Robin America DY30 Service Manual Download

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Summary of Contents for DY30

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Page 2: ...EH12 EHl5 EH17 EH21 EH25 EH30 EH30V EH34 EH34V EH43V EC13V DY23 DY27 DY3O DY35 DY41 WISCONSIN ROBIN S W1 080 W1 145 W1 145V Wl 185 WP 185V Wl 230 W1 280 W1 340 Wl 390 W1 45OV EY21W EY44W EY25W EY27W EY18 3W v WOl 115 wo1 120 WO1 150 WOI I 70 wo1 210 WO1 250 WO1 300 WO1 3OOV WO1 340 WO1 340V WO1 430V TWO CYCLE WT1 125V DIESEL WRDI 230 WRD1 270 WRDl 300 wRD1 350 WRD1 410 ...

Page 3: ... 3 Governor Mechanism and Operation 36 7 4 Lubrication System and Oil Pump 38 7 5 Oil Filter 38 7 6 Electric Apparatus 39 INSTALLATION 40 8 1 Installing 40 8 2 Ventilation 40 8 3 Exhaust Gas Discharge 40 8 4 Fuel System 40 8 5 Power Transmission to Driven Machines 40 CHECKS and CORRECTIONS 41 TABLE of CORRECTIONSTANDARDS 42 MAINTENANCE and STORING 45 11 1 Daily Checks and Maintenance 45 11 2 Every...

Page 4: ...I b R X i p m E E I W W X E E N a 3 0 R X 6 t N E E W D X E E W r W Y P v X m 4 I t 1 ...

Page 5: ...L c L c VI W m V L c 0 m w I I I I I I 2 ...

Page 6: ...ed by that engine when running continuously at an opti mum speed and most favorable from the viewpoint of engine life and fuel consumption ratio with the governor in opera tion It is suggested therefore that when designing a driving system for any mechanism with this engine as prime mover the continuouspower requirement of that mechanism be kept below the continuous rated outputspecified 2 3 MAXIM...

Page 7: ...PERFORMANCE CURVE MODEL DY35DtB 10 9 8 7 rv 6 5 4 3 PERFORMANCE CURVE MODEL DY41D B HP MAX TORQUE I g H P h ...

Page 8: ... vibration EASY to TAKE OUT POWER A faucet joint is set in the blower housing which enables direct coupling with a machine P T O shaft is connected to the flywheel and accordingly this engine is very easy to handle Furthermore as cooling air is taken into from the frontof case reverse side of the machine coupled it is unnecessary to arrange air intakeon the side of the machine Therefore it is easy...

Page 9: ...er end thin kelmetis fitted forincreas ing durability 4 3 2 PISTON Piston is made of cast aluminum alloy and it hastwo com pression rings and an oil ring Combustion chamber arranged at the pistion head where combustion gas is made up by mixing atomized fuel and air and ignites See Fig 3 4 4 CYLINDER and CYLiNDERHEAD 4 4 1 CYLINDER Cylinder is made of aluminum alloy diecasting in which special cast...

Page 10: ...ting engine by hand cranking See Fig 6 4 7 TAPPET and TAPPET GUIDE 4 7 1 TAPPET Tappet is made of forged steel and wholly sintered ground and then taftride finished The camshaft has oil holes for lubricating tappets 4 7 2TAPPET GUIDE Tappet guide is made of aluminum alloy die casting and de termines tappet positionsandis fitted to the gear case cover In the crankcase there is a blow bygas hole whi...

Page 11: ...ation at the 1 selected speed against load variations See Fig 8 Fig 8 4 I f LUBRICATION SYSTEM Lubrication is whollyfilteredandpressurizedlubrication system by trochoid type oil pump From the maingallery in the crankcase the pressurized oil runs through the crank journals and crankpins and from the larger part of the rod the oil is supplied in the form of splash to the parts neces sary to be lubri...

Page 12: ...andcools cylinder and cylinderhead See Fig lo 4 13 INJECTION PUMP The plunger of the fuel injection pump is operated by the injection pump cam and the fuel from the tank is pressur ized in thepumpandsupplied to the nozzle via the high pressure pipe See Fig 11 4 14 NOZZLE Into the combustion chamber thenozzle injects the pressur ized fuel supplied from the pump through the high pressure pipe See Fi...

Page 13: ...nspired air is passing throughthispart swirl is generated around the intake valve Thus intake port plays an im portant role in generatingswirl See Fig 13 SQUISH Squished air flow In the piston combustion chamber dish type com bustion chamber is formed When the piston comes up to TDC top dead center air in the gaps is squished in the combustion chamber and air flow is generated which iscalled squis...

Page 14: ...4 16 SECTIONAL VIEW of ENGINE 11 ...

Page 15: ...EXHAUST VALVE ROCKER COVER CYLINDER HEAD INTAKE VALVE AIR CLEANER CY L BA OIL PAN 12 ...

Page 16: ... prevent missing and misplacing temporarily assembleas much as possible each group or set of disassembled small parts suchas bolts and nuts etc 4 Carefully handle disassembled parts and clean them withwashing oil 5 Use the correct tools in the correct way 5 2 SPECIAL TOOLS I Tool No I I Tool Use I 228 95001 07 For pullingoff the flywheel Flywheel puller with bolt I 22895002 07 1 Box wrench For rem...

Page 17: ...nk Remove the fuel pipe Remove the fuel return pipe Removethe tank band Remove the banjo bolt There are2 sheets of on theside of the tank 8 x 18 banjo bolt 1 pce aluminum gasket There are2 sheets of aluminum gasket 6 x 45 round head cross recess bolt 2 pcs No SW W Muffler 6 x X mm flange bolt Remove the mufflercover 4 pcs Remove the muffler Be sure not to miss the gasket High pressure Pipe Remove ...

Page 18: ...e cylinderhead sw 3 pcs Nozzle holder 6 mm nut 2 pcs At the top end the Remove the nozzle holder from the cylinderhead sw 2 pcs gasket is fitted l 3 IRocker arm ILoosen thenuts fastening theLoosenthetappetadjust cylinderhead ing bolt and the decom pression adjusting bolt which latter is on the side of the intakevalve See Fig 19 Pull out the rocker shaft from the cylinderhead and remove the rocker ...

Page 19: ...move the injection pump from the gear case cover Remove the handleguide Remove the gear case cover from thecrankcase I t Fig 20 r c P Remarks I Bolts nuts etc used are rubber 0 ring and copper shim See Fig 20 6 mm nut 2 pcs sw 2 pcs A holder is necessary for not letfall the tappet See Fig 21 Check the position of 8 mm nut 3 pcs control rack s w 3 pcs See Fig 22 See Fig 23 6 x 6 hex bolt 2 pcs 8 x ...

Page 20: ...and pullout the piston Governor and From thecrankcase remove oil pump the governorand o i l pump in the form of one piece O i l pan Remove the o i l pan from the crankcase Watch the direction of the clip also pay atten tion to the direction of the piston f mark indicates to ward the fanside See Fig 25 6 x 20 7T bolt 2 pcs sw 2 pcs Be careful of the pack 6 x 12 bolt 8 pcs ings s w 8 pcs Fig 24 Fig ...

Page 21: ...e of crank gear with plastic hammer Remarks No lock washer Be careful of the direc tion of rod Fan mark is on the sideof the flywheel Be careful of the setting mark of the cap See Fig 26 Be careful of the copper shim and 0 ring be tween the bearing hous ing and thecase Also be carefulof the hole for o i l Bolts nuts etc used 8 x 22 7T bolt 6 pcs SW 6 pcs After pulling out the crankshaft from the c...

Page 22: ...etainer lock See Fig 30 J Fig 30 Se 2 3 Item Snap ring Balancer shaft Balancer Procedures Remove the snap ring Remove the balancer shaft Remove the balancer from the case Remarks Be sure not to miss the snap ring See Fig 31 Gently tap with plastic hammer Be careful not to damage the thrust metal on the side of the pump The gear and the needle bearing are in one piece See Fig 32 Bolts nuts etc used...

Page 23: ... the specified figures 7 Apply oil to therevolutionary parts and friction surfaces when reassembling 8 Check and cidjust the clearances of variouts portions and then reassemble 9 When some main Grtions are assembled in the course of reassembling turn or move the gadgets by hand and pay at tntion to the frictional noise and resistance 2 REASSEMBLING 1 Insert the crankshaft into the crankcase CAUTIO...

Page 24: ...Fig 35 u 3 Assemble the connecting rod CAUTION Pay attention to the directionof the rod FAN mark is to be set on theside of the flywheel NOTE Check the match mark on the cap NOTE The lock washer is not usedwhenfastening the bolt Tightening torque 250 270 kg cml See Fig 36 Fig 36 4 Assemble the oil pan 6 x 12 bolt 8 pcs Springwasher 8 pcs NOTE Pay attention to the packings See Fig 37 Fig 37 21 ...

Page 25: ...o bemade by the shim underneath thecylinder and availablethick ness of the shim are 0 1 mm and 0 2mm MOTE Fit the piston rings on the piston Punched mark N are to be faced up Open endof each ring must avoid the direction toward the thrust side and it is to be set to the different three directions NOTE Set the cylinder Be sure to fit rubber 0 ring and shim Notched portion of the cylinder skirtmust ...

Page 26: ...pring washer 2 pcs NOTE Thehole in the oil pump coveris to face downward NOTE Check if the governorsleeve moves smoothly Outer surface of the trochoid pump must face the case side See Fig 43 Tightening torque 80 100 kg crn Fig 42 10 Assemble the gear case cover Fig 43 8 x 5 7T bolt 4 pcs Springwasher 4 pcs NOTE When the pin is replaced apply Three Bond at theboth ends of the pin for cranking This ...

Page 27: ...3mm CAUTION Remove the oil filler cap and check if the control rack comes off fromthe governor lever See Figs 44 and 45 l _ l ___ I Fig 45 Assembe the tappet guide CAUTION Be careful not let thetappet fall in case NOTE The roll pin of the tappet guide is to be a t the rightside as viewed from the gearcase side See Fig 46 the set Fig 46 13 Temporarilyassemblethepushrod sleeve 6 mm nut 2 pcs Springw...

Page 28: ... 215 to twopieces of the stud bolt on the side of the rocker shaft andupperand reverse surfaces of the washer and then tighten the nuts Tightening torque 350 kg cm Tightening of the nuts is to be done in threerounds I e 1s t round 100 kg cm 2nd round 200 kg crn 3rd round 330 350 kgcm NOTE Fasten tightly the plate push rod sleeve 6 mm nut 4 pcs See Fig 48 15 Adjust the valve clearance NOTE Turnthef...

Page 29: ...ding of this screw is 1 O mm Turn the flywheelby hand and checka contact between thevalve and the piston Assemble the rocker cover 6 x 3 5 7Tbolt 3pcs Springwasher 3 pcs NOTE Check if there is an 0 ring for breather hole on the surface of the head intake breather s side NOTE Check if the gasket for the rocker cover is put correctly in the groove Install the nozzle holder 6 mm nut 2 pcs Springwashe...

Page 30: ...pcs NOTE Pay attention to the gasket Connect the high pressure pipe See Fig 52 It is advisable to remove the cap of the air cleaner and I then connect Mount the fuel tank 6 x 45 round head cross recess screw 2 pcs When installing the fuel filter once removed from the tank fasten the filter byhand andthen make 1 4 turn with a spanner Install theoil filter 6 x 12 bolt 2 pcs Springwasher 2 pcs The oi...

Page 31: ...lity 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 AIRRELEASE f UEL TANK FUEL FILTER FUEL PIPE PIPE TANK FILTER PIPE PUMP PRESSURE PIPE t FUEL RETURN PIPE Fig 5 3 28 ...

Page 32: ...uel are conducted See Fig 54 Suction of fuel Through the filter in the fuel tank fuel is supplied and is in full around the intake port of the plunger barrel When the topof the cam lobe passed the tappet and cam function ended plunger spring pushesdown the plunger When the plunger is pushed down passing the fuel intake fuelis sucked into the barrel and suctionis continued until arrival of the plun...

Page 33: ...ger is made by the control rack When this controlrack is shifted to left and or right thegeared pinion rotates which is connected to theplunger by means of the controlsleeve In other words the plunger turns as much amount as the rack rotates Accordingly the effective stroke varies coincident with the positionwhere the rack is set 1 Relation between the plunger and the barrel EFFECTIVE STROKE PLUNG...

Page 34: ...high pressure pipe is delivered forcibly When theplunger lead meets suctionport of the plunger barrel deliveryof fuel ends and the deliveryvalve is closed by the spring tension of the valve At this time delivery valve prevents reverse flow of the fuel Also suction back motion around the upper part of the plunger sucks back the fuel in the equal amount of the stroke A and decreases remaining pressu...

Page 35: ...L 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 Kiki K K Lead 2 46 kg cm Plunger springarbitrary Right twist lead Delivery valve opening pressure 0 51 kg mm Delivery valve spring constant 27 5 kg cm2 Pump rack friction load 16 mm Rack stroke 0 062 kg 32 ...

Page 36: ...n pressure is raised up to 195 kg cm2 3 Structure of the ignition nozzle holder IDENTIFICATION MARK Ths consists of the nozzleholderandnozzle The nozzle FUEL INLET holder fixes the nozzle to the cytinderhead and at the same timeitplaysthe role of fuel passage to thenozzle The valve opening pressure of nozzle is adjustable However the nozzle for DY30 and DY35 engines includes spacer in it and it is...

Page 37: ...sely processed parts utmost care and attention must be paid when inspecting and checking 1 Inspection After cleaning nozzle holder outside inspectin the be low sequence a Visual inspection Whether or not injection hole is damaged orclog ged with carbon Whether or not injection hole is clogged with dust and carbon b Inspectionbynozzletester Fit thenozzle holder to thenozzle tester CAUTION When remo...

Page 38: ... be sure to keep the parts freeof dust e If after dripping is found itispoorcontactbe tween the needle valve and the seat In such a case it is advisable to replace it in the form of a set nee Fig 66 dle valve and nozzle body However it is possible to coat chrome oxide on the tapered surface of the needle and get a good contact Wash very carefully after correc tion f Adjustment of the valve opening...

Page 39: ...flyweight The governor sleeve gets in touch with the governor yoke and through the governorlever it makes the controlrack of injection pump operate This mechanism enablesto maintain constant operation irrespective of load variation GOVERNOR FUELDECREASE 7 INJECTION PUMP FUEL INCREASE GOVERNOR GOVERNOR YOKE START SPRl OBLONG HOLE GOVERNOR LEVER 1 GOVERNOR SPRING CONTROL LINK SPEED CONTROL LEVER LOW...

Page 40: ...e load As a resut engine revolution decreases which meansthat the centrifugal force on the flyweight decreases Then the governor lever 2 moves to the position where it balances the tensionof the governor spring The control rack of injection pumpis pushed toward fuel increase and engine revolutionrevives 3 Stopping Thegovernorplaysa role exactly reverse to that of starting When the speed control le...

Page 41: ...o the cam shaft bearing and is sent to cam lobe of intake and exhaust valves and lubricate the tappets In the camshaft oil relief valve is assembled and it adjusts the o i l pressure at 3 kg cm2 Lubrication in the rocker chamber is conducted by the splash of oil pushed up by blow by gas which lubricates rocker arm etc Furthermore blow bygascontaining oil will pass through the breather intake port ...

Page 42: ...lectrically conducted completely to the crankcase of the engine 4 Other remarks 1 All lead wires are classified by coloring so when connecting select and connect by color Meantime insert the connectors each other up till the roots 2 The wire from terminal of the battery must be connected to terminal of the electric starter and thewire from the terminal must be connectedto the earthof the engme bod...

Page 43: ...rs If a long exhaust pipe is used in such a case the internalresistance increases causingloss of engine power Thus pipe inside diameter must in crease in proportion to exhaust pipe length Exhaust pipe Less than 3 m long pipeinside diameter 30 mm Less than 5 m long pipeinside diameter 38 mm 8 4 FUEL SYSTEM If the fuel tank is removed from the enginewhen mounting the enginewitha machine set the fuel...

Page 44: ...anings of the terms used inthe correction tableare as follows 1 Correction Repair adjustmentor replacement of any engine parts 2 Correction Limit The limit on wear damage or functional deterioration of engine parts beyond which normal engine performance can not be expected without repairing such parts 3 Use Limit The limit beyond which parts can no longer be used in respectof performance or streng...

Page 45: ...94 DY30D B 76 21 Oversize A 0 02 DY41D B O D at skirt in thrust direction Incl over size 0 1 0 13 0 1 1 DY30D B 1 76 46 I Oversize 0 DY35D DY4t D B 82 44 O 060 O 040 Width of groove for the rings 0 025 O 005 Piston pin hole 21 dia 1 M 008 to 001 0 03 0 15 0 2 0 15 I Skirtportion Clearance between piston and cylinder DYSOD B DY350 B 0 04OL 0 079L DY41D B 0 060L 0 1 02L 0 2 1 0 15 Clearance between ...

Page 46: ... parallelism Journal diameter 42 dia Journal roundness I D after main bearing being force fitted Main bearing Clearance between journal and main bearing Intake and exhaustcams 40 Injection pump cam 36 495 Cam lobe height Rear 22 dia Journal 0 0 Front 35 dia Intake Valve stem O D 7 dia Exhaust 0 02 0 016 0 0 005 0 018 0 01 L 0 068L Metal in centei 1 4 0 1 1 4 0 1 0 034 0 013 0 05 0 05 0 007L 0 034L...

Page 47: ...earance I I 0 016L 0 052L I I 0 15 I I 0 15 Valve spirng free length I 36 5 I P From injection pump a flunge surface to cam base 0 Static iniection timing 23 before TDC lo 76 O 05 Adjust E 4 l I Injectionstarting pressure 0 N nozzle Nozzle dia x number of 0 22 dia x 4 pcs TABLE of TIGHTENING TORQUE Description 200 230 kg cm Gear case cover Tightening torque Blower housing fasteningbolt 330 350 kg ...

Page 48: ...Not only wasteful but also dangerous Loose screws andnuts will result in vibration accidents If the engine isoperated without sufficient oil it will fail Checks and maintenance Reasons for requiring them Change crankcase oil To remove run in wear particles 11 3 EVERY 50 HOURS IODAYS CHECK and MAINTENANCE Checks and maintenance Reasons for requiring them Change crankcase oil If the engme is operate...

Page 49: ...ome outof order 11 7 EVERY 1500 HOURS OVERHAULS I Checks and maintenance Reasons for requiring them I Performoverhauls clean correct or replace parts I The engine output drops and become out of order I 11 8 PREPARATION for LONGABEYANCE 1 Perform the above 11 1 and 11 2maintenance job 2 Drainfuel from the fuel tank 3 To prevent rust in the cylinder bore apply oil throughthebreatherholeonthesurface ...

Page 50: ...12 1 2 REDUCER AIR CLEANER MUFFLER OIL GAUGE STARTING HANDLE FUEL FILTER OIL FILTER STOPLEVER DRAIN PLUG FUEL TANK REDUCTION GEAR P T O SHAFT 47 ...

Page 51: ...12 1 CONFIGURATION of 1 2 REDUCER 01L CHECKING PLUG M18 x 13 OIL EXHAUSTING PLUG M8x 13 Fig 12 1 48 ...

Page 52: ...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 ...

Page 53: ...ear B are wholly carburized products in which chrome molybudenum steelis used and are helical gears with moduleof 2 12 2 5 ADAPTOR and GEAR CASE The adaptor and thegear case are components of a bodyof the 1 2 reducer and are made of aluminum alloyed dicast 12 2 6 COUPLING The coupling is a component to deliver output from the engine to the 1 2 reducer and is fitted to the input shaftin spline enga...

Page 54: ...urface Remove the O ringof the input shaft 4 Be careful not to lose 8 x 40 7T bolt 6 pcs Be carefult not to lose the 4 pcs the packing 10 mmx 30 9T bolt sws 8 x 50 7T bolt 1 pce with SWs 7 Wind vinyl tape around the input outputshafts Cover whole surfaceof the shafts to protect the o i l seal 8 Separate the gear from the adaptor Hold the output shaft and strike the adaptor with a wood hammeror a p...

Page 55: ... the edge face side Then insert the shim between the bearing 6205 and the gear so that the clearance betweenthetwo bearings afterthey have beenpressure fitted is from 49 mm to 48 9 mm Two types of shm 0 3 mm thick and 0 1 mm thick are available See Fig 12 3 When installing the spline and the O rings in the case wind vinyl tape around their grooves to protect the oil seals See Fig 12 4 INPUT SHAFT ...

Page 56: ... shaftassembly in the adaptor See Fig 12 8 Put the packing on the mating face of the case Itis not necessary to supply sealing compund to the matingface Cover the gear case Don t give physical impacts with such tools as a hammer to compulsorily set it SeeFig 12 9 Clamp the case with six M8 40 7T bolts and an M8 50 7T bolt Never forget to set thrust washers for the bolts Tightening torque 250 kg cm...

Page 57: ...lampit to the engine s flywheel with four 10 mm x 30 9T bolts Tightening torque 550 700 kg cm c Apply grease to thecoupling and spline gear teeth of the input shaft d Setthe 1 2 reducerintheengineunder theconditionthatthe spline teethare engaged and clampitwithfour 8 mm x 65 7T bolts Tightening torque 200 230 kg cm r FLYWHEEL T SHAFT GREASE FILLER HOLE COUPLING Fig 12 70 54 ...

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