Robin America EH65 Service Manual
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Robin America EH65 Service Manual

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SERVICE
MANUAL
Model
EH65
Engine
PUB-ES1113
Rev. 8/98

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  • Page 1 SERVICE MANUAL Model EH65 Engine PUB-ES1113 Rev. 8/98...
  • Page 2 940 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...

  • Page 3: Table Of Contents

    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 ..................
  • Page 4 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.

  • Page 5: Specifications

    1. SPECIFICATIONS - r i n i l , t f n i l n i l n i l l l u e l i y t i , t f e l i n i l d i l y t i i r t Specifications are subject to change without notice.

  • Page 6: Performance

    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...

  • Page 7: Performance Curves

    2-4 PERFORMANCE CURVES EH63D ( kgf-m ) 45 ( 4.59 ) 35 ( 3.57 ) MAXIMUM TORQUE MAXIMUM HORSEPOWER ( 20.1 ) ( HP ) CONTINUOUS ( 13.4 ) RATED HP RECOMMENDED HORSEPOWER RANGE ( 6.7 ) 2000 2400 2800 3200 3600 REVOLUTION...
  • Page 8 EH64D ( kgf-m ) 45 ( 4.59 ) 35 ( 3.57 ) MAXIMUM TORQUE MAXIMUM HORSEPOWER ( 20.1 ) ( HP ) CONTINUOUS RATED HP ( 13.4 ) RECOMMENDED HORSEPOWER RANGE ( 6.7 ) 2000 2400 2800 3200 3600 REVOLUTION r.p.m - 4 -...
  • Page 9 EH65D ( kgf-m ) 45 ( 4.59 ) 35 ( 3.57 ) MAXIMUM TORQUE MAXIMUM HORSEPOWER ( 20.1 ) ( HP ) CONTINUOUS RATED HP ( 13.4 ) RECOMMENDED HORSEPOWER RANGE ( 6.7 ) 2000 2400 2800 3200 3600 REVOLUTION r.p.m - 5 -...

  • Page 10: Features

    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.

  • Page 11: General Description Of Engine Components

    4. GENERAL DESCRIPTION OF ENGINE COMPONENTS ROBIN EH63D/ 64D/ 65D series engine is air-cooled, 4-stroke, twin-cylinder, OHV arrangement gaso- line 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.

  • Page 12: Connecting Rod And Piston

    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.

  • Page 13: Cylinder Head

    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 cool- ing air to the exhaust valve area for the optimum cooling.

  • Page 14: Cooling System

    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 lubrica- tion system.

  • Page 15: Carburetor

    4-14 CARBURETOR The engines are equipped with a down draft car- buretor 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 con- sumption and sufficient output. Fuel cut solenoid valve is provided to prevent en- gine running on when the key switch is turned to off.

  • Page 16: Sectional View Of Engine

    4-17 SECTIONAL VIEW OF ENGINE CARBURETOR INTAKE MANIFOLD IGNITION COIL P.T.O.SHAFT OIL PUMP MAIN BEARING COVER FLYWHEEL OIL PUMP FILTER Fig. 4-15 - 12 -...
  • Page 17 AIR CLEANER GOVERNOR LEVER CAMSHAFT PUSH ROD ROCKER ARM INTAKE AND FUEL PUMP EXHAUST VALVES SPARK PLUG TAPPET PISTON RING GOVERNOR GEAR OIL FILTER ELECTRIC STARTER PISTON OIL PRESSURE SWITCH PISTON PIN CRANKCASE CRANKSHAFT CONNECTING ROD Fig. 4-16 - 13 -...

  • Page 18: Disassembly And Reassembly

    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.

  • Page 19: Disassembly Procedures

    5-3 DISASSEMBLY PROCEDURES l i o l i o OIL FILLER CAP GASKET OIL LEVEL GAUGE STEP 1 GASKET OIL DRAIN PLUG ( ON BOTH SIDE ) Fig. 5-2 - 15 -...
  • Page 20 n i l 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 -...
  • Page 21 n i l LINK PIVOT CHOKE WAVED CONTROL ROD WASHER M5 TAPPING BLOWER HOUSING SCREW : 1 pce. CLAMP CHOKE KNOB CHOKE RETURN CONTROL SPRING LINK STEP 5 STEP 4 M6 FLANGE BOLT : 8 pcs Fig. 5-5 - 17 -...
  • Page 22 r i f M8 FLANGE BOLT : 2 pcs. CARBURETOR FUEL PIPE Fig. 5-7 GASKET, carburetor STEP 6 Fig. 5-6 - 18 -...
  • Page 23 - f l M6 SELF LOCK NUT : 1 pce. GOVERNOR SPRING STOP PLATE M6 NUT : 1 pce. SPRING WASHER FRICTION WASHER M6 BOLT SPEED CONTROL AND WASHER : 1 pce. LEVER GOVERNOR SPRING FRICTION WASHER STEP 7 M6 FLANGE GOVERNOR BOLT : 3 pcs.
  • Page 24 l i o & . l i x i f . l i STEP 10 IGNITION M6 BOLT PLUG COIL AND WASHER TERMINAL ASSY : 2 pcs. SPARK PLUG CAP M6 BOLT AND WASHER TO STOP DIODE ASSY : 2 pcs. IGNITION COIL PLUG...
  • Page 25 n i l & CYLINDER BAFFLE #3 M6 FLANGE BOLT : 3 pcs. STEP 11 M6 FLANGE BOLT : 2 pcs. CYLINDER BAFFLE #1 CYLINDER BAFFLE #4 M6 FLANGE BOLT : 3 pcs. M6 FLANGE BOLT : 3 pcs. CYLINDER BAFFLE #2 Fig.
  • Page 26 M8 FLANGE NUT : 2 pcs. SPARK PLUG STEP 12 INTAKE MANIFOLD STEP 13 GASKET, muffler M8 FLANGE NUT : 2 pcs. GASKET, muffler SPARK PLUG STEP 13 Fig. 5-12 - 22 -...
  • Page 27 , t f y l f n i l " " T " " 1 " r " 2 n i l t i s . y l M6 FLANGE BOLT : 4 pcs. LIFT HOOK PUSH ROCKER M8 NUT : 2 pcs. ADJUSTING SCREW LIFT HOOK...
  • Page 28 & STEP 16 SPRING RETAINER SPRING RETAINER COLLET -VALVE COLLET -VALVE VALVE SPRING VALVE SPRING WASHER WASHER Fig. 5-15 GASKET BREATHER GASKET, breather BREATHER COVER M6 FLANGE BOLT : 2 pcs. EXHAUST VALVE INTAKE VALVE Fig. 5-14 - 24 -...
  • Page 29 l l u y l f e l l l i o M18 NUT : 1 pce. SPRING WASHER STEP 17 WASHER M5 BOLT AND WASHER : 4 pcs. Fig. 5-17 STEP 18 CHARGE COIL FLYWHEEL RING GEAR Fig. 5-16 Fig.
  • Page 30 . t f GOVERNOR SLEEEVE GOVERNOR GEAR WASHER : 2 pcs. GOVERNOR GEAR SHAFT THRUST BEARING M8 FLANGE BOLT : 10 pcs. GASKET STEP 19 MAIN BEARING COVER Fig. 5-20 Fig. 5-21 - 26 -...
  • Page 31 t i s . y l CAMSHAFT Fig. 5-23 TAPPET STEP 20 TAPPET CAMSHAFT Fig. 5-22 - 27 -...
  • Page 32 p i l t i s i l c . y l CLIP PISTON RING SET PISTON PIN CLIP STEP 21 CONNECTING PISTON CLIP ROD CAP RING SET PISTON CONNECTING ROD PISTON PIN STEP 21 CLIP M8 CONNECTING CONNECTING ROD BOLT : 2 pcs. CONNECTING ROD CAP M8 CONNECTING...
  • Page 33 t l i f c t i t l i f i l e & l l a M6 FLANGE BOLT : 4 pcs. OUTER ROTER INNER ROTOR O RING M8 FLANGE STEP 23 BOLT : 2 pcs. OIL PUMP COVER BRACKET, SNAP PIN magnetic switch...

  • Page 34: Reassembly Procedures

    5-4 REASSEMBLY PROCEDURES 5-4-1 PRECAUTIONS FOR REASSEMBLY 1) Clean parts thoroughly before reassembly. Pay most attention to cleanliness of piston, cylinder, crankshaft, connecting rod and bearings. 2) Scrape off all carbon deposits from cylinder head, piston top and piston ring grooves. 3) Check lip of oil seals.
  • Page 35 B. CYLINDER HEAD, VALVES and ROCKER ARM NOTE ; * Clean valves and wash cylinder head thoroughly. * Remove carbon and gum deposits from the valves, seats, ports and guides. * Inspect valves, valve seats and valve guides. * Replace valves that are badly burned, pitted or warped. * Valve guides should be replaced when valve stem clearance exceeds specifications.
  • Page 36 C. PISTON and CONNECTING ROD (1) Install oil ring first, then second ring and top ring. Spread ring only far enough to slip over piston and into correct groove. Use care not to distort ring. NOTE ; * Install second ring with punched mark beside the gap on the top side. * Top ring can be fit either way.
  • Page 37 5-4-3 Re-assembly CRANKSHAFT 1) CRANKSHAFT Install crankshaft onto crankcase. Note: Apply enough oil to bearing portion of crankcase. For easy installation, put crankcase on box or wood blocks. 2) PISTON and CONNECTING ROD Fig. 5-31 (1) Install piston and connecting rod assembly into cylinder by using a piston ring compressor to PISTON RING COMPRESSOR hold piston rings.
  • Page 39 5) MAIN BEARING COVER (1) Put a oil seal guide onto PTO shaft portion to avoid damaging the main bearing cover oil seal. (2) Place gasket onto the mating surface of crankcase. (3) Lubricate oil seal lip potion and bearing surfaces, and install main bearing cover. Tighten bolts evenly to the specified torque.
  • Page 40 (3) Insert push rods into the concave portion of tappet and set the other end to the concave portion of rocker arm adjust screw with valve spring depressed. (4) Temporally tighten adjust screw. 9) VALVE CLEARANCE ADJUSTMENT NOTE : Temporally fit the flywheel in position for easy operation. (1) Rotate crankshaft clockwise to the TDC (top dead center) of compression stroke by matching the mark "T"...
  • Page 41 10) ROCKER COVER Install rocker cover with new gasket. Tightening Torque : 2.9 - 4.9 N-m (30 - 50 kg-cm, 2.2 - 3.6 ft-lb.) 11) BREATHER PIPE and COVER Attach breather plate (breather valve) and breather cover to crankcase using proper gaskets. GASKET BREATHER Put breather plate in such position as its reed...
  • Page 42 14) STARTER MOTOR Install starter motor. Tightening Torque : 16.7 - 18.6 N-m (170 - 190 kg-cm) (12.3 - 13.7 ft-lb.) 15) CYLINDER BAFFLE Attach cylinder baffle #1, #2, #3 and #4. 16) INTAKE MANIFOLD M8 FLANGE NUT : 2 pcs. Set gasket (stainless steel) onto both #1 and #2 INTAKE MANIFOLD cylinder head and install intake manifold.
  • Page 43 19) CARBURETOR Set gasket onto intake manifold and install carburetor. Tightening Torque : 16.7 - 18.6 N-m (170 - 190 kg-cm) (12.3 - 13.7 ft-lb.) 20) GOVERNOR LEVER GOVERNOR SHAFT Attach governor rod and rod spring between GOVERNOR governor lever and carburetor throttle lever, and LEVER insert the governor lever to governor lever shaft.
  • Page 44 21) SPEED CONTROL LEVER Install speed control bracket onto intake manifold. Attach return spring, spacer, friction washer, wing nut, etc. to speed control lever as shown in the illustration. Attach governor spring between governor lever and speed control lever. Attach chock control link between carburetor chock lever and chock control lever.
  • Page 45 22) ADJUST GOVERNOR SYSTEM (1) Push speed control lever all the way to the high speed position and fix it by tightening nut. (2) Check that governor lever is pulled by gover- nor spring and carburetor throttle valve is fully open.
  • Page 46 26) OIL PRESSURE SWITCH OIL PRESURE SWITCH Install oil pressure switch onto crankcase. Tightening Torque : 5.9 - 9.8 N-m (60 - 100 kg-cm) (4.3 - 7.2 ft-lb.) Fig. 5-49 27) OIL FILTER Apply oil to O-ring and install oil filter by tighten- ing about 3/4 turns after attaching crankcase sur- face.

  • Page 47: Break-In Operation

    30) Refill engine oil and start the engine. Engine OIL GAUGE oil will be lubricated oil passages and oil filter. Check the engine oil level and refill again to the upper level of oil level gauge. UPPER LEVEL Note: * Total engine oil capacity is about 1.55 L. * Use "SE"...

  • Page 48: Magneto

    6. MAGNETO 6-1 OPERATION AND FUNCTION The ignition system is pointless flywheel magneto with automatic advancing characteristic. Being different from the breaker point type ignition system, this system is completely free from such troubles as starting-up failure owing to dirty, burnt or corroded point surface. The electronic automatic advancing ensures extremely easy starts and stable high performance at oper- ating speed by advancing the ignition timing to the most suitable point.
  • Page 49 (2) At lower engine revolution, when the flywheel reached the ignition point the low speed ignition timing control circuit operates to run the base current I3 to turn the signal transistor A "ON" allowing the current /1 to bypass as current I4. At this moment the power transistor turns "OFF"...

  • Page 50: Lubrication System

    7. LUBRICATION SYSTEM 7-1 OPERATION AND FUNCTION * Full lubrication system is adopted, in combination with large-size torchoid oil pump and cartridge type oil filter. * The large-size trochoid type oil pump is driven directly by crankshaft, and delivers pressurized engine oil to the journal and pin portions of crankshaft, camshaft etc.

  • Page 51: Carburetor

    8. CARBURETOR 8-1 OPERATION AND FUNCTION Fig. 8-1 - 47 -...
  • Page 52 8-1-1 FLOAT SYSTEM The float system is consists of a float and a needle valve, and maintains a constant fuel level during engine operation. The fuel flows from the fuel tank into the float chamber through needle valve. When the fuel rises to a specific level, the float rises, and when its buoyancy and fuel pressure are balanced, the needle valve closes to shut off the fuel, thereby keeping the fuel at the predetermined level.

  • Page 53: Compornent Parts

    8-2 COMPORNENT PARTS Fig. 8-2 1. BODY, lower 11. MAIN JET 2. GASKET, body upper 12. SOLENOID VALVE ASS’Y 3. BODY, upper 13. JET, slow 4. LEVER ASSY, choke 14. NEEDLE, idle adjust 5. SPRING, choke 15. THROTTLE SHAFT ASS’Y 6.

  • Page 55: Compornent Parts

    9-2 COMPORNENT PARTS ARMATURE BRUSH (4 pcs.) BRUSH HOLDER THROUGH BOLT (2 pcs.) PINION STOPPER CLIP SPACER PINION STOPPER PINION RETURN SPRING PINION ASSEMBLY GUIDE PLATE FRONT COVER YOKE ASSEMBLY Fig. 9-3 - 51 -...

  • Page 56: Troubleshooting

    10. TROUBLESHOOTING The following three conditions must be fulfilled for satisfactory engine start. (1) The cylinder filled with a proper fuel-air mixture. (2) Good compression in the cylinder. (3) Good spark, properly timed, to ignite the mixture. The engine cannot be started unless these three conditions are met. There are also other factors which make engine start difficult, e.g., a heavy load on the engine when it is about to start at low speed, and a high back pressure due to a long exhaust pipe.

  • Page 57: Starting Difficulties

    10-2 STARTING DIFFICULTIES y t l l i o l i o s t i l i o y t i y t i l i o y l f l l i f n i l n i l r t l c i f n i l...

  • Page 58: Insufficient Output

    10-3. INSUFFICIENT OUTPUT n i l n i l y t l l i o y t l l i o y l f z i t n i l n i l r t l y t l 10-4. OVERHEAT n i l l n i n i l...

  • Page 59: Rough Idling

    10-5. ROUGH IDLING n i l n i l n i l y t l 10-6. HIGH ENGINE OIL CONSUMPTION l i o l i f t t i s t l y t l n i l l i d l i o l i o y t l...

  • Page 60: High Fuel Consumption

    10-7. HIGH FUEL CONSUMPTION y t l . y l n i l 10-8. DETONATION / r i n i l t i s n i l n i l y t l - 56 -...

  • Page 61: Engine Misfire

    10-9. ENGINE MISFIRE l i o y t l / r i n i l n i l r t l - 57 -...

  • Page 62: Installation

    11. INSTALLATION Engine life, ease of maintenance and inspection, frequency of checks and repairs, and operating cost all depend on the way in which the engine is installed. Review the following instructions carefully for installing the engine. 11-1 INSTALLING When mounting the engine, carefully examine its position, the method of connecting it to a machine, the foundation, and the method of supporting the engine.

  • Page 63: Service Data

    12. SERVICE DATA 12-1 CLEARANCE DATA AND LIMITS Unit : mm (in) - 59 -...
  • Page 64 Unit : mm (in) - - - - - - - - - - - - - - - - - - - - - - - - n i l y t i - - - - - - - - - - - - t r i - 60 -...
  • Page 65 Unit : mm (in) n i l t r i - 61 -...
  • Page 67 Unit : mm (in) " " - 63 -...
  • Page 68 Unit : mm (in) - - - - - - - - - - - - - 64 -...

  • Page 70: Oil Grade Chart

    12-3 OIL GRADE CHART Use oil classified as SE or higher. Multi-grade oil tends to increase its consumption at high ambient temperature. Comparison between oil viscosity and temparature Single grade Specified Lubricant Quality 10W-30 Multi- grade 10W-40 40 °C - 20 - 10 104 °F - 66 -...

  • Page 71: Maintenance And Storage

    13. MAINTENANCE AND STORAGE 13-1 DAILY MAINTENANCE Every day before operating engine, check the following items; n i l y l l v i t s t l l i o l l u 13-2 PERIODIC MAINTENANCE SCHEDULE Periodic maintenance is vital to safe and efficient operation of engine. Check the table below for periodic maintenance intervals.
  • Page 72 l i a l l i f l l i y l i l l u ) . l l i o t l i f l i o *Note 1 : Initial oil change and oil filter replacement should be performed after 20 hours of operation. Thereafter change oil every 50 hours and replace oil filter every 200 hours.

  • Page 73: Engine Storage

    13-3 ENGINE STORAGE (1) Change the engine oil and perform the daily maintenance items above mentioned. (2) Drain fuel from carburetor float chamber. (3) To prevent rust in the cylinder bore, apply oil through the spark plug hole and turn the crankshaft several turns by hand.
  • Page 74 PRINTED IN THE USA...

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