2. PERFORMANCE 2-1 MAXIMUM OUTPUT The maximum output is the output of an engine with its throttle valve fully opened under the condition that all the moving parts are properly worn in after the initial break-in period. A new engine may not produce full maximum output while its moving parts are still not broken-in. NOTE : Power curves shown in the following charts are made in conformity to SAE internal combustion engine standard test code J1349...
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2-4 PERFORMANCE CURVES EH72D ( kgf-m ) 55 ( 5.61 ) 45 ( 4.59 ) MAXIMUM TORQUE ( 26.8 ) MAXIMUM HORSEPOWER ( HP ) (20.1) CONTINUOUS RATED HP (13.4) RECOMMENDED HORSEPOWER RANGE ( 6.7 ) 2000 2400 2800 3200 3600 REVOLUTION r.p.m...
3. FEATURES Highly rigid structure High-carbon steel, forged crank shaft Light-weight , tough alminum forged connectiong rod Ball-bearing Special cast iron cylinder liner Long-lasting structure Forced pressure lubrication of crankshaft by directly connected trochoid pump Standard equipped oil cooler ensures a good lubrication environment Ball bearing installed in the throttle bearing of the carbureter Reliability Unusually high dust proofing by a double compartment air cleaner and inner vent type carbureter...
4. GENERAL DESCRIPTION OF ENGINE COMPONENTS ROBIN EH72D engine is air-cooled, 4-stroke, twin-cylinder, OHV arrangement gasoline engine. The twin- cylinder is located in the angle of 90 degree; #1 cylinder is in the RH side and #2 cylinder in LH side as viewed from flywheel (cooling fan) side.
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4-4 CONNECTING ROD AND PISTON The connecting rod is forged aluminum alloy, and its large and small ends function as bearings. The piston is an aluminum alloy casting, and carries two compression rings and one oil ring. Fig. 4-4 4-5 PISTON RINGS The piston rings are made of special cast iron.
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4-7 CYLINDER HEAD The cylinder head is an aluminum die-casting which utilizes semi-spherical type combustion chamber for the high combustion efficiency. Fig. 4-7 4-8 VALVE ARRANGEMENT The intake valve is located on flywheel side of the cylinder head. The cooling fins and passages design lead cooling air to the exhaust valve area for the optimum cooling.
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4-10 COOLING SYSTEM The large fins on the flywheel provide sufficient cooling air capacity for cylinder and cylinder head. The cylinder baffle helps the cooling air flow efficiently. 4-11 LUBRICATION SYSTEM The engine is furnished with full pressure lubrication system. The trochoid type oil pump is driven by crankshaft and delivers pressurized engine oil through the full- flow type oil filter to the journal and pin portions of...
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4-14 CARBURETOR The engine is equipped with a down draft carburetor that has a float controlled fuel system and a fixed main jet. The carburetors are calibrated carefully for the sure FUEL CUT SOLENOID VALVE starting, low fuel consumption and sufficient output. Fuel cut solenoid valve is provided to prevent engine running on when the key switch is turned to off.
5. DISASSEMBLY AND REASSEMBLY 5-1 PREPARATIONS AND SUGGESTIONS When disassembling the engine, memorize the locations of individual parts so that they can be reassembled correctly. If you are uncertain of identifying some parts, it is suggested that tags be attached to them. Have boxes ready to keep disassembled parts by group.
5-3 DISASSEMBLY PROCEDURES Step Parts to remove Remarks and procedures Fasteners Drain engine oil by removing plugs located on Engine oil drain both side of crankcase. Muffler cover M6 x 12 : 6 pcs. Muffler M8 nut : 4pcs. M8 x 16 bolt and Muffler bracket washer : 2pcs.
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Step Parts to remove Remarks and procedures Fasteners Air cleaner cover and elements Remove breather pipe from #1 cylinder head. Air cleaner base M6 x 12 : 3 pcs. WING NUT CLEANER COVER BREATHER PIPE Fig. 5-4 STEP 5 M6 FLANGE BOLT : 3 pcs.
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Step Parts to remove Remarks and procedures Fasteners M6 x 12 : 2 pcs. Blower housing M6 x 14 : 6 pcs. (1) Remove the choke knob. Chock control lever and link M6 bolt : 1 pc. (2) Remove the choke contol link. LINK PIVOT WAVED BLOWER HOUSING...
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Step Parts to remove Remarks and procedures Fasteners Carburetor M8 x 80 : 2 pcs. At first remove fuel pipe. Take out carburetor along with governor rod and rod spring. M8 FLANGE BOLT : 2 pcs. CARBURETOR FUEL PIPE STEP 9 Fig.
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Step Parts to remove Remarks and procedures Fasteners Governor lever ; M6 x 12 : 3 pcs. Remove bolt and take out lever. M6 self-lock nut Speed control lever ; (1) Governor spring Governor lever and (2) Self lock nut Speed control lever (3) Stop plate (4) Spring washer...
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Step Parts to remove Remarks and procedures Fasteners Fuel pump Remove pluse pipe at first. M6 x 12 : 2 pcs. Ignition coil (1) Take out plug cap. M6 x 30 bolt & (2) Remove ignition coil. washer : 4 pcs. (3) Cut out stop wire fixing bands.
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Step Parts to remove Remarks and procedures Fasteners Remove key from crankshaft and then pull M18 nut, washer, Flywheel out flywheel by using puller. spring washer M5 x 20 : 4 pcs. (15A coil) Charge coil M5 x 25 : 4 pcs. (30A coil) M18 NUT : 1pce.
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Step Parts to remove Remarks and procedures Fasteners Cylinder baffles M6 flange bolt x 12 (#1, #2, #3 & #4) : 10 pcs. M6 flange bolt x 12 Regulator and Stop diode : 1 pce. TO OIL PRESSURE SWITCH STEP 18 TO IGNITION COIL M6 FLANGE BOLT : 2 pcs.
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Step Parts to remove Remarks and procedures Fasteners Oil cooler Take out oil hoses M6 Flange bolt : 4 pcs. BRACKET UNIT M6 FLANGE BOLT : 2 pcs. OIL COOLER STEP 19 M6 FLANGE BOLT : 2 pcs. HOUSE CLAMP HOUSE CLAMP HOUSE CLAMP...
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Step Parts to remove Remarks and procedures Fasteners Rocker cover M6 x 12 : 8 pcs. When removing “rocker arm” and “Bolt,pivot”, M10 x 65 : 8 pcs. turn and adjust flywheel at TDC with the Cylinder head and Push rod marking “T”...
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Step Parts to remove Remarks and procedures Fasteners M6 x 00 : 2 pcs. Intake & exhaust valves Breather cover Breather plate COLLET-VALVE COLLET-VALVE SPRING RETAINER VALVE SPRING SPRING RETAINER SEAL-INTAKE VALVE (BLACK) VALVE SPRING Fig. 5-20 GASKET , breather plate BREATHER PLATE GASKET , breather plate BREATHER COVER...
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Step Parts to remove Remarks and procedures Fasteners Main bearing cover M8 x 45 : 10 pcs. Take out key from PTO shaft. Rap PTO shaft with polyvinyl tape not to damage oil seal by key groove edge. GOVERNOR SLEEEVE GOVERNOR GEAR WASHER : 2 pcs.
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Step Parts to remove Remarks and procedures Fasteners Camshaft and tappet Mate the markings both on crankshaft gear and camshaft gear and then take out camshaft. Put the marking of original position onto each tappet for reassembly. Fig. 5-24 TAPPET STEP 26 TAPPET CAMSHAFT...
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Step Parts to remove Remarks and procedures Fasteners Piston and Connecting rod (1) Remove connecting rod bolts. M8 : 4 pcs. *Piston pin clip (2) Take out connecting rod cap. *Piston pin (3) Push the connecting rod upwards and *Piston rings take out along with piston.
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Step Parts to remove Remarks and procedures Fasteners Crankcase *Oil pump *Oil filter M6 x 00 : 3 pcs. *Oil pressure switch *Oil pump filetr 10-32 x 11 *Oil relief spring & ball *Governor lever shaft M6 FLANGE BOLT : 4 pcs. OUTER ROTER INNER...
5-4 REASSEMBLY PROCEDURES 5-4-1 PRECAUTIONS FOR REASSEMBLY 1) Clean parts thoroughly before reassembly. Pay most attention to cleanliness of piston, cylinder, crankshaft, connecting rod and bearings. 2) Scrape off all carbon deposits from cylinder head, piston top and piston ring grooves. 3) Check lip of oil seals.
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B. CYLINDER HEAD, VALVES and ROCKER ARM NOTE ; * Clean valves and wash cylinder head thoroughly. * Remove carbon and gum deposits from the valves, seats, ports and guides. * Inspect valves, valve seats and valve guides. * Replace valves that are badly burned, pitted or warped. * Valve guides should be replaced when valve stem clearance exceeds specifications.
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C. PISTON and CONNECTING ROD (1) Install oil ring first, then second ring and top ring. Spread ring only far enough to slip over piston and into correct groove. Use care not to distort ring. NOTE ; * Install second ring with punched mark beside the gap on the top side. * Top ring can be fit either way.
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5-4-3 Re-assembly CRANKSHAFT 1) CRANKSHAFT Install crankshaft onto crankcase. NOTE ; Apply enough oil to bearing portion of crankcase. For easy installation, put crankcase on box or wood blocks. Fig. 5-32 2) PISTON and CONNECTING ROD (1) Install piston and connecting rod assembly into PISTON RING COMPRESSOR cylinder by using a piston ring compressor to CONNECTING ROD...
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3) TAPPET and CAMSHAFT CAMSHAFT GEAR (1) Apply oil to tappets and install in their original position. Push in fully to avoid damage during camshaft installation. (2) Lubricate bearing surfaces of camshaft. Install camshaft into the crankcase with the timing mark on both crankshaft gear and camshaft alined.
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5) MAIN BEARING COVER (1) Put a oil seal guide onto PTO shaft portion to avoid damaging the main bearing cover oil seal. (2) Place gasket onto the mating surface of crankcase. (3) Lubricate oil seal lip portion and bearing surfaces, and install main bearing cover. Tighten bolts evenly to the specified torque.
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(3) Insert push rods into the concave portion of tappet and set the other end to the concave portion of rocker arm adjust screw with valve spring depressed. (4) Temporally tighten adjust screw. 9) VALVE CLEARANCE ADJUSTMENT NOTE ; Temporally fit the flywheel in position for easy operation. (1) Rotate crankshaft clockwise to the TDC (top dead center) THICKNESS GAUGE of compression stroke by matching the mark "T"...
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11) BREATHER PIPE and COVER Attach breather plate (breather valve) and GASKET , breather plate breather cover to crankcase using proper gaskets. BREATHER PLATE Put breather plate in such position as its reed valve opens outside. Tightening torque 2.9 - 4.9 N m (30 - 50 kgf cm) (2.2 - 3.6 ft lb.) M6 FLANGE...
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16) INTAKE MANIFOLD GASKET, muffler Set gasket (stainless steel) onto both #1 and #2 M8 FLANGE NUT : 2 pcs. cylinder head and install intake manifold. INTAKE MANIFOLD Tightening torque 16.7 - 18.6 N m (170 - 190 kgf cm) M8 FLANGE (12.3 - 13.7 ft lb.) NUT : 2 pcs.
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20) IGNITION COIL THICKNESS GAUGE IGNITION COIL Temporally fit ignition coil to crankcase. Adjust air gap between ignition coil and flywheel using a thickness gauge and tighten bolts. WIRE Ignition coil air gap 0.3 - 0.5 mm (0.012 - 0.020 in.) STOP DIODE Tightening torque...
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24) SPEED CONTROL LEVER Install speed control bracket onto intake manifold. Attach return spring, spacer, friction washer, wing nut, etc. to speed control lever as shown in the ilustration. Attach governor spring between governor lever and speed control lever. Attach chock control link between carburetor chock lever and chock control lever.
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25) ADJUST GOVERNOR SYSTEM (1) Push speed control lever all the way to the high speed position and fix it by tightening nut. (2) Check that governor lever is pulled by governor spring and carburetor throttle valve is fully open. GOVERNOR LEVER (3) Turn governor shaft counterclockwise all the GOVERNOR SHAFT...
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29) OIL PRESSURE SWITCH Install oil pressure switch onto crankcase. Tightening torque 5.9 - 9.8 N m (60 - 100 kgf cm) (4.3 - 7.2 ft lb.) OIL PRESSURE SWITCH Fig. 5-53 30) OIL FILTER Apply oil to O-ring and install oil filter by tighte- ning about 3/4 turns after attaching crankcase surface.
33) ENGINE OIL Refill engine oil and start the engine. Engine oil Standard Option will be lubricated oil passages and oil filter. OIL GAUGE Check the engine oil level and refill again to the upper level of oil level gauge. Oil Capacity 1.55 liter (0.41 U.S.
6. MAGNETO OPERATION AND FUNCTION The ignition system is pointless flywheel magneto with automatic advancing characteristic. Being different from the breaker point type ignition system, this system is completely free from such troubles as starting-up failure owing to dirty, burnt or corroded point surface. The electronic automatic advancing ensures extremely easy starts and stable high performance at operating speed by advancing the ignition timing to the most suitable point.
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(2) At lower engine revolution, when the flywheel reached the ignition point the low speed ignition timing control circuit operates to run the base current I to turn the signal transistor A "ON" allowing the current I bypass as current I At this moment the power transistor turns "OFF"...
7. LUBRICATION SYSTEM OPERATION AND FUNCTION * Full lubrication system is adopted, in combination with large-size torchoid oil pump and cartridge type oil filter. * The large-size trochoid type oil pump is driven directly by crankshaft, and delivers pressurized engine oil to the journal and pin portions of crankshaft, camshaft etc.
8. CARBURETOR 8-1 OPERATION AND FUNCTION Fig. 8-1 – 47 –...
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8-1-1 FLOAT SYSTEM The float system is consists of a float and a needle valve, and maintains a constant fuel level during engine operation. The fuel flows from the fuel tank into the float chamber through 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 closes to shut off the fuel, thereby keeping the fuel at the predetermined level.
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8-2 COMPORNENT PARTS Fig. 8-2 1. BODY, lower 16. SCREW, float pin set 31. SCREW and WASHER ASS'Y 2. GASKET, air horn 17. MAIN JET (#138) 32. SPRING 3. BODY, upper 18. GASKET 33. DIAPHRAGM ASS'Y 4. LEVER ASS'Y, choke 19.
9. ELECTRIC STARTER NOTE ; For Electric starter operation, electric wiring should be connected among electric starter, key switch and battery as shown in the diagram. OIL WARNING LAMP GRAY YELLOW PRESSURE SWITCH CARBURETOR BLACK BLACK / WHITE BLACK BLACK BLACK (HIGH TENSION CORD) STOP...
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9-2 COMPONENT PARTS Fig. 9-3 1. STARTING MOTOR ASS'Y 12. PINION ASS'Y 2. ARMATURE ASS'Y 13. GEAR CASE ASS'Y 3. THRUST WASHER KIT 14. STARTER METAL 4. PINION STOPPER SET 15. GEAR CASE METAL COVER 5. YOKE ASS'Y 16. DUST COVER KIT 6.
10. TROUBLESHOOTING The following three conditions must be fulfilled for satisfactory engine start. (1) The cylinder filled with a proper fuel-air mixture. (2) Good compression in the cylinder. (3) Good spark, properly timed, to ignite the mixture. The engine cannot be started unless these three conditions are met. There are also other factors which make engine start difficult, e.g., a heavy load on the engine when it is about to start at low speed, and a high back pressure due to a long exhaust pipe.
10-2 STARTING DIFFICULTIES Phenomenon Possible causes Remedy 1) Battery discharged Charge battery 2) Poor connection between battery and starter motor Clean or repair 1. Low engine 3) Poor connection between battery and ground Clean or repair speed at starting 4) Electric starter faulty Repair or replace Replace with recommended 5) Improper engine oil...
10-5 ROUGH IDLING Phenomenon Possible causes Remedy 1) Low idling speed Adjust 1. Carburetor 2) Carburetor slow system passage clogged Check and clean 2. Intake system 1) Air mixing from connecting portion of air intake system Check, tighten or replace gasket 3.
10-7 HIGH FUEL CONSUMPTION Phenomenon Possible causes Remedy 1) Over-size main jet Replace 2) Needle valve faulty and/or high fuel level in float 1. Fuel system Adjust or replace chamber 3) Chock valve does not open fully. Repair or replace 1) Low compression Check or repair 2.
10-9 ENGINE MISFIRE Phenomenon Possible causes Remedy 1) Improper spark plug gap or damaged electrode Cealn, adjust or replace 2) Ignition coil faulty Replace 1. Ignition system 3) Damaged ignition system wirings Replace 4) Poor connection of ignition system wirings Check and connect properly 1) Lean or rich air/fuel mixture Disassembly and repair...
11. INSTALLATION Engine life, ease of maintenance and inspection, frequency of checks and repairs, and operating cost all depend on the way in which the engine is installed. Review the following instructions carefully for installing the engine. 11-1 INSTALLING When mounting the engine, carefully examine its position, the method of connecting it to a machine, the foundation, and the method of supporting the engine.
12. SERVICE DATA "STD" in the following table is the parts dimension from the brand new engine or the spare parts. Whereas, "Limit" shows the maximum allowance for the parts to be used on the engine. If the measurement exceeds beyond the "Limit", the part needs to be replaced and/or repaired. 12-1 STANDARD DIMENSIONS AND SERVICE LIMITS Unit : mm(in.) EH72D...
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Unit : mm(in.) EH72D ITEM Limit CYLINDER * Inside dia. To be rebored when the difference between 84.000 - 84.022 max. and min. of (3.3071 - 3.3080) diameter reached to 0.1 (0.004). 84.250 - 84.272 Ditto reboring (3.3169 - 3.3178) 84.500 - 84.522 —...
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Unit : mm(in.) E72D ITEM Limit CONNECTING ROD * Big end inside dia. 39.000 - 39.016 39.100 (1.5354 - 1.5361) (1.5394) * Clearance between big end and crankpin 0.030 - 0.060 (0.0012 - 0.0024) (0.079) * Small end inside dia. 21.010 - 21.023 21.080 (0.8272 - 0.8277)
12-3 OIL GRADE CHART Use oil classified as SE or higher. Multi-grade oil tends to increase its consumption at high ambient temperature. Comparison between oil viscosity and temparature Single grade Specified Lubricant Quality 10W-30 Multi- grade 10W-40 40 °C - 20 - 10 104 °F –...
13. MAINTENANCE AND STORAGE 13-1 DAILY MAINTENANCE Every day before operating engine, check the following items : MAINTENANCE ITEMS REMARKS 1) Clean away dust and chaff from engine. Governor linkage is especially sensetive to dust. 2) Check fuel leakage from fuel system. If any, retighten fasteners or replace necessary parts.
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Periodic Maintenance Schedue Table Every 8 Every Every Every Every Every Maintenance Items hours 1000 (Daily) hours hours hours hours hours Clean engine and check bolts and nuts (Daily) (Refill daily Check and refill engine oil to upper level) Change engine oil (*Note 1) (Intial) Replace engine filter (*Note 1) (Intial)
13-3 ENGINE STORAGE (1) Change the engine oil and perform the daily maintenance items above mentioned. (2) Drain fuel from 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 hand.
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