Robin EH63, EH64, EH65 Service Manual
SERVICE
MANUAL
Model
EH65
Engine
PUB-ES1113
Rev. 8/98
940 Lively Blvd. Wood Dale, IL 60191 Phone: 630-350-8200 Fax: 630-350-8212
e-mail: sales@robinamerica.com • www.robinamerica.com
© Copyright 1998 Robin America, Inc.
EH65 '98 - 8
CONTENTS
Section Title Page
1. SPECIFICATIONS.......................................................................................................1
2. PERFORMANCE ........................................................................................................2
2-1 MAXIMUM OUTPUT ......................................................................................................... 2
2-2 CONTINUOUS RATED OUTPUT ..................................................................................... 2
2-3 MAXIMUM TORQUE ........................................................................................................ 2
2-4 PERFORMANCE CURVES .............................................................................................. 3
3. FEATURES..................................................................................................................6
4. GENERAL DESCRIPTION OF ENGINE COMPONENTS .......................................... 7
4-1 CYLINDER AND CRANKCASE........................................................................................ 7
4-2 MAIN BEARING COVER .................................................................................................. 7
4-3 CRANKSHAFT..................................................................................................................7
4-4 CONNECTING ROD AND PISTON .................................................................................. 8
4-5 PISTON RINGS ................................................................................................................8
4-6 CAMSHAFT ...................................................................................................................... 8
4-7 CYLINDER HEAD............................................................................................................. 9
4-8 VALVE ARRANGEMENT .................................................................................................. 9
4-9 GOVERNOR SYSTEM ..................................................................................................... 9
4-10 COOLING SYSTEM...................................................................................................... 10
4-11 LUBRICATION SYSTEM............................................................................................... 10
4-12 IGNITION SYSTEM ...................................................................................................... 10
4-13 CHARGING SYSTEM ................................................................................................... 10
4-14 CARBURETOR ..............................................................................................................11
4-15 AIR CLEANER ...............................................................................................................11
4-16 FUEL PUMP...................................................................................................................11
4-17 SECTIONAL VIEW OF ENGINE................................................................................... 12
5. DISASSEMBLY AND REASSEMBLY....................................................................... 14
5-1 PREPARATIONS AND SUGGESTIONS......................................................................... 14
5-2 SPECIAL TOOLS............................................................................................................ 14
5-3 DISASSEMBLY PROCEDURES..................................................................................... 15
5-4 REASSEMBLY PROCEDURES...................................................................................... 30
5-5 BREAK-IN OPERATION................................................................................................. 43
6. MAGNETO ................................................................................................................ 44
6-1 OPERATION AND FUNCTION ....................................................................................... 44
Section Title Page
7. LUBRICATION SYSTEM ......................................................................................... 46
7-1 OPERATION AND FUNCTION .......................................................................................46
8. CARBURETOR ........................................................................................................ 47
8-1 OPERATION AND FUNCTION .......................................................................................47
8-2 COMPORNENT PARTS .................................................................................................49
9. ELECTRIC STARTER .............................................................................................. 50
9-1 OPERATION AND FUNCTION .......................................................................................50
9-2 COMPORNENT PARTS .................................................................................................51
10. TROUBLESHOOTING ........................................................................................... 52
10-1. NO ENGINE OPERATION ...........................................................................................52
10-2. STARTING DIFFICULTIES .........................................................................................53
10-3. INSUFFICIENT OUTPUT.............................................................................................54
10-4. OVERHEAT..................................................................................................................54
10-5. ROUGH IDLING...........................................................................................................55
10-6. HIGH ENGINE OIL CONSUMPTION...........................................................................55
10-7. HIGH FUEL CONSUMPTION ......................................................................................56
10-8. DETONATION..............................................................................................................56
10-9. ENGINE MISFIRE........................................................................................................57
11. INSTALLATION ..................................................................................................... 58
11-1 INSTALLING..................................................................................................................58
11-2 VENTILATION...............................................................................................................58
11-3 EXHAUST GAS DISCHARGE ......................................................................................58
11-4 POWER TRANSMISSION TO DRIVEN MACHINES ....................................................58
12. SERVICE DATA...................................................................................................... 59
12-1 CLEARANCE DATA AND LIMITS.................................................................................59
12-2 TORQUE SPECIFICATIONS ........................................................................................65
12-3 OIL GRADE CHART .....................................................................................................66
13. MAINTENANCE AND STORAGE.......................................................................... 67
13-1 DAILY MAINTENANCE .................................................................................................67
13-2 PERIODIC MAINTENANCE SCHEDULE.....................................................................67
13-3 ENGINE STORAGE......................................................................................................69
1. SPECIFICATIONS
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Specifications are subject to change without notice.
- 1 -
2. PERFORMANCE
2-1 MAXIMUM OUTPUT
The maximum output is the output of an engine with its throttle valve fully opened under the condition that
all the moving parts are properly worn in after the initial break-in period.
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 to 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 engine's life and fuel consumption.
When the engine is installed on a certain equipment, it is recommended that the continuous output
required from the engine 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
certain revolution.
- 2 -
2-4 PERFORMANCE CURVES
EH63D
45 (4.59
N-m
(
)
kgf-m
)
kW
(HP)
15
(
20.1
10
(
13.4
35 (3.57
MAXIMUM TORQUE
MAXIMUM HORSEPOWER
)
)
CONTINUOUS
RATED HP
)
TORQUE
HORSEPOWER
5
(
)
6.7
2000 2400 2800 3200 3600
RECOMMENDED
HORSEPOWER RANGE
REVOLUTION r.p.m
- 3 -
EH64D
45 (4.59
N-m
(
kgf-m
)
)
kW
(HP)
15
(
20.1
10
(
13.4
35 (3.57
MAXIMUM TORQUE
MAXIMUM HORSEPOWER
)
CONTINUOUS
RATED HP
)
)
TORQUE
HORSEPOWER
5
(
)
6.7
2000 2400 2800 3200 3600
RECOMMENDED
HORSEPOWER RANGE
REVOLUTION r.p.m
- 4 -
EH65D
45 (4.59
N-m
(
)
kgf-m
)
kW
(HP)
15
(
20.1
10
(
13.4
35 (3.57
MAXIMUM TORQUE
MAXIMUM HORSEPOWER
)
CONTINUOUS
RATED HP
)
)
TORQUE
HORSEPOWER
5
(
)
6.7
2000 2400 2800 3200 3600
RECOMMENDED
HORSEPOWER RANGE
REVOLUTION r.p.m
- 5 -
3. FEATURES
The overhead valve arrangement is adopted for ensuring high power, low fuel consumption and low oil
consumption.
The adoption of twin-cylinder in the angle of 90 degree (V arrangement) and crankcase in one piece,
plastic blower housing etc. offers a compactness and light weight, making the arrangements for installing
the engine much easier into many kinds of power equipments.
The forged steel crankshaft and high loading capacity ball bearing offer high durability, and full pressure
lubrication system with trochoid type oil pump and large capacity air cleaner with dual elements enhance
the reliability.
The effective combustion chamber shape and the precisely tuned intake and exhaust valve system
enhance the low exhaust emission and ensure the engine characteristics of high torque at low speed.
The carburetor with fuel cut valve, 12V-15A alternator and pulse type fuel pump are employed as standard features so that the engine can be utilized for many usage.
- 6 -
4. GENERAL DESCRIPTION OF ENGINE COMPONENTS
ROBIN EH63D/ 64D/ 65D series engine is air-cooled, 4-stroke, twin-cylinder, OHV arrangement gasoline engine. The twin-cylinder is located in the angle of 90 degree; #1 cylinder is in the RH side and #2
cylinder in LH side as viewed from flywheel (cooling fan) side.
4-1 CYLINDER AND CRANKCASE
The twin-cylinder and crankcase is single piece
aluminum die-casting.
The cylinder liner, made of special cast iron, is
molded into the aluminum casting.
The crankcase has a mounting surface on the output shaft side, where the main bearing cover is
attached.
Fig. 4-1
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.
Pilots and bosses are machined on the cover for
direct mounting of the engine onto such machines
as generators and pumps.
It is easy to inspect inside of the engine, after removing the main bearing cover.
4-3 CRANKSHAFT
The crankshaft is forged carbon steel, and the
crank pin is induction-hardened.
The output end of the shaft has a crankshaft gear
pressed into position.
Engine oil passages are provided onto the journal and pin portions of crankshaft for lubrication.
Fig. 4-2
- 7 -
Fig. 4-3
4-4 CONNECTING ROD AND PISTON
The connecting rod is forged aluminum alloy, and
its large and small ends function as bearings.
The piston is an aluminum alloy casting, and carries two compression rings and one oil ring.
Fig. 4-4
4-5 PISTON RINGS
The piston rings are made of special cast iron.
The profile of the top ring is barrel face and the second ring has a tapered face.
The oil ring is designed for better sealing and less oil consumption, in combination with 3 pieces.
1
TOP
1
2
RING
BARREL
4-6 CAMSHAFT
The camshaft is made of special cast iron and
camshaft gears are casted together in one piece.
Each 2 cam robs are provided for intake and exhaust valves correspondingly.
Both sides of the shaft fit into the plane bearings
on the crankcase and main bearing cover.
3
Fig. 4-5
2
3
SECOND
RING
OIL
RING
TAPER
COMBINATION
RING
- 8 -
Fig. 4-6
4-7 CYLINDER HEAD
The cylinder head is an aluminum die-casting
which utilizes semi-spherical type combustion
chamber for the high combustion efficiency.
4-8 VALVE ARRANGEMENT
The intake valve is located on flywheel side of the
cylinder head.
The cooling fins and passages design lead cooling air to the exhaust valve area for the optimum
cooling.
Fig. 4-7
Hard alloy valve seats are molded in the cylinder
head and stellite is fused to the exhaust valve face.
4-9 GOVERNOR SYSTEM
The governor is a centrifugal flyweight type which
ensures constant operation at the selected speed
against load variations.
The governor gear with governor weights is installed inside of main bearing cover and driven
by the crankshaft.
INTAKE VALVE EXHAUST VALVE
Fig. 4-8
GOVERNOR
GEAR
- 9 -
Fig. 4-9
4-10 COOLING SYSTEM
The large fins on the flywheel provide sufficient
cooling air capacity for cylinder and cylinder head.
The cylinder baffle helps the cooling air flow efficiently.
4-11 LUBRICATION SYSTEM
The engine is furnished with full pressure lubrication system.
The trochoid type oil pump is driven by crankshaft
and delivers pressurized engine oil through the
full-flow type oil filter to the journal and pin portions of crankshaft and camshaft.
4-12 IGNITION SYSTEM
The ignition system is a transistor controlled magneto ignition system which consists of a flywheel
and an ignition coil with a built-in transistor installed
onto the crankcase.
IGNITION COIL
4-13 CHARGING SYSTEM
Multipolar charging coil is provided inside of flywheel. Charging capacity is 12V-15A.
FLYWHEEL
Fig. 4-10
Fig. 4-11
-
10
-
4-14 CARBURETOR
The engines are equipped with a down draft carburetor that has a float controlled fuel system and
a fixed main jet.
The carburetors are calibrated carefully for the
sure starting, good acceleration, low fuel consumption and sufficient output.
Fuel cut solenoid valve is provided to prevent engine running on when the key switch is turned to
off.
4-15 AIR CLEANER
The air-cleaner is a heavy-duty type with a dual
element system; primary side is urethane form
(half-wet) and secondary side is dry type.
Fig. 4-12
CLEANER COVER
WING NUT
4-16 FUEL PUMP
The engines are equipped with a diaphragm type
fuel pump which is operated by the crankcase inside vacuum pressure.
ELEMENT
URETHANE FOAM
Fig. 4-13
FUEL PUMP
Fig. 4-14
-
11
-
4-17 SECTIONAL VIEW OF ENGINE
CARBURETOR
INTAKE MANIFOLD
IGNITION COIL
OIL PUMP
FLYWHEEL
P.T.O.SHAFT
MAIN BEARING COVER
OIL PUMP FILTER
Fig. 4-15
-
12
-
AIR CLEANER
GOVERNOR LEVER
ROCKER ARM
INTAKE AND
EXHAUST VALVES
SPARK PLUG
TAPPET
GOVERNOR GEAR
ELECTRIC STARTER
PUSH ROD
CAMSHAFT
FUEL PUMP
PISTON RING
OIL FILTER
PISTON
OIL PRESSURE
PISTON PIN
CRANKCASE CRANKSHAFT CONNECTING ROD
Fig. 4-16
-
13
-
SWITCH
5. DISASSEMBLY AND REASSEMBLY
5-1 PREPARATIONS AND SUGGESTIONS
When disassembling the engine, memorize the locations of individual parts so that they can be reassembled correctly . If you are uncertain of identifying some parts, it is suggested that tags be attached to
them.
Have boxes ready to keep disassembled parts by group.
To prevent losing and misplacing, temporarily assemble each group of disassembled parts.
Carefully handle disassembled parts, and clean them with washing oil if necessary.
Use the correct tools in the correct way.
5-2 SPECIAL TOOLS
No Special Tool is needed for disassembling and reassembling the engine.
For pulling off the flywheel, universal type puller being popular in the market place as shown in the
illustration is needed.
FLYWHEEL PULLER
Fig. 5-1
-
14
-
5-3 DISASSEMBLY PROCEDURES
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1
OIL FILLER CAP
GASKET
OIL LEVEL GAUGE
.esacknarcfoedishtobnodetacol
Fig. 5-2
-
15
GASKET
-
OIL DRAIN PLUG
(
ON BOTH SIDE
STEP 1
)
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2
3esabrenaelcriA
BREATHER
PIPE
Fig. 5-4
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FLANGE BOLT
(
) :
Inch
3 pcs.
STEP 3
;mm11x23-01
.daehrednilyc
.scp3
WING NUT
CLEANER
COVER
STEP 2
CLEANER
ELEMENT
Fig. 5-3
-
16
CLEANER BASE
-
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5knildnarevellortnockcohC 6M
CHOKE
CONTROL ROD
RETURN
SPRING
STEP 5
LINK PIVOT
WAVED
WASHER
CHOKE
CONTROL
LINK
M5 TAPPING
SCREW : 1 pce.
CLAMP
CHOKE
KNOB
BLOWER HOUSING
STEP 4
Fig. 5-5
-
17
M6 FLANGE
BOLT : 8 pcs
-
petSevomerotstraPserudecorpdnaskrameRsrenetsaF
6
M8 FLANGE
BOLT : 2 pcs.
CARBURETOR
GASKET, carburetor
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FUEL PIPE
Fig. 5-7
STEP 6
Fig. 5-6
-
18
-
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7
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etalppotS.3
rehsawgnirpS.4
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M6 SELF LOCK
NUT : 1 pce.
STOP PLATE
SPRING WASHER
FRICTION
WASHER
SPEED CONTROL
LEVER
FRICTION
WASHER
M6 FLANGE
BOLT : 3 pcs.
M6 NUT : 1 pce.
M6 BOLT
AND WASHER : 1 pce.
STEP 7
ROD
SPRING
GOVERNOR
LEVER
GOVERNOR
ROD
GOVERNOR
SPRING
scp3;21X6M
tunkcol-fles6M
STEP 8
BRACKET UNIT,
speed control
Fig. 5-8
-
19
-
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