Robin America DY30 User manual

ROBIN AMERICA, INC.
ROBIN TO WISCONSIN ROBIN
ENGINE MODEL CROSS REFERENCE LIST
ROBIN
EY08
EYl5
EY15V
EY20
EY20V
EY23
EY28
EY35
EY40
EY45V
EY21
EY44
EY25
EY27
EY18-3
EHl1
EH12
EHl5
EH17
EH21
EH25
EH30
EH30V
EH34
EH34V
EH43V
EC13V
DY23
DY27
DY3O
DY3 5
DY4 1
WISCONSIN ROBIN
S-
W1-080
W1-145
W1-145V
Wl-185
WP-185V
Wl-230
W 1-280
W 1-340
Wl-390
W1-45OV
EY21 W
EY44W
EY25W
EY27W
EY18-3W
v
WOl-115
wo1-120
WO1-150
WOI-I 70
wo1-210
WO1-250
WO1-300
WO1-3OOV
WO 1-340
WO 1 -340V
WO1-430V
TWO CYCLE
WT1-125V
DIESEL
WRDI-230
WRD 1-270
WRDl-300
wRD1-350
WRD1-410

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 MaximumOutput
......................................... 3
2-2 Continuous RatedOutput ................................... 3
2-3 MaximumTorque and Fuel Consumption Ratio at MaximumOutput ....... 3
FEATURES ................................................. 5
GENERALDESCRIPTION of ENGINECONSTRUCTION .................. 5
4- 1 Crankcase .............................................. 5
4-2 Crankshaft ............................................. 6
4-4 Cylinder andCylinderHead .................................. 6
4-5 GearCaseCover .......................................... 7
4-6 Camshaft .............................................. 7
4-8 Rocker Arm ............................................ 7
4-9 Rocker Cover ............................................ 8
4-10 GovernorSystem
......................................... 8
4-1 1 Lubrication System ........................................ 8
4-13 Injection Pump
.......................................... 9
4-14 Nozzle
................................................ 9
4- 15 CombustionSystem ....................................... 10
4-16Sectional View of Engine
.................................... 11
DISASSEMBLY and REASSEMBLY ................. ! ............... 13
5-2 Special
Tools ............................................ 13
5-3 DisassemblySequence
...................................... 14
5-4 How to Reassemble ........................................ 20
FUEL ...................................................... 28
6-1 Qualityof Fuel .......................................... 28
GENERALDESCRIPTION of AUXILIARYGADGETS and PARTS ........... 29
7 . 1 Fuel Injection Pump Mechanism ............................... 29
7-2 Fuel Injection Nozzle Holder ................................. 33
7-3 GovernorMechanismand Operation
............................. 36
7-4 Lubrication Systemand
Oil Pump .............................. 38
7-5 OilFilter ............................................... 38
7-6 Electric Apparatus
........................................ 39
INSTALLATION .............................................. 40
8-1 Installing
............................................... 40
8-2 Ventilation ............................................. 40
8-3 ExhaustGasDischarge
...................................... 40
8-4 FuelSystem ............................................ 40
8-5 PowerTransmission to DrivenMachines .......................... 40
CHECKS and CORRECTIONS ..................................... 41
TABLE of CORRECTIONSTANDARDS .............................. 42
MAINTENANCE and STORING .................................... 45
11 -1 Daily Checks andMaintenance ................................. 45
11 -2 Every 25 Hours Checksand Maintenance ......................... 45
11
-3 Every 50 Hours (10 days)Checksand Maintenance ................... 45
11-4 Every
100 - 200 Hours (Monthly)Checksand Maintenance ............. 45
11
-5 Every 500 - 600 Hours(Semiannual) Checks and Maintenance ........... 46
11 -6 Every 1000 Hours (Yearly)Checksand Maintenance .................. 46
11 -7 Every 1500 Hours(Overhauls) ................................ 46
11 -8 Preparationfor LongAbeyance ................................ 46
REDUCTIONS for BTYPEENGINES ................................ 47
12-1 Configuration
of 1/2 Reducer ................................ : 48
12-2 Structure
of 1/2 Reducer .................................... 49
12-3 DisassemblyandReassembly of 1/2 Reducer ....................... 51
4-3 Connecting Rod andPiston
.................................. 6
4-7 TappetandTappetGuide .................................... 7
4-12 CoolingSystem .......................................... 9
5-
1 PreparationsandSuggestions ................................. 13

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2. PERFORMANCE
2-1 MAXIMUMOUTPUT
Themaximumouput ofan engine is suchstandardpower as developed by theengine,afterits initialbreakinperiod with all -
the moving partsproperlywornin,whenoperatingwith a fullyopeninjection pump. Therefore,anew engine may not
develop the maximum outputin the beginning because the moving parts are not
in a properly worn-in condition.
2-2 CONTINUOUS RATED OUTPUT
The continuous rated output of an engine is such power as developed 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 MAXIMUMTORQUE and FUELCONSUMPTION RATIO ATMAXIMUMOUTPUT
These mean the maximum torque of the output shaft and fuel consumption ratio at the maximum output of an engine,
PERFORMANCE CURVE
MODEL DYBOD,
B
HP
t
I
10
9
8
7
6
5
4
3
2
1
1c
(1 450) (1
2
1.5
1
kg-m
t
JIHP-h
- rpm.
-3-

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 usedfor various parts including the crankcase madeof aluminum die casting
2. Compact in outside dimensionsbecause-
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 theflywheel are single piece die casting; and the cooling fan is set on theside of the case so that it
may breathe in coolingair from the front, whichmeans that thesize of the fancasing becomes smaller and
total length
of the engine is also reduced.
FUEL ECONOMY and NOISELESS TYPE ENGINE
Low fuel consumption owing to improved fuel combustion system having adopted direct fuel injection; andnoiseless opera-
tion owing to the highly effective mufflerand air cleaner
As an optional part abalancer is available for minimizing 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 front of case
(reverse side
of the machine coupled), it is unnecessary to arrange air-intake on the side of the machine. Therefore, it is easy
to couple a machme to the engine.
4. GENERALDESCRIPTION of ENGlME CONSTRUCTION
This engine is a Forced Air Cooled, 4-Cycle, Vertical, Single Cylinder, Overhead ValveDiesel Engine, and the combustion
system is direct injection type.
4-1 CRANKCASE
Thecrankcase is madeofaone-piecealuminumalloy die
casting. On the side of pump,bearing is press-fitted; andon
the fanside cast iron bearing housing
is arranged, and it sup-
portsthecrankshaftbya ball bearingpress-fitted tothe
shaft.
Also, on the fanside,blowerhousingofaluminum
die casting
is fitted. This blower housing has a faucet joint
and it enables direct coupling with a machine. (See Fig. 1 .>
1
I
I.
Fig. 1
-
-5-

4-2 CRANKSHAFT
Thecrankshaft is madeofaforgedchromeandmolybdic
steelpiece 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 aredrilled through.
(See Fig.
2.)
4-3 CONNECTINGROD and PISTON
4-3-1 CONNECTING ROD
The connecting rod is made of forged pieces of aluminum
alloy designedwith sufficient strength to withstand buckling
and tensile forces inflicted on it under high-load operating
conditions.At the small end abushing is forcefitted towith-
stand thepressure resultant from pitching duringhigh-speed
operation. At the larger end thin kelmetis fitted forincreas-
ing durability.
4-3-2 PISTON
Piston is made of cast aluminum alloy, and it has two com-
pression rings and an oil
ring. Combustion chamber arranged
atthepistionhead, where combustion gas is made up
by
mixing atomized fuel and air, andignites. (See Fig. 3.)
4-4 CYLINDER and CYLiNDERHEAD
4-4-1 CYLINDER
Cylinder is made of aluminum alloy diecasting, in which
special cast iron liner is cast, andis provided with many cool-
Fig. 2
Fig. 3
ing fins designed for effective cooling.
4-4-2 CYLINDERHEAD
The most important part of the diesel engine is cylinderhead.
It is a one-piece of aluminum alloy die casting,
in which in-
take and exhaust ports, and rocker chamber are cast
in the
most ideal structure for the highest strength and the high-
est cooling efficiency. In thevalve seats fine quahty heat re-
sistance seats are pressure-fitted considering
high resistance
- to abrasionandcorrosionat high temperature. (See Fig. 4.)
Fig. 4
-
-6-

4-5 GEARCASECOVER
Gearcase cover is made of aluminumalloy die casting and is
fittedonthe reverse side ofthe flywheel. This coverem-
braces the injection pump, timing gear, operating lever and
supports the camshaft as abearing. To the gear case cover
the tappetguide is fitted and then the tappetsare assembled,
(See Fig.
5 .)
4-6 CAMSHAFT
The camshaftismade of forged chrome steel wholly sintered
and then ground. It carries three cams,
viz. one intake cam,
one exhaust cam, and one fuel injection pump cam, and the
shaft is supportedbya ball bearingpressure-fitted
in the
gear case cover and by thegear case. The camshaft
is assem
bled inside the gear case cover. To the shaft therelief valve
and a pin are fitted. The pin is used when starting 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,
andthentaftridefinished.Thecamshaft has
oil holesfor
lubricating tappets.
4-7-2 TAPPET GUIDE
Tappet guide is made of aluminum alloy die casting and de-
termines tappet positionsand
is fitted to the gear case cover.
In the crankcase there
is a blow-bygas hole,which hole goes
through up till rocker chamber via push rod sleeve.
(See Fig.
6.)
Fig. 5
i
Fig. 6
4-8 ROCKER ARM
Rocker arm is made of forged steel and is wholly sintered and then ground, and it is supported by the rocker shaft.At the
one end it has valve clearance adjusting screw.With this screw valve clearance
is adjusted to the specified gap and is fixed by
lock nut. Lubrication of the rocker arm
is carried out by the oil splash contained in the blow-by gas from the crankcase. In-
take rocker arm has decompression mechanism.(See Fig.
6.)
-7-