Robin EH63, EH64, EH65 Service Manual

SERVICE MANUAL

Model

EH65

Engine

PUB-ES1113

Rev. 8/98

940 Lively Blvd. • Wood Dale, IL 60191 • Phone: [phone] • Fax: [phone]

e-mail: [e-mail] • 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

	MODEL	EH63D		EH64D		EH65D
	Type	Air-Cooled, 4-Stroke, V-Twin Cylinder,
		Horizontal P.T.O. shaft, OHV Gasoline Engine
	Bore x stroke	2 - 3.15 in x 2.56 in (80 mm x 65 mm)
	Displacement			39.9 cu. in. (653 cm3)
	Compression Ratio		8.3
	Continuos output	10.8 (14.5) / 3,600		11.9 (16.0) / 3,600		13.4 (17.0) / 3,600
	kW (HP) / rpm
	Maximum output	13.4 (18.0) / 3,600		15.3 (20.5) / 3,600		16.4 (22.0) / 3,600
	kW (HP) / rpm
	Max. Torque N-m (kgf-m) / rpm	43.3 (4.41) / 2,000		44.3 (4.52) / 2,200		45.6 (4.65) / 2,500
	Direction of Rotation	Counterclockwise as viewed from P.T.O. shaft side
	Cooling System			Forced Air Cooling
	Valve Arrangements			Overhead Valve (OHV)
	Lubrication	Full presure type with Trochoid Pump
	Lubricant	Automobile Engine Oil SAE #20, #30 or 10W-30 ;
				Class SE or higher
	Capacity of Lubricant			52.48 oz. (1.55 Liters)
	Carburetor	Horizontal Shaft, Float Type
	Fuel	Automobile Unleaded Gasoline
	Fuel Feed System	Diaphragm Pump (Pulse type)
	Ignition System	Flywheel Magneto (Solid State)
	Spark Plug	NGKBP6ES (Champion - N9YC)
	Charging Capacity			12 V - 15 A
	Starting System			Electric Starter
	Governor System		Centrifugal Flyweight Type
	Air Cleaner			Double Element Type
	Dry Weight			97.0 lb. (44 kg)
	Dimension (L x W x H)	12.5 in x 18.8 in x 18.7 in (317 mm x 477 mm x 475 mm)

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
						N-m
					45 (4.59)	(kgf-m)
					35 (3.57)	TORQUE
		MAXIMUM TORQUE
	15	MAXIMUM HORSEPOWER
	(20.1)
kW
(HP)
HORSEPOWER	10				CONTINUOUS
	(13.4)
					RATED HP
					RECOMMENDED
					HORSEPOWER RANGE
	5
	(6.7)
	2000	2400	2800	3200	3600
		REVOLUTION			r.p.m
				- 3 -

EH64D
							N-m
					45 (4.59)		(kgf-m)
					35	(3.57)	TORQUE
			MAXIMUM TORQUE
		MAXIMUM HORSEPOWER
	15
	(20.1)
kW
(HP)
					CONTINUOUS
HORSEPOWER	10				RATED HP
	(13.4)
					RECOMMENDED
					HORSEPOWER RANGE
	5
	(6.7)
	2000	2400	2800	3200	3600
		REVOLUTION			r.p.m
				- 4 -

EH65D
							N-m
						45 (4.59)	(kgf-m)
						35 (3.57)	TORQUE
			MAXIMUM TORQUE
		MAXIMUM HORSEPOWER
	15
	(20.1)
kW
(HP)						CONTINUOUS
						RATED HP
HORSEPOWER	10
	(13.4)
						RECOMMENDED
						HORSEPOWER RANGE
	5
	(6.7)
	2000	2400	2800	3200	3600
		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-cast- ing, 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.

Fig. 4-2

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. 4-3

- 7 -

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
		1	TOP	BARREL
			RING
	2
	3	2	SECOND	TAPER
			RING
		3	OIL	COMBINATION
			RING	RING
		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 exhaust valves correspondingly.

Both sides of the shaft fit into the plane bearings on the crankcase and main bearing cover.

Fig. 4-6

- 8 -

4-7 CYLINDER HEAD

The cylinder head is an aluminum die-casting which utilizes semi-spherical type combustion chamber for the high combustion efficiency.

Fig. 4-7

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.

Hard alloy valve seats are molded in the cylinder head and stellite is fused to the exhaust valve face.

INTAKE VALVE

EXHAUST VALVE

Fig. 4-8

4-9 GOVERNOR SYSTEM

The governor is a centrifugal flyweight type which ensures constant operation at the selected speed

against load variations. GOVERNOR

GEAR

The governor gear with governor weights is installed inside of main bearing cover and driven by the crankshaft.

Fig. 4-9

- 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.

4-13 CHARGING SYSTEM

Multipolar charging coil is provided inside of flywheel. Charging capacity is 12V-15A.

IGNITION COIL

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

ELEMENT

URETHANE FOAM

Fig. 4-13

4-16 FUEL PUMP

The engines are equipped with a diaphragm type fuel pump which is operated by the crankcase inside vacuum pressure.

FUEL PUMP

Fig. 4-14

- 11 -

4-17 SECTIONAL VIEW OF ENGINE

CARBURETOR

INTAKE MANIFOLD

IGNITION

P.T.O.SHAFT

OIL

MAIN BEARING COVER

OIL PUMP FILTER

Fig. 4-15

- 12 -

	INTAKE	PUMP
	EXHAUST
	SPARK

TAPPET

RING

GOVERNOR

FILTER

ELECTRIC

Fig. 4-16

- 13 -

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

Step	Parts to remove	Remarks and procedures	Fasteners
	Engine oil drain	Drain engine oil by removing plugs
1		located on both side of crankcase.

OIL FILLER CAP

GASKET

OIL LEVEL GAUGE

	GASKET		STEP 1
		OIL DRAIN PLUG
		(ON BOTH SIDE)

Fig. 5-2

- 15 -

Step	Parts to remove	Remarks and procedures	Fasteners
2	Air cleaner cover and elements	Remove breather pipe from #1	10-32x11mm ;
		cylinder head.	3 pcs.
3	Air cleaner base
			WING NUT
			CLEANER
			COVER

BREATHER

PIPE

STEP 2

Fig. 5-4

FLANGE BOLT (Inch) : 3 pcs.

CLEANER

ELEMENT

STEP 3

CLEANER BASE

Fig. 5-3

- 16 -

Step	Parts to remove		Remarks and procedures	Fasteners
4	Blower housing			M6x12 ; 8 pcs.
5	Chock control lever and link			M6
	CHOKE	LINK PIVOT
		WAVED
	CONTROL ROD
		WASHER
		M5 TAPPING		BLOWER HOUSING
		SCREW : 1 pce.
		CLAMP
		CHOKE
		KNOB
	RETURN	CHOKE
		CONTROL
	SPRING
		LINK

STEP 5

STEP 4

M6 FLANGE

BOLT : 8 pcs

Fig. 5-5

- 17 -

Step	Parts to remove	Remarks and procedures	Fasteners
	Carburetor	At first remove fuel pipe.	M8x80 ; 2 pcs.
6		Take out carburetor along with
		governor rod and rod spring.

M8 FLANGE

BOLT : 2 pcs.

CARBURETOR

FUEL PIPE

Fig. 5-7

GASKET, carburetor

STEP 6

Fig. 5-6

- 18 -

Step	Parts to remove		Remarks and procedures	Fasteners
		Governor lever ;		M6X12 ; 3 pcs
		Remove bolt and take out lever.		M6 self-lock nut
		Speed control lever ;
7	Governor lever and	1. Governor spring
	Speed control lever	2. Self lock nut
		3.	Stop plate
		4.	Spring washer
		5.	Speed control lever
8	Speed control bracket unit			M6X12 ; 3 pcs

M6 NUT : 1 pce.

M6 BOLT

AND WASHER : 1 pce.

STEP 7

ROD

SPRING

GOVERNOR LEVER

	M6 SELF LOCK
GOVERNOR	NUT : 1 pce.
ROD	STOP PLATE
	SPRING WASHER
	FRICTION
	WASHER
	SPEED CONTROL
	LEVER
GOVERNOR
SPRING	FRICTION
	WASHER
	M6 FLANGE
	BOLT : 3 pcs.

STEP 8

BRACKET UNIT, speed control

Fig. 5-8

- 19 -