Honda GC135/160 GCV135/160 Owner's Manual

GC135/160 and GCV135/160
OEM Technical Manual
©1999 American Honda Motor Co., Inc.
All Rights Reserved
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PREFACE
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As a reminder, the specifications herein are prerequisites to
proper engine application matching for the engine models
listed. These specifications shouldbe used as a .guide to
evaluate the potential of an engine/product application
match.
Strict adherence to these specifications
and proceduresis not a
blanket endorsement of anOEM application or suitability of an
engine’s performanceor longevity in a specific application.
The Honda Engine Sales Departmentmust approve all engine
applications before sales of engines
to OEM applications can
begin.
APPLICATION OF GC AND GCV ENGINE SERIES
GC/GCV series engines were designed to bemounted on home-use, light-duty products.
For professional/commercial-use products, select aGX series engine,
Examples of home-useapplications :
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Walk-behind
lawnmower
Tiller
Generator
Snowblower
Pressure
washer
Compressor
Cylinder
mower
Edger
RECOMMENDED OUTPUT RANGE
Match the engine withthe application so that the power take-off falls within the recommended output
range of the engine.
Use the throttle valve opening confirmation
method to determine the engine poweroutput.
As a standard, the carburettor throttle valve opening
should be about 1/2 open at the rated performance.
If throttle valve movementis severe and throttle valve openingcannot be confirmed, carry out operating
endurance testingto check for engine overload conditions,
using the engine temperature conditions
given on the next pagesas a standard.
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Engine speed differencebetween loaded and unloaded condition : within 5 %.
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GC-ENGINE
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Operation must not exceed 90 %
of maximum output.
Recommended max. BHP =
0.9 x max. BHP
Continuous rated output must not
exceed 80 % of maximum output.
Continuous recommended BHP =
0.8 x max. BHP
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GCV-ENGINE
Use within 80 % of maximum
output.
Recommended maximum operating
output = 0.8 x max. BHP
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OPERATING ENGINE SPEED RANGE
Use the recommended engine speed rangeas shown in the output characteristics.
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Recommendedoperatingspeedrange :
GC :
GCV :
2000 - 3600RPM
2000 - 3250RPM
Maximum no-load engine
speed
GC :
GCV :
4000 RPM
3250
RPM
GC :
GCV :
1250 - 1550 RPM
1550 - 1850 RPM
Idling speed
:
FUEL SYSTEM
The fuel tank, providedas standard equipment,is equipped with a fuel strainerand is constructed so
that moisture, dirt,and other foreign matteris not fed into the carburettor, evenif such substances
collect at the bottom of the tank. The fuel strainer with a fine mesh(# 300) is mounted at the outlet of
the tank.
When an engine is to be mounted on a tiller, use an engine that complies with tiller specifications
regarding usage conditions and low frequency vibration whenthe machine is moving.
Applications which are generating a low frequency
but high displacement vibration,
can require the
installation of aT-joint in the fuel line between the carburettor and the fuel pump to avoid occasional
carburettor overflow ( see illustration).
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Do not use a tank other than the standard tank. Ifuse of another tankcannot be avoided,following
points should be observed :
If a separate tank is used, it shouldbe a graviw-feed type. A fuel pump shouldnot be used.
Be sure to install a fuel cock betweenthe tank and the carburettor.
install a # 300-mesh fuel strainer between the tank and thecarburettor,
Ensure that themaximum level differencebelween themaximum fuel level in
the tank and thefuel levelin the carburettor is
less than 50 cm.
If an electromagnetic pump must be used, consult with HM.
Check the safety characteristics of
the fuel tank regarding items such
as installation strengthand iocation,possibility of overturning,
and so on.
For the fuel tube, use a rubber tube that is oil resistant and weatherproof.
Clean the inside of the fuel tank and fuel line thoroughly, confirming
that there is no dirtor other foreign mattercontamination.
Make sure the fuel line is not hooked on or pinched by any part of the engine and that all connections are secure.
Also the tubeshould not be routed near the muffler or other part of the engine where itcan be affectedby heat.
Securely fastenthe fuel tube with clips, clamps or slmilar fasteners.
Anchor the fuel lineso that there is no dangerthat it will rubor tear or interfere with other parts due
to vibration.
COOLING SYSTEM
Use the engine within the indicated ambient temperature rangeof : GC engine : - 15°C to 40°C
GCV engine : - 5°C to 40°C
ENGINE TEMPERATURE CONDITIONS
(AT AMBIENTTEMPERATURE OF 40°C)
250 "C max.
Spark plug seat temperature :
"C
140
max.
Engine
oil
temperature :
Float chamber gasoline temp. :
60 "Cmax.
Fuel tank gasoline temp. :
60 "Cmax.
Fuel pump body temp.(GC engine) : 60 "C max.
Install the engine so that sufficient cooling capacity is assured. Operate the engine under actual
working conditions to confirm that engine temperature conditions are
satisfied.
In the case of lawnmowers, grass cutters,
and other machines used in dirty environments, prevent
the
entry of dirt or grass clippings. It should be confirmed that dirt and grass clippings removed bythe screen
grid do not accumulate around it.
ENGINEENCLOSURE
If cooling air intake is insufficient, engine output may drop and required temperature conditionsmay
not be satisfied.
REQUIRED
COOLiNGCAPACITY
4.3 m3/minute (at 3600 RPM)
3.2 m3/minute (at 3000 RPM)
ENCLOSURES
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Provide a cooling duct so that outside air can bedirectly fed in throughthe cover.
Install the duct so that the intake is positioned away from any litter or dust sources.
Seal the area between the duct andthe engine cooling air intake withpacking or similar material.
The minimum cooling duct opening must be at least 350 cm2.
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When the engine is used in a dirty environment, install a fixed screen the
on duct opening. The area of
the fixed screen must be atleast 1750 cm2 when the screen has a 60 % opening.
The screen must be constructed so that dirt will fall off naturally, the degree of dirt accumulation can be
readily observedand dirt easily removed.
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Since the shape of the duct andscreen and the engine installation conditionsaffect the cooling air flow
rate, operate the engine underactual working conditions to confirm that the required temperature
conditions are satisfied.
Exhausting cooling air outside the cover.
If necessary, provide aduct, ensuring that the smallest cross-sectional area of the duct is not smaller
than the area of the cooling air intake duct opening.
Since the muffler, exhaust pipe, and other parts ofthe exhaust system become very hot, separate them
from the engine room with wall
a and install them so that they are cooled by the air flow.
Make sure the exhaust gas is exhausted directlyto the outside of the cover.
Make sure the exhaust gas is not sucked into the cooling air duct. Use an exhaust duct or exhaust pipe
extension if necessary.
Provide a louver vent ontop of the coverso that the temperature inthe engine roomdoes not rise
when the engine is turned off.
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EXHAUST SYSTEM
Although the standard muffler has been designed to optimally suit this engine from the standpoint of
exhaust backpressure, noisereduction, durability, installational rigidity,
and other factors, consideration
should be given to the following items :
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c,
Exhaust the exhaust air directly to the atmosphere. Do not allow flammable items or items with low
heat resistance inthe vicinity of the exhaust.
c,
Make sure the exhaust air is not sucked into the cooling air intake.
When a deflector is used to change the direction of the exhaust, be especially carefulthat the
exhaust air is not sucked intothe cooling air intake.
VIBRATION
Mount the engine so that there is no resonance withinthe engine operating speed range.
Increase engine speed graduallyand make sure there is no excessively large vibrationat the specified
operating speed.
GENERAL
METHODS OF RESONANCEPREVENTION
Rigid-mountinstallation :
Increase the rigidityof the engine bed and frame,raising the resonance
point above the engine operating speed.
Rubber-mount installation :
Decrease the hardnessof the rubber in the direction of vibration, lowering
the resonance point below the engine operating speed.
When resonance occurs in engine auxiliary equipment or inthe application, increase the rigidity of
the part that is vibrating ,raising the resonance point above the engine operating speed.
Using a vibration meter, measure vibration acceleration in three directions : vertical, longitudinaland
lateral.
Confirm that the effective valuein each direction is less than 5 6 (RMS) within the operating speed range.
GC engine
GCV engine
Vibration pick-up
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Vertical
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Lateral
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Vibration pick-up
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Vertical
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Longitudinal
Lateral
Recommended vibration meter: SHOWA SOKKI Model 1340 - 500 Hz with low pass filter
B & K Model 2513 - 1 kHz with low pass filter (conform to IS053491
If the effective valueof vibration exceeds5G in any ofthe three directions,check the mounting conditions.
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ENGINE MOUNTING METHOD
RIGID MOUNT
Use a high-rigidity materialfor the engine bed and frame on whichthe engine is mounted,
taking into consideration strengthand durability.
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Confirm that there is no resonance withinthe operating speedrange.
Make sure the part supporting the engine bed andframe is leveled.
If the part that supports the engine has a large level difference, engine installation parts may
be damaged.
The part that supports the engine must be leveled within0.5 mm or less.
RUBBERMOUNT
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Use a rubber-mount installationmethod when the noise and vibration of the application must
be reduced.
Confirm that there is no resonance withinthe operating speedrange.
Make sure that the engine and auxiliary equipment do not interfere withthe application,
even whenthe engine's degree of deflection at startup and shutdown is large.
DIRECT
COUPLING
Make sure the engine does not overhang the application.
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Make sure the application does not overhang the engine.
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GOOD
m
unit
NO GOOD
NO GOOD
GCV LAWNMOWER APPLICATION
When mounting the engine on a lawnmower, secureat three points as shown in the figure below.
(Use this mount boss as the installation
boss for mounting other attachments)
When using a blade holder such as shown
in the figure, use a PTO shaft diameterof 25 mm
POWER TAKE-OFF GC-ENGINE
WHENTHE ENGINEIS DIRECTLY CONNECTEDTO AN APPLICATION
Line up the centers of the PTO shaft and the shaft of the application.
Center the shaft of the application and ensure that the shaft play is 0.05 mm maximum.
Make sure there is no static load applied in the crankshaft direction (thrust direction) by
the application.
POWEROUTPUT WITH V-BELT
When installing the pulley on the end of the PTO shaft, make surethe center of the pulley groove does
not extend beyond the end of the PTO shaft.
Belt static load must not
exceed the following standards :
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ENGINE
TYPE
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RADIAL LOAD
(PTO SHAFT END)
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THRUSTLOAD
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Standard type
90.8 kg
22.7 kg
Ball bearing type
181.5 kg
Internal : 22.7 kg
External : 227 kg
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For installation on a waterpump or other application that applies thrustload, use a ball bearing type
engine.
The thrust load of a water pump manufactured according
to the standards shown inthe following table for impeller
diameter, head, and thrust load is 227 kg. maximum.
Center of pulley groove
Crankshaft end
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Impeller diameter
30 m max.
40 m max.
50 m max.
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Ensure that the frame and engine bed are sufficiently rigid so that the belt does not produce resonance
in the operating speed range.An effective means of reducing resonance is to install a stay between the
engine and the application.
Select a shaft center distanceand pulley ratio that will not produce belt resonance or humming.
If there is a large drag resistance when the engine is started, be sure to install a clutch so that
the drag resistance can be cut
off.
If the temperature of the hydraulic transmission, hydraulic pump, or other hydraulic equipment drops
due to changes in the viscosity of the oil being used, the drag resistance will vary radically. Confirm
that
the engine can be properly started with the recoil starter even
at the minimum temperature conditions
at which the application can be.operated.
Adjust the direction of the recoil starter rope so that it can bepulled out smoothly. If the rope cannot be
pulled outstraight, installa ropeguide or similar device.
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Mounting GCV
The bite of the blade holder and/or pulley must not exceed the dimensions below.
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Lap the pulley boss at least 3 mm beyond
the end of the Woodruff key.
Also, the end of the pulley boss must be at
least 3 mm from the end of the uncovered
Woodruff groove.
The blade holder must be leveled within0.5 mm
or less and perpendicular within0.2 mm or less.
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WHENTHE ENGINE IS DIRECTLY CONNECTEDTO THE APPLICATION.
Line up the centers of the PTO shaft and application shaft.
Center the application shaft and ensure that the shaft play is 0.05 mm maximum.
0 Make sure there is no static load applied in the crankshaft direction (thrust direction)
by the application.
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POWEROUTPUT WITH V-BELT,
When installing the pulley onthe end of the PTO shaft, make surethe center of the pulley groove
does not extendbeyond the end of the PTO shaft.
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of pulley
Belt static load must not exceed the following standards :
RADIAL LOAD (PTO shaft end) : 90.8 kg
THRUST LOAD
: 22.7 kg
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GCV FLYWHEELBRAKE ( ATTACHMENT SIDE )
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Set the stroke of the attachment brake lever to 25 mm as standard.
(When the dispersion of the brake cable and brake lever loss are both 2.5 mm )
brake stroke + cable dispersion + lever loss = brakeleverstroke
+
20
2.5
+
2.5
=
25 mm
When the operating lever is a top mount handle, a return
spring must be installed becausethe lever may
exhibit a poor returndue to the weight of the lever.
When the stroke of the brake lever onthe attachment side cannot be set at 25 mm, make surethat the
cable length can beadjusted at the cable end.
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As a standard, whenthe recommended maximum engine speedis 3250 rpm, the blade should stop within
3 seconds, provided that the moment of inertia of the blade andthe blade holder is within 300Kg/cm2.
ADJUSTMENT
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Adjust the brake arm onthe engine side so that, inside the slit, the clearance between it and the plate
is 0.5 to 1.5 mm whenthe brake lever on the attachment side is squeezed.
Confirm that there is play in the cable after the brake lever on the attachment side has been released.
0.5- 1.5
=Zi?Blade stop time regulations:
- USA
within 3 sec.
- EUROPE
walk-behind lawnmower: 3 sec
ride-on lawnmower: 5 sec
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MAINTENANCE
When mounting the engine onan application, covered or not, makesure space is available to perform
the complete engine maintenance : engine oil check and drainage, carburettor adjustment, aircleaner
inspection,spark plug inspection,valve clearance adjustment and cleaning of the engine.
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OTR53013
Printed in USA