Robin America DY30 manual

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ROBIN AMERICA, INC. ROBIN TO WISCONSIN ROBIN ENGINE MODEL CROSS REFERENCE LIST ROBIN EY08 EYl5 EY 15V EY20 EY20V EY23 EY28 EY35 EY40 EY45V EY2 1 EY44 EY25 EY27 EY 1 8-3 EHl 1 EH12 EHl5 EH17 EH2 1 EH25 EH30 EH30V EH34 EH34V EH43V EC13V DY23 DY27 DY3O DY3 5 DY4 1 WISCONSIN ROBIN S- W 1-080 W1-145 W1-145V Wl-185 WP-185V Wl-230 W 1-280 W 1-340 Wl-390 W[...]

CONTENTS . . See ti0 1 . 2 . 3 . 4 . 5 . 6 . 7 . 8 . 9 . 10 . 11 . 12 . n Ti rle Page SPECIFICATIONS ............................................. 1 PERFORMANCE .............................................. 3 2-1 Maximum Output ......................................... 3 2-2 Continuous Rated Output ................................... 3 2-3 Maximum[...]

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2. PERFORMANCE 2-1 MAXIMUM OUTPUT The maximum ouput of an engine is such standard power as developed by the engine, after its initial break in period with all - the moving parts properly worn in, when operating with a fully open injection pump. Therefore, a new engine may not develop the maximum output in the beginning because the moving parts are [...]

PERFORMANCE CURVE MODEL DY35DtB ,,,, 10 - 9- 8- 7- rv 6- 5- 4- 3- PERFORMANCE CURVE - MODEL DY41 D, B HP MAX. TORQUE I g/H P- h[...]

LIGWWEIGWTand COMPACT 1. Lightweight because of aluminum alloy being used for various parts including the crankcase made of aluminum die casting 2. Compact in outside dimensions because- a) the camshaft is assembled inside of the gear case cover, and accordingly total width of the engine is reduced, b) the cooling fan and the flywheel are single pi[...]

4-2 CRANKSHAFT The crankshaft is made of a forged chrome and molybdic steel piece with the crank pins and the journals ground to high precision after induction hardening. It is fitted to the flywheel on the fan side, and connection of the drive shaft to it is also possible. In the center of the pins and the jour- nals, holes for forced lubrication [...]

4-5 GEARCASE COVER Gearcase cover is made of aluminum alloy die casting and is fitted on the reverse side of the flywheel. This cover em- braces the injection pump, timing gear, operating lever and supports the camshaft as a bearing. To the gear case cover the tappet guide is fitted and then the tappets are assembled, (See Fig. 5 .) 4-6 CAMSHAFT Th[...]

4-9 ROCKER COWER Rocker cover is made of aluminum ailoy die casting and it is fitted to the cylinderhead and covers the rocker chamber. Rocker cover has a breather; and the air breathed is brought to the intake port. (See Fig. 7.) Fig. 7 . .- 4-10 GOVERNOR SYSTEM ! The governor is a centrifugal flyweight type and is installed ’ on the governor ge[...]

4-12 COOLING SYSTEM CYLINDER BAFFLE The cooling fan and the flywheel are a single piece casting and it is fitted to the top end of the crankshaft. Cooling air produced by this fan blows through blower housing and cyl- inder baffle, and cools cylinder and cylinderhead. (See Fig. lo.) 4-13 INJECTION PUMP The plunger of the fuel injection pump is oper[...]

4-15 COMBUSTION SYSTEM For lower fuel consumption and easy starting of the engine, the direct injection system is adopted in the combusition chamber. 4-15-1 FORMING of COMBUSTION GAS and COMBUS- TION /INTAKE VALVE INTAKE PORT SWIRL CYLINDER PISTON Fig. 13 SWIRL (Inspiring swirl) In order to promote mixing injected fuel and air under the direct inje[...]

4-16 SECTIONAL VIEW of ENGINE - 11 -[...]

EXHAUST VALVE ROCKER COVER CYLINDER HEAD- INTAKE VALVE AIR CLEANER CY L BA OIL PAN-’ - 12 -[...]

5. DISASSEMBLY and REASSEMBLY 5-1 PREPARATIONS and SUGGESTIONS 1) When disassembling the engine, remember well the locations of individual parts so that they can be reassembled cor- ,- rectly. If you are uncertain of identifying some parts, it is suggested that tags should be attached to them. 2) Have boxes ready to keep disassembled parts by group[...]

5-3 DISASSEMBLING SEQUENCE b Se- quence 1 2 I 3 4 5 6 7 *Length of the bolt indicates the length from the bolt head bottom surface to the threaded end. * * SW + Spring water * **W + Plain washer Item Procedures Remarks Bolts, nuts etc. used ~~~~~~~ ~ ~~~ ~ ~ ~~~ ~ - Engine oil Remove the oil drain plug and discharge oil. Oil drain plug locates unde[...]

- Se- quence Item Bolts, nuts etc. used Remarks Procedures 8 9 10 Fly wheel Blower housing Remove the flywheel cover. Remove the driving shaft. Raise up lock washer, loosen lock nut (41 mm box spanner) and then remove the flywheel from the crankshaft using the flywheel puller. Remove the blower housing from the crankcase. Crankshaft, normal threadi[...]

b l"2L quence I l5 ICylrnder 17 Tappet guide 18 Injection pump 19 Gear case Procedures Remove the cylinder. Remove the push rod sleeve from the gear case cover. Remove the tappet guide from the gear case cover. Remove oil filler cap. Put the control rack at the center. Remove the injection pump from the gear case cover. Remove the handle guide[...]

Procedures Remarks Bolts, nuts etc. used 20 Camshaft Pull out the camshaft. Between camshaft and gear case there is a shim. (See Fig. 24.) 21 22 23 Piston Remove the piston from the connecting rod. (Remove the clip and pull out the piston.) Governor and From the crankcase remove oil pump the governor and oil pump in the form of one piece. Oil pan R[...]

Se- tuence 24 I_ 25 Item Connecting rod Bearing hous- ing and crank- shaft Procedures Remove the connecting rod from the crankshaft. From the crankshaft remove the key on the side of fan. Remove the bolt fastening the bearing housing. Pull the crankshaft together with the bearing housing. (Gently tap the side of crank gear with plastic hammer.) Rem[...]

Fj quence Item 1 T 1 1 Intake and exhaust valve Procedures I Remarks I Bolts, nuts ~Pc. used Remove the intake and exhaust valves from the cylinderhead. On the side of intake valve, there is a stem seal. Be sure not to miss retainer lock. (See Fig. 30.) J Fig. 30 Se- 2 3 I tem Snap ring Balancer shaft Balancer Procedures Remove the snap ring. Remov[...]

5-4 HOW TO REASSEMBLE 1. PRECAUTION IN REASSEMBLING 1) Every and each part should be cleaned thoroughly. Easpecially, pay utmost care and attention to the cleanliness of the piston, cylinder, crankshaft, connecting rod and bearings. 2) Scrape completely off carbons from the cylinder head and the upper part of the piston; especially the carbon adher[...]

NOTE: With the copper shim adjust the side clear- ance of the crankshaft be 0.1 - 0.2 mm. Three kinds of shim are available, viz. 0.1 mm, 0.2 mm, and 0.3 mm thick. [Tightening toruque: 200 - 230 kg-cm] (See Fig. 35.) :- Fig. 35 u 3) Assemble the connecting rod. CAUTION: Pay attention to the direction of the rod. (FAN mark is to be set on the side o[...]

Assemble the piston. MOTE: + mark in the upper part of the piston is to be faced to the fan side. MOTE: Piston rings are not assembled. MOTE: Shape of the piston pin.is (D . (See Fig. 38 .) Assemble the cylinder NOTE: Insert the piston into the cylinder (piston ring is not inserted.), and measure the dimensions of the head of piston and upper surfa[...]

8) Install the camshaft. NOTE: Apply oil or grease to the inside of oit seal for the gear case cover. NOTE: Set the match mark of the camshaft so as to fit to that of the crank gear. Side clearance is to be adjusted to 0.1 - 0.3 mm. Three kinds of shim are available, viz. 0.8 mm, 1 .O mm and 1.2 mm. r Fig. 41 9) Assemble the oil pump and the govern[...]

Assemble the injection pump. 8 mm nut ............... 3 pcs. Spring washer ............ 3 pcs. NOTE: Measure the distance between the face of the cam base and the surface to which the injection pump is to be fitted. And adjust it may become 76 k 0.05 mm, using the shims. Two kinds of the shim are available, viz. 0.1 mm, and 0.3 mm. CAUTION: Remove [...]

a Assemble the cylinderhead. 10 mrn flange nut .......... 4 pcs. Washer ................. 4 pcs. NOTE: Install the intake and exhaust valves. On the intake side there is a stem seal. NOTE: Insert the push rod. (Exhaust is on the side of the gear case.) Pay attention to the valve facing, UP- ward or downward, and direction of intake and ex- haust. N[...]

INTAKE, EXHAUST VALVE TIMING When valve clearance is at 0.4 mm and the engine is heated, intake valve opens at 16O before TDC, intake valve closes at 54' after BDC, exhaust valve opens at 54' before BDC, and exhuast valve closes at 14" after TDC. (See Fig. 50.) Adjust the decompression clearance. TDC (TOP DEAD CENTER) INTAKE VALV INT[...]

Install the tank brackets, left and right. 8 x 16 7T bolt ............ 2 PCS. Spring washer ............ 2 pcs. 8 mm nut bolt ............ 2 pcs. each Connect the fuel pipe and fuel return pipe securely. 8 x 18 banjo bolt .......... 2 pcs. Aluminum packing ......... 2 pcs. NOTE: Connect the pipe to the nozzle first, and then connect the fuel pipe t[...]

6. FUEL 0-1 QUALITY Of FUEL Because of the high speed diesel engine, be sure to use the good quality diesel light oil. If improper fuel is used, the injection pump, nozzle, and piston develop troubles. (See Fig. 53.) i FUEL RETURN PIPE NOZZLE HIGH PRESSURE PIPE FUEL INJECTION PUMP f T / AIR RELEASE f UEL TANK / " FUEL FILTER FUEL PIPE PIPE[...]

7. GENERAL DESCRIPTION of AUXILIARY GADGETS and PARTS 7-1 FUEL INJECTION PUMP MECHANISM It is not too much to say that the fuel injection pump is the heart of the diesel engine, and it must be precise enough to sat- isfy the following functions. Function Injecting fuel, starting with high pressure and ending with low pressure. Injecting the predete[...]

3. Variation in quantity of fuel to be injected The quantity of fuel injected vanes according to the condition of the engine, i. e. high speed or low speed operation and loaded or unloaded operation. (See Figs. 55 and 56.) The plunger lead is engraved on the surface of plunger in an inclined curve. By rotating the plunger, the distance between the [...]

4. Injection timing and effective starting When the plunger closes suction port of the barrel, forced delivery of fuel starts. But fuel is not injected from the noz- 2le.at ence because of contraction of,fuel,'etc. . Injection timing of this engine is fixed constant (23O before TDC) irrespective of engine rpm. On the other hand, in start- ing,[...]

0 FUEL INJECTION PUMP PUMP DAMPING VALVE DAMPING VALVE SPRING DELIVERY VALVE DELIVERY VALVE AIR RELEASE BOLT HOLDER HOUSING DELIVERY VALVE CONTROL RACK PLUNGER ASSEMBLY - STOP CONTROL SLEEVE PLUNGER SPRING SPRING SEAT PIN Fig. 60 0 SPECIFICATIONS of FUEL INJECTION PUMP for THIS DIESEL ENGINE Model Maker PFRIKD55/2NP1 5.5 mm Plunger diameter Diesel [...]

7-2 FUEL INJECTION NOZZLE HOLDER 1. Specifications Part Name ~ ~~ I NOZZLE HOLDER I Part No. 4 No. of nozzle hole C Identification mark 105 11840 00 (Diameter) 13.2 kg/cm2 Spring constant 195 kg/cm2 Valve opening pressure (0.22 mm) - a 2. Features Both the injection nozzle and the injection pump are very important parts for producing fuel fog for c[...]

5. Fuel passage From the plunger pump fuel is sent through the highpres- sure pipe 1 to the fuel passage 2. Then, at the nozzle body 3, it is pressurized up till 195 kg/cm2 and it lifts up the needle valve 4 for 0.18 mm, and is sprayed into the combustion chamber via the jet hole 5. An excess fuel which lubricated the inside of the nozzle and nozzl[...]

2) Maintenance If the test results are found not good (poor injection and "after dripping"), carefully check and repair in the following manner: a) Disassemble the nozzle holder and nozzle, and wash in clean light oil. When washng, use a wooden chip (for instance, wooden chopstick is servicable.) for peeling off the carbon adhered to the [...]

7-3 GOVERNOR MECHANISM and OPERATION 1. Mechanism The governor is centrifugal flyweight type, which means a flyweight is fitted to the governor gear. The governor sleeve is as- sembled so that it may slide toward the direction of the axis of the pump shaft, and it is in contact with the flyweight. The governor sleeve gets in touch with the governor[...]

2. Operation 1) Starting When the speed control lever is set on the side of high speed, the governor spring is pulled via the control link. The governor levers 1 and 2 are pulled by the tension of the governor spring. The control rack of injection pump is pushed toward “fuel increase.” The governor lever 1 has an oblong hole, and the governor l[...]

7-4 LUBRICATION SYSTEM and OIL PUMP Lubrication is forced lubrication and wholly fdtered system by trochoid type oil pump. The oil pump, and the governor are assembled in one piece, which is fitted to the crankcase. Revolution of the crankshaft is reduced by the reduction gear (1 : 1.4) of the pump; and from the main gallery oil is forcibly lubrica[...]

7-6 ELECTRIC APPARATUS (Electric Starter) 1. Wiring diagram KEY SWITCH GENERATOR ELECTRIC STARTE 1) Circulation 12V35AH When starting by the electric starter, (Key is at the position of start.) Battery (+) -+ BAT of key + ST of key + Starter + Battery (-) (earth) Charging, operating (Key is at the position of operation.) Generator "f Rectifier[...]

8. 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. Carefully observe the following instructions for installing the engine. 8-1 INSTALLING When mounting the engine, carefully examine its position, the method of connecting it to a[...]

9. CHECKS and CORRECTIONS After disassembling and cleaning the engine, check and repair, if necessary, according to the correction table. The correction table applies whenever the engines are repaired. It is important for the servicemen to be familiar with the contents of tlus table. Correct maintenance is recommended by observing the correction st[...]

10. TABLES of CORRECTION STANDARDS r ITEM :ORRECTIOP METHOD STANDARD CORRECTION LIMIT 0.05 2.2 Flatness 0.03 Intake Exhaust Valve seat contact width 1.4 Valve guide I.D. I 7 dia. to.015 0.1 5 1 DY30D. 6 I 76dia. +0.019 Inside dia. 0.1 0.25 DY35D. B DY41 D, B 82 dia' +0.022 +" Roundness after boring 0.01 5 Cylindricity after boring 0.01 I [...]

r I I u CORRECTION REMARKS :ORRECTlO! METHOD ITEM DIMENSIONS STANDARD USE LIMIT -0.1 I TOLERANCE LIMIT -0.1 Piston ring width Oil 4 +0.006 0 -0.02 Piston pin O.D. 21 dia. Large end I .D. 43 dia. Metal thickness of large end 1.5 Clearance between large end and crankpin Small end I.D. after the bush is force fitted. 21 dia. Clearance between small en[...]

ITEM STANDARD I , 1 USE I CORRECTION CORRECTIOP I TOLERANCE LIMIT REMARKS METHOD Intake 0.063 L - 0.093 L - Exhaust 0.083L-0.113L Clearance between valve stem dia. and valve guide 0.3 0.3 5 Valve clearance both intake and exhaust 0.07 - 0.1 (cool condition) Ill Stem O.D. I -0.01 3 -0.033 I -0.07 I -0.07 I c 8 dia. Guide I.D. +0.015 0 N.08 M.08 Tape[...]

11. MAINTENANCE and STORING The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated main- tenance intervals are by no means guarantees for maintenance free operations during these intervals. For example, if the engine is operated in extremely dusty conditions, the air cleaner should be clean[...]

11-5 EVERY 500 - 600 HOURS (SEMIANNUAL) CHECKS and MAINTENANCE Checks and maintenance Reasons for requiring them Remove cylinder head and remove carbon deposit. Check valve seats both intake and exhaust and The engine will be out of order. Replace fuel fdter. The engine will be out of order. The engine will be out of order. grind, if necessary. ~~ [...]

12. 1/2 REDUCER AIR CLEANER MUFFLER OIL GAUGE STARTING HANDLE FUEL FILTER OIL FILTER STOP LEVER (DRAIN PLUG) .”- FUEL TANK REDUCTION GEAR P.T.O. SHAFT - 47 -[...]

12-1 CONFIGURATION of 1/2 REDUCER 01L CHECKING PLUG (M18 x 13) OIL EXHAUSTING PLUG (M8 x 13) Fig. 12- 1 - 48 -[...]

12-2 STRUCTURE Of 1/2 REDUCER CRAN OIL FILLER PLUG BEARING (#6205) THRUST WASHER OUTPUT SHAFT BEARING (#6206) THRUST WASHER BEARING (#6204) INPUT SHAFT BEARING (#6205) GEAR CASE Fig. 72-2 - 49 - I /"[...]

12-2-1 INPUT SHAFT The input shaft is a wholly carburized. product in which chrome-molybudenum steel is used, and the gear A and spline are built in it. 12-2-2 OUTPUT SHAFT The output shaft is made of carbon steel, and the gear C is fitted in spline engagement. 12-2-3 SHAFT B The shaft B is made of chrome-molybudenum steel, and wholly carburized. 1[...]

12-3 DISASSEMBLY and REASSEMBLY of 1/2 REDUCER 12-3-1 DISASSEMBLY SEQUENCE Length of the bolt indicates the length from the bold head bottom surface to the threaded end. *SW = Spring washer Procedures Main Item to be disassembled Se- quence 1 2 Remarks Bolts, etc. Used Replace the gasket with a new one. 8mm hexagonal bolt Opposite side: 13 mm Drain[...]

12-3-2 REASSEMBLING SEQUENCE 1. Precautions in Reassembling Every and each part should be thoroughly cleaned. Especially, pay utmost care and attention to cleanliness of the bearing. Carefully check the lip portion of every oil seal. If damaged one is found, replace it with a new one. Replace all the gaskets with new ones. Replace the bolts, if nec[...]

Pressure-fit the oil seals into the adaptor and the gear case. Set the shaft B with the thrust washer in the adaptor. (See Fig. 12-6.) Set the gear A and the gear B in the adaptor, under the condition that their teeth are engaged in each other. (See Fig. 12-7 .) Set the thrust washer onto the edge face of the gear B. Set the output shaft assembly i[...]

3. Mounting to Engine a) Supply grease into the grease filler hole (the section shown with inclined lines in the figure) of the input shaft. b) Set the packing in the coupling, and then clamp it to the engine’s flywheel with four 10 mm x 30 9T bolts. Tightening torque: 550-700 kg-cm‘ c) Apply grease to the coupling and spline gear teeth of the [...]

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