Robin America EY33-2, Service Manual

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Page 2: ...EH15 EH17 EH21 EH25 EH30 EH30V EH34 EH34V EH43V EC13V DY23 DY27 DY30 DY35 DY41 WISCONSIN ROBIN SIDE VALVE W1 080 WI 145 W1 145V W1 185 W1 185V W1 230 W1 280 Wl 340 W1 390 W1 450V EY21W EY44W EY18 3W EY25W EY27W v WO1 115 wo1 120 WO1 150 WO1 170 wo1 210 WO1 250 WO1 300 WOI 3oov WO1 340 WO1 340V WO1 43OV TWO CYCLE WT1 125V DIESEL WRD1 230 WRD1 270 WRD1 300 WRD1 350 WRD1 410 ...

Page 3: ... 4 Crankcase 6 Main Bearing Cover 6 Crankshaft 6 Connecting Rod and Piston 6 Camshaft 6 Cylinder and Cylinder Head 6 Valve Arrangement 6 Balancer 6 Governor 7 Cooling 7 Lubrication 7 Ignition 7 Carburetor 7 Air Cleaner 7 Selenium Rectifier 7 5 lNSTALLATlON 8 5 1 Mounting 8 5 2 Ventilation 8 5 3 Exhaust Gas Evacuation 8 5 4 Fuel System 8 5 5 Power Transmission to Driven Machines 8 5 6 Wiring 9 6 DI...

Page 4: ...ficultes 26 11 2 Engine Misses 27 11 3 Engine Stops 27 11 4 Engine Overheats 27 11 5 Engine Knocks 28 11 6 EngineBackfiresThroughCarburetor 28 12 CHECKS and CORRECTIONS 29 13 MAINTENANCE and STORING 35 13 1 Daily Checks and Maintenance 35 13 2 Every20HoursChecksandMaintenance 35 13 4 Every 100 200 Hours Monthly ChecksandMaintenance 35 13 5 Every 500 600 Hours Semianual ChecksandMaintenance 36 13 6...

Page 5: ...1 SPEC1 FICATIONS 1 ...

Page 6: ...t follows that when designing i driving systemforanymechanism withamodel EY33 2 or EY44 2 engine as a primemover thecontinuouspowe requirement of that mechanism must be kept below the continuous rated output specified 2 3MAXIMUMTORQUEANDFUEL CONSUMPTION RATIOATMAX OUTPUT The maximum torque of an engine is that driving torque of the driving shaft at which the engine is driving an external load whil...

Page 7: ...4 Economicaladvantagewithminimizedfuelconsumption 5 Since power can be taken in any direction simply by pulling the belt and the feed and drain oil work can also be done easily in two directionsof engine the engineis easily coupled with operating machines 6 The use of dynamic balancer reduces vibrations to such an extant as in a two cylinder engine PERFORMANCE CURVE Model EY44 2 for B type RECOMME...

Page 8: ... FLYWHEEL COOLI GFAN I LIGHTING C O I L CRANKCASE 4 ...

Page 9: ...SEl 5 ...

Page 10: ...metal on thelarge end An oil scraper is provided onthe large endforthepurpose ofsplashinglubricatingoil Thepiston is machinedfron aluminum alloy casting and provided with grooves for two compression rings one oil rings and one skirt ring The EY44 2 piston has an offset structure at the piston pin centerso as to reduce striking sound of piston 4 6 CAMSHAFT Thecarbonsteelforgingcamshaftincorporatesi...

Page 11: ... abreaker andlighting charging coil Theflywheel servingalso as afan is mountedon crankcase while the other elements are directly assembled in crankcase For details refer to the MAGNETO section 4 14 CARBURETOR A horizontaldraftcarburetor is employed Itssettinghasbeencarefullyafterthoroughteststoachievebeststart up acceleration fuel consumption output and other performance For other details see the ...

Page 12: ...irculation of heated air after cooling engine and or temperature rise of operating machines The temperature of engine compartment should be kept below4OoC even in mid summer 5 3 EXHAUST GAS EVACUATION Since the exhaust gas from engine is toxic it must be exhausted outsideif engine is operated indoors As the output powerof an engine is considerably influenced by the length of exhaust duct its diame...

Page 13: ... JIS CA104 male terminal JIS LA 104 or LA108 plate terminal The dotted parts are not supplied with the engine 5 6 1 ROPE STARTINGENGINE MAGNETO _ N BUZZER 6 8W SPARK PLUG LAMP 12V 15W Fig 5 6 1 5 6 2 ENGINEwithSTARTINGMOTOR MAGNETO LA 104 g ...

Page 14: ...ery Paper Cloth 7 Drain fuel and oil without fail before disassembly To drain oil unscrew the oil drain plug located on the side of crankcase on carburetor side by turning it counter clockwise 8 Clamp cylinder head cylinder main bearing cover connecting rod spark plug and flywheel with specified torque when reassembling them 9 Replace all the packings and gaskets with new ones when reassembling I ...

Page 15: ...and baffle from cylinder head 6mm bolt X 36mm screw X 4 3 Remove baffle from cylinder block 6mm screw X 2 6 3 3 AIR CLEANER 1 Remove aircleanercoverandelement 2 Detach bottom plate of air cleaner from carburetor by loosening two 6mm bolts Also detach the choke button from the carburetor chocke lever 3 Disconnectbreatherpipe In reassembly Put air cleanerelement in gasolineandsufficientlywashitwhile...

Page 16: ...NT and 7 3 TIMING ADJUSTMENT 6 3 7 CYLINDER HEAD and SPARK PLUG 1 Detachsparkplugfromcylinderhead 2 Detach cylinder head and gasket from cylinder by loosening lOmm nut In reassembly 1 Remove carbon from combustion chamber and also remove dirt from the vicinity of cooling fins of cylinder head Check head face for distortion Replace cylinder head if needed 2 Replacegasketwithnew one 3 Clamping torqu...

Page 17: ... valve seats lap valves in place untilauniformring will showentirelyaroundtheface of the valve Clean valves andwashblockthoroughwith a hotsolution of soapandwater Wipecylinderwalls with clean lint free rags and light engine oil CAUTION DO NOT ASSEMBLE VALVE SPRINGS AND SPRING RETAINERS AFTER ADJUSTING TAPPET CLEARANCE Fig 6 3 3 VALVE and VALVESTEMHOLECLEARANCE A VALVE FACE ANGLE 45 I B SEAT ANGLE ...

Page 18: ...oves lnsert a doubling plate between piston skirt and crankcase and set piston to the cylinder center so that piston will not move easily Fig 6 3 6 Stagger the piston ring gaps 90 apart around piston Apply oil to piston ring and cylinder walls sufficiently NOTE Use new cylinder gasket 5 Check if piston moves smoothly after reassembly Clamping torque of cylinderis as shown below 8mm nut 170 190 kgc...

Page 19: ...T and TAPPET 1 To prevent tappets from falling out and being damaged when camshaft is removed turn crankcase over on its side as shown in Fig 6 3 9 Push tappets inward to clear cam lobes and remove camshaft 2 Withdraw tappets NOTE Mark them so that they can be reinstalled in the same holes In reassembly 1 Put tappets back in their corresponding hole first and then mount camshaft CAUTION DON T FORG...

Page 20: ...dusingpistonpinwith clips mounted to both endsof piston pin NOTES 7 Measure the cfearancebetween cylinder and piston on thrust surface at skirtbefore assembly If worn outseverer than specified replaceit 2 Since the piston pin center of piston for EY44 2 is offset from the center of piston by about 6mm set pistontothematch mark scribed at thetop of piston In case of Models B and D set BF and Fig 6 ...

Page 21: ... 0 031 0 07L PISTON RING SIDE CLEARNACE IN GROOVES CLEARANCE 0012 L 0028 L 0 03L 0 07 L SKIRT RING 0031 L 0044 L 0 08OL 0 112L 0016 L 0042 0 04OL 0 107L CONNECTING ROD TO CRANK PIN CLEARANCE 0079 L 0197 L 0 2L 0 5L 0079 L 0197 L 0 2L 0 5L 001 1 L OO18 L 0 027L 0 046L 0010 L 0019 L 0 025L 0 047L t6 3 13 CRANKSHAFT Fig 6 3 13 CONNECTING ROD TO PISTON PIN CLEARANCE PISTON PIN TO PISTON CLEARANCE 0003...

Page 22: ...following procedures see Fig 7 2 Remove point cover from crankcase Turnthecrankshaftuntilbreakerarmcomes in contactwiththehighestpoint of breakercam muximumpoint opening of 0 35mm Loosen contact support plate lock screw just enough to move bracket Insert a 0 35mm feelergauge between points Apply a screwdriver to adjusting tab and move contact support plate just enoughto obtain specified gap while ...

Page 23: ...s and stop immediately the moment the light lights up Check if the slit on the flywheel is in the time with the mark on the crankcase When the mark line is in alignment the timing is correct If thetimingmark linesare not in alignment thenre adjustthepointopeningaccordingtothe BREAKER POINT ADJUSTMENT by removing the flywheel and repeat the checking procedures 3 through 5 After completing the timin...

Page 24: ...and place it on cylinder head fin after connecting ignition cable to it Crank engine several times by starting pulley and check if plug gap spark is strong or weak If spark is weak check it according to steps 1 3 above Correct plug gap is 0 6 to 0 7mm 0236 0276 20 ...

Page 25: ...retorthrottle lever andgovernor lever withconnectingrod andmountthemontogovernor shaft 2 Connect governor lever and control lever with governor Fig 8 1 spring and install controllever to crankcase 3 Turn control lever counterclockwise until carburetor throttle valve is fully open Lock control lever with butterfly nut 4 With a screwdriver inserted into groove of governor shaft turn it fully clockwi...

Page 26: ...ve1at a consitant height by a joint action of float F and needle valve NV incorporated The fuel flowsfrom the fuel tank into float chambervia needle valve which is kept open while the fuel level is low but closed when the fuel level reaches a predetermined level cowing the float to move up THROTTLE VALVE r BY PASS r M A l N NOZZLE Fig 9 7 1 NEEDLE VALVE FLOAT CHAMBER 1 Fig 9 1 2 22 ...

Page 27: ...oke C closed thenegative pressure to main nozzle MN increases to introduce fuel inlarge quantities to make start up easy 9 2 DISASSEMBLY and REASSEMBLY Besides mechanical failures mosttroublesarecausedby incorrect mixing ratio Themostcommoncauses ofsuchincorrect fuel air mix tures are clogged jets restricted air and fuel passages and variations in fuel level In order to obtain the full performance...

Page 28: ...toa clamping torque of 70 80 kg cm 5 1 5 8 ft lbs 9 2 5 FLOAT SYSTEM After pulling out float pin 1 8 detach float 1 7 and needlevalve 4 In reassembly When replacing needle valve replace it together withvalve seat without fail CAUTION AVOID USINGA DRILL OR A WIRE WHEN CLEANING JETS OTHERWISE THE ORIFICEMAY BE DAMAGED CAUSING UNFAVORABLE EFFECTSTO FUEL FLOW US COMPRESSEDAIR WITHOUT FAIL 9 3 ADJUSTME...

Page 29: ...in operation is indispensable particularly when cylinder piston piston rings or valves are replaced The recommended run in schedule is as tabulated below LOAD SPEED EY33 2 EY44 2 TIME I I I No load 10 minutes 2500 r p m No load No load 10 minutes 3000 r p m No load No load 10 minutes 3600 r p m No load 3 25 HP 30 minutes 3600 r p m 4 HP 6 5 HP 60 minutes 3600 r p m 8 HP 25 ...

Page 30: ...iverhandle or thelike 6 Due tocarburetorflooding toomuch fuel introduced in thecylinderthroughcranking makingthemixturetoo rich to he ignited When thishappens removesparkplugandturntheengineover several times with starting pulley to evac uate over richmixturethroughtheplughole Keep carburetorchokeopenduringthisoperation Dry sparkplugthoroughly and reinstall and try to start again 11 1 2 COMPRESSIO...

Page 31: ...n breaker points Gasoline containing water 7 Poor compression 11 3 ENGINE STOPS 1 Fueltankempty Gasolinecontaminatedwithwater dirtorgum 2 Gasolinevaporizedinfuellines due to excessiveheatingaroundengine Vaporlock 3 Vapor lock in fuel lines or carburetor due to the use of too volatile winter gas in the hot season 4 Air vent hole in fueltankcapplugged 5 Seizure in rotating or sliding pairs in engine...

Page 32: ...ctane rating 2 Engine operating under heavy load at low speed 3 Carbon or lead deposits in cylinder head 4 Incorrectsparktiming 5 Losse or burntoutconnectingrodbearing 6 Worn or loose piston pin 7 Engine overheated 11 6 ENGINE BACKFIRES THROUGH CARBURETOR 1 Water or dirt ingasoline or poorgrade of gasoline 2 Sticky intake valve 3 Overheated valves orhotcarbonparticles in engine 4 Engine cold 28 ...

Page 33: ...rtsforthepurpose of improvingorrecoveringtheengineperformance consisting of repair readjustment and replacement STANDARD SIZE Design dimension of the part without the tolerance CORRECTION TOLERANCE Tolerance on the re finished part dimension oron the readjustment dimension CORRECTION LIMIT Limit onthepartandadjustment beyondwhichanydimensionalandfunctionalchange duetowear burnand other causes will...

Page 34: ... cylinder Clearance between piston ring and ring groove Fit between piston piston pin Ring gap Ring width 0 1 5 1 0 035 0 057 I 0 01 Boring t 0 0 15 Seat cutter Cylinder gauge Correct Replace o 15 IAtmiddle portion 8 1 0 0 036 0 1 5 STD 77 87 I 0 251 78 11 0 50 78 36 1 Mark over size Micro meter 0 1 0 1 Replace 0 02 1 Vernier calipers 0 04 0 02 SKIRT 4 0 0 15 Replece 18 1 0 002 0 009 0 035 0 035 R...

Page 35: ...kshaft journal O D Cam lobe height Journal O D 0 080 0 1 12 Replace E Y 44 2 0 040 0 107 EY33 2 0 038 0 027 Replace EY 44 2 0 038 0 025 EY33 2 Cylinder gauge Micro meter 0 027 0 046 Replace EY44 2 0 025 0 047 EY 33 2 EY44 2 Remachine or Replace 0 2 0 5 E Y 33 2 EY44 2 Test bar Dial indicator Re machine or Replace 0 06 EY33 2 123 EY44 2 132 0 080 0 096 EY 33 2 EY44 2 EY33 2 EY44 2 EY 33 2 EY44 2 EY...

Page 36: ...r total length EU33 2 EY44 2 Square 1 o 0 3 Replace Replace Replace Correct 0 030 0 055 0 15 0 1 10 Micro meter 0 3 EY33 2 Intake 0 030 0 09 1 EY44 2 Exhaust 0 090 0 146 A t middle 1 1 E 0 13 0 17 EY33 2 EY44 2 Feeler EY33 2 0 04 0 1 5 EY44 2 0 5 Feeler Correct Vernier calipers 1 0 5 EY33 2 EY44 2 0 5 Replace 1 EY44 2 0 05 1 0 5 Vernicr caliDers 0 5 Replace Cylinder gauge Micro meter EY33 2 1 I I ...

Page 37: ... MODEL I I I I L u b r i c t Consumption EY33 2 60 30 EY44 2 80 40 I I I I I Specified Lubricant Quality 1 4 L I I REMARKS I Use the class SC or higher grade Mobile Oil Below 10 C 14OF SA 1OW 30 10 C 14 F 2OoC 68 F SA 20 2OoC t68 F 40 C 104 F SA 30 1 I ITEM I MODEL I FREQUENCY OF OIL CHANGING I Oil Change EY33 2 First Time Change oil after 20 hours operation Second Time and Thereafter Change oil e...

Page 38: ...od b o l t s Magneto clamp nuts Main bearing cover bolts Spark plug MODEL EY33 2 EY44 2 EY33 2 EY44 2 EY33 2 EY44 2 EY33 2 EY44 2 EY33 2 EY44 2 kgcm 450 500 250 300 800 1 O O O 170 190 250 300 ft lb 32 5 36 18 2 1 7 57 9 72 3 12 3 13 7 18 21 7 TOOL REMARKS Torque wrench Torque wrench Toque wrench Torque wrench Torque wrench 34 ...

Page 39: ...susceptible to dust Not only wasteful but also dangerous Loose screws and nuts will result in vibration accidents If the engine is operated without sufficient oil it will fail 13 2 EVERY20HOURS CHECKS and MAINTENANCE i Checks and maintenance To remove run in wear particles Change crankcase o i l Reasons for requiring them 13 3 EVERY 50 HOURS 10DAY CHECKS and MAINTENANCE b Checks and maintenance Re...

Page 40: ...e parts The engine output drops and become out of order Change piston rings 13 7 PREPARATION for LONG ABEYANCE 1 Performtheabove 13 1 and 13 2maintenancejobs 2 Drain fuel from the fuel tank and carburetor float chamber 3 To prevent rust in the cylinder bore apply oil through the spark plug hole and turn the crankshaft several turns by hand Re installthe plug 4 Turn the starting pulley by hand and ...

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