Subaru Robin Power Products EH64 User Manual

INSTRUCTIONS FOR USE

CONTENTS

MODEL EH64 WELDER APPLICATION

WARNING

The engine exhaust from this product contains chemicals known to

the State of California to cause cancer, birth defects or other

reproductive harm.

LIMITED ENGINE WARRANTY..........................................................3

SAFETY PRECAUTIONS....................................................................6

INTRODUCTION.................................................................................9

DESCRIPTION.................................................................................. 11

SPECIFICATIONS.............................................................................12

INSTALLATION .................................................................................13

OPERATION......................................................................................21

PERIODIC MAINTENANCE..............................................................27

ADJUSTMENTS................................................................................33

TROUBLESHOOTING ......................................................................35

HOW TO SELECT A SERVICE DEALER..........................................53

NOTICE

The FEDERAL EMISSION COMPONENT DEFECT WARRANTY and CALIFORNIA EMISSION CONTROL WARRANTY stated in the beginning of this manual are only applicable to the engines sold and used in the U.S.A. To the engines exported to and used in the countries other than the U.S.A., warranty service shall be performed by the distributor in each country in accordance with the standard Robin engine warranty policy as applicable.

2ZZ-90201-07

3 Year Limited Engine Warranty

(Special Term for Welder Application)

(Effective with engines purchased from Robin America, Wood Dale, IL, after November 15,

1993)

Robin America, Inc., a division of Fuji Heavy Industries, Ltd. (herein “Robin”), warrants that each new engine sold by it will be free, under normal use and service, from defects in material and workmanship for a period listed below from the date of sale to the original retail purchaser. Robin’s obligation under this Limited Warranty shall be limited to the repair and replacement, at Robin’s option, of any part or parts which upon examination is/are found, in Robin’s judgment, to have been defective in material or work manship. It shall be a condition of Robin’s obligation under this Limited Warranty that Robin, directly or through one of its Distributors or Service Centers authorized to service the particular engine involved, receive prompt notice of any warranty claim and that the engine or the part or parts claimed to be defec tive be promptly delivered, transportation prepaid, to such Distributor or Service Center for inspection and repair. All repairs qualifying under this Limited Warranty must be performed by Robin or one

of its autho rized Distributors or Service Centers.

WARRANTY PERIODS:

Robin V-Twin, Welder ApplicationLimited 3 years Warranty

(Applies to Original OEM installed engine)

The repair or replacement of any part or parts under this Limited Warranty shall not extend the

term of the engine warranty beyond the original term as set forth above.

LIMITATIONS AND EXCLUSIONS: This Limited Warranty shall not apply to:

1. Bent or broken crankshaft or resultant damage caused by vibration related to a bent or broken crankshaft. Also, damage caused by loose engine mounting bolts or improper or imbalanced accessories or blades mounted to the crankshaft.

2. Repairs required because of prolonged storage including damage caused by old or contami nated fuel in the fuel tank, fuel lines or carburetor, sticky valves or corrosion and rust of engine parts.

3. Repair required due to overheating. (Most often caused by overloaded or clogged or damaged or missing ﬂ ywheel, fan, inlet air passages, cooling ﬁ ns or air shrouds.)

4. Dirt or grit related wear caused by improper air cleaner maintenance (most often

resulting in worn piston, piston rings, cylinders, valves, valve guides, carburetor or other internal compo nents).

6. Engine tune-ups and normal maintenance service including, but not limited to, valve adjust ment, normal replacement of service items, fuel and lubricating oil, etc.

7. Any engine which has been subject to negligence, misuse, accident, mis-

application or over-speeding.

8. Any engine that has been installed, repaired, or altered by anyone in a manner which in Robin’s sole judgment adversely affects its performance or reliability.

9. Any engine which has been ﬁ tted with or repaired with parts or components not manufactured or approved by Robin which in Robin’s sole judgment adversely affects its performance or reli ability.

10. Instances when normal use has exhausted the life of a component or an engine.

The customer is responsible for all transportation charges in connection with any warranty work.

Robin reserves the right to modify, alter or improve any engines or parts without incurring any oblig ation to modify or replace, any engine or parts previously sold without such modiﬁ cation, alternation or improvement.

No person is authorized to give any other warranty or to assume any additional obligation on Robin’s behalf unless made in writing and signed by an ofﬁ cer of Robin.

THIS WARRANTY, AND ROBIN’S OBLIGATION HERE UNDER, ARE IN LIEU OF ANY OTHER WARRANTIES OR OBLIGATIONS OF ANY KIND, EXPRESSED OR IMPLIED, INCLUDING ANY WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. THERE ARE NO WARRANTIES WHICH EXTEND BEYOND THE DESCRIPTION ON THE FACE HERE-OF. ROBIN SHALL IN NO EVENT BE LIABLE FOR ANY CONSEQUENTIAL OR INCIDENTAL

DAMAGES.

5. Broken or scored parts caused by low oil level, dirty or improper grade of oil.

NOTICE

To show compliance with California emission regulations, a hangtag has been provided displaying the Air Index level and durability period of this engine.

The Air Index level defines how clean an engine’s exhaust is over a period of time. A bar graph scaled from “0” (most clean) to “10” (least clean) is used to show an engine’s Air Index level. A lower Air Index level represents cleaner exhaust from an engine.

The period of time (in hours) that the Air Index level is measured is known as the durability period. Depending on the size of the engine, a selection of time periods can be used to measure the Air Index level (see below).

Descriptive Term Applicable to Emissions Durability Period Moderate - 50 hours (engine from 0 to 65 cc)

125 hours (engine greater than 65 cc)

Intermediate - 125 hours (engine from 0 to 65 cc)

250 hours (engine greater than 65 cc)

Extended - 300 hours (engine from 0 to 65 cc)

500 hours (engine greater than 65 cc)

Notice :

WARNING :

NOTICE

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

FEDERAL EMISSION COMPONENT DEFECT WARRANTY and CALIFORNIA EMISSION CONTROL WARRANTY are applicable to only those engines complied with EPA (Environmental Protection Agency) and CARB (California Air Resources Board) emission regulations in the U.S.A.

For the engines exported to and used in the countries other than the U.S.A., warranty service shall be performed by the distributor in each country in accordance with the standard Robin engine warranty policy as applicable.

AIR INDEX

This hangtag must remain on this engine or piece of equipment, and

only be removed by the ultimate purchaser before operation.

Safety Precautions

Before operating the engine, read this manual and become familiar with it and the equipment. Safe and efﬁ cient operation can be achieved only if the equipment is properly operated and maintained.

The following symbols, found throughout this manual, alert you to potentially dangerous conditions to the operator, service personnel, or the equipment.

This symbol warns of immediate hazards which will

! DANGER

result in severe personal injury or death.

This symbol refers to a hazard or unsafe practice

! WARNING

which can result in severe personal injury or death.

This symbol refers to a hazard or unsafe practice

! CAUTION

which can result in personal injury or product or property damage.

Fuels, electrical equipment, batteries, exhaust gases and moving parts present potential hazards that can result in severe personal injury. Take care in following these recommended procedures. All local, state and federal codes should be consulted and complied with.

This engine is not designed or intended for use in

! WARNING

any type of aircraft. Use of this engine in aircraft can result in engine failure and cause severe personal injury or death.

GENERAL

• Provide appropriate ﬁ re extinguishers and install them in convenient

locations. Use an extinguisher rated ABC by NFPA.

• Make sure that all fasteners on the engine are secure and

accurately torqued. Keep guards in position over fans, driving belts, etc.

• If it is necessary to make adjustments while the engine is

running, use extreme caution when close to hot exhausts,

moving parts, etc.

• Used engine oils have been identiﬁ ed by some state and federal agencies as causing cancer or reproductive toxicity. When checking or changing engine oil, take care not to ingest, breathe the fumes, or contact used oil.

• Do not work on this equipment when mentally or physically fatigued, or after consuming any alcohol or drug that makes the operation of equipment unsafe.

BATTERIES

• Before starting work on the engine, disconnect batteries to prevent inadvertent starting of the engine. Disconnect negative (-) cable ﬁ rst.

• DO NOT SMOKE while servicing batteries. Lead acid batteries give off a highly explosive hydrogen gas which can be ignited by ﬂ ame, electrical arcing or by smoking.

• Verify battery polarity before connecting battery cables. Connect negative (-) cable last.

PROTECT AGAINST MOVING PARTS

• Do not wear loose clothing in the vicinity of moving parts, such as PTO shafts, ﬂ ywheels, blowers, couplings, fans, belts, etc.

• Keep your hands away from moving parts

FUEL SYSTEMS

• DO NOT ﬁ ll fuel tank while engine is running

• DO NOT smoke or use an open ﬂ ame in the vicinity of the engine or fuel tank. Internal combustion engine fuels are highly ﬂ ammable.

• Fuel line must be made of steel tubing which adequately secured, and free from leaks. Tubing which connects to the carburetor should be factory approved ﬂ exible line. Do not use copper tubing as the ﬂ exible lines as copper will harden and become brittle enough to break.

• Be sure all fuel supplies have a positive shutoff valve.

• Benzene and lead, found in some gasoline, have been identiﬁ ed by some state and federal agencies as causing cancer or reproductive toxicity. When checking, draining, or adding gasoline take care not to ingest, breathe fumes, or contact the gasoline.

EXHAUST SYSTEM

• Exhaust products of any internal combustion engine are toxic and

can cause injury, or death it inhaled. When operating the engine in a conﬁ ned area, make sure the ventilation system is operating properly.

• DO NOT use exhaust gases to heat a compartment.

• Make sure that your exhaust system is free of leaks. Make sure that

exhaust manifolds are secure and are not warped by bolts unevenly torqued.

EXHAUST GAS IS DEADLY!

Exhaust gases contain carbon monoxide, a poisonous gas that can cause unconsciousness and death. It is an odorless and colorless gas formed during combustion of hydrocarbon fuels. Symptoms of carbon monoxide poisoning are:

• Dizziness

• Vomiting

• Headache

• Muscular Twitching

• Throbbing in Temples

• Weakness and Sleepiness

If you experience any of these symptoms, get out into fresh air immediately, shut down the unit and do not use it until it has been inspected. The best protection against carbon monoxide inhalation is proper installation and regular, frequent inspections of the complete exhaust system. If you notice a change in the sound or appearance of exhaust system, shut the unit down immediately and have it inspected and repaired at once by a competent mechanic.

KEEP THE UNIT AND SURROUNDING AREA CLEAN

• Make sure that oily rags are not left on or near the engine.

• Remove all unnecessary grease and oil from the unit. Accumulated

grease and oil can cause overheating and subsequent engine damage and present a potential ﬁ re hazard.

Introduction

ABOUT THIS MANUAL

This manual covers the operation and maintenance of the horizontalshaft Robin Subaru EH64 engines for welder applications (OHV220 Performer Series). Each operator of the power equipment should study this engine manual carefully and observe all of its instructions and precautions. Proper use and periodic maintenance are responsibilities

of the operator(s) and are essential for top performance.

MODEL IDENTIFICATION

Whenever contacting a dealer or distributor for information, parts or service, always provide the model number and the serial number marked on the nameplate of the engine. Robin engines are identiﬁ ed by MODEL, SPECIFICATION, and CODE NUMBER. For each model there may be many different versions called speciﬁ cations. Each speciﬁ cation will be unique in some way. The difference may only be the paint color or it may have a different type of PTO or some other signiﬁ cant difference. In order to identify the correct service part number, it is important to conﬁ rm the speciﬁ cation and code numbers for your engine. The speciﬁ cation and code number together are know as the PRODUCT NUMBER. All Robin 4 cycle engine have a Product Number label similar to the label illustrated to the right.

Description

FEATURES

• Overhead valve arrangement enables high power, and low fuel and oil consumption

• V-Twin, four stroke design

• Air-cooled and gasoline fueled

• The light weight and compact design makes it easy to install and utilize for many applications.

• A steel crankshaft and high-load bearing offer durability

• Pressure lubrication system and large capacity air cleaner enhance reliability of the engine.

• The combustion chamber shape, along with a tuned exhaust valve system, enhance the low exhaust emission and provides high torque at low speed.

Standard features include a fuel cut-of valve, a 12V-15 amp alternator and a pulse-type fuel pump.

The ﬂ ywheel-type governor gear provides constant operation at the selected speed against load variations.

The carburetor is a down draft, ﬂ oat controlled fuel system with a ﬁ xed main jet. A fuel cut-off valve is provided to secure engine shut-down when the switch is turned off. Carburetors are calibrated for sure starting, good acceleration, low fuel consumption and adequate power output. A throttle solenoid (optional) automatically senses when the engine needs to run at full power and when it requires idle speed. The solenoid operates using a 15 second delay before dropping to idle.

Speciﬁ cations

Engine Type

Rated Output 20.5 HP/3600 rpm (153. kW/3600)

Continuous Output 16.0 HP/3600 rpm (11.9kW/3600)

Bore X Stroke 80 mm x 65 mm (3.15” x 2.56”)

Displacement 653cc (39.90 cu in)

Compression Ratio 8.3:1

Maximum Output 15.3 kW/20.5 HP / 3600 rpm

Maximum Torque 32.7 ft/lbs @ 2200 rpm

Starting System Electric Start

Carburetor Down draft, Float Type

Fuel Unleaded Gasoline using a Diaphragm Pulse Pump

Lubrication Full Pressure with full Flow Spin-On Filter

Oil Type Automobile Engine Oil; Class SE

Oil Capicity 1550 cc (1.64qt)

Charging System 12 volt 15 amp

Dry Weight 44 kg (96.9 lbs)

Dimensions (L x W x H) 317mm x 477mm x 475mm (12.5” x 19.0” x 19.0”)

Direction of Rotation CCW as Viewed from the PTO shaft side

Cooling System Forced Air Cooling

Ignition System Flywheel Magneto (Solid State)

Spark Plug Type NGK-BP6ES or BRP6ES

Governor System Centrifugal Fly Weight

Air Cleaner Double Element Assembly

Valve Clearance (Intake & Exhaust) 0.003-0.005 in (0.07-0.10mm)

Emission Durability Period (California Only) 500 hours

Air-Cooled, 4-Stroke, V-Twin Cylinder, Horizontal Shaft, OHV Gasoline Engine

Installation

LOCATING

Locate the engine at least 1 meter (3.0 ft) away from buildings or other structures. Provide proper exhaust routing. Refer to EXHAUST SYSTEM below. Do not use the engine near ﬂ ammables or other hazard- ous materials such as trash, rags, lubricants, or explosives. When determining the mounting location, make sure of the following:

• Gas and oil can easily be checked and supplied

• Oil can be changed.

• The air cleaner can be serviced

• Spark plugs can be checked. Carefully examine the engines position, the method of connecting it to

a machine, and the foundation and support structure. Locate the engine in a safe area on a stable level surface free of small rock, loose gravel, etc.

! CAUTION

Operating the engine on an incline may cause

seizure due to improper lubrication; even at maximum oil level.

EXHAUST SYSTEM

EXHAUST GAS IS DEADLY! Engine-powered equipment must never be operated inside buildings or other enclosed spaces. If a long exhaust pipe is used, the internal resistance results in loss of engine power. The exhaust pipe ID must increase in proportion to exhaust pipe length. For example, if the exhaust pipe is: less than 3.0 m (9.8 ft.) long - pipe ID = 30mm (1-3/16in)

less than 5.0 m (16.4 ft)long - pipe ID = 33mm (1.3in)

It is the responsibility of the equipment operator(s) to check for exhaust leaks on a daily basis and to have all leaks repaired before continuing to operate the equipment.

FUEL Fuel Tank

The fuel tank system must be provided by the OEM. A fuel shut-off valve must connected between the fuel line and the fuel pump.

The fuel tank may be mounted up to 0.66 meters (2.0ft) below the

carburetor. If the tank is mounted above the carburetor, a fuel shut-off valve must be connected between the fuel tank and the fuel pump.

Note: To prevent fuel from ﬂ ooding the carburetor, the fuel valve must be closed when the engine is not running.

Properly install fuel lines to the carburetor bycompletely inserting the hose onto the ﬁ tting and then secure it with a hose clamp.

Gaseous fuels are ﬂ ammable and explosive and

! WARNING

can cause severe personal injury or death. Do not smoke if you smell gas or are near fuel tanks or fuel-buring equipment or are in an area sharing ventilation with such equipment. Keep ﬂ ames, sparks, pilot lights, electrical switches, arc-producing equipment and all other sources of ignition well away. Keep a type ABC ﬁ re extinguisher handy.

Do not reﬁ ll the fuel tank while the engine is running. Do not overﬁ ll the tank. Wipe away any spilled fuel and wait until it has dried before starting the engine.

Fuel recommendations

Use clean, fresh unleaded gasoline having a minimum octane rating (Anti-Knock Index) of 87. This engine is certiﬁ ed to operate on unleaded gasoline. During some periods of the year only mandated “oxygenated” gasolines may be available. These are acceptable for use, but not preferable. Do not use gasoline or gasoline additives (de-icers) containing methanol because methanol can be corrosive to fuel system components.

! CAUTION

Do not use gasoline or gasoline additives containing methanol because methanol can be corrosive to fuel system components.

13 14

Installation

ENGINE OIL Recommendations

Use premium quality motor oil, Class SE or higher. Look for the SAE (Society of Automotive Engineers) or API viscosity grade. Referring to the table below, choose the viscosity grade appropriate for the ambient temperatures expected during the period of time until the next scheduled oil change.

Check the oil level daily, before starting. Keep the oil level between the upper and lower level on the gauge.

EXPECTED AMBIENT TEMPERATURES

SAE VISCOSITY GRADE

32°F (0° C) and higher 30

0°F to 80°F (-18°C to 27°C)

Single-grade SAE 30 oil is preferable when temperatures are 50° and 90°F (10° - 32°C). If multi-grade oil is used, oil consumption tends to increase if the ambient temperature is high.

Filling and Change Interval

After the ﬁ rst 20 hours of operation the initial oil and oil ﬁ lter should be replaced. Thereafter, change the oil every 100 hours of operation and change the oil ﬁ lter every 200 hours. Apply a thin coat of oil to the oil ﬁ lter gasket surface and install by tightening the oil ﬁ lter about 3/4 turn after the seal has reached the crankcase surface. The oil capacity of the crankcase is 1.55L (53 ﬂ .oz.). When ﬁ lling the crankcase, keep the engine level and ﬁ ll up to the up- per mark of the oil gauge. Check the oil with the oil gauge pushed all the way in its seat.

Crankcase pressure can blow hot engine oil out

! WARNING

the ﬁ ll tube causing severe burns. Always stop the engine before removing the oil ﬁ ll cap or the oil gauge.

10W-30 10W-40

15 16

STARTING BATTERIES

An engine equipped with an electric starter requires a properly sized battery along with appropriately sized interconnecting cables to insure proper starting. Neither cranking performance or starter service life will be satisfactory if an undersized battery is used. Use a battery rated 12V-30 amp or larger. The customer must supply battery cables. Use the table below to select the proper cable for the positive side connection. Connect a ground strap to the negative terminal. Use a ﬂ at strap

25.0mm (0.25”) wide.

WIRE GAUGE

CABLE LENGTH CABLE DIA.

Less than 1.5m

(4.5ft)

1.5 - 2.5m

(4.5 - 7.6ft)

2.5 - 4.0m

(7.6 - 12.2ft)

7.3mm

(5/16 in.) 1 6 AV15

8.5 mm (3/8 in.) 0 4 AV20

108 mm (7/16in.) 3/0 2 AV30

AWG (BS)

BWG SAE JIS

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