PARTS MANUAL Models
DY23-2 / DY27-2 ENGINE
PUB-EP5754A Rev. 07/00
940 Lively Blvd. Wood Dale, IL 60191 Phone: 630-350-8200 Fax: 630-350-8212 e-mail:
[email protected] • www.robinamerica.com
© Copyright 2000 Robin America, Inc.
HOW TO USE THIS MANUAL Robin engines are identified by MODEL, SPECIFICATION, and CODE NUMBER. For each model there may be many different versions called specifications. Each specification will be unique in some way. The difference may only be the paint color or it may have a different type of PTO or some other significant difference. In order the identify the correct service part number, it is important to confirm the specification and code numbers for your engine. The specification and code number together are know as the PRODUCT NUMBER. All Robin 4 cycle engines have a Product Number label similar to the label illustrated below.
PRODUCT NUMBER LABEL
PRODUCT NUMBER LABEL LOCATIONS
The Product Number Label has a 15 digit alphanumeric string that consists of the SPECIFICATION (SPEC) number (11 digits) and the CODE number (4 digits). Please note the illustration below:
DY232
XXXX
SPEC NO. (11 digits)
CODE NO. (4 digits)
PRODUCT NO. (15 digits)
-3-
'00-07
MANUAL LAYOUT
1. SECTION NAME
Parts are broadly classified according to their functions. Refer to the Group Index (table of contents) for respective section name.
2. FIG. No.
The FIG. number indexes the reference and part numbers to the illustration. Figure numbers that vary only in the tens place (i.e..: 700 and 710) are in a group of the same section (i.e..:Electrical Device Group).
3. REF. No .
The Reference number identifies the part illustration with the corresponding part number in the part list.
4. SUBASSEMBLY
SUBASSEMBLY parts of part assembly are listed below the assembly part. The subassembly part reference number is indicated by the number led by "-" such as "-1", "-2".
5. PART NUMBER
It is the number assigned for sales unit. Use the PART No. when making an order.
6. DESCRIPTION
It is designation of the part.
7. QTY.
Quantity of each part used for each product.
8. REMARKS
This gives a distinctive feature and/or a supplementary comment for the type, the specification, and the part concerned. It also shows part number(s) interchangeable for the part.
9. FROM-TO
This section shows the CODE No. to indicate the history of progress in which improved parts have been introduced in the product. The FROM-TO CODE No. helps to identify PART No. being employed in the product concerned. See the examples below:
2101- 2100
The part is used in the product irrespective of CODE No. The part is used in the products with CODE No. of 2101 and after this number. The part is used in the products with CODE No. of 2100 and before this number.
-4-
'00-07
GROUP INDEX Group Name
Page
CRANKCASE GROUP ............................................................................... 6 CRANKSHAFT GROUP ............................................................................ 10 INTAKE and EXHAUST GROUP ............................................................... 12 GOVERNOR GROUP ............................................................................... 16 COOLING and STARTING GROUP ......................................................... 18 FUEL, LUBRICANT GROUP ..................................................................... 20 ELECTRIC DEVICE GROUP .................................................................... 24 ACCESSORIES GROUP .......................................................................... 28
INDEX OF DESCRIPTION SYMBOLS SYMBOL DESCRIPTION AY .......................... ASSEMBLY CP .......................... COMPLETE EX .......................... EXPORT (from Japan) FIG. ........................ FIGURE FR. ......................... FRONT " .............................. INCH INCL. ...................... INCLUDE ~L ........................... LITER L= ........................... LENGTH (in. mm) L.H. (LH) ................ LEFT-HAND SIDE MECH .................... MECHANICAL NO (NON) .............. NONE OPT. ....................... OPTIONAL O.S. ........................ OVER SIZE
SYMBOL DESCRIPTION P= .......................... PITCH (in mm) P.T.O. (PTO) .......... POWER TAKE OFF REF. ....................... REFERENCE R.H. (RH) ............... RIGHT HAND SIDE RR. ......................... REAR STD. ....................... STANDARD SW ......................... SWITCH T= ........................... THICKNESS (in mm) UN .......................... UNIT U.S. ........................ UNDER SIZE ~V .......................... VOLTAGE ~W ......................... WATT W/ .......................... WITH W/O ........................ WITHOUT
-5-
'00-07
SECTION 1
CRANKCASE GROUP
FIG. 100
DY23-2 / DY27-2
-6-
'00-07
SECTION 1
CRANKCASE GROUP
REF. 10
DESCRIPTION QTY. REMARKS CRANKCASE CP 1 DY23-2 CRANKCASE CP 1 DY23-2, Electric Start CRANKCASE CP 1 DY27-2 CRANKCASE CP 1 DY27-2, Electric Start OIL SEAL 1 OIL SEAL 1 BALL BEARING 1 DOWEL PIN 2 STUD 3 DOWEL PIN 1 PLUG 2 GASKET 2 DOWEL PIN 2 TENSION BOLT CP 3 TENSION BOLT CP 1 GROMMET 1 Electric Start MAIN BEARING COVER CP 1 OIL SEAL 1 GOVERNOR GEAR SET 1 FLYWEIGHT 2 PIN 2 GOVERNOR SLEEVE 1 OIL GAUGE 2 GASKET 2 GASKET, main bearing cover 1 BOLT and WASHER AY 12 BOLT and WASHER AY 1 MAIN BEARING 1 STD. MAIN BEARING 1 0.25mm undersize MAIN BEARING 1 0.50mm undersize BLIND PLUG 1
10 30 36 45 50 65 66 80 90 105 135 155 205 210 220 250 251 252 260 270 280 290 300 310 320
361
PART NO. 243-10101-61 243-10105-61 244-10101-61 244-10105-61 044-03000-60 044-00800-30 060-01700-40 005-26081-80 001-37062-21 031-00500-10 040-11400-30 021-11400-20 031-00600-10 244-16002-11 244-16002-11 243-75001-03 244-11009-21 044-03000-30 243-45011-07 220-41601-03 030-73000-70 205-41901-03 214-63601-13 021-32000-10 243-15026-03 001-13083-50 001-13084-00 243-15801-03 243-15802-03 243-15803-03 212-15008-13
DY23-2 / DY27-2
-7-
FROM-TO
FIG. 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100 100
'00-07
SECTION 1
CRANKCASE GROUP
FIG. 110
DY23-2 / DY27-2
-8-
'00-07
SECTION 1
CRANKCASE GROUP
REF. 20 60 610 620
DESCRIPTION VALVE GUIDE STUD CYLINDER HEAD CP GASKET, T= 0.2 GASKET, T= 0.3 GASKET, T= 0.2 GASKET, T= 0.3 FLANGE NUT STUD STUD ROCKER COVER CP GASKET, rocker cover FLANGE BOLT PLUG GASKET SET GASKET SET
620 635 650 660 680 690 710 730 *960 *960
PART NO. 243-14204-13 001-37082-01 243-13001-71 243-15027-13 243-15028-13 244-15027-13 244-15028-13 018-00900-10 001-39066-00 010-50601-50 243-17101-01 243-1 5032-13 011-00601-70 243-15030-03 255-99001-07 256-99001-07
QTY. 2 2 1 1 1 1 1 4 1 1 1 1 4 1 1 1
REMARKS
Select one piece only, DY23-2 Select one piece only, DY23-2 Select one piece only, DY27-2 Select one piece only, DY27-2
FROM-TO
FIG. 110 110 110 110 110 110 110 110 110 110 110 110 110 110
DY23-2 DY27-2
* The gasket set for the DY23-2 contains the following: Fig. 100 items 90, 280, 290 Fig. 110 items 620, 690 Fig. 310 items 340, 555 * The gasket set for the DY27-2 contains the following: Fig. 100 items 90, 280, 900 Fig. 110 items 620, 690 Fig. 310 items 340, 510-2, 555
DY23-2 / DY27-2
-9-
'00-07
SECTION 2
CRANKSHAFT GROUP
FIG. 200 430
440
DY23-2 / DY27-2
- 10 -
'00-07
SECTION 2
CRANKSHAFT GROUP
REF. 10 25 50 60 70 85
DESCRIPTION CRANKSHAFT CP BALL BEARING NUT SPRING WASHER WOODRUFF KEY THRUST WASHER, T=0.8 THRUST WASHER, T=1.0 THRUST WASHER, T=1.2 FLANGE BOLT BALANCER CP SPACER, T= 0.8 SPACER, T= 1.0 SPACER, T= 1.2 CONNECTING ROD AY CONNECTING ROD BOLT PISTON PIN PISTON PISTON PISTON PISTON PISTON PISTON PISTON RING SET PISTON RING SET PISTON RING SET PISTON RING SET PISTON RING SET PISTON RING SET CLIP LARGE END BEARING LARGE END BEARING LARGE END BEARING ADAPTER BOLT and WASHER AY FLYWHEEL
86 210 215
310 320 350 360
360
370
370
380 395
430 440 500
PART NO. 244-20401-11 060-03500-20 002-18180-00 003-20180-00 032-30300-10 243-25001-03 243-25002-03 243-25003-03 011-00600-10 243-24301-01 023-01700-20 023-01700-30 023-01700-40 243-22510-00 243-23002-03 243-23301-03 243-23401-13 243-23402-13 243-23403-13 244-23401-13 244-23402-13 244-23403-13 243-23501-27 243-23502-27 243-23503-27 244-23501-27 244-23502-27 244-23503-27 056-52000-30 243-22801-03 243-22802-03 243-22803-03 244-17501-13 001-13082-50 243-22410-13
DY23-2 / DY27-2
QTY. 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 1 4 1
- 11 -
REMARKS
Select one piece only Select one piece only Select one piece only
Select one piece only Select one piece only Select one piece only
STD., DY23-2 0.25mm oversize, DY23-2 0.50mm oversize, DY23-2 STD., DY27-2 0.25mm oversize, DY27-2 0.50mm oversize, DY27-2 STD., DY23-2 0.25mm oversize, DY23-2 0.50mm oversize, DY23-2 STD., DY27-2 0.25mm oversize, DY27-2 0.50mm oversize, DY27-2 STD. 0.25mm undersize 0.50mm undersize
FROM-TO
FIG. 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200 200
'00-07
SECTION 3
INTAKE and EXHAUST GROUP
FIG. 300
DY23-2 / DY27-2
- 12 -
'00-07
SECTION 3
INTAKE and EXHAUST GROUP
REF. 10 35 36 38 39 41 45 50 60 70 75 80 85 90 100
DESCRIPTION CAMSHAFT CP RELEASE LEVER SPRING PIN RELEASE LEVER SHAFT, release DOWEL PIN SPRING, release TAPPET VALVE SPRING SPRING RETAINER RETAINER LOCK INTAKE VALVE STEM SEAL EXHAUST VALVE SPACER, T= 0.8 SPACER, T= 1.0 ROCKER SHAFT PUSH ROD CP ROCKER ARM CP ADJUSTING SCREW NUT
200 210 220 230 240
PART NO. 255-31703-01 243-35503-23 005-19031-00 243-35505-03 243-35022-03 005-26081-80 243-35021-03 243-33301-03 243-33601-03 243-33701-13 243-33801-13 243-33401-23 237-16008-01 243-33501-23 023-01900-20 023-01900-30 243-35034-03 243-35032-01 243-36002-01 014-90800-21 017-00800-90
DY23-2 / DY27-2
QTY. REMARKS 1 1 1 1 1 1 1 2 2 2 4 1 1 1 1 Select one piece only 1 Select one piece only 1 2 2 2 2
- 13 -
FROM-TO
FIG. 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300 300
'00-07
SECTION 3
INTAKE and EXHAUST GROUP
FIG. 310
DY23-2 / DY27-2
- 14 -
'00-07
SECTION 3
INTAKE and EXHAUST GROUP
REF. 300 310 320 340 350 360 380 395 500 510 -2 -7 -110 -120 -160 -170 520 525 555 556 580 584 900
DESCRIPTION MUFFLER AY MUFFLER CP MUFFLER COVER CP GASKET, exhaust NUT BOLT and WASHER AY TAIL PIPE CP TAPPING SCREW INTAKE MANIFOLD AIR CLEANER AY PACKING PACKING COVER CP BACK PLATE CP WASHER WING BOLT ELEMENT CP ELEMENT GASKET, intake manifold BOLT and WASHER AY BOLT and WASHER AY BOLT and WASHER AY LABEL, air cleaner
PART NO. 255-30103-00 243-30101-51 243-34201-01 243-35002-03 002-19080-00 001-10061-00 243-37002-11 015-00400-60 243-33101-13 243-32601-00 243-32651-08 243-32650-08 243-32640-08 243-32620-08 243-32660-08 243-32670-08 243-32600-08 243-32611-08 243-35503-13 001-13083-50 001-13061-20 001-13081-60 243-92302-03
DY23-2 / DY27-2
QTY. REMARKS 1 1 1 1 2 4 1 3 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1
- 15 -
FROM-TO
FIG. 310 310 310 310 310 310 310 310 310 310 310 310 310 310 310 310 310 310 310 310 310 310 310
'00-07
SECTION 4
GOVERNOR GROUP
FIG. 400
DY23-2 / DY27-2
- 16 -
'00-07
SECTION 4
GOVERNOR GROUP
REF. 10 20 21 22 80 310 340 350 360 380 390 410 415 490 491 495 496 497 500 501 502 510 520 650 660
DESCRIPTION CONTROL LINK CP GOVERNOR LEVER NUT SPRING WASHER GOVERNOR SPRING CP SPEED CONTROL AY STOP PLATE SPRING WASHER SCREW SELF LOCK NUT WIRE BRACKET 1 CP WIRE BRACKET 2 CP RETURN SPRING NUT BOLT BOLT WASHER BOLT CONTROL PANEL CP BOLT and WASHER AY BOLT and WASHER AY LABEL, operation LABEL, operation SMOKE SET AY NUT
PART NO. 243-42902-21 243-42301-12 002-18080-00 003-20080-00 243-42503-01 243-43301-30 227-43501-13 227-45002-03 004-31041-00 017-60600-30 243-44202-01 243-44210-01 243-46001-03 002-18060-00 001-66063-00 243-45002-03 003-10060-00 010-00603-70 255-40166-01 001-14061-20 001-13081-60 243-92101-03 243-92102-03 243-45502-00 002-27100-00
DY23-2 / DY27-2
QTY. REMARKS 1 1 1 1 1 1 1 1 2 1 1 1 1 2 1 1 1 1 1 2 3 1 1 1 1
- 17 -
FROM-TO
FIG. 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400 400
'00-07
SECTION 5
COOLING and STARTING GROUP
FIG. 500
DY23-2 / DY27-2
- 18 -
'00-07
SECTION 5
COOLING and STARTING GROUP
REF. 10 40 60 80 150 210 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10 -11 215 230
DESCRIPTION BLOWER HOUSING CP BOLT and WASHER AY CYLINDER BAFFLE FLANGE BOLT BOLT and WASHER AY RECOIL STARTER AY SPIRAL SPRING REEL CP STARTER ROPE STARTER KNOB RATCHET FRICTION SPRING RETURN SPRING FRICTION PLATE THRUST WASHER CLIP STARTING PULLEY LABEL, diesel mark BOLT and WASHER AY
PART NO. 243-51201-21 001-13082-00 243-52601-33 011-00600-10 001-13083-00 243-50201-20 106-50116-08 239-50220-08 243-50110-08 236-50101-08 106-50128-18 106-50132-08 106-50136-18 106-50144-08 106-50185-08 106-50186-08 243-50145-08 243-95004-13 001-14061-20
DY23-2 / DY27-2
QTY. REMARKS 1 2 1 5 2 1 1 1 1 1 2 1 1 1 1 1 1 1 3
- 19 -
FROM-TO
FIG. 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500 500
'00-07
SECTION 6
FUEL, LUBRICANT GROUP
FIG. 600
DY23-2 / DY27-2
- 20 -
'00-07
SECTION 6
FUEL, LUBRICANT GROUP
REF. 10 16
DESCRIPTION FUEL TANK CP LABEL, trademark LABEL, trademark LABEL, instruction LABEL, warning FUEL TANK CAP CP FUEL FILTER RUBBER PIPE RUBBER PIPE CHECK VALVE CLAMP BOLT and WASHER AY HOSE CLAMP HOSE CLAMP VINYL PIPE BOLT and WASHER AY
20 27 30 40 80 81 86 88 89 90 95 100 105
PART NO. 243-60102-41 255-91701-03 256-91701-03 243-91907-13 073-20039-00 043-04300-15 064-13600-10 085-14500-00 085-14500-00 228-65032-13 150-75201-03 001-10061-00 056-10800-10 056-10800-20 085-00500-40 001-13082-00
DY23-2 / DY27-2
QTY. 1 1 1 1 1 1 1 1 1 1 1 1 5 1 1 2
- 21 -
REMARKS DY23-2 DY27-2
4.5 X 9 X 45 4.5 X 9 X 95
5 X 8 X 120
FROM-TO
FIG. 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600 600
'00-07
SECTION 6
FUEL, LUBRICANT GROUP
FIG. 610
DY23-2 / DY27-2
- 22 -
'00-07
SECTION 6 REF. 250 -1 260 265 270 300 -1 -2 -3 -4 -5 -6 -21 305
310 330 340 350 355 356 400 -7 -8 420 -1 -2 430 600 610 620 700 710 720 730
PART NO. 243-63201-00 243-63204-08 228-65004-03 002-38060-00 243-66001-01 255-63103-00 243-63131-08 243-63103-08 243-63104-08 243-63105-08 243-63107-08 243-63129-08 243-63130-08 243-65001-03 243-65002-03 243-65003-03 085-10600-00 085-10600-00 085-14500-00 085-14500-00 056-11100-20 056-10800-10 243-62101-20 228-62112-08 228-62111-08 243-66520-10 243-66521-08 243-66506-08 243-63301-21 243-64301-00 001-14061-60 006-26202-00 228-63902-03 006-26103-30 243-66020-01 004-11061-60
DY23-2 / DY27-2
FUEL, LUBRICANT GROUP DESCRIPTION NOZZLE AY NOZZLE GASKET, nozzle FLANGE NUT BRACKET CP, nozzle 1 INJECTION PUMP AY PLUNGER AY DELIVERY VALVE DELIVERY SPRING GASKET O RING O RING SCREW GASKET, T= 0.1 GASKET, T= 0.2 GASKET, T= 0.3 RUBBER PIPE RUBBER PIPE RUBBER PIPE RUBBER PIPE HOSE CLAMP HOSE CLAMP FUEL FILTER AY PACKING PLUG T-CONNECTOR AY NUT PACKING INJECTION PIPE CP OIL FILTER AY BOLT and WASHER AY O RING OIL PUMP, outer O RING COVER CP, oil pump SCREW, countersink
QTY. 1 1 1 4 1 1 1 1 1 1 1 2 2 1 1 1 1 1 1 1 4 4 1 1 1 1 1 1 1 1 2 1 1 1 1 3
- 23 -
REMARKS
Select one piece only Select one piece only Select one piece only 6 X 12 X 120 6 X 12 X 180 4.5 X 9 X 90 4.5 X 9 X 315
FROM-TO
FIG. 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610 610
'00-07
SECTION 7
ELECTRIC DEVICE GROUP
FIG. 700
DY23-2 / DY27-2
- 24 -
'00-07
SECTION 7
ELECTRIC DEVICE GROUP
REF. 10 11 20 35 90 92 130 170 200 210 220 -1 230 240 261 262 340
DESCRIPTION FLYWHEEL CP CHARGE COIL CP RING GEAR SCREW and WASHER AY CLAMP SCREW and WASHER AY BOLT and WASHER AY BOLT and WASHER AY CONTROL BOX CP LABEL, starter switch SWITCH KEY DIODE RECTIFER CP BOLT and WASHER AY CLAMP BOLT and WASHER AY WIRE 2 CP
PART NO. 243-70110-41 243-70102-21 243-71002-13 004-35062-50 226-75101-03 004-35061-00 001-14083-00 001-13081-60 243-40601-11 073-20010-90 066-00003-30 066-00099-80 243-71401-01 001-10061-00 056-60001-70 001-13081-20 243-73104-11
DY23-2 / DY27-2
QTY. REMARKS 1 1 1 2 1 1 2 1 1 1 1 2 1 1 2 1 1
- 25 -
FROM-TO
FIG. 700 700 700 700 700 700 700 700 700 700 700 700 700 700 700 700 700
'00-07
SECTION 7
ELECTRIC DEVICE GROUP - STARTER MOTOR
FIG. 710
DY23-2 / DY27-2
- 26 -
'00-07
SECTION 7
ELECTRIC DEVICE GROUP - STARTER MOTOR
REF. 120 -1 -2 -3 -4 -6 -7 -8 -9 -10 -11 -12 -14 -15 -17 -25 -29 -30 -32 140 160
DESCRIPTION STARTING MOTOR AY YOKE AY BRUSH SET BRUSH SPRING BRUSH HOLDER AY AMATEUR AY PINION AY PINION STOPPER SET GEAR CASE AY BRUSH (-) REAR COVER AY REAR COVER METAL SHIFT LEVER KIT MAGNETIC SWITCH AY THROUGH BOLT THRUST WASHER KIT REAR COVER METAL DUST COVER KIT BOLT NUT SPRING WASHER
PART NO. 255-70502-00 255-70580-08 255-70551-08 228-70516-08 255-70531-08 255-70561-08 255-70521-08 210-70534-08 255-70501-08 228-70514-08 255-70505-08 210-70542-08 243-70525-08 255-70515-08 207-70524-08 210-70533-08 210-70542-08 255-70570-08 228-70522-08 002-28080-00 003-20080-00
DY23-2 / DY27-2
QTY. REMARKS 1 1 1 4 1 1 1 1 1 2 1 1 1 1 2 1 1 1 2 1 1
- 27 -
FROM-TO
FIG. 710 710 710 710 710 710 710 710 710 710 710 710 710 710 710 710 710 710 710 710 710
'00-07
SECTION 8
ACCESSORIES GROUP
FIG. 800
40
DY23-2 / DY27-2
- 28 -
'00-07
SECTION 8
ACCESSORIES GROUP
REF. 10 30 40
DESCRIPTION TOOL KIT OIL FEEDER AY KEY
PART NO. 243-90301-00 243-65006-00 207-26001-03
DY23-2 / DY27-2
QTY. REMARKS 1 1 1
- 29 -
FROM-TO
FIG. 800 800 800
'00-07
PRINTED IN THE USA
