Robin America EY33-2 Specification

ROBIN AMERICA,

INC.

ENGINE

MODEL

CROSS

REFERENCE

LIST

ROSIN

TO

WISCONSIN ROBIN

I

ROBIN

EY08

EYl5

EY 15V

EY20

EY20V

EY23

EY28

EY3

5

EY40

EY45V

EY2

I

EY44

EY

18-3

EY25

EY27

EHl1

EH12

EHl5

EH17

EH2 1

EH25

EH3

0

EH30V

EH34

EH34V

EH43V

EC13V

DY

23

DY27

DY30

DY3

5

DY4

1

WISCONSIN

ROBIN

SIDE

VALVE

W 1-080

w1-145

W1-145V

W1-185

W1-185V

W 1-230

W 1-280

W 1-340

W 1-390

W

1

-450V

EY2

1

W

EY44W

EY 18-3 W

EY25W

EY27W

OVERHEAD

VALVE

WO1-115

wo1-120

WO1-150

WO1-170

wo1-210

WO1-250

WO1-300

WO

1

-300v

WO1-340

WO

1

-340V

WO

1-43

OV

TWO

CYCLE

WTI-125V

DIESEL

WRD

1-230

WRD

1-270

WRD

1-300

WRD1-350

WRDI-410

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

at

Maximum Output

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

2

3

.

FEATURES

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

3

4

.

GENERAL DESCRIPTION

of

ENGINE CONSTRUCTION

..........

3

4-1 Cylinder. Crankcase

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

3

4-2 Main Bearing Cover

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

4

4-3 Crankshaft

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

4

4-4 Connecting Rod and Piston

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

4

4-5 Camshaft

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

5

4-6

Valve Arrangement

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

5

4-7 Cylinder Head

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

5

4-8 Governor

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

6

4-9 Cooling

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

6

4-

10

Lubrication

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

6

4-11 Ignition

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

6

4-12 Carburetor

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

7

4-

13

Air Cleaner

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

7

4-14 Balancer

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

7

4-15 Sectional View

of

Engine

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

8

5

.

DISASSEMBLY

and

REASSEMBLY

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

10

5-

1

Preparation and Suggestion

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

10

5-2 Special

Tool

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

10

5-3 HowTo Disassemble

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

11

5-4

How To Reassemble

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

20

6

.

ENGINE SPEED SETTING

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

29

7 .

MAGNETO

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

30

7-1 Features

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

30

7-2

Basic

Theoryof T

.

I.C.

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

30

7-3 Wiring Diagram

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

30

7-4 Checking Procedures

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

31

Section

Title

Page

8

.

CARBURETOR

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

32

8-

1 Operation and Construction

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

32

8-2

Disassemblyand Reassembly

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

33

9

.

STARTING MOTOR

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

35

9-1 Disassembly

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

35

9-2

Inspection and Repair

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

38

9-3 Reassembly

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

41

10

.

BREAK-IN OPERATION

Of

REASSEMBLED ENGINE

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

42

11

.

TROUBLESHOOTING

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

43

11 -1 Starting Difficulties

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

43

11

-2

Engine Misfires

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

44

11-3 Enginestops

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

44

11 -4 Engine Overheats

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

44

11 -6 Engine Backfires through Carburetor

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

45

12 .

INSTALLATION

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

46

11 -5 Engine Knocks

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

45

12-1 Installing

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

46

12-2 Ventilation

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

46

12-3 Exhaust

Gas

Discharge

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

46

12-4 Power Transmission to Driven Machines

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

46

13

.

CHECKS

and

CORRECTIONS

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

47

14

.

TABLE

of

CORRECTION STANDARDS

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

48

15

MAINTENANCE

and

STORING

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

.

53

15-

1

Daily Checks and Maintenance

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

53

15-2 Initial 20 Hours Check

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

53

15-3

Every

50

Hours

(10

days) Checks and Maintenance

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

53

15-4 Every 100

-

200

Hours (Monthly) Checks and Maintenance

.....

53

15-5 Every

500

-

600 Hours (Semiannual) Checks and Maintenance

...

54

15-6 Every

1000

Hours (Yearly) Checks and Maintenance

...........

54

15-7 Preparation for Long Storage

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

54

.

1

SPEC1

F

ICATIONS

Model

I

EY45V

TY

Pe

Air-Cooled, 4-Cycle, Vertical Shaft, Single Cylinder Gasoline Engine

Bore

x

Stroke

90

mm

x

70 mm (3.54"

x

2.75")

~~

Piston Displacement

445 cc (27.15 cu. in)

Maximum

Horse

Power

12 HP/3600 r.p.m. (SAE Code-J607a)

Maximum Torque

Forced Air Cooling Cooling System

Counter-clockwise

as

viewed from

P.T.

0.

shaft side

Direction of Rotation

2.5

kg-m/2600 r.p.m. (18.08 ft-lbs./2600 r.p.m.)

Lubrication

Horizontal Draft, Float Type

Carburetor

Automobile Oil SAE

#20

-

30, Class

SC

Lubricant

Oil Pump

Fuel

Fuel Feed

Automobile Gasoline

Gravity Type

Governor Centrifugal Flyweight Type

Ignition System

Spark Plug

Flywheel Magneto Type (Solid

State

Ignition)

NGK BPMGA

Charging (Lighting) Capacity

DC 12V-1.5A Battery Charge

AC12V-15W or 1OOW Lighting Coil (Optional)

Starting System

41 5.5 mm

(1

6.35")

Length

Approx. 35 kg (77.1

lbs.)

Dry Weight

Electric Starter (Recoil Starter: Optional)

Dimensions

1

Width

I

373.5 mm (14.7")

I

Height

I

312 mm (12.28") excluding

P.T.

0.

Shaft

-1-

2.

PERFORMANCE

2-7 MAXIMUM OUTPUT

The maximum output

of

an engine is such a standard power as produced by the engine with its throttle valve

fully opened after its initial break-in period when all the

moving

parts are properly worn in. Therefore, a new

engine may not produce the maximum output in the beginning because the moving parts are not in a proper-

ly worn-in condition.

2-2

CONTINUOUS RATED OUTPUT

The continuous rated output of an engine is such a power as produced by the engine when running continu-

ously at an optimum speed, and most favorable from the viewpoint of engine life and fuel consumption ratio,

with the governor in operation.

It

is suggested, therefore, that when designing a driving system

for

any

mech-

anism, with this engine as prime mover, the continous power requirement of that mechanism

be

kept below

the continuous rated output specified.

2-3

MAXIMUM TORQUE AT MAXIMUM OUTPUT

These mean the maximum torque of the output shaft at the maximum output of an engine.

PERFORMANCE CURVES

12

Kg-m

2.5

f

2.3

6

5

Revolution

-

r.p.m.

3.

FEATU

RES

I.

The cylinder and crankcase is a light weight one-piece aluminum diecasting. The dimensions are

as

small

as those of a 10-horsepower engine.

2.

The engine is powerful with a wide torque range from low speed to high.

3.

The vibration-free design with twin balancer shafts.

4.

A pointless electronic ignition system is adopted as standard, which makes the ignition system mainte-

nance-free.'

You

will no longer be troubled by worn contact points or faulty sparking from wrong ignition

timing.

5.

The engine employs a special cast iron cylinder liner, a forged steel crankshaft, main ball bearings at both

sides and forced spray lubrication by oil pump for prolonged durability. All this adds up to improved

durability.

4.

GENERAL

DESCRIPTION

of

ENG

NE CONSTRUCTIO

4-1

CYLINDER. CRANKCASE

The cylinder and crankcase

is

single piece aluminum

diecasting. The cylinder liner, made

of

special cast

iron,

is

molded into the aluminum casting. The in-

take and exhaust ports are located on one side of

the cylinder.

The crankcase has a fitting surface on the output

shaft side, where the main bearing cover is attached.

(See Fig.

1

.)

Fig.

1

-3-

4-2

MAIN BEARING COVER

The main bearing cover is an aluminum diecasting, which is mounted on the output shaft side of the crank-

case. Remove the main bearing cover to expose the inside

of

the engine for inspection.

n

The main bearing cover also serves

as

an oil pan, with a trochoid oil pump, oil filler and oil drain plug. (See

Figs.

2

and

3.)

Fig.

2

4-3

CRANKSHAFT

The crankshaft is forged carbon steel, and the crank

is

induction-hardened. The output end of the

shaft has a crankshaft gear and balancer gear that are

pressed into position. (See Fig.

4.)

4-4

CONNECTING

ROD

and

PISTON

The connecting rod is forged aluminum alloy, and

its large and small ends serve as bearings. The piston

is

an

aluminum alloy casting, and carries two

com-

pression rings and one oil ring. The piston pin hole

is

offset from the center

of

the piston to reduce hit-

ting noise and improve durability.

(See

Fig.

5.)

Fig,

3

Induction Hardening

(Portion

of

Crankpin)

Crank Gear

(Press-fit)

Fig.

4

Fig.

5

-4-

The camshaft is a hollow special cast iron integrally

molded with the camshaft gear. The governor plate

is riveted to it, and one end of.the camshaft has a

for

driving the oil pump. (See Fig.

6

.)

4-6

VALVE ARRANGEMENT

The intake valve is located at flywheel side of the

crankcase.

Hard alloy valve seats are molded in the cylinder

block for added durability. (See

Fig.

7.)

4-7

CYLINDER HEAD

Fig.

6

Exhaust

intake

Valve

Fig.

7

The cylinder head is an aluminum die casting, and

forms a Ricardo type combustion chamber with am-

ple area for high combustion efficiency.

Fig.

8

-5-

The governor is a centrifugal flyweight type

which

permits constant operation at the selected speed

against load variations. Governor gear

is

installed on

the bearing cover, and it engages with the cam gear

after reassembling. (See Fig.

9.)

4-8

GOVERNOR

-

Fig.

9

4-9

COOLING

The cooling fans on the flywheel cool the cylinder and cylinder head by forced air cooling. Cylinder baffles

is provided

for

guiding the cooling air.

4-

10

LUBRICATION

The trochoid

oil

pump is mounted inside of the

main bearing cover.

Oil

pump

is

driven by the camshaft to supply

oil

for

the

rotating

or

sliding parts. (See Fig.

10.)

4-11

IGNITION

The ignition system is a flywheel magneto type with

ignition timing set at

23"

before TDC. The magneto

is

composed

of

a

flywheel and ignition

coil.

The fly-

wheel is mounted directly on the crankshaft, and

ignition coil

on

the crankcase. (See

Fig.

1

.)

(For further details, refer

to

page

30,

Section

"7.

MAGNETO".)

&

Camshaft

/

Oil Filter

Holder

(Camshaft

Oil Pump (Inner)

Oil

Pump (Outer)

Fig.

10

I

Ignition Coil

-6-

4-12

CARBURETOR

A

horizontal draft carburetor

is

employed. It has

been carefullyset after thorough tests

to

assure satis-

factory start up, acceleration, fuel consumption, out-

put performance, etc. (See Fig.

12.)

For construction and other details, refer to page

32

Section

"8.

CARBURETOR".

4-13

AIR CLEANER

The air cleaner is a semicyclone type with double

elements. (See

Fig.

13.)

4-14

BALANCERS

Unbalanced moments

of

inertia that are generated in

the vertical and horizontal directions are balanced

by the two balancers that rotate

1

to

1

with the

crankshaft to effectively reduce vibration.

(See

Fig.

14.)

Fig.

12

'leaner

Case

Cleaner Element

Cleaner Cover

~

Fig.

13

Fig.

14

-7-

4-15

SECTIONAL VIEW

of

ENGINE

Flywheel

/-(Cooling Fan)

f

Ignition

Coil

Housing

'

Head

-8-

r

Tappet Air Cleaner

Intake

and

Exhaust Valve

Muffler

rSpark

“Spark

Plug

Cap

1

Oil Filler Starting Motor

-9-

5.

DISASSEMBLY

and

REASSEMBLY

5-1

PREPARATIONS

and

SUGGESTIONS

1)

When disassembling the engine, memorize well the locations of individual parts

so

that they can be reas-

sembed correctly.

If

you are uncertain of identifying some parts,

it

is

suggested that tags be attached to

them.

2)

Have

boxes

ready to keep disassembed parts by group.

3)

To

prevent missing and misplacing, temporarily assemble each group

of

disassembed parts.

4)

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

5)

Use the correct tools in the correct way.

5-2

SPECIAL

TOOLS

For your reference, the following table shows special tools for disassembling Robin Engines.

Part

No.

209 95004

07

207

95003

07

Tool

Flywheel Puller

(with bolt)

Valve Spring

Retainer

Use

For

pulling

off

Flywheel

For mounting and

dismounting Valvc

Spring Retainer

and Retainer

Lock

Applicalbe

Model

EY10,13,14

EY15,18,20

EY25,27,28

EY33,35,40

EY44.45

EC05.07,lO

EC17,25,37

EY10, 13,14

EY15,18,20

EY25,27,28

EY33,35,40

EY44.45

Shape

-

10-

5-3

HOW

TO

DISASSEMBLE

E

Order

item

Engine

(Oil

drain plug)

Muffler and

bracket

*Bolt

length

is

the length from bolt end to the bottom surface of bolt head.

Procedure

Remove

oil

drain plug and discharge

oil.

(1)

Remove muffler bracket.

(2)

Turn

up heat deflector tabs,

and

remove

nuts.

Remarks

Tool

Be

careful

not

to

lose

gasket.

17

mm box wrench

10

mm box wrench

12

mm box wrench

Muffler

-

11

-

Order

I

item

+

Governor lever

Procedure

I

Remarks

I

Tool

(1)

Remove governor lever from shaft.

(2)

Remove governor spring

and

governor rod

the

governor spring

~ ~~~

Memorize or

mark

10

mm

box

wrench

’

from governor lever.

hooking

position.

(1)

Remove speed control assembly from crank-

(2)

Remove choke rod from speed control

10

mm box wrench

case.

assembly.

Rod

Spring Choke

Rod15

\

Go

V

Choke Lever

Governor

Spring

I

Ylarburetor Governor Lever

ltrol

Control

,”-

Fig.

15

-

12

-

Order

I

L

Item

Procedure

I

Air

cleaner

(1)

Remove wing nuts, cleaner cover, and ele-

ment.

(2)

Remove cleaner case.

Carburetor and

intake manifold

Oil

filler

Clamp

(Oil

Filler)

(1)

Remove support (elbow) bolt on crankcase

side.

(2)

Remove intake manifold nuts, and assembly

of intake manifold, carburetor and elbow

from engine.

manifold if necessary.

(1)

Remove clamp

(oil

filler).

(2)

Pull out

oil

filler from main bearing cover.

(3)

Separate carburetor and elbow from intake

Oil

Filler

/Crankcase

Remarks

Disconnect breather

pipe at elbow side

end.

Be careful not to

lose

O-ring.

Tool

10

mm wrench

10

mm box wrench

12

mm box wrench

12

mm box wrench

10

mm box wrench

%=.

.I#"-

Wing

Nut

Washer

Grommet

-Cleaner Cover

Intake Manifold

-

13

-

1

Order

I

Item

I

Procedure

I

Remarks

Tool

I

8

I

Starting motor

I

Remove starting motor.

1

12

mm

box

wrench

I

9/

Rotating

screen

Remove rotating screeen and spacer.

12 mm box wrench

I

/

I

lo

I

Blower

housing

and

head cover

(1

j

Remove blower housing.

(2

j

Remove cylinder baffle.

10

mm box wrench

I

(3

j

Remove head cover.

1

-

14

-

Order

11

12

Item

Igntion coil

Flywheel and

lighting

coil

Procedure Remarks

Tool

I

Remove ignition coil from crankcase.

(1)

Remove nut from tip of crankshaft.

(2)

Remove flywheel

using

flywheel puller.

(See Fig.

16.)

Be

sure

to

remove

ignition coil

fist.

(Ring gear

is

located

inward

of

ignition

coil,

so,

if flywheel

is

pulled out first,

case may become

broken.)

10

mm box wrench

24

mm box wrench

(3)

Remove charge coil. (See Fig.

17.)

Phillips screwdriver

Flywheel

Puller

Fig.

17

Fig.

16

-

15

-

Order

13

14

15

16

Item

Cylinder head

Breather

Intake and ex-

haust valves

Main bearing

cover

Procedure Remarks

Tool

(1)

Remove spark plug. 19 mm plug wrench

(2) Remove cylinder head.

14

mm box wrench

(1)

Remove breather cover.

(2)

Remove breather plate.

Be careful

of

gaskets.

(1) Remove tappet cover.

I

Intake and exhaust

..

(2)

Using

a

valve spring retainer, remove

"

valves use the same

valve spring, retainer,

and retainer lock, but

retainer lock from valve stem.

(3) Remove intake and exhaust valves. in case of reusing

(See

Fig.

18.)

them, reassemble

(4)

Remove spring retainers and valve springs.

fore.

them exactly as be-

10

mm

box wrench

10

mm

box wrench

Valve spring retainer

(1)

Remove bolts.

.Be

careful

not

to

12

mm

box

wrench

(2)

Remove main bearing cover by lightly tap-

damage Oil

with

PTO

shaft

keyway.

.Be careful

not

to

lose crankshaft

and camshaft

adjusting spacers.

ping its side with a plastic hammer.

(See Fig. 19.)

I

Fig.

18

/"-

I

Main Bearing Cover

,'

Fig.

19

-

16-

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Robin America EY33-2, EY45V Specification

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