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Robin EHO9-2D Service Manual

Air-cooled, 4-cycle gasoline engine for rammer
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Summary of Contents for Robin EHO9-2D

  • Page 2: Table Of Contents

    CONTENTS Section Title Page 1. SPECIFICATIONS ............1 2.

  • Page 3: Specifications

    1. SPECIFICATIONS MODEL EH09-2D Air-Cooled, 4-Cycle, Single-Cylinder, Type Horizontal P.T.O. Shaft, OHV, gasoline engine Bore x Stroke mm (in.) 51 x 42 (2.01 x 1.65) Piston Displacement ml (cu.in.) 86 (5.25) Compression Ratio Maximum Output kW (HP) / r.p.m. 2.1 (2.9) / 4200 Continuous Output kW (HP) / r.p.m.

  • Page 4: Disassembly And Reassembly

    2. DISASSEMBLY AND REASSEMBLY 2-1) DISASSEMBLY PROCEDURES Step Parts to remove Remarks and procedures Fasteners Engine oil drain (1) Remove oil drain plug and drain oil. 14 mm spanner (2) To discharge oil quickly, remove oil gauge. Adapter and Stiffener M8 x 25 : 4 pcs.
  • Page 5 Step Parts to remove Remarks and procedures Fasteners Recoil starter Remove recoil starter from blower housing. M6 x 8 : 3 pcs. Be careful of pulling direction of starter rope. 10 mm box spanner Blower housing Disconnect wire of stop switch first, then M8 x 35 : 4 pcs.
  • Page 6 Step Parts to remove Remarks and procedures Fasteners Muffler and cylinder baffle Remove spark plug cap first from M8 bolt and washer : 2 pcs. spark plug, muffler and cylinder baffle. M6 x 14 : 2 pcs. (with sealant) Be careful not to lose gasket (muffler). M8 flange nut : 2 pcs.
  • Page 7 Step Parts to remove Remarks and procedures Fasteners Governor lever (1) Loosen the bolt and remove governor lever. M6 x 25 : 1 pc. (2) Unhook governor spring from governor lever. 10 mm box spanner Mark the hole on which the governor spring is hooked.
  • Page 8 Step Parts to remove Remarks and procedures Fasteners Ignition coil Remove ignition coil from crankcase. M6 x 25 : 2 pcs. 10 mm box spanner Flywheel (1) Remove the starter pulley from flywheel. M14 nut, springwasher : Place socket wrench on flywheel fastening 1 pc.
  • Page 9 Step Parts to remove Remarks and procedures Fasteners Rocker cover Remove rocker cover, gasket, breather plate M6 x 75 : 4 pcs. and oil shelter plate from cylinder head. 10 mm box spanner Cylinder head (1) Remove cylinder head and gasket from M8 x 55 : 2 pcs.
  • Page 10 Step Parts to remove Remarks and procedures Fasteners Main bearing cover Be careful not to damage the oil seal. M6 x 30 : 9 pcs. Use a soft hammer and evenly tap around 10 mm box spanner outer surface of cover. soft hammer STEP 15 MAIN BEARING...
  • Page 11 Step Parts to remove Remarks and procedures Fasteners Camshaft and tappets Lay carnkcase on the flywheel side push tappets up into the block and remove camshaft. Be careful not to damage camshaft and tappets. TAPPET STEP 16 CAMSHAFT CAMSHAFT – 9 –...
  • Page 12 Step Parts to remove Remarks and procedures Fasteners Connecting rod and (1) Remove connecting rod bolts and M5 x 25 : 2 pcs. connecting rod cap. 8 mm box spanner piston (2) Turn crankshaft until piston comes to top dead center, push out connecting rod and piston assembly through top of cylinder.
  • Page 13 Step Parts to remove Remarks and procedures Fasteners Crankshaft Tap lightly on flywheel end of crankshaft with soft hammer a soft hammer to remove from crankcase. * Be careful not to damage oil seal. STEP 18 CRANKSHAFT – 11 –...
  • Page 14 Step Parts to remove Remarks and procedures Fasteners Intake and exhaust (1) Press down the spring retainer, take 10 mm spanner out collet valve, and then remove hexagonal wrench valves spring retainer and valve spring. (2) Remove intake and exhaust valves from cylinder head.

  • Page 15: Reassembly Procedures

    2-2 REASSEMBLY PROCEDURES PRECAUTIONS FOR REASSEMBLY ● 1) Clean parts thoroughly before reassembly. Pay close attention to the 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 16 2-2-3 PISTON AND PISTON RINGS OPEN ENDS OF PISTON RING 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. Install top and second ring with punched mark beside the gap face upward.
  • Page 17 2-2-4 PISTON AND CONNECTING ROD (1) The direction of piston on connecting rod is not "MA" MARK specified. (2) Apply oil to the small end of connecting rod, piston and piston pin before assembling. Be sure to use clips on the both side of the piston pin to secure piston pin in position.
  • Page 18 2-2-5 CONNECTING ROD (1) Turn crankshaft to bottom dead center, lightly tap top of the piston until large end of the rod meet crank pin. SPLASHER (2) Install connecting rod cap to connecting rod. LEFT SIDE Attach connecting rod cap to connecting rod so "MA"...
  • Page 19 2-2-7 MAIN BEARING COVER (1) ADJUST CRANKSHAFT END PLAY Adjust end play to 0.2 mm (0.008") using the DEPTH GAUGE proper spacer. The proper spacer may be determined in the following manner. 1) Measure the height “A” (From the mating surface to the inner race of the ball bearing.) 2) Measure the depth “B”...
  • Page 20 (2) MAIN BEARING COVER Lubricate the oil seal and bearing surfaces. *Coat the suface of the main bearing cover with sealant (Three bond 1280B or 1216). Place spacer chosen in STEP (1) on crankshaft. Use an oil seal guide when installing the main bearing cover to avoid damaging the oil seal. Tap the cover into place with a soft hammer.
  • Page 21 2-2-8 CYLINDER HEAD (1) Clean carbon and gum deposits from the valves, seats, ports and guides. Inspect valves, valve seats and valve guides. (2) Replace valves that are badly burned, pitted or warped. (3) When installing valves in cylinder head, oil the valve stems and insert them into valve guide. Then place cylinder head on flat table, install valve spring and spring retainer.
  • Page 22 2-2-9 ROCKER ARMS AND PUSH RODS (1) Insert push rods into crankcase. Put push rod tip in the hollow of tappet top. * An oil return slot is located next to the tappet boss. If you do not put the push rod in the tappet properly, the push rods will fall into the crankcase.
  • Page 23 2-2-10 VALVE CLEARANCE ADJUSTMENT Note: Temporally fit the flywheel in position for easy operation. (1) Position the piston at the top dead center of compression stroke by matching the alignment mark of cooling blower with the alignment mark of crankcase. ALIGNMENT MARKS FLYWHEEL...
  • Page 24 2-2-11 SPARK PLUG Install spark plug to cylinder head. Spark plug : NGK BMR4A (CHAMPION : RCJ14) Tightening torque New spark plug Retightening 12 - 15 N•m 23 - 25 N•m (120 - 150 kgf•cm) (230 - 250 kgf•cm) (8.7 - 10.9 ft•lb.) (16.6 - 18.1 ft•lb.) 2-2-12 FLYWHEEL MAGNETO (1) Put the woodruff key in the keyway of crankshaft.
  • Page 25 2-2-13 IGNITION COIL Install ignition coil to crankcase. Pay attention the direction of ignition coil and the location of code. Adjust air gap between ignition coil and flywheel using a thickness gauge and tighten bolts. M6 x 25 mm bolt and washer : 2 pcs. Air gap : 0.3 - 0.5 mm IGNITION COIL (0.012 - 0.020 in.)
  • Page 26 2-2-14 GOVERNOR, SPEED CONTROL SYSTEM AND CARBURETOR (1) Install governor lever to governor shaft, then tighten the locking bolt temporarily. (2) Install base plate to crankcase. (3) Install speed control lever, friction washer, pivot bolt, etc. to base plate as shown in illustration. (4) Hook governor spring to proper holes of governor lever and speed control lever.
  • Page 27 2-2-15 AIR CLEANER (1) Install the air cleaner gasket and the cleaner base and tighten them. M6 flange nut : 2 pcs. Tightening torque 8 - 10 N•m (80 - 100 kgf•cm) (5.7 - 7.2 ft•lb.) (2) Then connect breather pipe from rocker cover to cleaner base.
  • Page 28 2-2-17 CYLINDER BAFFLE AND MUFFLER (step 1; temporarily fitting) (1) Attach gasket with the crows faced inside of muffler. (2) Temporarily attach cylinder baffle and muffler onto cylinder head. MUFFLER CYLINDER SIDE HEAD SIDE (3) Fit grommet, holding ignition code and stop switch wiring, into the cutting portion of cylinder baffle.
  • Page 29 2-2-18 BLOWER HOUSING AND RECOIL STARTER (1) Attach blower housing to crankcase. Tighten four flange bolts. M8 x 35 mm flange bolt : 4 pcs. Tightening torque 17 - 19 N•m (170 - 190 kgf•cm) (12.3 - 13.7 ft•lb.) (2) Install recoil starter to blower housing. M6 x 8 mm flange bolt : 3 pcs.
  • Page 30 2-2-20 STOP SWITCH CLAMP (1) Install stop switch to blower housing. STOP SWITCH (2) Connect wires referring to the wiring diagram. STOP SWITCH WIRE - End of the reassembly - – 28 –...

  • Page 31: Break-In Operation

    2-3 BREAK-IN OPERATION A new engine or an engine that has been completely overhauled by being fitted with a new piston, rings, valves and connecting rod should be thoroughly RUN-IN before being put back into service. Good bearing surfaces and running clearances between the various parts can only be established by operating the engine under reduced speed and loads for a short period of time.

  • Page 32: Troubleshooting

    3. TROUBLESHOOTING If the engine shows any sign of malfunction, the cause should be determined immediately and appropriate countermeasures should be taken to prevent the problem from worsening. This section describes certain known problems, their possible causes and appropriate countermeasures. Note, however, that the list of problems presented here is not all.
  • Page 33 Problem and possible cause Remedy 1. Insufficient compression 1) Loosen spark plug Retighten; replace gasket 2) Leakage from cylinder head gasket Retighten; replace gasket 3) Piston ring 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 34 Problem and possible cause Remedy 1. Oil leakage 1) Loose oil drain plug Tighten 2) Faulty oil drain gasket Replace 3) Loose main bearing cover bolts Tighten 4) Faulty main bearing cover gasket Replace 5) Crankshaft oil seal (front, rear) defect Replace 2.

  • Page 35: Service Data

    4. SERVICE DATA “STD” in the following table is the parts dimension from the brand new engine or the spare parts. Whereas, “Limit” shows the maximum allowance for the parts to be used on the engine. If the measurement exceeds beyond the “Limit” the part needs to be replaced and/or repaired. 4-1 CLEARANCE DATA AND LIMITS Unit : mm (in.) Limit...
  • Page 36 Unit : mm (in.) Limit ITEM PISTON 0.035 - 0.080 0.15 * Ring groove side clearance (0.0014 - 0.0031) (0.006) 0.035 - 0.080 0.15 (0.0014 - 0.0031) (0.006) 0.010 - 0.065 0.15 Oil ring (0.0004 - 0.0026) (0.006) * Piston pin hole 10.991 - 11.035 11.035 (0.4327 - 0.4344)
  • Page 37 Unit : mm (in.) Limit ITEM CONNECTING ROD * Big end inside dia. 21.0 - 21.013 21.1 (0.8268 - 0.8273) (0.8307) * Clearance between big end and crankpin 0.02 - 0.046 (0.0008 - 0.0018) (0.008) * Small end inside dia. 11.010 - 11.021 11.08 (0.4335 - 0.4339)
  • Page 38 Unit : mm (in.) Limit ITEM CAMSHAFT * Cam height (IN. and EX.) 18.3 - 18.5 18.15 (0.720 - 0.728) (0.715) * Journal outside dia. "D" type 9.972 - 9.987 9.95 (0.3926 - 0.3932) (0.3917) 9.972 - 9.987 9.95 (0.3926 - 0.3932) (0.3917) VALVE * Valve stem outside dia.
  • Page 39 Unit : mm (in.) Limit ITEM TAPPET * Stem outside dia. 7.960 - 7.975 (0.3134 - 0.3140) * Guide inside dia. 8.000 - 8.015 (0.3150 - 0.3156) * Tappet guide clearance 0.025 - 0.055 (0.0010 - 0.0022) VALVE SPRING FREE LENGTH 26.7 (1.05) VALVE SEAT ANGLE (IN.

  • Page 40: Torque Specifications

    4-2 TORQUE SPECIFICATIONS Tightening torque ITEMS N•m kgf•cm ft•lb. Cylinder head bolts 19 - 21 190 - 210 13.7 - 15.2 Connecting rod cap bolts 6 - 8 60 - 80 4.3 - 5.7 Flywheel nut 45 - 50 450 - 500 32.5 - 36.2 Main bearing cover bolts 10 - 12...
  • Page 41 CHANGZHOU FUJI CHANGCHAI ROBIN GASOLINE ENGINE CO.,LTD ADD: 28 CHANGJIANG NORTH ROAD, XINBEI DISTRICT CHANGZHOU, JIANGSU, CHINA Tel: 86-519-85036812 Fax: 86-519-85109259 Http://www.fcrrobin.com 常州富士常柴罗宾汽油机有限公司 地址：中国·江苏省·常州市新北区 长江北路28号 PRINTED IN CHINA 电话：86-519-85036812 传真:86-519-5109259 January 2017 Http://www.fcrrobin.com...

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