Robin DY23, DY27 Service Manual
ROBIN
ENGINE
ROBIN
TO
MODEL
AMERICA,
WISCONSIN
INC.
ROBIN
CROSS REFERENCE LIST
ROBIN
EY 08
EY15
EY 15V
EY 20
EY20V
EY23
EY28
EY35
EY40
EY45V
EY2
1
EY44
18-3
EY
EY25
EY27
SIDE
VALVE
OVERHEAD
WISCONSIN
W 1-080
W1-145
W1-145V
W1-185
W1-185V
Wl-230
W 1-280
W 1-340
W
1-390
W
1
-450V
EY21W
EY44W
EY 18-3W
EY25W
EY27W
VALVE
ROBIN
EH11
EH12
EHl5
EHI
7
EH2
1
EH25
EH30
EH30V
EH34
EH34V
EH43 V
EC13V
DY23
DY27
DY30
DY3
5
DY4
1
TWO
CYCLE
DIESEL
WOI-115
WOI-120
WO1-150
WOI-170
wo1-210
WO1-250
WO
1-300
WO 1 -300v
WO1-340
WO
1
-340V
WO1-430V
WT1-125V
WRD
WRD
WRD
1-230
1-270
1-300
WRD1-350
WRD1-410
CONTENTS
Section Title Page
r
1.
SPECIFICATIONS
Model
Type
Bore X Stroke
Piston Displacement
Compression Ratio
output
DIN6270NB
output
DIN6270NA
Torque kg
DlN6270NB
Rotation
Cool
in
g
Lubrication
(
HP/ rpm
(Warnin”)
HP/ rpm
(KW-min”)
-
m
/
rpm
ft.lbs/
rpm
DY23-2D
DY23-2B
DY27-2
Air-Cooled. 4-cycle, Overhead Valve, Single vertical cylinder, Diesel engine
I
75 X 60 mm
(
2.95 X 2.36
(
16.1 1 cain.
/
3600
/
3600
/
2400
2400
265 cc
1
1
1
in.
1
)
5.5
/
1
800
(
4.0/ 1800
5.0
/
1
800
(
3.7/
1800
2.46/ 1200
(
17.W 1200
(
(
1.07/ 2200
1
(
I
I
I
70
(
2.76 X 2.36
(
14.04 cu.in.
4.8 / 3600
3.5 / 3600
/
3600
4.2
3.1
/
3600
7.7/
2200
Counterclockwise as viewd from PTO shaft side
X
230 cc
)
)
)
60
rnrn
in.
)
4.8
/
(
3.5/ 1800
4.2 / 1800
(3.1
/1800
2.14/ 1100
(15.4/11001
Forced oil lubrication
)
21
1
800
1
1
Forced air cooling
5.5
(
4.0/ 3600
5.0 / 3600
(
3.7
1.23
(
8.9/
1
1
1
Lubricant
Oil Pump
Fuel Injection Pump
Injection Nozzle
Fuel
Fuel Feed
Fuel Tank Capacity
Combustion System
Governor System
Lighting Capacity
Starting System
Dry Weight
I
I
I
(63.9
Diesel engine oil. service rank CC or CD
Recoil starter
Ibs.)
Trochoid gear pump
ZEXEL
ZEXEL
Automotive diesel
3.2 liters ( 0.84 U.S.gal.
Direct injection type
Centrifugal flyweight type
1
2V- 39W/
12V-43W/ 3600
(65.0
PFRIMD55
DLLAI
Gravity
3000
(
Electric starter as option
50PN052
type
Ibs.)
/
2NP1
fuel
(65.0
1
12V
-
39W
/
3000
12V - 43W / 3600
)
30
kg
lbs.) (66.1 Ibs.)
Dimension
LXWXH
329
x
357
x
402
mm
(1
2.95 x 14.06 x 15.82 in.)
Specifications are subject to change without notice.
-1-
339 x 357
(13.35 x 14.06
x
402
x
15.82
mm
in.)
2-
1
MAXIMUM OUTPUT
The maximum output
its
throttle valve fully open after it has been broken in properly.
Therefore, a brand-new engine
not produce the maximum output.
2-2
The continuous rated output of an engine is the output power
at the rated engine speed controlled by its governor system.
The operation of the engine at the continuous rated output
view point
CONTINUOUS RATED OUTPUT
of
engine life and fuel economy.
is
It
to
2-3
The maximum torque indicates the torque at the output shaft when the engine
producing the maximum output.
recommended, therefore, that the- equipment driven by the engine to be designed
require the engine power less than its continuous rated output.
MAXIMUM
TORQUE
of
an
engine is the output power
or
an engine which has not been broken in properly may
of
the engine operating with
of
the engine running
is
most
favorable
from
the
is
-2-
2
-
4
PERFORMANCE
CURVES
MODEL
DY23-2
HP
5
4
I
!z
23
W
v)
IT
0
I
2
1
FUEL CONSUMPTION
\
I
1500
(750)
L
2000
(1000)
REVOLUTION
TORQUE
2500
(1250) (1500) (1750) (2000)
"----+
RATIO
L
(NB)
(NB)
I
3000
\
r.
p.
I
3500 4/00
rn.
kg
1.2 (2.4)
1.1
(2.2)
1
.o
(2.0)
i
(1.8)
z
0
I-
y
g
W
2
c1:
O
I-
g/HP-h
-
3.9
240
220
200
&
22
-
m
MODEL
DY27-2
6
HP
5
4
I
9
5
0-3
W
v)
I1I
P
2
1
(
1
for
B
type
.3
.2 (2.4)
.1
.o
(2.6)
(2.2)
(2.0)
kg-
Y
m
2
g/
HP-
h
h
1500 2000
(750)
(1000)
REVOLUTION
2500
(1250) (1500)
3000
c
r. D.
-3-
3500
(1
750)
rn.
41
(21
3.
FEATURES
3-
1
ECONOMICAL RUNNING
The direct injection system using the newly developed micro fuel injection pump assures
superior combustion efficiency and minimized fuel consumption.
3-
2
EXTREMELY QUIET OPERATION
0
The precisely synchronized fuel injection and refined combustion chamber allow lower
combustion pressure which results in reduced combustion noise.
Q
Blower housing and cylinder baffle are made from “DUMPING
material for insulating noise and vibration.
0
Larger super silent muffler and double element air cleaner reduce the exhaust and
intake noise.
3-
3
EASY STARTING
8
Light pull recoil starter and centrifugal automatic decompressor allow effortless
starting similar to a gasoline engine.
0
An auxiliary fuel inlet is provided for easy starting in cold weather.
An
air check valve
3-
4
LESS
0
In
addition to the reduced weight
adopted for extremely smooth running with less vibration.
a
The automatic decompressor prevents shaky vibration at stopping.
VIBRATION
for
easy
air
bleeding
from
the fuel line.
of
reciprocating parts, a balancer shaft has been
SHEET”,
a special
3-
5
HIGH PERFORMANCE
Die-cast cylinder head generates
high output power and an exceptional fuel economy.
Its
flat torque characteristic provides tenacious running from slow speed to high speed.
3-
6
SUPERB RELIABILITY
The advanced Robin technology, such as well proven crankcase design, tension bolt
system
service life under the toughest operating conditions.
3-7
The newly developed micro fuel injection pump and crankcase structure originated in
the gasoline engine have .minimized the size and weight of the engine.
3-8
Robin’s new air - cooled diesel engine series assures maximum adaptability to any
application.
0
Direct output type
Selection
Variable muffler exhaust direction.
0
Recoil starter and optional electric starter.
0
Strong power from small and lightweight body.
Q
Lower noise and less vibration.
for
joining cylinder and cylinder head, and forced lubrication system, for longer
SMALL AND LIGHTWEIGHT
WIDE RANGE
of
P.T.O.
OF
APPLICATIONS
(D
type) and reduction type
shafts for various applications.
a
stable swirl of air-fuel mixture which results in the
(B
type) are available.
-4-
4.
GENERAL DESCRIPTION
OF
ENGINE
CONST
4-1
The cylinder and crankcase are single piece
aluminum die casting. The cylinder liner,
made of special cast iron, is built into
the alminum casting.
The crankcase is separable
shaft side, where the main bearing cover
is
CYLINDER
attached to
4-2
The main bearing cover made
die casting is built onto the output shaft
side of the crankcase
of the engine can readily be checked by
simply removing the cover. It is provided
with a flange and
mounting machines, such
and pumps.
Two oil gauges also serving
caps can be mounted.
MAIN
(See Fig.
2)
AND
it.
BEARING COVER
CRANKCASE
(See
so
boss
Fig.
for directly
on
the output
1.)
of
aluminum
that the inside
as
generators
as
oil filler
4-
3
CRANKSHAFT
Crankshaft is made from forged carbon
steel and its crankpin and journal are
induct ion
Crankshaft
at flywheel side and a kelmet bearing at
P.T.0:
A
passage for lubricating oil is provided
through the journal and crankpin to
lubricate the large end bearing of
connecting rod.
The crank gear is pressure-fitted
P.T.O. side of the crankshaft.
A
balancer gear is also pressure-fitted
for the engines with optional balancer.
(See Fig.
-
side.
3.)
hardened.
is
supported
by
a ball bearing
on
the
~~
FIG.
FIG.
2
3
-5-
4-4
CONNECTING
ROD
Connecting
rod
is made from forged
aluminum alloy which withstands high
combustion pressure and tension under
heavy load and high speed operation.
Kelmet bearings are provided as large end
bearing, while the material
rod itself serves
(See Fig.
4-
5
Piston
4.)
PISTON
is
casting, and
made from aluminum alloy
it
as
has three grooves
small end bearing.
of
connecting
for
piston
rings.
On
the piston top, a combustion chamber
is arranged where the injected fuel mixes
with air and ignites.
so
The piston profile is
minimize piston noise. (See Fig.
designed as to
5.)
FIG.
,
4
TOP RING
SECOND RING
OIL RING
4-6
PISTON
RINGS
Piston rings are made from special cast
of
iron. The profile
and that
of
second ring is taper with
top ring is barrel face,
under cut. The oil ring is the combination
of cutter rings and an expander which
is
excellent in gas sealing and reducing
oil
consumption. (See Fig.
4-7
Cylinder head
of
CYLINDER
HEAD
is
the most important part
the diesel engine. It
5.)
is
made from onepiece aluminum alloy die cast, in which
intake and exhaust ports, rocker arm room,
and cooling fins are molded in the most
ideal structure
for
the highest strength
and the highest cooling efficiency.
High quality heat resistant valve seats
are pressure- fitted considering high
resistance to abration and corrosion at
high temperature. (See Fig.
6.)
FIG.
FIG.
,
CONNECTING ROD
5
,-
6
-6-
4- 8 CAMSHAFT
Camshaft for
special cast
Camshaft for
PTO
shaft and is made from forged carbon
steel and the cam gear
"D"
type engine is made
iron
integrated with cam gear.
"B"
type engine
is
pressure-fitted.
Camshaft has three cams, one for intake,
one
for
exhaust, and one
pump.
A
release lever for centrifugal
decompressor
(See Fig.
4-
9
7.)
TAPPEU
is
assembled to the camshaft.
€or
Tappets are made from sintered steel.
They are precisely finished
after
sintering.
(See
Fig.
by
8.)
from
works
injection
grinding
as
I
FIG.
7
4-
10
VALVE
Valves are made from
forged
heat resistant
alloy.
Stellite
is
fused to the head
of
valve for added durability. (See
exhaust
Fig.
9.)
EXHAUST VALVE INTAKE VALVE
FIG.
FIG.
8
9
-7-
4-
11
ROCKER ARM
Rocker arms are made from forged steel
and are wholly sintered.
A
screw for adjusting valve clearance is
of
provided at the end
Rocker arms are lubricated
in
contained
crankcase.
4-
12
ROCKER COVER
the breathing air from
(See
Fig. lo.)
rocker arm.
by
the oil mist
Rocker cover is made from steel sheet.
A
breather plate
is
installed in the rocker
cover to breath air into intake port.
(See Fig.
1
1.)
I
FIG.
10
4-
13
AUTOMATIC DECOMPRESSION
SYSTEM
Automatic decompression system
posed
of
a release lever and a flyweight
assembled to the comshaft.
Below
lever
release compression.
the predetermined speed, the release
lifts
the exhaust tappet slightly to
(See
Fig. 12.)
is
com-
-8-
FIG.
FIG.
11
/-
12
4-
14
GOVERNOR
SYSTEM
The governor is
a
centrifugal flyweight
type which permits constant operation at
the selected speed against load variations
by controlling the quantity of fuel injected.
Governor system
is
driven by the governor
GOVERNOR LEVER
gear engaged with cam gear.
(See Fig.
Refer
4-
15
13.)
to
section
6-
LUBRICATION
4
for details.
SYSTEM
FIG.
13
Lubricant is forcibly supplied by the trochoid pump to the crank journal and crankpin.
Other rotating
parts
and moving parts are lubricated by the splash
of
oil.
Lubricant (engine oil) is wholly filtered by the oil filter installed on the main bearing
cover.
The trochoid pump
is
driven by the governor gear.
c
4-
16
COOLING
Cooling air
and cylinder head guided
Fuel injection pump is
is
driven
by
SYSTEM
is
forced
the camshaft.
by
the flywheel fan to blow through
by
the blower housing and the cylinder baffle.
BOSCH
type and
the
cooling fins of cylinder
The fuel from the tank is pressurized by
the injection pump and is supplied
to
the
injection nozzle through the high pressure
pipe. (See Fig.
14.)
-9-
FIG.
14
4-18
FUEL
INJECTION NOZZLE
Fuel is injected in the combustion chamber
as fine mist through the
of
fuel injection nozzle. (See Fig.
four
small ports
15.)
FIG.
15
4- 19
Air
AIR
cleaner is
CLEANER
dry
type double element
system.
Primary element is polyurethane foam and
the secondary element is paper.
The air cleaner cover
is
made from high
strength plastic and its air inlet is
specially designed to reduce intake noise.
(See Fig.
4-
20
Fuel filter
type.
outlet
the bottom. (See Fig.
16.)
FUEL
Its
has
on
the top and
FILTER
is
a
paper element disposable
a
automatic air bleeding
a
water drain on
17.)
PRIMARY ELEMENT
FIG.
SECONDARY
/
16
ELEMENT
/
FIG.
17
-
10-
4-
21
COMBUSTION
SYSTEM
For
lower fuel consumption and easy
starting
of
the .engine, the
direct
injection
system is adopted in the combustion
chamber.
4-21-4
(1
1
SWIRL
FORMING
AND
COMBUSTION
(Inspiring swirl)
OF
COMBUSTION
In order to promote mixing injected
fuel and air under the direct injection
system, swirl flow is utilized for good
combustion. Swirl is spiral flow
generated in the cylinder during
inspiring stroke, and it decreases
during compressing stroke but it still
remains and promotes mixing of fuel
and
air
toward ignition timing.
Spiral flow
by the shape of intake
called helical port
of
air (swirl) is generated
port,
or
spiral port.
which is
Tail end of intake port, i. e. upper part
of
intake valve seat, is made in the
spiral forrn : and while the inspired air
is
passing through this part, swirl is
generated around the intake valve.
Thus, intake port plays an important
role
in
generating swirl.
(See
Fig.
GAS
of
air
19.)
FIG.
/INTAKE
19
/c
SQUISH
INTAKE
SWIRL
CY
LlNDER
PISTON
VALVE
PORT
SQUISH
(Squished
air
flow)
In the piston, combustion chamber (dish
type combustion chamber)
When the piston comes up to
dead center), air in the
gaps
is
formed.
TDC
(top
is squished
FIG.
20
in the combustion chamber and air flow
is generated, which is called “squish.”
(See Fig.
FORMING
20.)
OF
COMBUSTION GAS AND COMBUSTION
For igniting quickly the fuel injected from the nozzle, it is essential to atomize very
fine fuel particles for distributing evenly in the combustion chamber.
For
this purpose, fuel should be injected through hole type nozzle by very high
pressure, i. e. 195 kg/c
m’.
The fuel, thus injected, is ‘mixed with air by the flow of
swirl and squish while piston is coming up. Accompanying crimb of the piston,
combustion gas compressed further and finally it automatically begins igniting and
while piston
is
going down,“squish” functions and promotes combustion.
-
11
-
4-
22
SECTIONAL VIEW
OF
ENGINE
INTAKE VALVE
/
EXHAUST VALVE
k/
CYLINDER
PISTON
MA‘N
CRANKSHAFT
TROCHOID
HEAD
PIN
BEARING
OIL
COVER
PI
JMP
/
FLYWHEEL
\
CRANKCASE
-
12
-
\
GOVERNOR
ROCKER COVER
AIR CLEANER
MUFFLER
\
\
/
PUSH
PISTON
PISTON RING
PUMP
ROD
FUEL
INJECTION
TAPPET
BALANCER
'
CAMSHAFT
OIL
GAUGE
\
OIL
DRAIN
-
13
-
5.
DISASSEMBLY
5-
1
PREPARATIONS AND
(1)
When disassembling the engine, memorize well the locations of individual parts
that they can be reassembled correctly.
AND
REASSEMBLY
SUGGESTIONS
If
you
are uncertain
of
identifying some parts,
it is suggested that tags to be attached to them.
(2)
Have boxes ready to
(3)
To
prevent missing and misplacing, temporarily assemble as much as possible each
group
(4)
Carefully handle disassembled parts, and clean them with washing oil.
(5)
Use the correct tools in the correct way.
5-2
SPECIAL
or
set
of
TOOLS
disassembled small parts such as bolts and nuts,etc.
keep
disassembled parts by
group.
/-
so
Tool
209-
95001 - 07
228-
95003-
No.
07
Tool
Flywheel puller with
Piston ring cqmpressor
PISTON
RING
COMPRESSOR
f
bolt
Use
For pulling
For placing piston ring
off
the
flywheel
.
FIG.
-
14
21
-
FLYWHEEL
PULLER
/-
5-
3
-DISASSEMBLY PROCEDURES
-
Step
-
1
Engine oil
2
Fuel
-
3
Injection pipe
(1)
(2)
(1)
(1)
Proocedures
Remove drain plug and discharge
oil from crakcase.
Drain plugs are located on both
sides of the crankcase.
To
discharge oil quickly, remove
oil gauge.
Remove drain plug from fuel
filter and discharge fuel from
fuel tank.
Loosen the two joint nuts at the
both ends of injection pipe
to
remove it.
Remarks
Be careful not to lose
the gasket.
Be careful not to lose
the gasket.
Be careful
to
keep
the inside of the
pipe, injection pump
and the nozzle free of
dust.
Tool
14
mm
spanner
10
mm
spanner
12 mm
spanner
INJECTION
PIPE
/
-
15
-
Step lPart to remove
’
4
Air cleaner
Procedures
(1)
Remove cleaner cover from the
cleaner body.
(2) Loosen the wing bolt to remove
element.
(3)
Remove cleaner body from intake
manifold.
6
4
X
12
mm flange bolt...-..2pcs
8
0
BOLT and WASHER
Remarks
Be careful not to lose
the washer and the
for
packing
bolt.
wing
.
Tool
10 mm
box wrench
12 mm
box wrench
I
Step I Part
5
Recoil
to
remove
starter
I
(1) Remove
blower housing.
6
4
Procedures
recoil
x
10
mm flange bolt**..**4pcs.
starter
from
PACKING
ELEMENT
I
CLEANER BODY
Remarks
3
spanner
FIG.
-
16
HOUSING
24
-
6
0
FLANGE BOLT
:
4pcs.
m
RECOIL STARTER
step
I
Part
to
remove
Procedures
I
Remarks
Tool
6
7
Fuel
tank
Muffler
6
+
BOLT
(1)
Disconnect fuel pipe from fuel
(2)
Disconnect fuel return pipe.
(3)
Disconnect rubber pipe from the check
tank.
valve.
(4)
Remove
8
8
(1)
Remove the muffler cover from muffler.
6
(2)
Remove the muffler.
8
8
:
4pcs.
the
fuel
tank.
Q
X
20mmbolt*****e.e* 1 pce.
@
X30mmbolt*****~***2pcs.
@
X
10
mm bolt
@nut
9
e
*
*
4
pcs.
Qspringwasher*****~*~~2pcs.
a
/
+
BOLT
Be careful
gasket.
not
to
lose the
10
mm
spanner
12
mm
box wrench
-
17
-
Step Part to remove Procedures Remarks Tool
8
Starting motor
9
Fuel filter
10
Blower
housing
(1)
Remove the wire harness from Reattach the terminal 1Omm
the starting motor. nut to the motor to spanner
(2)
Remove the starting motor from keep
crankcase.
8
4
x
30
mm bolt
(1)
Remove the fuel filter from the Wipe off spilt fuel
blower housing. thoroughly. box wrench
6
q-5
X
20
mm flange bolt.....*2pcs
(1)
Remove the blower housing from
crankcase.
8
q5
x
20
mm bolt and washer
...............
.....................
2pcs.
.
2pcs.
it
from missing. 12mm
spanner
10
mm
12 mm
box wrench
-
18
-
-
Step
Part
to
remove
Procedures
Remarks
Tool
11
Flywheel
(1)
Remove the starting pulley.
6
,$
X
12m
(2)
Remove the flywheel nut.
(See Fig.
(3)
Set the flywheel puller to the
flywheel. ( See Fig.
27.)
bolt
.......
28.
.....
)
Turn the center bolt clockwise to
pull out the flywheel.
(4)
Remove the key from crankshaft.
...
3pcs.
Flywheel can easily
be removed
by
striking with a
hammer the head of
the center bolt of
flywheel puller.
Be careful not to
lose the key.
10
mm
box wrench
24
mm
socket
wrench
FIG.
27
6
+
FLANGE BOLT
STARTING PULLEY
v
FIG.
28
:
3pcs.-@
FLYWHEEL
SPRING WASHER
NUT
FIG.
-
19
FLYWHEEL
29
-
Loading...