Robin EY35, EY40 Service Manual

ROBIN AMERICA,

INC.

ROBIN

TO

WISCONSIN

ROBIN

ENGINE

MODEL

CROSS

REFERENCE

LIST

ROBIN

EY08

EY15
EY 15V
EY20
EY20V
EY23
EY28
EY35
EY40

EY45V

EY2 1
EY44
EY 1 8-3
EY25
EY 27

EHll
EH12

EH15

EH17

EH21

EH25

EH3

0

EH3 OV

EH34

EH3 4V

EH43V

EC13V

DY23

DY27

DY30

DY3

5

DY4

1

WISCONSIN

ROBIN

-

Wf-080
W1-145
W1-145V
W1-185

W1-185V

W 1-230

W

1-280
W 1-340
W1-390

W

1

-450V

EY21W
EY44W

EY25W
EY27W

EY 18-3 W

-

wo1-115
wo1-120
WO1-150
WO1-170
wo1-210
wo1-250

WO

1-300

WO 1 -300v

WO

1

-340

WO 1 -340V

WQ 1

-430V

TWO

CYCLE

WT1-125V

DlESEL

WRD1-230

WRD

1

-270

WRD

1-300
WRD1-350
WRD1-410

1

.

See

tion

1

.

SPECIFICATIONS

2

.

PERFORMANCE

CONTENTS

Title

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

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

Page

1

2

2-1
2-2
2-3

3

.

FEATURES

4

.

GENERAL DESCRIPTION

4­4-2
4-3
4-4
4-5
4-6
4-7

4-8

4
4-10

4-1

4-12

4-13
4-14

4
4-16

4-17

Maximum Output
Continuous Rated Output
Maximum Torque and Fuel Consumption Ratio

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

1

Cylinder. Crankcase
Main Bearing Cover
Crankshaft
Connecting Rod and Piston
Camshaft
Cylinder Head
Valve Arrangement
Governor

Balancer

-9

Decompression Device
Cooling Device

1

Lubrication

Ignition Device

Carburetor

Air Cleaner

.

1.5

Diode Rectifier
Sectional View of Engine

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

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

at

of

ENGINE CONSTRUCTION

Max . Output

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

.......

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

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

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

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

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

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

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

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

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

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2

2
2

4

4

4

5
5
5

6

6

6

7

7

7

8

8

8

9

9
9

10

5 .

DISASSEMBLY

5-1
5-2

5-3

5-4

Preparations and Suggestion
Special

How

How

Tappet Clearance Adjustment

Ignition Timing Adjustment

Governor Setting Method

and

Tools

to Disassemble

to Reassemble

REASSEMBLY

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

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

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

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

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

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

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

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

12

12
12
13

18

22
23

25

See rion Title

6

.

CARBURETOR

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

Page

26

6-1 Operation and Construction
6-2 Disassembly and Reassembly

7

.

BREAK-IN OPERATION

8

.

ROBIN SOLID STATE IGNITION ENGINE (OPTION)

8-1 Features
8-2 Basic Circuit and Operating Theory
8-3 Checking
8-4 Measuring Resistances

9

.

TROUBLE SHOOTING.

9-1 Starting Difficulties
9-2 Engine Misfires
9-3 Enginestops
9-4 Engine Overheat
9-5 Engine Knocks
9-6 Engine Backfires through Carburetor

10

.

INSTALLATION

10-1 Installing
10-2 Ventilation
10-3 Exhaust Gas Discharge

10-4

10-5 Power Transmission to Driven Machines
10-6 Wiring

Fuelsystem

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

S.S.I.

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

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

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

of

REASSEMBLED ENGINE

Unit with Tester

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

..................................... 30

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

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

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

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

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

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

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

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

of

Exciter Coil and Pulser Coil

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

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

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

of

S.S.

I . System

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

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

:

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

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

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

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

26
27

28

29

29
29
29
29

30

31
31
31

32

32

33

33

33

33
33
34
34

11

.

CHECKS

12

.

TABLE

13

.

MAINTENANCE

13-1 Daily and Maintenance
13-2 Every 20 Hours Checks and Maintenance
13-3 Every
13-4 Every 100

13-5 Everv
13-6 Every 1000 Hours (Yearly) Checks and Maintenance

13-7 Preparation for Long Abeyance

and

CORRECTIONS

of

CORRECTION STANDARDS

and

STORING

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

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

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

50

Hours (10 days) Checks and Maintenance

-

200 Hours (Monthly) Checks and Maintenance

500-

600

Hours (Semiannual) Checks and Maintenance

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

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

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

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

..........

........

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

37

38

43

43
43
43
43
44
44
44

1.

SPECIFICATIONS

w

i

-1-

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 with

all

the m,oving parts properly worn in, when operating with a fully open throttle valve. Therefore, a new engine may not develop
the maximum output

in

the

beginning because the moving

parts

are not in a properly worn-in condition.

-

rpm

-2-

PERFORMANCE

CURVE

MODEL EY40D

kg-m

2.2

(4.4)

2.1

(4.2)

t

10

9

8

7

HP

I

6

5

4

3

2

1

0

-3-

3.

FEATURES

Small

in

size, light in weight

The cylinder and crankcase are
reduced as much as possible

Quiet

operation with

low

Intake and exhaust noises are reduced by use
chine noise is reduced by selection
up

to

a quiet engine. Vibration

of

a timing balancer and optimum balance factor.

Easy

to start

of

for

easy mounting.

level

of

vibration

is

a one-piece aluminum diecast structure, which

of

a newly designed muffler having glass wool and a cyclone cleaner. Ma-

of

a suitable cam shaft profile and optimum clearances

also reduced

to

a low level by weight reduction

is

light in weight. The dimensions are

for

inner parts.

of

reciprocating parts, and selection

These engines can easily be started because they employ an automatic decompression device and a newly designed re­coil starter.

of

Wide range

These models are available in various types

for

application to various kinds of machines. The engines have two

in any desired direction. Various optional parts are

adaptability

of

output shafts and also a type (Type

oil

drain ports, and their recoil starter can be pulled

also

available. All these combine

B)

with a built-in

to

increase adaptability to machines.

1

/2

reduction gear

Durable, reliable and safe

A

liner

of

special cast iron, hard-chrome-plate piston rings, forged rod, etc. are used to make these engines as reliable

and durable as the preceding models

of

the

EY

Series. Safety devices are also incorporated to assured added safety.

All

ths

adds

4.

GENERAL DESCRIPTION

4-1

CYLINDER,

CRANKCASE

of

ENGINE CONSTRUCTION

The cylinder and crankcase are single piece aluminum die
casting. The cylinder liner, made

of

special cast iron, is built
into the aluminum casting. The intake and exhaust ports are
located on one side

to

the casing.
The crankcase is separable
the main bearing cover is attached to it. (See Fig.

of

the cylinder, and are also inserted in-

on

the output shaft side, where

1

.)

-4-

Fig.

1

4-2

MAIN

BEARING COVER

B

The main bearing cover made of aluminum die casting is built onto the output shaft side of the crankcase

so

that the inside

of the engine can readily be checked by simply removing the cover. It is provided with a flange and boss for directly mount-

ing machines, such as generators and pumps.
Two

oil

gauges also serving as oil filler caps can be mounted. . (See Fig. 2 and Fig.

3

.)

RING

for

CENTERING

OIL

GAUGE

Fig.

2

Fig.

3

4-3

CRANKSHAFT

INDUCTION HARDENING

(PORTION

of

CRANKPIN)

The crankshaft

is

forged

of

carbon steel, and the crankpin

is

induction-hardened. It has a crank gear pressure-fitted on

the output end.

-

-

(See Fig.

4.)

CRANK GEAR (PRESSURE-FIT)

Fig.

4

4-4

CONNECTING

ROD

and

PISTON

The

connecting

rod

is

forged

of

aluminum alloy, which it-

self serves as bearings at both the large and small ends. The

large end has

a

built-in

oil

scraper

for

splashng the

lubri-

cating

oil.

The

piston

is cast

of

aluminum alloy, and has grooves

for

receiving two compression rings and one

oil

ring.

(See

Fig.

5.)

SECOND

RING

Fig.

5

-5-

4-5

CAMSHAFT

Models

EY3S-B,

3S-BS,

EY40-B

and

40-BS

have intake

and

exhaust cams

of

forged carbon steel, which are fitted with

a

cam gear under pressure. The assembly serves as output shaft
that

is

driven at one

half

the speed of the crankshaft.

The

cam gear has a governor fitted

to

it.

Model EY35-D,

35-DS,

EY40-D

and

40-DS

have a camshaft

of

special cast iron, which is integrally assembled with a cam

gear. The two ends of the shaft serve as plain bearings

so

no

ball bearings are used.
(See

Fig.

6.)

4-6

CYLINDER HEAD

The cylinder head

is

an

aluminum

die

casting,

and

forms a

Ricardo type combustion chamber with ample area

for

high
combustion effeciency. The spark plug is tilted for easy
mounting of the fuel tank.

(See

Fig.

7.)

0

Fig.

6

Fig.

7

4-7

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. The inner side

of

the valve head

is reinforced with hard alloy fused

to

it

for

added durability.

(See

Fig.

8.)

Fig.

8

-6-

4-8

GOVERNOR

The governor is a centrifugal flyweight type which permits
constant operation

at

the selected speed against load varia-

tions. (See

Fig.

9.)

4-9

BALANCER

The balancer is assembled with the main bearing cover. Un­balanced moments

of

inertia generated in vertical and hori­zontal directions by the crankshaft, piston and connecting
rod are balanced by the balancer whxh rotates at the same
rate as the crankshaft in opposite direction thereto, thus re­ducing vibration

due

to unbalanced moments

of

inertia.

(See

Fig.

10.)

4-10

DECOMPRESSION DEVICE

The intake cam has a special profile and the intake valve is sligh

of

compressed air out to make starting easy. (See

Fig.

11

.)

EXHAUST TAPPET

IN

TAPPET

'.O.

EXHAUST-CAM

DECOMP

LIFT

SHAFT

SIDE

Fig.

9

Fig.

10

.tly raised during the compression stroke to let a slight amou

IN

TAPPET

IN

CAM

Fig.

I

1

-7-

4-11

COOLING

DEVICE

The cooling fan serving also

as

flywheel cools the cylinder and cylinder head by forced air cooling.

An

air guide plate and

head cover are used to let the cooling air

go

through.

The cooling fan employs curved blades

so

Types B and D have cooling

fan

parts special to their own.

".

.

4-12

LUBRICATION

The rotating and sliding parts are being lubricated

by

scoop-

ing and splashing the oil in the crankcase with the

oil

scraper

attached to the connecting rod.

(See

Fig.

12.)

OIL

SCRAPER

Fig.

72

4-13 IGNITION

DEVICE

Models EY35 and

EY40

have a flywheel magneto type ignition system

(Fig.

13) with

an

ignition timing of 23" before TDC

(Top

Dead Center). The flywheel

(also

serving

as

fan) is fitted onto the crankshaft; and the ignition coil, contact breaker,

and

charging coil are directly assembled with the crankcase.

An

S.S.I.

electronic system (Fig.

14)

is

also

available in types,

including

a

1

SO-watt load type.

The

S.S.I.

system, except the 150-watt type, electrically advances the ignition timing. The ignition timing after this advance

is 23" before

TDC.

(See Figs.

13

and

14.)

POINT

COVER

Fig.

13

FLYWHEEL

IGNITI~N

COIL

Fig.

14

4-14

CARBURETOR

A

horizontal draft carburetor is employed.

It

has been care-

fully set after

thorough

tests to assure satisfactory start up,
acceleration, fuel consumption, output performance etc.
For construction and other details, refer

to

the Section

6.

CARBURETOR (Construction, Disassembly

and

Reassem-

blY

1.

(See Fig.

15.)

4-15

AIR

CLEANER

Cyclone type semi-wet double element air cleaner is used.
(See Fig.

16.)

4-16

DIODE

RECTIFIER

The engines with an electric starter have a diode rectifier
which converts the alternating current generated

by

the

charging coil into

a

direct current and charges the battery.

(See

Fig.

17.)

L,

Fig.

15

Fig.

16

Fig.

17

-9-

4-17

SECTIONAL VIEW

OF

ENGINE

/

RECOIL

STARTER

(OPTION)

-

I

MODEL

EY35D.

-

10

-

CRANKCASE

40D

BALANCER

FUEL TANK CAP

INTAKE

&

EXHAUST VALVE

FUEL

COCK

BALANCER

MODEL EY35D,

40D

-

11

-

5.

DISASSEMBLY

5-1

PREPARATIONS

1)

When disassembling the engine, remember well the locations
correctly.

2)

Have boxes ready to keep disassembled parts by group.

3)

To

prevent missing and misplacing, temporarily assemble each group

4)

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

5)

Use the correct

5-2

SPECIAL

For

your

reference, the following shows special tools

and

REASSEMBLY

and

SUGGESTIONS

If

you are uncertain

tools

in

the correct way,

TOOLS

of

identifying some parts, it

of

Robin Engine

of

individual parts

is

suggested that tags be attached to them.

of

disassembled parts.

for

Disassembly, Measuring and Inspection Instruments.

so

that they can be reassembled

Part

No.

2099500407

2079500307

Tool

Flywheel Puller

(with

bolt)

Valve

Spring

Retainer

~

Wse

For pulling
Flywheel

For mounting and
dismounting Valve
Spring Retainer
and Retainer

off

Lock

Applicable

Model

EY10,13,14

EY15,18,20

EY25,27,33

EY35,40,44

EC05,07,

ECf

EYIQ, 13.14

EY15,18,20

EY25,27,33

EY35,40,44

10

7,25,37

Shape

"20248

riming Tester

For adjusting
timing

EYlO, 13,14

EY15,18,20

EY25,27,33

EY35,40,44

EC03,04,05

EC07,10,17

EC25,37

-

12

-

,"-