Robin EY35 User 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

CONTENTS

.

See

tion

Title

Page

1

.

SPECIFICATIONS

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

1

2

.

PERFORMANCE

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

2

2-1

Maximum Output

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

2

2-2

Continuous Rated Output

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

2

2-3

Maximum Torque and Fuel Consumption Ratio

at

Max

.

Output

.......

2

3

.

FEATURES

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

4

.

GENERAL DESCRIPTION

of

ENGINE CONSTRUCTION

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

4

4-

1

4-2

4-3

4-4

4-5

4-6

4-7

4-8

4

-9

4-10

4-1

1

4-12

4-13

4-14

4

.

1.5

4-16

4-17

Cylinder. Crankcase

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

4

Main Bearing Cover

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

5

Crankshaft

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

5

Connecting Rod and Piston

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

5

Camshaft

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

6

Cylinder Head

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

6

Valve Arrangement

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

6

Governor

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

7

Balancer

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

7

Decompression Device

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

7

Cooling Device

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

8

Lubrication

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

8

Ignition Device

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

8

Carburetor

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

9

Air Cleaner

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

9

Diode Rectifier

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

9

Sectional View of Engine

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

10

5 .

DISASSEMBLY

and

REASSEMBLY

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

12

5-1

Preparations and Suggestion

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

12

5-2

Special

Tools

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

12

5-3

How

to Disassemble

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

13

5-4

How

to Reassemble

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

18

Tappet Clearance Adjustment

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

22

Ignition Timing Adjustment

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

23

Governor Setting Method

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

25

See rion Title

Page

6

.

CARBURETOR

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

26

6-1 Operation and Construction

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

26

6-2 Disassembly and Reassembly

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

27

7

.

BREAK-IN OPERATION

of

REASSEMBLED ENGINE

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

28

8

.

ROBIN SOLID STATE IGNITION ENGINE (OPTION)

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

29

8-1 Features

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

29

8-2 Basic Circuit and Operating Theory

of

S.S.

I

.

System

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

29

8-3 Checking

S.S.I.

Unit with Tester

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

:

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

29

8-4 Measuring Resistances

of

Exciter Coil and Pulser Coil

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

29

9

.

TROUBLE SHOOTING.

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

30

9-1 Starting Difficulties

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

9-2 Engine Misfires

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

31

9-3 Enginestops

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

31

9-4 Engine Overheat

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

31

9-5 Engine Knocks

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

32

9-6 Engine Backfires through Carburetor

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

32

10

.

INSTALLATION

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

33

10-1 Installing

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

33

10-2 Ventilation

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

33

10-3 Exhaust Gas Discharge

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

33

10-4

Fuelsystem

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

33

10-5 Power Transmission to Driven Machines

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

34

10-6 Wiring

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

34

11

.

CHECKS

and

CORRECTIONS

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

37

12

.

TABLE

of

CORRECTION STANDARDS

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

38

13

.

MAINTENANCE

and

STORING

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

43

13-1 Daily and Maintenance

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

43

13-2 Every 20 Hours Checks and Maintenance

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

43

13-3 Every

50

Hours (10 days) Checks and Maintenance

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

43

13-4 Every 100

-

200 Hours (Monthly) Checks and Maintenance

..........

43

13-5 Everv

500-

600

Hours (Semiannual) Checks and Maintenance

........

44

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

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

44

13-7 Preparation for Long Abeyance

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

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

of

a one-piece aluminum diecast structure, which

is

light in weight. The dimensions are

reduced as much as possible

for

easy mounting.

Quiet

operation with

low

level

of

vibration

Intake and exhaust noises are reduced by use

of

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

chine noise is reduced by selection

of

a suitable cam shaft profile and optimum clearances

for

inner parts.

All

ths

adds

up

to

a quiet engine. Vibration

is

also reduced

to

a low level by weight reduction

of

reciprocating parts, and selection

of

a timing balancer and optimum balance factor.

Easy

to start

These engines can easily be started because they employ an automatic decompression device and a newly designed re-

coil starter.

Wide range

of

adaptability

These models are available in various types

of

output shafts and also a type (Type

B)

with a built-in

1

/2

reduction gear

for

application to various kinds of machines. The engines have two

oil

drain ports, and their recoil starter can be pulled

in any desired direction. Various optional parts are

also

available. All these combine

to

increase adaptability to machines.

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.

4.

GENERAL DESCRIPTION

of

ENGINE CONSTRUCTION

4-1

CYLINDER,

CRANKCASE

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

of

the cylinder, and are also inserted in-

to

the casing.

The crankcase is separable

on

the output shaft side, where

the main bearing cover is attached to it. (See Fig.

1

.)

Fig.

1

-4-

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. Un-

balanced moments

of

inertia generated in vertical and hori-

zontal 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 re-

ducing 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

-

I

(OPTION)

CRANKCASE

BALANCER

MODEL

EY35D.

40D

-

10

-

FUEL TANK CAP

INTAKE

&

EXHAUST VALVE

FUEL

COCK

BALANCER

MODEL EY35D,

40D

-

11

-

5.

DISASSEMBLY

and

REASSEMBLY

5-1

PREPARATIONS

and

SUGGESTIONS

1)

When disassembling the engine, remember well 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 missing and misplacing, temporarily assemble each group

of

disassembled parts.

4)

Carefully handle disassembled 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 shows special tools

of

Robin Engine

for

Disassembly, Measuring and Inspection Instruments.

Part

No.

2099500407

2079500307

"20248

Tool

Flywheel Puller

(with

bolt)

Valve

Spring

Retainer

riming Tester

~

Wse

For pulling

off

Flywheel

For mounting and

dismounting Valve

Spring Retainer

and Retainer

Lock

For adjusting

timing

Applicable

Model

EY10,13,14

EY15,18,20

EY25,27,33

EY35,40,44

EC05,07,

10

ECf

7,25,37

EYIQ, 13.14

EY15,18,20

EY25,27,33

EY35,40,44

EYlO, 13,14

EY15,18,20

EY25,27,33

EY35,40,44

EC03,04,05

EC07,10,17

EC25,37

-

12

-

Shape

,"-

5-3

HOW

TO

DISASSEMBLE

Order

1

2

3

4

5

6

7

8

Item

Engine

Fuel tank

Tank bracket

Air cleaner

Muffler cover

Muffler

Carburetor

Governor

lever

*Length of the bolt indicates the length from the bolt head bottom surface to the threaded end.

Procedures

Remarks

Drain engine oil.

case

the gasket.

Drain plugs on both sides of the

Be careful not to lose the

(1) Close the strainer cock.

(2)

Move the fuel pipe clamp (on

strainer side) downward.

(3)

Remove the tank from tank

bracket.

Remove tank bracket.

(1)

Remove

air

cleaner cover and

(2)

Remove choke knob.

(3)

Remove the bottom plate of

element.

air cleaner.

Remove muffler cover.

(1)

Remove the flange portion

(2)

Remove the muffler bracket.

of the muffler.

Remove the carburetor.

etc.

Be careful

of

the packing

Joint sheet, insulator, and

then paper packing, in ths

order from the engine side

Remove the governor lever.

Be careful

of

the position

of the governor spring.

Bolts, nuts, etc. used

Flange bolt

8

mm

(No.2)

nut

. .

.4

pcs.

SpI-ing washer

.

.4

pcs.

10

mm flange nut

.

.4

pcs.

(tightened together with

cylinder head)

Swivel

6

x

12 mm flange bolt

. .

.

2

pcs.

6

x

8

(5T) Flange bolt

*

.

4

pcs.

8

mm brass nut

. . .

2

pcs.

8

x

16

(ST) Bolt

&

washer

.

. .

2

pcs., Washer

.

1

pce

6

mm nut

. .

.2

pcs.

Spring washer

.

2

pcs.

Washer

.

. .

2 pcs.

6

mm special nut.

.

,

1

pce.

Washer

.

1 pce.

6

x

25

(7T)

bolt

. . .

1

pce.

Fig.

18

-

13

-

I

Order

Speed control

9

Bolts,

nuts,

etc.

used

Remarks

Procedures

Item

Circle clip

. .

.

1

pce.

Remember the assembling Disassemble.

order

of

component parts.

(See Fig.

19.)

8

mm butterfly nut.

. .

1

pce.

-

Order

10

11

Item

Operation

case

Electric

starter

h

Fig.

19

(1)

Disconnect the high voltage

wire connecting the electric

starter to the magnetic switch

on the side

of

the switch.

(2)

Remove the bolts.

(3

pcs.)

Remove electric starter.

Remarks

Bolts, nuts, etc. used

(See Fig.

20.)

Two

of

the three

6

x

8

(5T)

flange bolts tighten the

cylinder buffle and fan cover

together.

8

x

30

reamer bolt

. . .

2

pcs.

Spring washer

.

. .

2

pcs.

Washer

.

.2

pcs.

Fig.

20

-

14-

Order

12

-

13

14

-

Item

I

Procedures

I

Remarks

I

Bolts,

nuts,

etc.

used

Fan cover

6

x

8

flange bolt

. .

.

6

pcs.

Removable by loosening

(1)

Remove the fan cover.

bolts

(2)

Remove the head cover.

(3)

Remove the cylinder buffle.

6

x

8

flange bolt

.

1

pce.

Starting pulley

8

x

12

(ST)

bolt

.

3

pcs. (See

Fig.

21

.)

Remove starting pulley.

Flywheel

I

Remove flywheel. Be sure

to

use the fly-

18

mm nut

. . .

1

pce.

wheel puller.

Do

not Spring washer

.

1

pce.

crankshaft.

Fig.

21

Fig.

22

b

--

15

-

Order

15

-

16

17

Item

Electric

devices

Cylinder head

Tappet cover

(breather

plate)

Intake and

exhaust valves

Procedures

(1)

Remove point cover.

(2)

Remove contact breaker.

(3)

Remove ignition coil and con-

denser.

(1)

Remove spark plug.

(2) Remove cylinder head.

Remove Tappet cover.

(1)

Remove intake valve.

(2)

Remove exhaust valve.

Remarks

Bolts,

nuts,

etc. used

4

x

12

screw

and

washer

. .

.

2

pcs.

4

x

8

screw and washer

I

Be careful

of

the primary

lead connecting direction.

.

1

pce.

before disassembly.

6

x

25

screw and washer Remove the lighting coil

. .

.

2

pcs.

10 mm flange nut

. .

.8

pcs.

1

Be

Of

the

breather

I

6

x

14 flange

bolt

. . .

2

pcs.

valve mounting position

and the order

of

assembl-

I

ing

packings.

(See

Fig.

23.)

Intake and exhaust valve

springs, retainers and re-

Use valve spring retainers.

but be sure to set up them

tainer locks are common;

on

the original valves.

(See Fig. 24.)

Fig.

23

-

16-

Fig.

24

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