ROBIN AMERICA, INC.
CONTENTS 1. Page Title Section SPECIFICATIONS" ""."O"""""• "O" O" C". O""" O" O"". O"""'"• """"" "S""" """"" """". ".""" """.--"".--.-......C... 1 2. PERFORMANCE 2-1 Maximum 2-2 Continuous 2-3 Maximum ..."............".........""..................".......""..".................."..C.". 2 output . . . . .. C. . . . . . . . . . .. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..". . ..". . . . . . . . . . . . . . . . . . 2 rated output . .. . . . . . . . . . . . . . . . . .
1. SPECIFICATIONS. Model I I EC03ER ECO4ER 1 Type Air-cooled,~2-cycle, inclined single cylinder, lead valve, horizontal P.T.O. shaft. : output I Max. torque I I Direction rotation of Coolingsystem I Lubrication X 34.4cm3 (2.1 0 cain.) Pistondisplacement fuel 32mm (1.57 X 1.26 in) 40.2cm3 (2.45 cu.in.) 1.2/6000 HP/rpm (0.9/6000 KW/min") .1.8/7000 HP/rpm (1.3/7000 KW/min") 0.2/5000 kgf m/rpm (2.0/5000 ft. Ibs/min") 1.4/6000 HP/rpm (1.0/6000 KW/mi n- '1 2.0/7000 HP/rpm (1.
2. PERFORMANCE 2-1 MAXIMUM OUTPUT The maximum output of an engine is the output power of the engine operating with the carburetor throttle valve fully open after it has .been broken in properly. Therefore, a brand-new engine or an engine which has not been broken in properlymay not produce the maximumoutput. 2 - 2 CONTINUOUS RATED OUTPUT The operation of the engine at the continuous rated output is most favorable from the view point of engine life andfuel economy.
3. DISASSEMBLY AND REASSEMBLY 3-1 PREPARATIONS AND SUGGESTIONS (1) When disassembling an engine , memorizewell the locations of individual parts so that they can be reassembled correctly. If you are uncertain of identifying some parts, it is suggested thattagstobeattachedto them. (2) Have boxes ready to keep disassembled parts by group. (3) To prevent missing and misplacing small parts such as boltsandnuts, etc., temporarily assemble as much as possible in each group or set.
3-3 DISASSEMBLY PROCEDURES Step Part to remove 1 Spark plug cap Procedures (1) Remove spark plug. plugcapfromspark ~ 2 Tank cap Tool Remarks ~ ~~ ~ ~ * (1) Remove tank cap from fuel tank. (2) Put a draining pan below fuel tank. (3) Removefuelpipefromcarburetor. (4) Drain fuelfrom tank. TANKCAP SPARK PLUG CAP Fig.
Procedures (1) Remove (Option) clutch center bolt from crankshaft M6 x 16mm bolt and washer * - * lpce. (2) Remove ki-eescrews fromclutch. M5 x 8mm screw and washer * e * Spa. (3) Attachclutch puller to clutch. (4) Pull outclutch assembly using cluch puller. (See Fig. 3.) , , - ~ m p sc srew driver Clutchpuller M5 SCREW : 3pcs. Fig. . 3 Fig.
Step Part to remove Procedures 4 Air cleaner (1) Removecleaner 5 Carburetor (1) Turn fuel cock off. (2) Loosen two screws and remove air Remarks Tool cover with element. Disassemble and reassemble carburetor refering to. page 25, cleaner base and carburetor. M6 x 65mm screw and washer....2 pcs. .'5. CARBURETOR".
Step Part to remove 6 Tank bracket and fuel tank I Procedures Remarks I I Fig. - 7 - 6 . I Phillips screw driver (1) Remove tank bracket from crankcase. (2) Removefuel tank, M5 x 14mm screw and washer---.2pcs.
art IStep 7 8 I Procedures to remove1 Rubber cushion (1) Remove mount rubbers from crank- Engine base (Option) (1) Remove engine base. M6 x 12mm bolt and washer Remarks I Tool fl and tank bracket. * - - - 3pcs. MOUNT RUBBERS I M6 BOLT : 3pcs. Fig.
&= * Procedures Step Part to remove cover (1) Removemuffler cover frommuffler. M5 x 8mm screw * * * a 3pc~: (2) Removemuffler. M6 bolt and washer :*-2pcs. Remarks Tool (1) Be careful not to lose the washer Phillips screw driver lOmm box wrench - ' (1) Remove cylinder cover. M5 X 14mm screw and waSher****2pcs.. M5 X 20mm screw and washer-. 0 . Phillips scniw driver lpce. . . . Fig. 8 . - 9 - .
to Step lpart Stopbutton 12 Recoil starter I. I Procedures remove1 Remarks I Tool (1) Disconnect couplers of stopbutton wire. (1 1 Remove recoil starter. 4mm (1) Disassemble and hexagonwrench reassemble recoil starter refering to page 21, "4. RECOIL STARTER". M5 X 50mm socket bolt and washer lpce. M5 X 22mm socket boltwith washer 2pcs. --- M5 SOCKET BOLT : Ppcs. Fig.
Procedures Step Part to remove 13 lgnition coil (1) Removeignition coil from crankcase. M5 x 2Omm SCEW * * e * 2pcs. Flywheel magneto (1) Removeflywheel bolt, M6 X 16mm bolt, spring washer and washer 1pce. (1) Be c a r e f u l not to lose washer s d spring washer. (2) Set clutch puller to flywheel. (See Fig. 10.1 Turn center boltclockwise to pull out flywheeL (2) Flywheel caq easily be removed by striking with a hammer the head of center bolt of clutch puller. 14 Remarks - - 11 - .
'art to rernova Procedures Remarks Woodruff key (1) Removewoodruffkey shaft. (See Fig. 12.) Insulator (1) Remove insulator and lead valve from and lead valve from crank - (1) Use a soft hammer and aluminum stick. (2) Be careful not to lose key. (3) Be careful not to damage key and crankshaft keyway. Phillips screw driver Crankcase. M5 X 20mm screw and washer- -2pcs. M5 x 22mm screw and washer- -2pcs. 0 . *a (NOTE1 Leadvalve is unreplaceable. Replace lead valve in completion from if necessaly.
. * .. . .. , 1 step Part to remove' '. Procedures 17' 'Spark plug * 18 . - Tool Remarks "19mm plug wrench (l).Remove spark plug. fromcylinder. r . . .L , . . 5mm hexagon wrench (1) -Remove cylinder from crankcase. M6 X 18mm socket bolt 4pcs. Cylinder +- *-*a , . . . . . ... I PACKING . I - CYLINDER . " _ .. .
Step ’art to remove Procedures Crank- (1) Disassemble front and mar crankcases. 19 M5 x 30mm socket bolt 20 Piston and piston ring Remarks (1) Be c a r e f u l not to damage oil sed 4pcs. both ends of piston pin. (2) Remove piston pinfrompiston. (3) Remove piston from connecting rod. (4) Remove piston ring frompiston. (1) Remove two clipsfrom 4mm. hexagon wrench (1) Be careful not to lose clips.
3- 4 REASSEMBLY PROCEDURES 0 PRECAUTIONSFORREASSEMBLY (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 fromcylinder head, piston top and piston ring grooves. (3) Check lips of oilseals.Replaceoil seal if alipis damaged. Applyoil to lips before reassembly. (4) Replace allgaskets with newones. (5) Replace keys, pins, bolts, nuts, etc., if necessary. (6) Torque bolts and.
(2) Install needle bearing to small end of connecting rod. (3) Assemble piston and connecting rod with piston pin and clips. (See page 14, Fig. 15.) Setthe "M"markstamped flywheel side of piston. onpistontop to Fig. 17 3-4-2 CRANKCASE (1) Insert magneto end of crankshaftinto front crankcase bearing. (2) Putgasket on thefitting surfaces of crankcase. (Usenew gasket.) (3) Insert FTO end of crankshaftintorearcrankcase bearing. (See Fig. 17.
3-4-5 CYLINDERCOVER (1) Install cylinder cover to cylinder. M5 X 14mm screw and washer 2pcs. M5 X 20mm screw and washer * * * lpce. I .TIGHTENING TORQUE 295 - 390 30 - 35 30 I 40 kgf cm N cm IN-LB 3 - 4 - 6 LEADVALVEAND INSULATOR (1) Install gasket lead valve, withgasket,insulatorand M5 X 20mm screw and washer 2pcs. M5 X 22mm screw and washer 2pcs. 395 - 490 N cm r I wire bracket t o crankc ase. Apply sealant (THREE BOND # 1360) to screws.
(4) Adjustingairgap between ignition coil and flywheel. (See Fig. 18.) I I n 1 AIR GAP / 0.0079 - 0.0157 IN (5) Tighten ignition coil to crankcase. I I TIGHTENING TORQUE 40 395 35 - 50 kgf * c m 490N cm Fig. 18 40 IN-LB r Before installing flywheel, wipe out oil from crankshaft andthe tapered center hole of flywheel. 3-4-9 SPARK PLUG (1) Install spark plug to cylinder.
3 - 4 - 1 1 FUELTANK ' I (1) Settankcaptofueltank. (See page 4, Fig. 2.) (2) Install mountrubbersto crankcase. (3) Connect fuel pipe tocarburetor. (4) Put fuel tank on crankcase. 3 - 4 - 1 2 TANK BRACKET (1) Attachtankbracket to crankcase. M5 X 14mm screw and washer 2pcs. - 0 I TIGHTENING TORQUE - 50 395 - 490 35 - 40 40 I I kgf cm N cm - IN-LB 3- 4- 13 MUFFLER .(1) -. Install muffler to crankcaseusing muffler gasket. (See Fig. 19.) M6 muffler bolt and washer 2pcs. 0 .
3-4- 14 MUFFLERCOVER (1) Install muffler cover to muffler. M5 X 8mm screw I 3pcs. TIGHTENING TORQUE 35 345 30 I - - 45 I kgf-cm 440 N - c m 35 IN-LB I 3-4-15 STOPBUTTON (1) Connect wire from ignition coil tostop button. (2) Check earthspringtoprotrudefrom the mounting surface of recoil starter. (SeeFig. 20.) Fig. 20 3-4- 16 RECOILSTARTER (1) Install recoil starterto crankcase. M5 X 22mm socket bolt with washer M5 X 50mm socket bolt and washer I ' TIGHTENING TORQUE 35 345 30 - 0 .
4. RECOIL STARTER When repairing recoil starter, disassemble and reassemble in the following procedures. Tools : Socket. wrench, Needlenose pliers, Screw driver. 4- 1 DISASSEMBLY (1) Removerecoil starterfrom engine. (2) Pull starting knob to pull out starter rope. (See Fig. 21.) Fig. 21 (3) Hold reel with thumb and pull starter rope inside case.(SeeFig.22.) (4)Rewind rope clockwise untilrotationstops by holding starter rope using the notch on the reel.
(6) Remove reel from starter case as shown in Fig. 24. Take out.reel slowly turning it lightly toward left and right to remove spring from hook. n - [NOTE] Do not remove reel quickly or the spring may escape fromstarter case. If the spring escapes, put it in the starter case as instructed in page 23, 4-4 HOW TO DO' IN TROUBLES. Fig. 24 (7) Untie starter rope from the knob and remove. 4- 2 REASSEMBLY (1) Check that spring is securely set in the reel.
(7) Reassemble parts in reverse order disassembly. (See Fig. 23.) Screw * * * * * 1pce. of TIGHTENING TORQUE - 390 30 - 40 295 30 0 - kgf cm N*cm 35 IN-LB This ,istheend of the disassembly and reassembly procedures. Test the reassembled recoil starter by the following checking procedures in the next section. 4- 3 CHECKINGPROCEDURES Fig. 27 AFTER REASSEMBLY (1) Pull starting knob 2 or 3 times, and pull out starter rope alittle.
0 Wind spring completely. Hook inner end of spring to reel. Remove tape from reel. Fig. 28 (2) IN CASE OF LUBRICATING Lubricate the rotating parts, frictional parts and spring with heat resistant grease, or mobile oil at the time of disassembly or at the end of season for use.
5. CARBURETOR - . b . .- -. 5-1 - DIAGNOSISOF TROUBLES , . 0 Engine . ' does not. start. Carburetor needle valve-is held open by dirt or gum. (See remedy 1) Pilot, jet partially is clogged. (See' remedy. 2 ) . . .. Unstable engine operation. Carburetor needle valve is held openby dirt or gum. (See remedy 1.) Main jet is partially clogged.(See remedy 3) Engine exhausts white smoke. Pilot jet is partially clogged. (See remedy 2) Main jet is partially clogged.(See remedy 3) Carburetor floods. . .
Rznnsdy 2 (1) Remove pilot screwfrom body. (2) Clean pilot screw and vent of screw by blowing compressed air. (3) Clean pilot vent in kerosene and blow compressed air. (See Fig. 30.) (4) Reset pilot screw at 1%turns from full closed position. Remedy 3 (1) Remove float chamber from body. (2) Remove main jetfrom body. (3) Clean main jet in kerosene. (4) Clean main nozzle in kerosene and blow compressed air. (5) Clean main airvent in kerosene and blow compressed air. (See Fig. 30.
6. MAGNETO 6- 1 MAGNETO TROUBLESHOOTING When engine does not start or starts with difficulty, or when its operation is unstable, the following .tests will clarify if theyare caused bya defect in magneto. (1) Check ignition cable for possible corrosion, broken, worn insulation or looseconnection. (2) Check sparks as described in the following - section. . . (3) If no sparkflys, replace ignition coil.
8- 2 TROUBLESHOOTING TABLE \ POSSIBLE CAUSES Fuel tankempty Improper orcontaminatedfuel Loose fittingsordefectivefuel lines 0 Carburetor not choked enough(cold engine) External fuel leaks Clogged fuel filtersor dirty lines Vapor lock (Fuel evaporating in fuel lines dueto excessive heataround engine) Carburetor needle valve held open by dirt or gum.
SYMPTOMS P ; ' b 0 "$ 0 4- 4.cn 4- 0 c .3r ma .C.
9. CHECKS AND CORRECTIONS After disassembling and cleaning engine, check and repair, if necessary, according to the correction table. The correction table applies whenever engines are repaired. It is important for the servicemen to be familiar withcontents of this table. Correct maintenance is recommended by observing the correction standards specified. The meanings of the terms used in correction tableare as follows : f-7 (1 CORRECTION Repair, adjustment or replacement of any engine parts.
Unit : rnm (in) ECOSER ITEM EC04ER ~~ Limit STD STD Limit Piston pin hole (maximum) n 0 Clearance between - - 9.99 1 10.002 0.3933-0.3938) 10.03 (0.3949) 9.99 1 10.002 (0.3933-0.3938) 10.03 (0.3949) 0.020-0.066 0.0008-0.0026) 0.1 05 (0.0041 0.034-0.080 (0.001 3-0.0031 0.1 19 (0.0047) TOD 0.07-0.1 1 0.0028-0.0043) 0.1 5 (0.0059) 0.07-0.1 1 (0.0028-0.0043) 0.1 5 (0.0059) 2nd 0.04-0.08 0.0016-0.0031 ) 0.15 (0.0059) 0.04-0.08 (0.001 6-0.0031 0.1 5 (0.0059) - 0.009-0.008 0.044 (0.
Unit : mm (in) I Piston ringend EC04ER ECOSER ITEM STD Limit I STD Limit gap I Piston ring width (minimum) TOP 0.1 -0.3 0.8 (0.0039-0.01 18) (0.031 5) 0.1 -0.3 (0.0039-0.01 18) 1.o (0.0394) 2nd 0.1 -0.3 (0.0039-0.01 18) 0.1 -0.3 (0.0039-0.01 18) 1.o (0.0394) 1.54-1 -56 <0.0606-0.0614) 1.5 (0.059 1 ’ 0.8 (0.031 5) TOP 1.54- 1-56 (0.0606-0.061 4) 2nd 1.54- 15 6 (0.0606-0.061 4) 1.5 (0.0591 ) 1.54- 1.56 (0.0606-0.061 4) 1.5 (0.05911 9.994- 10.000 (0.3935-0.3937) 9.986 (0.
Unit : mm (in) ECOBER iC04ER. . .. Limit STD ITEM X A N K SHAFT .. _ . D Journal dia. 14.994- 1 5.002 (0.5903-0.5906) 14.98 (0.5898) u u Sideclearance between crankcase andcrankshaft (at assembled) 0.48 (0.01 89) 0.8 (0.031 5) 0.05 (0.0020) 0.1 (0.0039) Gaskethasathickness in) o f 0.4mm(0.0157 (whentighting) 0 Runout of shaft 18.5mm CARBURETOR Pilot screw Returnthepilot screw 1 X turnsform position Sparkplug NGK BPM7A type B.T.D.C 23.5" "B.T.D.C.28.5" Spark timing Air gap 0.2-0.4 (0.
9-2 TABLE OF TIGHTENING TORQUE Tightening torque Description -- 60 590 55- Bolts for joining crankcase 80 kgf cm 780 N cm 65 IN-LB 110"; 130 kgf *cm 1080- 1270 N cm 95- 110 IN-LB Bolts for joining cylinder - - 40 kgf cm 390 N cm 35 IN-LB Screw for joining cylindercover 30 295 30- Screw for joining insulator and leadvalve 40- 50 kgf cm 395 -.
OPTION Tightening torque Description Bolts for joiningengine - 780 30 - base Screw for joining clutch 60 590 55- 80 kgf cm N cm 65 IN-LB 295 30- 40 kgf cm 390 N cm 35 IN-LB 120 kgf-cm 980- 1175 N * c m 90- 100 IN-LB 100- Bolts for joining clutch to engine - 35 -
10. MAINTENANCEAND STORAGE The following maintenance schedule applies tothe engines operatedcorrectlyunder normal conditions. The indicated maintenance schedule does not necessarily guarantee maintenance- free operations duringtheintervals. For example, if an engine is operated in extremely dusty condition, its air cleaner should be cleaned every day instead of every 50 hours. 10- 1 DAILY CHECKS ANDMAINTENANCE Checks and maintenanceworks Reasons for requiringthemaintenancework Remove dust, dirt, .
I0-4 YEARLY CHECKS AND MAINTENANCE ' I I I Checks and maintenance I works Remove the carbondeposit,from port andmuffler. Reasons for requiring the exhaust Clean the carburetor. the maintenance work Pooroperation of the engine. Pooroperation of the engine. 10-5 PREPARATION FORLONGSTORAGE (1) Perform the above maintenance works 10 - 1 through 10 - 4. (2) Drain fuel from' the tank.
Industrial Engines
