Robin EC05-2 Service Manual Download

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Summary of Contents for EC05-2

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Page 2: ...H21 EH25 EH30 EH30V EH34 EH34V EH43V EC13V DY23 DY27 DY30 DY35 DY41 WISCONSIN ROBIN SIDEVALVE W1 080 W1 145 W1 145V W1 185 W1 185V W1 230 W 1 280 W1 340 W 1 390 Wl 45OV EY21W EY44W EY18 3W EY25W EY27W OVERHEAD VALVE WO1 115 wo1 120 WO1 150 WO1 170 wo1 210 WOl 250 WO 1 300 WO1 300V WO1 340 WO1 340V WO 1 43 O V TWO CYCLE WT1 125V DIESEL WRD1 230 WRD1 270 1 300 WRD1 350 WRD1 410 0 0 0 ...

Page 3: ...haftandConnecting Rod Assy 14 Piston 14 DrivingShaft for Model B only 15 Cylinder 15 Cylinder Head Model EC10 17 2 5 2 only 15 Governor 15 Cool ing 15 Ignition 15 Carburetor 16 Air Cleaner 16 ReductionEquipment for Model B only 16 StartingPulleyorRecoilStarter 16 5 INSTALLATION 17 5 1 Mounting 17 5 2 Ventilation 17 5 3 Exhaust Gas Evacuation 17 5 4 Fuel System 17 5 5 Power Transmission to Drive Ma...

Page 4: ...BLESHOOTING 43 11 1 Starting Difficulties 43 1 1 2 Slow Speed out of order 44 1 1 3 Overheating and Knocking 44 1 1 4 Power Drop 45 1 1 5 Excessive FuelConsumption 45 1 1 6 Engine Hunting 45 11 7 Other Complaints 45 12 CHECKS and CORRECTIONS 46 13 MAINTENANCE and STORING 53 0 1 3 1 Daily Checks and Maintenance 53 13 2 Every 50Hours 10Day ChecksandMaintenance 53 1 3 4 Every 500 600 Hours Semiannual...

Page 5: ... 1 SPECIFICATIONS 1 0 0 4 c f Lo 5 0 m 0 0 Lo 0 9 ln T c a P a 1 ...

Page 6: ...nd fuel consumption ratio Therefore it follows that when designing a driving system for any mechanism with a model EC05 2 07 2 IO 17 or 25 2 engine as a prime mover the continuous pow er requirement ofthat mechanism must be kept below the continuous rated output specified 2 3 MAXIMUMTORQUE and FUELCONSUMPTIONRATIOATMAX OUTPUT The maximum torque of an engine is that driving torque of the driving sh...

Page 7: ...PERFORMANCE CURVE MODEL EC07 2D for B type HP t 4 3 HP t 2 1 0 PERFORMANCE CURVE MODEL ECIOD for B t j 1000 1200 1400 1600 1800 2000 rpm 3 ...

Page 8: ...HP HP t PERFORMANCE CURVE kg m PERFORMANCE CURVE MODEL EC25 2DS kg m 4 __c rpm ...

Page 9: ...ailable by installing special lighting coil Lighting Capacity EC05 2 07 2 1 2V 16V 6W EC10 17 6 8V 15W EC25 2 1 2V 18 25W VERSATILE APPLICATION Direct or reduction type engine with horizontal shaft or vertical shaft are available Wide selection of driving shaft size and shapes are also available beside standard specification Further consultwith dealer for smallerfuel tank heavy dutyfilterelementfo...

Page 10: ...4 GENERALDESCRIPTION of ENGINECONSTRUCTION 4 1 SECTIONAL VIEW of ENGINE FUEL TANK CAP MUFFLER COVER 7 I MUFFLER GOVERNOR CONTROLLEVER MODEL EC05 2 07 2 6 ...

Page 11: ...FUEL TANK PISTON PIN BLOWER HOUSING FLYWHEEL STARTING PULLEY NlTlON COIL MODEL EC05 2 07 2 I ...

Page 12: ...CYLINDER 7 MUFFLER COVER FUEL TANK CAP r FUEL TANK GOVERNOR ARM MODEL ECIO CLEANER ETOR ER 8 ...

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Page 14: ...CYLINDE CYLINDER MUFFLER f FUELTANK MODEL EC17 LEANER 10 ...

Page 15: ...1 1 MODEL EC17 11 ...

Page 16: ...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 ...

Page 17: ...P T 7 FUEL TANK SPARK PLUG CYLINDER H E A D 7 BLOWERHOUSING COOLING FAN IGNITION COIL STARTING PULLEY FLYWHEEL CRANKSHAFT MODEL EC25 2 1 3 ...

Page 18: ...is supporting the crankshaft and the other one is supporting the driving shaft 4 3 BASE PLATE Thebaseplatemade of aluminumalloydiecasting is to beattached to thefrontandrearcrankcase with 4 bolts 4 4 CRANKSHAFT and CONNECTINGROD ASSY Thecrankshaft is separable intothefrontcrankshaft rearcrankshaftandcrankpin Crankshaft is made of forged carbon steel Crank pin is made of chromium molybdenum steel h...

Page 19: ...ylinder one each of intake port exhaust port and four scavenging ports are positionedto the maximum engine performance 4 8 CYLINDER HEAD Model ECIO 17 25 2 only Thecylinderhead is made of heat conductivealuminumalloyand is providedwith the fins arrangedinthedirection of cooling air to achieve the efficient cooling The combusion chamber forms semi spherical and is provided with threaded hole for mo...

Page 20: ...PMENT For Model B only With the Model B engine rear crankcase and reduction cover forms the reduction chamber and the revolution of crankshaft reduced to 1 2 7 for Model EC05 2 07 2 to 1 25 for Model EClO and EC17 by reduction gear and pinion and then its transmitted to P T O shaft Governer is also equipped with reduction chamber and lubricated by same lubricant Use SAE 30 lubricant for EClO 17 4 ...

Page 21: ...h temperature environment will cause engine vapor lock deterioration of oil power reduction loss of engine life it is requested to keep the temperature of compartment not toexceed 50 C 5 3 EXHAUST GAS EVACUATION As the exhaust gas is toxic it must be exhausted outside in case engine is operated indoor Output power of 2 cycle engine is considerably influenced by the lengthof exhaust duct so ask for...

Page 22: ...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 c3JIS CB104 female terminal JIS CA104 male terminal 4LA104 or LA108 plate terminal CONDENSER ONTACTBREAKER STOP BUTTON LIGHTING SWITCH LAMP 6V 8V 1...

Page 23: ...5 6 2 ENGINE with STARTING MOTOR for EC25 2DSonly 1 START BWTTON I RECTlFIER YELLOW I PINK I I MAGNETO LIGHT BLUE WITH BLACK TUBE I I I BATTERY SPARK PLUG 19 ...

Page 24: ...horoughly Wash them twice first time remove visible dirt roughly and second time using fresh Kerosene 3 After washing blow them thoroughly with compressed air 4 Do not wash electric parts Wipe them with clean cloth and dry them 5 Accumulated carbon on the cylinder head gasket piston cylinder and inside the muffler to be carefully planed and wrap the piston withoil stone to get smooth surface 6 Par...

Page 25: ...0 kg cm 6 5 ft lbs 8 m m 250 kgcm 18 ft lbs 10 mm 370 kg cm 26 7 ft lbs If small screwsaretightened too hard theymaygetbroken Tightenthelargesizescrewssuchasonesforthe magneto flywheel enough by giving hammer blows on the socket wrench handle When tightening the several screws fastening the single part tighten them all evenly by alternately tightening diagonally located pairs 6 Do not apply oil to...

Page 26: ...20595001 07 2069500107 2079500107 Tool Flywheel Puller with bolt Valve Spring Retainer rlalve Guide Puller U S e For pulling off Flywheel For mounting and dismounting Valvc SpringRetainer and Retainer Lock For pulling off Valve guide Applicable Model EY10 13 14 EYl8 25 27 EY33 44 EC05 07 10 EC17 37 EY10 13 14 EY18 25 27 EY21 80 EY33 44 EY13 14 EY18 EY25 27 Shape f f 22 ...

Page 27: ...r Uu For checking C D 1 Unit For checking T C 1 Unit Foradjusting Timing For checking Ignition Coil Applicable Model EY10 13 14 EY18 25 27 EY33 44 21 EY80 EC03 04 EC05 07 EC10 17 EYlO 13 14 EY 18 25 27 EY33 44 21 EY80 EC03 04 05 EC07 10 17 EC37 EY10 13 14 EY 18 25 27 EY33 44 21 EY80 EC03 04 05 EC07 10 17 EC37 23 ...

Page 28: ...6 170 B and 25 2D DS After washed element with gasoline soak it into the mixed o i l of 2 4 kerosene and 1 engine oil then reassemble it after drip the oil off Model EClOV After washed outer and inner elements with gasoline soak them into the mixed o i l of 2 4 kerosene and 1 engine oil 6 3 3 CARBURETOR 1 Remove governor rod and rod spring from carburetor 2 Removecarburetorfromcylinderblock In rea...

Page 29: ...nsion cable of ignitoncoilandremoveignitioncoilfromcrankcase Take off the point cover and remove contact breaker and condenser from crankcase In reassembly Fig 6 3 1 Refer to 7 2 BREAKER POINT ADJUSTMENT 7 3 TIMING ADJUSTMENT sections 6 3 9 CYLINDERHEAD Model EC10 17 only 1 Remove spark plug from cylinder head 2 Unscrew mounting special bolts and remove cylinder head from cylinder 3 Removecylinder...

Page 30: ... ft lbs CAUTIONS r WHEN FASTENING CYLINDER TIGHTEN FOUR NUTS UNIFORMLY 2 BEFORE REASSEMBLE CYLINDER APPLY OIL ON NEEDLE BEARING LOCATED TO END OF CONNECTING ROD 6 3 1 1 PISTON 1 Remove both sidepistonpinclips 2 Pull out piston pin and disconnect the needle bearing from small end of connecting rod CAUTION IN ORDER NOT TO DAMAGE PISTON PULL OUT PISTON PIN BY FIRMLY HOLD PISTON ALSO TAKE A SPECIAL CA...

Page 31: ... 07 2 2 Removeboltandwasher from crankshaftend 3 Removebolts on crankcase 4 Detach cover gasket In reassembly 1 Replace covergasket to new one 2 Checkbailbearingand oil seal if there is any damage And replace it if necessary 3 Apply oil on bearing and oil seal and coat oil seal guide to the contact surface of crankcase cover Fig 6 34 Attach oil seal guide onend of crankshaftandmountcrankshaft in c...

Page 32: ...6 3 18 CRANKCASE Unscrew 4 bolts which fastening front crankcase and rear crankcase and separate both crankcase by tapping them with soft hammer and detach crankshaft connecting rod assy In reassembly Before reassemble the front and rear crankcase check bearings and oil seals if there is any damage and replace them in case any damage found Apply oil onto thebearings of both crankcase and ascertain...

Page 33: ... 2 0 35mm ECl7 0 30mm EC25 2 0 35mm I Ftg 7 2 i To adjust breaker poixit opening remove starting pulley blowerhoushg andflywheel from theeingine and proceed as follows 1 See Fig 7 2 1 Remove breaker cover from contact breaker 2 Turn crankshaft overuntil breakerarmcomesincontactwith thehighpoint of thebreaker cam maximumpoint opening of 0 4 mm 3 Loosen contact suppoit plate lock screw just enough s...

Page 34: ... using a timing light as shown in Fig 7 3 3 NOTE Spark advance of each model is as follows EC05 EC07 2 EC25 2 23 EClO 1 8 EC17 2 2 NOTE Refer to section 4 1I IGNITION and 12 CHECKSand CORRECTIONS 7 3 1 ALIGNMENT MARK for TIMING ADJUSTMENT See Fig 7 3 1 For timing adjustment the following alignment marks are provided as shown on Fig 7 3 1 Line mark on crankcase Line mark on flywheel circumference a...

Page 35: ...g the flywheel and repeat the checking procedures 3 through S Afer completing the timing adjustment re mount the blower housing and connect the coil primary lead to the stop button MAGNETO TROUBLE SHOOTING When the engine does not start or starts with difficulty or when its operation is unstable the following tests will clarify if they are caused by a defect in the magneto 1 Check ignition cable f...

Page 36: ...ng part of the governor shaft and this governor lever isconnected to the carburetor throt tle lever through the governor rod at the other end thus the throttle valve is opened or closed and engine speed andoutput are controled When the crankshaft rotation increases all the relevant members move in the direction indicatedby marks and the car buretor throttlevalve closes reducing the fuel supply and...

Page 37: ...I SPACER S E T PIN GOVERNOR SLEEVE Fig 8 1 2 Model ECIO 17 25 2 33 ...

Page 38: ...er with governor spring and install control lever on crankcase 8 2 1 IN CASE OF MODELS EC10 EC17 See Figs 8 2 1 8 2 2and 8 2 3 As shown by arrow mark on Fig 8 2 1 turn control lev er to high speed side clockwise until stop fully and fasten the controllever by tightening wing bolt Loosen lock nut at the end of governor shaft and set screw on adjusting plate As shown by the arrow on Fig 8 2 2 move a...

Page 39: ...ng wing nut 2 With a screw driver inserted in the groove of governor shaft turn it counter clockwise fully until it w i l lnot turn any more and then lock governor lever to governor shaft by tightening clampnut See Figs 8 2 4 and 8 2 5 GOVERNORSHAFT I GOVERNOR Fig 8 2 4 Fig 8 2 5 8 2 3 IN CASE OF MODEL EC25 2 See Fig 8 2 6 Governor adjustment procedure is exactly same as that for model EC10 LCLA N...

Page 40: ...control lever and other related parts 2 By turning control lever with governer spring on it increase gradually the engine speed upto specified engine speed 3 Thenfollow the below In case of models EC05 2 07 2 and 25 2 locatehigh speed stopper bolt on the controllever and lock it so that itwill work as stopper of control lever againstthe stopper plate In case of models EClO and EC17 locate stopper ...

Page 41: ... GOVERNOR SPRING ADJUSTING SCREW THROTTLE WIRE Fig 8 3 2Model EClO 17 SPRING ...

Page 42: ...LOT SCREW PILOT AIR JET PILOT OUTLET BANJOBOLT STRAINER CHOKELEVER NEEDLE VALVE BLEED AIR JET CHOKE VALVE THROTTLE VALVE PILOT JET BASIC FUEL LEVEL MAIN AIR JET MAIN NOZZLE MAIN JET C FUEL FUEL DRAIN PLUG I Fig 97 38 ...

Page 43: ...YSTEM This pilot system feeds fuel to engine during idle and slow speed operation The fuel fed through main jet MJ is measured by pilot jet PJ mixed with air measured by pilot air jet PAJ regulated by pilot screw and then fed to engine through pilot outlet PO and bypass BP The fuel is mainly fed from pilot outlet PO during idling This main system feeds fuel to engine during medium and high speed o...

Page 44: ...ng 24 by unscrewing throttle stop screw 23 9 2 2 CHOKE SYSTEM 1 Take out Philips screw 20 remove chokevalve 19 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 In reassembly 1 Insert spring 32 and steel ball 31 in the hole and install choke shaft 18 2 When assembling choke the flaton choke valve must be toward the main air...

Page 45: ...eed to remove mainnozzle because of main nozzlebeing incorporatedinto carburetor body In reassembly 1 Tighten main jet securely to guide holder and tighten guide holderto carburetor body 2 Tighten guide holder to 70 80 kg cm 5 5 lbs ft A too rich fuel mixturewill result if not tightened securely 9 3ADJUSTMENTS When the controllever is set at slow speed side the engine should be operated onidling s...

Page 46: ...ton or piston rings are replaced a thorough run in operation is indispensable The recommended run in schedule is as follows LOAD SPEED TIME EC05 2 EC25 2 EC17 EClO EC07 2 No load 10 rnin 2 000 rprn I No load I 3 000rprn I 10 rnin I No load 60 rnin 4 500 rprn 9 5 HP 5 5 HP 3 5 HP 2 3 HP 1 8 HP 30 min 4 000 rprn 8 0HP 5 0 HP 3 0 HP 2 0 HP 1 5 HP 10 rnin 4 000 rprn 42 ...

Page 47: ...urface with emery paper 400 2 If breaker point gap is incorrect adjust it to specified 0 4 0 05mm for Model EC10 by loosening contact support plate lock screws 3 If spark timing is incorrect adjust it t o 18 23 before TDC refer to 4 11 4 If breaker is defective in insulation replace breaker 5 If condenser is defective replace 1 If wire or insulation is broken replace 2 If magnetism is weak re magn...

Page 48: ...ure gasoline 25 oil 1 as fuel 1 Never close choke valve when engine is 2 When stoppingthe engine runitat slow speed for a while Thispracticenotonly favourably affects next starting but also improves engine life 3 Clogged air cleaner results in too rich air fuel mixture C ean it throughly warm Be careful clogged carburetor 1 Do not use poor grade oil 2 Use fuel of proper mixing ratio 11 2 SLOW SPEE...

Page 49: ...ower drop perform remedies for power drop according to 114 POWER DROP 11 6 ENGINE HUNTING 1 If the governorlever governorshaft governorspring or other members are incorrectlyadjusted re adjust or correct them 2 If the fuel air mixture is too lean Clean the carburetor 3 If the pilot screw in the carburetor is incorrectly adjusted re adjust it 4 If the governorspring is deformedpermanently replace i...

Page 50: ...ose of improving or recovering the engineperformance consisting of repairs readjustments and replacements STANDARD SIZE The design dimension of the part without the tolerance CORRECTION TOLERANCE The tolerance on the re finished part dimension or on the readjusted dimension CORRECTION LIMIT The limit on the part and adjustment beyond which any dimensional and functional changes due to wear burn an...

Page 51: ...59 4 0 02 OS 62 250 0 O S 62 500 O S 72 250 OS 72 500 Bore 0 1 5 0 65 I Roundness I 0 01 t Cylindricity 1 0 015 S T D 41 960 1 S T D 49 966 S T D 49 930 Iiameter at P 8 ECO5 07 5 23 EClO 3 28 EC17 om bottom n transverse o piston pin Irnax dia 0 25 EC25 2 Replace Outside Diameter Micrometer 0 1 0 03 0 035 0 1 0 03 0 035 0 1 5 62 196 I O S S T D 61 940 OS 62 440 S T D 71 920 O S 72 170 0 009 0 020 0...

Page 52: ...ston and piston pin 0 06 L Replace 10 005T 0 013L I EC05 2 TOP EC07 2 2nd 0 1 0 3 2nd TOP Ring gap 1 5 Replace 1 5 0 1 EC25 2 EC17 I2nd Top I 0 2 0 4 I EC05 2 Top 0 02 EC07 2 I2nd 1 8 1 0 04 EC10 Ring width 0 1 Micrometer Replace Top ringis keystone EC17 TOP 2 0 0 01 0 03 2nd 2 0 0 03 0 05 Keystone EC05 2 I 10 5 I 0 006 0 014 I EC07 2 0 008 0 0 16 0 005 0 0 13 0 03 0 03 Reolace Micrometer EC25 2 1...

Page 53: ... between large end and small end bores Twist EC07 2 I 1 1 1 1 EC10 EC25 2 0 1 Holding large end as refer ence measure test bar L 100 inserted in small end Test bar Dial indicator Replace 0 3 Large and smallend I 0 7 2 EC05 2 I Roundness I Max 0 005 I D roundness cylindricity EC05 2 EC05 2 1EC07 2 1 75 I 20 05 I Distance between large end small end bores EC17 Mandrels Micrometer Replace I EC25 2 I ...

Page 54: ...edles Micrometer Replace EC25 2 EC052 Fixed EC07 2 Metering needle unscrew Model BV18 Pilot screw unscrew EC17 I 7 Fixed Meteling needle unscrew Pilot screw unscrew Metering needle unscrew Pilot screw unscrew Model BV21 I Fixed EC25 2 Model BV28 I NGK B 6HS EC07 2 I EClO I NGK 8 4 Spark plug EC17 I NGK B 4 H EC25 2 1 NGK B 6HS EC07 2 Timing tester Spark timing before T D C Adjust EC25 2 I 23 fixed...

Page 55: ...00 ITEM REMARKS CORRECTIONLIMIT Literlhr MODEL EC05 2 3 97 EC25 2 2 33 EC17 1 44 1 14 EC07 2 0 95 Fuel Consumption EC10 up 135Qh rated output Standard consumption At continuous ITEM REMARKS MODEL EC05 2 EC07 2 Engine Oil for 2 cycle engine or SAEBO of high quality Lubricating oil EC25 2 EC17 EClO Mixture Fuel gasoline 25 oil 11 ITEM MODEL STANDARD CORRECTION TOLERANCE REMARKS EC05 2 EC07 2 EClO EC...

Page 56: ...00 I 18 22 EC25 2 QJ P EC05 2 EC07 2 90 1 00 6 5 7 3 G p Cylinder clamp nuts C EC17 180 220 EClO _ 0 13 16 c v1 LL EC25 2 340 400 25 29 B EC05 2 EC07 2 Crankcase clamp bolts 90 100 6 5 7 3 v I EC25 2 200 250 8 Reduction cover clamp bolts EC10 180 220 13 16 EC17 90 100 6 5 7 3 EC17 EClO Crankcase cover clamp bolts 180 220 13 16 EC 25 2 200 250 15 1 8 TOOL Toque wrench REMARKS f 7 52 ...

Page 57: ...evel ingovernor orreductionchamber will fail and add up asnecessary If the engine is operated withoutsufficientoil it 13 2EVERY 50 HOURS IO DAY CHECKS and MAINTENANCE Checks and Maintenance Reasons for requiring them Clean air cleaner Check spark plug If contaminated wash in gasoline Clogged air cleaner harms engine operation difficult or polish with emery paper Output power is reduced and startin...

Page 58: ...N for LONG ABEYANCE 1 Performtheabove 13 1 and 13 2 maintenance jobs 2 Drain fuel from the fuel tank and carburetor float chamber Drain oil from governor or reduction chamber 3 To preventrustin the cylinderbore apply oil throughthesparkplugholeandturnthecrankshaft several turns by hand Re install the spark plug Turn the starting pulley by hand and leave it where the resistanceis the heaviest 4 Cle...

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Robin EC05-2, Service Manual

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