Robin America EX30 Bedienungsanleitung

SERVICE

MANUAL

EX30

ENGINES

Model

PUB-ES2268

Rev. 10/06

940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212

e-mail: [email protected] • www.robinamerica.com

CONTENTS

Section Title Page

1. SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2.PERFORMANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

3. FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS . . . . . . . . . . . . . . . . . 5

5. DISASSEMBLY AND REASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5-1 PREPARATIONS AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5-2 SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11

5-3 DISASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

5-4 REASSEMBLY PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6. ENGINE OIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

7. MAGNETO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

8. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

9. ELECTRIC STARTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

10. OIL SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

11. AUTOMATIC DECOMPRESSION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

12. CARBURETOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

13. RECOIL STARTER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .55

14. INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .59

15. TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .61

16. STANDARD REPAIR TABLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

16-1 STANDARD DIMENSIONS AND LIMITS OF USE . . . . . . . . . . . . . . . . . . . .67

16-2 TIGHTENING TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .73

17. MAINTENANCE AND STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .74

- 1 -

1. SPECIFICATIONS

MODEL EX30D

Type Air-cooled, 4-cycle single cylinder, overhead camshaft, gasoline engine

Displacement mL (cc) 287

Direction of Rotation Counterclockwise, as Viewed from P.T.O. Shaft side

Lubricant Automotive detergent oil (API/ SE or higher grade, SAE/ 10W-30 etc.)

Oil Capacity Liter 1.0

Fuel Automotive Gasoline (Unleaded)

Spark Plug NGK BR-6HS

Starting System Recoil starter /Electric starter

Dry Weight kg 21

Dimensions (L x W x H) mm 415 x 424 x 319

Valve Clearance

(Intake and Exhaust)

0.12 mm (0.0047 in.)

Note : Adjust the valve clearance while the engine is cold.

Emissions Durability Period

(California only) 500 hours

+0.03

+0.0012

- 2 -

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.

2-2 CONTINUOUS RATED OUTPUT

The continuous rated output is the output of an engine at optimum governed speed which is most favorable from

the view point of engin's life and fuel consumption.

When the engine is installed on a certain equipment, it is recommended that the continuous output required from

the equipment to be kept below this continuous rated output.

2-3 MAXIMUM TORQUE

The maximum torque is the torque at the output shaft when the engine is producing maximum output at a

speciﬁc r.p.m..

2.PERFORMANCE

- 3 -

2-4 PERFORMANCE CURVES

2000 2400 2800 3200 3600 4000

0.5

1.0

1.5

2.0

2.5

3.0

3.5

4.0

4.5

5.0

5.5

6.0

6.5

7.0

17.0

18.0

19.0

20.0

[HP]

r.p.m.REVOLUTION

TORQUE

OUTPUT

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

1.7

1.8

1.9

2.0

RECOMMENDED

HORSEPOWER

RANGE

MAXIMUM HORSEPOWER

MAXIMUM TORQUE

CONTINUOUS

RATED HP

- 4 -

3-1 EXTREMELY EASY START - NO KICK-BACK

Reliable Starting and Less Pulling Force are achieved by:

- Sophisticated Mechanical Compression Release System as well as newly designed Combustion Chamber.

- EX engines start instantly even at minus (-) 10°C, without any perceptible kick-back.

3-2 EXTREMELY EASY MAINTENANCE

Extreme ease of maintenance is realized by:

- Only with ordinary tools, routine maintenance, assembly and disassembly can be performed.

3-3 EXTREMELY ADVANCED TECHNOLOGY

Extreme reliability and durability are achieved by:

- Heavy Duty Chain Driven OHC System

Oval type case-hardened steel links enhance performance and resist stretching, which result in extended

maintenance free operation.

- Completely New Main Bearing Cover's Design

Flush-mounted main bearing cover with lower moment of deformation significantly increases reliability and

engine life.

- Superior Cooling and Lubrication System

Heat reduction is achieved by more efﬁcient, larger and more numerous cooling ﬁns on crankcase, cylinder and

mounting base, as well as by outstanding oil delivery system.

- Large Ball Bearings on both ends of crankshaft for maximum stability under demanding loads.

- Cast Iron Cylinder Liner resists wear

3-4 EXTREME POWER AND PERFORMANCE

Extremely Higher Power and Lower Fuel Consumption are realized by:

- High speed and homogeneous combustion achieved by sophisticated Pentroof Combustion Chamber which

includes Intake and Exhaust Valves located at optimum angle.

- Straight Intake Port with minimal air ﬂow resistance.

Environmentally friendly

EX engines comply with EPA Phase 2 and CARB Tier II Emission Regulations in the USA.

Extreme application compatibility

With four versatile models, existing slant-cylinder engines can be easily replaced.

3. FEATURES

- 5 -

4-1 CYLINDER AND CRANKCASE

The cylinder and crankcase are aluminum die-casting

as a single piece. A special cast iron cylinder liner is

molded into the aluminum die-casting.

The crankcase has a mounting surface on the output

shaft side to which the main bearing cover is attached.

The cylinder is inclined to the right at an angle of 25

degrees from the horizontal as viewed from the output

shaft side.

4-2 MAIN BEARING COVER

The main bearing cover is an aluminum die-casting,

which is mounted on the output shaft side of the

crankcase. By removing the main bearing cover, the

inside of the engine can be inspected with ease. Pilots

and bosses are machined into the cover to facilitate the

direct coupling of the engine with machines such as

generators and pumps. There is an oil ﬁlling port, with

oil gauge, on either side of the cover.

4-3 CRANKSHAFT

The crankshaft is made of spheroidal graphite cast

iron, and the crank pin is high-frequency induction-

hardened. The crank sprocket used to drive the chain

and the gear used to drive the governor gear are

pressed into the output end of the shaft.

4-4 CONNECTING ROD AND PISTON

The connecting rod is a specially heat-treated

aluminum alloy die-casting. Its large and small

ends function as bearings. A splasher built into the

connecting rod lubricates by splashing engine oil.

The piston is an aluminum alloy casting with grooves

for mounting two compression rings and one oil ring.

4. GENERAL DESCRIPTION OF ENGINE COMPONENTS

- 6 -

4-5 PISTON RINGS

The piston rings are made of special cast iron. The proﬁle of the top ring is a barrel face or tapered face, and that of

the second ring is a tapered face. There are 2 types of oil ring depending on the engine speciﬁcation.

As those are interchangeable, the cutter ring with coil expander type can be selected as the spare part.

TOP

RING

OIL

RING

BARREL

THREE-PIECE

CONSTRUCTION

4-6 CAMSHAFT

The camshaft and the sprocket are made of special

sintered alloy. They are constructed as a single piece.

The camshaft is provided with intake and exhaust

cam, and the decompression release lever is mounted

on the sprocket shaft end side.

4-7 VALVE ARRANGEMENT

This engine has a chain-driven overhead cam and

overhead valve construction, with a single cam

performing both intake and exhaust operations.

4-8 CYLINDER HEAD

The cylinder head is an aluminum die-casting with

a pent roof combustion chamber construction. The

intake and exhaust ports are arranged in a cross

direction to improve combustion efﬁciency.

DECOMPRESSION

RELEASE

LEVER

EXHAUST VALVE INTAKE VALVE

- 7 -

4-9 GOVERNOR SYSTEM

This engine is equipped with a centrifugal flyweight

type governor that makes it possible to operate the

engine at a constant speed, even with load variations.

(The governor ﬂyweights are mounted on a governor

gear.)

GOVERNOR GEAR

4-10 COOLING SYSTEM

The engine uses a forced air-cooling system in which a cooling fan (which also works as a flywheel) forces

cooling air into the cylinder and the cylinder head. Bafﬂes are provided to guide the ﬂow of the cooling air.

4-11 LUBRICATION SYSTEM

The rotating parts, sliding parts and valves of the

engine are lubricated with oil in the crankcase. The oil

is splashed onto the parts by the oil splasher on the

connecting rod.

4-12 TIMING CHAIN

Timing chain system is adopted and designed for

lubricating for the upper portion of cylinder head.

The timing chain is engaged between the sprocket

portion of integrated camshaft in the cylinder head and

the crankshaft gear sprocket.

The sprocket teeth in particular shape are adopted to

enhance the durability and to realize low noise level.

4-13 IGNITION SYSTEM

The ignition system is a transistor controlled magneto

system with the ignition timing set at 23 degrees

before the top dead center. The magneto consists of

a ﬂywheel and ignition coil. The ﬂywheel (which also

works as a fan) is directly mounted on the crankshaft

and the ignition coil is directly mounted on the

crankcase.

※

Model EX30 has a smooth advanced ignition timing

system to improve starting performance.

(For further details, refer to page 43, section

"7. MAGNETO")

OIL SPLASHER

TIMING CHAIN

FLYWHEEL

IGNITION COIL

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