Robin EH12-2 Service Manual
SERVICE
MANUAL
Models
EH09,
EH12-2 Rammer
ENGINES
PUB-ES1330
Rev. 12/01
940 Lively Blvd. • Wood Dale, IL 60191 • Phone: 630-350-8200 • Fax: 630-350-8212
e-mail: sales@robinamerica.com • www.robinamerica.com
© Copyright 2001 Robin America, Inc.
CONTENTS
Section Title Page
1. SPECIFICATIONS....................................................................................................... 1
2. PERFORMANCE ........................................................................................................3
2-1 MAXIMUM OUTPUT........................................................................................................ 3
2-2 CONTINUOUS RATED OUTPUT .................................................................................... 3
2-3 MAXIMUM TORQUE ....................................................................................................... 3
2-4 PERFORMANCE CURVES ............................................................................................. 4
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 VALVE ARRANGEMENT ................................................................................................. 9
4-8 CYLINDER HEAD............................................................................................................ 9
4-9 GOVERNOR SYSTEM .................................................................................................... 9
4-10 COOLING SYSTEM..................................................................................................... 10
4-11 LUBRICATION SYSTEM.............................................................................................. 10
4-12 IGNITION SYSTEM ..................................................................................................... 10
4-13 CARBURETOR............................................................................................................ 10
4-14 AIR CLEANER ..............................................................................................................11
4-15 DECOMPRESSION SYSTEM ......................................................................................11
4-16 SECTIONAL VIEW OF ENGINE.................................................................................. 12
5. DISASSEMBLY AND REASSEMBLY ....................................................................... 16
5-1 PREPARATIONS AND SUGGESTIONS........................................................................ 16
5-2 SPECIAL TOOLS (EH12-2D)......................................................................................... 16
5-3 DISASSEMBLY PROCEDURES.................................................................................... 17
5-4 REASSEMBLY PROCEDURES..................................................................................... 30
5-5 BREAK-IN OPERATION ................................................................................................ 46
6. MAGNETO ................................................................................................................ 46
6-1 OPERATION AND FUNCTION ...................................................................................... 46
6-2 BASIC THEORY ............................................................................................................ 46
6-3 WIRING DIAGRAM....................................................................................................... 48
7. AUTOMATIC DECOMPRESSION SYSTEM............................................................. 49
8a. FLOAT TYPE CARBURETOR (EH09D) ................................................................. 50
8a-1 OPERATION AND CONSTRUCTION.......................................................................... 50
8a-2 DISASSEMBLY AND REASSEMBLY........................................................................... 51
Section Title Page
8b. FLOAT TYPE CARBURETOR (EH12-2D)............................................................. 53
8b-1 OPERATION AND CONSTRUCTION..........................................................................53
8b-2 DISASSEMBLY AND REASSEMBLY...........................................................................54
8c. DIAPHRAGM TYPE CARBURETOR (OPTION) ................................................... 56
8c-1 OPERATION AND CONSTRUCTION..........................................................................56
8c-2 DISASSEMBLY PROCEDURE ....................................................................................59
8c-3 INSPECTION PROCEDURE ......................................................................................59
8c-4 REASSEMBLY PROCEDURE .....................................................................................60
8c-5 DIAPHRAGM CARBURETOR ADJUSTMENT METHOD............................................61
9. STARTING SYSTEM.................................................................................................62
9-1 RECOIL STARTER ........................................................................................................62
10. TROUBLESHOOTING ........................................................................................... 66
10-1 STARTING DIFFICULTIES ..........................................................................................66
10-2 ENGINE MISFIRE........................................................................................................67
10-3 ENGINE STOPS ..........................................................................................................67
10-4 ENGINE OVERHEAT...................................................................................................68
10-5 ENGINE KNOCKS .......................................................................................................68
10-6 ENGINE BACKFIRES THROUGH CARBURETOR.....................................................68
11. INSTALLATION ..................................................................................................... 69
11-1 INSTALLING................................................................................................................. 69
11-2 VENTILATION ..............................................................................................................69
11-3 EXHAUST GAS DISCHARGE .....................................................................................69
11-4 POWER TRANSMISSION TO DRIVEN MACHINES...................................................69
12. SERVICE DATA...................................................................................................... 70
12-1 CLEARANCE DATA AND LIMITS ................................................................................70
12-2 TORQUE SPECIFICATIONS .......................................................................................76
12-3 OIL GRADE CHART ....................................................................................................76
13. MAINTENANCE AND STORAGE.......................................................................... 77
13-1 DAILY MAINTENANCE................................................................................................77
13-2 INITIAL 20 HRS. MAINTENANCE ...............................................................................77
13-3 EVERY 50 HRS. (10 DAYS) MAINTENANCE .............................................................77
13-4 EVERY 100-200 HRS. (MONTHLY) MAINTENANCE .................................................78
13-5 EVERY 300 HRS. or YEARLY MAINTENANCE ..........................................................78
13-6 EVERY 500-600 HRS. MAINTENANCE......................................................................78
13-7 EVERY 1000 HRS. (YEARLY) MAINTENANCE ..........................................................78
13-8 ENGINE STORAGE.....................................................................................................78
1. SPECIFICATIONS
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- 2 -
2. PERFORMANCE
2-1 MAXIMUM OUTPUT
The maximum output is the output of an engine with its throttle valve fully opened and considering that all
the moving parts are properly broken in.
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 with 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
a specified r.p.m..
- 3 -
2-4 PERFORMANCE CURVES
EH09D
MAXIMUM TORQUE
N・m kgf・m
6 0.6
0.5
5
HP kW
3
2
2
1
OUTPUT
1
MAXIMUM HORSEPOWER
CONTINUOUS
RATED HP
RECOMMENDED
HORSEPOWER
RANGE
0.4
4
TORQUE
0
0
2000
REVOLUTION
3000
4000
r.p.m.
- 4 -
EH12-2D
HP
kW
3
4
3
2
2
OUTPUT
1
MAXIMUM TORQUE
MAXIMUM HORSEPOWER
CONTINUOUS RATED HP
RECOMMENDED
HORSEPOWER
RANGE
N・m kgf・m
8
0.8
7
0.7
6
0.6
TORQUE
1
0
2000 3000 4000
REVOLUTION r.p.m.
- 5 -
3. FEATURES
1. The EH09D and EH12-2D engines are designed exclusively for rammers.
Optimum lubrication and better inclined operation are obtained thanks to upright cylinder design.
2. Easy operation
These engines, with its upright cylinder, reduce swinging moment and achieved easier operation for
rammers.
Because the direction of vibratory force caused by reciprocating parts, such as piston and connecting
rod, is the same as the jumping direction of the rammer itself. Furthermore, these engines are designed carefully to balance the weight on the rammer by locating the air cleaner and muffler symmetrically with the center line of the cylinder.
3. Improved durability
Vibration damping and durability are greatly improved by introducing a vibration-proof breather mechanism, thick sheet metal, reinforced casting parts with thick walls and ribs, and a carburetor that prevents fuel leakage when the engine is inclined.
4. Ideal engine performance for rammer
The overhead valve design offers ideal combustion characteristics.
More emphasis was placed on the continuous rated power of the engine than its maximum power,
considering operating characteristics when the engine is mounted on a rammer.
5. Easy starting
Combining an ignition system with an advanced spark timing and mechanical compression release
improves start-ability. Equipped with a low-speed governor, it can be started without operating the
throttle.
6. Economical and clean engine
These engines achieved fuel-efficiency and cleanliness, reducing polluting exhaust emission remarkably.
- 6 -
4. GENERAL DESCRIPTION OF ENGINE COMPONENTS
4-1 CYLINDER AND CRANKCASE
The cylinder and crankcase is a 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-casting with thick reinforcing walls and ribs, which is
mounted on the output shaft side of the crankcase.
OIL GAUGE
Remove the main bearing cover to inspect the inside of the engine.
Pilots and bosses are machined on the cover for
direct mounting of the engine onto rammers.
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
that is pressed into position.
Fig. 4-2
- 7 -
Fig. 4-3
4-4 CONNECTING ROD AND PISTON
The connecting rod is an aluminum alloy die-casting 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.
Model: EH09D
4-5 PISTON RINGS
The piston rings are made of special cast iron.
The profile of the top ring and the second ring are
shown in the illustration.
The oil ring is designed for better sealing and less
oil consumption.
①
②
③
1
2
3
TOP
RING
SECOND
RING
OIL
RING
EH09D
EH12-2D
EH09D
EH12-2D
EH09D
EH12-2D
Model: EH12-2D
Fig. 4-4
BARREL
TAPER
TAPER
UNDER CUT
CUTTER
CUTTER RING WITH
COIL EXPANDER
RING
4-6 CAMSHAFT
The camshaft is made of special cast iron, and
camshaft and gear are cast together in one piece.
Both sides of the shaft fit into the plain bearings
on the crankcase and main bearing cover.
Fig. 4-5
Fig. 4-6
- 8 -
4-7 VALVE ARRANGEMENT
The intake valve is located on the flywheel side of the cylinder head.
Hard alloy valve seats are molded in the cylinder head and satellite is fused to the exhaust valve face.
The cylinder baffle leads cooling air to the exhaust valve area for the optimum cooling.
IN
EX
IN
EX
INTAKE
VALVE
EXHAUST
VALVE
Model: EH09D
Fig. 4-7a
4-8 CYLINDER HEAD
The cylinder head is an aluminum die-casting
which utilizes wedge type combustion chamber
for the high combustion efficiency.
INTAKE
VALVE
EXHAUST
VALVE
Model: EH12-2D
Fig. 4-7b
Fig. 4-8
4-9 GOVERNOR SYSTEM
The governor is a centrifugal flyweight type which
ensures constant operation at the selected speed
during load variations.
The governor gear with governor weights is installed on the main bearing cover.
GOVERNOR GEAR
Fig. 4-9
- 9 -
4-10 COOLING SYSTEM
The large fins on the flywheel provide sufficient
cooling air capacity for the inlet and exhaust area
and cylinder. The cylinder baffle directs the cooling air flow efficiently.
4-11 LUBRICATION SYSTEM
All the rotating and sliding parts are splash- lubricated by the oil splasher on the connecting rod.
OIL SPLASHER
Fig. 4-10
4-12 IGNITION SYSTEM
The ignition system is a transistor controlled magneto system which consists of a flywheel and an
ignition coil with a built-in transistor mounted on
the crankcase.
This system has an automatic ignition timing advance system for easy starting.
4-13 CARBURETOR
The engine is equipped with a horizontal draft carburetor that has a float controlled fuel system and
a fixed main jet.
The carburetors are calibrated carefully for sure
starting, good acceleration, less fuel consumption
and maximum output.
IGNITION COIL
FLYWHEEL
Fig. 4-11
For details, refer to page 50, section “8a FLOAT
CARBURETOR (EH09D)” or refer to page 53,
section “8b FLOAT CARBURETOR (EH12-2D)”.
As an optional part, diaphragm type is available.
For details, refer to page 56, section “8c DIAPHRAGM CARBURETOR (OPTION)”.
-
10
FLOAT TYPE DIAPHRAGM TYPE
Fig. 4-12
-
4-14 AIR CLEANER
The air-cleaner is a heavy-duty type with a dual
element system ; the primary one is an urethane
foam (semi-wet) and secondary one is a semi wet
type element.
URETHANE FOAM
CLEANER
COVER
CLEANER BASE
ELEMENT
Model: EH09D
Fig. 4-13a
CLEANER BASE
ELEMENT
CLEANER
COVER
4-15 DECOMPRESSION SYSTEM
An automatic decompression mechanism which
opens the exhaust valve before the piston reaches
maximum compression is assembled on the camshaft for easy starting.
During engine operation the decompression system is overpowered by centrifugal force and compression is fully utilized to produce power.
PLATE,
AIR CLEANER
ELEMENT SET
Model: EH12-2D
Fig. 4-13b
AUTOMATIC DECOMPRESSION SYSTEM
RETURN SPRING
Fig. 4-14
-
11
-
4-16 SECTIONAL VIEW OF ENGINE
EH09D
INTAKE VALVE
EXHAUST VALVE
MUFFLER
PISTON
PISTON RING
CYLINDER HEAD
PISTON PIN
IGNITION COIL
BLOWER HOUSING
RECOIL STARTER
P.T.O. SHAFT
MAIN
BEARING
COVER
ADAPTER
(
FLANGE
)
FLYWHEEL
CRANKCASE
Fig. 4-15
-
12
-
ROCKER COVER
PUSH ROD
ROCKER ARM
SPARK PLUG
CONNECTING ROD
CARBURETOR
AIR CLEANER
TAPPET
CAMSHAFT
GOVERNOR LEVER
SPEED CONTROL
LEVER
OIL GAUGE
PLUG
Fig. 4-16
-
13
-
CRANKSHAFT
STIFFENER
EH12-2D
INTAKE VALVE
EXHAUST VALVE
PISTON
PISTON RING
P.T.O. SHAFT
CYLINDER HEAD
IGNITION COIL
BLOWER HOUSING
PISTON PIN
MAIN
BEARING
COVER
CRANKCASE
Fig. 4-17
-
14
-
RECOIL STARTER
FLYWHEEL
ROCKER COVER
PUSH ROD
ROCKER ARM
SPARK PLUG
MUFFLER
CONNECTING ROD
CARBURETOR
AIR CLEANER
TAPPET
GOVERNOR
LEVER
CAMSHAFT
OIL GAUGE
CRANKSHAFT
Fig. 4-18
-
15
-
SPEED CONTROL
LEVER
PLUG
5. DISASSEMBLY AND REASSEMBLY
5-1 PREPARATIONS AND SUGGESTIONS
1) 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.
2) Have boxes ready to keep disassembled parts by group.
3) To prevent losing and misplacing, temporarily assemble each group of disassembled parts.
4) Carefully handle disassembled parts, and clean them with washing oil if necessary.
5) Use the correct tools in the correct way.
5-2 SPECIAL TOOLS (EH12-2D)
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-
16
-
5-3 DISASSEMBLY PROCEDURES
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EH09D
EH09D
M8 NUT
: 4 pcs.
OIL LEVEL GAUGE
M8 WASHER
: 4 pcs.
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STEP 1
OIL DRAIN
PLUG
GASKET
M8 SPRING
WASHER : 4 pcs.
ADAPTER
STEP 2
M8 x 30 BOLT AND
WASHER : 2 pcs.
STIFFENER
M8 x 25 BOLT AND
WASHER : 4 pcs.
-
17
-
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EH09D
STEP 4
M6 x 8 FLANGE BOLT
BLOWER
GUIDE CP
M4 TAPPING SCREW : 2 pcs.
STOP SWITCH
CLAMP
: 1 pce.
M6 x 12 FLANGE
BOLT : 1 pce.
M6 x 12 FLANGE BOLT : 1 pce.
M6 x 12 FLANGE
BOLT : 2 pcs.
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BOLT : 3 pcs.
STEP 3
RECOIL
STARTER
M6 x 12 FLANGE
BOLT: 1 pce.
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STEP 4
CLAMP
M4 TAPPING
SCREW : 2 pcs.
STOP
SWITCH
M6 x 8 FLANGE
BOLT: 1 pce.
BLOWER HOUSING CP
M6 x 8 FLANGE BOLT
: 4 pcs.
STEP 3
RECOIL
STARTER
M6 x 55 FLANGE BOLT
: 4 pcs.
BLOWER HOUSING CP
Fig. 5-3
-
18
-
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WASHER AY : 2 pcs.
MUFFLER
BRACKET CP
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M6 FLANGE NUT : 2 pcs.
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BLOWER HOUSING
BRACKET CP 2
CYLINDER BAFFLE
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EH12-2D
M6 SELF LOCK
NUT : 2 pcs.
M8 x 16 BOLT AND
WASHER AY : 2 pcs.
MUFFLER
M8 SELF LOCK
NUT : 2 pcs.
M8 x 16 BOLT AND
WASHER AY : 2 pcs.
Do not touch
the flange bolts.
GASKET
(
MUFFLER
STEP 5
GASKET
(
MUFFLER
)
)
STEP 5
SPACER
(
EXHAUST
)
MUFFLER BRACKET
M8 WASHER : 2 pcs.
M6 x 18 FLANGE
BOLT : 2 pcs.
HEAD COVER
-
19
-
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PURSE LOCK
BREATHER PIPE
STEP 6
CLEANER BASE
URETHANE FOAM
ELEMENT
CLEANER COVER
M6 SELF LOCK NUT : 2 pcs.
EH12-2D
BREATHER PIPE
CLAMP
WASHER
BOTTOM PLATE
PLATE(AIR CLEANER
M6 NUT : 2 pcs.
M8 x 18 BOLT AND
SPRING WASHER AY : 1 pce.
Fig. 5-5
-
20
-
)
ELEMENT
ELEMENT SET
CLEANER COVER
STEP 6
EH09D
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M6 x 8 FLANGE
BOLT : 2 pcs.
SPACER
SPEED CONTROL
LEVER AY
STEP 9
BASE
PLATE CP
M6 BOLT AND
WASHER AY : 1 pce.
RETURN
SPRING
ROD SPRING
GOVERNOR LEVER
FRICTION WASHER
INSULATOR
GOVERNOR ROD
GOVERNOR SPRING
M6 PIVOT BOLT
: 1 pce.
GASKET (INSULATOR
CARBURETOR
STEP 8
STEP 7
)
Fig. 5-6
-
21
-
EH12-2D
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M6 NUT : 2 pcs.
M6 x 40 BOLT AND
WASHER : 1 pce.
STEP 8
INTAKE
PIPE
INSULATOR
CARBURETOR
STEP 9
WIRE BRACKET
ROD SPRING
GOVERNOR
LEVER
STEP 7
M6 BOLT AND
WASHER AY : 1 pce.
M6 x14 FLANGE BOLT : 1 pce.
Fig. 5-7
-
GOVERNOR
ROD
GOVERNOR
SPRING
NUT
22
-
GASKET
(
INSULATOR
M6 PIVOT BOLT : 1 pce.
)
STEP 9
SPEED CONTROL LEVER
M6 x 12 FLANGE
BOLT : 1 pce.
PROTECTOR
M8 x 16 BOLT AND
WASHER AY : 1 pce.
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