ROBIN AMERICA, INC.
CONTENTS Title Section . 1 SPECIFICATIONS 2. PERFORMANCE 2.1 2.2 2.3 . . . ........................................... 1 ............................................ 2 Maximum Output ....................................... ContinuousRated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MaximumTorque andFuelConsumptionRatio a t Max . Output . . . . . . . . . ................................................ 4 . GENERALDESCRIPTION of ENGINECONSTRUCTION . . . . . . . . . .
7. MAGNETO 7.1 . 7.2 . 7.3 . 7.4. ................................................ 29 Magneto. . . . . . . . . . . . . . . ; . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Breaker PointAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . TimingAdjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Magneto TroubleShooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 29 30 .....................................
. - 1. SPECIFICATIONS 1 T a P c a -1- f 5m Lo 0 0 0 0 Lo c '4 . 0 0 ln .
2. PERFORMANCE 2-1 MAXIMUM OUTPUT The maximum output of an engine is such standard power as developed by that engine, after its initial run-in period with all the movingparts properlyworn-in,whenoperatingwith engine may notdevelopthismaximum the fully open throttle valve. Therefore, it follows that a output in the beginning,becausemovingpartsarenot new inaproperlyworn-in condition.
PERFORMANCE CURVE MODEL EC07-2D ( ) for B type HP t PERFORMANCE CURVE MODEL ECIOD ( )for B tj 4 3 HP t 2 1 0 (1000) (1200) (1400) (1600) - rpm -3- (1800) (2000)
PERFORMANCE CURVE kg-m HP PERFORMANCE CURVE MODEL EC25-2DS kg-m HP t -4 - __c rpm
3. FEATURES COMPACT, LIGHT WEIGHT, HIGH PERFORMANCE and LOW FUEL CONSUMPTION. TROUBLE FREE because of simpledesign and easy to handle. 5. HIGH DURABILITY engine withstand long severe operation. 4. TILTED OPERATION available. As a special feature of 2-cycle engine, can operate at up to about 30' tilted position just before the fuel flooding out from the air-bent of carburetor. 5. EASY STARTING Recoil type starter is available at option. 6. *- LIGHTING for night operation.
4.
FUEL TANK PISTON PIN BLOWER HOUSING FLYWHEEL STARTING PULLEY NlTlON COIL MODEL'EC05-2.07-2 I .
FUEL TANK CAP r CYLINDER MUFFLER COVER- FUEL TANK 7 \\ CLEANER ETOR 'ER GOVERNOR ARM MODEL ECIO -8-
f FUELTANK CYLINDE CYLINDER \ :LEANER MUFFLER MODEL EC17 -10-
1 1, MODEL EC17 - 11 -
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 MUFFLER- MODEL EC25-2 - 12-
7 FUEL TANK SPARK PLUG CYLINDER H E A D 7 .BLOWER HOUSING -COOLING FAN . IGNITION COIL .STARTING PULLEY P.
4-2 CRANKCASE All parts related with crankcase assy are aluminium alloy diecastings, which removed all unnecessary excess thickness for extreme lightness, consist of split-type front crankcase, rear crankcase and crankcasecover (for Model D) or reduction cover (for Model B) depending upon the model as per the following table, Model Front Crankcase D EC05-2 Crankcase Cover Rear Crankcase Reduction Cover for D type B Exclusive for B Exclusive for B ~ D EC07-2 - EC10 Exclusive for D for D type
4-6 DRIVING SHAFT (P.T.O. shaft) (for Model B only) The driving shaft is made of forged carbon steel and reduction gear i s force-fitted. 4-7 CYLINDER ‘Model EC05-2, EC07-2 Monoblockcylinderandcylinderhead .is made of aluminum alloy diecastingand-insidethecylinder is treatedwith hard-chromium plating to withstand against the wear by reciprocal motion of the piston.
4-12 CARBURETOR A horizontal draft float type carburetor is employed. Its setting has been carefuily determined after thorough testing to achieve best starting, accelerating, fuel consumption, output and performances. As to the detail suchas construction, refer to section “9. CARBURETOR”.
- 5. INSTALLATION Since the installation method affects the service life, easy of maintenance, frequency of check and repair, and operating cost of engine, the following contentsshall be carefully examined before installing your engine. 5-1 MOUNTING When installing the engine, its mounting position, coupling condition with operating machines, and anchoring or supporting m&o& must be carefully examined.
* * * Mount the driving pulley as close to the engine as possible. Span the driving belt horizontally, if possible. p" When starting the engine, disconnect the load. If a clutch is not available, a tension pulley or other means must be employed. 5-5-2 FLEXIBLE COUPLING When a flexible coupling is used, the run out and mis-alignment between the driven shaft and the engine shaft must be made as small as possible. The tolerance on the runout and mis-alignment are specified by each coupling manufacturer.
5-6-2 ENGINE with STARTING MOTOR (for EC25-2DS only) START BWTTON 1 +- I I R ECTl F I ER YELLOW^ I PINK I - I I I MAGNETO LIGHT BLUE WITH BLACK TUBE SPARK PLUG - 19- BATTERY
6. DISASSEMBLY and REASSEMBLY 6-1 PREPARATIONS and SUGGESTIONS 6-1-1 DISASSEMBLY When disassembling the engine, memorize where and how each part is assembled in order to be able to reassemble it correctly. Tag parts if there is a possibility of confusion. Take care not t o damagepackingsandgaskets,whicharefragile. Inorderto prevent missing and misplacing, grouprelatedpartstogether,tentativelyassemblingthem,immedi- ately after disassembled each sub-assemb!y.
' 6-1-4 REASSEMBLY 1) Before reassembly, wash parts in gasoline.and blow 2) Apply mobile oil on the rotating andsliding surface. them with compressed'air. 3) Take care not t o contaminate the parts with dust duringreassembly. 4) Be sure t o assemble those parts provided with alignment marks by bringing the marks in alignment. 5) Tighten'bolts, nuts and' screws to the correct torque specified.
5-2 SPECIAL TOOLS For your reference, the following'showsspecial tools of Robin Engine for Disassembly, Meauring and Inspection instruments. Part No. Tool USe Applicable Model f- Shape EY10,13,14 EYl8,25,27 2099500407 Flywheel Puller (with bolt) For pulling off Flywheel EY33,44 EC05,07,10 EC 17,37 EY10,13,14 207 95003.
~~ Part No. - Tool' Uu, Applicable Model EY10,13,14 EY18,25,27 214 91301 00 C. D. 1. Unit Checker For checking C. D. 1. Unit EY33,44,21 EY80 EC03,04 1067990100 T. C. 1. Unit Checker For checking T.C. 1. Unit EC05,07 EC10,17 EYlO, 13,14 EY "20248 Timing Tester .
6-3 DISASSEMBLY and REASSEMBLYPROCEDURE 6-3-3 FUELTANK and FUELTANKBRACKET ’ 1) Disconnect fuel pipe between strainer and carburetor at carburetor side. 2) Remove mounting bolts, and detach fuel tank from cylinder head or cylinder. 3) For Model ECl OV \ ’ Unscrew 6 x M8 bolts, then remove fuel tank from blowerhousing. CAUTION: REPLACE FUEL PIPE ONCEA YEAR IN ORDER TO PREVENT FROM THE OCCURANCE OF DANGER CAUSED BY THE FUEL LEAKAGE.
6-3-7 RECOIL STARTER Standard configuration on Model EClOV, 17V. Optional equipment for other models. M6 bolts (4 1) Remove recoil starter from blower housingb y unscrew 3 2) Remove starting pulley from flywheel by loosing bolts clamped. X X M6 bolts for Model EC17) NOTE: Unless it is necessary, do not disassemble recoil starter as special tools are required for reassembly. 6-3-8STARTING PULLEY and MAGNETO (Fig. 6-3-1) Remove’ starting pulley from flywheel. Remove flywheel from crankshaft.
, 6-3-10CYLINDER 1) Remove cylinder from crankcase by removing nut and spring washer. NOTE: For Model EC05:2,07-2 Remove spark plug prior to removing cylinder. 2) Removecylindergasket. 3) For Model EClOV remove intake pipe from cylinder. In reassembly: 1) Clean carbon deposit from cylinder head and combustion chamber. CAUTION:WITHOUTCLEANINGTHECARBON DEPOSIT, ITMAYDAMAGETHE PISTON ANDINNER SURFACE OF CYLINDER WHEN REASSEMBLY. Replace cylinder gasket to new one.
TOP RING SECOND RING .......... ISTON RING Fig. 6-3-2 Fig. 6-3-3 PISTON “F” mark of piston to blower side and reassemble 1) Position the the piston and connecting rod by firmly striking the piston pin, and needle bearing. OIL TO THE NEEDLE BEARING BEFORE CAUTION: APPLY 2) Assemblepistonpinclip. CAUTION: 3) REASSEMBLE I T TO PISTON-PIN. REPLACE PISTON PIN CLIP I F THERE IS ANY LOOSENESS AFTER REASSEMBLE IT. Be sure that piston and connecting rod moves smoothly after reassembled.
6-3-14REDUCTIONCOVER (Model B) 1) Discharge oil by opening oil drain plug. 2) Remove reduction cover by loosen the bolts on crankcase. 3) Remove washer and bolt on driving shaft end. 4) PUn out driving shaft with reduction gear from reduction cover. f “. 5) Opentaboflock-washerandpulloutpinion,governerplatp,governersleeve,washerandclipfromcrankshaft,and detach 2 woodruff keys. In reassembly: Reassemble with reverse sequences. After tighten the nut, bend the tabof lock-washer without fail.
. . . , 7 . MAGNETO . 7-1 ' MAGNETO ._ . The spark for ignition ' ". .' , r is furnished by a magneto assembly. The magneto consists of a flywheel, ignition coil and breaker assembly.(.includingcondenser), o f whichflywheel is 'mountedon.crankshaftandignitioncoilandbreakerassemblyare . - in crankcase directly. mounted 7-2 BREAKER POINT ADJUSTMENT (Fig.
With the Model EC05-2,07:2, 10, 17 and 25-2 engines, the spark is timed t o occur 18" TDC on the compression stroke. This spark advance of 18" - 23" is controlled - 23" before the position reaches by the breaker point opening and this ad- vance is obtained when the breaker point openingis adjusted according to theBREAKER POINT ADJUSTMENT to its proper point opening. However, the advance timing is more accurately adjusted through the following proceduresusing a timing light as shown in Fig. 7-3-3.
7-3-3 FOR TIMING ADJUSTMENT, THE FOLLOWING PROCEDURES USING A TIMING,TESTER: Disconnect the stop buttonlead wires and the coil primary wire. Remove blower housing from engine. Connect the timing tester lead with red rubber cap t o the coil primary wire and ground the lead with black rubber cap t o crankcase. (See Fig. 7-3-3.) While the points are open, the buzzer within tester remains ringing and when the points are closed, the tester remains silent.
8. GOVERNOR 8-1 CONSTRUCTION and OPERATION In the model EC05-2, 07-2, 10, 17 and 25-2 engines, a centrifugal flyweight type governor is used. The governor plate complete, governor sleeve and governor arm are installed in the governor chamber (EClOD, lev, 17D and 25-2D), in the crankcase (EC05-2D, 07-2D) or in the reduction chamber (type B and V), and lubricated by the lubricating oil (in the model EC05-2, 07-2, by the mixture fuel).
I . .., \-SPACER \“SET . . PIN GOVERNOR SLEEVE .. .. Fig.
8-2 GOVERNOR ADJUSTMENT The governor linkage should be adjusted, after reassemble it accordingto thefollowing procedures. 1) Connect governor rod and rod spring to carburetor throttle leverandgovernorlever, then install these t o governor shaft. NOTE: Never tighten adjusting plate set screw at this time, and do not fixed adjusting plate, governor lever and governor shaft 2) Connect governor lever and control lever with governor spring, and install control lever o n crankcase.
8-2-2 IN CASE ' OF MODELS EC05-2, EC07-2 (See Figs. 8-2-4 and 8-2-5.) 1) As shown by arrow mark on Fig. 8-2- 5 turn control lever t o high speed side (counter-clockwise) until stop fully, and fasten the controllever by tightening wing nut. 2) With a screw driver inserted in the groove of governor shaft, turn it counter-clockwise fully (until it w l inot turn any more) and then lock governor. lever t o governor shaft by tightening clampnut. (See Figs. 8 - 2 4 and 8 -2-5.
8-3 HIGH SPEED ADJUSTMENT (Fig. 8-31 * Maximum speed for standard engine: . . . . . . . . . . . . . . . . 5,000 r.p.m. 5-2 . . . . . . . . . . . . . . . 5,000 r.p.m. . . . . . . . . . . . . . . . 5,500 r.p.m. EC2 EC07-2 . . . . . . . . . . . . . . . 5,500 r.p.m. EClO . . . . . . . . . . . . . . . . 5,000 r.p.m. EC17 EC05-2 8-3-1 WHEN NO TACHOMETER IS AVAILABLE Unless required in the process of disassembling, do not remove control lever stopper plate and/or other related parts from crankcase.
GOVERNOR SPRING /- ' ADJUSTING SCREW (THROTTLE WIRE) Fig.
9.
9-1 CONSTRUCTION and OPERATION 9-1-1 FLOAT SYSTEM The float chamber is located just below carburetor main body and serves to maintain the fuel level at a constant height by a joint action of float (F) and needle valve (NV) incorporated. The fuel flows from the fuel tank into float chamber via needle valve, which is kept open while the fuel level is low, but closed when the fuel level reaches a predetermined level causing the float t o move up.
22 \ 25."-3& 31 Fig. 9 2 9-2-1THROTTLESYSTEM 1) Remove guide screw (22), Philips-screw (171, remove throttle valve (16), and then pull out throttle shaft(1 5). CAUTION: TAKE CARE 2) NOT TO DAMAGE'ENDS OF THROTTLE VALVE. Remove spring (24) by unscrewing throttle stop screw (23). 9-2-2CHOKESYSTEM 1) Take out Philips-screw (20), remove choke valve (1 9), pull out choke shaft (18). 2) When choke shaft is pull out, choke spring (32) and steel ball (31) should be removed, lest they be lost.
9-2-3 PILOT SYSTEM. . . 1) Remove pilot jet (21) using a suitable tool while taking care not t o damage it. 2) Remove pilot screw (25) and spring (26) In reassembly: . . 1) Tighten pilot jet and pilot 2) . 1 1 - . I plug firmly t o prevent fuel leakage. * Replace pilot screw if tapered end is damaged. CAUTION: DO IQOT OVERTIGHTEN. 9-2-4FLOAT SYSTEM 1) Remove guide holder (5) and float chamber (1 1). 2) Remove screw (14) and float arm (8) by taking out!float pin (9).
10. R U N IN OPERATION of REASSEMBLEDENGINE An overhauled engine must on newly installedparts. be carefully run-in to get proper surface condition Especially when cylinder, piston o r piston rings are replaced, a thorough run-in operation is indispensable. The recommended run-in schedule is as follows: LOAD EC05-2 EC17 EClO No load I SPEED TIME 2,000 rprn 10 rnin. EC07-2 EC25-2 I No load 3,000rprn I 10 rnin. ~ No load 4.000 rprn 10 rnin. 1.5 HP 2.0 HP 3.0 HP 5.0 HP 8.
. I 11. TROUBLE SHOOTING For a gasoline engine to start and run satisfactorily, the following three reyuirements must be met: 1) The cylinder filled with a proper fuel-air mixture. 2) An appropriatecompressioninthecylinder. 3) Good sparkat correct time to ignite the mixture. If all the three requirements are not met simultaneously, an engine can not be started.
Defects in fuel tank system Preventive measure Remedy Cause 1) Clean clogged tank outlet. 2) Clean clogged fuel strainer. 3) I f incorrectfuel is poured i n t o tankor water is mixed, drain tank completely and fill it w i t h correct fuel. 4) When fuel pipe is locked w i t h air, expel1 air. 11 Be sure t o use a filter when adding fuel. 2) Use mixture (gasoline 25 : oil 1 ) as fuel. 1 ) I f clogged w i t h dust, clean. Defects in carburetor 2 ) I f defective, replace. Clean jets andother clogged.
114 POWER DROP 1) If the cylinder, piston or piston rings are worn, replace them or re-finish the cylinder by boring and fit oversize piston and piston rings. Replace or clean sticking piston rings. NOTE: No oversize for EC052, 07-2. , j , , 2) If the carburetor is out of order, re-adjust or clean it. 3) If the spark plug is faulty (contamination, gas leakage or faulty insulation), clean it or replace it. 4) If combustion gas leaks through the cylinder, and cylinder head.
12. CHECKS and CORRECTIONS After disassembling and cleaning the engine parts, check them, and if necessary, correct them according to the correction table. The correction table applies whenever engines are repaired. Its contents should be thoroughly understood by those who undertake the repairing. Its specifications must be abided by to effect correct maintenance. Below, terms employed in the correction table are explained.
CORRECTION TABLE ITEM ~ ~~~~ I ENGINE MODEL LIMIT EC05-2 EC07-2 Flatness of cylinder head USE LIMIT REMARKS _c EC10 EC17 EC25-2 I EC05-2 Surface plate, Feeler 0.2 Oel 40.01 6 -TOOL :ORRECTlOh METHOD Correct 0.1 5 EC07-2 S.T.D. 500 EC10 OS. 50.259 EC17 OS. O.S. 62.250 62.500 O.S. 72.250 Bore EC25-2 4-0.02 0.1 5 0 0.65 Boring OS. 72.500 I Roundness All Cylindricity .All I 0.01 -1t" 0.015 ECO5-2 S.T.D. 41.960 EC07-2 S.T.D. 49.966 1 Iiameter at S.T.D. 49.
USE LIMIT ITEM Clearance between piston ring and piston groove EC05-2 EC07-2 TOOL -eeler 0.15 EC17 awe 0.05-0.1 2nd u 1-1 EC05-2 Replace 0.08-0.04 Clearance between piston and cylinder 0.1 1-0.07 0.25 0.25 0.06L 0.06 L 1.5 1.5 -0.1 -0.1 0.10-0.06 EC25-2 2ORRECTIOF METHOD 0.05-0.09 EC25-2 F i t between piston and piston pin REMARKS I I 0.10-0.04 EC05-2 EC07-2 0.006L- EC70 0.007L0.0 12T EC17 EC25-2 10.005T-0.013L Max. cylinder 3ia. and max. piston dia. 3ylinder )awe.
ournal I STANDARD ENGINE CORRECTION (MODEL SIZE ITEM USE 1 I I EC07-2 EC10 EC17 kl EC05-2 EC07-2 I 1 M.011 r i m :8 -0.005 a.020 0.03-0.01 I ECO5-2 Large end side or small end side Clearance in 0.055 tion ' I :ylinderJauge, Micrometer Feelerj a w 0.8-0.1 Large and small end I.D. roundness & cylindricity Replace 3btain correct Aearance by replacing parts I 0.6-0.1 0.6-0.1 Large end side clearance EC25-2 EC07-2 :ORRECTION METHOD 0.025-0.003 0.5-0.1 EC10 3ylinderlauw 4.0.
+ I iNGlNE STANDARD MODEL ITEM Thrust clearance between crankshaft & crankcase EC05-2 EC07-2 EClO EC17 EC25-2 I EC05-2 EC07-2 EC10 EC17 EC25-2 Runout of crankshaft EC05-2 I 1- Replace Dialindicator Correct Micrometer Replace Timing. tester Adjust I Model BV18 *x Meteling needle unscrew Fixed EC17 I 7 Fixed Model BV21 I- Model BV28 EC25-2 Pilot screw unscrew Spark plug 0.12 Supporting assembled crankshaft between centers, measure journal :ORRECTION METHOD 0 -0.
ITEM Max. Output' Continuous Rated Output ITEM Fuel Consumption ITEM Lubricating oil ITEM Min. Accelerating revolution CORRECTIONLIMIT MODEL HP/rpm EC05-2 EC07-2 EClO EC17 EC25-2 2.515.500 3.3/5,500 EC05-2 ECO 7-2 EClO EC17 EC25-2 1.715.500 2.215,500 314,000 5.014,OOO 8.514.000 MODEL Literlhr EC05-2 EC07-2 EC10 EC17 EC25-2 0.95 1.14 1.44 2.33 3.97 REMARKS Below 110% of rated output 415,000 6.515,OQO 1215.
8 I ITEM MODEL I I 400-500 Magneto clamp nuts I kg-cm I I EC05-2 28-30 EC07-2 I TOOL REMARKS f-7 390-420 \ EClO 29-36 EC17 1 ft-lbs I EC25-2 450-500 I 800-1000 33-36 I 58-72 I 18-22 EC05-2 EC07-2 Spark plug 250-300 EC25-2 QJ EC05-2 90-1 EC07-2 P G p ._ C Cylinder clamp 00 6.5-7.3 180-220 13-16 EClO nuts EC17 0) c v1 25-29 LL 340-400 B EC05-2 EC07-2 6.5-7.
13 MAINTENANCE and STORING I Thefollowing.maintenancejobsapplywhentheengine is operated.correctlyundernormalconditions. The indicated maintenance intervals areb y n omeans guarantees for maintenance free operations during theseintervals. For example, if the engine is operated in extremely dusty conditions, the air cleaner -should be cleaned every day, instead of every 50,hours. 13-1 DAILY CHECKS and MAINTENANCE Checks and Maintenance Removedustfromwhateverparts lated dust.
13-5 EVERY 1000 HOURS (YEARLY) CHECKS and MAINTENANCE I Reasons Maintenance and Checks 1 them for requiring Perform overhauls, clean correct or replace parts. The engine output drops and become out of order. Change piston rings. To prevent from danger caused by the fuelleakage. Replace fuel pipe once a year. 13-6 PREPARATION for LONG ABEYANCE 1) Perform the above 2) 13-1 and 13-2 maintenance jobs. Drain fuel from the fuel tank and carburetor float chamber.
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Industrial Engines