ROBIN AMERICA, mc.
CONTENTS Section Title . Page ........................................... 1 ........................................... 2 ........................................ 2-1 Maximum Output 2-2 Continuous Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 MaximumTorque andFuel ConsumptionRatio a t Max . Output . . . . . . . 2 2 2 1 SPECIFICATIONS 2. PERFORMANCE .. 3 . FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.MAGNETO 7-1 7-2 7-3 74 ................................................ 29 Magneto . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breaker PointAdjustment .................................. Timing Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magneto TroubleShooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 29 30 ................................... 32 ................................
1.
2. PERFORMANCE 2-1 MAXIMUM OUTPUT n The Maximum output of an engine is such standard power as developed by that engine, after its initial run-in period with all the moving parts properly worn-in, when operating with the fully openthrottlevalve.Therefore,it follows t h a t a newenginemaynotdevelopthismaximum output in t h e beginning, because moving parts are not in a properly worn-in condition.
PERFORMANCE CURVE MODEL EY23 ( ) for B type 1.5(3.0) 1.0 (2.0) 6 I kg-m 5 HP I 4 I 3 g1HP.h 350 300 2 250 3000 2000 (1000) rpm ( 1500) 4000 (2000) __c PERFORMANCECURVE MODELEY27-2 ( ) f o r 8 type PERFORMANCECURVE MODELEY25-2 ( ) for B type 1.4(2.8) 1.3(2.6) I 7 kg-m 6 5 HP I4 I 3 g1HP.h 340 .
FEATURES A compact,lightweightanddurable4-cycleair-cooledenginewithhighpoweroutput, embodying ingenious design technique advanced and production skill. n Simple construction, smart appearance, easystart. Reliable power for wide. variety of purposes, with smooth speed controll by under varying load conditions. Economical advantage throughlow fuel consumption. a governor, Great versatility in installation through a 360° belt extension possibility and a two side oil fill and drain arrangement.
4-6 VALVEARRANGEMENT The exhaust valve is positioned in t h e upstream side of the cooling - air with the result that the exhaust valve is intensively cooled for engine life improvement. 4-7 CYLINDER HEAD A Ricardo type combustion chamber of ample area is employed for good combustion efficiency. The spark plug is mounted obliquely to facilitate fuel tank mounting. 4-8 GOVERNOR The flyweight type governor effectively operates to maintain the selected speed a t varying load.
4-14 SECTIONAL VIEW of ENGINE 4-14-1 MODEL EY14 Blower Housing FIywheel (Cooling ver Starting Pulley- MODEL EY14 -6-
Fuel Tank MODEL EY14 -7 -
4-14-2 MODEL EY18-3 Cover MODEL EY18-3 -a-
/- / MODEL EY18-3 -9- Tank
4-14-3 MODEL EY23 Flywheel Star 7g MODEL EY23 - 10 - Cover
/" Tank Con Cam Shaft MODEL EY23 - 11 -
4-14-4 MODEL EY25-2 and EY27-2 Cover MODEL EY25-2 and EY27-2 - 12 -
I I ti I \Cam MODEL EY25-2 and EY27-2 - 13 - Shaft
5. INSTALLATION The life, ease of maintenance, frequency of check and repair, and operating cost are g r e a t l y affected by the way the engine is installed. When installing the engine, therefore, the following contents must be studied carefully. n 5-1 INSTALLING When installingtheengine, its position,couplingconditionswiththeoperatingmachineand anchoring or supporting method must be carefully studied.
5-5-2 FLEXIBLECOUPLING When a flexible coupling is used, t h e runout and mis-alignment between t h e driven shaft and t h e engine driving shaft must be made as s m a l l as possible. The tolerances on t h e runout and mis-alignment are specified by each coupling maker. 5-6 WIRING 5-6-1 START by RECOIL STARTER, or by ROPE The wiring is indicated in the wiring diagram given below. Normally, dotted line are not wired in the engine at the factory.
2) Electronic ignition system MODEL EY14: CDI (Capacitor Discharge Ignition) system Stop Button BlackMlhite Pulser Coil """.J Optional Lamp Coil Fig. 58-2 MODEL EY23 STD: TIC (Transistor Ignition Circuit) system Connector CoilIgnition i Spark Plug Stop Button " L m7 Fig.
MODEL EY23: TIC with Lamp Coil System Stop Button Ignition Coil Spark Plug 77!7 Lamp Coil / Flywheel Fig. 5-64 MODEL EY25-2, EY27-2: PIT (Pulser Ignition Transistor) system Ignition Pulser C o i l \ Spark Plug I Optional Lamp C o i l etc. 1 Stop Button Flywheel Fig.
. CELL START as showninthefigurebelow.Thesection,inthefigure,describedwithdotted Thewiringis lines is normally not prepared in the engine side.
MODEL EY23, EY25-2, EY27-2: PIT with Cell System Spark plug Flywheel i Magnetic Switch Starting Motor F&.
1) Specifications P a r t s No. Name Manufacturer Voltage Output Weight 14 2147050110 (Model EY18-3BS, 23BS, 25-2BS, 27-2BS), 2147050210 (Model EY23DS, 25-2DS, 2 7-2DS) Starting Motor HITACHI 12v 0.6 kW 131.5 - 31.5 F&. 5-6-8 2) Operation The battery is connected to t h e t e r m i n a l 66 of the magnetic switch. The condition when the starting motor is ON is as shown in the figure below. iM t “ S ;. tM Starting Motor Switch Fig. 5-6-9 Thiscircuitconsists circuit.
6. DISASSEMBLY and REASSEMBLY 0 6-1 PREPARATION and SUGGESTIONS 1) When disassembling the engine, memorize the locations of individual parts so as to be able to reassemble them correctly. Tag parts if there is a possibility of confusion. t o keep parts beginning to certain groups together. Group those partsrelatedeachother,tentatively assembling where they belong, immediately after removing, in order to prevent missing and misplacing. Handle the disassembled parts carefully and wash them in kerosene.
Part No.
0 2) Remove flywheel from crankshaft. Apply a socket wrench over the flywheel nut and give the wrench a sharp blow with a softhammer.Removenutandspring washer. (EY14: 1 2 mm nut/EY18-3, EY23, EY25-2, EY27-2: 14 mm nut) to flywheel as Attachedflywheelpuller illustratedinFig. 6-3-1, t u r n c e n t e r bolt clockwiseuntilflywheelbecomes loose enough to be removed. 3) Remove spark plug cap from high tension cable of ignition coil and remove ignition Flywheel Puller Flywheel (6 x 25 mmscrew coilfromcrankcase.
Replace valves if the valve face is pitted or warped. Correct t h e valve seat by using 4S0 seat c u t t e r tool as illustrated in Fig. 6-3-3. The finished seat width should be 1.2 ~ 1 . 5 mrn. Valve guides should be replaced when valve stem clearance becomes excessive. (See Fig. 6 - 3 4 ) Drawvalveguidesoutusing-valveguide puller tool as shown in Fig. 6-3-4 and press new guides in, using the same puller tool. Assemble valve springs and spring retainers after adjusting tappet clearance.
4) Tappet Adjustment (SeeFig. 6-3-6) With tappet in its lowest position, hole valve down and insert feeler gauge between valve and tappet stem. The clearance for both intake and exhaust, with engine cold, must beand 0.16 % 0.20 m m for EY14, EY18-3, EY23, EY25-2 and EY27-2. If theclearance is less than it should be, grind the end of valve stem a very little at a time and remeasure. If theclearance is too large, sink valve seat with seat cutter tool.
Adjusting Collar Fig. 6-3-8 * Fig. 6-3-9 Correct fastening torque for main bearing cover mounting screws is: EY 14 80 %lo0 kg-cm (5.7%7.2 ft-lb) EY18-3, EY23, EY25-2 and EY27-2 (12.2 13.7 ft-lb) 170 ~ 1 9 kg-cm 0 Q CAUTION: Fig. 6-3-9 SHOWS ONEMETHOD OF MEASURING THECRANKSHAFTEND PLAY. THEDISTANCE BETWEEN THEMACHINEDSURFACE OF CRANKCASEAND OF BEARING ADJUSTING COLLAR IS MEASURE’D. THE COMPRESSED THICKNESS COVER PACKINGIS 0.25 m m (EY14,EY18-3andEY23)and 0.
6-3-11 CONNECTING ROD and PISTON 1) Straighten out t h e bent tabs of rod lock washer and remove bolts from connecting rod. 2) Take off oil scraper, rod lock washer and connecting rod cap.. 3) Scrape off all carbon deposits t h a t might interfere with removal of piston from upper end of 4) 5) 6) 7) cylinder. Turn crankshaft until piston is at top, then push connecting rod and piston assembly upward and out through top of cylinder.
The correct connecting rod capfastening torque values are as follows: EY 14 90 % 115 kg-cm (6.5 % 8.3 ft-lb) EY18-3 170 % 200 kg-cm (12.3 EY 23 EY25-2 200 % 25Okg-m EY 27-2 (14.4 % % 14.4 ft-lb) 18.0 ft-lb) Refer to c h a r t Fig. 6-3-15 for clearance between piston, cylinder and connecting rod. I f J I I I EY 18-3 EY14 W EY EY27-2 23 L I EY25-2 D (crankshaft pin Dial I I ~ ~ & ~ N $ ~ AT > PISToN ! ~ ~ ~ 10.037L-0.
7. MAGNETO 7-1 MAGNETO The spark for ignition is furnished by a magneto in models EY14, EY18-3, EY23, EY25-2 and by KOKUSANDENKI K.K. are used. (The EY27-2. In thesemodels,magnetosmanufactured model EY23 is based on noncontact ignition system.) The magneto consists of a flywheel, ignition coil, and breaker assembly (including condenser), of which flywheel is mounted on crankshaft and ignition coil and breaker assembly are mounted in crankcase directly.
7-3 TIMING ADJUSTMENT With the Model EY14,EY18-3,EY25-2 and EY27-2 engines, the spark is timed to occur 23O before the pistonreachesTDCon the compression stroke. Thissparkadvance of 23O is controlled by the breaker point opening and this advance is obtained when the breaker point opening is adjusted according to t h e BREAKER POINT ADJUSTMENT to 0.35 mm (0.014 inch). However, the advancetiming is moreaccuratelyadjustedthrough the followingprocedures, using a timing light as shown in Fig. 7-3-1.
7-4 MAGNETOTROUBLESHOOTING When the engine does not start or starts with difficulty, or when its operation is unstable, the following tests wiU clarify if they are caused by a defect in the magneto. 1) Check ignition cable for possible corrosion, broken, worn insulator or loose connection. 2) Check the sparking as described later in this section. 3) Check if the breaker points requirecleaning, or adjusting or not. If the points are badly corroded or pitted. (Condenser may have t o be replaced.
8. GOVERNOR ADJUSTMENT In the model EY 14, EY 18-3,EY23,EY25-2 and EY27-2 engines, acentrifugal flyweight type governor is used.The flyweight assembly is mounted on a separate governor gear in EY14, EY18-3 and EY23 and on the camshaft gear in EY25-2 and EY27-2, and automatically regulate the throttle valve of the carburetor in such a way that the engine speed is maintained constant under varying loads.
9. CARBURETOR 9-1 OPERATION and CONSTRUCTION (See Figs. 9-1-1and 9-1-2) 9-1-1 FLOAT SYSTEM The float chamber located directly beneath the main carburetor structure serves to maintain at a constantheight by a jointaction of t h e float andtheneedlevalve thefuellevel incorporated in it. Fuel from the fuel tank enters the float chamber through the needle valve, which is kept open while the fuel level is low butis closed when t h e fuel level reaches a predetermined level cousing the float to move up.
9-1-2 PILOT SYSTEM The pilot system supplies fuel to t h e engine during idle and low speed operation. The fuel taken through t h e main jet is measured by t h e pilot jet t o mix with t h e air measured by the pilot air jet and is then regulated by the pilot screw before being supplied to the engine through t h e pilot o u t l e t and by-pass. ,- During idle operation, the engine is supplied with fuel mainly through the pilot outlet.
9-2-4 MAIN SYSTEM 1) Removemain jet holder (9) and dismount float chamber-bowl(6). 2) Remove main jet (8) from main jet holder (9). '3) Removemain nozzle (2) from carburetor body. 4) Reassembly a. Tighten main jet securely to main jet holder. If not tightened securely an engine disorder may result through a too rich fuel mixture. b. Tightenmain jet holder to 90 kg-cm (6.5 ft. lbs) torque. 9-2-5 FLOATSYSTEM 1) Extract float pin (5) and remove float (4) and needle valve (14).
9-3 ADJUSTMENTS 1) Pilot screw is adjusted by'back screwing (counter-clockwise) after closing it fully once. EY14 . . . . . . . . . . . . . . . . . . . 1 turn 2 BV18 . . . . . . . . . . . turn EY 18-3 BV21 . . . . . . . . . . . 1 turn EY23 BV21 . . . . . . . . . . . 1-3/8 turn EY25-2BV24 . . . . . . . . . . . . 1-5/8 t u r n EY27-2BV24 . . . . . . . . . . . 1-1/2 turn CAUTION: DO NOT OVERTIGHTEN PILOT SCREW WHEN CLOSING IT FULLY. THE NEEDLE POINT MIGHT BE DAMAGED BY OVERTIGHTENING.
10. RUN-INOPERATION of REASSEMBLED ENGINE run-in to get propersurfaceconditiononnewly An overhauledenginemustbecarefully installed parts. Especially when cylinder, piston, piston rings or valves are replaced, a thorough run-in operation is indispensable. The recommended run-in schedule is as follows: r I 1 I LOAD TIME SPEED EY14 EY27-2EY18-3 EY25-2 I EY 23 NO LOAD 2,500 rpm 10 minutes NO LOAD 3,000 rpm 10 minutes I NO LOAD 3,600 rpm I 10 minutes 1.25 HP 1.75 HP 2.25 PS 2.
11. TROUBLE SHOOTING For a satisfactory starting andrunningconditionsof a gasoling engine, the following three requirements must be met: 1. The cylinder filled with a proper fuel-air mixture. 2. An appropriate compression in the cylinder. 3. Good spark at c o r r e c t t i m e to ignite the mixture. If all three requirements are not met simultaneously, an engine can not be started.
11-1-3 ELECTRIC SYSTEM When there is no spark, the following must be checked. 1) Disconnected cable leading to ignition coil, spark plug or contact breaker. 2) Broken ignition coil winding, causing short circuit. 3) Wet or oil soaked spark.plug cable. 4) Dirty or wet spark plug. 5) Incorrect spark plug electrode gap. 6 ) Short connection of spark plug.electrodes. 7) .Pitted or fused breaker points. 8) Sticking breaker arm. 9) Leaking or grounded condenser. 10) Incorrect ignition timing.
7) Engine operated in closed space without fresh supply of cooling air. 8) Restricked exhaust gas outlet. Carbon deposit in combustion space. 9) Engine detonating due to low octane gasoline with heavy load at low speed. 11-5 ENGINE KNOCKS 1) Gasoline of poor quality or low octane rating. 2) Engine operating under heavy-load at low speed. 3) Carbon or lead deposits in cylinder head. 4) Incorrect spark timing. 5) Lose or burnt out connecting rod be.aring. 6) Worn or loose piston pin. 7) Engine overheated.
12. CHECKS and CORRECTIONS After'dismantling and cleaning the engine parts, according to the correction table. check them, and if necessary, correct them, The correction table applieswhenever the engines are repaired.Itscontentsshould thoroughly understood by those who undertake the repairing. Its specifications must be abided by t o e f f e c t c o r r e c t m a i n t e n a n c e . be Below, terms employed in the correction table are explained.
13. CORRECTIONTABLE t ITEM 7 ENGINE Flatness of cylinder head CORRECT1 N STANDARD SIZE MODEL TOLERANCE LIMIT USE "IT REMARKS TOOL surface ,late, 'eeler 0.1 5 EY25-2 EY27-2 CORRECTION METHOD Correct M.018 Bore Roundness Cylindricity Valve seat contact width Valve guide I.D. 65 dia. EY 18-3 EY23 EY25-2 EY27-2 68 dia. 7 2 dia. 7 4 dia. 1.15 0 EY14 EY18-3 EY23 EY25-2 EY27-2 EY14 EY18-3 EY23 EY25-2 EY27-2 Boring 0.01 0.01 5 EY14 EY18-3 EY 23 EY25-2 EY27-2 1.2- 1.5 EY14 6 dia.
USE L,MIT Clearance between piston ring groove I EY18-3 EY23 0.01OL-0.055L TOP Oil 2nd EY18-3 0.15L ' 2: Fl Ring gap REMARKS TOOL CORRECTION METHOD 0.050L-0.095L 0.040 L- 0.085 L EY25-2 2nd EY27-2 Top EY14 Oil Feeler 0.15 w w 0.050L-0.095L 0.04OL-0.085L 0.01OL-0.065L EY 14 0.009T-0.010L 18-3 EY F i t betweenpistonEY23 & piston pin EY25-2 EY27-2 r l Replace 0.06L 0.06L Cylinder gauge Micrometer Replace 1.5 1.
1 CORRECTION STANDARD ENGINE ITEM MODEL z 1 SIZE EY -14 EY 18-3 Crankpin O.D. EY25-2 EY27-2 I EY14 EY18-3 EY 23 EY25-2 EY27-2 Crankpin O.D. roundness EY14 EY18-3 EY23 EY25-2 EY*7-2 I I 1 Crankpin O.D. cylindricity I Crankpin O.D. parallelism EY14 EY 18-3 EY25-2 EY23 EY27-2 I 1 TOLERANCE 2 4 dia. -0.050-0.063 2 6 dia. -0.037-0.050 28 dia. -0.040.- 0.053 USE LIMIT LIMIT I I I 1 Micrometer I I I I Micrometer below 0.
ITEM STANDARD SIZE ENGINE MODEL EY14 Tappet clearance Clearance between groove and retainer I CORRECTION TOLERANCE LIMIT USE LIMIT REMARKS TOOL CORRECTION METHOD 0.10L-0.14L below EY 18-3 EY 23 E Y 25-2 EY27-2 0.0: 0.16L-0.2OL EY14 EY18-3 FY23 2.5 0.04L-0.12L EY25-2 EY27-2 2.5 0.04L-0.15L Correct above 0.25 0.5 0.5 Correct EY14 Stem end length 4.0 -2 .o -2 .
ITEM MODEL Max. Output Continuous Rated output ITEM Fuel Consumption ITEM CORRECTION LIMIT HPIrpm EY14D 3.5l4.000 EY183D 5.0/4,000 EY23D 6.014,OOO EY25-2D 7.014,000 EY27-2D 7.514.000 EY14D 2.513.600 EY18-3D 3.513.600 EY23D 4.513.600 EY25-2D 5.013.600 EY27-2D 5.513.600 MODEL literlhr EY14 1.o EY 18-3 1.5 EY23 1.9 EY25-2 2.2 EY27-2 2.3 MODEL EY14 REMARKS ,”.
I I ITEM 14 MODEL I kg/ud/rpm EY 4.61420 18-3EY 5.91360 Cylinder Pressure EY23 6.7 1380 EY25-2 5.51420 EY27-2 5.51420 ITEM Min. accelerating revolution I MODEL EY23 EY18-3 EY14 2 Connecting r o d bolts EY 18-3 EY23 :LzP I- EY27-2 EY14 F nuts 1 kg-crn I 1 330-360 340-370 I 90-115 170- 200 1 I I I 1 I 23.8-25.9 24.6-26.7 6.5-8.3 12.3-14.4 I I 200-250 450-500 1 I 1 I I I I 14.4- 18.0 I I I 1 I 32.6-36.
14. MAINTENANCE and STORING n Thefollowingmaintenancejobsapplywhentheengineisoperatedcorrectlyundernormal conditions. The indicated maintenance intervals are by no means guarantees free operations during these intervals. For example, if t h e engine is operated in extremely dusty conditions, the cleaned every day, instead of every 5 0 hours.
14-5 EVERY 500 -600 HOURS(SEMIANUAL) CHECKS and MAINTENANCE Reasons for requiring them Checks and maintenance Remove cylinder head and remove carbon deposit. The engine will be o u t of order. Disassemble and clean carburetor. ~ 14-6 EVERY 1000 HOURS (YEARLY) CHECKS and MAINTENANCE > Reasons for requiring them Checks and maintenance Perform overhauls, clean correct or replace parts. The engine output drops and become out of order.
Industrial Engines
