Robin America EH63V Service Manual
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Robin America EH63V Service Manual

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  • Page 2: Table Of Contents

    CONTENTS Page Section Tifle ....................... SPECIFICATIONS ......................PERFORMANCE ......................MAXIMUM OUTPUT ......................2-2 MAXIMUM TORQUE ....................PERFORMANCE CURVES ........................FEATURES .......... GENERAL DESCRIPTION ENGINE COMPONENTS ..................4-1 CYLINDER AND CRANKCASE ....................4-2 MAIN BEARING COVER ........................4-3 CRANKSHAFT .................. 4-4 CONNECTING AND PISTON ........................
  • Page 3 Section Title Page ......................CARBURETOR ..................8-1 OPERATION AND FUNCTION ....................8-2 COMPORNENT PARTS ....................ELECTRIC STARTER ..................9-1 OPERATION AND FUNCTION ....................9-2 COMPORNENT PARTS ................... TROUBLESHOOTING ................... . NO ENGINE OPERATION 10-1 ..................10-2 STARTING DIFFICULTIES ....................INSUFFICIENT OUTPUT 10-3 ........................

  • Page 4: Specifications

    1 SPECIFICATIONS EH65V MODEL EH63V Air-Cooled, 4-Cycle, V-Twin Cylinder, Type Vertical P.T.O. Shaft, OHV Gasoline Engine 2-80 mm x 65 mm (3.15 x 2.56 in.) Bore Stroke 653 cm3 (39.8 cu.in.) Piston Displacement Compression Ratio kW (18.0 HP) /3600 r.p.m. 16.4 kW (22.0 HP) /3600 r.p.m.

  • Page 5: Performance

    2. PERFORMANCE 2-1 MAXIMUM OUTPUT The maximum output is the output of a .n engine with its throttle valve fully open led under the c mdition that 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 broken-in.

  • Page 6: Performance Curves

    2-3 PERFORMANCE CURVES EH63V (kgf-m) 45 (4.59) (3.57) MAXIMUM TORQUE HORSEPOWER MAXIMUM (20.1 (1 3.4) (6.7) 2000 2800 3600 2400 3200 SPEED r.p.m...
  • Page 7 EH65V 35 (3.57) /MAXIMUM TORQUE MAXIMUM HORSEPOWER (20.1 /" (1 3.4) (6.7) 2000 2400 2800 3200 3600 SPEED r.p.m...

  • Page 8: Features

    FEATURES The overhead valve arrangement is adopted for ensuring high power, low fuel consumption and low consumption. The adoption of twin-cylinder in the angle 90 degree (V arrangement) and crankcase in one piece, plastic blower housing etc. offers a compactness and light weight, making the arrangements for installin the engine much easier for various powered equipments.

  • Page 9: General Description Of Engine Components

    4. GENERAL DESCRIPTION ENGINE COMPONENTS /" ROBIN EH63V/ 65V series engine is air-cooled, 4-stroke, twin-cylinder, OHV arrangement gasoline en- gine. The twin-cylinder is located in the angle of 90 degree; cylinder is in the RH side and #2 cylinder in LH side as viewed from flywheel (cooling fan) side.

  • Page 10: 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. 4-5 PISTON RINGS The piston rings are made of special cast iron.

  • Page 11: Cylinder Head

    4-7 CYLINDER HEAD The cylinder head an aluminum die-casting which utilizes semi-spherical type combustion chamber the high combustion efficiency. Fig. 4-7 4-8 VALVE ARRANGEMENT The intake valve is located on flywheel side cylinder head. The cooling fins and passages design lead cool- ing air to the exhaust valve area for the optimum cooling.

  • Page 12: Cooling System

    4-10 COOLING SYSTEM The large fins 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. The trochoid type oil pump is driven by crankshaft and delivers pressurized engine oil through the...

  • Page 13: Carburejor

    4-14 CARBURETOR car- The engine is equipped with horizontal draft float fuel has a buretor that controlled system and a fixed main jet. The carburetors are calibrated carefully for sure less starting, good acceleration, fuel consumption and sufficient output. Fuel cut solenoid valve is provided to prevent en- when gine running on key switch is turned to...

  • Page 14: Sectional Viewo Fengine

    4-17 SECTIONAL VIEW OF ENGINE CAMSHAFT PUMP CRANKSHAFT Fig. 4-15...
  • Page 15 SWITCH PRESSURE PUMP FUEL CRANKSHAFT PISTON RING CARBURETOR ROCKER COVER PLUG ELECTRIC SPARK CYLINDER INTAKE AND EXHAUST HEAD STARTER Fig. 4-16...

  • Page 16: 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 suggested that tags be attached to them.

  • Page 17: Disassembly Procedures

    5-3 DISASSEMBLY PROCEDURES , " - . Parts to remove Fasteners Step Remarks and procedures Engine oil drain Drain engine oil by removing plugs of crankcase. located on both sides OIL DRAIN Fig. 5-2 1 4 -...
  • Page 18 Parts remove Fasteners Step Remarks and procedures cleaner cover and elements Remove breather pipe from pcs. cleaner base cylinder head. cleaner CLEANER BASE GASKET, / ” ” “ ” _ CLEANER COVER BREATHER PIPE Fig. Fig.
  • Page 19 remove Remarks and Fasteners Parts procedures M6x14 pce. Remove pipe and Fuel pump bracket pulse fuel pipe. M6x28 pce. Rotating screen and M4x20 4 pcs. Blower housing M6x14 pcs. SCREW AND WASHER pcs. PULSE PIPE FUEL FILTER I ” ’ Fig.
  • Page 20 Parts remove Fasteners Remarks Step and procedures Carburetor Take out carburetor along with governor rod, rod spring and choke rod. control Governor lever and speed control bracket M5 BOLT AND INSULATOR WASHER : 1 pce. LEVER CHOKE FLANGE BOLT CHOKE CONTROL : 1 pce.
  • Page 21 Step Parts remove and procedures Fasteners Remarks 1. Take out plug cap. M6x30 bolt & 2. Remove ignition coil. washer ; pcs. Ignition cojl wire fixing bands. 3. Cut out stop wires Disconnect stop from ignition coil. M8 flange nut ; Intake manifold 4pcs.
  • Page 22 Fasteners Parts to remove Remarks and procedures Step M6x18 ; 2 pcs. Regulator M6x12 ; 6 pcs. Cylinder baffles (#1, #2, #3, to IGNITION COIL to IGNITION COIL pcs. FLANGE BOLT : 4 CYLINDER BAFFLE 5 BOLT FLANGE pcs. CYLINDER BAFFLE 1 Fig- 5-10 1 9 -...
  • Page 23 to remove Fasteners Parts Step Remarks and procedures Electric starter M8x65 ; 2 pcs. coil Charge M 5 x 2 0 ; 4 p c s . BPGES NGK : BPRGES Spark plug SPARK PLUG Fig. 5- 1...
  • Page 24 remove Parts Remarks procedures Fasteners M6x12 ; 4 pcs. Rocker cover Temporally fit the flywheel, when MlOx65 pcs. removing rocker arm, turn and adjust Cylinder head, Push rod, flywheel at TDC with the marking " T Rocker arm and oil filler faced to "1 or "2"...
  • Page 25 Parts to remove Fasteners and procedures Step Remarks Intake & exhaust valves Breather cover Breather plate EXHAUST VALVE Fig. 5-13...
  • Page 26 Parts to remove Remarks procedures Fasteners Take out key from shaft. Main bearing cover M8x44 ; 7 pcs. *Oil pump Wrap PTO shaft with polyvinyl tape M8x75 ; pcs. 'Oil filter not to damage oil seal by key groove *Oil pressure switch edge.
  • Page 27 Parts to remove Fasteners Remarks and procedures Step Mate the markings both on Camshaft and tappet camshaft crankshaft gear and gear and then take camshaft. Fig. p""""' TAPPET Fig. 5-1 7...
  • Page 28 Step Parts to remove Fasteners Remarks and procedures Piston and Connecting rod 1. Remove connecting rod bolts. ; 4 pcs. 'Piston pin clips Take out connecting rod cap. 'Piston pin 3. Push the connecting rod upwards 'Piston rings and take out along with piston. Put the marking of original position onto each piston, ring, clip, piston pin, connecting rod and cap for...
  • Page 29 Parts to remove Fasteners Step Remarks procedures Crankcase shaft *Governor lever *Leaf valve CRANKCASE GOVERNOR LEVER SHAFT LEAF VALVE RETAINER PLATE SCREW AND WASHER : 2 pcs " SNAP PIN Fig. 5-21...

  • Page 30: Reassembly Procedures

    5-4 REASSEMBLY PROCEDURES 5-4-1 PRECAUTIONS FOR REASSEMBLY 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. oil seals.
  • Page 31 CYLINDER HEAD. VALVES 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 varve guides. * Replace valves that are badly burned, pitted or warped. Valve guides should be replaced when valve stem cIearance exceeds specifications.
  • Page 32 C. PISTON and CONNECTING ROD ring. (1) Install oil ring first, then second ring and top 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 face upward. Top ring can be fit either way.
  • Page 33 Main bearina cover and aovemor aear Insert washer into governor gear shaft. (2) Insert governor gear along with sleeve into governor gear shaft. hole and tighten bolt by the specified torque. (3) Insert ball and spring into the relief valve 90 kg acm, 5.1 Tightening Torque : 6.9...
  • Page 34 2) PISTON and CONNECTING ROD PISTON RING COMPRESSOR Install piston and connecting rod assembly into CONNECTING ROD cylinder by using a piston ring compressor hold piston rings. Note: The "1 mark the connecting cylin- cylinder and "2" mark for #2 der should faced to the main bear- ing cover side when assembled.
  • Page 35 Adjust crankshaft play (1) Adjust end play to the specified values using the proper spacer. The proper spacer may be determined following manner. i ) Measure the depth "A" (From the mating surface to the boss.) 0 - 0) the height Measure "B"...
  • Page 36 MAIN BEARING COVER seal (1) Put a oil guide onto 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 37 7) CYLINDER HEAD NOTE ; Be sure to check dowel pin, and replace with new one if damaged. (1) Place new head gasket onto crankcase. (2) Install #I and #2 cylinder heads. Tighten bolts evenly in three steps by the specified torque. Tightening torque Final 1 st step...
  • Page 38 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" of flywheel with the mark "1" of #1 cylinder head. (2) Loosen the nut on rocker am and turn the pivot to adjust the clearance between rocker arm and valve stem end,...
  • Page 39 ROCKER COVER Install rocker cover with new gasket. lightening Torque : 8 . 8 (5.1 6.5 ft Ib.) 11) BREATHER PIPE and COVER valve) Attach breather plate (breather and breather GASKET breather plate cover to crankcase using proper gaskets. & Put breather plate in such position as its reed valve opens outside.
  • Page 40 13) CHARGE COIL Install charge coil with the wiring located at 5- o’clock position. 3.4 N lightening Torque : 1.5 35 kg (1.1 I b . ) 14) ELECTRIC STARTER starter. Install electric Tightening Torque : 16.7 18.6 N 190 kg (170 (1 2.3 13.7 ft...
  • Page 41 OIL FILLER and SUPPORT (BLOWER HOUSING) Install oil filler and support (blower housing) 16) CYLINDER BAFFLE Attach cylinder baffle # I , #2, #3 REGULATOR baffle. Attach regulator to cylinder FLANGE BOLT : 4 pcs. CYLINDER BAFFLE 5 Fig. 5-39 M6 FLANGE BOLT pcs.
  • Page 42 18) FLYWHEEL Wipe o f f oil and grease thoroughly from portion tapered of crankshaft and flywheel center hole. (2) Install flywheel to crankshaft and tighten flywheel nut with spring washer and washer. Tightening Torque 93.1 N 8 3 . 3 (850 (61.5 68.7 ft...
  • Page 43 22) GOVERNOR LEVER Attach governor rod and spring between governor lever and carburetor throttle lever, and insert the , - . governor lever to governor shaft. Tighten locking bolt temporarily. 23) SPEED CONTROL LEVER and CHOKE LEVER Attach governor spring between governor lever and speed control lever as shown the illustration.
  • Page 44 24) ADJUST GOVERNOR SYSTEM (1) Turn the speed control lever the way to- ward the high speed position and fix by tight- ening nut. (2) Check that governor lever is pulled by gover- is fully nor spring and carburetor throttle valve open.
  • Page 45 PRESSURE SWITCH 28) OIL Install oil pressure switch onto main bearing cover. Tightening Torque : 5.9 9.8 N -'IO0 (4.3 Ib.) Fig. 5-46 Apply oil to O-ring and install oil filter by tighten- ing about 314 turns after attaching main bearing cover surface.

  • Page 46: Break-In Operation

    ENGINE LEVEL Refill engine oil and start the engine. Engine GAUGE oil will be lubricated oil passages and filter. Check the engine level and refill again to FILLER the upper level oil level gauge. LEVEL Note: Total engine capacity about 2.0 * Use "SE"...

  • Page 47: Magneto

    6. MAGNETO 6-1 OPERATION AND FUNCTION The ignition system is a 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 due to dirty, burnt or corroded point surface. starts electronic automatic advancing ensures extremely easy and stable high performance at oper-...
  • Page 48 (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 to turn the signal transistor A "ON" allowing the current bypass as current turns At this moment the power transistor "OFF"...

  • Page 49: Lubrication System

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

  • Page 50: Carburetor

    8. CARBURETOR 8-1 OPERATION AND FUNCTION c u m Fig. 8-1...
  • Page 51 8-1 -1 FLOAT SYSTEM The float system is consists of float and a float valve, and maintains a constant fuel level during engine operation. The fuel flows from the fuel tank into the float chamber through float valve. When the fuel rises a specific level, the float rises, and when its buoyancy and fuel pressure are balanced, the float valve closes to shut the fuel, thereby keeping the fuel at the predetermined level.

  • Page 52: Compornent Parts

    8-2 COMPORNENT PARTS 1. Carburetor Ass’y Choke arm return spring 29. Round machine screw Slow jet Ass’y Choke lever ring 30. Solenoid valve Ass’y Main nozzle Choke collar 31. Vaccum hose Float Throttle valve 32. Fuel hose 5. Float valve Screw, valve set 33.

  • Page 53: Electric Starter

    9. ELECTRIC STARTER NOTE; For Electric starter operation, electric wiring should be connected among etectric starter, key switch battery as shown in the diagram. Oil Warning Lamp (Option Parts) " " " " " I f , " " " " " "...

  • Page 54: Compornent Parts

    9-2 COMPORNENT PARTS Fig. 1. Starting motor Ass’y 15. Gear case metal cover Armature Dust Ass’y cover kit 3. Thrust washer Shift lever kit Pinion stopper set Magnetic switch Ass’y 5. Yoke Ass’y 19. Through bolt Rear cover Ass’y 20. Bolt 7.

  • Page 55: Troubleshooting

    TROUBLESHOOTING The following three conditions must be fulfilled for satisfactory engine start. The cylinder filled with a proper fuel-air mixture. (2) Good compression in the cylinder. Good spark, properly timed, to ignite the mixture. The engine cannot started unless these three conditions are met. also There are other factors which make engine start difficult,...

  • Page 56: Starting Difficulties

    10-2 STARTING DIFFICULTIES Phenomenon Possible causes Remedy Charge battery 1) Battery discharged 2) Poor connection between battery and starter motor Clean or repair Low engine Clean or repair Poor connection between battery and ground speed at starting faulty 4) Electric starter repiace Repair...

  • Page 57: Insufficient Output

    10-3. INSUFFICIENT OUTPUT Possible causes Remedy 1 ) Loosen spark plug Retighten or replace gasket 2) Cylinder head gasket leakage Retighten or replace gasket 3) Piston ring(s) seizure or wear Replace 4) Piston or cylinder wear Repair or replace 5) Incorrect valve and seat contact Repair or replace 6) Valve stem seizure Repair or replace...

  • Page 58: Rough Idling

    10-5. ROUGH IDLING causes Remedy Possible Adjust idling speed 2) Carburetor slow system passage clogged Check and clean 2. Intake Air mixing from connecting portion of air intake Check , tighten or replace gasket svstem Cylinder Cylinder head gasket faulty (blow-by) Replace head 1) Improper valve clearance...

  • Page 59: High Fuel Consumption

    10-7. HIGH FUEL CONSUMPTION Phenomenon Possible causes Remedy Over-size main jet Replace 2) Needle valve faulty and/or high fuel level in float Fuel system Adjust or replace chamber Chock valve does not open fully. Repair or replace compression Check or repair 2.

  • Page 60: Engine Misfire

    ENGINE MISFIRE 10-9. Possible causes Phenomenon Remedy Clean, adjust or replace 1) lmprpper spark plug gap or damaged electrode 2) ignition coil faulty Replace 1. Ignition system 3) Damaged ignition system wirings Replace connection of ignition system wirings Check and connect properly 4) Poor Disassembly and repair Lean or rich aidfuel mixture...

  • Page 61: Installation

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

  • Page 62: Service Data

    12. SERVICE DATA 12-1 CLEARANCE DATA AND LIMITS Unit : mm (in: EH63V / 65V ITEM Limit CYLINDER HEAD Flatness less 0.05 (0.002 or less) (0.004) seat contact Valve width 0 . 7 1 . 0 2 . 0 IN. EX. (0.028 0.039) (0.079)
  • Page 63 Unit mm (in) EH63V / ITEM Limit CYLINDER inside dia. T o be rebored when :he difference between 80.000 8 0 . 0 1 9 nax. and min. (3.1496 3.1504) liameter reached to 1 . 1 (0.004). 80.250 - 80.269 Ditto reboring (3.159...
  • Page 64 Unit : mm (in) EH63V ITEM Limit 'ISTON 0.05 0 . 0 9 Ring groove side clearance (0.0002 0.0035) (0.006) 0.03 0.07 0 . 1 5 (0.0012 0.0028) (0.006) 0.175 0.057- Oil ring (0.0022 0.0069) (0.006) Piston pin hole 21.002 21.035 20.989 (0.8263...
  • Page 65 Unit : rnm (in) EH63V 165V Limit CONNECTING ROD Big end inside dia. 39.000 39.016 39.100 -5354 - 1.5361) (1.5394) 120' Clearance between big end and crankpin 0.030 0.060 (0.0012 0.0024) (0.0079) Small end inside dia. 21.01 0 21.023 21.080 (0.8272 0.8277) (0.8299)
  • Page 66 (in) Unit : EH63V / ITEM Limit :AMSHAFT height (IN. and EX.) 3 6 . 1 3 6 . 3 35.95 (1.4213 1.4291) ( 1 . 4 1 outside dia. Journal ’ “D” type 19.950 19.967 19.980 (0.7854) (0.786l 0.7866) JALVE stem ’...
  • Page 67 Unit : EH63V/65V ITEM Limit FAPPET Stem outside dia. 8.960 8.975 8.93 (0.3528 0.3533) (0.351 Guide inside dia 9.00 9.015 9.08 (0.3543 - 0.3549) (0.3575) Tappet guide clearance 0.025 0.055 0.15 (0.001 0 0.0022) (0.0059) FREE dALVE SPRING LENGTH 39.5 (1.5551) ~~~~ VALVE SEAT ANGLE (IN.

  • Page 68: Torque Specifications

    12-2 TORQUE SPECIFICATIONS Tightening Torque ITEMS ft-l b. Kg-cm Breather cover 2 . 9 4 . 9 2 . 2 3 . 6 Carburetor 6 . 9 8 . 8 5 . 1 6 . 5 b o k Charge c o i l 1 .

  • Page 69: Oil Grade Chart

    12-3 OIL GRADE CHART Use oil classified as SE or higher. Multi-grade tends to increase its consumption at high ambient temperature. Comparison between oil viscosity and temparature Single grade # E O Specified Lubricant Quality 1OW-30 Multi- grade 1 OW-40 40 "C 104 O F...

  • Page 70: Maintenance And Storage

    13. MAINTENANCE AND STORAGE 13-1 DAILY MAINTENANCE Every day before operating engine, check the following items; MAINTENANCE ITEMS REMARKS Governor linkage is especially sensitive to dust. Clean away dust and chaff from engine. Check fuel leakage from fuel system. If any, retighten fasteners replace necessary parts.
  • Page 71 Every Every Every Every Eve@ Maintenance Items hours 1,000 hours hours hours hours (daily) Clean and check bolts and nuts engine X (Daily) (Refill Check and refill engine oil daily to full level.) Change engine oil (‘Note Check battery electrolyte fluid level spark plug Clean Clean air cleaner...

  • Page 72: Engine Storage

    ENGINE STORAGE 13-3 Change engine oil a n d perform the daily maintenance items above mentioned. carburetor float chamber. (2) Drain fuel from prevent rust in the cylinder bore, apply oil through spark plug hole and turn crankshaft (3) To t h e several turns hand.
  • Page 74 SU6ARU ~bin America, Inc. 940 Lively Blvd. Wood Dale, IL 60191 Phone: 630-350~8200 Fax: 630-350-8212 e-mail: sale.s@robinamerica.com www.robinamerica.com PRINTED IN THE USA...

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Eh65v

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