ROBIN AMERICA, INC.

ROBIN TO WISCONSIN ROBIN

ENGINE MODEL CROSS REFERENCE LIST
WISCONSIN ROBIN

ROBIN

SIDE VALVE
W 1-080
W1-145
W1-145V
W1-185
W1-185V
Wl-230
W 1-280
W 1-340
W 1-390
W 1-450V
EY21W
EY44W
EY 18-3W
EY25W
EY27W

EY 08
EY15
EY 15V
EY 20
EY20V
EY23
EY28
EY35
EY40
EY45V
EY2 1
EY44
EY 18-3
EY25
EY27

OVERHEAD VALVE
WOI-115
WOI-120
WO1-150
WOI-170
wo1-210
WO1-250
WO 1-300
WO 1-300v
WO1-340
WO 1-340V
WO1-430V

EH11
EH12
EHl5
EHI 7
EH2 1
EH25
EH30
EH30V
EH34
EH34V
EH43 V

TWO CYCLE
WT1-125V

EC13V

DIESEL
DY23
DY27
DY30
DY3 5
DY4 1

WRD 1-230
WRD 1-270
WRD 1-300
WRD1-350
WRD1-410

CONTENTS
Section

Title

Page

1. SPECIFICATIONS
DY23-2D

Model

DY23-2B

DY27-2

Air-Cooled. 4-cycle, Overhead Valve, Single vertical cylinder, Diesel engine

Type

70 X 60

Bore X Stroke

75 X 60 mm

rnrn

( 2.76 X 2.36 in. )

( 2.95 X 2.36 in.

230cc

PistonDisplacement

265 cc
( 16.1 1 cain. )

( 14.04 cu.in. )

CompressionRatio

21

output
rpm HP/
DIN6270NB
(Warnin)

4.8 / 3600
( 3.5 / 3600 )

4.8 / 1800
( 3.5/ 1800

5.5 / 3600
( 4.0/ 3600 1

HP/ rpm

4.2 / 3600
( 3.1 / 3600 )

4.2 / 1800
(3.1 /1800

1.07/ 2200
7.7/2200 )

2.14/ 1100
(15.4/11001

output
DIN6270NA

(KW-min)

Torque
kg
DlN6270NB

( ft.lbs/ rpm

- m / rpm
1

Rotation

Lubrication

5.5 / 1 800
( 4.0/ 1800

5.0 / 3600
3.7/ 3600 1

1.23 / 2400
( 8.9/ 2400

Counterclockwise as viewdfrom

I
I

Cool ing

5.0 / 1 800
3 . 7 / 1800 1

2.46/ 1200

( 17.W 1200

PTO shaft side

Forced air cooling

Forcedoil

Lubricant

lubrication

Diesel engineoil.servicerank

Oil Pump

CC or CD

Trochoid gear pump

Fuel InjectionPump

ZEXEL PFRIMD55 / 2NP1

ZEXEL DLLAI 50PN052

Injection Nozzle
Fuel

Automotive diesel fuel

Fuel Feed

Fuel TankCapacity

Gravity type
3.2 liters

CombustionSystem

( 0.84 U.S.gal.

Directinjectiontype

GovernorSystem

Centrifugalflyweighttype

StartingSystem

Recoil starter

DryWeight

LXWXH

12V - 39W / 3000

12V - 43W / 3600

1 2V- 39W/3000
1 2 V - 4 3 W / 3600

Lighting Capacity

Dimension

( Electricstarter

as option )

30 kg
(65.0 Ibs.)

(63.9Ibs.)

329 x 357 x 402 mm

(12.95 x 14.06 x 15.82 in.)

Ibs.)
(65.0
(66.1lbs.)

339 x 357 x 402 mm

(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.
equipmentdrivenby
the engine to be designed
It is recommended, therefore,thattheto requirethe engine power less thanitscontinuousratedoutput.

2-3 MAXIMUM TORQUE

The maximum torqueindicatesthetorque
producing the maximum output.

attheoutputshaft

-2-

when the engine is

2 - 4 PERFORMANCE CURVES
MODEL DY23-2

kg - m

1.2

(2.4)

1.1 (2.2)

1 .o (2.0)
3.9 (1.8)

2
W

c1:

O
I-

\ TORQUE

(NB)

HP

z!2 3
W

v)

g/HP-h

IT

0
I

0
I240

220
200
FUELCONSUMPTION
I

RATIO (NB)
I

1500
2000
2500
3000
3500
4/00
(750) (1000) (1250)(1500)(1750)(2000)
REVOLUTION

"
+

MODEL DY27-2

y
g-

&
22

r. p. rn.

1for B

type

kg- m

.3 (2.6)
.2

(2.4)

.1 (2.2)

.o (2.0) Y

6
HP

0-3
W

v)

g / HP- h

I1I

h
2

1500
2000
2500
3500
41
3000
(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
superiorcombustion efficiency and minimized fuel consumption.

assures

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
and
centrifugal
automatic
starting similar to agasoline engine.
0 An auxiliary fuel inletis provided foreasystarting
An air check valve for easy air bleeding from the fuel line.

decompressor allow effortless

in cold weather.

3- 4 LESS VIBRATION
0 In addition tothe reduced weight of reciprocatingparts, abalancer
adopted forextremelysmoothrunningwith
lessvibration.
a The automatic decompressor preventsshakyvibration a t stopping.

shafthas

been

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.
on the
Thecrankgearispressure-fitted
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.
so designedasto
Thepistonprofileis
minimizepistonnoise.
(See Fig. 5.)

TOPRING
SECONDRING
OILRING

4 - 6 PISTON RINGS

Pistonringsaremadefromspecialcast
face,
iron. The profile of top ring is barrel
andthat
of secondringistaperwith
under cut. The oil ring is the combination
of cutterringsandanexpanderwhich
is excellentingassealingandreducing
oil consumption. (See Fig. 5.)

CONNECTINGROD

FIG. 5

4 - 7 CYLINDER HEAD
Cylinderhead is themostimportantpart
of the diesel engine.It is made fromonepiece 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.)
-6-

,-

FIG. 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.)

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
Rocker armsare madefromforgedsteel
andare
whollysintered.
A screwforadjustingvalveclearanceis
of rockerarm.
provided attheend
Rocker arms are lubricated by the oil mist
breathing
air
from
contained in the
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 composed 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
by controlling the quantity of fuel injected.
Governor system is driven by the governor
gearengagedwithcamgear.
(See Fig. 13.)
Refer to section 6 - 4 fordetails.

GOVERNOR
LEVER

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.
c

4- 16 COOLING SYSTEM
Cooling air is forced by the flywheel fanto blow through the cooling fins of cylinder
cylinder baffle.
and cylinderhead guided by the blower housingandthe

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
strength
plastic
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

starting of the .engine, the direct injection
systemis adopted inthe combustion
chamber.

/INTAKE

VALVE

INTAKE PORT

SWIRL

4 - 2 1 - 4 FORMING OF COMBUSTION GAS

AND COMBUSTION

CY LlNDER

( 1 1 SWIRL (Inspiring swirl)

In orderto promotemixinginjected
fuelandairunderthedirect
injection
system,swirl flow is utilizedfor good
combustion. Swirl isspiral flow of air
generatedinthe
cylinder during
inspiringstroke,andit
decreases
during compressing stroke but it still
remainsand promotesmixing of fuel
and air towardignitiontiming.
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
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
in the combustion chamber and air flow
isgenerated, which is called squish.
(See Fig. 20.)
FORMING OF COMBUSTION
GAS

PISTON

FIG. 19

/c SQUISH

FIG. 20

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/

BEARING COVER
MAN

CRANKSHAFT

TROCHOID OIL PIJMP

CRANKCASE

GOVERNOR

/
FLYWHEEL

12 -

MUFFLER

ROCKER COVER

AIR CLEANER

PUSH ROD

PISTON

PISTON RING

FUEL INJECTION
PUMP

TAPPET

'

CAMSHAFT

OIL GAUGE

BALANCER

13 -

OIL DRAIN

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

Tool No.

209- 95001 - 07

228-95003-07

Flywheelpuller

Use

with bolt

Piston ring cqmpressor

For pulling off the flywheel

For placing piston ring

PISTON RING COMPRESSOR

FLYWHEEL PULLER

/-

FIG. 21
- 14 -

5- 3 -DISASSEMBLY PROCEDURES

1
Engine oil

Remarks

(1) Remove drain plug and discharge

Be careful not to lose

thegasket.

14 mm
spanner

(1) Remove drain plug from fuel

filter
and
discharge
fuel
from
fueltank.

Be careful not to lose

thegasket.

10 mm
spanner

(1) Loosen the two joint nuts at the

Be careful to keep
the inside of the
pipe, injection pump
and the nozzle free of
dust.

12 mm
spanner

oil from crakcase.

Drain plugs are located on both
sides of the crankcase.
(2) To discharge oil quickly,remove
oil gauge.

Fuel

3
Injection pipe

Tool

Proocedures

Step

both
ends
removeit.

of injection pipe to

INJECTION PIPE

- 15 -

Step lPart to remove

Air cleaner

Procedures

Tool

Remarks

(1) Remove cleaner cover from the

cleaner body.
(2) Loosen the wingbolt to remove
element.
(3) Remove cleaner body from intake
manifold.
6 4 X 12 mm flange bolt...-..2pcs .

Be careful not to lose

the washerand the
packing for wing
bolt.

10 mm
box wrench
12 mm
box wrench

8 0 BOLTandWASHER
PACKING
CLEANERBODY

ELEMENT

IStep I Part to remove I

5

Recoil starter

Procedures

Remarks

(1) Remove recoil starter from

blower housing.
6 4 x 10 mm flange bolt**..**4pcs.

3
spanner

6 0 FLANGE BOLT

HOUSING

: 4pcs.

m
RECOILSTARTER

FIG. 24
-

16 -

step Part to remove

6

Procedures

Remarks

(1) Disconnect fuel pipe from fuel tank.

Fuel tank

(2) Disconnect fuel return pipe.

(3) Disconnect rubber pipe from the check
valve.
(4) Remove the fuel tank.
8 Q X 20mmbolt*****e.e* 1 pce.
8 @ X30mmbolt*****~***2pcs.

Tool

Muffler

10 mm
spanner

(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
8 @nut
gasket.
8 Qspringwasher*****~*~~2pcs.

a+

+ BOLT : 4pcs.

BOLT

- 17 -

12 mm
box wrench

Tool

Step

Starting motor

(1) Remove the wire

harness
from
Reattach
the
terminal

Fuel
filter

(1) Remove the fuel filter

from
the
Wipe
off
spilt
fuel
blower housing.
thoroughly.
6 q-5 X 20 mm flange bolt.....*2pcs .

10 mm
box wrench

10

Blower
housing

(1) Remove the blower housing from

12 mm
box wrench

1Omm
thestarting motor.
nuttothe
motor tospanner
(2) Remove thestarting motor fromkeep
it from missing. 12mm
crankcase.
spanner
8 4 x 30 mm bolt ...............2pcs.

crankcase.
8 q5 x 20 mm bolt and washer
..................... 2pcs.

- 18 -

Step Part to remove

Procedures

Flywheel

(1) Remove the starting pulley.

6$
, X 1 2 m bolt ...............3pcs.
(2) Remove the flywheel nut.
(See Fig. 27.)
(3) Set the flywheel puller tothe
flywheel. ( See Fig. 28. )

11

Remarks

Turn the center bolt clockwise to

pull outthe flywheel.
(4) Remove the key from crankshaft.

Flywheel can easily

beremoved by
striking witha
hammerthehead
of
thecenter bolt of
flywheel puller.

Tool

10 mm
boxwrench
24 mm
socket
wrench

Be carefulnotto
lose the key.

FIG. 27

FIG. 28
FLYWHEEL NUT

+ FLANGE BOLT

: 3pcs.-@

STARTINGPULLEY

SPRINGWASHER

FLYWHEEL

FIG. 29
-

19 -

Step Part to remove

Procedures

Tool

Remarks

12

Cylinder
baffle

13

Rocker cover

( I ) Remove the rocker cover from

cylinder head.
6 4 X 40 mm flange bolt-......lpcs .

Fuel injection
nozzle

(1) Remove thebracket, nozzle.

6 4 nut ..............................
2pcs.
(2) Remove thefuel injection nozzle

(1) Remove the cylinderbafflefrom

cylinder.
6 q5 X 10 mm flange bolt-.-..-lpce.
~~

from cylinderhead.

10 mm
box wrench

Be careful not to lose

thegasket atthe
bottomend of the
nozzle.

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

15

Rocker arm

Procedu.res

Remarks

( 1 ) Loosen the adjusting bolts on the

rockerarms.
(2) Push the rocker shaftoutfrom
the cylinder head to remove the Make the rocker arms
andpushrods
rockerarms.
distinguishable of
(3) Remove the push rods.
intakesideand
exhaust side.
16

Cylinder
head

(1) Remove the cylinder head from

cylinder.
8 4 flange nut ....... ..........4pcs.

Be careful of the

8 6 FRANGE NUT : 4DC.s.

Tool

10 mm
spanner
screw driver

12 mm
spacer.
socket
wrench

ADJUSTING BOLT

CYLINDER H E A D

ARM

ROCKER

ROD

FIG. 32

- 21 -

Step )art to remove

17

Fuel injection
pump

18

Procedures

(1) Remove the fuel injection pump

fromcrankcase.
6 4 nut .............................. 2pcs.

Tool

Remarks

Be careful of the
position of the
control rack.

10 mm
socket
wrench
~

Main bearing
cover

Be carefulnot to
(1) Remove the bolts joining the
damagethe oil seal.
mainbearing
cover and
crankcase.
8 @ X 35 mm bolt..-.----.--.1lpcs.
8 @ x 40mm bolt ............... 1pce.
(2) Lightlytappingwith
a plastic
hammer, remove the main
bearing cover from the
crankcase. (See Fig. 33.)

~~

12 mm
box wrench

plastic
hammer

+ NUT : 2pcs.

Step F'arttoremove

19

Procedures

Camshaft

Remarks

(1) Remove thecamshaftfromthe

crankcase. (See Fig. 35.)

(2) Remove thetappetsfromthe

crankcase.

20

Balancer
(Optional
part)

i (1) Remove the balancer fromthe

~

crankcase.

SPACER

FIG. 36
- 23 -

(1) To preventthe
tappetfromfalling
andgetting damages,
putthe crankcase
injection pump side
down.
(2) Put marks on the
tappets to distinguish
intaketappet from
exhaust.

Be careful of the
spacer on the
balancershaft.

Tool

r
Step 'art to remove

21

Connecting
rod

Procedures

Remarks

(1) Scrape off the carbon

deposit

from the piston top and cylinder.

10 mm
box wrench

(2) Remove the connectingrodbolts

andthelarge
end cap.
(3) Turnthecrankshafttothetop
dead
center.
Then, push the connectingrod
upand
pull the piston and
connectingrodoutfrom
the
cylinder.
22

Pistonand
pistonpin

( 1) Remove

the twoclipsfrom
the
piston at the both ends of piston
pin.
(2) Push the piston pin out from the
piston.
Remove the pistonfrom
the
connecting rod.
(3) Remove the piston rings from
the piston by spreading
their
open ends.

PISTON RING
CLIP

PISTON PIN

CONNECTING ROD

LARGE
BEARING'
END

Tool

UII

Be careful not to give

damagestothe
piston and connecting
rod.
Be careful not to
breaktherings
by
spreading too much
ortwistingthem.

Step Part to remove

23

Procedures

(1) Lightly tap thecrankshaft end

at the flywheel side using a
plastic hammer to remove it
fromthecrankshaft.
(See Fig. 38.)

Crankshaft

FIG. 38

CRANKSHAFT

FIG. 39
- 25 -

Remarks

The ball bearing

comes off with the
crankshaft.

Tool

Step IPart to remove

Tool

Remarks

Procedures

~~

Intake
and
exhaust valve

( 1 ) Press the valve springs and

Oil filter

(1) Remove the oil filter

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

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

Putmarks on the
valves, valve springs
andspringretainers
todistinguishthem
for intakesidefrom
exhaust side.
Be careful
not
thespanner
0 - ring.

to lose

-8

.pliers

10 mm

R E T A I N E R LOCK

I &----

STEM S E A L

FIG. 40
h

VALVE

7-

OIL FILTER

MAIN B E A R I N G COVER

+ FLANGE

J
FIG. 41
-

26 -

BOLT : 2pcs

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
crankshaft intothecrankcase.

U /

OIL SEAL GUIDE

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
to slip them intothe correct ring grooves.

only far enough

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.

OPEN
ENDS
OF
PISTON RING

FIG. 43

Topring

Barrelface

Second ring

Taper

......
...
...

:e
...........

...........
..........
.........

Oil ring

Cutter

ring with expander

......

.......
................
......
...........
..........

FIG. 44

(2) Assemble the pistonandconnecting

rod withthepiston

pin.

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.
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,
and cylinder

connectingrodbearings
borebefore
assembly.
2. Setthe open end of the pistonrings
90 degreesapartfrom
one another
beforeassembly.

FIG. 45

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

match the alignment mark

end cap,
on the rod.

1. No. lockwasher

is used forthe
connecting rod bolts.
2. Tightenthe rodbolts securely by the
specifiedtighteningtorque.
Tightening torque : 180-200 Kg- cm

- 29 -

FIG. 46

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
of thecrankcase.

holes

Be sure t o assemble theintaketappet

tointake
side andexhausttappetto
exhaust side.

(2) Install the camshaft into the crankcase

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

FIG. 48

- 30 -

5-4- 6 MAIN BEARINGCOVER

(1) Installation of governorgear

AND GOVERNORGEAR

shaft set.

MAIN

GOVERNORGEAR

GEAR

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

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.

and balancer shaftto
Adjusttheside
clearancefor
thecrankshaft,camshaft
specified valuesusingthe
properspacer and thrust washer.

CRANKSHAFT

CAMSHAFT

.
D type

SIDE
CLEARANCE

0.1 -0.3 mm

ADJUSTING
DEVICE

THRUST WASHER
T = 0.1 mm
T = 0.2 mm
T = 0.3 mm

0.05-0.25 mm

SPACER
T = 0.8 mm
T = 1.0 mm

BALANCER
SHAFT

type

0.05-0.3
mm

SPACER
T = 0.6 mm
T =.0.8mm
T = 1.2 mm

the

0.05-0.25

mm

SPACER
T = 0.8 mm
T = 1.0 mm
T = 1.2 mm
A

- 32 -

1. As the governor
gear is mounted on
themainbearingcover
side, install
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
seal rip
before
installing
the
main
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
8 @ X 35 mm bolt andwasherassy.
-1lpcs.
8 q5 X 40 mm bolt and washer assy. . * * * * - - 1pce.

FIG. 53

cover to the crankcase.

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)

(2) Wipeoff
oil andgreasethoroughly
flywheel center hole.

(3) ( ELECTRIC START MODEL )

Installthecharge
coil tothe
'

in place.

from thetaperedportion

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 -

of the crankshaft and

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.
(See Fig. 55.)

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,
one.
replace i t withanew
d) Insert the intake valve and the exhaust
valveintothevalveguide.
e) Assemble the valve springs, spring
retainersandtheretainer
locks.

FIG. 56

(2) Check the clearance between the piston

topandthe.cylindertop.
(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.)

APPLY THREE BOND 1 2 1 5 .

(3) Put the cylinder head on the cylinder.

(4)Apply sealant (THREE BOND 1215) to

the two studs on the rocker shaft
Apply oil totheothertwostuds.
(See Fig. 57.)

FIG. 57

side.

(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
shaft.Attachthesnapringstothebothends

- 35 -

to the cylinder head using the rocker

of therockershaft.

5- 4- 11 VALVE CLEARANCE
ADJUSTMENT

(1) Set thecrankshafttothetopdead

center by matching the mark
"T" of the
"TOP" mark of the
flywheelwiththe
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
engine is cold.

(3) Turn the flywheel by hand and

the
valves
move
smoothly
without
hittingpiston.

'the

check

FIG. 58

0 INTAKE, EXHAUST VALVE TIMING

Thevalveclearanceshallincreaseto
0.4 mm whileengineisrunninghot.
In thiscondition,thevalvetiming
is as
follows :
Intakevalveopensat16"before
TDC.
Intakevalveclosesat
5 4 " after BDC.
Exhaustvalveopensat
Exhaustvalveclosesat

TDC (TOP DEAD CENTER)

INTAKE V A L V E 1 6 "

1 4 " EXHAUSTVALVE

54" before BDC.

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 -

lv

5 - 4- 12 FUEL INJECTION NOZZLE

SPRING WASHER

(1) Insertthe nozzleassemblyintothe

cylinderheadattachi-ngthegasket
(nozzle)t hteo
nozzle tip.
(2) Attachthefuelreturnpipetothe
injectionnozzle.

(3) Attach the BRACKET (nozzle 2) and

BRACKET (nozzle l),' and tighten the
twonutswithspringwashers
tentatively.

to the

(4)Attach the fuel injection pipe

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

(I) Attachthecylinder

AND BLOWERHOUSING

baffle tothe

(2) Attachthe blower housingtothe

Tighten
the
upper
two
bolts
tentatively
mountingfueltankafterwards.

cylinder.
crankcase.
because these
bolts
shall

be used for

5-4- 14 MUFFLER

(1) Attachthe

muffler cover to the

muffler.

(2) Attachthe mufflerand

thegasket (muffler) tothe
Tightenthe boltand
nuts tentatively.

cylinderhead.

5-4-15 FUEL TANK

(1) Attachthe

fuel pipes tothe

fuel tank.

(2) Installthe fuel tanktothe

engine.
Tightentheboltsandnutsforjoiningthe
cylinderhead
atthis step.

blower housingandthe

- 37 -

muffler tothe

5 - 4 - 1 6 FUEL PIPES

(1) Attachthe

fuel filtertothe

blower housing.

(2) Attach
the
fuel pipes between the fuel tank, fuel filter, injection pump
and
the
injection nozzle.
Clamp the each end of rubber pipes using the proper hose clamps.

,r

5 - 4 - 17 AIRCLEANER

(1) Attachthe

cleaner body totheintake

(2) Attachthe

elements to the

(3) Attachthe

cleaner cover to the

manifold.

cleaner body.
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

Tightenthetwoflange

the main bearing cover.

bolts.

5-4- 20 ENGINE OIL

Fill thecrankcasewith

oil tothe

Besure
to use the dieselengineoil
Neve use the gasolineengineoilor

upper level of the oil gauge.

of proper grade.
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
INJECTION
NOZZLE

FUEL RETURN
PIPE
CHECK
VALVE

FUEL TANK

U
3
m
q-ju

U U %

TIL&
w
a
a
U
w
m
m

FUEL INJECTION
PUMP

flI

PIPE
FUEL

FUEL FILTER

RUBBER PIPE
1

FW EL
TANK

-b

FUEL
FILTER

FUEL
PIPE

FUEL
HIGH
FUEL
-F INJECTION -b PRESSURE -b INJECTION
PUMP
PIPE
NOZZLE

FUEL RETURN PIPE

FIG. 61

39

COMBUSTION
CHAMBER

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.
( 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.)
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

FIG. 64
- 41 -

NO DELIVERY

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
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.)

FIG. 65

6- 2 - 5 FUNCTION OF THE DELIVERY VALVE

By theplungerstroke,
fuel pressure
is
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.
of the plungerbarrel,delivery
of fuelends,
When theplunger lead meetssuctionport
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
of deliveryvalveat
seatbeforearrival
theseat.Thesmallorificeinthevalve
isthepassage
of fueltothechamber
in the deliveryvalveholder.Accordingly,
descendingvelocity of the delivery valve
is decreased,which prevents the negative
pressurebeingproducedsuddenly.
As aresult,proper
injection is conducted
andtheenginenoiseisdecreased.
(See Fig. 67.)

DAMPING V A L V E

DELIVERY VALVE

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
6 mm

Lift

Right hand twist

Lead

Plunger
spring
arbitrary~

Deliveryvalvespringconstant
Rack stroke

~~

~~

~~~~

~~~

Approx 1 5 k g / cm*

Deliveryvalveopeningpressure

2.21 kg/rnm
~~

1.1 k g / m m

10mm

- 43 -

6-3 FUEL INJECTION NOZZLE

6- 3- 1 SPECIFICATfONS

Part
Name

/-

NOZZLE ASSEMBLY

Type No.

DLLA150PN52

No. of nozzle hole

(Diameter)

4
(0.22 mm)

Valve opening pressure

195 kg/ ern'

Spring constant

13.2 kg/ mm

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
of nozzleholderandnozzle.Thenozzle
holderfixesthenozzletothecylinder
head andatthesametimeitplaysthe
role of fuelpassagetothe
nozzle.

ADJUSTING WASHER

The nozzle consists of the nozzle body

andneedlevalve.
When the fuel pressure reaches up to the
valveopeningpressure,the
needle valve
is raised
up
and
the
fuel
is injected
throughthesmall
holes at the tip of the
nozzle body.

NOZZLE SPRING

FIG. 69
VALVE CLOSED

VALVE OPENED

.The valve opening pressure is adjustable

by changingtheadjustingwashers.

FIG. 70
- 44 -

NOZZLE BODY

6-3-4FUEL PASSAGE
From
the
plunger
pump
fuel
is
sent
throughthehighpressure
pipe 1 tothe
fuelpassage 2. Then, a t t h e nozzle body
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
5.
chamberviathejethole
An excess fuel which lubricated
the inside
of the nozzle and nozzle holderreturns
tothefueltankviathe
needlevalve-,
nozzle spring 6 -overflowpipe
7 +-fuel
tank. (See Fig. 7 1.>

a
7

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
from the nozzle. Also keep
fuel
mist
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 :
NEEDLE
a ) Disassemble the nozzle holder and nozzle,
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
FIG. 74
deadweight.
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 valve
opening
pressure
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.

FIG. 75

- 47

+
4

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
pump all the way t o fuel shut off position to stop the engine.

of the injection

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

LUBRICATION
BY SPLASH

111,

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.
over the crescent cam opening theexhaustvalveto
release
The exhausttappetrides
compression.

TAPPET
FLYWEIGHT

CRESCENT C A M

2LtL/l
/

EXHAUST C A M

EXHAUSTCAM

RELEASELEVER

SNAPRING
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

engines, however the principle of operationis the same.

- 50 -

by D typeand

B type

7 . STARTING SYSTEM
-

7 - 1 RECOIL STARTER
The recoil starterhardlyhasatrouble
in the normal use, .however, in case ithasa
time of lubrication, perform
disassembly
and reassembly
in
the
trouble or atthe
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

enginewitha
box spanner.

STARTER ROPE

(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
stops
in
the
arrowheaddirection,brakingthereel
rotationwithathumb.

(3) When removing,takeouttheparts

Fig.
in the order of the numbering in
80.
1. U type snap ring
2. Thrust washer
3. Friction spring cover
4. Return spring
5. Friction spring
6. Ratchet
Meantime, for removing the U type
snapring,niptheshaftwithcutting
it out.
pliersandpush

/q

STARTER NKOB

FIG. 79

FIG. 80

- 51 -

(4) Takeoutthereelfromstartercase

81.
as
In this case, slowly take out it turning
thereellightlytowardleftandright
so thatthespringis
removedfrom
the reel
hook
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 case as instructed in
Fig. 86.)
Finally, release and take out the starter
ropetiedtoboththereelsideand
thestartingknobside.
Thus,thedisassembly
work ends.

REEL

STARTER

FIG. 81

INO. 2

7 - 1 - 2 HOW TO REASSEMBLE (D Type)

(1) First,havethestarterropepass
through the starting knob, and tie the
82 No. 1.
ropeasshowninFig.
Then,havetheoppositeside
of the
rope pass through the starter case and
i t asshownin
Fig.
the reel,andtie
82 No.2. Thensurelyhousetheend
inthe
reel.(In
theFig.82boththe
ropesaretiedquitelightly,asyou
seeinfigures
No.1 and No.2. Please
of
notethisisjustforthepurpose
easyunderstanding.Therefore,when
actually tying, tie the rope as tightely
a s possible.

FIG. 82

OUTER END OF SPRING

(2) Confirm that the spring is surely set

in the starter case housing section, and
so that its
havethespringtoform
innerendwill
be about3mm
from
thestartershaftandthat
it hooks
surelythereelhook.
Meantime, with the pliers about
10cm
longspringfromtheinnerendcan
easily be formed.

STAR1'ER SHAFT

11
/

INNEREND

FIG. 83
-

REEL HOOK

52 -

OF SPRING

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
the
arrowhead
direction.
When
woundup,firmlypressthereelnot
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
85 so t h a t
upwardasshowninFig.
thefrictionplatecaneasily
be put
intheholeforit.
Next,turnthefrictionplateinthe
arrowheaddirectiontilltheposition
where
its
notch
matches
with
the
ratchet. Push firmly the friction plate
t o thereelside,andputthethrust
U
washerandthenclampitwitha
typesnapring.
(Use
pliers
to
set
the
snap
ring
securely.)

FIG. 84

CH

FIG. 85

.This
isthe
end of the disassemblyandreassemblyprocedures.
Testthe reassembled recoil starter by the following checkingproceduresin
page.

- 53 -

thenext

7 - 1 - 3 CHECKING PROCEDURESAFTERREASSEMBLY

(1) Pull thestartingknob

2 or 3 times,andpull

a) If the starting knob is felt heavy to

partsareinstalled
correctly.
b) If theratchet

(D Type)

does notfunction,

outthestarter
ropealittle.
pull or cannot be pulled, check whether all the

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.
(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 -

FIG. 86

7 - 2 ELECTRIC STARTING MOTOR (OPTIONAL PART)

7 - 2 - 1 SPECIFICATIONS
Part Name
Maker

BOLT

Starting Motor

MAGNET SWITCH

Nihon Denso K. K.

DRIVE SPRING

Output

0.6 kW

Weight

3.0 k g

DRIVELEVER
DRIVE

BRUSH

PIS1

FRAME

STOP COLLER

FIG. 87

7-2-2 WIRING DIAGRAM

LIGHT BLUE
LIGHT

BLUE
KEY SWITCH

RED

IC

r----

Connect positive (+) battery terminal to 8 rnm magnetic

switch treminal.

L------J
BATTERY 12V-24AH
~

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
couplingmethode withtheequipment,

asufficientattentiontothemountingposition,
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
of fuel tanknot less than 50 mm higherthanthe
fuelinjection pump.
setthebottom
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

(5) Span the belthorizontally

possible.

if possible.

(6) Disengage the load at startingthe

If the clutch is notadaptable,usea

engine.
belt tensioner or the like to disengage load.

8- 5- 2 FLEXIBLE COUPLING

When usinga
flexiblecoupling,
minimize therunoutandmisalignment
engineshaftandthedrivenshaft.
The allowance are specified bythecouplingmaker.

- 57 -

between the

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
(5)

of new partsminus

tolerance.

CORRECTION
TOLERANCE

Tolerance on the dimensions of engineparts

refinished or adjusted.

9 - 1 SERVICE DATA
Engine

Unit : mm (in)

CYLINDER HEAD
@ Flatness

DY27

DY23

ITEM

Limit

STD

0.05

0.05

(0.002)

(0.002)

@Valveseatcontactwidth

(@)
e V a l v e guide inside dia.

2.2

1.6

(0.087)

(0.063)

I
5.5-5.518
(0.21

- 58 -

65-0.21

5.65
72)

(0.2224)

Unit : rnm (in)

DY23

ITEM

STD

Limit

75.000-75.01 9

75.25

CYLINDER
@Inside
dia.

70.000-70.01 9

PISTON
OPiston size ( A t skirt, in
thrustdirection)

clearance

Piston pin hole

OPiston pin outside dia.

70.25

(2.7559-2.7567)

(2.7657)

(2.9528-2.9535)

(2.9626)

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

1st o / s

70.21 1-70.231
(2.7642-2.7650)

70.1 21
(2.7607)

75.21 1-75.231
(2.961 1-2.961 9)

75.1 21
(2.9575)

2nd o / s

70.461 -70.481
(2.7741 -2.7748)

70.371
(2.7705)

75.461 -75.481
(2.9709-2.9717)

75.371
(2.9674)

0.05-0.09
(0.0020-0.0035)

0.1 5
(0.0059)

0.05-0.09
(0.0020-0.0035)

0.1 5
(0.0059)

0.01 5-0.055
(0.0006-0.0022)

0.1
(0.0039)

0.015-0.055
(0.0006-0.0022)

0.1
(0.0039)

18.03

18.001 -18.008

18.03

(0.7087-0.7090)

(0.7098)

STD

Ringgrooveside

DI 27

18.001

- 18.008

(0.7087-0.7090)
(0.7098)

-1

18.000- 18.006

17.980

(0.7087-0.7089)
(0.7079)

18.000-1 8.006

17.980

(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)

0.3-0.5

1.o

0.1 -0.3

0.8

0 Pistonringendgap

To P
2nd

(0.01 18-0.01 97)

(0.0394)

(0.0039-0.01

0.25-0.45

1 .o

(0.0098-0.0177)

(0.0394)

18)

0.25-0.45

(0.031 5)

1 .o

Oil

- 59 -

(0.0098-0.01 77)

(0.0394)

Unit : mm (in)

DY23/DY27

ITEM
CONNECTING ROD
.Big
endinsidedia.
(Metalisfitted)

STD

Limit

33.050-33.090

33.2

(1.301 2- 1.3028)

.Clearance
between
big endandcrankpin

(1.3071 )

0.023-0.081

0.1

(0.0009-0.0032)

(0.0039)

Smallendinsidedia.

18.013- 18.034

OClearancebetweensmallend
pin
andpiston

0 Big endsideclearance

(0.7092-0.7100)

(0.71 06)

0.007-0.034

0.08

(0.0003-0.0013)

(0.0031 )

0.10-0.30

0.5

A
CRANKSHAFT
0 Crankpinoutsidedia.

18.05

(0.0039-0.01 18)

(0.01 97)

33.01 1-33.027

32.85

(1.2996-1.3003)

(1.2933)

32.984-33.000

32.85

(1.2986-1.2992)

(1.2933)

0.014-0.oa6

0.1 2

0 Journal dia.

OClealancebetween
journalandmainbearing

(0.0006-0.0034)

- 60 -

(0.0047)

Unit : rnm (in)

DY23/DY27

ITEM
CAMSHAFT
0 Cam height

STD
IN. EX.

0
.Journal
outside dia.
"D' type

cams

( 1 2650- 1.2689)

Injection
pump
cam

Flywheel
side R1

PTO side

R2

VALVE
.Valve
stemoutside

32.1 3-32.23

dia.

Limit
31.98
(1.2591

29.95-30.05

29.85

(1.1791-1.1831)

(1.1 752)

24.934-24.947

24.90

(0.981 7-0.9822)

(0.9803)

14.973- 14.984

14.90

(0.5895-0.5899)

(0.5866)

5.422-5.437

5.35

(0.21 35-0.2141 )

(0.21 06)

5.402-5.417

5.35

(0.21 27-0.21 33)

(0.21 0 6 )

IN.

EX.

.Clearance
betweenvalve
stem dia. andvalveguide

0.063-0.096

0.3

(0.0025-0.0038)

(0.01 18)

IN.

0.083-0.1 16

0.3

EX.

(0.0033-0.0046)

(0.01 18)

0 Valve clearance

IN./ EX.
(cold)

-61 -

0.07-0.1
Adjustable

(U.OO28-U.OU39)

ITEM
TAPPET
0 Stem outside dia.

Unit : mm (in)

DY23/DY27

STD

Limit

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)

11.937-1 1.984

11.92

ROCKER A R M
0 Rockershaftoutsidedia.

(0.4714-0.4718)

0 Rockerarm

(0.4693)

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

- 62 -

32.5

31 .O

(1.2795)

(1.2205 1

Unit : mrn (in)

DY23/DY27

ITEM

STD

INJECTION PUMP
Frominjectionpumpflangesurface
e Staticinjectiontiming

65.95-66.05
(2.5965-2.6004)
21 -23
ETDC

t o cam base

NOZZLE
0 Injectionstartingpressure
Nozzle dia./Number of nozzle

Limit

Adjustable

195 kg / cmz
(2773 I b j in2)
0.22 (0.009)/4PCS.

ENGINECOMPRESSION
(at 400 r. P. m. by hand)

18 k g / c m 2

13 kg/ cmz

(256.0 Ib/ in2)

( 1 84.9 I b / in2)

17- 17.5 k g / cmz

1 2 k g / cmz

DY23

DY27
(241.6-248.9

( 1 70.7 Ib/ in2)

Ib/ in2)

VALVE SEAT ANGLE (IN. EX.)

.Valve
cutterangle(a)
.Valve
contactwidth (b)

b : 2.2 mm

b : 1.6 mrn

(0.0866in)

(0.0630in)

a
I

TABLE OF TIGHTENING TORQUE

Tightening Torque

Description
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)

DY 27

330-350 k g - c m (23.9-25.3

ft

Ib)

Boltsforjoiningconnectingrodcap

180-200 kg-cm

(13.0-14.5

ft

Flywheelnut

600-650 kg- cm

(43.4-47.0

ft

Oil drainplug

200-230 k g - cm (14.5-1 6.6 f t

Nuts for joining cylinderhead

Nutsforjoininginjection

nozzle

Ib)
Ib)

Ib)

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
of every 50 hours.
be cleaned everydayinstead

10- 1 DAILY CHECKS AND MAINTENANCE

Reasons for requiring the maintenance work

Checks and maintenance works

Remove dust,dirt,debris,grassandany
foreignobstaclesfromcylinder,cylinderhead,
carburetorandgovernorsystem.

(1) Engine overheats.

(2) Enginedoesnotoperateproperly.

Check fuel leakage. If leakage is found, tighten

the loose joint and/orreplaceleakingpart.

Danger of fire.

Check boltsand nuts for looseness.

Tightenthe loose bolt and/ornut
if any.

Enginemalfunctionscausingdamages
engineand/ortheequipment.

Check oil level and fill upas

Insufficient oil causesengineseizure.

necessary.

to the

10- 2 INITIAL 25 HOURS CHECK AND MAINTENANCE

Reasons for requiring the maintenance work

Checks and maintenance works

Changeengine

To remove break- in dregs.

oil.
I

- 64 -

2.

10-3 EVERY 100 HOURS (MONTHLY) CHECKS ANDMAINTENANCE

Reasons for requiring the maintenance work

Checks and maintenance works

Changeengine

Contaminated oil accelerateswear.

oil.

Clean oil filter.

Insufficient oil causesenginefailure.

Clean aircleaner.

Clogged air cleanercauses

operation.

Check batteryelectrolyte

poor engine

Insufficientelectrolytelowers
performanceandshortenbattery

level.

battery
life.

Waterinthefuelcauses
poor engine
operation,badstartingandcorrosion
in the
injection pump and nozzle.

Dischargewaterfromfuelfilter.

10- 4 EVERY 500 HOURS CHECKS AND MAINTENANCE

Reasons for requiring the maintenance work

Checks and maintenanceworks

Check and adjustvalveclearance.

Impropervalveclearance
output.

Check and cleaninjection

Poor operation of the engine.

nozzle.

I Remove carbondepositfromcylinderhead.

causes poor engine

Poor operation of theengine.

10- 5 EVERY 1000 HOURS (YEARLY) CHECKS ANDMAINTENANCE

I
Checks and maintenance works

Reasons for requiring the maintenance work

I

Replace pistonrings.

Poor performance of theengine.

Replacefuel

To preventfromfuelleaking.

lines.

Replace fuelfilter
Check valveseats
Grindvalveseats

Poor operation of theengine.

both intakeandexhaust.
if necessary.

Poor operation of the engine.

- 65 -

Check and maintenance works

Overhaulthe

engine.

Reasons for requiring the maintenance work

To recover theenginepower
engine life.

and extend

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.)

Bo not pour too much oil or the oil rernaines in the combustionchamber
top.

(4)Pull the recoil starter slowly andstopitatthe

(5) Clean theengineoutsidewith
a oily cloth.
(6) Put a cover over the engine andstoreitin

- 66 -

of the piston

compression point.
a dryand

well ventilatedarea.

Industrial
Engines