Robin EX30D User Manual

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Page 1

MODEL

EX30D

2ZZ9990095

Page 2

Page 3

WARNING:

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

NOTICE

FEDERAL EMISSION COMPONENT DEFECT WARRANTY and CALIFORNIA EMISSION CONTROL WARRANTY are applicable to only those engines complied with EPA (Environmental Protection Agency) and CARB (California Air Resources Board) emission regulations in the U.S.A.

NOTICE

To the engines exported to and used in the countries other than the U.S.A., warranty service shall be performed by the distributor in each country in accordance with the standard Robin engine warranty policy as applicable.

AIR INDEX

To show compliance with California emission regulations, a hangtag has been provided displaying the Air Index level and durability period of this engine.

The Air Index level defines how clean an engine’s exhaust is over a period of time. A bar graph scaled from “0” (most clean) to “10” (least clean) is used to show an engine’s Air Index level. A lower Air Index level represents cleaner exhaust from an engine.

The period of time (in hours) that the Air Index level is measured is known as the durability period. Depending on the size of the engine, a selection of time periods can be used to measure the Air Index level (see below).

Descriptive Term Applicable to Emissions Durability Period

Moderate - 50 hours (engine from 0 to 80 cc)

125 hours (engine greater than 80 cc)

Intermediate - 125 hours (engine from 0 to 80 cc)

250 hours (engine greater than 80 cc)

Extended - 300 hours (engine from 0 to 80 cc)

500 hours (engine greater than 80 cc)

Notice : This hangtag must remain on this engine or piece of equipment, and only be removed by the ultimate purchaser before operation.

Page 4

FEDERAL EMISSIONS COMPONENT DEFECT WARRANTY

EMISSIONS COMPONENT DEFECT WARRANTY COVERAGE

This emission warranty is applicable in all States, except the State of California.

Fuji Heavy Industries Ltd. and Robin America Inc., Wood Dale Illinois, (herein “ROBIN AMERICA”) warrant(s) to the initial retail purchaser and each subsequent owner, that this Nonroad engine (herein “engine”) has been designed, built, and equipped to conform at the time of initial sale to all applicable regulations of the U.S. Environmental Protection Agency (EPA), and that the engine is free of defects in materials and workmanship which would cause this engine to fail to conform with EPA regulations during its warranty period.

For the components listed under PARTS COVERED, the service dealer authorized by ROBIN AMERICA will, at no cost to you, make the necessary diagnosis, repair, or replacement necessary to ensure that the engine complies with applicable U.S. EPA regulations.

EMISSISON COMPONENT DEFECT WARRANTY PERIOD

The warranty period for this engine begins on the date of sale to the

initial purchaser and continues for a period of 2 years.

PARTS COVERED

Listed below are the parts covered by the Emission Components

Defect Warranty. Some of the parts listed below may require scheduled maintenance and are warranted up to the first scheduled

replacement point for that part.

(1) Fuel Metering System

(i) Carburetor and internal parts (and/or pressure regulator or

fuel injection system). (ii) Air/fuel ratio feedback and control system, if applicable. (iii) Cold start enrichment system, if applicable. (iv) Regulator assy (gaseous fuel, if applicable)

(2) Air Induction System

(i) Intake manifold, if applicable (ii) Air filter.

(3) Ignition System

(i) Spark plugs. (ii) Magneto or electronic ignition system. (iii) Spark advance/retard system, if applicable.

(4) Exhaust manifold, if applicable

(5) Miscellaneous Items Used in Above Systems

(i) Electronic controls, if applicable (ii) Hoses, belts, connectors, and assemblies. (iii) Filter lock assy (gaseous fuel, if applicable)

OBTAINING WARRANTY SERVICE

To obtain warranty service, take your engine to the nearest authorized Robin America service dealer . Bring your sales receipts indicating date of purchase for this engine. The service dealer authorized by ROBIN AMERICA will perform the necessary repairs or adjustments within a reasonable amount of time and furnish you with a copy of the repair order. All parts and accessories replaced under this warranty become the property of ROBIN AMERICA.

WHAT IS NOT COVERED

* Conditions resulting from tampering, misuse, improper adjustment

(unless they were made by the service dealer authorized by ROBIN AMERICA during a warranty repair), alteration, accident, failure to use the recommended fuel and oil, or not performing required

maintenance services. * The replacement parts used for required maintenance services. * Consequential damages such as loss of time, inconvenience, loss

of use of the engine or equipment, etc. * Diagnosis and inspection charges that do not result in warranty-

eligible service being performed. * Any non-authorized replacement part, or malfunction of authorized

parts due to use of non-authorized parts.

OWNER’S WARRANTY RESPONSIBILITIES

As the engine owner, you are responsible for the performance of the required maintenance listed in your owner’s manual. ROBIN AMERICA recommends that you retain all receipts covering maintenance on your engine, but ROBIN AMERICA cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

As the engine owner, you should however be aware that ROBIN AMERICA may deny warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

You are responsible for presenting your engine to the nearest service dealer authorized by ROBIN AMERICA when a problem exists.

If you have any questions regarding your warranty rights and responsibilities, you should contact the Robin America customer service department at 1-630-350-8200 for the information.

THINGS YOU SHOULD KNOW ABOUT THE EMISSION CONTROL SYSTEM WARRANTY MAINTENANCE AND REPAIRS

You are responsible for the proper maintenance of the engine. You should keep all receipts and maintenance records covering the performance of regular maintenance in the event questions arise. These receipts and maintenance records should be transferred to each subsequent owner of the engine. ROBIN AMERICA reserves the right to deny warranty coverage if the engine has not been properly maintained. Warranty claims will not be denied, however, solely because of the lack of required maintenance or failure to keep maintenance records.

MAINTENANCE, REPLACEMENT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY REPAIR ESTABLISHMENT OR INDIVIDUAL; HOWEVER, WARRANTY REPAIRS MUST BE PERFORMED BY A SERVICE DEALER AUTHORIZED BY ROBIN AMERICA. THE USE OF PARTS THAT ARE NOT EQUIVALENT IN PERFORMANCE AND DURABILITY TO AUTHORIZED PARTS MAY IMPAIR THE EFFECTIVENESS OF THE EMISSION CONTROL SYSTEM AND MAY HAVE A BEARING ON THE OUTCOME OF A WARRANTY CLAIM.

If other than the parts authorized by ROBIN AMERICA are used for maintenance replacements or for the repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to the parts authorized by ROBIN AMERICA in their performance and durability.

HOW TO MAKE A CLAIM

All repair qualifying under this limited warranty must be performed by a service dealer authorized by ROBIN AMERICA. In the event that any emission-related part is found to be defective during the warranty period, you shall notify Robin America customer service department at 1-630350-8200 and you will be advised of the appropriate warranty service dealer or service providers where the warranty repair can be performed.

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CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT

YOUR WARRANTY RIGHTS AND OBLIGATIONS

The California Air Resources Board and Fuji Heavy Industries Ltd. (herein “FUJI”) are pleased to explain the emission control system warranty on your 2005 and later Small Off-Road engine (herein "engine"). In California, new engine must be designed, built and equipped to meet the State's stringent anti-smog standards. FUJI must warrant the emission control system on your engine for the periods of time described below, provided there has been no abuse, neglect or improper maintenance of your engine. Your emission control system may include parts such as the carburetor or fuel-injection system, and the ignition system. Also included may be hoses, belts, connectors and other emission-related assemblies. Where a warrantable condition exists, FUJI will repair your engine at no cost to you including diagnosis, parts and labor.

MANUFACTURER'S WARRANTY COVERAGE:

The 2005 and later engines are warranted for two (2) years. If any emission related part on your engine is defective, the part will be repaired or replaced by FUJI.

OWNER'S WARRANTY RESPONSIBILITIES:

-As the engine owner, you are responsible for the performance of the required maintenance listed in your Owner's Manual. FUJI recommends that you retain all receipts covering maintenance on your engine, but FUJI cannot deny warranty solely for the lack of receipts or for your failure to ensure the performance of all scheduled maintenance.

-As the engine owner, you should ,however, be aware that FUJI may deny you warranty coverage if your engine or a part has failed due to abuse, neglect, improper maintenance or unapproved modifications.

-You are responsible for presenting your engine to a service dealer or warranty station authorized by ROBIN AMERICA Inc. 940 Lively Blvd., Wood Dale, IL 60191 (herein ROBIN AMERICA) as soon as a problem exists. The warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.

If you have any questions regarding your warranty rights and responsibilities, you should contact the Robin America Inc. Customer Service Department at 1-630-350-8200.

LIMITED WARRANTY

on Emission Control Systems

California Only

FUJI warrants to the owner of the 2005 and later engine that the engine (1) has been designed, built and equipped so as to conform at the time of manufacture with the applicable regulations of the California Air Resources Board, and (2) is free from defects in materials and workmanship that could cause it to fail to conform with those regulations as may be applicable in the terms and conditions stated below.

A. COMMENCEMENT DATE

The warranty period begins on the date the engine is delivered to a first retail purchaser.

B. LENGTH OF COVERAGE

FUJI warrants to a first retail purchaser and each subsequent purchaser that the engine is free from defects in materials and workmanship that cause the failure of a warranted emission-related part for a period of two (2) years after the date of delivery to the first retail purchaser.

C. WHAT IS COVERED:

1. REPAIR OR REPLACEMENT PARTS Repairs and replacement of any warranted part will be performed at no charge to you by an authorized service dealer or a warranty station. You may contact the Robin America Inc. Customer Service Department at 1-630-350-8200 to obtain the name of the nearest appropriate location where your warranty repairs are performed.

2. WARRANTY PERIOD This warranty continues for a period of two (2) years and applies only to the repair, replacement or adjustment of the component parts that are not scheduled for replacement as required maintenance. Further, component parts which are scheduled only for regular inspection to the effect of "repair or replace as necessary" are warranted for the warranty period. Any warranted part which is scheduled for replacement as required maintenance is warranted for the period of time up to the first scheduled replacement point for that part.

3. DIAGNOSIS

You will not be charged for diagnostic labor that leads to the determination that a warranted part is defective, if the diagnostic work is performed at an authorized service dealer or warranty station.

4. DAMAGES

If a warranted part failed causing damage to other engine components, consult an warranty station.

D. WHAT IS NOT COVERED

2. Add-on or modified parts

3. Expenses incurred by processing warranty claims

E. HOW TO FILE A CLAIM

All repairs qualifying under this Limited Warranty must be performed by a dealer who sold you the engine or warranty station authorized by ROBIN AMERICA. In the event that any emission-related part is found to be defective during the warranty period, you must notify the Robin America Inc. Customer Service Department at 1-630-350-8200 and you will be advised of the appropriate warranty service facilities where the warranty repair is to be performed.

F. WHERE TO OBTAIN WARRANTY SERVICE

It is recommended that warranty service be performed by the authorized dealer who sold you the engine, although warranty service will be performed by any authorized service dealers or warranty stations anywhere in the United States.

1. This limited warranty does not cover any part which malfunctions, fails or is damaged due to failure to follow the maintenance and operating instructions set forth in the 2005 and later Owner's Manual including: (1) improper maintenance of any warranted parts (2) improper installation, adjustment or repair of the engine or of

any warranted part unless performed by an authorized service dealer

(3) failure to follow recommendations on fuel use contained in

the 2005 and later Owner's Manual

(4) repairs performed outside of the authorized warranty service

dealers

(5) use of parts which are not authorized by FUJI.

This warranty does not cover any part that malfunctions, fails or is damaged due to alterations by changing, adding to or removing parts from the engine.

FUJI, any authorized service dealer and warranty station shall not be liable for any loss of use of the engine, for any alternative usage, for any damage to goods, loss of time or inconvenience.

Page 6

When warranty repair is needed, the engine must be brought to an authorized service dealer or warranty station’s place of business during normal business hours. In all cases, a reasonable time, not to exceed 30 days, must be allowed for the warranty repair to be completed after the engine is received by the authorized service dealer or warranty station.

G. MAINTENANCE, REPLACEMENT AND

REPAIR OF EMISSION-RELATED PARTS

Only warranted engine replacement parts approved by FUJI should be used in the performance of any warranty maintenance or repairs on emission-related parts. If other than authorized parts are used for maintenance, replacement or repair of components affecting emission control, you should assure yourself that such parts are warranted by their manufacturer to be equivalent to authorized parts in performance and durability. FUJI ,however, assumes no liability under this warranty with respect to parts other than authorized parts. The use of nonauthorized replacement parts does not invalidate the warranty on other components unless the non-authorized parts cause damage to warranted parts.

H. PARTS COVERED UNDER THE CALIFORNIA EMISSIONS

WARRANTY

(1) Fuel Metering System

(i) Carburetor and internal parts (and/or pressure regulator or

fuel injection system). (ii) Air/fuel ratio feedback and control system, if applicable. (iii) Cold start enrichment system, if applicable. (iv) Regulator assy (gaseous fuel, if applicable)

(2) Air Induction System

(i) Intake manifold, if applicable (ii) Air filter.

(3) Ignition System

(i) Spark plugs. (ii) Magneto or electronic ignition system. (iii) Spark advance/retard system, if applicable.

(4) Exhaust manifold, if applicable

(5) Miscellaneous Items Used in Above Systems

(i) Electronic controls, if applicable (ii) Hoses, belts, connectors, and assemblies. (iii) Filter lock assy (gaseous fuel, if applicable)

I. MAINTENANCE STATEMENTS

It is your responsibility to have all scheduled inspection and maintenance services performed at the times recommended in the 2005 and later

Owner's Manual and to retain proof that inspection and maintenance services are performed at the times when recommended. FUJI will not deny a warranty claim solely because you have no record of maintenance; however, FUJI may deny a warranty claim if your failure to perform

required maintenance resulted in the failure of warranted part. The proof which you maintain should be given to each subsequent owner of the engine. You are responsible for performing the scheduled maintenance described below based on the procedures specified in the 2005 and

later Owner's Manual. The scheduled maintenance below is based on a normal engine operating schedule.

PROCEDURE INTERVAL

1) Change engine oil

2) Clean air cleaner (element) : Every 50 hours

3) Replace air cleaner element : Every 200 hours

4) Clean and adjust spark plug and electrodes : Every 200 hours

Note: More frequent maintenance may be necessary under dusty, dirty or severe conditions.

: Initial 20 hours and every 100 hours afterward

Page 7

SER NO.

FOREWORD

Thank you very much for purchasing a ROBIN ENGINE.

Your ROBIN ENGINE can supply the power to operate various sorts of machines and equipment.

Please take a moment to familiarize yourself with the proper operation and maintenance procedures in order to maximize the safe and efficient use of this product.

Keep this owner’s manual at hand, so that you can refer to it at any time.

Due to constant efforts to improve our products, certain procedures and specifications are subject to change without notice.

When ordering spare parts, always give us the MODEL, PRODUCTION NUMBER and SERIAL NUMBER of your engine.

Please fill in the following blanks after checking the production number on your engine. (Location of label is different depending on the engine specification.)

PROD NO.

PROD No. / SER No. (

)

Label

SER No. (Stamping

CONTENTS

1. SAFETY PRECAUTIONS… ............................................................................. 2

2. COMPONENTS ................................................................................................ 4

3. PRE-OPERATION CHECKS…......................................................................... 5

4. ELECTRIC STARTER MODELS ...................................................................... 5

5. OPERATING YOUR ENGINE........................................................................... 6

6. MAINTENANCE ............................................................................................... 7

7. PREPARATIONS FOR STORAGE ................................................................... 9

8. OIL SENSOR INSTRUCTIONS (OPTIONAL) .................................................. 9

9. EASY TROUBLESHOOTING ........................................................................... 9

10. SPECIFICATIONS ............................................................................................ 10

)

Page

NOTE Please refer to the illustrations on the back page of the front

cover or back cover for Fig.

1 1

1 to

1 1

6 6

6 indicated in the sentence.

6 6

Page 8

1. SAFETY PRECAUTIONS

Please make sure you review each precaution carefully. Pay special attention to statement preceded by the following words.

WARNING

“WARNING” indicates a strong possibility of severe personal injury or loss of life if instructions are not followed.

CAUTION

“CAUTION” indicates a possibility of personal injury or equipment damage if instructions are not followed.

WARNING

■

Never inhale exhaust gasses.

They contain carbon monoxide, a colorless, odorless and extremely dangerous gas which can cause unconsciousness or death.

■

Never operate the engine indoors or in a poorly ventilated area, such as tunnel, cave,

etc.

■

Exercise extreme care when operating the engine near people or animals.

■

Keep the exhaust pipe free of foreign objects.

WARNING

■

Gasoline is extremely flammable and its vapors can explode if ignited.

■

Do not refuel indoors or in a poorly ventilated area.

■

Be sure to stop the engine prior to refueling.

■

Do not remove fuel tank cap nor fill fuel tank while engine is hot or running.

Allow engine to cool at least 2 minutes before refueling.

■

Do not overfill the fuel tank.

■

If fuel is spilt, wipe it away carefully and wait until the fuel has dried before starting the

engine.

■

After refueling, make sure that the fuel cap is secured to prevent spillage.

: EXHAUST PRECAUTIONS

: REFUELING PRECAUTIONS

WARNING

■

Do not operate the engine while smoking or near an open flame.

■

Do not use around dry brush, twigs, cloth rags, or other flammable materials.

■

Keep cooling air intake (recoil starter area) and muffler side of the engine at least

1 meter (3 feet) away from buildings, obstructions and other burnable objects.

■

Keep the engine away from flammables and other hazardous materials (trash, rags,

lubricants, explosives).

WARNING

■

Place the protective covers over the rotating parts.

If rotating parts such as the drive shaft, pulley, belt, etc. are left exposed, they are potentially hazardous. To prevent injury, equip them with protective covers or shrouds.

■

Be careful of hot parts.

The muffler and other engine parts become very hot while the engine is running or just after it has stopped. Operate the engine in a safe area and keep children away from the running engine.

: FIRE PREVENTION

: OTHER SAFETY PRECAUTIONS

Page 9

■

Do not touch the spark plug and ignition cable when starting and operating the engine.

■

Never make adjustments on the machinery while it is connected to the engine, without

first removing the ignition cable from the spark plug. Turning the crankshaft by hand during adjusting or cleaning might start the engine, and cause serious injury to the operator.

■

Operate the engine on a stable, level surface.

If the engine is tilted, fuel spillage may result.

NOTE

Operating the engine at a steep incline may cause seizure due to improper lubrication even with a maximum oil level.

■

Do not transport the engine with fuel in tank or with fuel strainer cock open.

■

Do not move the engine while in operation when it has been removed from the

equipment.

■

Keep the unit dry (do not operate it in rainy conditions).

WARNING

■

Battery electrolyte contains sulphuric acid. Protect your eyes, skin and clothing. In

case of contact, flush thoroughly with water and get prompt medical attention, especially if your eyes are affected.

■

Batteries generate hydrogen gas, which can be highly explosive. Do not smoke or

allow flames or sparks near a battery, especially during charging.

■

Charge the battery in a fully ventilated location.

■

Be sure to confirm Battery polarity.

: WHEN CHARGING THE BATTERY

CAUTION

■

Carefully check fuel hoses and joints for looseness and fuel leakage. Leaked fuel

creates a potentially dangerous situation.

■

Check bolts and nuts for looseness. A loose bolt or nut may cause serious engine

trouble.

■

Check the engine oil and refill if necessary.

■

Check the fuel level and refill if necessary. Take care not to overfill the tank.

■

Keep cylinder fins and recoil starter free of dirt, grass and other debris.

■

Wear snug fitting working clothes when operating the engine.

Loose aprons, towels, belt, etc., may be caught in the engine or drive train, causing a dangerous situation.

: PRE-OPERATION CHECKS

Page 10

SYMBOLS

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.ecafrustohehtforaelcyatS

.suonosiopsisagtsuahxE

.aeradetalitnevnunanietarepotonoD

.gnileufererofebenigneehtpotS

.detibihorpgnikomsdnaemalfnepo,eriF

)nuR(nOytiralopevitisoP;sulP

)potS(ffOyrettaB

lioenignE)tratscirtcelE(tratsenignE

lioddA

2. COMPONENTS

(See Fig.

NOTE Please refer to the illustrations on the back page of the front

cover or back cover for Fig.

q SPARK PLUG

1 1

1 to

1 1

6 6

6 indicated in the sentence.

6 6

o STOP SWITCH

w DUCT

e STARTER HANDLE

r RECOIL STARTER

t AIR CLEANER

y CARBURETOR

u CHOKE LEVER

i OIL SENSOR UNIT

!0 EXHAUST PIPE

!1 P.T.O. SHAFT

!2 OIL GAUGE (OIL FILLER)FUEL CUP

!3 OIL DRAIN PLUG

!4 ENGINE SERIAL NO. (STAMPING)

!5 ENGINE NAME LABEL (SPEC. No.)

Page 11

3. PRE-OPERATION CHECKS

ELECTRIC STARTER MODELS

NOTE

Engine shipped from our factory is without oil. Before starting engine, fill with oil. Do not over-fill.

CHECK ENGINE OIL (See Fig.

Before checking or refilling engine oil, be sure the engine is

located on stable, level surface and stopped.

■

Do not screw the oil gauge into the oil filler neck to check

oil level. If the oil level is low, refill to the upper level with

the following recommended oil.

■

Use 4-stroke automotive detergent oil of API service

class SE or higher grade.

■

Select the viscosity based on the air temperature at the

time of operation as shown in the table. (See Fig.2

OIL CAPACITY : 1.0 liter

Explanation of Fig.2

q Oil Gauge w Upper Level e Lower Level

For electric starter operation, proper electric wiring

arrangements are needed before normal engine operation.

1. BATTERY

■

Use a battery rated 12V-24AH or larger.

WARNING

■

Charge the battery in a fully ventilated location.

■

Batteries generate hydrogen gas, which can be highly explosive. Do not smoke or allow flames or sparks near a battery, especially during charging.

■

Be sure to confirm Battery polarity. Connect positive (+) terminal first when mounting battery, and disconnect negative ( dismounting.

■

Battery electrolyte contains sulphuric acid. Protect your eyes, skin and clothing. In case of contact, flush thoroughly with water and get prompt medical attention, especially if your eyes are affected.

) terminal first when

2. BATTERY CABLE

■

Use a proper cable and ground wire to connect battery.

■

For GROUND WIRE, use a flat braided wire of 20 sq.

mm. or larger sectional area.

6.5 CABLE

LA406 LA406

6.5 EARTH (GROUND) WIRE

25mm

eguageriW

htgnelelbaC.aidelbaC

m5.1nahtsseLmm3.71651VA

m5.2otm5.1mm4.80402VA

m4otm5.2mm8.010/32 03VA

GWA

)SB(

GWB

EASSIJ

3. KEY SWITCH CABLE

If a remote key switch is used, select wires of proper gauge to connect it and magnetic switch of the engine.

eguageriW

htgnelelbaC.aidelbaC

m5.1nahtsseLmm5.1416152.1VA

m3otm5.1mm9.121412VA

m5otm3mm4.201313VA

GWA

GWBSIJ

)SB(

Page 12

4. WIRING

MAGNETIC SWITCH

CABLE

To KEY SWITCH (TERMINAL "ST")

EARTH WIRE

BATTERY

(1) Connect positive (+) terminal of the magnetic switch and

positive (+) terminal of the battery with battery cable.

Make sure the polarity of battery terminals. Never connect

the

battery cable with the battery negative (-) terminal.

When connecting the battery cable with the battery negative

(-)

terminal, diode rectifier chips will be burned out or

damaged in a moment.

(2) Ground negative terminal of the battery to the engine

body or machine with ground wire.

(3) When installing the key switch on the machine, install

with its drain hole at the bottom.

NOTE

Tighten bolts and nuts on terminals securely so that they will not be loosened by vibration.

5. WIRING DIAGRAM (RECOIL STARTER MODELS)

Spark plug

CAUTION

Ignition coil

Black

To LED

Lamp

Oil sensor control unit

WIRING DIAGRAM

Flywheel

Oil sensor

(ELECTRIC STARTER MODELS)

Spark plug

Magneto

EX30

To Di od e rectifier

To Ba ttery

Black

Ignition coil

Charge coil

To Key switch (B)

LA108

LA408

To Key switch

(ST)

Electric

starter

Optional hardware shown by dotted lines.

To LE D Lamp

Diode rectifier

LA306

Electric starter

Key switch

LA106 LA406

Magnetic switch

Stop switch

Oil sensor control unit

Oil sensor

Battery

5. OPERATING YOUR ENGINE

(See Fig.

1. STARTING

(1) Open the fuel cock.

(2) Turn the STOP SWITCH to the position “ I ” (ON).

(See Fig.3

(3) Close the choke lever. (See Fig.3

■

If the engine is cold or the ambient temperature is low, close the choke lever fully.

■

If the engine is warm or the ambient temperature is high, open the choke lever half-way, or keep it fully open.

(4) Pull the starter handle slowly until resistance is felt. This

is the “compression” point. Return the handle to its original position and pull swiftly. Do not pull out the rope all the way. After starting the engine, allow the starter handle to return to its original position while still holding the handle. (See Fig.3

FOR ELECTRIC STARTER MODELS.

Insert the key into the key slot and set it at the “ I ” (ON) position. Turn it to the right (START position) to start the engine. (See Fig.3

■

Do not operate the electric starter continuously for more than 5 secounds, even if the engine dose not start.

■

If the engine failed to start, set the key to the “ I ” (ON) position and wait for about 10 secounds before retrying.

■

Never turn the key switch to the START position while engine is running.

(5) After starting the engine, gradually open choke by turning

the choke lever and finally keep it fully opened. Do not fully open the choke lever immediately when the engine is cold or the ambient temperature is low, because the engine may stop. (See Fig.3

2. RUNNING

After the engine starts, warm it up without load for a few minutes.

3. STOPPING

(1) Allow the engine to run for 1 or 2 minutes before stopping.

(2) Turn the STOP SWITCH (or KEY SWITCH) counterclock-

wise to the position “ ○ ” (OFF). (See Fig.4

(3) Close the fuel cock.

(4) Pull the starter handle slowly and return the handle to its

original position when resistance is felt. This operation

is necessary to prevent outside moist air from intruding into the combustion chamber. (See Fig.4

Page 13

2. PERIODIC INSPECTION

※ STOPPING ENGINE WITH THE FUEL COCK

Close the fuel cock and wait for a while until the engine stops. Avoid to let the fuel remain in the carburator over long periods, or the passages of the carburator may become clogged with impurities, and malfunctions may result.

6. MAINTENANCE

(See Fig.

MAINTENANCE, REPLACEMENT OR REPAIR OF THE EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY NONROAD ENGINE REPAIR ESTABLISHMENT OR INDIVIDUAL.

1. DAILY INSPECTION (See Fig.

Before running the engine, check the following service items.

q Loose or broken bolts and nuts

w Clean air cleaner element e Enough clean engine oil

r Leakage of gasoline and engine oil t Enough gasoline

y Safe surroundings

u Excessive vibration, noise

Periodic Maintenance Schedule table

Maintenance Items

CLEAN ENGINE AND CHECK BOLTS AND NUTS

CHECK AND REFILL ENGINE OIL

CHANGE ENGINE OIL (*Note 1) ● (Initial 20 hours) ●

CLEAN SPARK PLUG

CLEAN AIR CLEANER ●

REPLACE AIR CLEANER ELEMENT ●

CLEAN FUEL CUP ●

CLEAN AND ADJUST SPARK PLUG AND ELECTRODES

REPLACE SPARK PLUG ●

REMOVE CARBON FROM CYLINDER HEAD (

CHECK AND ADJUST VALVE CLEARANCE (*Note 2)

CLEAN AND ADJUST CARBURETOR (*Note 2) ●

REPLACE FUEL LINES

OVERHAUL ENGINE IF NECESSARY (*Note 2) ●

*Note: 1. Initial oil change should be performed after first twenty (20) hours of operation. Thereafter change oil every

*Note: 2. As to the procedures for these items, please refer to the SERVICE MANUAL or consult your nearest Robin

Every

8 hours

(Daily)

● (Daily)

● (Refill daily up to upper level)

Note 2)

hundred (100) hours. Before changing oil, check for a suitable way to dispose of old oil. Do not pour it down into sewage drains, onto garden soil or into open streams. Your local zoning or environmental regulations will give you more detailed instructions on proper disposal.

service dealer.

Periodic maintenance is vital to the safe and efficient operation of your engine. Check the table below for periodic maintenance intervals.

IT IS ALSO NECESSARY FOR THE USER OF THIS ENGINE TO CONDUCT THE MAINTENANCE AND ADJUSTMENTS ON THE EMISSION-RELATED PARTS LISTED BELOW TO KEEP THE EMISSION CONTROL SYSTEM EFFECTIVE.

The emission control system consists of the following parts :

(1) Carburetor and internal parts

(2) Cold start enrichment system, if applicable

(3) Intake manifold, if applicable

(4) Air cleaner elements

(5) Spark plug

(6) Magneto or electronic ignition system

(7) Spark advance/ retard system, if applicable

(8) Exhaust manifold, if applicable.

(9) Hoses, belts, connectors, and assembles

The maintenance schedule indicated in the following table is based on the normal engine operation. Should the engine be operated in extremely dusty condition or in heavier loading condition, the maintenance intervals must be shortened depending on the contamination of oil, clogging of filter elements, wear of parts, and so on.

Every 50 hours (Weekly)

● (Every 100 hours)

●

Every

200 hours

(Monthly)

●

Every

500

hours

●

Every

hours

● (yearly)

1000

Page 14

3. INSPECTING THE SPARK PLUG

(See Fig.

(1) Clean off carbon deposits on the spark plug electrode

using a plug cleaner or wire brush.

(2) Check electrode gap. The gap should be 0.6 mm to 0.7

mm (0.02 inch. by carefully bending the side electrode.

Recommended Spark Plug : NGK BR-6HS

ENGINE OIL CHANGE (See Fig.

Initial oil change : After 20 hours of operation Thereafter : Every 100 hours of operation

(1) When changing oil, stop the engine and loosen the drain

plug. Drain the used oil while the engine is warm. Warm oil drains quickly and completely.

To prevent injury, pay attention to the hot oil.

0.03 inch.). Adjust the gap, if necessary,

(CHAMPION RL86C)

CAUTION

(2) Re-install the drain plug before refilling oil.

OIL CAPACITY : 1.0 liter

(3) Refer to page 5 for the recommended oil.

■

Always use the best grade and clean oil. Contaminated oil, poor quality oil and shortage of oil cause damage to engine or shorten the engine life.

NOTE

Clean and replace air cleaner elements more often when operating in dusty environments. Replace the element in case that dirt or dust can not be removed and/or that the element is deformed or deteriorated.

6. FUEL HOSE REPLACEMENT (See Fig.

WARNING

Take extreme caution when replacing fuel hose ; gasoline is extremely flammable.

Replace the fuel hose every 1,000 hours or every year. If fuel leaks from fuel hose, replace the fuel hose immediately.

CHECKING BOLTS, NUTS AND SCREWS

■

Retighten loose bolts and nuts.

■

Check for fuel and oil leaks.

■

Replace damaged parts with new ones.

8. CHECK BATTERY

WARNING Flame Prohibited

If the electrolyte fluid is below level line, refill with distilled water to the upper level line.

)

5. CLEANING AIR CLEANER

(See Fig.

A dirty air cleaner element will cause starting difficulty, power

loss, engine malfunctions, and shorten engine life extremely. Always keep the air cleaner element clean.

WARNING Flame Prohibited

A. Urethane Foam Element Type (See Fig.5

Remove the element and wash it in kerosene or diesel fuel. Then saturate it in a mixture of 3 parts kerosene or diesel fuel and 1 part engine oil. Squeeze the element to remove the mixture and install it in the air cleaner. (See Fig.5

B. Dual Element Type (Urethane Foam and Paper

elements) (See Fig.5

■

Urethane Foam cleaning (See Fig.5-y-q,5-u-q) Wash and clean the urethane foam with detergent. After cleaning, dry it.

Clean the urethane foam every 50 hours.

■

Paper Element Cleaning (See Fig.5-y-w,5-u-w) Clean by tapping gently to remove dirt and blow off dust. Never use oil. Clean the paper element every 50 hours of operation, and replace element set every 200 hours.

-t-

q,5-i-q)

thru

y,u)

)

t,i)

Page 15

7. PREPATIONS FOR STORAGE

9. EASY TROUBLESHOOTING

1. DISCHARGE FUEL (See Fig.

WARNING Flame Prohibited

If you do not use the engine more than 1 month, discharge fuel to prevent gum in the fuel system and carburetor parts.

■

Remove the fuel cup, place it over a container and open the fuel cock to discharge fuel from the fuel tank.

■

Remove the drain screw of the carburetor float chamber and discharge fuel.

2. ENGINE OIL

■

Change the engine oil with fresh oil.

■

Remove the spark plug, pour about 5 cc of engine oil into the cylinder, slowly pull the starter handle of the recoil starter 2 or 3 times, and reinstall the spark plug.

3. CLEAN AND STORE

■

Slowly pull the recoil starter handle until resistance is felt and leave it in that position.

■

Clean the engine thoroughly with an oiled cloth, put the cover on, and store the engine indoors in a well

ventilated, low humidity area.

4. BATTERY CHARGING

WARNING Flame Prohibited

■

The battery discharges itself even when not connected, therefore it is necessary to recharge it once a month.

8. OIL SENSOR INSTRUCTIONS

(OPTIONAL)

1. FUNCTION OF OIL SENSOR

The engine will stop automatically when the oil level falls below the safety limit. The engine cannot be started unless the level is raised above the prescribed limit. (See Fig.2-w)

2. RESTARTING

(1) Fill the crankcase with oil up to the proper level.

(2) As for restarting and operating the engine, refer to section

“5. OPERATING YOUR ENGINE” on page 6 .

■

Check the wire connector from the engine. It must be connected securely to the wire from oil sensor.

■

When selecting the engine oil, refer to page 5 for the recommended oil.

WHEN ENGINE WILL NOT START :

Perform the following checks before you take the engine to your Robin dealer. If you still have trouble after completing the checks, take the engine to your nearest Robin dealer.

1. Is there a strong spark across the electrode ?

(1) Is the stop switch at position “ I ” (ON)?

(2) Remove and inspect the spark plug.

If the electrode is fouled, clean or replace it with new one.

(3) Remove the spark plug and connect it to the plug cap.

Pull the starter handle while grounding spark plug against engine body. Try with a new spark plug if the spark is weak or there is no spark. The ignition system is faulty if there is no spark with a new spark plug.

WARNING

■

Wipe out spilled fuel carefully before testing. Place spark plug as far away from spark plug hole as possible.

■

Do not hold spark plug by hand while pulling recoil starter.

NOTE

The engine with oil sensor will stop automatically when the oil level falls below the prescribed limit. Unless the oil level is raised above the prescribed limit, the engine will stop immediately after starting.

2. Is there enough compression?

Pull the starter handle slowly and check if resistance is felt. If little force is required to pull the starter handle, check if the spark plug is tightened firmly. If the spark plug is loose, tighten it.

3. Is the spark plug wet with gasoline?

(1) Is the fuel cock opened?

(2) Choke (close choke lever) and pull the starter handle

five or six times. Remove the plug and check if its electrode is wet. If the electrode is wet, fuel is well supplied to your engine.

(3) When the electrode is dry, check where the fuel stops.

(Check the fuel intake of the carburetor.)

(4) In case the engine does not start with well supplied fuel,

try using fresh fuel.

4. Is the battery well charged?

If the battery for the electric starter is discharged, the engine will not start.

Page 16

10. SPECIFICATIONS

MODEL EX30D

Type Air-cooled, 4-cycle single cylinder, overhead camshaft, gasoline engine

Displacement mL (cc) 287

Continuous Output

Maximum Output

Direction of Rotation Counterclockwise, as Viewed from P.T.O. Shaft side

Lubricant Automotive detergent oil (API/ SE or higher grade, SAE/ 10W-30 etc.)

Oil Capacity Liter 1.0

Fuel Automotive Gasoline (Unleaded)

Spark Plug NGK BR-6HS (CHAMPION RL86C)

Starting System Recoil starter /Electric starter

Dry Weight kg 21

Dimensions (L x W x H) mm 415 x 424 x 319

Valve Clearance (Intake and Exhaust)

Emissions Durability Period (California only)

kW/rpm (HP/rpm)

5.5/3600

(7.5/3600)

6.6/4000

(9.0/4000)

+0.03

0.12 mm (0.0047 in.)

Note : Adjust the valve clearance while the engine is cold.

500 hours

+0.0012 0

Page 17