Robin DY23-2D User manual

ROBIN AMERICA, INC.
ROBIN TO WISCONSIN ROBIN
ENGINE MODEL CROSS REFERENCE LIST
ROBIN
EY08
EY15
EY 15V
EY20
EY20V
EY23
EY28
EY35
EY40
EY45V
EY2 1
EY44
EY
18-3
EY25
EY27
EH11
EH12
EHl5
EHI 7
EH2 1
EH25
EH30
EH30V
EH34
EH34V
EH43 V
EC13V
DY23
DY27
DY30
DY3 5
DY4 1
WISCONSIN ROBIN
SIDE VALVE
W1-080
W1-145
W1-145V
W1-185
W1-185V
Wl-230
W1-280
W 1-340
W 1-390
W 1 -450V
EY21W
EY44W
EY 18-3W
EY25W
EY27W
OVERHEAD VALVE
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
TWO CYCLE
WT1-125V
DIESEL
WRD 1-230
WRD 1-270
WRD 1-300
WRD1-350
WRD1-410

CONTENTS
Section Title Page

r

1. SPECIFICATIONS
Model DY27-2 DY23-2B
DY23-2D
Type
Air-Cooled. 4-cycle, Overhead Valve, Single vertical cylinder, Diesel engine
I
Bore X Stroke
PistonDisplacement
70 X 60 rnrn
( 2.76 X 2.36 in. )
230cc
( 14.04 cu.in. )
75 X 60mm
( 2.95 X 2.36 in. 1
265 cc
( 16.1 1 cain. )
CompressionRatio
output HP/rpm
( 3.5 / 3600 )
DIN6270NB (Warnin”)
4.8 / 3600
output HP/ rpm 4.2
/ 3600
DIN6270NA
(KW-min”)
( 7.7/ 2200 )
DlN6270NB ( ft.lbs/ rpm 1
1.07/ 2200
Torquekg
- m / rpm
( 3.1 / 3600 )
21
4.8 / 1 800
( 17.W 1200 1
( 8.9/ 2400 1 (15.4/11001 2.46/ 1200
1.23
/ 2400
2.14/ 1100
( 3.7/ 1800 1
( 3.7 / 3600 1 (3.1 /1800 1
5.0 / 1 800
5.0 / 3600 4.2 / 1800
( 4.0/ 1800 1
( 4.0/ 3600 1 ( 3.5/ 1800 1
5.5 / 1 800
5.5 / 3600
Rotation
I
Counterclockwise as viewdfrom PTO shaft side
Cool in g
I
Forced air cooling
Lubrication
I
Forcedoil lubrication
Lubricant
Trochoid gear pump
Oil Pump
Diesel engineoil.servicerank CC or CD
Automotive diesel
fuel
Fuel
ZEXEL DLLAI 50PN052
Injection Nozzle
ZEXEL PFRIMD55 / 2NP1
Fuel InjectionPump
Fuel Feed
I Gravity type
Fuel TankCapacity
I
3.2 liters ( 0.84 U.S.gal. 1
CombustionSystem
Centrifugalflyweighttype
GovernorSystem
Directinjectiontype
Lighting Capacity
1 2V- 39W/ 3000
12V-43W/ 3600 12V
- 39W / 3000
12V - 43W / 3600
StartingSystem Recoil starter
( Electricstarter as option )
DryWeight
30 kg
I (63.9 Ibs.) (65.0 Ibs.) (65.0 lbs.)(66.1Ibs.)
Dimension
LXWXH
329 x 357 x 402 mm
(1 2.95 x 14.06 x 15.82in.)
339 x 357 x 402 mm
(13.35 x 14.06 x 15.82 in.)
Specifications are subject to changewithoutnotice.
-1-

2- 1 MAXIMUM OUTPUT
The maximum output of an engine istheoutput power of the engine operatingwith
its throttle valvefully open afterithas been broken in properly.
Therefore, abrand-new engine
or an engine which hasnot been broken in properlymay
not produce the maximum output.
2-2 CONTINUOUSRATEDOUTPUT
The continuousratedoutput of anengineistheoutput power of theenginerunning
attherated engine speed controlled by its governorsystem.
Theoperation of the engine atthe continuousratedoutput
is most favorable from the
view point
of engine life and fuel economy.
It
is recommended, therefore,thatthe- equipmentdrivenby the engine to be designed
to requirethe engine power less thanitscontinuousratedoutput.
2-3 MAXIMUM TORQUE
The maximum torqueindicatesthetorque attheoutputshaft when the engine is
producing the maximum output.
-2-

2 - 4 PERFORMANCE CURVES
MODEL DY23-2
HP
I
5
4
!z
23
W
v)
IT
0
I
2
1
MODEL DY27-2
6
HP
I
5
4
9
5
P
0-3
W
v)
I1I
2
1
\ TORQUE (NB)
kg - m
1.2 (2.4)
1.1 (2.2)
1 .o (2.0) i
3.9 (1.8) 2
c1:
I-
O
W
g/HP-h
240
220
y
200 g
z
0
I-
FUELCONSUMPTION RATIO (NB) \
I
I L L I &
-
1500 2000 2500 3000 3500 4/00 22
(750) (1000) (1250)(1500)(1750)(2000)
REVOLUTION "----+ r. p. rn.
( 1 for B type
(750)
(1000) (1250) (1500) (1 750) (21
1500 2000 2500 3000 3500
41
REVOLUTION c r. D. rn.
kg- m
.3 (2.6)
.2 (2.4)
.1 (2.2)
.o (2.0) Y
2
g/ HP- h
h
-3-

3. FEATURES
3- 1 ECONOMICALRUNNING
Thedirect injection systemusingthe newlydeveloped micro fuelinjectionpump assures
superiorcombustion efficiency and minimized fuel consumption.
3- 2 EXTREMELYQUIETOPERATION
0 The precisely synchronizedfuel injection and refined combustionchamber allow lower
Q Blower housingandcylinderbaffleare made from “DUMPING SHEET”, aspecial
0 Largersupersilentmufflerand double element air cleaner reduce theexhaustand
combustion pressure which resultsin reduced combustion noise.
materialforinsulating noise andvibration.
intake noise.
3- 3 EASYSTARTING
8 Light pull recoil starterandcentrifugalautomatic decompressor allow effortless
0 An auxiliary fuel inletis provided foreasystarting in cold weather.
starting similar to agasoline engine.
An air check valve for easy air bleeding from the fuel line.
3- 4 LESS VIBRATION
0 In addition tothe reduced weight of reciprocatingparts, abalancer shafthas been
a The automatic decompressor preventsshakyvibration at stopping.
adopted forextremelysmoothrunningwith lessvibration.
3- 5 HIGHPERFORMANCE
Die-castcylinder head generates a stableswirl of air-fuelmixture which resultsinthe
highoutput power and an exceptional fuel economy.
Its flattorquecharacteristic provides tenacious running from slow speed tohigh speed.
3- 6 SUPERB RELIABILITY
Theadvanced Robin technology,such as well provencrankcasedesign,tensionbolt
system
for joiningcylinder and cylinder head, and forced lubricationsystem,forlonger
servicelifeunder thetoughestoperating conditions.
3-7 SMALLANDLIGHTWEIGHT
The newly developed micro fuel injection pumpandcrankcasestructureoriginatedin
the gasolineenginehave .minimized the size andweight of the engine.
3-8 WIDERANGE OF APPLICATIONS
Robin’s new air - cooled diesel engineseries assures maximum adaptabilitytoany
application.
0 Direct outputtype (D type)and reduction type (B type)are available.
Selection
of P.T.O. shaftsforvarious applications.
Variable muffler exhaust direction.
0 Recoil starterand optionalelectric starter.
0 Strong power from smallandlightweight body.
Q Lower noise and lessvibration.
-4-

4. GENERALDESCRIPTION OF ENGINE CONST
4-1 CYLINDER AND CRANKCASE
Thecylinder andcrankcasearesingle piece
aluminumdiecasting.Thecylinderliner,
made of specialcastiron,isbuiltinto
thealminumcasting.
Thecrankcaseisseparable
on theoutput
shaftside,wherethemainbearingcover
is attachedto it. (See Fig. 1.)
4-2 MAIN BEARINGCOVER
Themainbearing cover made of aluminum
die castingisbuiltontotheoutputshaft
side of thecrankcase
so thattheinside
of theenginecanreadily be checked by
simplyremovingthe cover. Itisprovided
withaflangeand
boss fordirectly
mountingmachines,such
as generators
andpumps.
Two oilgaugesalsoserving
as oil filler
capscanbemounted.
(See Fig.
2)
4- 3 CRANKSHAFT
Crankshaftismadefromforgedcarbon
steelanditscrankpinandjournalare
induct ion
- hardened.
Crankshaft
is supported by a ball bearing
at flywheelsideandakelmetbearing at
P.T.0: side.
A passageforlubricating oil isprovided
throughthejournalandcrankpinto
lubricatethelargeendbearing of
connectingrod.
Thecrankgearispressure-fitted
on the
P.T.O. side of thecrankshaft.
A balancergearisalsopressure-fitted
fortheengineswithoptionalbalancer.
(See Fig.
3.)
~~
FIG. 2
FIG. 3
-5-

4-4 CONNECTING ROD
Connecting rod ismadefromforged
aluminumalloywhichwithstandshigh
combustionpressureandtensionunder
heavyloadandhighspeedoperation.
Kelmet bearingsare provided aslarge end
bearing,whilethematerial
of connecting
roditselfserves
as smallendbearing.
(See Fig.
4.)
4- 5 PISTON
Piston is madefromaluminumalloy
casting,and
it hasthree grooves for piston
rings.
On thepistontop,acombustionchamber
isarrangedwheretheinjectedfuelmixes
withairandignites.
Thepistonprofileis
so designedasto
minimizepistonnoise. (See Fig.
5.)
4-6 PISTON RINGS
Pistonringsaremadefromspecialcast
iron.Theprofile
of topringisbarrel face,
andthat
of secondringistaperwith
undercut.The oil ringisthe combination
of cutterringsandanexpanderwhich
is excellentingassealingandreducing
oil consumption. (See Fig. 5.)
4-7 CYLINDER HEAD
Cylinderhead is themostimportantpart
of the diesel engine.It is made fromone-
piece aluminumalloydiecast,inwhich
intakeandexhaustports, rocker arm room,
andcoolingfinsare molded inthemost
ideal structure
for thehigheststrength
andthehighestcoolingefficiency.
High qualityheatresistantvalveseats
arepressure-fittedconsideringhigh
resistancetoabrationandcorrosionat
hightemperature. (See Fig.
6.)
FIG. 4
TOPRING
SECONDRING
OILRING
CONNECTINGROD
FIG. 5
FIG. 6
,
,
,-
-6-

4- 8 CAMSHAFT
Camshaftfor "D" typeengineis made from
special cast iron integratedwith cam gear.
Camshaftfor
"B" typeengine works as
PTO shaftandis made fromforgedcarbon
steelandthe cam gear
is pressure-fitted.
Camshafthasthreecams,oneforintake,
one
for exhaust,andone €or injection
pump.
A releaseleverforcentrifugal
decompressor
is assembled tothecamshaft.
(See Fig.
7.)
I
FIG. 7
4- 9 TAPPEU
Tappetsaremadefromsinteredsteel.
Theyarepreciselyfinished
by grinding
after sintering. (See Fig. 8.)
FIG. 8
4- 10 VALVE
Valves are made from forged heatresistant
alloy.
Stellite
is fusedtothehead of exhaust
valveforaddeddurability. (See
Fig. 9.)
EXHAUSTVALVEINTAKEVALVE
FIG. 9
-7-

4- 11 ROCKER ARM I
Rocker armsare madefromforgedsteel
andare whollysintered.
A screwforadjustingvalveclearanceis
provided attheend
of rockerarm.
Rocker armsarelubricated
by the oil mist
contained
in thebreathingairfrom
crankcase.
(See Fig.lo.)
4- 12 ROCKERCOVER
Rocker coverismadefromsteelsheet.
A breatherplate is installed in therocker
covertobreathairintointakeport.
(See Fig.
1 1.)
4- 13 AUTOMATICDECOMPRESSION
SYSTEM
Automaticdecompressionsystem is com-
posed
of areleaseleverandaflyweight
assembledtothecomshaft.
Below the predetermined speed, the release
lever
lifts theexhausttappetslightlyto
releasecompression.
(See Fig. 12.)
FIG. 10
FIG. 11
/-
FIG. 12
-8-

4- 14 GOVERNOR SYSTEM
Thegovernoris a centrifugalflyweight
typewhichpermitsconstantoperationat
the selectedspeedagainst load variations
bycontrolling the quantity of fuel injected.
Governor system
is drivenbythegovernor
gearengagedwithcamgear.
(See Fig.
13.)
Refer to section 6- 4 fordetails.
GOVERNORLEVER
FIG. 13
4- 15 LUBRICATION SYSTEM
Lubricantisforcibly supplied bythe trochoidpump tothecrankjournalandcrankpin.
Other rotating
parts andmoving partsare lubricated bythesplash of oil.
Lubricant (engine oil) is wholly filteredby the oil filterinstalled on the mainbearing
cover.
Thetrochoidpump
is drivenbythegovernor gear.
c
4- 16 COOLING SYSTEM
Cooling air is forced by the flywheel fanto blow through the cooling fins of cylinder
and cylinderhead guided
by the blower housingandthe cylinder baffle.
Fuelinjectionpumpis
BOSCH typeand
is driven by thecamshaft.
Thefuelfromthetankispressurizedby
theinjectionpumpandissupplied
to the
injection nozzle throughthehighpressure
pipe. (See Fig.
14.)
FIG. 14
-9-

4-18 FUEL INJECTIONNOZZLE
Fuel is injected inthe combustionchamber
asfinemistthroughthe
four smallports
of fuelinjection nozzle. (See Fig. 15.)
4-19 AIR CLEANER
Air cleaneris dry typedoubleelement
system.
Primary element ispolyurethane foam and
thesecondaryelementispaper.
Theaircleanercover
is madefromhigh
strengthplasticanditsairinletis
speciallydesigned to reduceintake noise.
(See Fig.
16.)
4- 20 FUEL FILTER
Fuelfilter is a paperelementdisposable
type.
Its has a automaticairbleeding
outlet
on thetopand a waterdrainon
thebottom. (See Fig.
17.)
FIG. 15
SECONDARY ELEMENT
/
PRIMARYELEMENT
FIG. 16
/
FIG. 17
- 10-

4- 21 COMBUSTION SYSTEM
For lower fuelconsumption andeasy
starting
of the .engine,the direct injection
systemis adopted inthe combustion
chamber.
4-21-4 FORMING OF COMBUSTION GAS
AND COMBUSTION
(1 1 SWIRL (Inspiringswirl)
In orderto promotemixinginjected
fuelandairunderthedirect injection
system,swirl flow is utilizedfor good
combustion. Swirl isspiral flow
of air
generatedinthe cylinder during
inspiringstroke,andit decreases
during compressing strokebutitstill
remainsand promotesmixing of fuel
and
air towardignitiontiming.
Spiral flow
of air (swirl) isgenerated
bytheshape of intake
port, which is
called helical port
or spiralport.
Tailend of intakeport, i. e. upper part
of intakevalveseat,is made inthe
/INTAKE VALVE
INTAKE PORT
SWIRL
CY LlNDER
PISTON
FIG. 19
/c SQUISH
FIG. 20
spiral forrn : and while the inspired air
is passingthroughthispart,swirlis
generatedaround theintake valve.
Thus,intakeportplaysanimportant
role
in generating swirl. (See Fig. 19.)
SQUISH (Squished air flow)
In thepiston, combustionchamber(dish
type combustionchamber)
is formed.
When thepiston comes upto
TDC (top
dead center), air in the
gaps is squished
in the combustionchamber and air flow
isgenerated, which is called “squish.”
(See Fig.
20.)
FORMING OF COMBUSTIONGAS AND COMBUSTION
For igniting quickly the fuel injected fromthe nozzle, itisessentialto atomize very
finefuelparticlesfordistributing evenly inthe combustionchamber.
For this purpose,fuelshould be injected through hole type nozzle by veryhigh
pressure, i.e.195 kg/c
m’. The fuel, thus injected, is‘mixedwithairbythe flow of
swirlandsquish while pistoniscomingup. Accompanying crimb of thepiston,
combustion gas compressed furtherandfinallyitautomatically begins ignitingand
while piston
is goingdown,“squish”functionsand promotes combustion.
- 11 -

4- 22 SECTIONAL VIEW OF ENGINE
/
INTAKE VALVE
EXHAUST VALVE
CYLINDER HEAD
CRANKSHAFT
TROCHOID OIL PI
/ \ \
PISTON PIN
k/ MA‘N
BEARING COVER
JMP
FLYWHEEL CRANKCASE GOVERNOR
- 12 -

MUFFLER \ \ /
ROCKER COVER AIR CLEANER
PUSH ROD
PISTON
PISTON RING
FUEL INJECTION
PUMP
TAPPET
' CAMSHAFT
OIL GAUGE
BALANCER
\
OIL DRAIN
- 13 -

5. DISASSEMBLY AND REASSEMBLY
5- 1 PREPARATIONS AND SUGGESTIONS /-
(1) When disassembling the engine, memorizewell the locations of individualparts so
thatthey can be reassembled correctly. If you areuncertain of identifying some parts,
itissuggested thattagsto be attachedto them.
(2) Have boxes readyto keep disassembled parts by group.
(3) To preventmissingand misplacing, temporarily assemble as much as possible each
group or set of disassembled small partssuchasboltsandnuts,etc.
(4) Carefullyhandle disassembled parts,and clean themwithwashing oil.
(5) Use the correct tools inthe correct way.
5-2 SPECIAL TOOLS
Tool No.
Use Tool
209- 95001 - 07
For pulling off the flywheel
Flywheelpuller with
bolt
228- 95003- 07
For placing piston ring
Piston ring cqmpressor
.
f
PISTON RING COMPRESSOR
FLYWHEEL PULLER
/-
FIG. 21
- 14 -

5- 3 -DISASSEMBLYPROCEDURES
-
Step
1
-
2
-
3
Engine oil
Proocedures
(1) Remove drain plug anddischarge
oil from crakcase.
Drain plugs are located on both
sides of the crankcase.
(2) To discharge oil quickly,remove
oil gauge.
Remarks
Be carefulnot to lose
thegasket.
Fuel
Injection pipe
(1) Remove drain plug from fuel
filteranddischarge fuelfrom
fueltank.
(1) Loosen thetwo joint nutsatthe
bothends of injection pipe to
removeit.
Be careful not to lose
thegasket.
Be careful
to keep
the inside of the
pipe, injection pump
andthe nozzle free of
dust.
Tool
14 mm
spanner
10 mm
spanner
12mm
spanner
INJECTION PIPE
/
- 15 -

SteplParttoremove
’ 4
Air cleaner
Procedures
(1) Remove cleaner cover from the
(2) Loosen the wingbolt to remove
(3) Remove cleaner body fromintake
6 4 X 12 mm flange bolt...-..2pcs .
cleaner body.
element.
manifold.
Remarks
Be carefulnotto lose
the washerand the
packing
for wing
bolt.
Tool
10mm
box wrench
12mm
box wrench
8 0 BOLTandWASHER
PACKING CLEANERBODY
ELEMENT
I Step I Part to remove I Procedures
I
Remarks
5 (1) Remove recoil starter from Recoil starter blower housing.
6 4 x 10 mm flange bolt**..**4pcs.
HOUSING
3 spanner
6 0 FLANGEBOLT : 4pcs.
m
RECOILSTARTER
FIG. 24
- 16 -