappetbecause the gravity force on the weights larger than the centrifugal force on the weight.
CRESCENT CAM
EXHAUST CAM
LEVER
CAMSHAFTFig. 7-1
When the crankspeed reaches up to a certain revolution,he cresent cam s retracted into the camshaftcam profile becausehe centrifugal force applied ontohe flyweight becomes largerhan the gravity forceand the weight and is shifted to the position shownn the illustration.
FLYWEIGHT
CRESCENT CAM
EXHAUST CAM
LEVER
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8. CARBURETOR8-1 OPERATION AND CONSTRUCTION8-1-1 FLOAT SYSTEM
The float chamber is located below the carbure-tor body and, with a float and a needle valve,maintains a constant fuel level during engineop-eration.The fuel flows from the fuel tank into the floatchamber through needle valve. When the fuelrises to a specific level, the float rises, and whenits buoyancy and uel pressure are balanced, theneedle valve closes to shutoff the fuel, therebykeeping the fuelat the predetermined level.
PILOT OUTLET1
_ _' _ESIX
Fl
Fig. 8-1
PILOT JET_
I I-OAT
- \ MAIN JETFig. 8-2
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8-1-2 PILOT SYSTEMThe pilot system feeds the fuel to the engine during idling and low-speed operation. The fuel is fedthrough the mainet to the pilot jet, wheret is metered, and mixed with the air meteredy the pilot air jet.The fuel-air mixture ised to the engine through the pilot outlet and the by-pass.t idling speed, the fuelis mainly fed from the pilot outlet.
8-1-3 AIN SYSTEMThe main system feeds the fuel tohe engine at mediumand high-speed operation.The fuel is meteredby the main jet and fed to the main nozzle. The air metered by the main air jet is mixed with the fuelthrough the bleed holes n the main nozzle, and the mixtures atomized outof the main bore. It is mixedagain with the air taken throughhe air cleaner into an optimum fuel-air mixture, whichs supplied to theengine.
8-1-4 CHOKEThe choke s used for easy start when engines cold. When he starter is operated ith a closed choke,the negative pressure applied to the mainnozzle increases and draws much fuel accordingly ; thuseasily start uphe engine.
8-2 DISASSEMBLY AND REASSEMBLYApart from mechanical failures, most of carbure-tor troubles are caused by an incorrect mixingratio, which may arise mainly due toclogged upair or fuel passage in jets, or fuel level variations.In order to assure proper flowof air and fuel, thecarburetor must be kept clean at all times. Thecarburetor disassembly and reassembly proce-dures are as follows.
8-2-1 THROTTLE SYSTEM(1 The spring (4) can be taken out by removing
the throttle stop screw 5).(2) Remove the Phillips screw1) and throttle valve(2), and pull out the throttle shaft (3).*Exercise care not to damage throttle valve ends.
1 2 3 1 1
1921
13
1 8 dl 2-
ig. 8-3- 48-
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8-2-2 CHOKE SYSTEM1) Remove the Phillips screw(6) and choke valve 7),and pull out the choke shaft (8).(2) When reassembling the choke shaft, makeure that the cutout in the choke valve faces the pilot a
jet. Meantime, when reassembling sethe rings (9) and 1 0 ) at the right position.
8-2-3 ILOT SYSTEM(1) emove the pilot jet ll), using correct ool to avoid damage to it.(2) Reassembly
Tighten the pilot et securely. Otherwise, the fuel may leak, causing engine malfunction.
8-2-4 MAIN SYSTEM(1) Remove the bolt (12) nd take out float chamber body13).(2) From the body(14)emove the main jet 16) nd guide holder.And then remove the main nozzle1 53)Reassembly
a) Fasten the main jet and main nozzle securelyo the body. Otherwise, the fuel may become toand cause engine malfunction.
b) The bolt (12)ightening torque is 90 kg-cm. Be sure to set the gasket 19) and washer (18) fochamber (13).
8-2-5 FLOAT SYSTEM(1) Pull out the float pin (20) and remove the loat (21) nd then remove the clip (22) nd needle val
(23).f the needle valve need o be replaced, replace it with rubber needle.
CAUTION :When cleaning the jets, use neither adrill nor a wi re (because of possib le damage of theorifice which will adversely affect fuel low). Be sure to use compressed air to blow themclean.
(2) When removing the needle valve and float, gently tap the reverse side using the rod more slendthan the float pin and remove, since theloat pin is calked to the carburetor body.
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9. STARTING SYSTEM9-1 RECOIL STARTER
Trouble in the recoil starter rarely happens while t is in normal operation.If the starter develops trouble or when it is lubricated, carry out in accordance with following disassembling and assembling procedures.
Tools ; Box spanner (spanner)PliersScrewdriverNippers or Knife
9-1-1 HOW TO DISASSEMBLE (type D)(1) Remove the recoil starter from engine.(2) Pull the starter knob to draw, out the starter
rope by about30 cm and tie a tentative knotas show in Fig. 9-1.
(3) Untie the knot nside the knob to remove theknob.
4) Hold the starter case and the reel firmly withyour left hand nd untie the tentative knot with
, your ighthand.Continue to hold the case and the reel withyour left hand and hold the reel center withyour right hand, then loosen both hands alter-nately to allow the reel graduallyo turn to thearrow direction until the spring is completelyreleased.(Do this carefully to avoid dangers caused byspring-back.)
7Y STARTER ROPEFig. 9-
STARTERCASE
Direction to releaseFig. 9-2
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(5) Remove each part in accordance with Fig.-31. Center screw2. Friction plate3. Friction spring4. Ratchet5. Ratchet spring6. Reel
Take out the reel slowly while turning it backand forth gently, otherwise the spring mays-cape from he case which may nvite danger.(If the spring escapes, putt in the housing byfollowing procedures shown n Fig. 9-8.)Untie the starter rope knot at reel end and with-draw it to complete disassembling.
9-1-2 HOW TO REASSEMBLE (D-Type)(1) Cut off a part of the reel shown n Fig. 9-4 witha nippers ora knife to form a which is required
when pre-winding he spring.
(2) Check that the spring s securely set in thereel and formhe spring end to measuremmto 2 mm for clearance between inner end ofthe spring and the reel bushing edge so thatthe hook catches securely as shown inFig. 9-5.The shapeof spring inner end (approx.0cmfrom the end) may be adjusted with a plier ifnecessary.
(3) Apply a small amountof grease to the startershaft and to the spring.
STARTER SHAFTGrease is to be applied)
Fig. 9-3
Fig. 9-4
Outer end of sprinSPRINGOUSING \ er end of spring
Apply greaREEL BUSHING
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(4) Pass the starter rope throughhe starter knoband tie the rope endo make a tight overhandknot as shown in Fig. 9-6. Then put the knotinto the knob.
(5) Pass the other endf the .rope from the startercase to he reel andmake a knot as llustratedabove, then put the rope end securelynto therope housing n the reel.
6) Wind the starter rope by1.5 turns in the arrowdirection as shown in Fig.9-7 to let the ropeout of the reel through the notch, then installthe reel securely in the starter caseso thatthe hook catches inner end ofhe spring.
(7) Hold the starter rope as shown n the Fig.9-7and rotatehe reel 6 tums by applyinghe forcedirectly to the reel notch. (pre-winding)Hold the reel securely to prevent it from re-verse turn and pull the starter knob o stretchthe rope tight then release the knob slowly.
Reassemble the parts in reverse orderof dis-assembling shown in Fig. 9-3.Tighten the center screw securely.
*This concludesdisassembling/reassembling.Be sure to check the followingo make sureofit.
Puli the rope
Fig.9-6
STARTER CASE
Strech rope them release itafter pre-wound
Fig. 9-7
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9-2 ELECTRIC STARTER
I NOTE;For Electric starter operation, lectric wiring should be connected among electric starter,magnetic switch, key switch nd battery as shown in the diagram.
Ignitionoilnit BlackI I
Green
'Electrictarteragneticwitch
Fig. 9-9
wire
9-2-1 OPERATION AND FUNCTIONWhen key switch is turnedN, lower electric currentM -) flows through coilf magnetic switch and thecoil is excited. The plunger is pulled and higher current (S- flows through electric starter.When electric starter is operated, pinion gear is pushed out by means of centrifugal force of weightlocated in the spline of armature shaft. The pinion gear is engaged with ring gear and flywheel andcrankshaft are rotated.
M'
S S
B A l T E R YELECTRIC STARTER
KEY SWITCH
Fig 9-70
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9-2-2 COMPORNENT PARTS
Fig. 9-11
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The following three conditions must beulfilled for satisfactory engine start.1.The cylinder illed with a proper fuel-air mixture.2. Good compression in the cylinder.3. Good spark, properly timed,o ignite the mixture.The engine cannot betarted unless these three conditions are met. There are also other factors whmake engine start difficult,. g., a heavy load on he engine when t is about to start at low speed, andhigh back pressure due o a long exhaust pipe.The most common causes f engine troublesare given below :
10-1 STARTtNG DlFFtCULTtES10-1 1 FUEL SYSTEM
(1) No gasoline in the fuel tank,or the fuel cock closed.(2) The carburetor s not choked 'sufficiently especially whenhe engine is cold.(3) Water, dust or gum in the gasolinenterfering he fuel flow o the carburetor.(4) Inferior grade gasolineor poor quality gasoline ot vaporized enough o produce the correct fuel-air
mixture.(5) he carburetor needle valves held open by dirt or gum. This trouble can be detecteds the fuel flows
out of the carburetor when he engine is idling. (Overflow)This troublemay be remedied by lightly tapping the float chamber with the gripf a screwdriver or thelike.(6) If the carburetor overflows, excessive fuel runs into the cylinder when starting the engine, making fuel-air mixture too rich to burn.f this happens, remove the spark plug, and turn the starting pulleyfew turns in order to let the ich fuel-air mixture out of the spark plug hole into the atmosphere.Keep the choke valve open during his operation.Dry the spark plug well, screw it into place, and try o start again.
10-1 2 COMPRESSIONSYSTEMIf starting difficulties and loss of power are not due to the uel system or ignition system, the followingsmust be checked for possible lack f compression.(1) Engine inside s completely dried up because f a long period of storage.(2) Loose or broken spark plug. This causeshissing noise made by mixture gas running outf cylinder
in compression strokeduring cranking.(3) Damaged head gasketor loose cylinder head.A similar hissing noise is produced during compres-
sion stroke.
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(4) Incorrect Valve clearanceIf the correct compression s not obtained even after remedying he above, disassemble he engiand check further asollows :a) Valve stuck open due to carbon r gum on the valve stem.b) If the piston ringsare stuck on the piston, remove he piston and connecting rod from the.eng
Clean or replace he parts.10-1 3 IGNITION SYSTEM
Check the followings forack of sparks.(1) Wires of the ignition coil, spark lug or contact breaker disconnected.(2) Ignitioncoil damaged and shorted.(3) Spark plug cable wet or soaked with oil.(4) Spark plug dirty or wet.5)Spark plug electrode gap incorrect.
(6) Spark plug electrodes re connected or bridged.(7) Incorrect spark timing.
10-2 ENGINE MISFIRES(1) Incorrect spark plug electrode gap. Adjustt to anywhere between0.7 and 0.8 mm.(2) Ignition cable wornand leaking.(3) Sparks weak.(4) Ignition wire connections loose.5 )Water in gasoline.
(6) Insufficient compression.
10-3 ENGINESTOPS(1) Fuel tank empty, Water, dirt, gum, etc. in gasoline.(2) Vapor lock, i. e., gasoline evaporating n the fuel lines dueo overheat around the engine.(3) Vapor lock n the fuel lines or carburetor dueo the use of too volatile winter gas n the hot seaso(4) Air vent hole n the fuel tank capplugged.(5) Bearing parts seized dueo lack of oil.(6) Magneto or ignition coil faulty.
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10-4 ENGINE OVERHEATS(1) Crankcase oil level low. Add oil immediately.(2) Spark timing incorrect.(3) Low grade gasoline is used, or engine is overloaded.(4) Cooling air circulation restricted.5 )Cooling air path misdirected causesoss of cooling efficiency.(6) Cylinder head cooling fins clogged up with dirt.(7) Engine operated n an enclosed space without sufficient coolingir.(8) Exhaust gas discharge restricted, or carbon depositsn the combustion chamber.(9) Engine running on low-octane gasoline detonates dueo heavy loadat low speed.
10-5 ENGINE KNOCKS(1 Poor quality gasoline.(2) Engine operating under heavy loadt low speed.(3) Carbon or lead depositsn the cylinder head.(4) Spark timing incorrect.(5) Loose connecting rod bearing due to wear.(6) Loose piston pin due to wear.(7) Curses of engine overheat.
10-6 ENGINE BACKFIRES THROUGH CARBURETOR(1 Water or dirt in gasoline, or low-grade gasoline.(2) Intake valve stuck.(3) Valves overheated, or hot carbon particles n the combustion chamber.(4) Engine cold.
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11. INSTALLATIONEngine ife,easeofmaintenance and inspection, requency of checksand epairs, and operatingcost aldepend on the way in which the engines installed. Review he following instructions carefully for insting the engine.
11-1 INSTALLINGWhen mounting he engine, carefully examinets position, the method f connecting it to a machine, thfoundation, and the method f supporting the engine.When determining its mounting position, in particular, make sure that gasoline and oil can easily besupplied and checked,he spark plug can easily be checked, their cleaner can easily be serviced, that the oil can easily be discharged.
11-2 VENTILATIONFresh air is necessary for cooling the engine nd burning the fuel.In the case the engine s operated under a hood or in a small room, temperature risen the engine roocan cause vapor lock, oil deterioration, increased oil consumption,oss of power, piston seizure, shorteengine life, etc., makingt impossible to operate the engine properly. Its necessary, therefore, o providea duct orbaffle to guide cooling air to the engine to prevent recirculation of he hot air used for enginecooling, and temperature riseof the machine. Keep the engine room temperature below0'C even in thehottest period of the year.
11-3EXHAUST GAS DISCHARGEExhaust gas is noxious. When operating the engine indoors, be sure to discharge the exhaust gasoutdoors. If a long exhaust pipes used in such a case, the internal resistance increases causingoss oengine power. Thus pipe inside diameter must be increased in proportion to exhaust pipe lengthExhaust pipe : Less than3 m long, pipe inside diameter0 mm ,Less than 5 m long, pipe inside diameter3 mm.
11-4 POWER TRANSMISSION TO DRIVEN MACHINES11-4-1 BELT DRIVE
Take the following notes nto consideration.* V-belts are preferable to lat belts.* The driving shaft of the engine must be parallelo the driven shaft of the machine.* The driving pulley of the engine must be inine with the drivenpulley of the machine.* Install the engine pulley asclose to the engine as possible.* If possible, span the belt horizontally.* Disengage the oad when starting the engine.If no clutch is used, use a belt tension pulley orhe like.
11-4-2 FLEXIBLE COUPLINGWhen using a flexible coupling, run out and misalignment between the driven shaft and engine shafmust be minimized. Run out and misalignment tolerance are specifiedy the coupling manufacturer.
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12. SERVICE DATA12-1 CLEARANCE DATA AND LIMITS
ITEM
'Valve seat contactwidth
Valve guide inside dia.
~ ~~
IN. EX.
Unit :mm (in:EH36EH41
STD
, 0.05or less(0.002 r less)
0.7 1.O(0.028 0.039)
6.035 6.053(0.2376 0.2383)
Limit
0.1(0.004)
2.0(0.079)
6.15(0.242)
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Unit :mm (in
~:YLINDERInside dia.
' Roundiness after reboring.
' Cylindricity after reboring.
I ST0N' Piston size At skirt in thrust direction)
t
STD
1 streboring
2 streboring
STD
1 s t o / s
2nd o / s
EH36EH41STD
89.000 89.022(3.504 3.505)
89.250 89.272(3.514 3.515)
89.500 .89.522(3.524 3.525)
0.01(0.004)
0.015(0.0006)
88.96 80.98(3.502 3.503)
89.21 89.23(3.512 3.513)
89.46 89.48(3.522 3.523)
Limit
To be rebored whenhe difference betweennax. and min. ofiiameter reached o1.1 (0.004).
Ditto
88.07(3.499)
89.1(3.509)
89.37(3.51 9)
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Unit :m m (in)EH36EH41ITEM STD Limit
0.15(0.006)0.15
(0.006)0.20
(0.008)
0.05 - 0.09(0.002 - 0.0035)
ISTONRing groove side clearance
0.03 - 0.07(0.0012 - 0.0028)nd
~~
Oil ring 0.045- .140(0.0018 0.0055)' Piston pin hole
Piston pin outside dia.
21.035(0.8281)
20.989 - 21.002(0.826 - 0.827)
20.991 - 21.OOO(0.8264 - 0.8268) 20.960(0.8251)
* Clearance between piston and cylinder at skirtarea.
0.025 - 0.064(0.0010 0.0025)
0.25(0.0098)
* Piston ring end gap 1.5(0.0591)
0.15 0.35(0.0059 - 0.0138)
~
2nd 1.5(0.0591)0.40.6
(0.0157 - 0.0236)
0.2 0.7(0.0079 0.0276)
1.5(0.0591)il ring
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Unit :mm inITEM
CONNECTING RODBig end inside dia.
Clearance between big endand crankpin
Small end inside dia.
* Clearance between smallend and piston pin
120'
* Big end side clearance
CRANKSHAFT
* Journal dia.
* Clealance betweenjournal and main bearing
EH36EH41STD
38.000 38.016(1.4961 1.4967)
0.030 0.060(0.0012 0.0024)
21.010 21.023(0.8272 0.8277)
0.010 0.032(0.0004 0.0013)
0.1 0.7(0.0039 0.0276)
37.956 37.970(1.4943 1.4949)
34.986 34.997(1.3774 I .3778)
-0.009 0.014(-0.00035 0.00055)
Limit
38.100(1.5000)
~~
0.2(0.0079)
21.080(0.8299)
0.1(0.0047)
1 .o(0.0394)
37.85(1.4902)
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EH36EH41ITEM STD LimitCAMSHAFTCam height (1N. and EX.)
35.26 35.46(1.3882 1.3961)
35.1(1.3823)
I * Journal outside dia.D type 24.967 24.980
(0.9830 0.9835)24.950(0.9822)l
D2
IN.
D
19.950(0.7854)
19.967 19.980(0.7861 0.7866)
VALVE* Valve stem outside dia.
*Clearance between valvestem dia. and valveguide.
5.970 5.985(0.2350 0.2356)
5.850(0.2303)
5.960 5.975(0.2346 0.2352)
5.850(0.2303)X.
0.30(0.01 18)
0.050 0.083(0.0022 0.0033)N.
0.060 0.093(0.0024 0.0037)
0.30(0.01 18)X.
I Valve clearance
0.085 0.1 15(0.0034 0.0045)
IN. EX.cold)
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Unit :m m (in)EH36EH41ITEM
TAPPETStem outside dia.
VALVE SPRING FREE LENGTH
VALVE SEAT ANGLE (IN. and EX.)Valve cutter angle (a)* Valve contact width b)
~~ ~~
U
l a
STD
7.960 7.975(0.3134 0.3140)
8.00 8.01 5(0.3150 0.3156)
0.025 0.055(0.0010 0.0022)
36.5(1.4370)
a : 90b : 0.7 1 O(0.028 0.039)
Limit
7.93(0.31 2)
8.08(0.31 81
0.15(0.0059)
2.0(0.079)
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13.MAINTENANCE AND STORAGEThe following maintenance jobs apply when the engine is operated correctly undernormal conditionsThe indicated maintenance intervals arey no means guaranteesor maintenance free operationsduring these intervals.For example, f the engine is operated in extremely dusty conditions, the air cleaner shoulde cleaneevery day insteadof every 50 hours.
13-1 DAILY MAINTENANCEMAINTENANCE ITEMS
2) Check fuel leakage from fuel system.f any,Governor linkage is especially sensitive to dust.) Clean away dust and chaff from engine.
REMARKS
retighten fasteners or replace necessary parts.3) Inspect for loose hardware and retightenf Loose bolts and nuts may come and result in
necessary. I breakageof other parts.4) Check oil level and add to full mark.
I-
13-2 INITIAL 20 HRS. MAINTENANCEMAINTENANCE ITEMS REMARKS
1) Clean crankcase oil. To remove sludge from run-in operation.
13-3 EVERY 50 HRS. (10 DAYS) MAINTENANCEMAINTENANCE ITEMS
1) Change crankcase oil.2) Clean air cleaner.3) Check and clean spark plug.
REMARKSContaminated oil quickens wear.
If dirty, wash in gasolineor polish with emery paper.
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13-4 EVERY 100-200 HRS. (MONTHLY) MAINTENANCEMAINTENANCE ITEMS REMARKS
1) Clean fuel filter and fuel tank.2) Inspect cooling system and remove dirt andhaff.
Remove blower housing and clean up betweeninsand housina.
13-5 EVERY500-600 HRS. MAINTENANCEMAINTENANCE ITEMS REMARKS
1) Remove carbon from cylinder head. Carbon deposits n combustion chamber causes lackof power.2)Disassemble and clean carburetor.
13-6 EVERY 1000 HRS. (YEARLY) MAINTENANCEMAINTENANCE ITEMS REMARKS
1) Overhaul engine. I Clean and correct parts.Replace piston rings and other necessary parts.2) Replace fuel lines once a year I Avoidazardsaused by fuel leakage. I
13-7 ENGINE STORAGE1) Perform the above 13-1 and 13-2 maintenance jobs.(2) rain fuel from the fuel tank and carburetor float chamber.(3) To prevent rust in the cylinder bore, apply oil through the spark plug holeand turn the crankshaft. several urns by hand. Reinstall the plug.(4) Turn the starting pulleyby hand and eave it where the resistance is the heaviest.(5) Clean outsideof the engine with oiled cloth.(6) Put a plastic over or the like over the engine and store the enginen dry place.
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SU6ARU
~bin America Inc.