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Robin America DY30 Service Manual

Robin industrial engine service manual.

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   Summary of Contents for Robin America DY30

  • Page 2

    ROBIN AMERICA, INC. ROBIN TO WISCONSIN ROBIN ENGINE MODEL CROSS REFERENCE LIST ROBIN WISCONSIN ROBIN EY08 EYl5 EY 15V EY20 EY20V EY23 EY28 EY35 EY40 EY45V EY2 1 EY44 EY 1 8-3 EY25 EY27 EHl 1 EH12 EHl5 EH17 EH2 1 EH25 EH30 EH30V...

  • Page 3: Table Of Contents

    SPECIFICATIONS PERFORMANCE 2 - 1 Maximum Output 2 - 2 Continuous Rated Output 2 - 3 Maximum Torque and Fuel Consumption Ratio a t Maximum Output FEATURES GENERAL DESCRIPTION 4 - 1 Crankcase 4 - 2 Crankshaft 4 - 3 Connecting Rod and Piston 4 - 4 Cylinder and Cylinder Head...

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    ” - 2 -...

  • Page 6: Performance, Maximum Output, Continuous Rated Output

    2. PERFORMANCE MAXIMUM OUTPUT The maximum ouput of an engine is such standard power as developed by the engine, after its initial break in period the moving parts properly worn in, when operating with develop the maximum output in the beginning because the moving parts are not in a properly worn-in condition. RATED CONTINUOUS OUTPUT...

  • Page 7

    PERFORMANCE CURVE , , , , DY35DtB MODEL CURVE PERFORMANCE MODEL DY41 M A X . TORQUE g/H P- h...

  • Page 8: Crankcase

    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 piece die casting;...

  • Page 9: Crankshaft

    CRANKSHAFT The crankshaft is made of a forged chrome and molybdic steel piece with the crank pins and the journals ground t o 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.

  • Page 10: Gearcase Cover, Camshaft, Tappet And Tappet Guide, Rocker Arm

    4-5 GEARCASE COVER Gearcase cover is made of aluminum alloy die casting and is reverse side of the flywheel. This cover em- fitted on the 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 5 .) (See Fig.

  • Page 11: Rocker Cover, Governor System, Lubrication System

    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.

  • Page 12: Cylinder And Cylinder Head, Cooling System, Injection Pump, Nozzle

    4-12 COOLING SYSTEM 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.

  • Page 13: Combustion System

    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 SWIRL (Inspiring swirl) In order to promote mixing injected fuel and air under the direct injection system, swirl flow is utilized for good Combustion.

  • Page 14: Sectional View Of Engine

    4-16 SECTIONAL VIEW of ENGINE...

  • Page 15

    ROCKER COVER I N T A K E V A L V E E X H A U S T V A L V E CYLINDER HEAD-\ AIR CLEANER CY L PAN-’ O I L...

  • Page 16: Disassembly And Reassembly, Preparations And Suggestions, Special Tools

    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.

  • Page 17

    DISASSEMBLING Item quence ~~~~~~~ Engine o i l Fuel Fuel tank Muffler pressure High Pipe cleaner bracket Tank SEQUENCE *Length of the bolt indicates the length from the bolt head bottom surface to the threaded end. Procedures Remove the oil drain plug and discharge oil.

  • Page 18

    Item quence Fly wheel Remove the flywheel cover. Remove the driving shaft. Raise up lock washer, loosen lock nut and then remove the flywheel from the crankshaft using the flywheel puller. Blower housing Remove the blower housing from the crankcase. Cylinder baffle Remove the cylinder baffle from the cylinder.

  • Page 19

    l " 2 L quence ICylrnder Tappet guide Injection pump 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 o i l filler cap. Put the control rack at the center.

  • Page 20

    Procedures Camshaft Pull out camshaft. Between camshaft Piston Remove the piston from the connecting rod. (Remove the clip and pull out the piston.) Governor From the crankcase remove the governor and o i l pump in pump the form of O i l pan Remove the o i l pan from...

  • Page 21

    Item Procedures tuence Remove the connecting rod Connecting from the crankshaft. Bearing hous- From the crankshaft remove ing and crank- the key on the side of fan. shaft 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.) Fig.

  • Page 22

    Item quence Intake and Remove the intake and exhaust exhaust valve valves from the cylinderhead. Snap ring Remove the Balancer shaft Remove the balancer shaft. Balancer Remove the balancer from the case. Fig. Procedures Remarks On the side of intake valve, there is a stem seal.

  • Page 23: How To Reassemble

    5-4 HOW TO REASSEMBLE PRECAUTION I N 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 adhered in the groove of the piston ring should be carefully and completely taken out.

  • Page 24

    NOTE: With the copper shim adjust ance of the crankshaft be 0.1 Three kinds of shim are available, viz. mm thick. [Tightening toruque: 200 kg-cm] (See Fig. 35.) Assemble the connecting rod. CAUTION: Pay attention to the direction of the rod. (FAN mark is to be set on the side of the flywheel.) NOTE: Check the match mark NOTE: The lock washer is not used when fastening...

  • Page 25

    Assemble the piston. mark in the upper part of the piston is to MOTE: 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 surface of the cylinder.

  • Page 26

    Install the camshaft. NOTE: Apply oil or grease to the inside of oit seal for t h e gear case cover. NOTE: Set the match mark of the camshaft mm. Three kinds of shim are available, viz. Fig. 41 oil pump Assemble the and the governor.

  • Page 27

    Assemble the injection pump....8 mm ... . Spring washer NOTE: Measure the distance between the face of the cam base and the surface to which the injection pump is to be fitted.

  • Page 28

    Assemble cylinderhead... 10 mrn flange ....Washer NOTE: Install the intake and exhaust valves. On the intake side there i s a stem seal.

  • Page 29

    INTAKE, EXHAUST VALVE TIMING 0.4 mm When valve clearance is a t heated, intake valve opens a t 16O before TDC, intake valve closes a t after BDC, exhaust valve opens a t before BDC, and exhuast valve closes a t 14" after TDC. (See Fig.

  • Page 30

    Install the tank brackets, left right... . . 16 7T bolt 2 PCS... . . Spring washer 2 pcs... . . 2 pcs.

  • Page 31: Fuel

    6. FUEL 0-1 QUALITY 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.) NOZZLE " HIGH PRESSURE PIPE FUEL INJECTION PUMP F I L T E R...

  • Page 32: General Description Of Auxiliary Gadgets And Parts, Fuel Injection Pump Mechanism

    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 t o sat- isfy the following functions.

  • Page 33

    Variation in quantity of fuel The quantity 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 upper part of the plunger and the suction port is varied.

  • Page 34

    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 ( 2 3 O before TDC) irrespective of engine rpm.

  • Page 35: Specifications

    0 FUEL INJECTION PUMP VALVE DAMPING VALVE BOLT RELEASE PUMP HOUSING PLUNGER RACK STOP SPECIFICATIONS of FUEL INJECTION PUMP for THIS DIESEL ENGINE Model Maker Plunger diameter Lead Plunger spring arbitrary Delivery valve opening pressure Delivery valve spring constant Pump rack friction load Rack stroke DAMPING D E L I V E R Y V A L V E...

  • Page 36: Features, Fuel Injection Nozzle Holder

    Both the injection nozzle and the injection pump are very important parts for producing fuel fog for combustion. There are two types of injection nozzle, one is hole type and the other is pintle type. The injection nozzle for DY30 and DY35 Diesel engine is developed as a result of joint research and development project by Diesel Kiki, direct combustion system, having the special hole type nozzle.

  • Page 37

    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 u p till 195 kg/cm2 and it lifts up the needle valve for 0.18 mm, and is sprayed into the combustion chamber via the jet hole...

  • Page 38

    2) Maintenance If the test results are found not good (poor injection and "after dripping"), carefully check and repair 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 t o the nozzle.

  • Page 39: Governor Mechanism And Operation

    GOVERNOR MECHANISM and OPERATION 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 yoke, and through the governor lever it makes the control rack of injection This mechanism enables t o maintain constant operation irrespective of load variation.

  • Page 40

    Operation 1) Starting When the speed control lever is set on the side of high speed, the governor spring is pulled via the control governor levers are pulled by the tension of the governor spring. The control rack toward “fuel increase.” The governor lever oblong hole by means of the start spring tension.

  • Page 41: Oil Filter

    LUBRICATION SYSTEM and OIL PUMP Lubrication is forced lubrication 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 lubricated to the crank journal.

  • Page 42: Electric Apparatus

    ELECTRIC APPARATUS (Electric Starter) 1. Wiring diagram GENERATOR Circulation When starting by the electric starter, (Key is at the position of start.) Battery (+) BAT of key Charging, operating (Key is at the position of operation.) IC of Generator Rectifier "f Lead wire electric starter...

  • Page 43: Installation, Installing, Ventilation, Exhaust Gas Discharge, Fuel System

    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. INSTALLING When mounting the engine, carefully examine its position, the method of connecting it to a load (machine), the foundation, and the method of supporting the engine.

  • Page 44: Checks And Corrections

    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.

  • Page 45: Table Of Correction Standards

    10. TABLES of CORRECTION STANDARDS ITEM Flatness Intake Valve seat contact width Exhaust Valve guide I.D. DY30D. Inside dia. DY35D. B DY41 D, B Roundness after boring Cylindricity after boring DYSOD, B S. 1. CY-35D. B DY41 D. B DY30D, B O.D.

  • Page 46

    I T E M Piston ring width Piston p i n O.D. Large end I .D. Metal thickness o f large end Clearance between large end and crankpin Small end I.D. after the bush i s force fitted. Clearance between small end and piston Large end side clearance Parallelism between large end and small e n d bores...

  • Page 47

    I T E M Clearance between valve stem dia. and valve guide Valve clearance both intake and (cool condition) O.D. Stem Guide I.D. guide Tapet Rocker shaft O.D. Rocker arm hole dia. Rocker arm shaft clearance Valve spirng free length From injection pump flunge surface t o cam base timing...

  • Page 48: Daily Checks And Maintenance, Every 100 - - 200 Hours (monthly) Checks And Maintenance

    11. MAINTENANCE STORING The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated 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 cleaned every day instead of every 50 hours.

  • Page 49: Every 1500 Hours (overhauls), Preparation For Long Abeyance

    600 HOURS (SEMIANNUAL) CHECKS and MAINTENANCE 11-5 EVERY 500 Checks and maintenance Remove cylinder head and remove carbon deposit. Replace fuel fdter. Check valve seats both intake and exhaust and grind, if necessary. 11-6 EVERY 1000 HOURS (YEARLY) CHECKSand MAINTENANCE Checks and maintenance Reasons for requiring them rings.

  • Page 50

    12. 1/2 REDUCER MUFFLER OIL GAUGE O I L F I L T E R (DRAIN PLUG) FUEL FILTER STOP LEVER AIR CLEANER STARTING HANDLE . ” - FUEL TANK REDUCTION GEAR P.T.O. SHAFT...

  • Page 51

    12-1 1/2 REDUCER CONFIGURATION 01L CHECKING PLUG (M18 x 13) Fig. 12- 1 O I L E X H A U S T I N G P L U G...

  • Page 52

    12-2 STRUCTURE 1/2 REDUCER BEARING (#6205) THRUST WASHER CRAN OIL F I L L E R PLUG OUTPUT SHAFT BEARING (#6206) THRUST WASHER BEARING (#6204) 72-2 Fig. INPUT SHAFT BEARING (#6205) GEAR CASE / "...

  • Page 53

    12-2-1 INPUT SHAFT The input shaft is a wholly carburized. product in which chrome-molybudenum steel is used, and the gear 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 is The shaft...

  • Page 54: Disassembly Sequence, Disassembly And Reassembly Of 1/2 Reducer

    12-3 DISASSEMBLY and REASSEMBLY of 1/2 REDUCER 1 2 - 3 - 1 DISASSEMBLY SEQUENCE Length Spring washer Procedures quence Drain the gear oil. The oil drain plug is located under the gear case cover. Remove the clamping bolt from the adaptor. Remove the 1/2 reducer assembly from the engine.

  • Page 55

    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.

  • Page 56

    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.

  • Page 57

    Mounting to Engine Supply grease into the grease filler hole (the section shown with Set the packing in the coupling, and then clamp it to the engine’s flywheel with four 10 mm Tightening torque: 550-700 kg-cm‘ Apply grease to the coupling and spline gear teeth of the input shaft. d) Set the 1/2 reducer in the engine under 8 mm 65 7T bolts.

  • Page 59

    Industrial Engines...

This manual also for:

Dy41, Dy35

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