Robin America EY20-3 Service Manual
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Robin America EY20-3 Service Manual

Robin America EY20-3 Service Manual

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SERVICE
MANUAL
Models
EY15-3, EY20-3
ENGINES
PUB-ES1609
Rev. 12/01

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Summary of Contents for Robin America EY20-3

  • Page 1 SERVICE MANUAL Models EY15-3, EY20-3 ENGINES PUB-ES1609 Rev. 12/01...
  • Page 2 940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212 e-mail: sales@robinamerica.com • www.robinamerica.com © Copyright 2001 Robin America, Inc.

  • Page 3: Table Of Contents

    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.

  • Page 4: Specifications

    1. SPECIFICATIONS - r i n i l n i l ・ ・ ・ ・ n i l n i l e l i y t i ) . l , t f e l i n i l ・ ・...

  • Page 5: Performance

    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.

  • Page 6: Performance Curves

    2-4 PERFORMANCE CURVES EY15-3D (kgf . m) N . m MAXIMUM TORQUE (HP) MAXIMUM HORSEPOWER CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE 2 0 0 0 3 0 0 0 4 0 0 0 r.p.m. REVOLUTION - 3 -...
  • Page 7 EY20-3D (kgf . m) N . m MAXIMUM TORQUE (HP) MAXIMUM HORSEPOWER CONTINUOUS RATED HP RECOMMENDED HORSEPOWER RANGE 2 0 0 0 3 0 0 0 4 0 0 0 r.p.m. REVOLUTION - 4 -...

  • Page 8: Features (Compared With Former Models)

    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.

  • Page 9: General Description Of Engine Components

    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.

  • Page 10: Connecting Rod And Piston

    4-4 CONNECTING ROD AND PISTON Top Ring The connecting rod is forged of aluminum alloy, Second Ring and its large and small ends fanction as bearings. Oil Ring The large end has a built-in oil scraper for splash- ing the lubricating oil. Connecting Rod The piston is an aluminum alloy casting, and car- ries two compression rings and one oil ring.

  • Page 11: Cylinder Head

    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. Fig. 4-7 4-8 GOVERNOR SYSTEM The governor is a centrifugal flyweight type which ensures constant operation at the selected speed during load variations.

  • Page 12: Ignition System

    4-11 IGNITION SYSTEM The ignition system is a transistor controlled mag- Ignition Coil neto system which consists of a flywheel and an Flywheel ignition coil with a built-in transistor mounted on the crankcase. Fig. 4-10 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.

  • Page 13: Sectional View Of Engine

    4-14 SECTIONAL VIEW OF ENGINE Fuel Tank Spark Plug Cap Cylinder Head Ignition Coil Spark Plug Piston Pin Piston Piston Ring Recoil Starter Crankshaft Main Bearing Cover Flywheel Blower Housing Fig. 4-13 - 10 -...
  • Page 14 Speed Control Lever Air Cleaner Stop Switch Connecting Rod Carburetor Intake and Exhaust Valve Muffler Tappet Crankcase Camshaft Oil Scraper Fig. 4-14 - 11 -...

  • Page 15: Disassembly And Reassembly

    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.

  • Page 16: Disassembly Procedures

    5-3 DISASSEMBLY PROCEDURES . l i l i o l i o M6 x 8 Flange bolt : 4 pcs. STEP 2 Recoil Starter STEP 2 Gasket Drain Plug STEP 1 Crankcase Fig. 5-3 - 13 -...
  • Page 17 n i l n i l n i l l f f l f f l f f n i l Fuel Tank STEP 3 M6 x 14 Flange bolt : 2 pcs. Blower Housing Muffler Cover STEP 4 Head Cover M6 x 8 Flange bolt : 3 pcs.
  • Page 18 v i t , t l . t f . t l n i l STEP 8 Governor Spring Rod Spring Governor Rod Governor Shaft Speed Control Lever Governor Lever Fig. 5-5 M6 x 25 Bolt : 1 pc. STEP 9 Speed Control Lever Rod Spring Governor Spring...
  • Page 19 k i l y l l l i t Ignition Coil M6 x 25 Bolt : 2 pcs. STEP 10 Spring Washer Flywheel Spark Plug Cap M14 Nut : 1 pc. STEP 12 STEP 11 Starting Pulley Fixing Nut STEP 12 Crankshaft Carburator Flywheel...
  • Page 20 n i l n i l n i l n i l ) - ( l l u l l u e l i n i l ) - ( x i f g i l y l t c i t M8 x 40 Bolt : 8 pcs.
  • Page 21 Push the Valve Polyvinyl tape Main Bearing Cover (-) Driver Plastic Hammer Fig. 5-10 Fig. 5-11 n i l y l f Exhaust Valve Intake Valve Valve Spring Spring Retainer Tappet Camshaft STEP 18 STEP 17 Camshaft Tappet Governor Gear Fig.
  • Page 22 s t i n i l . t l l i o . t f l i t n i l p i l l l u l l a l i o g i l y l t y l f Clip Piston Ring STEP 20...

  • Page 23: Reassembly Procedures

    5-4 REASSEMBLY PROCEDURES ● PRECAUTIONS FOR REASSEMBLY 1) Clean parts thoroughly before reassembly. Pay most attention to cleanliness of piston, cylinder, crankshaft, connecting rod and bearings. 2) Scrape off all carbon deposits from cylinder head, piston top and piston ring grooves. 3) Check lip of oil seals.
  • Page 24 3) Oil scraper is to be set on the magneto side. NOTE : After reassembly, confirm that the con- necting rod moves lightly. NOTE : Connecting rod cap tightening torque : EY15-3 EY20-3 9-11.5N . m 17-22N . m (90-115kg . cm) (170-200kg . cm)
  • Page 25 5-4-4 TAPPET AND CAMSHAFT Insert the tappets into the crankcase holes first, and then mount the camshaft. Timing Mark NOTE : Align the timing mark on the root of the cam gear with the one on the crank gear. If the valve timing is wrong, the engine cannot operate properly or at all.
  • Page 26 NOTE: Fig 5-24 shows one of the methods mea- suring the crankshaft side clearance between the machined face of the crankcase and shims. As a Dial Indicator paper packing is used on the machined face of the crankcase, adjust the clearance by taking this thickness of 0.22mm into account.
  • Page 27 5-4-7 TAPEET ADJUSTMENT Lower the tappet all the way down, push the valve, and insert a thickness gauge between the valve and tappet stem to measure the clearance. (See Fig.5-28.) NOTE: The correct tappet clearance for both intake and exhaust valves is 0.1mm ±0.02mm when the engine is cold.
  • Page 28 The pitch of the mounting holes and the outer circumference dimensions of the gasket for EY15-3 and EY20-3 are same. However, the inner dimensions are different each other. Furthermore, the marking is provided at the position shown below for identification.
  • Page 29 5-4-10 IGNITION COIL, FLYWHEEL AND STARTER PLLEY Fit the flywheel on to the crankshaft. Also, fasten the starter pulley together with the flywheel. NOTE: Before installing, wipe out oil from the crankshaft and the tapered portion of the flywheel. Flywheel Tightening torque 60-65N ・...
  • Page 30 5-5 BRAKE-IN OPERATION OF REASSEMBLED ENGINE An overhauled engine must be operated at low speed to break-in the parts. A thorough break-in is indis- pensable particularly when the cylinder, piston, piston rings or valves are replaced with new ones. The recommended break-in schedule is shown below. .

  • Page 31: Governer Adjustment

    6. GOVERNER ADJUSTMENT Models EY15-3 and EY20-3 employ a centrifugal fly- Speed Control Lever weight type governor. The governor is mounted on the governor gear and the throttle valve of the car- Rod Spring buretor is automatically regulated by a lever which is connected to the governor in order to maintain con- stant engine speed against load variations.
  • Page 32 (Longer Hook Side) Fig. 6-5 *For EY15-3 and EY20-3, the governor spring longer in the length of (A) is for 50 Hz. *Both ends of the spring for EY15-3 are bended to the same direction, while both ends of the spring for EY20-3 are bended to contrary directions.

  • Page 33: Carburetor

    7. CARBURETOR 7-1 OPERATION AND CONSTRUCTION (See Fig.7-1) 7-1-1 FLOAT SYSTEM The float chamber is located just below the carburetor body, and the float (F) and the float valve (F.V) maintain a constant fuel level during engine operation. The fuel flows from the fuel tank into the float chamber through the float valve. When the fuel rises to a specific level, the float (F) rises;...
  • Page 34 7-1-2 SLOW SYSTEM The pilot system feeds the fuel to the engine during idling and low-speed operation. The fuel is fed through the main jet (M.J) to the slow jet (S.J), where it is metered, and mixed with the air metered by the slow air bleed (S.A.B).
  • Page 35 7-2-3 SLOW SYSTEM (1) Remove the slow jet (-5), using correct tool to avoid damage to it. (2) When fitting the slow jet, screw it in fully and turn it back, accurately by the rotation specified in the table of correction standards. 7-2-4 MAIN SYSTEM (1) Remove the bolt (-12) and take out float chamber body (-16).

  • Page 36: Magneto

    8. MAGNETO 8-1 FEATURES Ignition system of the model EY15-3 and EY20-3 is a maintenance-free electronic pointless magneto system. The electronic circuit is based on the cut off of the electric current by power transistor, and employs U.T.C.I. (Universal Transistor Control Ignition) circuit which always controls the ignition voltage to maxi- mum.

  • Page 37: Magneto Troubleshooting

    8-3 MAGNETO TROUBLESHOOTING When the engine does not start or starts with difficulty, or when its operation is unstable, the following checks will clarify if they are caused by a defect of the magneto. (1) Check ignition cable for possible damage, worn insulator or loose connection. (2) Check the spark.
  • Page 38 9. OIL LEVEL SENSOR (OPTION) 9-1 FUNCTION When the oil level sensor detects the insufficient level of engine oil, it halts engine for warning and protection of engine. 9-2 PRINCIPLE (1) Though it is very little, engine oil has electrical conductivity, while air is completely nonconductive. Utilizing this difference, presence of oil is identified by the current between electrodes of the sensor.

  • Page 39: Recoil Starter

    10. RECOIL STARTER 10-1 RECOIL STARTER (STEEL) Tools to be prepared: Driver, Pinchers (Pliers) and Protective Glasses WARNING Before starting the disassembly, make sure to wear the protective glasses. 10-1-1 DISASSEMBLY STEPS (1) Relieve the spring power -1: Hold the starter knob and extract the starter rope.
  • Page 40 -2: Hold up the reel gradually and slowly and remove it from the case. -3: If the spring in the reel likes to jump out, redo the steps of (3)-1 and (3)-2 again. WARNING Do not drop nor shake the reel. Put it on a level table because the spring is set in the disassembled reel.
  • Page 41 -2: Holding the latchet position, mount the Set screw latchet-guide sub-assembly. (Fig.10-5) Ratchet guide (3) Tightening the set-screw. -1: Push the latchet-guide lightly by hand so that the latchet guide won’t move and tighten the set-screw. (4) Storing the spring-power. -1: Hold the case tightly and wind up the reel Friction Spring counter-clockwise 6 times by both hands.
  • Page 42 10-1-3 CHECK AFTER REASSEMBLY (1) Pull the starter knob a few times to check if : A. The starter knob is too heavy to pull, check that each part has been assembled as specified. B. The ratchet does not function, check if parts such as friction spring have been missing. (2) Pull the starter knob and pull out the rope fully to see if: A.
  • Page 43 10-2 RECOIL STARTER (SYNTHETIC RESINS) Tools to be prepared: Driver, Pinchers (Pliers) and Protective Glasses WARNING Before starting the disassembly, make sure to wear the protective glasses. 10-2-1 DISASSEMBLY STEPS (1) Relieve the spring power -1: Hold the starter knob and extract the starter rope.
  • Page 44 -2: Hold up the real gradually and slowly, and remove it from the case. -3: If the spiral spring in the reel likes to jump out of the reel, stop the procedure and push the reel against the case to redo the step of section (3)-1 and (3)-2. WARNING Since the spiral spring is set in the reel, do not drop or shake it.
  • Page 45 (4) Wind the spiral spring. -1: Hold the case tightly and rotate the reel counterclockwise until it stops. (It stops when it is wound approx. 6 turns.) -2: Turn back the reel slowly by approx. 3/4 turns and hold the reel at the position where the rope hole of the reel and the rope guide of the case are aligned.
  • Page 46 10-2-3 CHECK AFTER REASSEMBLY (1) Pull the starter knob a few times to check if : A. The starter knob is too heavy to pull, check that each part has been assembled as specified. B. The ratchet does not function, check if parts such as friction spring have been missing. (2) Pull the starter knob and pull out the rope fully to see if: A.
  • Page 47 11. INSTALLATION Engine life, ease of maintenance and inspection, frequency of checks and repairs, and operating cost are all depend on the way in which the engine is installed. Review the following instructions carefully for installing the engine. 11-1 INSTALLING When mounting the engine, carefully examine its position, the method of connecting it to a machine, the foundation, and the method of supporting the engine.
  • Page 48 11-5 POWER TRANSMISSION TO DRIVEN MACHINES 11-5-1 BELT DRIVE Take the following notes into consideration. * V-belts are preferable to flat belts. * The driving shaft of the engine must be parallel to the driven shaft of the machine. * The driving pulley of the engine must be in line with the driven pulley of the machine. * Install the engine pulley as close to the engine as possible.

  • Page 49: Troubleshooting

    13.TROUBLESHOOTING 13-1 STARTING DIFFICULTIES If a sign of malfunction is found on the engine it is necessary to find out the cause immediately and take proper measures to prevent it from spreading. The section can not cover all the cause and measures to be taken for the faults but covers them only for possible faults.

  • Page 50: Insufficient Output

    13-2. INSUFFICIENT OUTPUT n i l n i l y t l l i o y t l l i o y l f z i t n i l n i l r t l y t l 13-3. OVERHEAT n i l r i a o l f...

  • Page 51: Rough Idling

    13-4. ROUGH IDLING n i l n i t o i t n i l n i l y t l 13-5. HIGH ENGINE OIL CONSUMPTION s t l y t l n i l l i d l i o l i o y t l - 48 -...

  • Page 52: High Fuel Consumption

    13-6. HIGH FUEL CONSUMPTION y t l o l f . y l n i l 13-7. DETONATION / r i n i l n i t o i t t i s n i l n i l y t l - 49 -...

  • Page 53: Service Data

    14. SERVICE DATA “STD” in the following table is the parts dimension from the brand new engine or the spare parts. Whereas, “Limit” shows the maximum allowance for the parts to be used on the engine. If the measurement exceeds beyond the “Limit”, the part needs to be replaced and/or repaired. 14-1 CLEARANCE DATA AND LIMITS Unit : mm (in.) - 50 -...
  • Page 54 Unit : mm (in.) - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - - -...
  • Page 55 Unit : mm (in.) n i l t r i - 52 -...
  • Page 56 Unit : mm (in.) l l a l l a - 53 -...
  • Page 57 Unit : mm (in) " " - 54 -...
  • Page 58 Unit : mm (in) ° ° - 55 -...

  • Page 59: Torque Specifications

    14-2 TORQUE SPECIFICATIONS - t f n i l s t l s t l s t l 14-3 OIL GRADE CHART Comparison between oil viscosity and temparature Single grade Specified Lubricant Quality 10W-30 Multi- grade 10W-40 20W-40 - 20 - 10 - 56 -...

  • Page 60: Maintenance And Storage

    15. MAINTENANCE AND STORAGE The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated maintenance intervals are by no means guarantees for maintenance free operations dur- ing these intervals. For example, if the engine is operated in extremely dusty conditions, the air cleaner should be cleaned every day instead of every 50 hours.
  • Page 61 15-4 EVERY 100-200 HRS. (MONTHLY) MAINTENANCE t l i f n i l t r i . f f 15-5 EVERY 500-600 HRS. MAINTENANCE s t i n i l 15-6 EVERY 1000 HRS. (YEARLY) MAINTENANCE n i l 15-7 ENGINE STORAGE (1) Perform the above 13-1 and 13-2 maintenance jobs.
  • Page 62 PRINTED IN THE USA...

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