Robin EY15-3 Service Manual

SERVICE MANUAL

Models

EY15-3, EY20-3 ENGINES

PUB-ES1609 Rev. 12/01

940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212

e-mail: sales@robinamerica.com • www.robinamerica.com

CONTENTS

Section Title Page

1. SPECIFICATIONS....................................................................................................... 1

2. PERFORMANCE ........................................................................................................2

2-1 MAXIMUM OUTPUT........................................................................................................ 2

2-2 CONTINUOUS RATED OUTPUT .................................................................................... 2

2-3 MAXIMUM TORQUE ....................................................................................................... 2

2-4 PERFORMANCE CURVES ............................................................................................. 3

3. FEATURES (compared with former models)........................................................... 5

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS .......................................... 6

4-1 CYLINDER AND CRANKCASE....................................................................................... 6

4-2 MAIN BEARING COVER ................................................................................................. 6

4-3 CRANKSHAFT.................................................................................................................6

4-4 CONNECTING ROD AND PISTON ................................................................................. 7

4-5 CAMSHAFT ..................................................................................................................... 7

4-6 VALVE ARRANGEMENT ................................................................................................. 7

4-7 CYLINDER HEAD............................................................................................................ 8

4-8 GOVERNOR SYSTEM .................................................................................................... 8

4-9 COOLING SYSTEM......................................................................................................... 8

4-10 LUBRICATION SYSTEM ............................................................................................... 8

4-11 IGNITION SYSTEM........................................................................................................ 9

4-12 CARBURETOR.............................................................................................................. 9

4-13 AIR CLEANER ...............................................................................................................9

4-14 SECTIONAL VIEW OF ENGINE.................................................................................. 10

5. DISASSEMBLY AND REASSEMBLY ....................................................................... 12

5-1 PREPARATIONS AND SUGGESTIONS........................................................................ 12

5-2 SPECIAL TOOLS ........................................................................................................... 12

5-3 DISASSEMBLY PROCEDURES.................................................................................... 13

5-4 REASSEMBLY PROCEDURES..................................................................................... 20

5-5 BREAK-IN OPERATION OF REASSEMBLED ENGINE ............................................... 27

6. GOVERNER ADJUSTMENT.....................................................................................28

7. CARBURETOR ......................................................................................................... 30

7-1 OPERATION AND CONSTRUCTION............................................................................ 30

7-2 DISASSEMBLY AND REASSEMBLY ............................................................................ 31

8. MAGNETO ................................................................................................................ 33

8-1 FEATURES .................................................................................................................... 33

8-2 BASIC PRINCIPLE OF U.T.C.I. ..................................................................................... 33

8-3 MAGNETO TROUBLESHOOTING................................................................................ 34

1. SPECIFICATIONS

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- 1 -

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.

NOTE : 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 engine'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 should 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 specified r.p.m..

- 2 -

2-4 PERFORMANCE CURVES

(kgf.m) N.m

0.7

EY15-3D

MAXIMUM TORQUE

TORQUE

OUTPUT

0.6

(HP) kW

MAXIMUM HORSEPOWER

CONTINUOUS RATED HP

2 0 0 0

RECOMMENDED HORSEPOWER RANGE

3 0 0 0

REVOLUTION

- 3 -

4 0 0 0

r.p.m.

(kgf.m) N.m

EY20-3D

1.0

TORQUE

0.9

OUTPUT

(HP) kW

MAXIMUM TORQUE

MAXIMUM HORSEPOWER

CONTINUOUS RATED HP

2 0 0 0

RECOMMENDED HORSEPOWER RANGE

3 0 0 0

REVOLUTION

4 0 0 0

r.p.m.

- 4 -

3. FEATURES (compared with former model)

1. Re-designed outlook Thinner recoil starter, newly designed air cleaner and muffler are adopted. Also, innovate the image that express the reliability of Robin engine more by adopting new labels and new color.

2. Shorter length increased mount-ability Thinner recoil starter realized shorter length than former model. It eases to mount the engines to many applications.

3. Development of dust proof air cleaner Newly developed dual element air cleaner, which has bigger dust holding capacity, realized higher reliability in dusty condition than former model.

4. Deep consideration on human and environment New muffler realized quieter operation. Also, the engine meets with EPA Phase 1 exhaust emission regulation, European emission gas regulations starting from 2002, and Japanese voluntary reguations start from 2003, with dual element or cyclone type air cleaner.

5. Unchanged durability Durability is the same as that of former model. Robin keeps producing reliable and dependable engine.

6. Parts interchangeability Almost of all spare parts are interchangeable between new and former models. The air cleaner and carburetor should be exchanged at the same time.

- 5 -

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS

4-1 CYLINDER AND CRANKCASE

The cylinder and crankcase are single piece aluminum die-casting.

The cylinder liner, made of special cast iron, is molded into the aluminum casting.

The intake and exhaust ports are located on one side of the cylinder, and are also inserted into the casting.

The crankcase has a mounting surface on the output shaft side, where the main bearing cover is attached.

4-2 MAIN BEARING COVER

The main bearing cover is an aluminum die-casting, which is mounted on the output shaft side of the crankcase.

Fig. 4-1

Remove the main bearing cover to inspect inside of the engine.

Pilots and bosses are machined on the cover for direct mounting of the engine onto such machines as generators and pumps.

Oil gauges (fillers) are on both sides of the cover for easy maintenance.

4-3 CRANKSHAFT

The crankshaft is forged carbon steel, and the crank pin is induction-hardened.

The output end of the shaft has a crankshaft gear that is pressed into position.

Oil Gauge Oil Gauge

Governor Gear

Fig. 4-2

- 6 -

Crank Gear

Fig. 4-3

4-4 CONNECTING ROD AND PISTON

The connecting rod is forged of aluminum alloy, and its large and small ends fanction as bearings. The large end has a built-in oil scraper for splashing the lubricating oil.

The piston is an aluminum alloy casting, and carries two compression rings and one oil ring.

4-5 CAMSHAFT

The camshaft is made of special cast iron, and camshaft and gear are cast together in one piece.

Both sides of the shaft fit into the plain bearings on the crankcase and main bearing cover.

Top Ring Second Ring Oil Ring

Connecting Rod

Oil Scraper

Fig. 4-4

4-6 VALVE ARRANGEMENT

The exhaust valve is located upstream of the cooling air with the result that the exhaust valve is intensively cooled for improved engine durability .

Fig. 4-5

Exhaust Valve

Intake Valve

Fig. 4-6

- 7 -

4-7 CYLINDER HEAD

The cylinder head is an aluminum die-casting, and forms a Ricardo type combustion chamber with squish area for high combustion efficiency. The spark plug is tilted for easy mounting of the fuel

tank.

4-8 GOVERNOR SYSTEM

The governor is a centrifugal flyweight type which ensures constant operation at the selected speed during load variations.

The governor gear with governor weights is installed on the main bearing cover.

Fig. 4-7

Main Bearing Cover

Governor Gear Complete

Fig. 4-8

Governor Sleeve

4-9 COOLING SYSTEM

The large fins on the flywheel provide sufficient cooling air capacity for the cylinder and cylinder head. The cylinder baffle and head cover are provided for guiding the cooling air.

4-10 LUBRICATION SYSTEM

All the rotating and sliding parts are splash- lubricated by the oil scraper on the connecting rod.

- 8 -

Oil Scraper

Fig. 4-9

4-11 IGNITION SYSTEM

The ignition system is a transistor controlled magneto system which consists of a flywheel and an ignition coil with a built-in transistor mounted on the crankcase.

4-12 CARBURETOR

The engine is equipped with a horizontal draft carburetor that has a float controlled fuel system and a fixed main jet.

The carburetors are calibrated carefully for sure starting, good acceleration, less fuel consumption and sufficient output.

Ignition Coil

Flywheel

Fig. 4-10

For details, refer to page 30, section “7 CARBURETOR”.

4-13 AIR CLEANER

The air cleaner of the standard engine is an oblong type using an urethane foam(semi-wet).

As optional parts,dual-element type and cyclone chimney type are available.

STD type

Fig. 4-11

Dual-element type (Option)

Cyclone chimney type (Option)

- 9 -

Fig. 4-12

4-14 SECTIONAL VIEW OF ENGINE

Fuel Tank

Cylinder Head

Ignition Coil

Piston Pin

Spark Plug Cap

Spark Plug

Piston

Recoil Starter

Blower Housing

Piston Ring

Crankshaft

Main Bearing Cover

Flywheel

Fig. 4-13

Stop Switch

Connecting Rod

Crankcase

Speed Control Lever

Air Cleaner

Carburetor

Intake and Exhaust Valve

Muffler Tappet

Camshaft

Oil Scraper

Fig. 4-14

5. DISASSEMBLY AND REASSEMBLY

5-1 PREPARATIONS AND SUGGESTIONS

1) 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.

2) Have boxes ready to keep disassembled parts by group.

3) To prevent losing and misplacing, temporarily assemble each group of disassembled parts.

4) Carefully handle disassembled parts, and clean them with washing oil if necessary.

5) Use the correct tools in the correct way.

5-2 SPECIAL TOOLS

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STEP 1

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Fuel T ank

STEP 4

M6 Nut : 2 pcs.

Head Cover

STEP 3

Blower Housing

Breather Pipe

M6 x 14 Flange bolt : 2 pcs.

Muffler Cover

M6 x 12 Flange bolt : 2 pcs.

M8 Nut : 2 pcs.

M6 x 8 Flange bolt : 3 pcs.

STEP 6

Muffler

STEP 7

Fig. 5-4

Fuel Pipe

M6 Nut : 2 pcs.

Air Cleaner

STEP 5

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STEP 9

Governor Lever

Fig. 5-5

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Speed Control Lever

Rod Spring

Governor Spring

Governor Rod

Carburetor

Governor Lever

Governor Shaft

Bolt

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STEP 10

Spark Plug Cap

Ignition Coil

Crankshaft

Crankcase

M6 x 25 Bolt : 2 pcs.

Flywheel

STEP 12

Carburator

Fig. 5-7

Spring Washer

STEP 11

Starting Pulley

M14 Nut : 1 pc.

STEP 12

Fixing Nut

Flywheel

Hammer

Fig. 5-8

+ 43 hidden pages