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
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
I
I
I
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
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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