ROBIN AMERICA, INC.
CONTENTS See ti0 n Tirle 1. SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Maximum Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2 Continuous Rated Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 Maximum Torque and Fuel Consumption Ratio a t Maximum Output . . .
I b R X i? 4 p? m I E E I W W X E E N a3 - t 0 R X 6, ?t N E E W [D X E E W r. + W Y .
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2. PERFORMANCE 2-1 MAXIMUM OUTPUT Themaximumouput ofan engine is suchstandardpower as developed by theengine,afterits the moving parts properly worn in, when operating with a fully open injection pump. initialbreakinperiod with all Therefore, a new engine may not develop the maximum output in the beginning because the moving parts are not in a properly worn-in condition.
PERFORMANCE CURVE MODEL DY35DtB 10 , - I M A X .
LIGWWEIGWTand COMPACT 1 . Lightweight because of aluminum alloy being usedfor various parts including the crankcase madeof aluminum die casting 2.
- 4-2 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. In the center of the pins and the journals, holes for forced lubrication aredrilled through. (See Fig. 2.) Fig.
4-5 GEARCASECOVER Gearcase cover is made of aluminum alloy die casting and is fitted on the reverse side of the flywheel. This cover em- 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 are assembled, (See Fig. 5 .) Fig. 5 4-6 CAMSHAFT The camshaftis made of forged chrome steel wholly sintered and then ground. It carries three cams, viz.
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 theair breathed is brought to the intake port. (See Fig. 7.) Fig. 7 . .- ! 4-10 GOVERNOR SYSTEM The governor is a centrifugal flyweight type and is installed ’ on the governor gear. Through the lever it adjusts the rack : of fuel injection pump and keeps constant operation at the 1 selected speed against load variations.
CYLINDER BAFFLE 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 cylinder baffle, andcools cylinder and cylinderhead. (See Fig. lo.) Fig. 70 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 the pump and supplied to the nozzle via the high pressure pipe.
4-15 COMBUSTION SYSTEM /INTAKE For lower fuel consumption and easy starting of the engine, the direct injection system is adopted in the combusition VALVE INTAKE PORT chamber. 4-15-1 FORMING of COMBUSTION GAS and COMBUS- SWIRL TION CYLINDER SWIRL (Inspiring swirl) In order to promote mixing injected fuel andair under the direct injection system, PISTON swirl flow is utilized for good Combustion.
4-16 SECTIONAL VIEW of ENGINE - 11 -
EXHAUST VALVE CYLINDER HEAD-\ ROCKER COVER INTAKE VALVE \ \ AIR CLEANER CY L BA O I L PAN-’ - 12 -
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, itis suggested that tags should be attached to them. 2 ) Have boxes ready to keep disassembled parts by group. 3) To prevent missing and misplacing, temporarily assemble as much as possible each group or set of disassembled small parts such as bolts and nuts, etc.
b 5-3 DISASSEMBLING SEQUENCE *Length of the bolt indicates the length from the bolthead bottom surface to the threaded end. * * SW + Spring water * **W + Plain washer Sequence Item ~~~~~~~ Procedures ~ ~~~ ~ ~ ~~~ Remarks - ~ ~~~ ~ Bolts, nuts etc. used ~~ 1 Engine oil Remove the oil drain plug and discharge oil. Oil drain plug locates under the gearcase cover. (Remove oil filter.) Be sure not to miss the “0” ring. The drain plug serves as anoil fiIter too. (See Fig. 16.) 6 mrn hex. bolt .
Sequence Fly wheel 8 9 Bolts, nuts etc. used Remarks Procedures Item Remove the flywheel cover. Remove the driving shaft. Raise up lock washer, loosen lock nut (41 mm box spanner) and then remove the flywheel from the crankshaft using the flywheel puller. Crankshaft, normal threading (See Fig. 18.) Blower housing Remove the blower housing from the crankcase. Just loosen theflange bolts. CylinderbaffleRemove the cylinderbaffle from the cylinder. Be sure not t o miss 5 mm nut.
l"2L I Procedures Remarks I Bolts, nuts etc. used quence l5 Remove the cylinder. are rubber "0" ring and copper shim. (See Fig. 20.) ICylrnder 6 mm nut . . . 2 pcs. sw . . . 2 pcs. Remove the push rodsleeve from the gear case cover. 17 Tappet guide Remove the tappet guide from the gear case cover. A holder is necessary for not let fall the tappet. (See Fig. 2 1 .) 18 Injection pump Remove oil filler cap. Put the control rack at the center. Remove the injection pump from the gear case cover.
Procedures Remarks 20 Camshaft Pull camshaft. theout Between camshaft and gear case there is a shim. (See Fig. 24.) 21 Piston Remove the piston from the connecting rod. (Remove the clip and pull out the piston.) Watch the direction of the clip, also pay attention t o the direction of the piston. ( mark indicates "toward the fan side.") (See Fig. 25.) Bolts, etc. nuts used "f 22 Governor and oil pump From the crankcase remove the governor and oil pump in the form of one piece.
Setuence Item Procedures Remarks Bolts, nuts etc. used I _ 24 Connecting rod Remove the connecting rod from the crankshaft. No lock washer. Be careful of the direction of rod. (Fan mark is on the sideof the flywheel.) Be careful of the setting mark of the cap. (See Fig. 26.) 25 Bearing housing and crankshaft From the crankshaftremove the key on the side of fan. Be careful of the copper shim and “0” ring between the bearing housing and thecase. Remove the bolt fastening the bearing housing.
1 Fj quence 1 1 T Item Intake and exhaust valve I Procedures Remarks Remove the intake and exhaust valves from the cylinderhead. I Bolts, nuts ~Pc.used On theside of intake valve, there is a stem seal. Be sure not to miss retainer lock. (See Fig. 30.) J Fig. 30 Se- I tem Procedures Remarks Snap ring Remove the snap ring. Be sure not to miss the snap ring. (See Fig. 3 1 .) 2 Balancer shaft Remove the balancer shaft. Gently tap with plastic hammer.
5-4 HOW TOREASSEMBLE 1. 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 partof the piston; especially the carbon adhered in the groove of the piston ring should be carefully and completely takenout. 3) Carefully check the lip portion of every oil seal.
:- NOTE: With thecoppershimadjust ance of the crankshaft be 0.1 - 0.2 the side clearmm. Three kinds of shim are available, viz.0.1 mm, 0.2 mm, and 0.3 mm thick. [Tightening toruque: 200 - 230 kg-cm] (See Fig. 35.) Fig. 35 3 ) Assemble the connecting rod. CAUTION: Pay attention to the directionof the rod. (FAN mark is to be set on the side of the flywheel.) NOTE: Check the match mark on the cap. NOTE: The lock washer is not usedwhenfastening the bolt.
Assemble the piston. MOTE: + mark in the upper part of the piston is to be faced to the fanside. MOTE: Piston rings are not assembled. MOTE: Shape of the piston pin.is (D . (See Fig. 38 .) Assemble the cylinder NOTE: Insert thepiston into thecylinder(piston ring is not inserted.), and measure the dimensions of the head of piston and upper surface of the cylinder. NOTE: The concave dimensions of the pistion is -0.6 - Fig. 38 -0.7 mm from the upper Surface of the Piston.
8) Installthecamshaft. 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 so as to fit to t h a t of the crank gear. Side clearance is to be adjusted to 0.1 - 0.3 mm. Three kinds of shim are available, viz. 0.8 mm, 1.O mm and 1.2 mm. Fig. 42 Fig. 41 9) Assemble the oil pump and the governor. 6 x 2 0 7 T b o l t . . . . . . . . . . . . 2 pcs. Spring washer . . . . . . . . . . . . 2 pcs.
Assemble the injection pump. 8 mm nut . . . . . . . . . . . . . . . 3 pcs. Springwasher . . . . . . . . . . . . 3 pcs. NOTE: Measure the distance between the face of the cam base and the surface to which the injection pump is to be fitted. And adjust it may become 76 k 0.05 mm, usingthe shims. Two kindsof t h e shim are available, viz. 0.1 mm, and 0.3 mm. CAUTION: Remove the oil filler cap and check if the control rack comes off from the governor lever. (See Figs. 44 and 45 .) - . .- ___ l.
a Assemble the cylinderhead. 10 mrn flange nut . . . . . . . . . . 4 pcs. Washer NOTE: ................. 4 pcs. Install the intake and exhaust valves. On the intake side there i s a stem seal. NOTE: Insert the push rod. (Exhaust is on the side of the gear case.) Pay attention to the valve facing, UPwardordownward,and direction of intake and ex- haust. NOTE: Install the rocker arm to the cylinder. It is advisable to insert the rocker shaft before clamp- ing the head. Fig. 47 (See Fig. 47 .
TDC (TOP DEAD CENTER) INTAKE, EXHAUST VALVE TIMING When valve clearance INTAKE VALV is a t 0.4 mm and the engine is heated, intake valve opens a t 16O before TDC, intake valve closes a t 54' after BDC, exhaust valve opens a t 54' before BDC, and exhuast valve closes a t 14" after TDC. (See Fig. 50.) AUST VALV VALVE INTAKE BDC (BOTTOM DEAD CENTER) Adjust the decompression clearance. Fig. 50 NOTE: The decompression device locates in the rocker arm on the intake valve side.
Install the tank brackets, left and right. 8 x 16 7T bolt . . . . . . . . . . . . 2 PCS. . . . . . . . . . . . . 2pcs. 8 mm nut bolt . . . . . . . . . . . . 2 pcs. each Springwasher Connect the fuel pipe and fuel return pipe securely. . . . . . . . . . . 2 pcs. Aluminum packing . . . . . . . . . 2 pcs. 8 x 18 banjo bolt NOTE: Connect the pipe t o the nozzle first, and then connect the fuel pipe t o the tank. Install the air cleaner. 8 mm nut . . . . . . . . . . . . . . .2 pcs. Springwasher . . . .
6. FUEL 0-1 QUALITY Of 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.) i F U E L R E T U R N PIPE f T \ / AIR RELEASE fUEL TANK NOZZLE / \ " FUEL F I L T E R HIGH PRESSURE PIPE F U E L PIPE FUEL INJECTION PUMP FILTER T A NPRESSURE K PUMP t PIPE PIPE FUEL RETURN PIPE Fig.
7. GENERAL DESCRIPTION of AUXILIARY GADGETS and PARTS 7-1 FUEL INJECTION PUMP MECHANISM It is not too much tosay that the fuel injection pumpis the heart of thediesel engine, and it must beprecise enough t o satisfy the following functions. Function Injecting fuel, starting withhigh pressure and ending with low pressure. Injecting the predetermined amount of fuel accurately at each stroke. Injecting fuel at specified time within a specified time interval.
3. Variation in quantity of fuel to be injected The quantity of 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 portis varied. (Variation in effective stroke) Rotation of the plunger is made by the control rack.
4. Injection timing andeffectivestarting When the plunger closes suction port of the barrel, forced delivery of fuel starts.But fuel is not injected from the noz2le.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.On the other hand,in starting, a proper delay from the timing for high speed running andincreasedfuelinjection INSTALLED ONLY TO D Y 3 0 is indispensable for effective starting.
0 FUEL INJECTIONPUMP VALVE DAMPING VALVE DAMPING SPRING DELIVERY VALVE DELIVERY VALVE BOLT SEMBLY RELEASE AIR PUMP HOUSING DELIVERY VALVE - PLUNGER RACK CONTROL STOP CONTROL SLEEVE PLUNGER SPRING SPRING SEAT PIN Fig. 60 0 SPECIFICATIONS of FUEL INJECTION PUMP for THIS DIESEL ENGINE Model PFRIKD55/2NP1 Maker Diesel Kiki K.K. 5.5 mm Plunger diameter Lead Right twist lead Plunger spring arbitrary 2.46 kg/cm Delivery valve opening pressure 27.
7-2 1. FUEL INJECTION NOZZLE HOLDER Specifications ~ ~~ Part Name I I NOZZLE HOLDER Part No. 105 11840 00 Identification mark C No. of nozzle hole 4 (Diameter) (0.22mm) Valve opening pressure 195 kg/cm2 Spring constant 13.2 kg/cm2 a 2. Features Both the injection nozzle and the injection pump are very important parts for producing fuelfog for combustion. There are two types of injection nozzle, one is hole type and the otheris pintle type.
5. 1 Fuel passage From the plunger pump fuel is sent through the highpres- 3, sure pipe 1 to the fuelpassage 2. Then, at the nozzle body 2 it is pressurized u p till 195 kg/cm2 and it lifts up the needle 7 valve 4 for 0.18 mm, and is sprayed into the combustion chamber via the jet hole5 . An excess fuel which lubricated the inside of the nozzle and 6 3 nozzle holder returns to the fuel tank via the needle valve + nozzle spring 6 + overflow pipe 7 + fuel tank, (See Fig. 63 .) 6. 4 5 Fig.
2) Maintenance shing, After If the test results are found notgood (poor injection and "after dripping"), carefully check and repair in the following manner: a) Disassemble the nozzle holder and nozzle, andwash in clean light oil. When washng, use a wooden chip (for instance, wooden chopstick is servicable.) for peeling off the carbon adheredt o the nozzle. b) the pull outfrom halfway needle NEEDLE the body of nozzle with your fingers and then let check And it go.
7-3 GOVERNOR MECHANISM and OPERATION 1. Mechanism The governor is centrifugal flyweight type, which means aflyweight is fitted to the governorgear. The governor sleeve is assembled so that it may slide toward the direction of the axis of the pump shaft, and itis in contact with the flyweight. The governor sleeve gets in touch with the governor yoke, and through the governorlever it makes the control rack of injection pump operate.
2. Operation 1) Starting When the speed control lever is set on the side of high speed, the governor spring is pulled via the control link.The governor levers 1 and 2 are pulled by the tension of the governor spring. The control rack of injection pump is pushed toward “fuel increase.” The governor lever 1 has an oblong hole, and thegovernor lever 2 moves to the extent of this oblong hole by means of the start spring tension.
7-4 LUBRICATION SYSTEM and OIL PUMP Lubrication is forced lubrication and wholly fdtered system by trochoid type oil pump. The oil pump, and thegovernor are is fitted to thecrankcase. assembled in one piece, which main gallery oil is forcibly Revolution of the crankshaft is reduced by the reduction gear (1 : 1.4) of the pump; and from the l i further be supplied to the crankpin,large end of the connecting rod, and then lubricated to the crank journal.
7-6 1. ELECTRICAPPARATUS (ElectricStarter) Wiring diagram KEY SWITCH GENERATOR ELECTRIC STARTE 1) Circulation 12V35AH When starting by the electric starter, (Keyis at the position of start.) Battery (+)-+ BAT of key + ST of key + Starter + Battery (-) (earth) Charging, operating (Key is at the position of operation.) Generator 2. "f Rectifier + IC of key +. BAT of key +.
8. 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. 8-1 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. 8-2 VENTILATION Fresh air is necessary for cooling theengine and burning the fuel.
9. 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. Correct maintenance is recommended by observing the correction standards specified.
10. TABLES of CORRECTION STANDARDS r CORRECTION STANDARD ITEM :ORRECTIOP METHOD LIMIT Flatness 0.03 0.05 Intake Valve seat contact width 2.2 1.4 Exhaust I Valve guide I.D. 1 DY30D. 6 I to.015 7 dia. 0.1 5 +0.019 76dia. Inside dia. 0.1 DY35D. B DY41 D, B 82 dia' Roundness after boring 0.01 Cylindricity after boring 0.01 5 S. 1.D. I DYSOD, B II 75.96 CY-35D. B DY41 D. B 81.94 DY30D, B 76.21 0.25 +0.022 +" 1 ~ O.D. at skirt, in thrust direction (Incl.
r I STANDARD DIMENSIONS ITEM Piston ring width Oil 4 Piston p i n O.D. 21 dia. Large end I .D. 43 dia. Metal thickness o f large end I CORRECTION TOLERANCE -0.1 -0.1 -0.02 -0.02 -0.005 -0.01 8 1.4 1.4 0.01 L-0.068L 0.1 0.1 0.05 0.05 0.08 0.08 0.5 0.5 0.1 0.1 0.15 0.5 0.1 5 0.15 0.1 5 0.15 +0.006 0 Small end I.D. after the bush i s force fitted. +0.034 +0.013 0.007L-0.034L Large end side clearance 0.07L Parallelism between large end andsmall e n d bores - 0.
arance I ITEM Clearance between valve stem dia. and valve guide - STANDARD - 0.063 L 0.093 L Exhaust 0.083L-0.113L exhaust 0.07 I 0.013L-0.048L 0.15 0.15 -0.01 6 -0.034 a . *.Of 0 Rockerarmholedia. 0 I CORRECTIOP METHOD REMARKS l -0.07 I M.08 -0.08 -0.08 +O .07 +O .07 12 dia. L al Y I -0.07 N.08 Rocker shaft O.D. E l +0.015 0 Guide I.D. Tapet I -0.01 3 -0.033 USE 0.3 I 8 dia. c 1 0.3 - 0.1 Stem O.D.
11. MAINTENANCE and STORING The following maintenance jobs apply when the engine is operated correctly under normal conditions. The indicated maintenance intervals are by no means guarantees for maintenance free operations during these intervals. I For example, if the engine is operated in extremely dusty conditions, the air cleaner should be cleaned every day instead of every 50 hours.
11-5 EVERY 500 - 600 HOURS (SEMIANNUAL) CHECKS and MAINTENANCE Reasons for requiring them Checks and maintenance ~~ Remove cylinder head and remove carbon deposit. The engine will be out of order. Replace fuel fdter. The engine will be out of order. Check valve seats both intake and exhaust and The engine will be out of order. grind, if necessary. 11-6 EVERY 1000 HOURS (YEARLY) CHECKSand MAINTENANCE I Checks and maintenance Reasons for requiring them ~ Change piston rings.
12. 1/2 REDUCER AIR CLEANER MUFFLER OIL GAUGE STARTING HANDLE FUEL FILTER STOP LEVER OIL FILTER (DRAIN PLUG) .”- FUEL TANK REDUCTION GEAR P.T.O.
12-1 CONFIGURATION of 1/2 REDUCER 01L CHECKING PLUG (M18 x 13) OIL EXHAUSTING PLUG Fig.
12-2 STRUCTURE Of 1/2 REDUCER OIL F I L L E R PLUG BEARING (#6205) THRUST WASHER OUTPUT SHAFT BEARING (#6206) I THRUST WASHER BEARING (#6204) INPUT SHAFT CRAN BEARING (#6205) GEAR CASE Fig.
12-2-1INPUTSHAFT The input shaft is a wholly carburized. product in which chrome-molybudenum steel is used, and the gear A and spline are built in it. 12-2-2 OUTPUT SHAFT The output shaftis made of carbon steel, and the gear C is fitted in spline engagement. 12-2-3 SHAFT B The shaft B is made of chrome-molybudenum steel, and wholly carburized.
12-3 DISASSEMBLY and REASSEMBLY of 1/2 REDUCER 1 2 - 3 - 1 DISASSEMBLY SEQUENCE Length of the bolt indicates the length from the bold head bottom surface to the threaded end. *SW = Spring washer Sequence Main Item to be disassembled Procedures 8mm hexagonal bolt Opposite side: 13 mm The oil drain plug is located Replace the gasket with a new one. under the gear case cover. 1 Drain the gear oil. 2 Remove the clamping bolt from the adaptor. 3 Remove the 1/2 reducer assembly from the engine.
12-3-2 REASSEMBLINGSEQUENCE 1. Precautionsin 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 ofevery oil seal. If damaged one is found, replace it with anew one. Replace all the gaskets with new ones. Replace the bolts,if necessary, with new ones. As for the places where tightening torqueis specified, apply the specified torque.
Pressure-fit the oil seals into the adaptorand 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. 12-7.) Set the thrustwasher onto the edge face of the gear B. Set the output 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.
3. Mounting to Engine a) Supply grease into the grease filler hole (the section shown with inclined lines in the figure) of the input shaft. b) Set the packing in the coupling, and then clampit to the engine’s flywheel with four 10 mm x 30 9T bolts. Tightening torque: 550-700 kg-cm‘ c) Apply grease to the coupling and spline gear teeth of the input shaft. d) Set the 1/2 reducer in the engine under the condition that the spline teeth are engaged, and clamp it with four 8 mm x 65 7T bolts.
Industrial Engines
