Robin America EY20 User manual

Category
Engine
Type
User manual

This manual is also suitable for

SERVICE
MANUAL
EY15-3, EY20-3
ENGINES
Models
PUB-ES1609
Rev. 12/01
© Copyright 2001 Robin America, Inc.
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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-
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
1
2
2
3
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
0
1
1
2
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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Fig. 5-3
Crankcase
Gasket
Drain Plug
Recoil Starter
M6 x 8 Flange bolt : 4 pcs.
STEP 1
STEP 2
-
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-
Fig. 5-4
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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 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
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
-
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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
-
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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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Robin America EY20 User manual

Category
Engine
Type
User manual
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