Robin EY35 User manual

ROBIN AMERICA, INC.
ROBIN TO WISCONSIN ROBIN
ENGINE MODEL CROSS REFERENCE LIST
ROBIN
EY08
EY15
EY15V
EY20
EY20V
EY23
EY28
EY35
EY40
EY45V
EY21
EY44
EY1 8-3
EY25
EY27
EHll
EH12
EH15
EH17
EH21
EH25
EH3 0
EH3OV
EH34
EH3 4V
EH43V
EC13V
DY23
DY27
DY30
DY3 5
DY4 1
WISCONSIN ROBIN
-
Wf-080
W1-145
W1-145V
W1-185
W1-185V
W1-230
W 1-280
W1-340
W1-390
W 1 -450V
EY21W
EY44W
EY25W
EY27W
EY18-3 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
WQ1 -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
MaximumTorque and FuelConsumption Ratio at Max . Output ....... 2
3 . FEATURES .............................................. 4
4 . GENERALDESCRIPTION of ENGINECONSTRUCTION ............... 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
MainBearingCover ..................................... 5
Crankshaft .......................................... 5
Connecting RodandPiston ............................... 5
Camshaft ........................................... 6
Cylinder Head ........................................ 6
Valve Arrangement ..................................... 6
Governor ........................................... 7
Balancer ............................................ 7
DecompressionDevice ................................... 7
CoolingDevice ........................................ 8
Lubrication ........................................... 8
IgnitionDevice ........................................ 8
Carburetor .......................................... 9
Air Cleaner .......................................... 9
Diode Rectifier ....................................... 9
SectionalView of Engine ................................. 10
5. DISASSEMBLY and REASSEMBLY .............................. 12
5-1 PreparationsandSuggestion ............................... 12
5-2
Special Tools ......................................... 12
5-3 How to Disassemble .................................... 13
5-4
How to Reassemble ..................................... 18
Tappet Clearance Adjustment .............................. 22
IgnitionTiming Adjustment ...............................
23
Governor Setting Method .................................
25

Seerion Title Page
6 . CARBURETOR ............................................ 26
6-1 Operationand Construction
............................... 26
6-2 DisassemblyandReassembly
.............................. 27
7 . BREAK-INOPERATION of REASSEMBLEDENGINE ................. 28
8 . ROBINSOLIDSTATEIGNITIONENGINE(OPTION) ................. 29
8-1 Features
............................................ 29
8-2 Basic CircuitandOperatingTheory
of S.S. I . System ............... 29
8-3 Checking
S.S.I. Unitwith Tester ............ : ............... 29
8-4 MeasuringResistances
of Exciter Coil andPulser Coil .............. 29
9 . TROUBLESHOOTING. ...................................... 30
9-1 Starting Difficulties
..................................... 30
9-2 EngineMisfires ........................................ 31
9-3 Enginestops
......................................... 31
9-4 EngineOverheat
....................................... 31
9-5 EngineKnocks
........................................ 32
9-6 EngineBackfires 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 PowerTransmission to Driven Machines
....................... 34
10-6 Wiring
............................................. 34
11
. CHECKS and CORRECTIONS .................................. 37
12
. TABLE of CORRECTIONSTANDARDS ........................... 38
13
. MAINTENANCE and STORING ................................. 43
13-1 Daily andMaintenance
.................................. 43
13-2 Every 20 HoursChecksandMaintenance
...................... 43
13-3 Every
50 Hours (10days)Checks andMaintenance ................ 43
13-4 Every 100
- 200 Hours (Monthly)ChecksandMaintenance .......... 43
13-5 Everv
500- 600 Hours(Semiannual)ChecksandMaintenance ........ 44
13-6 Every 1000Hours (Yearly)ChecksandMaintenance
............... 44
13-7 Preparationfor 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 theengine, after itsinitial break in period with all
the m,ovingparts properly worn in,when operating with a fully open throttlevalve. 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
MODELEY40D
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 andcrankcase 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 operationwith low level of vibration
Intake and exhaustnoises are reduced byuse
of a newly designed muffler having glass wool anda cyclone cleaner. Ma-
chine noise is reduced by selection
of a suitable cam shaft profile and optimumclearances 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 automaticdecompression device and a newly designed re-
coil starter.
Wide range
of adaptability
These models are available in various types
of output shafts andalso a type (Type B) with a built-in 1 /2 reduction gear
for application tovarious kinds ofmachines. Theengines have two oil drain ports, and theirrecoil starter can be pulled
in anydesired direction. Various optional parts are
also available. Allthese combine to increase adaptabilitytomachines.
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 durableas the preceding models
of the EY Series. Safety devices are alsoincorporated toassured added safety.
4. GENERALDESCRIPTION of ENGINECONSTRUCTION
4-1 CYLINDER, CRANKCASE
Thecylinderandcrankcaseare single piece aluminum die
casting. The cylinder liner, made
of special castiron, is built
into the aluminumcasting.The intake and exhaust portsare
located on one side
of the cylinder, and arealso 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 BEARINGCOVER
B
The main bearing cover made of aluminum die casting is built onto the output shaftside of the crankcase so that the inside
of the engine can readily be checked by simplyremoving the cover. It is provided witha 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
INDUCTIONHARDENING
(PORTION
of CRANKPIN)
The crankshaft is forged of carbon steel, andthe crankpin is
induction-hardened.Ithas a crank gear pressure-fittedon
the output end.
-
- (See Fig. 4.)
CRANKGEAR(PRESSURE-FIT)
Fig. 4
4-4 CONNECTING ROD and PISTON
The connecting rod is forged of aluminumalloy,whichit-
selfserves as bearings at both the large and small ends. The
large endhas
a built-in oil scraper for splashngthe lubri-
cating oil.
The piston is cast of aluminumalloy,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 asoutput 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 castiron, which is integrallyassembled with a cam
gear. The two ends of the shaftserve as plainbearings
so no
ball bearings are used.
(See
Fig. 6.)
4-6 CYLINDERHEAD
Thecylinderhead is an aluminum die casting, and formsa
Ricardo type combustion chamber withample area
for high
combustioneffeciency.Thesparkplug is tiltedfor easy
mounting of thefuel tank.
(See
Fig. 7.)
0
Fig. 6
Fig. 7
4-7 VALVEARRANGEMENT
. "
. ". .._ _.
The exhaust valve is located upstream of the coolingair with
the result thattheexhaust valveis intensivelycooled 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-
zontaldirections by the crankshaft, piston and connecting
rod are balanced by the balancer whxh rotates at thesame
rate as the crankshaft in opposite direction thereto, thusre-
ducing vibration
due tounbalanced moments of inertia.
(See
Fig. 10.)
4-10 DECOMPRESSIONDEVICE
The intakecam has aspecial profile and the intakevalve is sligh
of compressed air out tomake startingeasy. (See Fig. 11 .)
EXHAUSTTAPPET IN TAPPET
'.O.
EXHAUST-CAM
DECOMP LIFT
SHAFT
SIDE
Fig. 9
Fig. 10
.tlyraised during the compression stroke tolet 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 coolingair
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 andsliding parts are being lubricated by scoop-
ing and splashing the oil in the crankcase withthe
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-wattload type.
The
S.S.I. system, except the 150-watt type, electrically advances the ignition timing. The ignition timing after thisadvance
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 carburetoris employed. It has beencare-
fully set after
thorough tests to assure satisfactory start up,
acceleration, fuel consumption,outputperformance etc.
Forconstructionandother details, refer
to theSection 6.
CARBURETOR(Construction,Disassembly and Reassem-
blY 1.
(See Fig. 15.)
4-15 AIR CLEANER
Cyclone type semi-wet double elementair cleaner is used.
(SeeFig.
16.)
4-16 DIODE RECTIFIER
Theengineswithanelectric starter have a dioderectifier
whichconvertsthealternatingcurrentgenerated
by the
charging coil into
a direct current andcharges the battery.
(See
Fig. 17.)
L,
Fig. 15
Fig. 16
Fig. 17
-9-

4-17 SECTIONALVIEW 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) Whendisassembling theengine,remember well thelocations of individualparts so thatthey can be reassembled
correctly.
If you are uncertain of identifying some parts, it is suggested that tags be attached to them.
2) Have boxesready to keep disassembled parts by group.
3) To prevent missing and misplacing, temporarily assemble each group of disassembled parts.
4) Carefully handle disassembled parts, andclean them with washing oil.
5) Use thecorrect tools in thecorrect 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
FlywheelPuller
(with bolt)
Valve Spring
Retainer
rimingTester
~
Wse
For pulling off
Flywheel
For mountingand
dismounting Valve
Spring Retainer
andRetainer
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 bottomsurface tothe threaded end.
Procedures Remarks
Drain engine oil.
case the gasket.
Drain plugs on bothsides of the Be careful not tolose the
(1) Close thestrainercock.
(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) Removechoke knob.
(3) Remove the bottom plate of
element.
air cleaner.
Remove mufflercover.
(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 engineside
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-ingwasher . . .4 pcs.
10 mm flange nut . . .4 pcs.
(tightened together with
cylinder head)
Swivel
6 x 12mm 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 assemblingDisassemble. 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) Disconnectthe high voltage
wire connecting the electric
starter to themagnetic switch
on theside
of the switch.
(2) Remove thebolts. (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 Removeflywheel. Be sure to use thefly- 18 mm nut .. . 1 pce.
wheelpuller.
Do not Springwasher . . . 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 pointcover.
(2) Remove contactbreaker.
(3) Remove ignition coil and con-
denser.
(1) Remove spark plug.
(2) Remove cylinderhead.
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 washerRemove the lighting coil
.. . 2 pcs.
10mm flange nut
.. .8 pcs. 1
Be Of the breather I 6 x 14flange 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 arecommon;
on the originalvalves.
(See Fig. 24.)
Fig. 23
- 16-
Fig. 24