Robin EY20, EY28 Service Manual

ROBIN

AMERICA, INC.

ROBIN

TO

WISCONSIN

ROBIN

ENGINE

MODEL

CROSS REFERENCE

LIST

ROBIN

EY08

EY15 EY 15V EY20 EY2OV EY23

EY28

EY3

5

EY40

-

EY45V EY2

1

EY44 EY 18-3 EY25 EY27

EH11 EH12

EH15

EH17 EH21

EH25

EH30 EH30V EH34 EH34V EH43V

EC13V

DY23 DY27 DY30 DY3

5

DY4 1

WISCONSIN

ROBIN

SIDE

VALVE

W

1-080

W1-145 W1-145V W1-185 W1-185V W1-230 W 1-280

W

1-340 W 1-390 Wl-45OV EY21W EY44W EY18-3W EY25W EY27W

OVERHEAD

VALVE

WO1-115 wo1-120 WO1-150 WO1-170 wo1-210 WOl-250 WO 1-300 WO1-300V WO1-340

WO

1

-340V

WO 1-43 OV

TWO CYCLE

WT1-125V

DIESEL

WRD

1-230

WRD

1-270

-1-300 WRD1-350 WRD1-410

0

CONTENTS

Section

1

.

SPECIFICATIONS

2

.

PERFORMANCE

2-

1

Maximum Output

2-2

Continuous Rated Output

2-3

Maximum Torque

3 . FEATURES

4

.

GENERAL DESCRIPTION

Cylinder. Crankcase

4- 1

Main Bearing Cover

4-2

Crankshaft

4-3

Connecting Rod and Piston

4-4

Camshaft

4-5

Valve Arrangement

4-6 4-7

Cylinder Head Governor

4-8

Cooling

4-9

Lubrication

4-10 4-1

1

Ignition

Carburetor

4-12

Air Cleaner

4-

13

4-14

Sectional View

Title

...............................................

............................................

..............................................

.............................................

Page

...........................................

1

...........................................

.......................................

.................................

.......................................

3

of

ENGINE CONSTRUCTION

...............

.....................................

......................................

...........................................

................................

......................................

.........................................

...........................................

of

Engine

..................................

4 4

4

5

6 6

7

8

8 8 9 9

10

5

.

DISASSEMBLY

5-1

Preparation and Suggestion

5-2

Special

5-3

Haw

5-4

How To Reassemble

6

.

MAGNETO

6-1

Magneto

6-2

Breaker Point Adjustment

6-3

Timing Adjustment for

6-4

Magneto Trouble Shooting

6-5

Solid

7 .

GOVERNOR ADJUSTMENT

8

.

CARBURETOR

8-

1

Operation and Construation

8-2

Disassembly and Reassembly

9 . BREAK-IN OPERATION

and

REASSEMBLY

Tools

..........................................

To

Disassemble

...............................................

.............................................

State

Ignition

............................................

...............................

.................................

.....................................

.................................

EY15. EY20

.................................

......................................

...................................

................................

Of

REASSEMBLED ENGINE

Point Type Ignition System

........

...............................

................

18 18

18 20 27

37 37

37 38 39 39

40 42

42 43

45

Section

10

.

ROBIN SOLID STATE IGNITION ENGINE

Features

10-1 10-2

Basic Theory of T Basic Theory of

10-3

11

.

TROUBLE SHOOTING

.

1

Starting Difficulties

11 11

-2

Engine Misfires

1

1 -3

Engine Stops

11

-4

Engine Overheats Engine Knocks

11-5 11

-6

Engine Backfires through Carburetor

12

.

INSTALLATION

12-1

Installing

12-2

Ventilation Exhaust Gas Discharge

12-3 12-4

Power Transmission to Driven Machines

12-5

Wiring

13

.

ELECTRIC STARTING MOTOR

13-

1

Specifications Operation

13-2

Title

.............................................

.

I.C.

...................................

P

.

I.T.

...................................

.......................................

......................................

.........................................

..........................................

.......................................

.........................................

............................................

.............................................

...........................................

....................................

..............................................

.........................................

............................................

(Option)

(T.I.C. and P.I.T.)

............

..........................

........................

..........................

pese

46 46

47 47

48 48 48

49

50

50 50 50 51

53

53 53

14

.

RECOIL STARTER DISASSEMBLY

14-1

How

To Disassemble (Type D)

How

14-2 14-3 14-4

15

.

CHECKS

16

.

TABLE

17

.

MAINTENANCE

17-1

17-2

17-3 17-4 17-5 17-6

17- 7 Preparation for

To Reassemble (Type

Check Items after Reassembly

How

To Do in Such

and

CORRECTIONS

of

CORRECTION STANDARDS

and

STORING

Daily Checks and Maintenance Every

20

Hours

Checks and Maintenance

Every

50

Hours Checks and Maintenance

Every

100

-

200

Every

500 - 600

Every

1000

Hours (Yearly) Checks and Maintenance

Long

and

REASSEMBLY

................

..............................

D)

...............................

Cases!

.................................

...................................

...........................

.................................

..............................

.......................

Hours (Monthly) Checks and Maintenance Hours (Semiannual) Checks and Maintenance

................

Abeyance

..............................

...........

.........

54 54

55 57 57

58 59 65

65 65 65 65 66 66 66

.

2.

PERFORMANCE

2-1

MAXIMUM

OUTPUT

The maximum ouput of an engine is such standard power as developed by the engine, after its initial break in period the

moving

the maximum output

2-2

The continuous rated output of mum tion. It the continuous power requirement

23

These mean the maximum torque

parts properly

CONTINUOUS

speed,

and

most favorable from the viewpoint of engine life and fuel consumption ratio,

is

suggested, therefore, that when designing a

MAXIMUM

worn

in, when operating with a fully open throttle valve. Therefore, a new engine may not develop

in

the beginning because the moving

RATED

OUTPUT

an

engine

is

of

that mechanism be kept below

TORQUE

of

the output shaft and fuel consumption ratio at the maximum output of an engine.

4

parts

are not

sudrpower as developed

driving

PERFORMANCE

MODEL EY15D,

Ma;.

Torque

system

the

in

a

properly

by

that engine when

worn-in

running

condition.

continuously at

with

for

any mechanism, with this engine

continuous rated output specified.

CURVES

15B

(

1

for

B

type

~

0.7

the governor

as

prime mover,

kg-m

-

I

7

0.6

with

an

in

opera-

all

opti-

HP

I\ I

tii

2000

(1

000)

Revolution

3000

(1

500)

-2-

I

4000

r.p.m.

(20001

5

4

3

HP

L.

B

w

r

22

PERFORMANCE CURVES

MODEL EYZOD

Max.

Toraue

PERFORMANCE CURVES

MODEL

1

.o

EY28D,

288

I

)

for B tvm

1

2000

3.

FEATURES

1.

Compact, lightweight, durable, powerful 4-cycle air-cooled engine embodying ingenious design techques

3000

Revolution

4000

r.p.m.

2000

(1

000)

3000

(

15001

Revolution

r.p.rn.

and

workmanship.

2.

Simple construction, smart appearance, maximum easiness of start owing to automatic decompression device

3.

Pointless

4.

Reliable prime mover for variety of purposes with smooth speed control by a governor under varying load conditions.

5.

Economical because fuel consumption is very low.

6.

Great ve:satility in installation through a

Solid

State ignition system is newly adopted

for

preventing poor igniting as option.

360"

belt extension possibihty and a two-side

oil

fill

and drain arrangement.

4000

I20001

skilful

-3-

4.

GENERAL DESCRIPTION

4-1

CYLINDER, CRANKCASE

The cylinder and crankcase are single piece aluminum die casting. The cyhder liner, made of special cast into the alminum casting. The intake

located on one side

into the casting.

of

the cyhder,

and

exhaust

and

of

ENGINE CONSTRUCTION

iron,

is built

ports

are

are also inserted

The crankcase

the main bearing cover

(See Fig.

4-2

MAIN

The main of

the engine can readily be checked by simply removing the cover. It

ing machmes, such as generators and pumps.

Two

oil

The

EY

(See

Fig.

is

separable on the output shaft side, where

is

attached to it.

1

.)

BEARING

bearing

gauges also serving as

15B engine has 2 chain guides and a built-in shelter plate to prevent

4.)

cover made

COVER

of

aluminum die casting is built

oil

filler caps can be mounted. (See Fig. 2 and Fig.

Ring

for

/

Centering

Fig.

onto

the output shaft side of the crankcase

is

provided with a flange

3.)

oil

from

being

1

and

boss

stirred

so

that the inside

for directly mount-

by

the governor gear

Oil

Gauge

Fig.

2

Oil

Gauge

-4-

I

Governor Gear

Fig.

3

Chain

Guide

-

Shelter

1

Fig.

4

(E

Y

15B)

Plate

4-3

CRANKSHAFT

The crankshaft output end.

"he

EY

(See

15B

type has a built-in drive sprocket. (See Fig.

Induction Hardening (Portion

is

forged of carbon steel, and the crankpin

Fig.

5.).

of

Crankpin)

Crank Gear

(Pressure-Fit)

Fig.

5

is

induction-hardened. It has a crank gear premred-fitted on the

6.)

Drive Sprocket

-

Fig.

6

(E

Y

158)

4-4

CONNECTING

ROD,

PISTON

and

PISTON

The connecting rod is forged of aluminum alloy, which itself serves as bearings at both the large and

has

a

large end cating

oil.

built-in

oil

scraper for splashing the lubri-

small

ends. The

The piston is cast of aluminum alloy, and has grooves for

rings

receiving two compression (See

Fig.

7.)

PISTON RINGS

for

EY28 ENGINE

and one

This piston rings are made of special cast iron

shape

of

the top ring

taper under cut; and the

is

barrel face, that of second

oil

ring has cutter expander. These

rings are very much effective for decreasing engine

oil

ring.

and

ring

the

oil

consumption.

RING

is

1

Fig.

Connecting

Rod

Oil Scraper

7

Lock

Rod

Washer

-5-

4-5

CAMSHAFT

In

the D type, the camshaft

the camshaft has aluminum

In

the B type, the camshaft is made of carbon steel, and

9.)

(See Fig. are used

The camshaft functions also as an output shaft, and is driven by

in

the output shaft side.

is

integrally built with a cam gear

plain

bearings attached to both ends.

of

(No

EYlSB

J

special cast iron, and has intake and exhaust cams. Also

ball bearing is used.) (See Fig.

8.)

type has a pressured-fitted cam gear and a driven sproket.

1/2

rotation

of

the crankshaft,

Ball

bearings

Driven Sprocket

(Pressure-Fit)

Cam

Gear

Fig.

8

4-6

VALVE ARRANGEMENT

The exhaust vahe is located upstream the result that the exhaust valve improved engine durability. The inner side

of

the coolingair with

is

intensiveiy cooled

of

the valve head

for

is reinforced with hard alloy fused to it for added durability.

(See Fig.

10.)

I

Fig.

9

Exhaust Valve

Fig.

(E

Y

70

156)

Direction

of

Cooling

Wind

-6-

4-7

CYLINDER

HEAD

The cylinder head

is

an aluminum die casting,

and

forms a

Ricardo type combustion.chamber with ample area for high

is

combustion effeciency. The spark plug mounting (See Fig.

4-8

of

the fuel tank.

11.1

GOVERNOR

tilted for easy

The governor is a centrifugal flyweight type which permits constant operation at the selected speed against load variations. Governor gear out fail, and

Fig.

(See

it

12.)

is

installed on the bearing cover with-

engages with the cam gear afterreassembling.

Fig.

1

/

Main

Bearing Cover

Governor Gear

Fig.

Complete

12

Governor

Sleeve

-7-

4-9

COOLING

The cooling fan serving

also

as a flywheel

cools

head cover are provided for guiding the coohg

4-10

The

ing and splashing the attached (See Fjg.

LUBRICATION

rotating and sliding parts are being lubricated by

oil

in the crankcase with the

to

the connecting

13.)

rod.

the cyhder and cylinder head by forced air cooling. Cylinder baffles

air.

scoop-

oil

scraper

and

4-1

1

IGNITION

The ignition system is a flywheel magneto type with ignition timing set at

flywheel and ignition

the crankcase.

(For

(BREAKER

coil.

The flywheel serving also as a fan is mounted directly

further detds, refer to Section on the Magneto.) (See Fig.

POINT IGNTION TYPE)

23"

before

(SOLID

Fig.

13

TDC.

The magneto

on

the crankshaft, and the ignition

14

and Fig.

STATE IGNITION TYPE)

Ignition

15.)

Coil

is

composed

Ea\?

of

coil

a

in

Fig.

14

-8-

Fig.

15

D

4-12

A

CARBURETOR

horizontal draft carburetor is employed. It fully set after thorough tests to assure satisfactory start up, acceleration, fuel consumption, output performance etc. For construction and order details, refer to the Section on Carburetor Construction, Disassembly (See

Fig.

i6.)

has

and

Reassembly.

been care-

Fig.

16

m

4-13

The air cleaner type using a sponge element. double element air cleaner is optionally available.)

(See

AIR

Fig.

CLEANER

of

17.)

the standard type engine is an oblong

(A

cyclone type semi-wet

Air

Cleaner for

Standard Type

Cyclone Type

(Option)

Mushroom Cyclone Type (Option)

Fig.

17

-9-

4-14

SECTIONAL

VIEW

OF

ENGINE

4-14-1

Blower

MODEL

Cylinder

Ignition

Head

Housing

Coil

Piston

Flywheel

(Cooling Fan)

EY15D

Starting

Recoil

Pulley

Starter

MODEL

(BREAKER POINT IGNITION TYPE)

-

EY15D

10

-

Governor

\

I

i

/-Speed Control Lever

Piston

Stop Button

Connecting

Rod

Air Cleaner

'Carburetor

.Muffler

.Intake and

Exhaust Valve

Tappet

Oil

Scraper-

MODEL

-

11

EY15D

-

1

Camshaft

4-14-2

MODEL

EY15B

Cvlinder Head

Blower Housing

Ignition

(Cooling Fan)

Coil

Piston Pin

Flywheel

Spark Plug Cap

Spark Plug

Piston Ring

Crankcase

Chain Guide

Crankshaft

Main Bearing Cover

Starting Pulley

Recoil

Starter

--/

MODEL

(SOLID STATE

EY15B

IGNITION

-

12

-

TYPE)

L

Governor

Fuel

Tank

I

1

Piston

Stop Button

Connecting Rod

\r

Speed Control Lever

Air Cleaner

Carburetor

Muff

I

er

Intake and Exhaust Valve

Tappet

Oil

Scraper

MODEL

EY15B

-

13

Chain

-

4-14-3

MODEL

EY20D

Recoil

Starter

(BREAKER

MODEL EYPOD

POINT IGNITION

-

14

-

Cover

Governor

TYPE)

Speed Control

Lever

Piston

Stop Button

Connecting

Oil Scraper

Air Cleaner

Rod

Carburetor

.Muffler

Camshaft

1

MODEL

-

EY20D

15

-

\-

\“Tappet

Intake and

Exhaust Valve

4-14-4

MODEL

EY28

,Spark

Spark

Plug

Cap

Flywhe

Piston

Crankcase

-Governor

Ring

lg

Cover

(SOLID

MODEL

EY28

STATE IGNITION TYPE)

-

16

-

Fuel Tank

-0

I

MODEL

-

17

EY28

-

Intake and

Exhaust

Tappet

Valve

PREPARATIONS

and

SUGGESTIONS

When disassembling the engine, remember well the correctly.

Have boxes ready

To

If

you are uncertain

to

keep disassembled parts by group.

of

identifying some parts, it is suggested that tags be attached

prevent missing and misplacing, temporarily assemble each

locations

Carefully handle disassembled parts, and clean them with washing oil. Use the correct

SPECIAL

For

your reference, the following shows special tools

Part

No.

2099500407

tools

in the correct way.

TOOLS

Tool

Flywheel Puller

bolt)

(with

Use

For pulling Flywheel

of

off

Robin Enpne

Applicable

E

YO8 EY10,13,14 EY 15,18,20 EY23,25,27 EY28,33,35 EY40,44

group

Model

of

individual parts

of

disassembled parts.

for

Disassembiy, Measuring and Inspection Instruments.

so

that they can

to

Shape

them.

be

reassembled

23095001

227 95003

230

95002

205 95001

07

Valve

Spring

Retainer

Valve

Guide

Puller

For mounting and dismounting Valve Spring Retainer and Retainer

For pulling

Valve

guide

Lock

off

EC05.07,lO

EC17,25,37

€YO8

EY10,13,14 EY 15,18,20 EY23,25,27 EY28,33,35 EY40,44

EY08

EYlO

EY13, 14

-

18-