Robin EY45V User manual

ROBIN AMERICA, INC.
ENGINE MODEL CROSS REFERENCE LIST
ROSIN TO WISCONSINROBIN I
ROBIN
EY08
EYl5
EY15V
EY20
EY20V
EY23
EY28
EY3 5
EY40
EY45V
EY2 I
EY44
EY 18-3
EY25
EY27
EHl1
EH12
EHl5
EH17
EH21
EH25
EH3 0
EH30V
EH34
EH34V
EH43V
EC13V
DY 23
DY27
DY30
DY3 5
DY4 1
WISCONSIN ROBIN
SIDE VALVE
W1-080
w1-145
W1-145V
W1-185
W1-185V
W1-230
W1-280
W1-340
W1-390
W 1 -450V
EY2 1 W
EY44W
EY18-3W
EY25W
EY27W
OVERHEAD VALVE
WO1-115
wo1-120
WO1-150
WO1-170
wo1-210
WO1-250
WO1-300
WO 1 -300v
WO1-340
WO 1 -340V
WO 1-43 OV
TWO CYCLE
WTI-125V
DIESEL
WRD 1-230
WRD 1-270
WRD 1-300
WRD1-350
WRDI-410

CONTENTS
Section Title Page
1 . SPECIFICATIONS .......................................... 1
2 . PERFORMANCE ........................................... 2
2-1 MaximumOutput
...................................... 2
2-2 Continuous RatedOutput ............................... 2
2-3 MaximumTorque at Maximum Output ..................... 2
3 . FEATURES ............................................... 3
4 . GENERALDESCRIPTION of ENGINECONSTRUCTION .......... 3
4-1 Cylinder. Crankcase
..................................... 3
4-2 Main BearingCover
.................................... 4
4-3 Crankshaft ........................................... 4
4-4 Connecting Rodand Piston
.............................. 4
4-5 Camshaft ............................................ 5
4-6 Valve Arrangement ..................................... 5
4-7 Cylinder Head ........................................ 5
4-8 Governor ............................................ 6
4-9 Cooling .............................................. 6
4- 10 Lubrication .......................................... 6
4-11Ignition ............................................. 6
4-12 Carburetor ........................................... 7
4- 13 Air Cleaner ........................................... 7
4-14 Balancer ............................................. 7
4-15 Sectional View of Engine ................................ 8
5 . DISASSEMBLY and REASSEMBLY ............................ 10
5- 1 PreparationandSuggestion .............................. 10
5-2 Special
Tool .......................................... 10
5-3HowTo Disassemble
................................... 11
5-4 HowTo Reassemble .................................... 20
6 . ENGINE SPEED SETTING ................................... 29
7. MAGNETO ............................................... 30
7-1 Features
............................................. 30
7-2 Basic Theoryof T . I.C. .................................. 30
7-3 Wiring Diagram
........................................
30
7-4 Checking Procedures
................................... 31

Section Title Page
8 . CARBURETOR ............................................ 32
8- 1Operation and Construction .............................. 32
8-2 DisassemblyandReassembly ............................. 33
9 . STARTINGMOTOR ........................................ 35
9-1 Disassembly
.......................................... 35
9-2 InspectionandRepair .................................. 38
9-3 Reassembly
.......................................... 41
10 . BREAK-INOPERATION Of REASSEMBLED ENGINE ............. 42
11 . TROUBLESHOOTING ...................................... 43
11-1 Starting Difficulties .................................... 43
11
-2 EngineMisfires ........................................ 44
11-3 Enginestops
......................................... 44
11-4 EngineOverheats
...................................... 44
11-6 EngineBackfiresthrough Carburetor
....................... 45
12. INSTALLATION ........................................... 46
11-5 EngineKnocks ........................................ 45
12-1 Installing
............................................ 46
12-2 Ventilation
........................................... 46
12-3 Exhaust
Gas Discharge ..................................
46
12-4 PowerTransmission to Driven Machines
..................... 46
13 . CHECKS and CORRECTIONS ................................ 47
14 . TABLE of CORRECTIONSTANDARDS ........................ 48
15 MAINTENANCE and STORING ...............................
. 53
15-
1 Daily Checksand Maintenance ............................ 53
15-2Initial 20 HoursCheck .................................. 53
15-3 Every 50 Hours (10 days)Checksand Maintenance ............ 53
15-4 Every 100 - 200 Hours (Monthly)Checksand Maintenance ..... 53
15-5 Every
500 - 600 Hours (Semiannual)Checksand Maintenance ... 54
15-6 Every
1000 Hours (Yearly)Checksand Maintenance ........... 54
15-7 Preparationfor LongStorage
............................. 54
.

1 SPEC1 F ICATIONS
Model
I
EY45V
TY Pe
Air-Cooled, 4-Cycle, VerticalShaft, Single Cylinder Gasoline Engine
Bore
x Stroke
90 mm x 70 mm(3.54" x 2.75")
~~
Piston Displacement 445 cc (27.15cu. in)
Maximum
Horse Power 12 HP/3600r.p.m. (SAE Code-J607a)
Maximum Torque
Forced Air Cooling CoolingSystem
Counter-clockwise
as viewed from P.T. 0. shaft side
Direction of Rotation
2.5 kg-m/2600 r.p.m. (18.08 ft-lbs./2600r.p.m.)
Lubrication
Horizontal Draft, Float Type
Carburetor
Automobile OilSAE
#20 - 30, Class SC
Lubricant
Oil Pump
Fuel
Fuel Feed
Automobile Gasoline
Gravity Type
Governor Centrifugal Flyweight Type
IgnitionSystem
Spark Plug
FlywheelMagnetoType (Solid
State Ignition)
NGK BPMGA
Charging (Lighting) Capacity DC 12V-1.5A Battery Charge
AC12V-15W or 1OOW Lighting Coil (Optional)
StartingSystem
415.5 mm
(1 6.35")
Length
Approx. 35 kg (77.1
lbs.) Dry Weight
Electric Starter (RecoilStarter: Optional)
Dimensions
1 Width I 373.5 mm(14.7")
I Height I 312mm(12.28")excluding P.T. 0. Shaft
-1-

2. PERFORMANCE
2-7MAXIMUM OUTPUT
The maximum output of an engine is such a standard poweras produced by the engine with its throttlevalve
fully opened after itsinitial break-in periodwhen all the
moving parts are properly worn in. Therefore, a new
engine may not produce the maximum outputin the beginning because the moving parts are not in a proper-
ly worn-in condition.
2-2 CONTINUOUSRATEDOUTPUT
The continuous rated output of an engine is such a power as produced by the engine when running continu-
ouslyat an optimum speed, and most favorable from the viewpointof enginelife and fuel consumption ratio,
with the governor in operation.
It is suggested, therefore, that whendesigning a driving system for any mech-
anism, with this engine as prime mover, the continous power requirement of that mechanism be kept below
the continuous rated output specified.
2-3 MAXIMUMTORQUEATMAXIMUM OUTPUT
These mean the maximum torque of the output shaft at the maximum outputof an engine.
PERFORMANCECURVES
12
Kg-m
2.5 f
2.3
6
5
Revolution - r.p.m.

3. FEATU RES
I. The cylinder and crankcase is alight weightone-piece aluminum diecasting. The dimensions are as small
as those of a 10-horsepower engine.
2. The engineis powerful with a wide torque range from low speed tohigh.
3. The vibration-free design with twin balancer shafts.
4. A pointlesselectronicignitionsystem is adopted as standard,whichmakestheignitionsystemmainte-
nance-free.'
You will no longer be troubled by worn contact points or faulty sparking from wrong ignition
timing.
5. The engine employs a special cast iron cylinder liner, a forged steel crankshaft, mainball bearings at both
sides andforcedspraylubricationby oil pumpforprolongeddurability. All thisaddsup to improved
durability.
4. GENERAL DESCRIPTION of ENG NE CONSTRUCTIO
4-1 CYLINDER.CRANKCASE
The cylinder and crankcase is single piece aluminum
diecasting.Thecylinderliner,made
of special cast
iron,
is moldedintothealuminumcasting.The in-
takeandexhaustportsarelocatedonone side of
the cylinder.
Thecrankcase has afittingsurfaceontheoutput
shaft side, where the main bearing cover is attached.
(See Fig.
1 .)
Fig. 1
-3-

4-2 MAINBEARINGCOVER
The main bearing cover is an aluminum diecasting, which is mounted on the output shaftside of the crank-
case. Remove the main bearingcover to exposethe inside
of the engine forinspection. n
The main bearing cover also serves as an oil pan, with a trochoid oil pump, oilfiller and oil drain plug. (See
Figs.
2 and 3.)
Fig. 2
4-3 CRANKSHAFT
The crankshaft is forged carbon steel, and the crank
pin
is induction-hardened.The outputend of the
shaft has a crankshaft gear and balancer gear that are
pressed into position. (See Fig.
4.)
4-4 CONNECTING ROD and PISTON
Theconnecting rod is forgedaluminumalloy,and
its large and small ends serve as bearings. The piston
is
an aluminumalloycasting,andcarries two com-
pression rings and one oil ring. The piston pin hole is
offsetfromthecenter of the piston to reducehit-
ting noise and improve durability.
(See Fig. 5.)
Fig, 3
Induction Hardening
(Portion
of Crankpin)
CrankGear
(Press-fit)
Fig. 4
Fig. 5
-4-

The camshaft is a hollow special cast iron integrally
molded with the camshaft gear. Thegovernor plate
is riveted toit, andone end of.the camshaft hasa
pin
for driving the oil pump. (See Fig. 6 .)
4-6 VALVEARRANGEMENT
Theintake valveis located at flywheelsideof the
crankcase.
Hardalloy valve seats are moldedinthecylinder
block for added durability. (See
Fig. 7.)
4-7 CYLINDERHEAD
Fig. 6
Exhaust
intake Valve
Fig. 7
Thecylinderhead is analuminum die casting,and
forms a Ricardo type combustion chamber with am-
ple area for high combustion efficiency.
Fig. 8
-5-

The governor is acentrifugalflyweighttype which
permitsconstantoperationatthe selectedspeed
against load variations. Governor gear
is installed on
the bearing cover, and it engages with the cam gear
afterreassembling. (See Fig.
9.)
4-8 GOVERNOR
-
Fig. 9
4-9 COOLING
The cooling fans on the flywheel cool the cylinder and cylinder head by forcedair cooling. Cylinder baffles
is provided
for guiding the coolingair.
4- 10 LUBRICATION
Thetrochoid oil pump is mountedinside of the
main bearing cover.
Oil pump is driven by the camshaft to supply oil for
the rotating or sliding parts. (SeeFig. 10.)
4-11 IGNITION
The ignition system is a flywheel magneto type with
ignition timing set at
23" before TDC. The magneto
is composed of a flywheel andignition coil. The fly-
wheel is mounteddirectlyonthecrankshaft,and
ignition coil
on the crankcase. (See Fig. 1 1 .)
(Forfurtherdetails, refer to page 30, Section
"7. MAGNETO".)
& Camshaft
/
OilFilter
Holder (Camshaft
Oil Pump (Inner)
Oil Pump (Outer)
Fig. 10
I IgnitionCoil
-6-

4-12 CARBURETOR
A horizontaldraftcarburetor is employed.It has
been carefullyset after thorough tests
to assure satis-
factory start up, acceleration, fuel consumption, out-
put performance, etc. (SeeFig.
12.)
For construction and other details, refer to page 32
Section "8. CARBURETOR".
4-13 AIRCLEANER
The air cleaner is asemicyclonetypewithdouble
elements. (See Fig.
13.)
4-14 BALANCERS
Unbalanced moments of inertia that are generatedin
the verticalandhorizontaldirections are balanced
bythetwobalancersthatrotate
1 to 1 withthe
crankshaft to effectively reduce vibration.
(See
Fig. 14.)
Fig. 12
'leaner Case CleanerElement Cleaner Cover
~
Fig. 13
Fig. 14
-7-

4-15 SECTIONALVIEW of ENGINE
Flywheel
/-(Cooling Fan)
f
Ignition Coil
Housing
' Head
-8-

r
Tappet Air Cleaner Intake
and
Exhaust Valve
Muffler
rSpark
“Spark Plug Cap
1 Oil Filler Starting Motor
-9-

5. DISASSEMBLY and REASSEMBLY
5-1 PREPARATIONS and SUGGESTIONS
1) When disassembling the engine, memorize well the locations of individual parts so that they can be reas-
sembed correctly.
If you are uncertain of identifying some parts, it is suggested that tags be attached to
them.
2) Have boxes ready to keep disassembed parts by group.
3) To prevent missing and misplacing, temporarily assemble each group of disassembed parts.
4) Carefully handle disassembed parts, and clean them with washing oil.
5) Use the correct tools in the correct way.
5-2 SPECIAL TOOLS
For yourreference, the following table showsspecial tools for disassembling Robin Engines.
Part No.
209 95004 07
207 95003 07
Tool
Flywheel Puller
(with bolt)
Valve Spring
Retainer
Use
For pulling off
Flywheel
For mounting and
dismounting Valvc
Spring Retainer
andRetainer
Lock
Applicalbe
Model
EY10,13,14
EY15,18,20
EY25,27,28
EY33,35,40
EY44.45
EC05.07,lO
EC17,25,37
EY10, 13,14
EY15,18,20
EY25,27,28
EY33,35,40
EY44.45
Shape
- 10-

5-3 HOW TO DISASSEMBLE
E
Order item
Engine
(Oil drain plug)
Muffler and
bracket
*Bolt length is the length from bolt endto the bottom surfaceof bolt head.
Procedure
Remove oil drain plug and discharge oil.
(1) Removemufflerbracket.
(2) Turn up heat deflector tabs, and remove
nuts.
Remarks Tool
Be careful not to lose
gasket.
17 mm box wrench
10 mm box wrench
12 mm box wrench
Muffler
- 11 -

Order I item
+
Governor lever
Procedure I Remarks
I I
Tool
(1) Remove governor lever from shaft.
(2) Remove governor spring and governor rod
the governor spring
~ ~~~
Memorize or mark
10 mm box wrench ’
from governorlever. hooking
position.
(1) Remove speed control assembly from crank-
(2) Removechoke rod from speed control
10 mm box wrench
case.
assembly.
Rod Spring Choke Rod15 \
Go V ChokeLever
Governor Spring
I Ylarburetor Governor Lever
ltrol
Control
,”-
Fig. 15
- 12 -

Order
I
L
Item
Procedure
I
Air cleaner
(1) Remove wing nuts, cleaner cover, and ele-
ment.
(2) Removecleaner case.
Carburetor and
intake manifold
Oil filler
Clamp (Oil Filler)
(1) Remove support (elbow) bolt on crankcase
side.
(2) Remove intake manifold nuts, and assembly
of intake manifold, carburetorand elbow
from engine.
manifold if necessary.
(1) Removeclamp (oil filler).
(2) Pull out oil filler from main bearing cover.
(3) Separate carburetor and elbow from intake
Oil Filler
/Crankcase
Remarks
Disconnect breather
pipe at elbowside
end.
Be careful notto
lose
O-ring.
Tool
10 mm wrench
10 mm box wrench
12 mm box wrench
12 mm box wrench
10 mm box wrench
%=.
.I#"- Wing Nut
Washer
Grommet
-Cleaner Cover
Intake Manifold
- 13 -

1 Order I Item I Procedure I Remarks
Tool I
I 8 I Startingmotor I Remove starting motor.
1 12 mm box wrench I
I 9/
Rotating
screen Remove rotating screeen and spacer. 12mm boxwrench
I
/
I lo I
Blower housing
and head cover
(1 j Remove blower housing.
(2 j Remove cylinder baffle.
10 mm boxwrench
I
I
(3 j Remove head cover.
1 1
- 14 -

Order
11
12
Item
Igntion coil
Flywheel and
lighting
coil
ProcedureRemarks Tool
I I
Remove ignition coil from crankcase.
(1) Remove nut from tip of crankshaft.
(2) Remove flywheel using flywheel puller.
(See Fig.
16.)
Be sure to remove
ignition coil fist.
(Ring gear is located
inward
of ignition
coil, so, if flywheel
is pulled out first,
case may become
broken.)
10 mm box wrench
24 mm box wrench
(3) Remove charge coil. (See Fig. 17.) Phillips screwdriver
Flywheel Puller
Fig. 17
Fig. 16
- 15 -

Order
13
14
15
16
Item
Cylinder head
Breather
Intake and ex-
haust valves
Main bearing
cover
ProcedureRemarks Tool
(1) Remove spark plug. 19mm plug wrench
(2) Removecylinderhead.
14 mmboxwrench
(1) Remove breathercover.
(2) Removebreather plate. Be careful
of gaskets.
(1) Remove tappet cover.
I Intakeand exhaust
..
(2) Using a valve spring retainer, remove
"
valves use the same
valve spring, retainer,
and retainer lock, but
retainer lock from valve stem.
(3) Remove intake and exhaust valves. in case of reusing
(See
Fig. 18.) them, reassemble
(4) Remove spring retainers and valve springs. fore.
them exactlyas be-
10 mm box wrench
10 mm box wrench
Valve spring retainer
(1) Removebolts. .Be careful not to 12 mm box wrench
(2) Remove main bearing cover by lightly tap- damage Oil
with
PTO shaft
keyway.
.Be careful
not to
lose crankshaft
and camshaft
adjusting spacers.
ping its side with a plastic hammer.
(See Fig. 19.)
I I
Fig. 18
/"-
I
Main Bearing Cover
,'
Fig. 19
- 16-