Robin EH63V, EH65V Service Manual
CONTENTS
Section
Tifle
Page
1
.
SPECIFICATIONS
.......................................................................................................
1
2
.
PERFORMANCE
........................................................................................................
2
2-1
MAXIMUM OUTPUT
.........................................................................................................
2
2-2
MAXIMUM TORQUE
........................................................................................................
2
2-3
PERFORMANCE CURVES
..............................................................................................
3
3
.
FEATURES
..................................................................................................................
5
4
.
GENERAL DESCRIPTION
OF
ENGINE COMPONENTS
..........................................
6
4-1
CYLINDER AND CRANKCASE
........................................................................................
6
4-2
MAIN
BEARING
COVER
..................................................................................................
6
4-3
CRANKSHAFT
..................................................................................................................
6
4-4
CONNECTING
ROD
AND PISTON
..................................................................................
7
4-5
PISTON RINGS
................................................................................................................
7
4-6
CAMSHAFT
......................................................................................................................
7
4-7
CYLINDER HEAD
.............................................................................................................
8
4-8
VALVE ARRANGEMENT
..................................................................................................
8
4-9
GOVERNOR SYSTEM
.....................................................................................................
8
4-1 0 COOLING SYSTEM
........................................................................................................
9
4-11
LUBRICATION SYSTEM
.................................................................................................
9
4-12
IGNITION SYSTEM
........................................................................................................
9
4-1
3 CHARGING SYSTEM
.....................................................................................................
9
4-14
CARBUREJOR
.............................................................................................................
10
4-1 5 AIR CLEANER
..
..........................!.................................................................................
10
4-1 6 FUEL PUMP
..................................................................................................................
10
4-17
SECTIONAL
VIEW
OF
ENGINE
....................................................................................
11
5
.
DISASSEMBLY
AND
REASSEMBLY
.......................................................................
13
5-1
PREPARATIONS AND SUGGESTIONS
.........................................................................
13
5-2
SPECIAL
TOOLS
............................................................................................................
13
5-3 DISASSEMBLY PROCEDURES
.....................................................................................
14
5-4 REASSEMBLY PROCEDURES
.............
........................................................................
27
5-5
BREAK-IN OPERATION
.................................................................................................
43
6
.
MAGNETO
................................................................................................................
44
6-1
OPERATION
AND
FUNCTION
.......................................................................................
44
7
.
LUBRICATION
SYSTEM
..........................................................................................
46
7-1
OPERATION AND FUNCTION
.......................................................................................
46
Section
8
.
CARBURETOR
8-1
OPERATION AND FUNCTION
8-2
COMPORNENT PARTS
9
.
ELECTRIC STARTER
9-1
OPERATION
9-2
COMPORNENT PARTS
Title
........................................................................................................
.......................................................................................
.................................................................................................
..............................................................................................
AND
FUNCTION
.................................................................................................
.......................................................................................
Page
47
47
49
50
50
51
10 . TROUBLESHOOTING
10-1
.
NO
ENGINE OPERATION
10-2 . STARTING DIFFICULTIES
10-3
.
INSUFFICIENT OUTPUT
10-4
.
OVERHEAT
10-5
.
ROUGH IDLING
10-6
.
HIGH ENGINE OIL CONSUMPTION
10-7
.
HIGH FUEL CONSUMPTION
10-8
.
DETONATION
10-9
.
ENGINE MISFIRE
11
.
INSTALLATION
11-1
INSTALLING
11 -2
VENTlLATlON
11
-3
EXHAUST GAS DISCHARGE
11-4
POWER
12
.
SERVICE
12-1
CLEARANCE DATA AND LIMITS
12-2
TORQUE SPECIFICATIONS
12-3
OIL GRADE CHART
..................................................................................................................
...........................................................................................................
..............................................................................................................
........................................................................................................
......................................................................................................
..................................................................................................................
...............................................................................................................
TRANSMISSION TO DRIVEN MACHINES
DATA
...................................................................................................... 59
...........................................................................................
...........................................................................................
.........................................................................................
.............................................................................................
...........................................................................
......................................................................................
......................................................................................
....................................................
.................................................................................
........................................................................................
.....................................................................................................
52
52
53
54
54
55
55
56
56
57
58
58
58
58
58
59
65
66
A
13
.
MAINTENANCE AND STORAGE
13-1 DAILY MAINTENANCE
13-2 PERIODIC MAINTENANCE SCHEDULE
13-3
ENGINE STORAGE
.................................................................................................
......................................................................................................
..........................................................................
.....................................................................
67
67
67
69
1
SPECIFICATIONS
MODEL
Type
Bore
x
Stroke
Piston Displacement
Compression Ratio
Maximum Output
Max.
Torque
Direction of Rotation
Cooling system
Valve Arrangement
Lubrication
Lubricant
Capacity of Lubricant
Caburetor
Fuel
Fuel Feed System
Ignition System
Spark Plug
Charging Capacrty
Starting System
Governor System
Air Cleaner
Dry
Weight
Dimensions (L
x
W
x
H)
-
EH63V
Vertical P.T.O. Shaft, OHV Gasoline Engine
Air-Cooled, 4-Cycle, V-Twin Cylinder,
EH65V
2-80 mm x 65
mm (3.15 x 2.56 in.)
653 cm3
(39.8
cu.in.)
Overhead Valve
(OHV)
Forced Air Cooling
Counterclockwise
as
viewed from P.T.O. shaft side
45.6 N.rn(4.65 kgf m)
/2500
r.p.m.
43.3 N.rn(4.41 kgf
-
m)
/2000
r.p.m.
16.4
kW
(22.0
HP) /3600 r.p.m. 13.4
kW
(18.0 HP) /3600 r.p.m.
8.3
Forced Lubrication
with
Trochoid Pump
Automobile Engine Oil
SAE
#20,
#30 or 1OW-30
;
Class
SE or higher
2.0
liters (0.53
U.S.
gal.)
Horizontal Draft, Float
Type
Automobile Unleaded Gasoline
Diaphragm Pump
Flywheel Magneto (Solid State)
NGK
BP6ES
12V-15A
Electric Starter
Centrifugal Flyweight Type
Double Element Type
44.0
kg
(97.0
Ib.)
475 mm x 469 mm x 353 mm
(18.7
in.
x
18.5
in.
x
13.9 in.)
Specifications
are
subject
to
change
without notice.
-
1-
2.
PERFORMANCE
2-1
MAXIMUM OUTPUT
The maximum output is the output
all the moving parts are properly broken in after the initial break-in period.
A
new engine may not produce full maximum output while its moving parts are still
NOTE
Power curves shown in the following charts are made in conformity with
standard test code
2-2
The maximum torque
certain revolution.
:
J1349
MAXIMUM TORQUE
is
the torque at the output shaft when the engine is producing maximum output at
of
a
.n engine with its throttle valve fully open
SAE
led under the c mdition that
not
broken-in.
internal combustion engine
-
2-
2-3
PERFORMANCE CURVES
EH63V
15
(20.1
1
t
10
(1
3.4)
5
(6.7)
MAXIMUM TORQUE
.I
I
MAXIMUM
HORSEPOWER
-
I
t
I
N-m
(kgf-m)
45
(4.59)
t
35
(3.57)
2000
2400
2800
3200
3600
SPEED
-
r.p.m
-
3-
EH65V
X
/1
/MAXIMUM
TORQUE
35
(3.57)
N-m
W
3
0
K
0
F
15
(20.1
10
(1
3.4)
MAXIMUM
\I
HORSEPOWER
I
I
I
I
/"
5
(6.7)
2000
2400
SPEED
2800 3200
-
-
r.p.m
4-
3600
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 for various powered equipments.
The forged steel crankshaft and high loading direct supporting aluminum 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 stan-
dard features
so
that the engine can be utilized for many usage.
-
5-
4.
GENERAL DESCRIPTION
OF
ENGINE
COMPONENTS
/"
ROBIN
gine. The twin-cylinder is located in the angle
in
4-1
CYLINDER
The twin-cylinder and crankcase is single piece
aluminum die-casting.
The cylinder liner, made
molded into the aluminum casting.
The crankcase has a mounting surface on the out-
put shaft side, where the main bearing cover is
attached.
4-2
MAIN
EH63V/
LH
side as viewed from flywheel (cooling fan) side.
BEARING
65V
AND
series engine is air-cooled, 4-stroke, twin-cylinder,
CRANKCASE
of
special cast iron,
COVER
of
90 degree;
is
#I
cylinder is in the
OHV
arrangement gasoline en-
RH
side and
Fig.
4-1
#2
cylinder
The main bearing cover is an aluminum die-casting, which
the crankcase.
It
is
easy to inspect inside
moving the main bearing cover.
4-3
CRANKSHAR
The crankshaft is
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 jour-
nal and pin
is
mounted on the output shaft side
of
the engine, after re-
forged
portions
carbon
of
crankshaft
steel, and the
for
lubrication.
of
Fig.
4-2
-
6-
I
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 car-
ries
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.
TOP
@
RING
BARREL
@
TAPER
RING
@
RING
RING
OIL
COMBINATION
Fig.
4-5
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 ex-
haust valves correspondingly.
Both sides of the shaft
fit
into the plane bearings
on the crankcase and main bearing cover.
Fig.
4-6
-
7-
4-7
CYLINDER
HEAD
The cylinder head
is
an aluminum die-casting
which utilizes semi-spherical type combustion
chamber
4-8
VALVE ARRANGEMENT
The intake valve is located on flywheel side
for
the high combustion efficiency.
of
cylinder head.
The cooling fins and passages design
lead
cooling air to the exhaust valve area for the optimum
cooling.
Hard
alloy
valve
seats
head and stellite is fused
are molded in the cylinder
to
the
exhaust valve face.
the
Fig.
f'
4-7
,A
4-9
GOVERNOR
The
governor is a centrifugal flyweight type which
SYSTEM
ensures constant operation at the selected speed
against load variations.
The
governor gear with governor weights is
stalled inside
by
the crankshaft.
of
main bearing cover and driven
in-
EXHAUST
VALVE
Fig.
Fig.
4-8
4-9
INTAKE
VALVE
-
8-
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 effi-
ciently.
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.
4-1 2 IGNITION SYSTEM
The ignition system
is
a transistor controlled mag-
neto system which consists of
a
flywheel and
an
ignition coil with a built-in transistor installed onto
the crankcase.
This system
has
an automatic ignition timing ad-
vance characteristic for easy starting.
1
Fig.
4-10
4-13 CHARGING SYSTEM
Multipolar charging coil is provided inside of flywheel. Charging capactty
is
12V-15A.
Fig.
4-71
-
9-
4-14
CARBURETOR
The engine is equipped with a horizontal draft
buretor that
a fixed main jet.
The
carburetors are calibrated carefully for sure
starting, good acceleration,
and sufficient output.
Fuel
cut solenoid valve is provided
gine running on
Off
-
4-15
AIR
Air-cleaner is a heavy-duty
ment system
(semi-wet) and secondary one
per element.
has
a
float
when
CLEANER
;
the primary one is an urethane foam
controlled
the
key switch is turned to
fuel
system and
less
fuel consumption
to
prevent en-
type
with a dual ele-
is
a
dry
type
car-
pa-
CLEANER
COVER
WING NUT
4-16
FUEL
The engine is equipped with a diaphragm type
fuel pump which is operated
side vacuum pressure.
PUMP
by
the crankcase
in-
URETHANE
FUEL
FOAM
Fig.
4-13
INLET
Fig.
4-14
FUEL
FILTER
-
10-
4-17
SECTIONAL
VIEW
OF
ENGINE
/
oti
PUMP
CRANKSHAFT
Fig.
4-15
\
CAMSHAFT
-
11
-
CRANKSHAFT
OIL
PRESSURE
SWITCH
FUEL PUMP
PISTON
CARBURETOR
ROCKER COVER
RING
ELECTRIC
STARTER HEAD EXHAUST VALVES
SPARK
PLUG
Fig.
-
12
CYLINDER
4-16
-
INTAKE
AND
5.
DISASSEMBLY AND REASSEMBLY
5-1
PREPARATIONS
AND
SUGGESTIONS
When disassembling the engine, memorize the locations of individual parts
so
that they can be reas-
sembled 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
-
13-
5-3
DISASSEMBLY PROCEDURES
to
Step
Parts
remove
Remarks and procedures
Fasteners
w
,"-.
1
OIL
Engine
DRAIN
oil
drain
Drain
engine
located
on
oil
both
by
removing
sides
plugs
of
crankcase.
Fig.
-
5-2
14-
Step
Fasteners
Remarks and procedures
Parts
to
remove
2
Air
cleaner cover and elements
Remove breather
pipe
from
#1
M6
nut
;
2
pcs.
cylinder head.
3
Air
cleaner base
CLEANER
COVER
BREATHER
PIPE
Fig.
5-4
CLEANER BASE
GASKET,
cleaner
/-
/””“
”_
Fig.
5-3
15
-
I
1 4 I
I
I
Fuel pump bracket
Parts
to remove
I
I
I
Remove
I
Remarks
pulse
and
pipe
procedures
and
fuel pipe.
I
I
I
M6x14
M6x28
Fasteners
;
1
pce.
;
1
pce.
1
1
I
/1
5
Rotating screen and
Blower housing
-/
M4
SCREW
AND
WASHER
M4x20
M6x14
:
4
pcs.
;
4 pcs.
;
6
pcs.
PULSE
I”’
Fig.
5-5
-
16-
PIPE
4
RT
U
FUEL
I
FILTER
Step
Fasteners
Remarks
and
procedures
Parts
to
remove
Carburetor
governor rod, rod spring and
choke
6
Take
out
carburetor along
with
control
rod.
Governor lever and speed
control bracket
INSULATOR
@
SPACER
M6
NUT
:
1
pce.
\
GOVERNOR
M5 BOLT AND
WASHER
:
1
pce.
CHOKE LEVER
\
FLANGE BOLT
CHOKE
CONTROL
:
1
pce.
!
ROD
LE
M5 BOLT AND
WASHER
:
1
pce.
RETURN SPRlN
I
ROD SPRING
/
I
I
L.
\
SPEED CONTROL LEVER
M6
FLANGE NUT : 1
pce.
i
3
BRACKET,
speed
control
/
M5 NUT
:1
pce.
-.J
'P
\
M5B0LT
1
:
1
pce.
M6 FLANGE
BOLT
:
1
pce.
'.
7%
I
.
GOVERNOR SPRING
M5
NUT
:1
pce.
/
GOVERNOR
ROD
M5 BOLT
:
1
pce.
I
-
17-
Step
8
9
10
1
Ignition cojl
I
Intake manifold
Parts
I
Flywheel
to
remove
I
I
Remarks
1.
Take out plug
2.
Remove ignition coil.
3.
Cut out stop
4.
Disconnect
coil.
Remove flywheel from crankshaft
using
puller.
and
wire
stop
M6
BOLT
WASHER
procedures
cap.
fixing bands.
wires
from ignition
AND
:
4
pcs.
by
I
Fasteners
M6x30
washer
M8
flange nut
I
4pcs.
I
MI
8
spring
SPRING
bolt
&
;
4
pcs.
;
nut, washer,
washer
WASHER
I
/?
Fig-
58
M6
BOLT
AND
BLOWER UNIT
M6
BOLT AND
WASHER
IGNITION COIL
:
2
pcs.
.-
SPARK PLUG
Fig.
CAP-
5-7
gd-1'
-
18-
Fig.
5-9
I
I
I
I
Step
Fasteners
Remarks and procedures
Parts
to
remove
M6x18 ; 2
pcs.
11
Regulator
Cylinder
baffles
(#1,
#2,
#3,
#4)
M6x12
; 6 pcs.
to
IGNITION
COIL
to
IGNITION COIL
-
FLANGE BOLT
:
4
pcs.
CYLINDER BAFFLE
5
FLANGE
BOLT
:
2
pcs.
CYLINDER BAFFLE
1
Fig-
5-10
-
19-
Step
Parts
to
remove
Remarks and
procedures
Fasteners
13
14
15
Electric
Charge
Spark
starter
coil
plug
NGK
:
BPGES
or
BPRGES
M8x65
M5x20;4pcs.
;
2
pcs.
Fig.
-
5-
1
I
20-
I
SPARK
PLUG
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