Robin America EY15-3 User manual

SERVICE

MANUAL

EY15-3, EY20-3

ENGINES

Models

PUB-ES1609

Rev. 12/01

940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212

e-mail: [email protected] • www.robinamerica.com

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 ....................................................................................................... 2

2-4 PERFORMANCE CURVES ............................................................................................. 3

3. FEATURES (compared with former models)........................................................... 5

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS .......................................... 6

4-1 CYLINDER AND CRANKCASE ....................................................................................... 6

4-2 MAIN BEARING COVER ................................................................................................. 6

4-3 CRANKSHAFT.................................................................................................................6

4-4 CONNECTING ROD AND PISTON ................................................................................. 7

4-5 CAMSHAFT ..................................................................................................................... 7

4-6 VALVE ARRANGEMENT ................................................................................................. 7

4-7 CYLINDER HEAD............................................................................................................ 8

4-8 GOVERNOR SYSTEM .................................................................................................... 8

4-9 COOLING SYSTEM......................................................................................................... 8

4-10 LUBRICATION SYSTEM ............................................................................................... 8

4-11 IGNITION SYSTEM........................................................................................................ 9

4-12 CARBURETOR.............................................................................................................. 9

4-13 AIR CLEANER ...............................................................................................................9

4-14 SECTIONAL VIEW OF ENGINE.................................................................................. 10

5. DISASSEMBLY AND REASSEMBLY.......................................................................12

5-1 PREPARATIONS AND SUGGESTIONS........................................................................ 12

5-2 SPECIAL TOOLS........................................................................................................... 12

5-3 DISASSEMBLY PROCEDURES.................................................................................... 13

5-4 REASSEMBLY PROCEDURES..................................................................................... 20

5-5 BREAK-IN OPERATION OF REASSEMBLED ENGINE ............................................... 27

6. GOVERNER ADJUSTMENT..................................................................................... 28

7. CARBURETOR ......................................................................................................... 30

7-1 OPERATION AND CONSTRUCTION............................................................................ 30

7-2 DISASSEMBLY AND REASSEMBLY ............................................................................ 31

8. MAGNETO ................................................................................................................ 33

8-1 FEATURES .................................................................................................................... 33

8-2 BASIC PRINCIPLE OF U.T.C.I. ..................................................................................... 33

8-3 MAGNETO TROUBLESHOOTING................................................................................ 34

-

1

-

1. SPECIFICATIONS

Specifications are subject to change without notice.

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3

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.m.p.r0063/)PH7.2(Wk0.2

.m.p.r0003/)PH0.3(Wk2.2

.m.p.r0063/)PH5.3(Wk6.2

.xaM.m.p.r0004/)PH5.3(Wk6.2.m.p.r0004/)PH0.5(Wk7.3

euqroT.xaM

N7.6 fgk86.0(m .m.p.r0082/)mN3.9 fgk59.0(m .m.p.r0082/)m

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-

2

-

2. PERFORMANCE

2-1 MAXIMUM OUTPUT

The maximum output is the output of an engine with its throttle valve fully opened and considering that all

the moving parts are properly broken in .

A new engine may not produce full maximum output while its moving parts are still not broken-in.

NOTE :

Power curves shown in the following charts are made in conformity with SAE internal combustion engine

standard test code J1349.

2-2 CONTINUOUS RATED OUTPUT

The continuous rated output is the output of an engine at optimum governed speed which is most favor-

able from the view point of engine's life and fuel consumption.

When the engine is installed on a certain equipment, it is recommended that the continuous output

required from the equipment should be kept below this continuous rated output.

2-3 MAXIMUM TORQUE

The maximum torque is the torque at the output shaft when the engine is producing maximum output at

a specified r.p.m..

-

3

-

2-4 PERFORMANCE CURVES

MAXIMUM TORQUE

(kgf

.

m) N

.

m

TORQUE

(HP) kW

MAXIMUM

HORSEPOWER

OUTPUT

CONTINUOUS

RATED HP

RECOMMENDED

HORSEPOWER RANGE

REVOLUTION

2 0 0 0

3 0 0 0

4 0 0 0

00

1

2

3

6

7

0.6

0.7

EY15-3D

4

r.p.m.

-

4

-

EY20-3D

TORQUE

3

MAXIMUM

HORSEPOWER

CONTINUOUS

RATED HP

RECOMMENDED

HORSEPOWER RANGE

REVOLUTION

2 0 0 0

3 0 0 0

4 0 0 0

0

1

2

3

4

5

3

4

OUTPUT

(HP) kW

(kgf

.

m) N

.

m

1.0

10

9

0.9

MAXIMUM TORQUE

r.p.m.

-

5

-

3. FEATURES (compared with former model)

1. Re-designed outlook

Thinner recoil starter, newly designed air cleaner and muffler are adopted.

Also, innovate the image that express the reliability of Robin engine more by adopting new labels

and new color.

2. Shorter length increased mount-ability

Thinner recoil starter realized shorter length than former model. It eases to mount the engines to

many applications.

3. Development of dust proof air cleaner

Newly developed dual element air cleaner, which has bigger dust holding capacity, realized higher

reliability in dusty condition than former model.

4. Deep consideration on human and environment

New muffler realized quieter operation. Also, the engine meets with EPA Phase 1 exhaust emission

regulation, European emission gas regulations starting from 2002, and Japanese voluntary reguations

start from 2003, with dual element or cyclone type air cleaner.

5. Unchanged durability

Durability is the same as that of former model. Robin keeps producing reliable and dependable en-

gine.

6. Parts interchangeability

Almost of all spare parts are interchangeable between new and former models. The air cleaner and

carburetor should be exchanged at the same time.

-

6

-

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS

4-1 CYLINDER AND CRANKCASE

The cylinder and crankcase are single piece alu-

minum die-casting.

The cylinder liner, made of special cast iron, is

molded into the aluminum casting.

The intake and exhaust ports are located on one

side of the cylinder, and are also inserted into the

casting.

The crankcase has a mounting surface on the out-

put shaft side, where the main bearing cover is

attached.

4-2 MAIN BEARING COVER

The main bearing cover is an aluminum die-cast-

ing, which is mounted on the output shaft side of

the crankcase.

Remove the main bearing cover to inspect inside

of the engine.

Pilots and bosses are machined on the cover for

direct mounting of the engine onto such machines

as generators and pumps.

Oil gauges (fillers) are on both sides of the cover

for easy maintenance.

4-3 CRANKSHAFT

The crankshaft is forged carbon steel, and the

crank pin is induction-hardened.

The output end of the shaft has a crankshaft gear

that is pressed into position.

Fig. 4-1

Fig. 4-2

Fig. 4-3

Oil Gauge Oil Gauge

Governor Gear

Crank Gear

-

7

-

4-4 CONNECTING ROD AND PISTON

The connecting rod is forged of aluminum alloy,

and its large and small ends fanction as bearings.

The large end has a built-in oil scraper for splash-

ing the lubricating oil.

The piston is an aluminum alloy casting, and car-

ries two compression rings and one oil ring.

4-5 CAMSHAFT

The camshaft is made of special cast iron, and

camshaft and gear are cast together in one piece.

Both sides of the shaft fit into the plain bearings

on the crankcase and main bearing cover.

4-6 VALVE ARRANGEMENT

The exhaust valve is located upstream of the cool-

ing air with the result that the exhaust valve is

intensively cooled for improved engine durability.

Fig. 4-4

Fig. 4-6

Fig. 4-5

Top Ring

Second Ring

Oil Ring

Connecting Rod

Oil Scraper

Exhaust Valve

Intake Valve

-

8

-

4-7 CYLINDER HEAD

The cylinder head is an aluminum die-casting, and

forms a Ricardo type combustion chamber with

squish area for high combustion efficiency. The

spark plug is tilted for easy mounting of the fuel

tank.

4-8 GOVERNOR SYSTEM

The governor is a centrifugal flyweight type which

ensures constant operation at the selected speed

during load variations.

The governor gear with governor weights is in-

stalled on the main bearing cover.

4-9 COOLING SYSTEM

The large fins on the flywheel provide sufficient cooling air capacity for the cylinder and cylinder head.

The cylinder baffle and head cover are provided for guiding the cooling air.

4-10 LUBRICATION SYSTEM

All the rotating and sliding parts are splash- lubri-

cated by the oil scraper on the connecting rod.

Fig. 4-7

Fig. 4-8

Fig. 4-9

Main Bearing Cover

Governor Sleeve

Governor Gear Complete

Oil Scraper

-

9

-

4-11 IGNITION SYSTEM

The ignition system is a transistor controlled mag-

neto system which consists of a flywheel and an

ignition coil with a built-in transistor mounted on

the crankcase.

4-12 CARBURETOR

The engine is equipped with a horizontal draft car-

buretor that has a float controlled fuel system and

a fixed main jet.

The carburetors are calibrated carefully for sure

starting, good acceleration, less fuel consumption

and sufficient output.

For details, refer to page 30, section “7 CARBU-

RETOR”.

4-13 AIR CLEANER

The air cleaner of the standard engine is an ob-

long type using an urethane foam(semi-wet).

As optional parts,dual-element type and cyclone

chimney type are available.

Fig. 4-10

Fig. 4-11

Fig. 4-12

Ignition Coil

Flywheel

Cyclone chimney type

(Option)

STD type

Dual-element type

(Option)

-

10

-

Fig. 4-13

4-14 SECTIONAL VIEW OF ENGINE

Fuel Tank

Cylinder Head

Spark Plug Cap

Spark Plug

Piston Pin

Recoil Starter

Piston

Crankshaft

Flywheel

Blower Housing

Main Bearing Cover

Piston Ring

Ignition Coil

-

11

-

Fig. 4-14

Stop Switch

Connecting Rod

Crankcase

Oil Scraper

Air Cleaner

Intake and

Exhaust Valve

Carburetor

Tappet

Camshaft

Speed

Control Lever

Muffler

-

12

-

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5. DISASSEMBLY AND REASSEMBLY

5-1 PREPARATIONS AND SUGGESTIONS

1) When disassembling the engine, memorize 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 losing and misplacing, temporarily assemble each group of disassembled parts.

4) Carefully handle disassembled parts, and clean them with washing oil if necessary.

5) Use the correct tools in the correct way.

5-2 SPECIAL TOOLS

-

13

-

5-3 DISASSEMBLY PROCEDURES

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STEP 2

Fig. 5-3

Crankcase

Gasket

Drain Plug

Recoil Starter

M6 x 8 Flange bolt : 4 pcs.

STEP 1

STEP 2

-

14

-

Fig. 5-4

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rennapSmm21

STEP 3

STEP 4

STEP 5

STEP 6

STEP 7

Fuel Tank

Head Cover

Blower Housing

Air Cleaner

Muffler

Muffler Cover

M6 Nut : 2 pcs.

M6 x 14 Flange bolt : 2 pcs.

M6 x 8

Flange bolt : 3 pcs.

M8 Nut :

2 pcs.

Fuel Pipe

M6 x 12

Flange bolt

: 2 pcs.

Breather

Pipe

-

15

-

Fig. 5-6

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STEP 8

STEP 9

Fig. 5-5

Governor Shaft

Governor Lever

Speed Control Lever

Governor Spring

Governor Rod

Carburetor

Governor Shaft

Bolt

Rod Spring

Governor Lever

Governor Spring

Rod Spring

Governor Rod

M6 x 25 Bolt : 1 pc.

-

16

-

Fig. 5-7

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STEP 12

Fig. 5-8

Fixing Nut

Hammer

Flywheel

STEP 10

STEP 11

STEP 12

M14 Nut : 1 pc.

Spring Washer

Starting Pulley

Crankshaft

Flywheel

Carburator

Ignition Coil

M6 x 25 Bolt : 2 pcs.

Spark Plug Cap

Crankcase

-

17

-

Fig. 5-9

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STEP 13

STEP 16

STEP 15

STEP 14

Intake & Exhaust Valve

Cylinder Head

Spark Plug

Main Bearing Cover

Oil Gauge

M6 x 30 Bolt : 8 pcs.

M6 x 12 Bolt : 2 pcs.

Tappet Cover

Crankcase

Drain Plug

M8 x 40 Bolt : 8 pcs.

Breather Plate

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