SERVICE MANUAL
Contents
1. xe 74 15 4 AIR GAP AND CLEARANCE 2 45 14 16 MAINTENANCE AND STORAGE 75 1 SPECIFICATIONS Ipe Air Cooled 4 Cycle Single Cylinder Horizontal P T O Shaft OHC Gasoline Engine Bore x Stroke mm in 60 x 43 2 36 x 1 69 69 Piston Displacement ml Cu in 121 7 38 Maximum Output KW HP r p m 2 6 3 5 3600 7 3 2400 Maximum Torque Kgf m r p m 0 74 2400 ft lb r p m 5 38 2400 Direction of Rotation Counterclockwise as viewed from the P T O shaft side Valve Arrangement Overhead cam system Cooling System Forced air cooling system Lubrication System Trochoid Pump Forced and Splash lubrication system Automotive detergent oil SAE 20 30 10W 30 Lubricant API service class SE or higher SG SH or SJ is recommended Capacity of Lubricant L U S gal Dry Weight kg Ib 9 9 21 78 264 x 288 x 334 10 39 x 11 34 x 13 15 Float type Caburetor 264 x 288 x 336 10 39 x 11 34 x 13 23 Diaphragm type Caburetor Specifications are subject to change without notice 2 PERFORMANCE 2 1 MAXIMUM OUTPUT The Maximum output is the output of an engine with its throttle valve fully opened and considering that all the moving parts are properly broken in A new engine may not produce full maximum output while its moving parts are still not broken in NO2. M14 FLANGE NUT 1pc J FLYWHEEL 18 m Spark plug Remove the spark plug from the cylinder head 16mm plug wrench 11 Rocker cover 1 Remove the rocker cover from the cylinder head 10mm box spanner 42 2 Remove the gasket rocker cover M6x14mm 2pcs Rocker arm Remove the pin rocker arm and the rocker arm from the cylinder head at the compression top dead center 13 See Fig 4 c woe PLUG M6x20 FLANGE BOLT 2pcs ROCKER COVER GASKET ROCKER COVER ADJUSTMENT SCREW NUT Remove the pin the allow direction ROCKER ARM EXHAUST SIDE PIN ROCKER Matching mark ROCKER ARM INTAKE SIDE Cylinder head surface Fig 4 c 19 Step Parts to remove Remarks and procedures Fasteners Oil pump Remove oil pump cover o ring outer rotor and inner amm box wrench 14 rotor M6x12mm 4pcs MAIN BEARING COVER OUTER ROTOR OIL PUMP COVER M6x12 FLANGE BOLT 4pcs INNER ROTOR O RING SYNTHETIC RUBBER 2 Main bearing cover Remove the flange bolts of main bearing cover from 12mm box wrench the crankcase M8x55mm 6pcs Remove the main bearing cover while tapping gently around the cover using a plastic hammer or similar tool See Fig 4 d Be careful not to damage the oil gauge or oil seal or not to lose the pipe knocks SPACER 8 CRANKCASE M8x55 FLANGE BOLT 6pcs MAIN BEARING COVER MAIN BEARING COVER 21 Step Par
3. NOTE Turn the lever portion of governor shaft does to the engine base Also apply sealant GOVERNOR SHAFT Three Bond 1280 to the surface MAIN BEARING COVER SPACER je 4 ENGINE BASE Turn the lever portion GOVERNOR GEAR M8x55 FLANGE BOLT 6pcs of governor shaft does Tightening torgue 24 0 26 0 Nem to the engine base 240 260 kgf cm 17 7 18 8 ft lb dee 10 OIL PUMP and COVER 1 Apply oil to inner and outer rotors of oil pump O RING and attach them in position OIL PUMP COVER SYNTHETIC RUBBER 2 Set O ring in position OUTER ROTOR ALLOW 3 Install oil pump cover with the allow marking MARKING upwards M6x12mm flange bolt 4pcs 54 EN i ry Tightening torque 7 0 9 0 N m 70 90 kgf cm 5 1 6 5 ft lb a ch INNER ROTOR M6x12 FLANGE MAIN BEARING COVER BOLT 4pcs 11 ROCKER ARM a Conduct this job at the compression top dead center The position of two matching marks on campulley is in parallel with the cylinder head surface at a time NOTE Make sure that the piston is at the compression top dead center by checking mutual position between the flywheel and the ignition coil is at the top b Pass the pin rocker arm through the rocker arm and mount them on the cylinder head CAMPULLEY Matching mark Cylinder head surface 34 12 VALVE CLEARANCE ADJUSTMENT Adjust
4. 2 M6 nut 2pcs GASKET INTAKE BREATHER PIPE CLEANER BASE CLEANER COVER M6 SELF LOCK NUT 2pcs ELEMENT URETHANE FOAM GASKET Rubber GASKET OIL GAUGE Aluminum M8 DRAIN PLUG 1pc 13 Muffler and Muffler cover Remove the muffler cover from the muffler and 10mm box spanner or gasket muffler spanner 2 Remove the muffler from the cylinder head 13mm box spanner Take care not to lose the gasket M6x18mm 3pcs Take care not to cut your hand with muffler gasket M6 nut 2pcs Recoil starter Disconnect wire of stop switch first then remove recoil 10mm box spanner starter M6x20mm 2pcs 4 M6x14mm 1pc RECOIL ASSY MUFFLER M6 x 14 GASKET FLANGE BOLT 1 pc MUFFLER M6 SELF LOCK NUT 2pcs M6 x 18 M4 SCREW 2 pcs FLANGE BOLT 3 pcs Do Not remove the plug STOP SWITCH MUFFLER COVER M6 x 20 FLANGE BOLT 2 pcs 14 Carburetor Insulator Remove the linkage bushing from governor rod 10mm box spanner or spanner M6x20mm 1pc M6 Nut 1pc 1 Loosen the and remove the governor lever from the governor shaft There is no need to remove the bolt 2 Remove the governor spring 3 Remove the governor rod and the rod spring from the carburetor Remove the carburetor from the cylinder head Remove the insulator GASKET INSULATOR INSULATOR BLACK GASKET ROD SPRING CARBURETOR BROWN gt LINKAGE BUSHING gt CAR
5. Nem 4 0 5 0 Nem 70 90 kgf cm 40 50 kgf cm 5 1 6 5 ft Ib 2 9 3 6 ft Ib Then install the element and cleaner cover GASKET INSULATOR RUBBER PIPE c5 GASKET L CARBURETOR Q 2 N AR LOY Ar A kk A DS 5 INSULATOR 2 SL Re GASKET CARBURETOR ELEMENT FLOAT TYPE CARBURETOR IH CLEANER COVER 39 GASKET M5 x 70mm BOLT 2 pcs AR v bo er Pe Up n 2 lt GASKET gt CARBURETOR on RUBBER PIPE INSULATOR 1 OM INTAKE GASKET Am INSULATOR dii lt HL J N AIR CLEANER BASE GASKET MA CARBURETOR 4 RUBBER PIPE 22 ADJUST GOVERNOR SYSTEM 1 Turn the speed control lever all the way toward the high speed position 2 Check that the governor lever is pulled by the governor spring and carburetor throttle valve is fully open 3 Turn the governor shaft clockwise all the way using a screw driver and tighten lock bolt to secure the lever on the shaft 40 AIR CLEANER COVER DIAPHRAGM TYPE CARBURETOR GOVERNOR ROD E z A aue SA e A GOVERNOR ROD SPRING amt Te GOVERNOR n LEVER a a Normal hooking position y AN FA Siete a m JX SPRING ag 1 SPEED A CE IHE LEVER ee qos Q 23 RECOIL STARTER Attach recoil starter to crankcase Tighten flange bolts M6 x 20 mm flange bolt 2 pc M6 x 14 mm flange bolt 1 pcs Tightening to
6. by operating the engine under reduced speed and loads for a short period of time While the engine is being tested check for oil leaks Make final carburetor adjustment and regulate the engine operating speed den Engine Speed Speed Time x uio s 6 ENGINE OIL Using engine oil of the correct grade and viscosity greatly lengthens engine life and improves performance Too much or too little oil can also result in serious problems including engine seizure 6 1 CLASSIFICATION BY OIL GRADE API American Petroleum Institute Grades suited for Robin Engine SE or higher SG SH or SJ in recomended 6 2 CLASSIFICATION BY OIL VISCOSITY SAE Society of Automotive Engineers at E 10W Single grade wax 1 1011 4 0 ri Ambient 10 0 10 20 30 40 C temperature 4 14 32 50 68 86 104 F Be sure to use automobile engine oil of the viscosity shown in the table above depending on environmental air temperature When the air temperature falls below 20 C or rises above 40 C be sure to choose engine oil of appropriate viscosity and grade according to the prevailing conditions Care must be taken when using multi grade engine oil because the oil consumption rate tends to increase when the air temperature is high 6 3 ADDING AND CHANGING ENGINE OIL Engine oil inspection and filling up Every time you use the engine add engine oil up to the designated maximum lev
7. the exhaust valve before the compression top thereby alleviating the compression EXHAUST VALVE SIDE pressure and reducing the force required to pull the yyy recoil starter During engine operation the decompression system is overpowered by centrifugal force and compression is fully utilized to produce power CAMSHAFT 4 17 SECTIONAL VIEW OF THE ENGINE Cross sectional view across the shaft CYLINDER HEAD SPARK PLUG PISTON 45 E GE EIE f e T IGNITION COIL LA KA 1 PISTON RING ad PISTON PIN I 7 RECOIL STARTER wei OIL PRESSURE SWITCH i ap dh a LT OIL PUMP m C JB OO E P T O SHAFT fak Tp ee AH CRANKSHAFT Y S lt gb ADAPTER M E A A FLYWHEEL MAIN BEARING COVER CRANKCASE TT SER No Stamping SUCTION PIPE 10 Cross sectional view along the shaft ROCKER COVER HOEREBABN FLOAT TYPE CARBURETOR CAMPULLEY INTAKE VALVE CARBURETOR pr ENT M AN a DIAPHRAGM TYPE EXHAUST VALVE 270 Q ESL tel MUFFLER Ti a Ab LED uS m le L NO __ AIR CLEANER SN T pa Ena S BE c REA pa y i PISTON RING GOVERNOR LEVER TIMING BELT EE STOP SWITCH A X LZ es CONNECTING ROD He SPEED CONTROL LEVER OIL GAUGE GOVERNOR GEAR BREAT
8. the valve clearance Temporarily fit the flywheel insert the thickness gauge to pua portions Rotate the crankshaft up to the compression top dead center and insert the thickness gauge between the valve and the adjusting screw of rocker arm to measure the clearance Adjustment method Loosen the nut on the adjustment screw and turn the screw to adjust the valve clearance When the valve clearance is correct tighten the nut Valve clearance when the engine is cold Intake valve side 0 11 0 16 mm Exhaust valve side 0 0043 0 0063 in Tightening torque 5 0 7 0 Nem 50 70 kgf cm 3 6 5 1 ft lb NOTE After adjusting the valve clearances rotate the crankshaft and check again that the intake and exhaust valve clearance are correct mm APPLY OIL 13 ROCKER COVER Replace the gasket with a new one and mount ROCKER COVER the rocker cover M6 x 20 mm flange bolt 2 pcs Tightening torque 5 0 7 0 Nem GASKET ROCKER COVER 50 70 kgf cm 3 6 5 1 ft lb SPARK PLUG 35 14 SPARK PLUG Remove any carbon deposits from the spark plug and inspect the electrode for damage before mounting Replace with a new one if necessary Spark plug NGK CR5HSB 16 mm plug wrench 6 0 7 Electrode gap 0 024 6028 In Tightening torque New spark plug Re tightening torque 10 0 12 0 Nem 23 0 27 0 Nem 100 120 kgf 230 270 kgf cm 7 2 8 7 ft lb
9. 16 6 19 5 ft lb 15 FLYWHEEL 1 Put the woodruff key in the keyway of crankshaft Wipe off oil and grease thoroughly from the tapered portion of crankshaft and flywheel center hole FLYWHEEL 2 Install the flywheel to crankshaft Tighten the flywheel nut Tightening torque 60 0 70 0 Nem 600 700 kgf cm 43 4 50 6 ft Ib M14 nut 1 pc 19mm box wrench 16 IGNITION COIL When mounting the ignition coil insert a thickness gauge between the ignition coil and the flywheel to check the air gap 0 3 0 5 0 012 0 020 in SWITCH OIL PRESSURE Tightening torque 7 0 9 0 Nem 70 90 kgf cm 5 1 6 5 ft lb M6 x 20 mm bolt and washer 2 pcs Connect wires referring to the wiring diagram 36 CHAIN WRENCH SPARK PLUG RUBBER CAP amp IGNITION COIL 17 BREATHER Assemble gasket breather plate breather plate gasket breather cover refer to the following M6 x 20 mm flange bolt 4 pcs Tightening torque 7 0 9 0 N m 70 90 kgf cm 5 1 6 5 ft lb BREATHER PLATE BREATHER COVER M6x20 FLANGE BOLT 4pcs 1 1 37 z Wr pu si E 4 E wal dot Per V LE M v an lt lt B mal 11 D E a e P T O SHAFT P T O SHAFT SIDE FLYWHEEL SIDE FLYWHEEL SIDE SIDE GASKET BREATHER PLATE GASKET BREATHER COVER 18 BAFFLE Mount t
10. 8x98 INTAKE ONLY FLANGE BOLT 4pcs SPRING RETAINER TM s e VALVE SPRING e G ASKET Lj 2 4 E HEAD LEER E ee 238 Se CYLINDER HEAD CLE KNOCK PIN E EXHAUST VALVE CRANKCASE VALVE 24 Connecting rod and piston Scrape off any carbon from the cylinder and the 8mm box spanner piston head then remove the connecting rod bolt M5x25mm 2pcs 2 Remove the connecting rod cap 3 Rotate the crankshaft until the piston comes to its top position Push the connecting rod and remove the piston from the upper part of the cylinder Piston and piston rings 1 Remove the piston clips 2pcs Take out the piston pin and then remove the piston from the connecting rod small end taking care not to damage the connecting rod small end 2 Remove the piston rings from the piston by spreading them at the gap Take special care not to damage the rings when doing this CLIP PISTON RING lt C STEP 22 PISTON PISTON PIN CONNECTING ROD c CLIP UPPER PART OF THE CYLINDER CRANKSHAFT CONNECTING ROD CAP Y CONNECTING ROD BOLT 2pes 25 Parts to remove Remarks and procedures Fasteners Crankshaft 1 Remove the woodruff key for the flywheel magneto 2 Remove the crankshaft from the crankcase Plastic hammer 23 by tapping its magneto side end with a plastic hammer taking care not to damage the oil seal OIL SEAL PRESS FITTI
11. BURETOR FLOAT WM 0 d CYLINDER HEAD hi Y GOVERNOR ROD STEP 5 A A E AN GOVERNOR LEVER ux m ad cm i San iian GOVERNOR tg SPRING CYLINDER HEAD 5 GASKET X INSULATOR BLACK NUT INSULATOR 2 GASKET DETAIL A STEP 5 CARBURETOR BLACK CARBURETOR GASKET DIAPHRAGM TYPE CARBURETOR BROWN SELF LOCK NUT INSULATOR 1 GASKET INSULATOR BLACK INTAKE PIPE 415 Step Parts to remove Remarks and procedures Fasteners Speed control lever and Remove the speed control lever and base plate from Base plate the crankcase If necessary 10mm box spanner M6x10mm 2pcs 14mm box spanner Pivot bolt 1pc STEP 6 3 ET SCREW HIGH SPEED se sonew cua sree BASE PLATE Pae SET SCREW LOW SPEED F A SPEED CONTROL d ON Sy LEVER ye Nt 24 SWIVEL NUT M4 x 0 7 z E fS FRICTION WASHER NYLON i if 2 PIVOT BOLT RETURN SPRING SPACER M6x10 FLANGE BOLT 2pcs PIVOT BOLT Tightening torque 7 0 9 0 Nem 70 90 kgf cm 5 1 6 5 ft lb SPEED CONTROL AY GOVERNOR SPRING STEP 6 M6x20 BOLT GOVERNOR LEVER 6 NUT 16 Cylinder baffle Remove the Cylinder baffle If necessary 10 mm box spanner M6 x 10 mm 3 pcs Breather Remove the breather cover and plate If necessary 8 mm box spanner M6 x 20 mm 4 pcs 10 mm box spanner Ignition coil Remove the spark plug cap from the spa
12. CAMSHAFT M6 x 8 FLANGE BOLT 1pc 8 ADJUST CRANKSHAFT END PLAY 1 Adjust end play to 0 2 mm 0 008 using the roper spacer idu DEPTH GAUGE The proper spacer may be determined in the following manner 1 Measure the height A From the mating surface to the inner race of the ball bearing 2 Measure the depth B From the mating surface to the drive pulley DRIVE PULLEY CRANKCASE B A SIDE CLEARANCE mm MAIN BEARING COVER SIDE CLEARANCE 0 2 mm THICKNESS OF CRANKSHAFT SHIM mm T BALL BERARING B A SIDE CLEARANCE in SBAMKSHEET 7 SIDE CLEARANCE 0 008 in THICKNESS OF CRANKSHAFT SHIM in Following are available spacer shims C CRANKSHAFT SPACER 8 mm 0 031 in SHIMS T 0 T 1 0 mm 0 039 in T 1 2 mm 0 047 in CRANKCASE This image slightly differs from the actual engines Em 9 MAIN BEARING COVER a Insert the plug suction pipe and oil pressure switch PLUG SUCTION PIPE OIL PRESSURE SWITCH 0 8 1 2 Nem 6 0 8 0 Nem 8 0 10 0 Nem 8 12 kgf cm 60 80kgf 80 100 kgf cm 0 6 0 9 ft lb 4 3 5 8 ft lb 5 8 7 2 ft lb b Apply oil to the bearing and the oil seal lip when mounting the main bearing cover Also apply sealant Three Bond 1208 to the surface of the crankcase To avoid damaging the oil seal lip wrap the crankshaft key way portion with polyvinyl tape before mounting the main bearing cover
13. Cx SUBARU Industrial Power Products ER12 CONTENTS Section Title Page 1 SPECIFICATIONS geese ease eade alia 1 PERFORMANGE 5222 Eod kina Dun aedes 2 S PEATURES caters ues Su aire US wees eA enor ee 4 4 GENERAL DESCRIPTION OF ENGINE COMPONENTS 5 5 DISASSEMBLY AND REASSEMBLY 12 5 1 PREPARATIONS AND PRECAUTIONS 12 9 2 DP EON TOOLS riui a doas att td As ee we ik cc 12 5 9 DISASSEMBLY PROCEDURE 73 35 a 13 5 4 REASSEMBLY PROCEDURE 000 020 ce eee es 27 ENGINE MI LR 43 fs LUBRICATION SYSTEM 22 o eos E dub En xt bos 44 BS MAGNETO 3x eux iS Sem Ese Sd DEI RE em SEE s 47 9 WIRING 48 10 AUTOMATIC DECOMPRESSION 5 5 49 1 CARBURETOR 257 ene eee tet ce ebrii utes od dance 50 12 RECOIL STARTER 6 55 ips ete rus bI EESTI EE REESE 58 Rm 63 14 TROUBLESHOOTING 253 2522522 ERI REI TES 65 15 STANDARD REPAIR 5 68 15 1 STANDARD DIMENSIONS AND LIMITS OF USE 68 15 2 SERVICE DATA The following are only for your reference 73 15 9
14. HER COVER SER No Stamping CRANKCASE CRANKSHAFT OIL DRAIN PLUG 41 5 DISASSEMBLY AND REASSEMBLY 5 1 PREPARATIONS AND PRECAUTIONS 1 When disassembling the engine memorize the location of each part so that you can reassemble the engine correctly If necessary attach identification tags with the required assembly information to the parts 2 Store groups of parts in separate boxes This will make reassembly easier 3 To prevent parts from being mislaid Keep each group provisionally assembled after removing the parts from the engine 4 Handle the disassembled parts with the utmost care Clean them with cleaning oil if necessary 5 Use the correct tools in the correct way when disassembling and reassembling the engine 9 2 SPECIAL TOOLS Commercially available product Flywheel puller For pulling off the flywheel For removing and Commercially available product Piston ring plier installing piston rings Piston ring Commercially available product For holding piston rings Commercially available product For locking the flywheel FLYWHEEL PULLER PISTON RING PLIER PISTON RING COMPRESSER CHAIN WRENCH 5 3 DISASSEMBLY PROCEDURE Drain the engine oill Remove a drain plug M8 x 12mm located on both 12 mm spanner sides of the case Take care not to lose the gaskets To discharge oil quickly remove the oil gauge M22 Air cleaner Remove breather pipe from rocker cover 10mm box spanner
15. NG WASHER E CLIP Ex CRANKSHAFT GOVERNOR SHAFT WASHER 96 5 4 REASSEMBLY PROCEDURE 5 4 1 NOTES ON REASSEMBLY 1 Clean the each parts carefully taking special care with the piston cylinder crankshaft connecting rod and bearings 2 Scrape off any carbon deposits on the cylinder head and the piston head Be particularly careful when removing carbon from the piston ring grooves 3 Inspect the oil seals for any damage to the lip Replace them if damaged Apply oil to the lip before reassembly 4 Replace all the gaskets with new ones 5 Replace the keys pins bolts and nuts with new ones if necessary 6 Tighten nuts and bolts to the specified torque settings 7 When reassembling the engine apply oil to all moving parts 8 Check clearances and end plays and adjust if necessary 9 When mounting any major part during reassembly of the engine rotate it with your hand to check for any jamming or abnormal noise 5 4 2 ASSEMBLY STEPS AND PRECAUTIONS 1 CRANKSHAFT a Wrap the key way portion of the crankshaft with polyvinyl tape and insert the crankshaft into the crankcase taking care not to damage the oil seal lip b Insert the woodruff key for the flywheel magneto NOTE Do not insert the woodruff key before inserting the crankshaft into the POLYVINYL TAPE crankcase s DT i 2 PISTON AND PISTON RINGS OPEN ENDS OF PISTON RING a Insta
16. TE Power curves shown in the following charts are made in conformity with SAE internal combustion engine standard test code J1349 2 2 CONTINUOUS RATED OUTPUT The continuous rated output is the output of an engine at optimum governed speed which is most favorable from the view point of engin s life and fuel consumption When the engine is installed on a certain equipment it is recommended that the continuous output required from the equipment to be kept below this continuous rated output 2 3 MAXIMUM TORQUE The maximum torque is the torque at the output shaft when the engine is producing maximum output at a specific r p m 2 4 PERFORMANCE CURVES lt JNOYOL o Neo t ON T M A X IM UM HORS EPOWER o o o o CN T 4 0 o o CN lt LNdLNO 1 0 0 3000 4000 REVOLUTION r p m 2000 3 FEATURES 3 1 DEVELOPED EXCLUSIVELY FOR RAMMER The new 12 has been developed exclusively for rammer which especially requires the engine for high durability high power output and superb mountability among many construction machineries 3 2 LIGHTWEIGHT AND COMPACT DESIGN ER12 has realized lightweight and compact design while achieving high power output of 2 6kW engine displacement 120cc that enables to widely fulfill the operating weight of 60 to 80kg class rammers the lightest in class weight of 9 9kg and the smallest in class o
17. een stem seal and Cylinder head STEM SEAL CYLINDER HEAD VALVE GUIDE COLLET VALVE SPRING AN STEM SEAL INTAKE ONLY RETAINER I VALVE SPRING w CYLINDER HEAD Apply oil Apply oil EXHAUST VALVE INTAKE VALVE 6 CYLINDER HEAD a Inspect and repair any scratches on mounting surface and replace head gasket to new one before installing b Insert the pipe knocks between crankcase and cylinder head Install cylinder head onto cylinder with new head gasket Apply oil to the screw thread Tighten four flange bolts evenly in three steps by the following tightening torque Cylinder head M8x98mm bolt 4pcs Tightening torque 5 0 Nem 9 8 Nem 20 0 24 0 Nem 50 100 kgf cm 200 240 kgf 3 6 ft lb 7 2 ft lb 14 4 17 7 ft lb 7 SETTING THE TIMING BELT a Set the crankshaft to the top dead center b Set the timingbelt to the drive pulley on the crankshaft c Install the campulley to the cylinder head Meet the matching mark of campulley and cylinder head d Mounting the campulley on the cylinder head Mount the campulley on the cylinder head by inserting the pin campulley through the head 3 Fix the bolt to prevent the pin campulley fro coming out M6x8mm flange bolt 1pc Tightening torque 4 0 6 0 Nem 40 60 kgf cm 2 9 4 3 ft lb Matching mark CAMPULLEY TIMING BELT CRANKSHAFT CYLINDER HEAD PIN
18. el O Engine oil change Firsttime After 20 hours use Thereafter Every 100 hours use
19. haust cam and the decompression release lever is mounted on the sprocket shaft end side 4 7 VALVE ARRANGEMENT EXHAUST VALVE INTAKE VALVE i con pecu Q O This engine has a belt driven overhead cam and overhead valve construction with a single cam performing both intake and exhaust operations 4 8 CYLINDER HEAD The cylinder head is on aluminum die casting with a lens shaped combustion chamber The intake and exhaust ports are arranged in a cross direction to improve combustion efficiency 4 9 GOVERNOR SYSTEM This engine is equipped with a centrifugal flyweight type governor that makes it possible to operate the engine at a constant speed even with load GOVERNOR variations The governor flyweights are mounted on a governor gear 4 10 COOLING SYSTEM The engine uses a forced air cooling system in which a cooling fan on the frywheel reduce noise and forces cooling air into the cylinder and cylinder head Baffle is provided to guide the flow of cooling air 4 11 LUBRICATION SYSTEM Lubricant engine oil is sprayed onto the parts with pressure spray by the trochoid type of oil pump and those parts splashes to the parts necessary to be lubricated The trochoid pump is driven by the crankshaft Lubricant is wholly filtered by the oil pump filter plugged in the under of the main bearing cover 4 12 TIMING BELT CAMPULLEY Timing belt system is adopted and designed for lubricating for the
20. he cylinder baffle to the crankcase with the bolts M6 x 10 mm bolt 3 pcs 19 SPEED CONTROL Install the speed control to the top breather BREATHER COVER FLANGE BOLT cover with the bolts oN M6 x 10 mm flange bolt 2 pcs SPEED CONTROL AY NUT Fi SET SCREW HIGH SPEED fi BASE PLATE a SET SCREW LOW SPEED E s r SPEED CONTROL if Oy LEVER i SWIVEL NUT M4 x 0 7 la FRICTION WASHER iH a NYLON k i i a Fr d pO tr f 4 PIVOT BOLT RETURN SPRING SPACER M6x10 FLANGE BOLT 2pcs 38 20 GOVERNOR LEVER CARBURATOR ROD SPRING LINKAGE BUSHING lever yet GOVERNOR ROD a Mount the governor lever on the governor shaft Do not adjust the bolt on the governor b Attach the governor rod and rod spring to the governor lever GOVERNOR LEVER c Replace the gasket of insulator with a new and mount the insulator on the cylinder e head intake side us d Hook governor rod to the governor lever M and throttle lever of carburator aes BOLT AND mount the carburator to the cylinder head WASHER AY e Hook the linkage bushing to the governor rod 21 AIR CLEANER BASE Insert the breather pipe into the breather cover and air cleaner base then mount the air cleaner base M6 salf lock nut 2pcs Tightening torque Float type carburetor Diaphragm type carburetor 7 0 9 0
21. ib for oil shelter which to inprove the breather function and stiffness 4 2 MAIN BEARING COVER The main bearing cover is an aluminum die casting with heavy duty structure to endure to install on rammers which is mounted on the output shaft side of the crankcase By removing the main bearing cover the inside of the engine can be inspected with ease Pilots and bosses are machined into the cover for direct mounting of the engine onto rammers And it have suction pipe oil pump oil filter and oil pressure switch 4 3 CRANKSHAFT The crankshaft is forged carbon steel and the crank pin is high frequency inductionhardened The crank pulley used to drive the timing belt and the gear used to drive the governor gear are pressed into the output end of the shaft 4 4 CONNECTING ROD AND PISTON The connecting rod is a specially heat treated aluminum alloy die casting Its large and small ends function as bearings The piston is an aluminum alloy casting with grooves for mounting one compression ring and one oil ring 4 5 PISTON RINGS The piston rings are made of special cast iron The profile of the top ring is a tapered face The oil ring is designed for better sealing and less oil consumption in combination with 3 pieces TOP e RING TAPER OIL THREE PIECE RING CONSTRUCTION 4 6 CAMPULLEY The campulley is made of special nylon They are constructed as a single piece The campulley is provided with intake and ex
22. ll each piston ring in the correct groove of the piston by widening it enough to slide it over the piston NOTE Be careful not to twist the rings too much as they may be damaged Install the oil ring first followed by the top ring When installing the piston ring make sure that the R mark is face up 7 TO TAPER RING OIL THREE PIECE 7 RING CONSTRUCTION MARK 2 9 a 3 PISTON AND CONNECTING ROD The piston is attached to the connecting rod by the piston pin When assembling the piston and connecting rod make sure to align the mark on the piston When assembling the piston and head with the JCC mark on the connecting rod connecting rod me NOTE 1 Before assembling the connecting rod make sure to align the mark on the apply oil to its small end M Ed piston head with the on the NOTE 2 Be sure to insert the clips in the two connecting rod ends of the piston pin and check the clips for any play 4 CONNECTING ROD a Install the piston and connecting rod assembly into the cylinder by holding the piston rings PISTON RING GUIDE AND PISTON RING with the ring guide with the JCC mark on the connecting rod on the flywheel side If you do not have a ring guide hold the piston rings JCC MARK with the fingers and tap the upper part of the piston with a piece of wood NOTE 1 Apply oil to the piston rings the la
23. n the length and width 3 3 DESIGNED TO OFFER SUPERIOR MOUNTABILITY ER12 has been designed to offer superior mountability which is valued for rammer engine by the optimal center of gravity for right and left balance 3 4 USER S SAFETY AS WELL AS USER FRIENDLINESS ER12 offers several new functions as standard equipment which has been required to rammer engine for user s safety as well as user friendliness such as oil sensor that monitors the oil level not only at starting up but also during operation and automatic shutoff device that stops engine when the rammer rolls over or has no operation with idling 3 5 EASE OF MAINTENANCE AND ECONOMICAL EFFICIENCY ER12 has beeh designed in consideration of ease of maintenance and economical efficiency such as adopting solid crank case or the newly developed resinous dust proof air cleaner for realizing ease of maintenance realizing longer operational hours without oil refilling FHI researches 4 GENERAL DESCRIPTION OF ENGINE COMPONENTS 4 1 CYLINDER AND CRANKCASE The cylinder and crankcase are aluminum die casting as a Single piece A special cast iron cylinder liner is molded into the aluminum die casting The crankcase has a mounting surface on the output shaft side to which the main bearing cover is attached And the lib is made for the crankcase room center cum oil shelter plate that improvement breather function and strength up And inside of the crankcase has large r
24. rge end of the connecting rod and FLYWHEEL SIDE cylinder before installing the connecting rod into the cylinder NOTE 2 The piston ring gaps should be positioned around the piston at lt lt P T O pi ELS 180 degree intervals oy RING rouen SIDE TOP RING JCC MARK SIDE gt 29 b Rotate the crankshaft down to the bottom dead center and lightly tap the piston head until the large end of the connecting rod touches the crank pin c To mount the connecting rod line up the matching marks and fit the clinch portions firmly together M5x25mm Connecting rod bolt 2pcs 8mm box wrench Tightening torque 6 0 8 0 Nem 60 80 kgf cm 4 3 5 8 ft lb d Check for free movement of the connecting rod by turning the crankshaft slowly 5 INTAKE AND EXHAUST VALVES Take the following points into account when mounting the intake and exhaust valves on the cylinder head NOTE 1 Replace the valve with a new one if it shows signs of wear NOTE 2 Carefully scrape off any carbon deposits on the combustion chamber Apply oil to the valve stems before mounting the intake and exhaust valves Insert the valves in the cylinder head and place it on a level workbench Next mount the valve springs the spring retainers and collet valves Mount the stem seal on the intake valve guide 30 H ALIGNMENT MARKS Make sure press fitting to contact exactly betw
25. rk plug Disconnect wire of oil pressure switch x 25 mm 2 pcs Remove the ignition coil from the crankcase YLINDER BAFFLE STEP 7 M6x10 FLANGE BOLT 3pcs 6 20 FLANGE BOLT 4pcs 2 1 TL A fai m a m MEC L5 BREATHER gt PLATE E GASKET BREATHER COVER BREATHER PLATE GASKET STEP 8 BREATHER COVER Disconnect the wire from the portion Sen SPARKPLUG RUBBER CAP IGNITION COIL M6x20 BOLT 2pcs SWITCH OIL PRESSURE 17 Parts to remove Remarks and procedures Fasteners Flywheel Remove the starting pully from the flywheel 19 mm socket wrench Fit a box wrench or a socket wrench on the flywheel nut M14 nut 1pc and loosen the nut by knocking the wrench sharply with a hammer See Fig 4 a NOTE 1 Do not insert screwdriver or other object between the flywheel blades which is a synthetic resin otherwise the risk of damaging the blades might be occurred 10 Knock the wrench with a hammer in a counter clockwise direction Remove the flywheel from the crankshaft Leave the nut Flywheel puller temporarily to prevent the flywheel from dropping out Fit the flywheel puller as shown in Figure4 b and remove the flywheel from the crankshaft by rotating the bolt at the center in a clockwise direction Knock the center bolt with a hammer sometimes HAMMER ALUMINUM BAR NUT PULLER Fig 4 b SCREWDRIVER 59 WOODRUFF KEY
26. rque 7 0 9 0 Nem 70 90 kgf cm 5 1 6 5 ft lb Insert the high tension cord from the ignition coil into the notch of the blower housing so as not to pinch the cord 24 STOP SWITCH 1 Install stop switch to blower housing 2 Connect wires referring to the wiring diagram 25 MUFFLER 1 Mount the muffler and the gasket on the cylinder head Self lock nut 2 pcs Tightening torque 19 0 21 0 Nem SF E 190 210 kgf cm 13 7 15 2 ft Ib NI AN zi E 2 Mount the muffler cover on the muffler GASKET M6 x 18 mm bolt 3 pcs MUFFLER MUFFLER Tightening torque 7 0 9 0 N m 70 90 kgf cm 5 1 6 5 ft lb End of the reassembly 41 26 EXTERNAL INSPECTION Reassembly is completed Check that the wiring is correct and that there are no loose nuts and bolts or any other faults visible on the outside of the engine 27 FILLING WITH ENGINE OIL Use the automobile engine oil of API service class SE or higher grade The amount of oil refer to the table below Engine oil volume 0 35L maximum 28 BREAK IN OPERATION A new engine or an engine that has been completely overhauled by being fitted with a new piston rings valves and connecting rod should be thoroughly RUN IN before being put back into service Good bearing surfaces and running clearances between the various parts can only be established
27. ts to remove Remarks and procedures Fasteners Switch Oil pressure Remove the oil pressure switch If necessary 24mm spanner Plug and suction pipe Remove the plug and suction pipe from the main M5x12mm 2pcs bearing cover If necessary SWITCH OIL PRESSURE MAIN BEARING COVER PLUG AY gt OIL FILTER SUCTION PIPE MESH SCREEN M14 13 ge me EB O RING M5x12 SCREW 2pcs SYNTHETIC RUBBER VIEW A mum Parts to remove Remarks and procedures Fasteners Campulley 1 Remove the retaining bolt of pin campulley from the 10mm box spanner cylinder head M6x8mm 1pc 2 Remove the pin campulley taking care not to scratch the Pliers O ring 18 3 Remove the timing belt from the campulley and then take out the campulley 4 Remove the timing belt from the crankshaft PIN CYLINDER HEAD CAMPULLEY O RING SYNTHETIC RUBBER M6x8 FLANGE BOLT 1pc Gr TIMING BELT CAMPULLEY TIMING BELT CRANKSHAFT DRIVEPULLEY 5170 Step Parts to remove Remarks and procedures Cylinder head Remove the cylinder head from the crankcase 12mm box spanner P Remove the cylinder head gasket from the cylinder head M8x98mm 4pcs Take care not to lose the pipe knock Intake and exhaust 1 Remove the collet valve from the spring retainer valves If necessary 2 Remove the intake valve and the exhaust valve COLLET VALVE STEM SEAL M
28. upper portion of cylinder head The pulley and the gear teeth in round shape are DRIVEPULLEY adopted to enhance the durability and to realize low noise level The timing belt is engaged between the campulley TIMING BELT the cylinder head and the crankshaft gear CRANKSHAFT 4 13 IGNITION SYSTEM The ignition system is a pointless flywheel magnet by a digital control FLYWHEEL The magneto consists of a flywheel and ignition coil ALGE with CPU Central Processing Unit and CDI Capacitor Discharge Ignition The flywheel is directly mounted on the crankshaft and the ignition coil is directly mounted on the crankcase 4 14 CARBURETOR The engine is equipped with two types of horizontal draft carburetors one has a float controlled fuel system and a fixed main jet and another is diaphragm type The carburetors are calibrated carefully for sure starting good acceleration less fuel consumption and maximum output For details refer to page 50 section 11 3 FLOAT CARBURETOR As details of diaphragm type refer to page 53 section 11 4 DIAPHRAGM CARBURETOR 4 15 AIR CLEANER AIR CLEANER BASE ELEMENT The air cleaner is a heavy duty type with a dual URETHANE FOAM element system the primary one is an urethane foam semi wet and secondary one is a semi wet type element AIR CLEANER COVER 4 16 DECOMPRESSION SYSTEM The automatic decompression system is mounted on RETURN SPRING the campulley It opens
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