Dy 232 D

Downloaded from www.Manualslib.
com manuals search engine

ROBIN AMERICA, INC.
ROBIN TO WISCONSIN ROBIN
ENGINE MODEL CROSS REFERENCE LIST
ROBIN WISCONSIN ROBIN
SIDE VALVE
EY 08 W 1-080
EY15 W1-145
EY 15V W1-145V
EY 20 W1-185
EY20V W1-185V
EY23 Wl-230
EY28 W 1-280
EY35 W 1-340
EY40 W 1-390
EY45V W 1-450V
EY2 1 EY21W
EY44 EY44W
EY 18-3 EY 18-3W
EY25 EY25W
EY27 EY27W
OVERHEAD VALVE
EH11 WOI-115
EH12 WOI-120
EHl5 WO1-150
EHI 7 WOI-170
EH2 1 wo1-210
EH25 WO1-250
EH30 WO 1-300
EH30V WO 1-300v
EH34 WO1-340
EH34V WO 1-340V
EH43 V WO1-430V
TWO CYCLE
EC13V WT1-125V
DIESEL
DY23 WRD 1-230

DY27 WRD 1-270
DY30 WRD 1-300
DY3 5 WRD1-350
DY4 1 WRD1-410
Downloaded from www.Manualslib.com manuals search engine

CONTENTS
Section Title Page

r

1. SPECIFICATIONS
Model DY23-2D DY23-2B DY27-2

Type Air-Cooled. 4-cycle, Overhead Valve, Single vertical cylinder, Diesel engine
I
70 X 60 rnrn 75 X 60 mm
Bore X Stroke
( 2.76 X 2.36 in. ) ( 2.95 X 2.36 in. 1
230cc 265 cc
PistonDisplacement
( 14.04 cu.in. ) ( 16.1 1 cain. )
CompressionRatio 21
output rpm HP/ 4.8 / 3600 4.8 / 1800 5.5 / 3600 5.5 / 1 800
DIN6270NB (Warnin) ( 3.5 / 3600 ) ( 3.5/ 1800 1 ( 4.0/ 3600 1 ( 4.0/ 1800 1
output HP/ rpm 4.2 / 3600 4.2 / 1800 5.0 / 3600 5.0 / 1 800
DIN6270NA (KW-min) ( 3.1 / 3600 ) (3.1 /1800 1 ( 3.7/ 3600 1 ( 3 . 7 / 1800 1
Torque
kg - m / rpm 1.07/ 2200 2.14/ 1100 1.23 / 2400 2.46/ 1200
DlN6270NB ( ft.lbs/ rpm 1 (7.7/2200 ) (15.4/11001 ( 8.9/ 2400 1 ( 17.W 1200 1
Rotation
I Counterclockwise as viewdfrom PTO shaft side
Cool ing I Forced air cooling
Lubrication I Forcedoil lubrication
Lubricant Diesel engineoil.servicerank CC or CD
Oil Pump Trochoid gear pump
Fuel InjectionPump ZEXEL PFRIMD55 / 2NP1

Injection Nozzle ZEXEL DLLAI 50PN052
Fuel Automotive diesel fuel
Fuel Feed I Gravity type
Fuel TankCapacity
I 3.2 liters ( 0.84 U.S.gal. 1
CombustionSystem Directinjectiontype
GovernorSystem Centrifugalflyweighttype
1 2V- 39W/3000 12V - 39W / 3000

Lighting Capacity
1 2 V - 4 3 W / 3600 12V - 43W / 3600
StartingSystem Recoil starter ( Electricstarter as option )
DryWeight
I (63.9Ibs.) (65.0 Ibs.) Ibs.)
(66.1lbs.)
(65.0
30 kg
329 x 357 x 402 mm 339 x 357 x 402 mm

Dimension LXWXH
(12.95 x 14.06 x 15.82 in.) (13.35 x 14.06 x 15.82 in.)
Specifications are subject t o changewithoutnotice.
-1-
2-1 M A X I M U M OUTPUT
The maximum output of an engine istheoutput power of the engine operatingwith
its throttle valvefully open afterithas been broken in properly.
Therefore, a brand-new engine or an engine which has not been broken in properly may
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 at the 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
kg - m
i
1.2 (2.4)
1.1 (2.2)
1 .o (2.0)
3.9 (1.8) 2
W
c1:
O
I-
\ TORQUE (NB)
HP
I
z!2 3
W
v)
IT
5
g/HP-h
0
I
2 z
0
I-
240
1 220 y
200 g-
FUELCONSUMPTION
I L L
RATIO (NB)
I
\ I &
1500 2000 2500 3000 3500 4/00 22
(750) (1000) (1250)(1500)(1750)(2000)
REVOLUTION "----+ r. p. rn.
MODEL DY27-2 ( 1for B type

kg- m
.3 (2.6)
.2 (2.4)
.1 (2.2)
.o (2.0) Y
6
2
HP
I
9
5
0-3
W
v)
I1I
5
g / HP- h
P 2
h
1500 2000 2500 3000 3500 41

(750) (1000) (1250) (1500) ( 1 750) (21
REVOLUTION c r. D. rn.
-3-
3. FEATURES
3- 1 ECONOMICALRUNNING
The direct injection system using the newlydeveloped micro fuel injection pump assures
superiorcombustion efficiency and minimized fuel consumption.
3- 2 EXTREMELYQUIETOPERATION
0 The precisely synchronizedfuel injection and refined combustionchamber allow lower
combustion pressure which resultsin reduced combustion noise.
Q Blower housingandcylinderbaffleare made from DUMPING SHEET, aspecial
materialforinsulating noise andvibration.
0 Largersupersilentmufflerand double element air cleaner reduce theexhaustand
intake noise.
3- 3 EASY STARTING
8 Light pull recoil starter andcentrifugal
automatic decompressor allow effortless
starting similar to agasoline engine.
0 An auxiliary fuel inletis provided foreasystarting in cold weather.
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
adopted forextremelysmoothrunningwith lessvibration.
a The automatic decompressor preventsshakyvibration a t stopping.
3- 5 HIGH PERFORMANCE
Die-castcylinder head generates a stableswirl of air-fuel mixture which results in the
highoutput power and an exceptional fuel economy.
Its flattorquecharacteristic provides tenacious running from slow speed to high 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
Robins 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
The cylinder and crankcase are single piece
aluminum die casting. The cylinder liner,
made of specialcastiron,isbuiltinto
thealminumcasting.
Thecrankcaseisseparable on the output
shaftside,wherethemainbearingcover
is attachedto it. (See Fig. 1.)
4 - 2 MAIN BEARINGCOVER
The main bearing cover made of aluminum
die casting is built onto the output shaft
side of thecrankcase so thattheinside
of theenginecanreadily be checked by
simply removing the cover. It is provided
withaflangeand boss fordirectly
mountingmachines,such as generators
andpumps.
Two oilgaugesalsoserving as oil filler
capscanbemounted.
(See Fig. 2)
~~
4- 3 CRANKSHAFT FIG. 2
Crankshaftismadefromforgedcarbon
steelanditscrankpinandjournalare
induct ion - hardened.
Crankshaft is supported by a ball bearing
a t 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. 3
-5-
4 - 4 CONNECTING ROD
Connecting rod ismadefromforged
aluminumalloywhichwithstandshigh ,
combustionpressureandtensionunder
heavyloadandhighspeedoperation.
Kelmet bearings are provided as large end
bearing,whilethematerial of connecting
roditselfserves as smallendbearing.
(See Fig. 4.)
4- 5 PISTON FIG. 4
Piston is madefromaluminumalloy
casting, and i t has three grooves for piston
rings.
On the piston top, a combustion chamber
is arranged where the injected fuel mixes
withairandignites. TOPRING
Thepistonprofileis so designedasto SECONDRING

minimizepistonnoise. (See Fig. 5.)
OILRING
4 - 6 PISTON RINGS ,
Pistonringsaremadefromspecialcast
CONNECTINGROD
iron. The profile of top ring is barrel face,
andthat of secondringistaperwith
under cut. The oil ring is the combination
of cutterringsandanexpanderwhich
FIG. 5
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
intake and exhaust ports, rocker arm room,
andcoolingfinsare molded inthemost
ideal structure for thehigheststrength
andthehighestcoolingefficiency.
High qualityheatresistantvalveseats
are pressure- fitted considering high ,-
resistancetoabrationandcorrosionat
high temperature. (See Fig. 6.) FIG. 6
-6-
4- 8 CAMSHAFT
Camshaft for "D" type engine is made from
special cast iron integrated with cam gear.
Camshaftfor "B" typeengine works as
PTO shaft and is made from forged carbon
steel and the cam gear is pressure-fitted.
Camshafthasthreecams,oneforintake,
one for exhaust,andone or injection
pump. A releaseleverforcentrifugal
decompressor is assembled to the camshaft.
(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 heat resistant
alloy.
Stellite is fusedtothehead of exhaust
valveforaddeddurability. (See Fig. 9.)
EXHAUST
VALVE
INTAKE
VALVE
FIG. 9
-7-
4- 11 ROCKER A R M I
Rocker armsare madefromforgedsteel
andare whollysintered.
A screwforadjustingvalveclearanceis
provided attheend of rockerarm.
Rocker arms are lubricated by the oil mist
contained in the breathing
air
from
crankcase. (See Fig.lo.)
FIG. 10
4- 1 2 ROCKERCOVER
Rocker coverismadefromsteelsheet.
A breather plate is installed in the rocker
covertobreathairintointakeport.
(See Fig. 1 1.)
FIG. 1 1
4- 1 3 AUTOMATIC DECOMPRESSION
SYSTEM
Automaticdecompressionsystem is com-
posed of areleaseleverandaflyweight
assembledtothecomshaft.
Below the predetermined speed, the release
lever lifts theexhausttappetslightlyto
releasecompression. (See Fig. 12.)
/-
FIG. 12
-8-
4- 14 GOVERNOR SYSTEM
Thegovernoris a centrifugalflyweight
typewhichpermitsconstantoperationat
the selectedspeedagainst load variations
GOVERNOR
LEVER
by controlling the quantity of fuel injected.
Governor system is driven by the governor
gearengagedwithcamgear.
(See Fig. 13.)
Refer to section 6 - 4 fordetails.
FIG. 13
4- 15 LUBRICATION SYSTEM
Lubricantisforcibly supplied by the 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.
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 through the high pressure
pipe. (See Fig. 14.)
FIG. 14
-9-
4 - 1 8 FUEL INJECTIONNOZZLE
Fuel is injected in the combustion chamber
as fine mist through the four small ports
of fuelinjection nozzle. (See Fig. 15.)
FIG. 15
4 - 19 AIR CLEANER SECONDARY ELEMENT

/
A i r cleaneris dry typedoubleelement
system.
Primary element is polyurethane foam and
thesecondaryelementispaper.
Theaircleanercover is madefromhigh
strengthplastic
and
its
air
inlet
is
speciallydesigned t o reduceintake noise.
(See Fig. 16.) PRIMARYELEMENT
FIG. 16
/
4 - 20 FUEL FILTER
Fuelfilter is a paperelementdisposable
type. Its has a automaticairbleeding
outlet on thetopand a waterdrainon
the bottom. (See Fig. 17.)
FIG. 17
- 10-
4- 21 COMBUSTION SYSTEM
For lower fuelconsumption andeasy /INTAKE VALVE
starting of the .engine, the direct injection INTAKE PORT

systemis adopted inthe combustion
chamber. SWIRL
4 - 2 1 - 4 FORMING OF COMBUSTION GAS
AND COMBUSTION
CY LlNDER
( 1 1 SWIRL (Inspiring swirl)
In orderto promotemixinginjected PISTON
fuelandairunderthedirect injection
system,swirl flow is utilizedfor good
combustion. Swirl isspiral flow of air
generatedinthe cylinder during
inspiringstroke,andit decreases
during compressing stroke but it still
remainsand promotesmixing of fuel
and air towardignitiontiming. FIG. 19
Spiral flow of air (swirl) isgenerated
by the shape of intake port, which is
called helical port or spiralport.
Tail end of intake port, i. e. upper part
of intakevalveseat,is made in the
spiral forrn : and while the inspired air /c SQUISH
is passingthroughthispart,swirlis
generatedaround theintake valve.
Thus,intakeportplaysanimportant
role in generating swirl. (See Fig. 19.)
SQUISH (Squished air flow)
In the piston, combustion chamber (dish
type combustionchamber) is formed.
When the piston comes up to TDC (top
dead center), air in the gaps is squished FIG. 20
in the combustion chamber and air flow
isgenerated, which is called squish.
(See Fig. 20.)
FORMING OF COMBUSTION
GAS AND COMBUSTION
For igniting quickly the fuel injected from the nozzle, it is essential to 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 mixed with air by the flow of
swirlandsquish while pistoniscomingup. Accompanying crimb of thepiston,
combustion gas compressed furtherandfinallyitautomatically begins ignitingand
while piston is goingdown,squishfunctionsand promotes combustion.
- 11 -
4- 22 SECTIONAL VIEW OF ENGINE
INTAKE VALVE
/
EXHAUST VALVE
CYLINDER HEAD
PISTON PIN
k/ MAN
BEARING COVER
CRANKSHAFT
TROCHOID OIL PIJMP
/ \ \
FLYWHEEL CRANKCASE GOVERNOR
- 12 -
ROCKER COVER AIR CLEANER
MUFFLER \ \ /
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

that they can be reassembled correctly. If you are uncertain 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 a s 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. Tool Use
209- 95001 - 07 Flywheelpuller with bolt For pulling off the flywheel
228-95003-07 Piston ring cqmpressor For placing piston ring

.
PISTON RING COMPRESSOR

f
FLYWHEEL PULLER
/-
FIG. 21
- 14 -
5- 3 -DISASSEMBLY PROCEDURES
-
Step Proocedures Remarks Tool
-
1 Engine oil (1) Remove drain plug and discharge Be careful not to lose 14 mm
oil from crakcase. thegasket. spanner
Drain plugs are located on both
sides of the crankcase.
(2) To discharge oil quickly,remove
oil gauge.
2 Fuel (1) Remove drain plug from fuel Be careful not to lose 10 mm
filter
anddischarge fuel
from thegasket. spanner
fueltank.
-
3 Injection pipe (1) Loosen the two joint nuts at the Be careful to keep 12 mm
both
ends of injection pipe to the inside of the spanner
removeit. pipe, injection pump
and the nozzle free of
dust.
INJECTION PIPE
- 15 -
Step lPart to remove Procedures Remarks Tool
4 Air cleaner (1) Remove cleaner cover from the

cleaner body.
(2) Loosen the wingbolt to remove Be careful not to lose
element. the washerand the 10 mm
(3) Remove cleaner body from intake packing for wing box wrench
manifold. bolt. 12 mm
6 4 X 12 mm flange bolt...-..2pcs . box wrench
8 0 BOLTandWASHER
PACKING
CLEANERBODY
ELEMENT
IStep I Part to remove I I
3
Procedures Remarks
5 Recoil starter (1) Remove recoil starter from

blower housing.
6 4 x 10 mm flange bolt**..**4pcs.
spanner
6 0 FLANGE BOLT : 4pcs.
HOUSING
m
RECOILSTARTER
FIG. 24
- 16 -
I
step Part to remove Procedures I Remarks Tool
6 Fuel tank (1) Disconnect fuel pipe from fuel tank.

(2) Disconnect fuel return pipe.
(3) Disconnect rubber pipe from the check
valve.
(4) Remove the fuel tank. 10 mm
8 Q X 20mmbolt*****e.e* 1 pce. spanner
8 @ X30mmbolt*****~***2pcs.
7 Muffler (1) Remove the muffler cover from muffler.

6 @ X 10 mm bolt 9 e * * 4 pcs.
(2) Remove the muffler. Be careful not to lose the 12 mm

8 @nut gasket. box wrench
8 Qspringwasher*****~*~~2pcs.
a+ BOLT
6 + BOLT : 4pcs. /
- 17 -
Step Tool
8 Starting motor (1) Remove the wire

harness
from
Reattach
the
terminal 1Omm
thestarting motor. nuttothe motor tospanner
(2) Remove thestarting motor fromkeep it from missing. 12mm
crankcase. spanner
8 4 x 30 mm bolt ...............2pcs.
9 Fuel
filter (1) Remove the fuel filterfromthe Wipe
off spilt
fuel 10 mm
blower housing. thoroughly. box wrench
6 q-5 X 20 mm flange bolt.....*2pcs .
10 Blower (1) Remove the blower housing from 12 mm

housing crankcase. box wrench
8 q5 x 20 mm bolt and washer
..................... 2pcs.
- 18 -
-
Step Part to remove Procedures Remarks Tool
11 Flywheel (1) Remove the starting pulley. 10 mm

, X 1 2 m bolt ...............3pcs.
6$ Flywheel can easily boxwrench
(2) Remove the flywheel nut. beremoved by 24 mm
(See Fig. 27.) striking witha socket
(3) Set the flywheel puller tothe hammerthehead of wrench
flywheel. ( See Fig. 28. ) thecenter bolt of
Turn the center bolt clockwise to flywheel puller.
pull outthe flywheel.
(4) Remove the key from crankshaft. Be carefulnotto
lose the key.
v
FIG. 27 FIG. 28
FLYWHEEL NUT
6 + FLANGE BOLT : 3pcs.-@
STARTINGPULLEY
SPRINGWASHER
FLYWHEEL
FIG. 29
- 19 -

-
12 Cylinder (1) Remove the cylinderbafflefrom
baffle cylinder.
6 q5 X 10 mm flange bolt-.-..-lpce.
~~
13 Rocker cover ( I ) Remove the rocker cover from 10 mm

cylinder head. box wrench
6 4 X 40 mm flange bolt-......lpcs .
Fuel injection (1) Remove thebracket, nozzle.
nozzle 6 4 nut .............................. 2pcs.
(2) Remove thefuel injection nozzle Be careful not to lose
from cylinderhead. thegasket atthe
bottomend of the
nozzle.
I
6 4 NUT : 2 p c s .
-e9 - 6 4 FLANGE BOLT : 4pcs.
ROCKERCOVER
NOZZLE
BRAC
FUEL INJECTION NOZZ
LANGE BOLT
FIG. 30
-20-

StepParttoremove Procedu.res Remarks Tool
15 Rocker arm ( 1 ) Loosen the adjusting bolts on the 10 mm

rockerarms. spanner
(2) Push the rocker shaftoutfrom screw driver
the cylinder head to remove the Make the rocker arms
rockerarms. andpushrods
(3) Remove the push rods. distinguishable of
intakesideand
exhaust side.
16 Cylinder
head (1) Remove the cylinder head from Be careful of the 12 mm
cylinder. spacer.
socket
8 4 flange nut ....... ..........4pcs. wrench
8 6 FRANGE NUT : 4DC.s. ADJUSTING BOLT
CYLINDER H E A D\ I
ARM
ROCKER
ROD
FIG. 32
- 21 -
Step )art to remove Procedures Remarks Tool
-
17 Fuel injection (1) Remove the fuel injection pump Be careful of the 10 mm
pump fromcrankcase. position of the socket
6 4 nut .............................. 2pcs. control rack. wrench
- ~ ~~
18 Main bearing (1) Remove the bolts joining the Be carefulnot to 12 mm

cover mainbearing cover and damagethe oil seal. box wrench
crankcase.
8 @ X 35 mm bolt..-.----.--.1lpcs.
8 @ x 40mm bolt ............... 1pce.
(2) Lightlytappingwith a plastic plastic
hammer, remove the main hammer
bearing cover from the
crankcase. (See Fig. 33.)
6 + NUT : 2pcs.

Step F'arttoremove Procedures Remarks Tool
19 Camshaft (1) Remove thecamshaftfromthe (1) To preventthe

crankcase. (See Fig. 35.) tappetfromfalling
andgetting damages,
putthe crankcase
injection pump side
down.
(2) Remove thetappetsfromthe (2) Put marks on the
crankcase. tappets to distinguish
intaketappet from
exhaust.
20 Balancer i (1) Remove the balancer fromthe Be careful of the
(Optional ~ crankcase. spacer on the
part) balancershaft.
SPACER
FIG. 36
- 23 -

r
Step 'art to remove Procedures Remarks Tool
21 Connecting (1) Scrape off the carbon

deposit
rod from the piston top and cylinder.
(2) Remove the connectingrodbolts 10 mm
andthelarge end cap. box wrench
(3) Turnthecrankshafttothetop
dead
center.
Then, push the connectingrod
upand pull the piston and
connectingrodoutfrom the
cylinder.
22 Pistonand ( 1) Remove the twoclipsfrom the Be careful not to give
pistonpin piston at the both ends of piston damagestothe
pin. piston and connecting
(2) Push the piston pin out from the rod.
piston.
Remove the pistonfrom the
connecting rod. Be careful not to
(3) Remove the piston rings from breaktherings by
the piston by spreading their spreading too much
open ends. ortwistingthem.
PISTON RING
CLIP
PISTON PIN
CONNECTING ROD I
BEARING'
LARGE END
/ UII /

23 Crankshaft (1) Lightly tap thecrankshaft end The ball bearing

at the flywheel side using a comes off with the
plastic hammer to remove it crankshaft.
fromthecrankshaft.
(See Fig. 38.)
FIG. 38
CRANKSHAFT
\ t
FIG. 39
- 25 -

3Step IPart to remove
Intake
and
exhaust valve
Oil filter
Procedures
( 1 ) Press the valve springs and

remove the
retainer
the valvestems.
locks from
(See Fig. 40.)
(2)Remove the valves fromthe
cylinder head.
(1) Remove the oil filter

bearing
main cover.
from
the
6 4 X 12mm flange bolt...---2pcs.

Remarks
Putmarks on the
valves, valve springs
andspringretainers
todistinguishthem
for intakesidefrom
exhaust side.
Be carefulnot
thespanner
0 - ring.
-8
to lose
~~ ~
.pliers
10 mm
Tool
R E T A I N E R LOCK
I &---- STEM S E A L
FIG. 40
VALVE
7- OIL FILTER
MAIN B E A R I N G COVER 6 + FLANGE BOLT : 2pcs
FIG. 41
J
- 26 -
EASSEMBLY PROCEDURES
PRECAUTIONS FOR REASSEMBLING
(1) Clean parts thoroughly before reassembly.
Pay most attention to cleanliness of piston, cylinder, crankshaft, connecting rod and bearings.
(2) Scrape off all carbon deposits from cylinder head, piston top and piston ring grooves.
(3) Check lips of oil seals. Replace oil seal if a lip is damaged.
Apply oil to lips before reassembly.
(4) Replace all gaskets with new ones.
(5) Replace keys, pins, bolts, nuts, etc., if necessary.
(6) Torque bolts and nuts to specification refering to the Table of tightening torque.
(7) Apply oil to rotating and sliding portions.
(8) Check and adjust clearances and end plays where specified in this manual.
5 - 4 - 1 CRANKSHAFT
(1) Fit the oil sealguide onto the end
of thecrankshaft,andinsertthe
U / OIL SEAL GUIDE
crankshaft intothecrankcase.
FIG. 42
- 27 -
5 - 4- 2 PISTON AND PISTON RING
(1) If the piston ring expander is unavailable, install the piston rings by placing the open
ends over the top land of the pistonand spreading the ringends only far enough I
to slip them intothe correct ring grooves.
1. Pay attentionnot t o break thepiston ring bytwisting.

2. Installtheoilringfirstfollowed by the second ring and thentop ring.
3.Second ring haveNmarksstampedon the ring ends.These Nmarks
have t o faceupwardwhen installedon the piston.
OPENENDS OF
PISTON RING I
FIG. 43
Topring Barrelface
Second ring Taper ......

...
...
Oil ring Cutter ring with expander :e

...........
...........
..........
.........
......
.......
................
......
...........
..........
FIG. 44
(2) Assemble the pistonandconnecting rod withthepiston pin.
I
1. Set the DorBmarkstampedonpiston top to the FANmark side of the
connecting rod. ,
2. Apply enough oil t o the small end ofthe connecting rod.
3.Be sure t o set the clips on both ends of thepiston pin.
- 28 -

PlSTON RING COMPRESSOR
assemblyintothecylinder.
Use the piston ring compressor to hold
thepistonrings.
D The FANmark of the connecting rod
have
face
toflywheel
side
when
assembled. (See Fig. 45.)
1. Apply enough oil t o t h e piston rings,

connectingrodbearings and cylinder
borebefore assembly. FIG. 45
2. Setthe open end of the pistonrings
90 degreesapartfrom one another
beforeassembly.
5 - 4 - 3 CONNECTING ROD
(1) Turnthecrankshaft t o thebottom
dead center, lightly hammer the piston
head until the connecting rod contacts
thecrankpin,andassemble,
(2) When reassembling the large end cap,
match the alignment mark on the rod.
1. No. lockwasher is used forthe

connecting rod bolts.
2. Tightenthe rodbolts securely by the FIG. 46
specifiedtighteningtorque.
Tightening torque : 180-200 Kg- cm
- 29 -

5- 4- 4 BALANCER (Optional part) -IAFT
Installthebalancertothecrankcase.
Align the matching marks of the balancer
gear and crank gear as shown in Fig, 47.
FIG. 47
5 - 4 - 5 TAPPET AND CAMSHAFT

(1) Insert the tappets into the tappet holes
of thecrankcase.
Be sure t o assemble theintaketappet

tointake side andexhausttappetto
exhaust side.
(2) Install the camshaft into the crankcase FIG. 48

matchingthetimingmarks on the
crank gear and cam gear. (See Fig. 48.)
- 30 -

5-4- 6 MAIN BEARINGCOVER AND GOVERNORGEAR
(1) Installation of governorgear shaft set.
MAIN GEAR
GOVERNORGEAR S
243-4501 1-01
(GOVERNORGEARSHAFT SET)
FIG. 49
a)Insert GOVERNOR GEAR SHAFT to the mainbearing cover.

b) Put GOVERNOR GEAR on thegovernorgearshaft.
c) Press the iron sleeve of governor gear using a pressing machine to fit on the governor
gear shaft. (See Fig. 50.)
Be suretomakea clearance of 1 mm (0.04 in) between governorgearandmounting
boss of main bearing cover. (See Fig. 5 1.)
FACE OF
MAINBEARINGCOVER
S THEIRON SLEEVE
OVERNORGEAR
I
CLEARANCE 1 rnm (0.04in)
FIG. 50 FIG. 51
1. When replacing the governor gearor governor gear shaft, be sure to replace them
a t the same time.
2. Do not press the plastic part of governor gear a t assembling.
- 31 -

(2) Installthe main bearing cover to the crankcase.
Adjusttheside clearancefor thecrankshaft,camshaft and balancer shaftto the
specified valuesusingthe properspacer and thrust washer.
CAMSHAFT BALANCER
CRANKSHAFT .
SHAFT
D type type
SIDE
CLEARANCE
0.1 -0.3 mm I 0.05-0.25 mm I 0.05-0.3
mm I 0.05-0.25 mm I
THRUST WASHER SPACER SPACER SPACER
ADJUSTING T = 0.1 mm T = 0.8 mm T = 0.6 mm T = 0.8 mm
DEVICE T = 0.2 mm T = 1.0 mm T =.0.8mm T = 1.0 mm
T = 0.3 mm T = 1.2 mm T = 1.2 mm
A
- 32 -
1. As the governor gear is mounted on
themainbearingcover side, install
I the mainbearingcoverwhilechecking
t h a t it meshes with the teeth of the
cam gear. (See Fig. 53.)
2. If the replacement of
oil seal is
necessary, press-fit the new oil seal
before installing
the
main
bearing
cover.
3.Applyoiltotheballbearingand oil 1
seal rip before installingthe
main FIG. 53
bearingcover.
4. Be carefulnottoinjuretheoil seal
r i p a t reassembly. Use oil seal guide
t op r o t e c t it.
(3) Tightenthe twelve boltsevenlyto join the mainbearing cover to the crankcase.
8 @ X 35 mm bolt andwasherassy. -- 1lpcs.
8 q5 X 40 mm bolt and washer assy. . * * * * - - 1pce.
Tightening torque : 170-190 kg- cm
Attachthetwo clamps t o the main bearing cover for electricstart model.
5-4-*7 FLYWHEEL AND STARTING PULLEY

(1) Put the woodruff key(formagneto) in place.
(2) Wipeoff oil andgreasethoroughly from thetaperedportion of the crankshaft and
flywheel center hole.
(3) ( ELECTRIC START MODEL )
' Installthecharge coil tothe crankcase.
(4)Installthe flywheel tothecrankshaft.
Tightenthe flywheel nut with a spring washer.
Tightening torque : 600-650 kg-cm
(5) Attachthestarting pulley to the flywheel.
6 @ x 12mm bolt andwasher assy. - . . - . 3pcs.
'Tightening torque : 70-90 kg-cm
- 33 -
5 - 4 - 8 FUELINJECTIONPUMP
(1) Measure the distance between the face
of the cambaseandthepump
mounting face of the crankcase.
(See Fig. 54.)
Select thegasket(injectionpump) of
the proper thickness so as the distance
t o be adjusted to 66 -+ 0.05mm.
Thegasket(injectionpump) of three
differentthicknessareavailable.
(T= 0.1 mm, T = 0.2 mm and T = 0.3 mm)
FIG. 54
(2) Apply sealant (THREEBOND 1215)

to the both side of the gasket (injection
pump).
/-
(3) Installthefuelinjectionpumptothe
crankcasecheckingthecontrolrack
of theinjectionpumptoengagewith
thegovernorlevercorrectly.
FIG. 55
(See Fig. 55.)
- 34 -
5 - 4 - 9 CYtlNDER HEAD
(1) Assemble the intake valve and exhaust
valvetothecylinder head.
a) Remove carbondepositsfromvalves,
valve seats, intake and exhaust ports,
andvalveguides.
b) If thevalveface is wornout,replace
it with a new one.
c) Check the stem seal in the intake valve
guidefor a damage.
If the rip of thestemsealisinjured,
replace i t withanew one. FIG. 56
d) Insert the intake valve and the exhaust
valveintothevalveguide.
e) Assemble the valve springs, spring
retainersandtheretainer locks.
(2) Check the clearance between the piston
topandthe.cylindertop. I APPLY THREE BOND 1 2 1 5 .
(See Fig. 56.)

Select theproper SPACER (head) so
as the clearanceto be within
0.6-0.7 mm.
SPACER (head) of twodifferent
thickness (T = 0.6 mm and 0.7 mm) are
available. (See Fig. 56.)
(3) Put the cylinder head on the cylinder.
(4)Apply sealant (THREE BOND 1215) to
the two studs on the rocker shaft side. FIG. 57
Apply oil totheothertwostuds.
(See Fig. 57.)
(5) Tightenthefourflangenutsevenly
inthreestepsbythefollowing
tighteningtorque.
1st step . . . . . . . . . . . . . 100 kg-cm
2.nd s t e p . . . . . . . . . . . . . 200 k g - cm
3rd step . . . . . . . . . . . . . 300-330 k g - cm
5-4- 10 ROCKER ARMS

(1) Insertthepushrodsintothetappets in thecrankcase.
(2) Apply oil to the rocker arms and installthem to the cylinder head using the rocker
shaft.Attachthesnapringstothebothends of therockershaft.
- 35 -
5- 4- 11 VALVE CLEARANCE
ADJUSTMENT
(1) Set thecrankshafttothetopdead
center by matching the mark "T" of the
flywheelwiththe "TOP" mark of the
crankcase.
(2) Loosen the lock nut on the rocker arm

and turn the adjusting screw to adjust
theclearance between the rockerarm
andvalvestemendto 0.1 mm.
(bothintakeandexhaust)
Then,tightenthelocknut.
Adjustthevalveclearancewhile 'the
engine is cold.
(3) Turn the flywheel by hand and check

the
valves
movesmoothly
without
hittingpiston.
FIG. 58
0 INTAKE, EXHAUST VALVE TIMING

Thevalveclearanceshallincreaseto
0.4 mm whileengineisrunninghot.
TDC (TOP DEAD CENTER)
In thiscondition,thevalvetiming is as INTAKE V A L V E 1 6 " 1 4 " EXHAUSTVALVE
follows :
Intakevalveopensat16"before TDC.
Intakevalveclosesat 5 4 " after BDC.
Exhaustvalveopensat 54" before BDC.
Exhaustvalveclosesat 14" after TDC.
(4)Apply sealant (THREE BOND 1215) t o

thejoiningsurface of the rocker cover. I N T A KV
EA L V E
CLOSES.
BDC (BOTTOM DEAD CENTER)
(5) Install the rocker cover and the gasket

(rockercover)tothecylinderhead. FIG. 59 ,
- 36 -
5 - 4- 12 FUEL INJECTION NOZZLE I SPRING WASHER
(1) Insertthe nozzleassemblyintothe

cylinderheadattachi-ngthegasket
V (nozzle)t hteo nozzle tip.
(2) Attachthefuelreturnpipetothe
injectionnozzle.
(3) Attach the BRACKET (nozzle 2) and
BRACKET (nozzle l),' and tighten the
twonutswithspringwashers
tentatively.
(4)Attach the fuel injection pipe to the FIG. 60
injection nozzle and the injection pump.
Tightenthe lock nutstentatively.
(5) Tighten the two nuts on the BRACKET
(nozzle 1).
Tightening torque : 50-60 kg- em
(6) Tightenthe lock n u t s on bothends
of theinjectionpipe.
5-4- 13 CYLINDERBAFFLE AND BLOWERHOUSING

lv
(I) Attachthecylinder baffle tothe cylinder.
(2) Attachthe blower housingtothe crankcase.
Tighten
the
upper
two
bolts
tentatively because these
bolts
shall be used for
mountingfueltankafterwards.
5-4- 14 MUFFLER
(1) Attachthe muffler cover to the muffler.
(2) Attachthe mufflerand thegasket (muffler) tothe cylinderhead.
Tightenthe boltand nuts tentatively.
5-4-15 FUEL TANK

(1) Attachthe fuel pipes tothe fuel tank.
I (2) Installthe fuel tanktothe engine.
Tightentheboltsandnutsforjoiningthe blower housingandthe muffler tothe
cylinderhead atthis step.
- 37 -
5 - 4 - 1 6 FUEL PIPES
(1) Attachthe fuel filtertothe blower housing.
(2) Attachthe fuel pipes between the fuel tank, fuel filter, injection pump
and
the ,r
injection nozzle.
Clamp the each end of rubber pipes using the proper hose clamps.
5 - 4 - 17 AIRCLEANER
(1) Attachthe cleaner body totheintake manifold.
(2) Attachthe elements to the cleaner body.
(3) Attachthe cleaner cover to the cleaner body.
5 - 4- 18 RECOIL STARTER
Install the recoil startertothe blower housing.
6 4 X 10 mm flange bolt . . . . . . . . . . . . . . . . . . . . . . 4 pcs.
Do not use the bolt longer than 10 mm or theflywheelfan may bedamaged.

,
5-4- 19 OIL FILTER

(1) Clean the oil filter and check if its mesh is notbroken.
( 2 ) Insertthe oil filterwiththeO-ringinto the main bearing cover.
Tightenthetwoflange bolts.
5-4- 20 ENGINE OIL

Fill thecrankcasewith oil tothe upper level of the oil gauge.
Besure to use the dieselengineoil of proper grade.

I
Neve use the gasolineengineoilor the engine may be seriouslydamaged.
- 38 -

6. GENERAL DESCRIPTION OF FUEL SYSTEM,
GOVERNOR SYSTEM, LUBRICAT ON. SYSTEM AND
AUTOMATIC DECOMPRESSION
6- 1 FUEL
As DY23-2 and DY27-2 are the high speed type diesel engine, be sure to use the fuel of good
quality automotive diesel fuel.
FUEL SYSTEM
FUEL RETURN
FUEL PIPE
INJECTION CHECK
NOZZLE VALVE
FUEL TANK
W
U
3
m
q-ju
U U %
TIL&
w
a
a
FUEL INJECTION U
PUMP w
m
m
3
U
e
flI PIPE
FUEL I
FUEL FILTER
RUBBER PIPE
1
FUEL HIGH FUEL

FW EL
TANK
-b
FUEL
FILTER
* FUEL
PIPE
-F INJECTION -b PRESSURE -b INJECTION
PUMP PIPE NOZZLE
COMBUSTION
CHAMBER
L
4
FUEL RETURN PIPE 4
FIG. 61
- 39 -
6 - 2 FUEL INJECTION PUMP
0 FUEL INJECTION PUMPMECHANISM
It is not too much to say that the fuel injection pump is the heart of the diesel engine,
and it must be precise enoughtosatisfythe following functions.
6 - 2 - 1 FUNCTION
Injectingfuel,startingwithhighpressureandendingwith low pressure.
Injectingthe predetermined amount of fuel accurately at each stroke.
Injecting fuel at specified timewithina specified timeinterval.
Quantity being injected is closely variedby thegovernortosuittovarying load.
Thisengine has no automaticadvancing device, butinstarting (max. delivery),the
injection timingisto be delayed.
6 - 2 - 2 THEORY OF THEINJECTION PUMP MECHANISM
The plunger of the injection pumpispushedup bythe cam of thecamshaft,andit
is pushed down by the plunger spring. By this up and down motion in a stroke, suction
and forced supply of fuel are conducted. (See Fig. 62.)
( 1 ) SUCTION OF FUEL
Through the filter in the fuel tank, fuel is supplied and is in full around the intake
port of the plungerbarrel. When the top of the camlobe passed the tappet and cam
function ended, plunger spring pushes down the plunger. When the plunger is pushed
down passing the fuel intake, fuel is sucked into the barrel, and suction is continued
untilarrival of theplungerat t h e . bottom of its stroke.Thisis on thestage of
suction. I
( 2 ) FORCED SUPPLY OF FUEL

The camshaft rotates and pushes up the plunger. Forced supply of the fuel is started
only when the upper part of the plunger closed the fuel intake in the course of being
pushed up by the cam rotation. The fuel in the barrel is pressurized by a very strong
force (100 kg/cm2 and up), and as a result, the force of the fuel pushes up the delivery
valve and thedampingvalve, andq then i t injects the fuel into combustionchamber.
This is on thestage of pressurized supply.
DAMPING VALVE
DELIVERY VALVE
VERTICAL HOLE
PLUNGER BARREL
PLUNGER
SUCTIONPORT
(DELIVELY PORT)
LEAD
EFFECTIVESTROKE
FIG. 62
- 40 -
6 - 2 - 3 VARIATION INQUANTITY OF FUEL TO BE INJECTED
The quantity of fuelinjected varies according to the condition of the engine, i. e. high
speed or low speed operationand loaded or unloaded operation. (See Figs. 63 and 64.)
I The plunger lead is engraved on the surface of plunger in an inclined curve. By rotating
theplunger,thedistance between theupperpart of theplungerandthesuctionport
is varied.(Variation in effective stroke)
Rotation of the plungeris made by the controlrack. When thiscontrolrack is shifted
to left and/orright,the geared pinion rotates, whichis connected totheplunger by
means of thecontrol sleeve. In other words, the plunger turns as much amount as the
rackrotates. Accordingly, the effective strokevaries coincident withthe positionwhere
therack is set.
( 1 1 RELATIONBETWEENTHEPLUNGER AND THEBARREL
PLUNGERBARREL
SUCT'ION/ DELIVERY PORT
LEAD
PLUNGER
INJECTION
INJECTION
INJECTION
INJECTION
STARTS ENDS. STARTS. , ENDS.
D E L I V EMRA
H
YXA.LD
FE L I V E R Y NO DELIVERY
FIG. 63
(2) RELATIONBETWEENTHEPLUNGERANDTHE RACK
NTROL SLEEVE
MAX. DELIVERY HALF DELIVERY NO DELIVERY
FIG. 64
- 41 -

6- 2 - 4 INJECTION TIMING AND EFFECTIVE
STARTlNG
When theplungerclosessuctionport of
thebarrel,forceddelivery of fuel starts.
Butfuel is notinjectedfromthe nozzle
a t oncebecause of contraction of
fuel, etc.
Injectiontiming of thisengineisfixed
constant (23" before TDC) irrespective of
engine rpm. On the other hand, in starting,
aproperdelayfromthetimingforhigh
speed running and increasedfuelinjection
FIG. 65
is indispensableforeffectivestarting.
For this purposeanotch is made a t t h e
plunger head, which reserves to delay the
injection timingbynearly 8" tofacilitate
starting. (See Fig. 65.)
6- 2 - 5 FUNCTION OF THE DELIVERY VALVE

By theplungerstroke, fuel pressureis
raised. And when it becomes higherthanthe ,-
pressure remained in the highpressure pipe, the deliveryvalve springis pushed down
and the valve opens. As the result, the fuel in the high pressure pipe is delivered forcibly.
When theplunger lead meetssuctionport of the plungerbarrel,delivery of fuelends,
and the delivery valve is closed by the spring tension of the valve. A t this time, delivery
valve prevents reverse flow of the fuel. Also suction back motion around the upper part
of the plunger sucks back the fuel in the equalamount of the stroke [A] and decreases
remainingpressureinthehighpressure pipe. The nozzle jetsthe fuelclearlyoff and
prevents after dripping. (See Fig. 66.)
DELIVERY V A L V E SPRING
DELIVERY V A L V E
BACK STROKE
FIG. 66
- 42 -

6 - 2 - 6 FUNCTION OF THEDAMPING
VALVE
Thedampingvalve is assembledinthe
end of injectionpum-pand it reaches the
seatbeforearrival of deliveryvalveat
theseat.Thesmallorificeinthevalve
isthepassage of fueltothechamber
DAMPING V A L V E
in the deliveryvalveholder.Accordingly,
descendingvelocity of the delivery valve
is decreased,which prevents the negative
pressurebeingproducedsuddenly. DELIVERY VALVE
As aresult,proper injection is conducted
andtheenginenoiseisdecreased. FIG. 67
(See Fig. 67.)
FUEL INJECTIONPUMP
VALVE DAMPING
DELIVERY VALVE
HOLDER
PUMP HOUSIN
DAMPINGVALVE
DELIVERY VALVE DELIVERY VALVE
PLUNGER
ASSEMBLY
CONTROL RACK CONTROL SLEEVE
SPRING
SEAT
PLUNGER
SPRING
SPRING SEAT
PIN
FIG. 68
0 SPECIFICATIONS OF FUEL INJECTIONPUMP FOR THIS DIESEL ENGINE
Model PFRIMD55/ 2NP1

Maker ZEXEL
Plungerdiameter 5.5 mm
Lift 6 mm
Lead Right hand twist
I Plunger
spring
arbitrary~ I ~~ ~ ~
2.21 kg/rnm
~~ ~~ ~~~~ ~~~ ~
I
Deliveryvalveopeningpressure Approx 1 5 k g / cm*
Deliveryvalvespringconstant 1.1 k g / m m
I Rack stroke I 10mm I
- 43 -
6-3 FUEL INJECTION NOZZLE
6- 3- 1 SPECIFICATfONS
I Part
Name NOZZLE ASSEMBLY
/-
Type No. DLLA150PN52
No. of nozzle hole 4

(Diameter) (0.22 mm)
Valve opening pressure 195 kg/ ern'
Spring constant 13.2 kg/ mm

I
6 - 3-2 FEATURES
Both the injection nozzle and the injection pump are very important parts for producing
fuelmist for combustion. There are two types of injection nozzle, oneis hole type and
theother is pintle type.
The injection nozzle for DY23 and DY27Diesel enginesis developed as aresult of joint
researchand development project by DieselKiki andour company, andit is direct
combustion system,havingthe special hole type nozzle.
For producing better air-fuel mixture, it utilizes swirl and squish flows and deliver the
fuelmist most effectively, injection pressure is raised up to 195 kg/cm2.
IDENTIFICATION MARK
6 - 3 - 3 STRUCTURE OF THEINJECTION
NOZZLE ASSEMBLY
Theinjectionnozzleassemblyconsists ADJUSTING WASHER
of nozzleholderandnozzle.Thenozzle
holderfixesthenozzletothecylinder
head andatthesametimeitplaysthe
role of fuelpassagetothe nozzle.
The nozzle consists of the nozzle body NOZZLE SPRING
andneedlevalve.
When the fuel pressure reaches up to the NOZZLE BODY
FIG. 69
valveopeningpressure,the needle valve
VALVE CLOSED VALVE OPENED
is raised
upand
thefuel is injected
throughthesmall holes at the tip of the
nozzle body.
.The valve opening pressure is adjustable
by changingtheadjustingwashers.
FIG. 70
- 44 -

6-3-4FUEL PASSAGE
From the
plungerpumpfuel
is
sent
throughthehighpressure pipe 1 tothe a
fuelpassage 2. Then, a t t h e nozzle body 7
3, it is pressurized up till 195 kg/c m and
i t lifts up the needle valve 4 for 0.18 mm,
and
injected
is into
the
combustion
chamberviathejethole 5. 3
An excess fuel which lubricated the inside
of the nozzle and nozzle holderreturns
tothefueltankviathe needlevalve-, 4 5
nozzle spring 6 -overflowpipe 7 +-fuel
tank. (See Fig. 7 1.> FIG. 71
6- 3-5 INSPECTION AND MAINTENANCE

Fuel injecting condition of the nozzle and the valve opening pressure are quite influential
to the engineoperation,insufficient output, increase of noise and exhaust smoke. Useof
improper fuel or contaminatedfuelis one of the main causes of the nozzle trouble.
Therefore,exert good care forusing good fuel. As the nozzle is assembled fromvery
precisely finished parts,utmostcareandattentionmust be paid when inspectingand
checking.
( 1 ) INSPECTION
After cleaning nozzle holder outside, inspect
in thefollowingsteps :
a) Visual inspection
Whether or notinjectionhole is
damaged,orcloggedwithcarbon.
Whether or not injection hole is clogged
withdustandcarbon.
b) Checkingby nozzle tester
Fit the nozzle assy to the nozzle tester.
When removing the nozzle ~ ~ Q P Vthe

I
engine or fitting,ittotester, besure
t o .keep t h e nozzle free o f dust. FIG. 72
Move thelever of the nozzle testerup

anddownfor 2-3 timesand suck the
airinsidethe nozzle.
Newer bring your face near theinjected

fuel
mist from the nozzle. Also keep
a w a y your hands fromthemist.
- 45 -
@Gently push down the lever of the nozzle
testerandreadthepressuregaugejust
before thefuelbeinginjected. If the
figurecoincideswiththestandard
value, the nozzle is ina good condition.
@Pushfurtherand check whetherornot
thefuelmist is injectedstraight.
NOZZLE
Good injection is straightforward.
Justafterinjection,checkafter
dripping.
FIG. 73
( 2 ) MAINTENANCE
If the test results are found not good (poor
injectionandafterdripping),carefully
check and repair
the
following
in
procedure :
a ) Disassemble the nozzle holder and nozzle, NEEDLE
andwashincleanlight oil.
When washing,use a wooden chip . BODY
(forinstance, wooden toothpick is
serviceable.)forpeeling off thecarbon
adheredtothe nozzle.
b) After washing, pull
out
the
needle
halfway from the body of nozzle with
yourfingersandthenletit go. And
check i f the needle sinks by its own
deadweight. FIG. 74
c) If it doesnotsink,replace i t in the
form of a set.
d) Frinctionsurfaces of boththe needleand nozzle body are ultra precise finish. So, be
sureto keep theparts free of dust.
e>If afterdripping is found, it is poor contact between the needle valve and the seat.
In such a case, it is advisable to replace it in the form of a set, needle valve and nozzle
body. However, it is possible t o coat chrome oxide on the tapered surface of the needle
andgeta good contact. Wash very carefully after correction.
f > The spacer is animportantparttoset positions of the nozzle holder and the nozzle
body.Pay attention to the position of the pin.
g ) When fitting the nozzle body to the nozzle holder, conform to the specified tightening
toruqe.
Tightening torque : 300-400 kg- cm
h) Recheck with the nozzle tester. If the adjustment of valveopeningpressure is
necessary, adjust it to 200-210 kg/c m. ,
Thevalve opening pressureshall decrease to 195 kg/c mz after the running in.
- 46 -
6 - 4 GOVERNOR MECHANISM AND OPERATION
6 - 4- I MECHANISM
Thegovernor is centrifugalflyweighttype,whichmeans a flyweightisfittedto the
governor gear. The governor sleeve is assembled so that it may slide toward the direction
of theaxis of the pump shaft,andit is in contactwiththe flyweight.Thegovernor
sleeve getsintouchwiththe governor yoke, andthroughthe governor lever itmakes
the control rack of injection pump operate. This mechanism enables to maintain constant
operationirrespective of load variation.
\
SMOKE SET
SMOKE SET SPRING
Operation when load is applied or starting. +

Operation when load is decreased or removed. 4
FIG. 75
- 47 -

6- 4- 2 OPERATION
1 . STARTING
When the speed control lever issettothehigh speed (start) position, thegovernor /-
lever is pulled by thegovernorspringthroughthecontrol link.Thecontrollink

compress the smoke set spring at the same time to allow the injection pump to deliver
extra fuel for starting.
2. OPERATION UNDER LOAD
When the engine starts up,theflyweightsexpandbythecentrifugal force pushing
the governor sleeve. The governor lever pushed by the governor sleeve moves to push
the controlrack of the fuel injection pump in the direction of reducing fuel.
Thus,the engine speed risesup to the predetermined level, andmaintainsthis speed
where thecentrifugal force balanceswith the tension of the governorspring.
When a load is applied tothe engine, the engine reduces its speed for a moment.
A t this moment, asthecentrifugal force at theflyweightsis weakened, the governor
lever being pulled by the governor spring moves to push the control rack of the fuel
injection pump in the direction of increasing fuel. Thus, the enginerecovers its speed
to the predetermined level. When the load is reduced or removed, the governor system
operatesexactly in reverse tomaintainthe engine speed.
When theengineisover-loaded, the controllinktouches the smokeset. However, the
tension of the governor springis weaker than the combined force of thecentrifugal
force of theflyweightsandthe smoke setspring,the governor iever can not move
furtherto increasefuel. Under this condition, the engine speed is reduced andthe
engine exhausts blacksmoke.
/-
3. STOPPING
By pushing the stop lever, the governor lever pushes the control rack of the injection
pump all the way t o fuel shut off position to stop the engine.
6 - 5 LUBRICATION SYSTEM AND OIL PUMP

Forced lubricationsystem is adopted to DY23 and DY27 engines. Thetrochoid type oil
pump is mounted on the.mainbearing cover co- axialywiththegovernorgearandis
driven by the cam gear.
The oil in the oil pan is filteredby the oil filterandisforcibly delivered by the oil
pump tothecrank jounalandthen tothecrank pin lubricatingthe main bearingand
thelarge end bearing.
The oil splashesfromthecrankjournalandthecrank pin t o lubricatecylinder wall,
piston, small end, cam shaftandthegovernorsystem.The rocker arms,valvesystem
etc. inside of the rockerchamber are lubricatedby the oil mistcontainedin the blow
-bygas supplied from crankcase.
The blow- by gas enters into the combustion chamber through the breather valve, and
the oil contained inthe blow- by gas is finallyburntout.
- 48 -
-
FORCEDLUBRICATION
BY OIL PUMP * 1
LUBRICATION
111,
c BY SPLASH
LUBRICATION SYSTEM
FIG. 76
0 OIL FILTER
Oil filter is made of nylon mesh and is reusable after cleaning.
As the oil flowsfrom the inside of thefilter to the outside, be sure to clean the inside
thoroughly.
Clean the oil filterevery time of oil change.
- 49 -

6- 6 AUTOMATIC DECOMPRESSION SYSTEM
The decompression systemoperates to release compression byliftinguptheexhaust
valve at starting. ,
The release lever mountedon thecamshafthas aflyweight a t one end and a crescent
cam at theother end. When startingthe engine, the crescent cam jutsoutfromthe
exhaust cam. .
The exhausttappetrides over the crescent cam opening theexhaustvalveto release

compression.
TAPPET RELEASELEVER
CRESCENT C A M
FLYWEIGHT
2LtL/l
SNAPRING
EXHAUST C A M
EXHAUSTCAM
/ CAMSHAFT
FIG. 77
,--
When thecrank speed reaches a certainrevolution,theflyweight of the releaselever

moves outward by the centrifugal force turning the release lever to retract the crescent
cam. Thustheexhaust valve closes allowingasufficient compression forthe engine to
start up.
LEASELEVER
FLYWEIGHT
SNAPRING
CAMSHAFT
FIG. 7 8
The components of the decompression systemaredifferent by D typeand B type /
engines, however the principle of operationis the same.
- 50 -
7 . STARTING SYSTEM
- 7 - 1 RECOIL STARTER
The recoil starterhardlyhasatrouble in the normal use, .however, in case ithasa
trouble or atthe time of lubrication, perform
disassembly and reassembly
in the
following procedures :
Tools to be used : Box spanner(spanner),Cuttingpliers(pliers)and Screw driver
The following explanationisapplicable tothe recoil starterfor Dtype engines.

For B type models,reverse the direction of rotation to achieveproperservice work.
7 - 1 - 1 HOW TO DISASSEMBLE (D Type)

( 1 ) Remove t h e recoil s t a r t e r from the STARTER ROPE
enginewitha box spanner.

(2) Pullthestartingknobandpullout
the starter rope for 30 to 40 cm. Firmly
press the reel with a thumb as shown
in Fig. 79 so that the reel should not
make reverse turn at the place where
the reelnotch comes totheoutlet of
starter rope. Pull out the starter rope
totheinside of recoil starterwith
ascrewdriver.
Then, utilize the reel notch, and rewind
it
until
the
rotation
stopsin
the
/q
STARTER NKOB
arrowheaddirection,brakingthereel
FIG. 79
rotationwithathumb.
(3) When removing,takeouttheparts
in the order of the numbering in Fig.
80. 2
1. U type snap ring
2. Thrust washer
3. Friction spring cover
4. Return spring
5. Friction spring
6. Ratchet
I
Meantime, for removing the U type
snapring,niptheshaftwithcutting
pliersandpush it out.
FIG. 80
- 51 -
(4) Takeoutthereelfromstartercase
as 81. REEL
In this case, slowly take out it turning
thereellightlytowardleftandright
so thatthespringis removedfrom
the reelhook section.
If the reel is suddenly taken out, there
isafearthatthespringjumpsout
in the form as it is hooked,which is
very dangerous, so be careful1 of it. (If
the spring jumped out, house it in the
SPRING CASE STARTER
starter case as instructed in Fig. 86.)
Finally, release and take out the starter FIG. 81
ropetiedtoboththereelsideand
thestartingknobside.
Thus,thedisassembly work ends.
INO. 2 I
7 - 1 - 2 HOW TO REASSEMBLE (D Type)
(1) First,havethestarterropepass
through the starting knob, and tie the
ropeasshowninFig. 82 No. 1.
Then,havetheoppositeside of the
rope pass through the starter case and
the reel,andtie i t asshownin Fig.
82 No.2. Thensurelyhousetheend
inthe reel.(In theFig.82boththe FIG. 82
ropesaretiedquitelightly,asyou
seeinfigures No.1 and No.2. Please
notethisisjustforthepurpose of
easyunderstanding.Therefore,when
actually tying, tie the rope as tightely OUTER END OF SPRING REEL HOOK
a s possible. /
(2) Confirm that the spring is surely set
in the starter case housing section, and
havethespringtoform so that its
innerendwill be about3mm from
thestartershaftandthat it hooks
surelythereelhook.
Meantime, with the pliers about 10cm STAR1'ER SHAFT 11
longspringfromtheinnerendcan /
easily be formed. INNEREND OF SPRING
FIG. 83
- 52 -
Before putting the reelinthestarter
case,windthestarterropeinthe
arrowheaddirectionasshowninFig.
84, a n d a t 2.5 windingstakeoutthe
rope from the reelnotch.Setthe reel
hook to the inner end of the spring,
andputthereelinthestartercase.
( A t thistime,confirmthatthereel
hook isdulysettothespring.)
Then,holdthestarterropeasshown *
inFig. 84, and turn the reel 4 times
in
thearrowhead direction. When
woundup,firmlypressthereelnot FIG. 84
t o allowreverseturn,andpullthe
starting knob. Then, pull out from the
startercasethestarterropeutilized
forwinding,andslowlyreturnthe
s t a r t i n g knob.
When reassemblingtheparts, follow

upinthereverseordertoFig. 80.
When putting the friction plate in the
hole for it, set the return spring a little
CH
upwardasshowninFig. 85 so t h a t
thefrictionplatecaneasily be put
intheholeforit.
Next,turnthefrictionplateinthe
arrowheaddirectiontilltheposition
where its
notch matcheswiththe
ratchet. Push firmly the friction plate
t o thereelside,andputthethrust
washerandthenclampitwitha U FIG. 85
typesnapring.
(Usepliersto
set
the
snap
ring
securely.)
.This isthe end of the disassemblyandreassemblyprocedures.

Testthe reassembled recoil starter by the following checkingproceduresin thenext
page.
- 53 -
7 - 1 - 3 CHECKING PROCEDURESAFTERREASSEMBLY (D Type)
(1) Pull thestartingknob 2 or 3 times,andpull outthestarter ropealittle.
a) If the starting knob is felt heavy to pull or cannot be pulled, check whether all the
partsareinstalled correctly.
b) If theratchet does notfunction, check whetherthespringis hooked properly.
(2) Pull thestarting knob, and pull outthestarter ropeall the way long.
a) If thestarter roperemainsleft in the reel or thestarter rope does not returnat
all,immoderate strain i s imposed on thespring. So rewind thestarter rope 1 or 2
times as per instructionin Fig.79.
b) If the return power of the starter rope is weak or the starter ropecannot be fully
rewind,injecta few drops of mobileoilin thefrictionalportions. If it does not
recover yet, wind the rope 1 or 2 times.
(In this case,refer t o theinstructions explained intheparagrapha)aboveand
confirmwhether or notimmoderate strain is imposed on thespring.)
c ) If thesoundisheardthatthespring is falling off, andthestarter rope cannot be
wound in relay,reassemble once again from thebiginning.
7 - 1 - 4 USEFUL REMINDERS
( 1 ) IN CASE THE SPRING JUMPS OUT WHEN
DISASSEMBLING
With thinwiremake a ringsmaller
thanthecaseforspring,and hook
theouterend of spring on thepart
of the ring as shown in Fig. 86. Store
i t inthespringhousingsection of
the reel, and carefully remove the ring,
pressingthespringwithfingers so
as not to come out. The ring can easily
be removed by squeezing itwiththe
t i p of thescrewdriver or thelike.
Refer toFig.83for not t o mistake
thedirection of thespring. FIG. 86
(2) LUBRICATE RECOIL COMPONENTS

Lubricate the rotating parts, frictional
partsandspringwithheatresistant
grease, or mobile oil atthetime of
disassembly or at theend of season
f o r use.
,
- 54 -
7 - 2 ELECTRIC STARTING MOTOR (OPTIONAL PART)
7 - 2 - 1 SPECIFICATIONS
Part Name Starting Motor BOLT
MAGNET SWITCH
Maker Nihon Denso K. K.
DRIVE SPRING \
Output 0.6 kW DRIVELEVER
Weight 3.0 k g DRIVE
BRUSH
PIS1
FRAME
STOP COLLER
FIG. 87
7-2-2 WIRING DIAGRAM
LIGHT BLUE
LIGHT BLUE
KEY SWITCH RED
IC
I
r----
I
L------J
Connect positive (+) battery terminal to 8 rnm magnetic BATTERY 12V-24AH
switch treminal.
~
FIG. 88
- 55 -
8. PRECAUTIONS FOR MOUNTING THE ENGINE ON THE
EQUIPMENT
The installation of an engine to the equipment effects greatly to the ease of maintenance.
8- 1 INSTALLATION
When designingtheequipment,pay asufficientattentiontothemountingposition,
couplingmethode withtheequipment, base andsupports.
8 - 2 VENTILATION
Enginerequiresasufficientamount of clean and fresh air for. combustion of fuel and
cooling.
If theengineis covered withan enclosure, or theengineisoperatedin asmall room,
the enginemay overheatsunless a sufficientamount of freshair is supplied fromthe
outside of theengine room.
High surroundingtemperaturealsocausesthedeterioration of engine oil, increased oil
consumption, lower output,andpiston seizure resultingintheshorterengine life.
Therefore,itisnecessaryto providea ductor abaffle totheenginetoprevent
recirculation or reflection of hot cooling air.
A prudential attention have to be paid to keep the engine room temperature below 50C
(122" F).
8 - 3 EXHAUST GAS
/
Exhaust gas is noxious. Be suretodischargeexhaustgasoutdoors when operatingthe

engineindoors or in a poorly ventilatedareasuch as inacave, tunnel, etc.
If anexhaust pipe extensionis used todischargeexhaustgas, be careful of theinner
diameter of the pipe toprevent power loss.
Recommendation of exhaust pipe extension :
Less than 3 m long : inner diameter 35 mm.
Less than 5 m long : inner diameter 38 mm.
8 - 4 FUEL SYSTEM
If the fuel tankisseparately mountedon theequipmentfromthe engine, be sureto
setthebottom of fuel tanknot less than 50 mm higherthanthe fuelinjection pump.
If thetank is mountedtoo low, thefuelmaynotbe suppliedproperly tothe engine.
When pipingthe engine, be carefuI of heatconduction, pipe size, bends, andleaksfrom
thejointsand make thefuel pipe asshortas possible t o preventairandvaporfrom
beingtrapped.
- 56 -
8 - 5 POWERTRANSMISSIONTO DRIVEN MACHINES
8 - 5 - 1 BELT DRIVE
Takethefollowingnotesintoconsideration.
(1) V-beltsare preferable to flat belts.
(2) The driving shaft of the engine must be parallel to the driven shaft of the equipment.
(3) Thedriving pulley of theenginemust be in linewith thedriven pulley of the
equipment.
(4) Installthedriving pulley as close totheengineas possible.
(5) Span the belthorizontally if possible.
(6) Disengage the load at startingthe engine.
If the clutch is notadaptable,usea belt tensioner or the like to disengage load.
8- 5- 2 FLEXIBLE COUPLING
When usinga flexiblecoupling, minimize therunoutandmisalignment between the
engineshaftandthedrivenshaft.
The allowance are specified bythecouplingmaker.
- 57 -
9. CHECKS AND CORRECTIONS
After disassembling and cleaning the engine, check and repair, if necessary, according to
the correctiontable. The correctiontableapplieswhenever the engines are repaired.
Itisimportantforthe servicemen to be familiarwiththecontents of this table.
Correct maintenance isrecornrnendk by observingthe correction standards specified.
The meanings of theterms used inthe correction tableareas follows :
( 1 1 CORRECTION
Repair, adjustment or replacement of anyengineparts.
( 2 1 CORRECTION LIMIT
The limit onwear,damage or functionaldeterioration of engine parts beyond which
normalengineperformancecannot be expected withoutrepairingsuchparts.
( 3 ) USE LIMIT
Thelimit beyond which parts can no longer be used in respect of performance or
strength.
( 4 ) STANDARDDIMENSIONS
Thedesigndimensions of new partsminus tolerance.
(5) CORRECTION
TOLERANCE
Tolerance on the dimensions of engineparts refinished or adjusted.
9 - 1 SERVICE DATA
Engine I
Unit : mm (in)
DY23 DY27
ITEM
STD Limit
CYLINDER HEAD
@ Flatness I / 0.05 0.05
(0.002) (0.002)
@Valveseatcontactwidth
(@) 1.6
(0.063)
2.2
(0.087)
e V a l v e guide inside dia.

I I 5.5-5.518 5.65
(0.21 65-0.21 72) (0.2224)
- 58 -
Unit : rnm (in)
DY23 DI 27
ITEM
STD Limit
CYLINDER I
@Inside
dia. 70.000-70.01 9 70.25 75.000-75.01 9 75.25
(2.7559-2.7567) (2.7657) (2.9528-2.9535) (2.9626)
PISTON
OPiston size ( A t skirt, in
thrustdirection)
I STD
69.961 -69.981
(2.7544-2.7552)
69.871
(2.7508)
74.961 -74.981
(2.9512-2.9520)
74.07 1
(2.9477
I
70.21 1-70.231 70.1 21 75.21 1-75.231 75.1 21
1st o / s
(2.7642-2.7650) (2.7607) (2.961 1-2.961 9) (2.9575)
70.461 -70.481 70.371 75.461 -75.481 75.371

2nd o / s
(2.7741 -2.7748) (2.7705) (2.9709-2.9717) (2.9674)
Ringgrooveside clearance 1
f
0.05-0.09 0.1 5 0.05-0.09 0.1 5
(0.0020-0.0035) (0.0059) (0.0020-0.0035) (0.0059)
r
0.01 5-0.055 0.1 0.015-0.055 0.1
(0.0006-0.0022) (0.0039) (0.0006-0.0022) (0.0039)
Piston pin hole
18.001 - 18.008 18.03 18.001 -18.008 18.03
(0.7087-0.7090)
(0.7098) (0.7087-0.7090) (0.7098)
f
OPiston pin outside dia. -1
18.000- 18.006 17.980 18.000-1 8.006 17.980
(0.7087-0.7089)
(0.7079) (0.7087-0.7089) (0.7079)
@Clearance betweenpiston
andcylinderatskirt area.
0.01 9-0.058 0.1 5 0.019-0.058 0.2
(0.0007-0.0022) (0.0059) (0.0007-0.0022) (0.0079)
0 Pistonringendgap
To P 0.3-0.5 1.o 0.1 -0.3 0.8
2nd (0.01 18-0.01 97)

(0.0394) (0.0039-0.01 18) (0.031 5)
0.25-0.45 1 .o 0.25-0.45 1 .o
Oil
(0.0098-0.0177) (0.0394) (0.0098-0.01 77) (0.0394)
- 59 -
Unit : mm (in)
DY23/DY27
ITEM
STD Limit
CONNECTING ROD
.Big endinsidedia.
(Metalisfitted) 33.050-33.090 33.2
(1.301 2- 1.3028) (1.3071 )
.Clearance between
big endandcrankpin
0.023-0.081 0.1
(0.0009-0.0032) (0.0039)
Smallendinsidedia.
18.013- 18.034 18.05
(0.7092-0.7100) (0.71 06)
OClearancebetweensmallend
andpiston pin
0.007-0.034 0.08
(0.0003-0.0013) (0.0031 )
0 Big endsideclearance
I
A 0.10-0.30
(0.0039-0.01 18)
0.5
(0.01 97)
8
CRANKSHAFT
0 Crankpinoutsidedia.
33.01 1-33.027 32.85
(1.2996-1.3003) (1.2933)
0 Journal dia.
32.984-33.000 32.85
(1.2986-1.2992) (1.2933)
OClealancebetween I
journalandmainbearing 0.014-0.oa6 0.1 2
(0.0006-0.0034) (0.0047)
- 60 -

Unit : rnm (in)
DY23/DY27
ITEM
STD Limit
CAMSHAFT
0 Cam height 32.1 3-32.23 31.98
IN. EX.
0
cams
( 1 2650- 1.2689) (1.2591
Injection 29.95-30.05 29.85

pump
cam (1.1791-1.1831) (1.1 752)
.Journal outside dia.

"D' type 24.934-24.947 24.90
Flywheel
side R1
(0.981 7-0.9822) (0.9803)
14.973- 14.984 14.90

PTO side
R2
(0.5895-0.5899) (0.5866)
VALVE
.Valve stemoutside dia. 5.422-5.437 5.35
IN.
(0.21 35-0.2141 ) (0.21 06)
5.402-5.417 5.35
EX.
(0.21 27-0.21 33) (0.21 0 6 )
.Clearance betweenvalve
stem dia. andvalveguide 0.063-0.096 0.3
IN.
(0.0025-0.0038) (0.01 18)
0.083-0.1 16 0.3
EX.
(0.0033-0.0046) (0.01 18)
0 Valve clearance
0.07-0.1
IN./ EX.
Adjustable
(cold)
(U.OO28-U.OU39)
-61 -

Unit : mm (in)
ITEM
r STD
DY23/DY27
Limit ,
TAPPET
Q
0 Stem outside dia.
7.960-7.975 7.93
(0.3134-0.3140) (0.3122)
0 Guideinsidedia.
8.000-8.01 5 8.08
(0.31 50-0.31 56) (0.31 8)
0 Tappet guide clearance
0.025-0.055 0.1 5
(0.001 0-0.0022) (0.0059)
ROCKER A R M
0 Rockershaftoutsidedia.
11.937-1 1.984 11.92
(0.4714-0.4718) (0.4693)
0 Rockerarm hole dia.
12.000-12.01 8 12.07
(0.4724-0.4731 ) (0.4752)
@Rockerarmshaftclearance
0.01 6-0.045 0.1 5
(0.0006-0.0018) (0.0059)
VALVE SPRING FREE LENGTH
32.5 31 .O
(1.2795) (1.2205 1
- 62 -
Unit : mrn (in)
DY23/DY27
ITEM
STD I Limit
INJECTION PUMP 65.95-66.05
Frominjectionpumpflangesurface t o cam base (2.5965-2.6004)
Adjustable
e Staticinjectiontiming 21 -23
ETDC
NOZZLE
195 kg / cmz
0 Injectionstartingpressure
(2773 I b j in2)
Nozzle dia./Number of nozzle
0.22 (0.009)/4PCS.
ENGINECOMPRESSION
18 k g / c m 2 13 kg/ cmz
(at 400 r. P. m. by hand)
DY23
(256.0 Ib/ in2) ( 1 84.9 I b / in2)
17- 17.5 k g / cmz 1 2 k g / cmz

DY27
(241.6-248.9 Ib/ in2) ( 1 70.7 Ib/ in2)
I
VALVE SEAT ANGLE (IN. EX.)

.Valve cutterangle(a)
.Valve contactwidth (b)
b : 1.6 mrn b : 2.2 mm
(0.0630in) (0.0866in)
a
I
TABLE OF TIGHTENING TORQUE
Description Tightening Torque
Bolts for joining main bearing cover 170-1 90 kg- cm (1 2.3-1 3.7 f t Ib)
DY23 300-330 kg- cm (21.7-23.9 ft Ib)

Nuts for joining cylinderhead
DY 27 330-350 k g - c m (23.9-25.3 ft Ib)
Boltsforjoiningconnectingrodcap 180-200 kg-cm (13.0-14.5 ft = Ib)
Flywheelnut 600-650 kg- cm (43.4-47.0 ft Ib)
Oil drainplug 200-230 k g - cm (14.5-1 6.6 f t 0 Ib)
Nutsforjoininginjection nozzle 50-60 kg- cm (3.6-4.3 f t * Ib)
- 63 -
IO. MAINTENANCEAND STORI
The following maintenance schedule applies to the
engines
operated
correctly
under ,
normalconditions.
Theindicatedmaintenanceschedule does notnecessarily guaranteemaintenance- free
operationsduringtheintervals.
For example, if the engine is operated in extremely dusty condition, the air cleaner should
be cleaned everydayinstead of every 50 hours.
10- 1 DAILY CHECKS AND MAINTENANCE
Checks and maintenance works Reasons for requiring the maintenance work
Remove dust,dirt,debris,grassandany (1) Engine overheats.

foreignobstaclesfromcylinder,cylinderhead, (2) Enginedoesnotoperateproperly.
carburetorandgovernorsystem.
Check fuel leakage. If leakage is found, tighten Danger of fire.

the loose joint and/orreplaceleakingpart.
Check boltsand nuts for looseness. Enginemalfunctionscausingdamages to the

,
Tightenthe loose bolt and/ornut if any. engineand/ortheequipment.
Check oil level and fill upas necessary. Insufficient oil causesengineseizure.
10- 2 INITIAL 25 HOURS CHECK AND MAINTENANCE
Changeengine oil. To remove break- in dregs.
I I
- 64 -
2.
10-3 EVERY 100 HOURS (MONTHLY) CHECKS ANDMAINTENANCE
Changeengine oil. Contaminated oil accelerateswear.
Clean oil filter. Insufficient oil causesenginefailure.
Clogged air cleanercauses poor engine

Clean aircleaner.
operation.
Insufficientelectrolytelowers battery
Check batteryelectrolyte level.
performanceandshortenbattery life.
Waterinthefuelcauses poor engine

Dischargewaterfromfuelfilter. operation,badstartingandcorrosion in the
injection pump and nozzle.
10- 4 EVERY 500 HOURS CHECKS AND MAINTENANCE
Checks and maintenanceworks Reasons for requiring the maintenance work
I
Impropervalveclearance causes poor engine
Check and adjustvalveclearance.
output.
I Check and cleaninjection nozzle. Poor operation of the engine.
I Remove carbondepositfromcylinderhead. Poor operation of theengine.

I
10- 5 EVERY 1000 HOURS (YEARLY) CHECKS ANDMAINTENANCE
I I
I Checks and maintenance works
I
Reasons for requiring the maintenance work
Replace pistonrings. Poor performance of theengine.
Replacefuel lines. To preventfromfuelleaking.
1 Replace fuelfilter Poor operation of theengine.
Check valveseats both intakeandexhaust.

Grindvalveseats if necessary.
Poor operation of the engine.
- 65 -
Check and maintenance works Reasons for requiring the maintenance work
To recover theenginepower and extend

Overhaulthe engine.
engine life.
IO - 7' PREPAWATIO S FOR LON6 STORAGE

(1) Perform the above maintenance works 10- 1 through 10- 4.
Also perform 10- 5 and 10- 6 as necessary.
(2) Drain fuel from thetank.
(3) To protectcylinder bore from rusting,pour asmallamount (4-5 cc)of engine oil
throughtheauxiliary fuel inletinto the cylinder and pull the recoil starter slowly
2 to 3 times. (Do not startthe engine.)
1 Bo not pour too much oil or the oil rernaines in the combustionchamber
top.
of the piston
,
(4)Pull the recoil starter slowly andstopitatthe compression point.

(5) Clean theengineoutsidewith a oily cloth.
(6) Put a cover over the engine andstoreitin a dryand well ventilatedarea.
- 66 -
Industrial
Engines

Dy 232 D

Încărcat de

Informații document

Titlu original

Drepturi de autor

Formate disponibile

Partajați acest document

Partajați sau inserați document

Opțiuni de partajare

Vi se pare util acest document?

Este necorespunzător acest conținut?

Drepturi de autor:

Formate disponibile

Dy 232 D

Încărcat de

Drepturi de autor:

Formate disponibile

Downloaded from www.Manualslib.

com manuals search engine

ROBIN WISCONSIN ROBIN

DY23 WRD 1-230

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Downloaded from www.Manualslib.com manuals search engine

Model DY23-2D DY23-2B DY27-2

Cool ing I Forced air cooling

Lubrication I Forcedoil lubrication

Lubricant Diesel engineoil.servicerank CC or CD

Oil Pump Trochoid gear pump

Fuel InjectionPump ZEXEL PFRIMD55 / 2NP1

Fuel Feed I Gravity type

1 2V- 39W/3000 12V - 39W / 3000

StartingSystem Recoil starter ( Electricstarter as option )

329 x 357 x 402 mm 339 x 357 x 402 mm

Specifications are subject t o changewithoutnotice.

2-3 MAXIMUM TORQUE

MODEL DY27-2 ( 1for B type

1500 2000 2500 3000 3500 41

Thepistonprofileis so designedasto SECONDRING

Fuelinjectionpumpis BOSCH typeand

4 - 19 AIR CLEANER SECONDARY ELEMENT

starting of the .engine, the direct injection INTAKE PORT

TROCHOID OIL PIJMP

Downloaded from www.Manualslib.com manuals search engine

(1) When disassembling the engine, memorizewell the locations of individualparts so

Tool No. Tool Use

228-95003-07 Piston ring cqmpressor For placing piston ring

PISTON RING COMPRESSOR

4 Air cleaner (1) Remove cleaner cover from the

IStep I Part to remove I I

5 Recoil starter (1) Remove recoil starter from

6 Fuel tank (1) Disconnect fuel pipe from fuel tank.

7 Muffler (1) Remove the muffler cover from muffler.

(2) Remove the muffler. Be careful not to lose the 12 mm

8 Starting motor (1) Remove the wire

10 Blower (1) Remove the blower housing from 12 mm

11 Flywheel (1) Remove the starting pulley. 10 mm

6 + FLANGE BOLT : 3pcs.-@

Downloaded from www.Manualslib.com manuals search engine

13 Rocker cover ( I ) Remove the rocker cover from 10 mm

FUEL INJECTION NOZZ

Downloaded from www.Manualslib.com manuals search engine

15 Rocker arm ( 1 ) Loosen the adjusting bolts on the 10 mm

8 6 FRANGE NUT : 4DC.s. ADJUSTING BOLT

18 Main bearing (1) Remove the bolts joining the Be carefulnot to 12 mm

Downloaded from www.Manualslib.com manuals search engine

19 Camshaft (1) Remove thecamshaftfromthe (1) To preventthe

Downloaded from www.Manualslib.com manuals search engine

21 Connecting (1) Scrape off the carbon

Downloaded from www.Manualslib.com manuals search engine

23 Crankshaft (1) Lightly tap thecrankshaft end The ball bearing

Downloaded from www.Manualslib.com manuals search engine

( 1 ) Press the valve springs and

(1) Remove the oil filter

6 4 X 12mm flange bolt...---2pcs.

MAIN B E A R I N G COVER 6 + FLANGE BOLT : 2pcs

to slip them intothe correct ring grooves.

1. Pay attentionnot t o break thepiston ring bytwisting.

Second ring Taper ......

Oil ring Cutter ring with expander :e