Farymann Diesel 15W Series Operator'S Manual Download Page 1

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Table of contents

2008-12-09

Operator´s manual

Diesel engine

Series 15W / 18W

Doc-ID: Grea-8247

Read the operating instructions before starting work!

Summary of Contents for 15W Series

Page 1: ...Table of contents 2008 12 09 Operator s manual Diesel engine Series 15W 18W Doc ID Grea 8247 Read the operating instructions before starting work ...

Page 2: ...n Diesel GmbH Industriestraße 19 68623 Lampertheim Germany Tel 49 0 62 06 5 07 0 Fax 49 0 62 06 5 07 111 E Mail info farymann de Internet www farymann de Release Created by Kothes Technische Kommunikation GmbH Co KG www kothes de ...

Page 3: ...13 2 3 Appropriate use 14 2 4 Personal protective equipment 15 2 5 Specific dangers 16 2 6 Safety devices 20 2 7 Behaviour in the case of danger and accidents 20 2 8 Environmental protection 21 3 Technical data 22 3 1 Technical specifications 22 3 2 Applications 22 3 3 Standard configuration 23 3 4 Options 23 3 5 Engine type plate 24 3 6 Engine type code 24 3 7 Engine data 25 3 8 Performance data ...

Page 4: ...rect sea water cooling with thermostat 37 4 3 3 Closed cooling water circuit with radiator and thermostat 38 4 4 Galvanic corrosion electrolysis on engines for marine generators applications 38 5 Transport packing and storage 39 5 1 Safety notes for transport 39 5 2 Transport inspection 39 5 3 Packing 40 5 4 Transport 40 6 Installation and commissioning 42 6 1 Safety 42 6 2 Installation 42 6 2 1 M...

Page 5: ...hanging engine oil 75 8 5 1 Version with oil drain plug 75 8 5 2 Version with oil drain valve 76 8 5 3 Removing and installing oil strainer 78 8 6 Changing oil filter for D W crankcase version 79 8 7 Fuel system 81 8 7 1 Replacing fuel filter 81 8 7 2 Replacing fuel filter with thread 82 8 7 3 Replacing fuel filter standard 84 8 8 Replacing air filter 86 8 8 1 Dry type air cleaner standard engine ...

Page 6: ... water hoses and hose clamps 111 8 14 4 Precautions in the case of engine overheating 111 8 15 Checking level of the coolant for engines with radiator 112 8 15 1 Replacing coolant for engines with radiator 113 9 Faults 114 9 1 Safety 114 9 2 Troubleshooting chart 117 9 2 1 Engine does not start 117 9 2 2 Engine starts however runs irregularly or stops 119 9 2 3 Bad engine performance 120 9 2 4 Ope...

Page 7: ...rsonnel The personnel must have carefully read and understood this manual before starting all work The basic prerequisite for safe working is compliance with all the safety and handling instructions stated in this manual Furthermore the local accident prevention regulations and general safety conditions for the application of the machine are also applicable Illustrations in this manual are provide...

Page 8: ...ANGER points out a directly dangerous situation which results in death or severe injuries if it is not avoided WARNING points out a potentially dangerous situation which can result in death or severe injuries if it is not avoided CAUTION points out a potentially dangerous situation which can result in minor or slight injuries if it is not avoided CAUTION points out a potentially dangerous situatio...

Page 9: ...rained personnel Unauthorised modifications Technical changes Use of non original spare parts The actual scope of delivery can be different from the explanations and illustrations stated here for special versions the use of additional ordered options or due to the latest technical changes The agreed obligations in the supply contract the general terms and conditions and the delivery conditions of ...

Page 10: ...or internal purposes Violations oblige to compensation The right for further claims remains reserved 1 5 Warranty terms The warranty terms are provided in the manufacturer s terms and conditions 1 6 Customer service Our customer service is pleased to provide further technical information Please refer to our website www farymann de or telephone us on 49 0 6206 507 0 for a list of our sales and serv...

Page 11: ...ring the complete usage time of the machine the owner must check whether the operating instructions created by him correspond with the current status of the regulations and must adapt these if necessary The owner must clearly regulate and specify the responsibilities for installation operation maintenance and cleaning The owner must ensure that all employees involved with the machine have read and...

Page 12: ...ntactness before every start up In the case of doubt always contact the nearest Greaves Farymann Diesel service partner before starting the engine Only regular maintenance in accordance with the information in this operator s manual maintains the operational readiness of the engine Only perform maintenance and cleaning work when the engine is switched off Strictly observe all the information in th...

Page 13: ... and possible dangers in the case of improper behaviour Technical personnel are persons who on the basis of their professional training by Greaves Farymann Diesel GmbH experience and knowledge of the relevant conditions can perform the work assigned to them using the operating and repair instructions and can recognise and avoid possible dangers themselves Only persons who are expected to perform t...

Page 14: ... The installation must be made so that all applicable safety regulations for the operation of diesel engines are complied with Proper use also includes compliance with all the information in this operator s manual Any use beyond the intended use and or other types of use is considered misuse and can result in dangerous situations WARNING Danger due to misuse Misuse can result in dangerous situatio...

Page 15: ... entangled by moving machine parts Do not wear any rings and other jewellery Safety boots to protect against heavy parts falling down or slipping on slippery ground Personal protective equipment for special tasks When performing special tasks it is necessary to wear personal protective equipment This personal protective equipment will be separately specified in the chapters of this manual This spe...

Page 16: ...o reduce health hazards and to avoid dangerous situations Rotating parts WARNING Risk of injury due to rotating parts Rotating parts can cause severe injuries Therefore Do not reach into or work on rotating parts during operation Do not open or remove covers during operation Pay attention to the run on time after switching off the engine Ensure there are no parts still moving or the engine is not ...

Page 17: ...ring affected person into the open air immediately Contact a doctor Contact doctor immediately in the case of swallowing Rinse mouth thoroughly with water Avoid skin and eye contact Apply suitable skin protection cream before working on tanks piping or supply equipment Wear protective gloves made of plastic or rubber during the work In the case of contact with the skin or eyes rinse immediately wi...

Page 18: ...ave the danger zone until the all clear signal is given Hot operating materials WARNING Risk of burns due to hot operating materials Operating materials can reach high temperatures during operation and cause burns in the case of contact Therefore Check whether operating materials are hot before handling them If necessary let them cool down to the ambient temperature Hot surfaces of the engine comp...

Page 19: ...shes or allergies Therefore Observe the safety data sheet of the antifreeze manufacturer Wear rubber gloves when handling antifreeze Never mix different types of antifreeze Contact a doctor immediately in the case of swallowing Rinse mouth thoroughly with water Avoid skin and eye contact Wear protective gloves made of plastic or rubber during the work Collect coolant drained from the engine in a s...

Page 20: ...devices 2 7 Behaviour in the case of danger and accidents Preventive measures Always be prepared for accidents or fire Keep first aid equipment first aid kit blankets etc and fire extinguishers ready to hand Familiarise personnel with accident reporting first aid and rescue equipment Keep access routes clear for rescue vehicles Actions in the case of accidents Operate the EMERGENCY STOP button on ...

Page 21: ...ways observe the instructions mentioned below Take immediate action if environmentally hazardous materials reach the environment Inform the responsible local authorities about the damage in the case of doubt The following environmentally hazardous substances are used Lubricants fuels Fuels coolants and lubricants such as e g diesel fuel antifreeze and engine oil contain toxic substances They must ...

Page 22: ...pump oil filter option for increased operational reliability Exhaust silencer Dry type air filter or oil bath filter Cooling water pump neoprene impeller pump Fuel feed pump and fuel filter Crankcase of high tensile light alloy Plain bearings on conrod and crankshaft on the control side Roller bearing on output side Engine mounting points integrally cast on the crankcase Environmentally friendly d...

Page 23: ...ne impeller pump Exhaust silencer Crank handle rigid 3 4 Options The engine is available with the following options Crankcase with oil filter version D W crankcase Dry type air cleaner various versions Water cooled exhaust manifold Electric water pump 12 V or 24 V Starter 12 V or 24 V Solenoid valve open or closed with zero current 12 V or 24 V Alternator 12 V or 24 V Oil pressure switch Temperatu...

Page 24: ... digit code in addition to the serial number e g 18W 430 0001 M5 Fig 3 Trim No speed governor version Type No engine version Start 0 crank handle 5 electric start 6 alternator without starter 7 alternator with starter Bearings 3 roller bearing on the flywheel side Crankshaft 4 horizontal position Basic engine design A vertical cylinder anticlockwise rotation old version B vertical cylinder clockwi...

Page 25: ... as seen from output or flywheel side Type of cooling Water cooled Valve control Overhead valves with push rods and rocker arms Valves Two valve technology Valve clearance cold engine Intake valve Exhaust valve 0 2 mm 0 2 mm Type of starting all engines Option Manual starting with crank handle Starter 12 V or 24 V Required battery capacity 36 Ah 12 V 72 Ah 2 batteries a 12 V for 24 V Permitted ope...

Page 26: ...roke 55 mm Displacement 290 cm3 Mean piston speed 6 6 m s 3600 rpm Compression ratio 20 1 IFN ISO Blocked performance for intermittent load ICFN ISO Power for constant speed and constant load Contact the manufacturer for continuous use outside the stated performance limit Power reduction Reduction approx 1 for each 100 m height and approx 2 for each 5 C over 20 C Performance guaranteed with 5 devi...

Page 27: ... Dry weight standard engine with air filter and exhaust silencer 39 kg 3 10 Temperatures Description Value Max permissible air intake temperature 50 C Max permissible exhaust temperature 580 C Max permissible cooling air temperature 50 C Max permissible fuel temperature 70 C Max permissible engine oil temperature 130 C Max permissible cooling water temperature 90 C ...

Page 28: ...cription Value Fuel Diesel EN 590 DIN 51601 OK BS 2869 A1 A2 ASTM D 975 1D D2 Engine oil Multigrade oil SAE 10W40 mineral oil API CD or higher Max engine oil filling quantity version with oil filter Max engine oil filling quantity version with oil strainer approx 1 2 litres approx 1 1 litres Engine oil refill quantity bottom top mark oil dipstick Standard engine approx 0 3 litres Engine oil consum...

Page 29: ...r application of the engine is crucial for the selection of the correct viscosity class Too high viscosity can result in starting difficulties too low viscosity can endanger the lubrication effect and result in high lubrication oil consumption The viscosity is classified according to SAE Basically use mulltigrade oils Depending on the lubrication oil temperature we recommend the following common v...

Page 30: ...ase version Fig 5 Front view Left view 1 Valve cover 2 Dry type air cleaner oval flange option 3 Decompression unit 4 Engine mounting point 5 Cooling water pump neoprene impeller pump 6 Oil drain plug 7 Starting handle support bearing 8 Speed adjusting lever 9 Fuel feed pump 10 Lifting eye for transport 11 Starter NOTE The engine with D W crankcase has an oil filter ...

Page 31: ... 31 Fig 6 Output side Right view 12 Thermostat housing 13 Bell housing option 14 Stub shaft option 15 Oil dipstick 16 Oil filter D W crankcase 17 Injection pump 18 Water cooled exhaust manifold option 19 Oil filler cap 20 Excess fuel device 21 Fuel filter standard ...

Page 32: ...Left view 1 Valve cover 2 Oil bath air cleaner 3 Decompression unit 4 Engine mounting point 5 Cooling water pump neoprene impeller pump 6 Oil drain plug 7 Excess fuel device 8 Starting handle support bearing 9 Speed adjusting lever 10 Fuel feed pump 11 Lifting eye for transport NOTE The standard engine 15W 18W has an oil strainer and no oil filter ...

Page 33: ...on 15 Oil filler cap 16 Injection pump 17 Oil dipstick 18 Fuel filter 4 2 Electrical System 4 2 1 Alternator option Fig 9 Example Alternator The permanent magnets on the magnet carrier 1 on the flywheel side induce an alternating current proportional to speed in the coils of the stator 3 NOTE The connector at cable 2 on the alternator can be one of various versions ...

Page 34: ...r coils input can be connected either way z 1 x red charging current output z 1 x brown charge indicator connecting terminal 15 ignition switch z Earth connection is made using mounting surface 4 2 3 Operating conditions Permitted operating temperatures 20 C to 70 C measured on the alternator regulator surface There must be an intact earth connection between alternator regulator and engine and bet...

Page 35: ...r External start with jump leads for defective or completely discharged battery Destruction of the alternator regulator Manual starting with disconnected battery Destruction of the alternator regulator Interruption of the earth connection of the alternator regulator to the engine Destruction of the alternator regulator Welding work WARNING Material damage due to welding work on the machine Welding...

Page 36: ...act Replace defective indicator lamps immediately Do not remove the ignition key during operation Do not disconnect the battery while the engine is running occurring voltage peaks can destroy electronic components e g the alternator regulator Do not spray parts of the electrical system during engine cleaning with a water jet or high pressure jet Always disconnect the minus terminal of the battery ...

Page 37: ...is possible 4 3 2 Open cooling water circuit with direct sea water cooling with thermostat Fig 12 The cooling water is also circulated here using an impeller pump 1 The temperature of the cooling water circulating around the cylinder and cylinder head is regulated by a thermostat in the cylinder head The cooling water thermostat is set to a maximum temperature There are two versions of cooling wat...

Page 38: ...nic decomposition process electrolytically caused corrosion where the cause is outside the affected application for marine electricity generation applications External influences become effective due to electrical voltage As aluminium as a material reacts very sensitively to these influences this problem should be paid a lot of attention to in advance so that damage can be detected in good time or...

Page 39: ...notices on the packing Only use the attachment points provided Do not remove packing until just before the installation 5 2 Transport inspection Check the delivery immediately on receipt for completeness and transport damage If externally detectable transport damage is found proceed as follows Do not accept the delivery or only with reservation Record the extent of transport damage in the transpor...

Page 40: ...materials are valuable raw materials and can continue to be used in many cases or sensibly reconditioned and recycled Therefore Dispose of packing materials environmentally Follow the locally valid waste disposal regulations If necessary employ a special waste disposal company to dispose of packing material 5 4 Transport Transport of the engine with the crane Fig 13 Transport with the crane The en...

Page 41: ...of storage for longer than 3 months check the general condition of all parts and the packing regularly If required refresh or renew the anti corrosion protection Storage of the engines up to 12 months is possible under the above conditions CAUTION Damage due to improper storage Parts of the engine can corrode and become non functional in the case of too high relative humidity or air containing sal...

Page 42: ...ed by a specialist Additional protective equipment required z Safety footwear Special tool needed z Torque wrench Fig 14 NOTE Always check the flywheel nut with a torque wrench set for 216 to 226 Nm before every installation in or attachment to the machine 1 Install engine on suitable mounting 2 Turn engine slowly with the crank handle until the keyway 1 in the crankshaft 3 faces upwards NOTE This...

Page 43: ...es with alternator can be damaged The alternator does not function correctly if the magnets are damaged 6 After the installation of the flywheel check without fail that the key arrow is seated in the keyway of the crankshaft before screwing on the flywheel nut NOTE In the case of improper mounting of the flywheel the key can fall out of the crankshaft keyway This results in the flywheel not being ...

Page 44: ...d provided on the flywheel 9 Fix the flywheel with a suitable lever e g tyre lever 7 10 Tighten the flywheel nut with a torque wrench 8 to 216 226 Nm 11 Turn the flywheel by hand and examine for unobstructed movement must not jam 6 2 2 Attaching stub shaft option Fig 19 Example Stub shaft Example Not all applications need a stub shaft 12 Attach stub shaft 1 to the flywheel NOTE Depending on the ty...

Page 45: ...n and installation position of the engine the speed controller can be installed differently by the device manufacturer Depending on the version and installation position of the engine different versions for the speed controller can be attached e g rods Bowden cables manual electric etc Fig 20 Example Speed controller with Bowden cable ...

Page 46: ...d in the technical data Observe the filling quantities Before first use or after a long decommissioning more than 6 months operate the engine after starting for approx 1 minute at low speed and without load Due to this action an optimum lubrication of all bearings is achieved and a lack of lubrication is avoided CAUTION Engine damage due to cold start aids The use of cold starting aid results in e...

Page 47: ...ity Too high or too low an engine oil level can result in damage to the engine Therefore Never exceed the maximum level Never drop below the minimum level The engine must stand up straight for checking the oil level Fig 21 1 Release oil filler cap 1 e g with a 13mm jaw spanner and screw off by hand Fig 22 2 Fill engine oil into the filling opening 2 ...

Page 48: ...ck 3 and clean the bottom end with a clean and fluff free cloth 4 Replace the oil dipstick 3 and pull it out again Fig 24 5 Check the oil level quantity The oil level should be just under the Max marking 6 Fill with engine oil if needed Fig 25 7 Only tighten the oil filler cap 1 by hand risk of breakage ...

Page 49: ...fter refilling is ensured by the self venting The venting can be accelerated using the lever 1 on the fuel feed pump 2 Fig 26 8 Using the lever 1 on the fuel feed pump 2 pump by hand until the counter pressure becomes noticeable This builds up the primary pressure in the fuel system and accelerates the venting NOTE The 15W 18W engine is supplied without fuel tank Due to the design no fuel tank is ...

Page 50: ...n before starting the work Never deactivate safety devices during operation Ensure tidiness and cleanliness in the working area Loose components and tools lying around or on top of each other cause accidents Rotating parts WARNING Risk of injury due to rotating parts Rotating parts can cause severe injuries Therefore Do not reach into or work on rotating parts during operation Do not open covers d...

Page 51: ...of burns due to hot surfaces of the engine components The engine can become very hot during operation Contact with the exhaust system and the engine can cause burns Therefore Never touch the engine during operation Ensure that all parts have cooled down to the ambient temperature before all work Engine oil and fuel WARNING Danger of fire due to fuel and engine oil Oil and fuel vapours can ignite o...

Page 52: ...anger of poisoning and danger of skin rashes and allergies Antifreeze contains substances harmful to health and can result in severe poisoning and skin rashes or allergies Therefore Observe the safety data sheet of the antifreeze manufacturer Wear rubber gloves when handling antifreeze Never mix different types of antifreeze Contact a doctor immediately in the case of swallowing Rinse mouth thorou...

Page 53: ... at the usage location 3 Rescue people from the danger zone initiate First Aid actions 4 Switch off the main switch on the machine if present and secure it against being switched on again 5 Keep access routes clear for rescue vehicles After the rescue actions 6 If required for the severity of the emergency inform the responsible authorities 7 Assign specialist personnel to the fault rectification ...

Page 54: ...fuel if necessary Check cooling water level refill if necessary Check air filter for soiling clean if necessary or replace air filter element Check engine mounting Check machine for completeness of the safety equipment Check engine and machine for missing covers Check engine for damaged oil and fuel lines Check engine for damaged electrical cables and insulation Check engine and cooling system for...

Page 55: ...off 2 Partial load range 3 Cold start and full load 7 3 Manual start NOTE In the case of outdoor temperatures below 5 C the engine must be rotated to the speed adjustment max position Put the speed adjustment lever into the increased idle speed position in the case of a cold engine If the engine does not start the starting speed is too low Constant and accelerated turning the starting handle suppo...

Page 56: ...operates for the manual starting of the engine with the crank handle If the decompression unit s pin has moved to the operating position the decompression has finished The compression begins and the engine starts Neutral position In the neutral position the compression is switched off By turning the engine with the crank handle all bearings are provided with engine oil e g following repair or befo...

Page 57: ...sition 3 Operating position Fig 32 Example Adjusting the automatic decompression on the starting handle with the adjusting spanner The automatic decompression Fig 31 is adjusted on the starting handle Fig 33 with the adjusting spanner Fig 33 Adjusting spanner on the starting handle Starting handle 1 with adjusting spanner 2 ...

Page 58: ...shaft to stop and the starting excess button returns to its starting position Therefore it is important that the engine is started without load and can reach its maximum speed Otherwise the starting excess button does not return to its starting position and the engine is overloaded NOTE When starting the engine when warm operating temperature do not pull out the excess fuel device Manual start Fig...

Page 59: ... handle limited kickback crank handle is not possible due to the design Only the rigid version shown as an example in picture 36 can be used Fig 37 RD crank handle NOTE Due to the design the RD limited kickback crank handle shown in picture 37 cannot be used for engines with a cooling water pump neoprene impeller pump Fig 38 5 Erect on the right in front of the engine and ensure a secure position ...

Page 60: ...he crank handle supports starting the engine NOTE The automatic decompression operates for the manual starting of the engine If the pin has moved to the operating position Fig 29 3 the decompression is finished The compression begins and the engine starts 8 Absolutely continue turning after the first compression until the crank handle is overtaken by the running engine and disengaged NOTE If the e...

Page 61: ...he starter for longer than 10 to 20 seconds and release the key when the engine is running Wait approx 30 seconds before repeating starting CAUTION Engine damage due to cold start aids The use of cold starting aid results in engine damage Therefore Never use cold starting aids The engine in the version with a starter is started using a key switch see e g operating instructions of the device manufa...

Page 62: ...charge check etc 3 Press in the key turn as far as position II and release immediately after the engine starts NOTE If the engine does not start the battery voltage can be too low Charge the battery or replace it if necessary 7 5 Operation CAUTION Engine damage due to incorrect operation The lifetime of the engine can be reduced due to incorrect operation Therefore Strictly observe the following i...

Page 63: ...o be checked by the nearest Greaves Farymann Diesel service partner see Chapter 8 10 Adjusting valve clearance Note Replace oil filter engines with D W crankcase Normal operation Let the engine warm up for approx 5 minutes after starting Increase load slowly Do not let the engine idle longer than 30 minutes and do not operate without load longer idling of the engine can result in excessive carboni...

Page 64: ...ine runs on for approx 10 to 20 seconds Therefore Wait until the engine is at a standstill before starting all work CAUTION Engine damage due to premature switching off Switching off under load can reduce the lifetime of the engine Therefore During full load operation let the engine idle for approx 5 minutes without load before switching off ...

Page 65: ...atic decompression at full load Before turning off first let the engine run for approx 5 minutes in idle mode and then pull the speed adjustment lever to the stop position Fig 42 1 and hold it there until the engine stops after approx 10 to 20 seconds 7 6 2 Engine with electric starter Fig 43 Example of key switch NOTE See e g operating instructions of the device manufacturer 1 Turn the key switch...

Page 66: ... adjustment lever in full load position Turn the automatic decompression to the neutral position and rotate the engine slowly for approx 20 revolutions with the crankhandle 5 Drain the cooling system of the engine by detaching the cooling water pump neoprene impeller pump cover 6 Seal inlet and exhaust openings with textile adhesive tape 7 Store the engine in a dry place and protected against the ...

Page 67: ...on protection oil from the engine into a suitable container and dispose of in accordance with the environmental regulations 4 Fill engine with engine oil see Chapter 6 4 Filling engine oil and replace oil filter engine with D W crankcase 5 Connect fuel supply hose to fuel feed pump and tighten hose clamp 6 Fill the fuel tank on the machine side with diesel fuel 7 Filling cooling system 8 Start eng...

Page 68: ...ent installation clearance before starting work Ensure tidiness and cleanliness at the workplace Loose components and tools lying around or on top of each other are sources of accidents Only perform maintenance work using commercially available tools and special tools Incorrect or damaged tools can result in injuries Engine oil and fuel WARNING Danger of fire due to fuel and engine oil Oil and fue...

Page 69: ... work described here can be performed by the operator unless otherwise indicated Other maintenance work must only be performed by specially trained qualified personnel or by specialist workshops Greaves Farymann Diesel service partners This particularly applies to work on the valve adjustment diesel injection system and for the engine repair Personal protective equipment Wear the following protect...

Page 70: ...ce of dust shorten the maintenance intervals by at least half In the case of low operating time the engine oil and oil filter engines with D W crankcase must be replaced at least every 12 months irrespective of the actual operating hours Only use original Greaves Farymann Diesel spare parts 8 2 Maintenance plan The various tasks are listed in the maintenance plan The maintenance intervals must be ...

Page 71: ...oil strainer and clean replace if necessary X Suction area Check area for intake air clean if necessary X X X Clean air filter element and air filter case X Dry type air cleaner Replace air filter element and clean air filter case X Check oil contamination and oil level several times a day in the case of a high occurrence of dust if necessary fill oil up to marking or change it X Oil bath air clea...

Page 72: ...ase at least every 4 years by a Greaves Farymann Diesel service partner X Electric cables Check for damage replace by a Greaves Farymann Diesel service partner if necessary X Cooling water hoses and hose clamps Check replace if necessary and in any case at least every 2 years by a Greaves Farymann Diesel service partner X Thermostat Replace thermostat Recommendation after 2000 operating hours Cool...

Page 73: ...rrence of dust shorten the maintenance intervals by at least half Low operating time In the case of low operating time the engine oil and oil filter for the D W crankcase version must be replaced at least every 12 months irrespective of the actual operating hours 8 3 Cleaning the intake area CAUTION Engine damage due to dust in the intake area Dust in the combustion chamber can result in premature...

Page 74: ...damaged Therefore Only check and tighten threaded connections with appropriate commercially available tools and respective special tools Do not exceed the tightening torques stated here CAUTION Cylinder head nuts must not be tightened Therefore Do not tighten cylinder head nuts without authorisation Arrange for work on the cylinder head to be carried out by a Greaves Farymann Diesel service partne...

Page 75: ...crankcase Only tighten oil filter by hand Valve cover 8 12 Oil drain plug 12 Oil strainer bolts 3 4 Thermostat housing bolts 10 8 5 Changing engine oil NOTE Only change engine oil when the engine is at a standstill and at operating temperature Always replace engine oil and oil filter together 8 5 1 Version with oil drain plug Fig 45 1 Switch off the engine 2 Slacken oil drain plug 1 e g with a rin...

Page 76: ...a flat wrench wrench size 13 mm and screw off by hand 10 Fill with engine oil 11 Pull out oil dipstick 2 and clean the bottom end with a clean and fluff free cloth 12 Replace the oil dipstick 2 and pull it out again 13 Check the oil level quantity The oil level should be just under the Max marking 14 Only tighten the oil filler cap 3 by hand risk of breakage 15 Start engine and check for leaks 8 5...

Page 77: ... necessary 7 Tighten the sealing cap 5 by hand Fig 51 8 Release oil filler cap 3 e g with a flat wrench wrench size 13 mm and screw off by hand 9 Fill with engine oil 10 Pull out oil dipstick Fig 47 2 and clean the bottom end with a clean and fluff free cloth 11 Replace the oil dipstick Fig 47 2 and pull it out again 12 Check the oil level quantity The oil level should be just under the Max markin...

Page 78: ...d or new oil strainer 4 with new gasket 3 carefully 8 Screw in both bolts 5 with new copper seals 6 and tighten Tightening torque 3 4 Nm 9 Screw in oil drain plug 7 with new copper seal 8 and tighten with ring spanner SW 13 Tightening torque 12 Nm Fig 54 10 Release oil filler cap 9 e g with a flat wrench wrench size 13 mm and screw off by hand 11 Fill with engine oil 12 Pull out oil dipstick Fig 4...

Page 79: ...ther Changing engine oil see Chapter 8 5 Fig 55 1 Slacken oil filter 3 with an oil filter wrench 1 and e g a ring spanner 27 2 off and unscrew and remove by hand NOTE The oil filter can be hot Fig 56 2 Collect the engine oil from the oil filter 4 and oil filter case in a suitable container 5 and dispose of in accordance with the environmental regulations ...

Page 80: ...ce 80 2008 12 09 Fig 57 3 Clean the sealing surface on the oil filter case 4 Use new oil filter 7 and wet seal 6 with clean engine oil Fig 58 5 Tighten the oil filter 7 only by hand 6 Fill with engine oil 7 Start engine and check for leaks ...

Page 81: ...ection nozzle holder 4 Fuel feed pump 5 Connection for fuel line to the fuel tank feed 6 Fuel filter standard 7 Injection pump 8 Electric solenoid valve option 8 7 1 Replacing fuel filter Fig 60 Fuel filter with thread There are two versions of the fuel filter Fuel filter 1 with thread version option With this version the fuel lines are screwed on to the fuel filter ...

Page 82: ...re fixed using hose clamps 8 7 2 Replacing fuel filter with thread Fig 62 1 Switch off the engine 2 Disconnect fuel line 1 using special fuel line disconnecting tool 2 Fig 63 3 Unscrew fuel line 3 from the fuel filter 4 4 Collect the fuel from the fuel line 3 in a suitable container 5 and dispose of in accordance with the environmental regulations ...

Page 83: ...12 09 83 Fig 64 5 Detach fuel line 6 from the fuel filter 4 Fig 65 5 Undo hose clamp 7 and remove fuel filter 4 Fig 66 6 Collect the fuel from the fuel line 6 in a suitable container 5 and dispose of in accordance with the environmental regulations ...

Page 84: ...low direction The arrow 8 must point in the direction of the injection pump Fig 68 7 Check banjo bolts 9 for damage and replace copper seals 10 8 Assembly is in the reverse order to the dismantling 9 Start engine and check the fuel system for leaks 8 7 3 Replacing fuel filter standard Fig 69 1 Switch off the engine 2 Undo hose clamp 1 on the mounting 2 of the fuel filter ...

Page 85: ...ig 71 4 Undo hose clamp 4 and pull off the fuel line 2 from the fuel filter 5 Fig 72 5 Collect the fuel from the fuel line 2 and from the fuel filter 5 in a suitable container 6 and dispose of in accordance with the environmental regulations 6 Undo hose clamp Fig 71 7 and pull off the fuel line Fig 71 8 from the fuel filter Fig 71 5 ...

Page 86: ... Tighten screw 1 of the hose clamp on the mounting 8 Start engine and check the fuel system for leaks 8 8 Replacing air filter CAUTION Engine damage due to use of non original air filter Unfiltered air can result in rough engine running and engine damage A dusty air filter reduces the engine power and increases the fuel consumption Therefore Do not operate the engine without the air filter Clean o...

Page 87: ...ype air cleaner standard engine Fig 75 1 Switch off the engine 2 Unscrew and remove the wing nut 1 3 Release sealing clips 2 and remove air filter case 3 Fig 76 4 Remove air filter element 4 Fig 77 5 Remove air filter cover 5 with air filter pot 6 and centring ring 7 ...

Page 88: ...g the air filter and when cleaning the air filter case always ensure that no dirt gets into the intake tract 7 After cleaning assemble the centring ring air filter pot and air filter cover While doing this only tighten the wing nut Fig 75 1 by hand Fig 79 8 Install new air filter element 4 Fig 80 9 Position air filter case 3 straight in the process pay attention to correct seating and close sealin...

Page 89: ...the engine 2 Unscrew and remove the wing nut 1 3 Remove air filter cover 2 Fig 82 4 Remove air filter element 3 Fig 83 5 Clean suction area Fig 83 4 and air filter cover Fig 81 2 thoroughly NOTE When removing the air filter and when cleaning the air filter case always ensure that no dirt gets into the intake tract ...

Page 90: ...n with the wing nut 1 8 8 3 Oil bath air cleaner standard engine Fig 86 NOTE Check oil contamination and oil level several times a day in the case of a high occurrence of dust if necessary fill oil up to marking or change it see maintenance plan 1 Open fasteners 2 and remove oil container 1 2 Remove contaminated oil and sludge from oil container Collect old oil and dispose of it in accordance with...

Page 91: ...ner NOTE Before assembly of the filter let the diesel fuel drip off sufficiently or wipe off NOTE Do not pull out the filter material 3 from the filter case The filter must be completely dry before fitting Fig 88 5 Fill oil container up to marking 4 with engine oil use oil in accordance with the viscosity classes on page 29 6 Fix oil container to the filter whilst doing so make sure the filter sit...

Page 92: ...s Therefore Disconnect the high pressure line on the injection nozzle holder before starting work Personnel This work must only be carried out by trained specialist personnel In the absence of the required qualifications arrange for the work to be carried out by a Greaves Farymann Diesel service partner Prerequisites Only check and adjust the valve clearance when the engine is cold less than 35 C ...

Page 93: ...ine and plastic seals valve cover and valve cover gasket Fig 90 3 Detach the high pressure line 4 on the injection nozzle holder in order to prevent accidental starting of the engine Fig 91 4 Turn automatic decompression to operating position 5 pin faces forward 9 o clock position NOTE The decompression must be turned off at the valve adjustment operating position pin faces forward 9 o clock posit...

Page 94: ...ntil the O T marking 7 on the flywheel corresponds to the crankcase marking 8 Fig 94 In this position both valves inlet and exhaust valves are closed max clearance between rocker arm and valve stem Exhaust valve setting 6 Slide a feeler gauge 10 with thickness 0 2 mm between rocker arm 9 and the exhaust valve stem and check the valve clearance of the exhaust valve The feeler gauge must be able to ...

Page 95: ...able to be pulled through without noticeable resistance drag 8 Hold the adjusting screw in place with a screwdriver and tighten the lock nut 9 Check the valve clearance again Fig 96 Inlet valve setting 10 Setting the inlet valve is carried out in exactly the same way as for the exhaust valve see Fig 94 and 95 Fig 97 11 Tighten the high pressure line 4 on the injection nozzle holder Tightening torq...

Page 96: ... gasket 13 Fig 99 13 Install valve cover 2 using two new plastic seals 14 14 Mounting bracket 3 of the fuel line 15 Tighten both nuts 1 of the valve cover 2 Tightening torque 8 12 Nm NOTE Always replace the valve cover gasket and the two plastic seals under the nuts of the valve cover ...

Page 97: ...fuel line and plastic seals valve cover and valve cover gasket Fig 101 3 Detach the high pressure line 4 on the injection nozzle holder in order to prevent accidental starting of the engine Fig 102 4 Turn automatic decompression to operating position 5 Pin faces forward 9 o clock position NOTE The decompression must be turned off at the valve adjustment operating position pin faces forward 9 o clo...

Page 98: ... gauge 10 with thickness 0 2 mm between rocker arm 9 and the exhaust valve stem and check the valve clearance of the exhaust valve The feeler gauge must be able to be pulled through without noticeable resistance drag Fig 105 7 If the clearance is too large or too small undo the lock nut 12 and adjust the clearance with the adjusting screw 11 The feeler gauge must be able to be pulled through witho...

Page 99: ...ler gauge 10 with thickness 0 2 mm between rocker arm 9 and the inlet valve stem and check the valve clearance of the inlet valve The feeler gauge must be able to be pulled through without noticeable resistance drag Fig 108 12 If the clearance is too large or too small undo the lock nut 11 and adjust the clearance with the adjusting screw 12 The feeler gauge must be able to be pulled through witho...

Page 100: ...tening torque 25 Nm Fig 110 16 Replace valve cover gasket 13 Fig 111 17 Install valve cover 2 using two new plastic seals 14 18 Mounting bracket 3 of the fuel line 19 Tighten both nuts 1 of the valve cover 2 Tightening torque 8 12 Nm NOTE Always replace the valve cover gasket and the two plastic seals under the nuts of the valve cover ...

Page 101: ...eries 15W 18W Maintenance 2008 12 09 101 8 10 Cooling water diagram standard Fig 112 Cooling water diagram standard 1 Cylinder head 2 Cylinder 3 Cooling water flow direction 4 Cooling water pump neoprene impeller pump ...

Page 102: ... 102 2008 12 09 8 11 Cooling water diagram with water cooled exhaust manifold Fig 113 Cooling water diagram 1 Cylinder head 2 Cylinder 3 Cooling water flow direction 4 Cooling water pump neoprene impeller pump 5 Water cooled exhaust manifold ...

Page 103: ...ifferent and depends solely on the operating conditions Fig 114 1 Switch off engine and let it cool down to the ambient temperature 2 Place suitable container under the cooling water pump 3 Mark cooling water pump e g with a touch up stick see arrow Fig 115 4 Unscrew the 4 bolts 1 on the cooling water pump cover 2 5 Collect water in a suitable container and dispose of in accordance with the enviro...

Page 104: ... see arrow NOTE It is ensured by the marking that the neoprene impeller is inserted in the correct position in the event of reinstallation Fig 117 8 Carefully remove the neoprene impeller 3 using two screwdrivers 4 Fig 118 9 Remove calcium deposits and gasket residues from the cooling water pump case 5 ...

Page 105: ...lace if necessary NOTE Coat the neoprene impeller with some Vaseline before installing in the water pump case Fig 120 11 Insert neoprene impeller 3 in the recess of the pump shaft see black arrow in doing so ensure that it is fixed properly NOTE If the old neoprene impeller is reused place this on the previously applied marking see arrow ...

Page 106: ... tighten with a screwdriver 15 Fill with water 16 Start engine and check cooling system for leaks NOTE Never operate the neoprene impeller pump without sea water never let it run dry Even very short dry running can result in destruction of the impeller NOTE If there is a danger of frost during the process of decommissioning remove water from the cooling system by undoing the screws 1 of the coolin...

Page 107: ...n to the ambient temperature 2 Drain coolant and collect in a suitable container 3 Unscrew both bolts 1 4 Remove thermostat housing 2 with gasket Fig 124 5 Remove thermostat 3 Functional check Fig 125 6 Fill a container with water 7 Attach thermostat 3 to a wire 4 and submerge in the water 8 Heat the water slowly using for example a submersible heater ...

Page 108: ...ith a suitable temperature measuring instrument 10 The thermostat must be completely open at 50 C water temperature for the salt water version or at 70 C water temperature for the fresh water version Fig 127 Example Thermostat completely opened see arrow Fig 128 Example Thermostat closed see arrow ...

Page 109: ...d Fig 130 12 Install thermostat 3 NOTE Ensure when installing the thermostat that the small bore hole see arrow is not covered or closed and that the split pin is in the hole Fig 131 13 Replace thermostat housing 2 with new gasket 14 Screw in and tighten both bolts 1 Tightening torque 10 Nm 15 Fill with coolant for engines with radiator or water for engines with neoprene impeller pump 16 Start eng...

Page 110: ...ater pump and cooling water hoses switch off the engine immediately and make the following checks Checking the cooling system for leaks Checking thermostat Ö Chapter 8 12 Check electric water pump e g pay attention to running noises If the cause of the error cannot be determined contact your nearest Greaves Farymann Diesel service partner or call us 8 14 2 Engines with direct sea water cooling In ...

Page 111: ...autions in the case of engine overheating If the engine overheats during operation and the cooling liquid temperature rises to near or even above boiling point the following actions must be performed immediately Switch off the engine immediately in the unloaded condition Immediately leave the area around the engine or the machine and maintain a safety distance Never remove covers or other parts on...

Page 112: ...tifreeze for engines with radiator and e g electric water pump WARNING Danger of poisoning and danger of skin rashes and allergies Antifreeze contains substances harmful to health and can result in severe poisoning and skin rashes or allergies Therefore Observe the safety data sheet of the antifreeze manufacturer Wear rubber gloves when handling antifreeze Never mix different types of antifreeze C...

Page 113: ...until the cooling water has cooled down to the ambient temperature Opening the radiator cap at operating temperature can result in severe skin burns scalding If the radiator cap is loose or not mounted properly the engine can overheat due to loss of coolant This can result in engine damage 8 15 1 Replacing coolant for engines with radiator If the cooling water freezes the engine and cooling system...

Page 114: ... Farymann Diesel service partner or the manufacturer 9 1 Safety Personnel The work described here for fault clearance can be performed by the operator unless otherwise indicated Some work must only be performed by a Greaves Farymann Diesel service partner this is specially pointed out in the description of the individual faults Personal protective equipment Wear the following protective equipment ...

Page 115: ...ved pay attention to correct assembly reinstall all fixing elements and comply with the tightening torques for threaded connections Engine oil and fuel WARNING Danger of fire due to fuel and engine oil Oil and fuel vapours can ignite on contact with ignition sources Therefore No naked flames during work on the engine Do not smoke Remove oil and fuel residues from the engine and floor CAUTION Dange...

Page 116: ...th thoroughly with water Avoid skin and eye contact Wear protective gloves made of plastic or rubber during the work Collect coolant drained from the engine in a container and dispose of in accordance with the environmental regulations Procedure for faults The basic rule is 1 Stop the engine immediately in the case of faults which represent an immediate danger for persons or property 2 Determine t...

Page 117: ...rmation caused by too hot fuel Let fuel cool down Operator Paraffin precipitation in the fuel for low external temperature approx 10 C Drain and flush fuel system replace fuel filter use winter fuel Skilled employee Failure of the fuel system turn engine by hand and pay attention to the typical chatter of the injection nozzle Defective injection nozzle Check injection nozzle replace if necessary S...

Page 118: ... gasket Replace cylinder head gasket Skilled employee Sticking piston rings Check piston rings replace if necessary and check piston ring grooves Skilled employee Piston and cylinder worn Overhaul engine change piston and cylinder Skilled employee Compression too low Starting load too high Reduce load Operator Engine oil too viscous Change engine oil use correct viscosity Operator Engine can only ...

Page 119: ...ion nozzle repair or replace Skilled employee Bad fuel supply Injection pump defective Check injection pump repair or replace Skilled employee Incorrect valve clearance Adjust valve clearance Skilled employee Worn valves Replace cylinder head Skilled employee Sticking piston rings Check piston rings replace if necessary and check piston ring grooves Skilled employee Bad compression Piston and cyli...

Page 120: ...tall seal or correct the number of seals check injection nozzle holder Skilled employee Defective injection nozzle Check injection nozzle replace if necessary Skilled employee Bad fuel supply Injection pump defective Check injection pump repair or replace Skilled employee Incorrect valve clearance Adjust valve clearance Skilled employee Incorrect end of delivery Adjust end of delivery Skilled empl...

Page 121: ...cooling water Check the cooling system for leaks Operator Temperature switch or temperature sensor defective Check temperature switch or temperature sensor replace if necessary Skilled employee Cylinder head gasket or cylinder head defective Check cylinder head gasket and cylinder head replace if necessary Skilled employee Overheating engine becomes too hot End of delivery of the injection pump in...

Page 122: ...ck fuel system for leaks Operator Speed governor jammed or defective Check speed governor replace if necessary Skilled employee Fuel filter blocked Replace fuel filter Operator Strong speed fluctuations Adjusting lever jammed or defective Check adjusting lever replace if necessary Skilled employee Empty tank Filling with fuel Operator Ventilation in the fuel filler cap blocked Replace fuel filler ...

Page 123: ...nt level Operator Coolant temperature switch defective Replace coolant temperature switch Skilled employee Coolant thermostat defective Check coolant thermostat replace if necessary Operator Coolant temperature warning lamp lights if present Impeller of the neoprene impeller pump defective Replace impeller of the neoprene impeller pump Operator Oil level too low Correct oil level Operator Oil pres...

Page 124: ...engine oil use correct viscosity Operator Paraffin precipitation in the fuel Drain and flush fuel system replace fuel filter use winter fuel Skilled employee Cold start problems Starting speed too low Check battery replace if necessary Operator 9 3 Startup after eliminating fault After rectifying the fault carry out the following steps for restarting 1 Ensure there are no persons in the danger zon...

Page 125: ...spare parts from the manufacturer Spare parts can be ordered from the nearest Greaves Farymann Diesel service partner Please refer to our website www farymann de or telephone us on 49 0 6206 507 0 for a list of our sales and service partners 10 2 Ordering spare parts Fig 132 Always state the following when ordering spare parts 1 MODEL e g 18W 430 see type plate 2 TYPE e g 0001 see type plate Spare...

Page 126: ...r filter element filter element for the version with oval flange 1 541 038 2 Fuel filter standard 1 541 069 2 Fuel filter with thread 1 890 74 18 Copper sealing ring A14x18x1 5 for fuel filter with thread 4 770 142 4 Valve cover gasket 1 890 08 15 Plastic seals 8 0x17x2 2 E734 032 8 Oil strainer complete 1 770 168 4 Gasket for oil strainer 1 890 74 04 Copper sealing ring A6x10x1 5 for the bolts on...

Page 127: ... number Description Quantity 555 003 2 Cooling water thermostat 50 C salt water 1 555 006 2 Cooling water thermostat 70 fresh water 1 890 07 03 Split pin for thermostat 1 770 108 4 Thermostat housing gasket 1 538 219 2 Neoprene impeller for cooling water pump with gasket 1 ...

Page 128: ...008 12 09 Special tools Order number Description 748 115 6 Fuel line disconnecting tool 748 173 2 for engines with D W crankcase Oil filter wrench dismantling the oil filter Special tools can be ordered from the nearest Greaves Farymann Diesel service partner ...

Page 129: ...nformation on to the proof of purchase and arrange confirmation There is a type plate on the engine with the following information 1 Model 2 Type number 3 Version of the speed governor 4 Serial number 5 Date of manufacture Description Please fill in 1 Model 2 Type number 3 TRIM 4 Serial number S N 5 Date of manufacture Date of purchase by Dealer stamp ...

Page 130: ...t not be exceeded by more than 10 or maximum 25 operating hours Engine equipment installation and handover Dealer stamp after 25 operating hours 1 month Dealer stamp after 250 operating hours 6 months Dealer stamp Hours Date Hours Date Hours Date after 500 operating hours 12 months Dealer stamp after 750 operating hours 18 months Dealer stamp after 1000 operating hours 24 months Dealer stamp Hours...

Page 131: ... stamp Hours Date Hours Date Hours Date after 2750 operating hours 66 months Dealer stamp after 3000 operating hours 72 months Dealer stamp after 3250 operating hours 78 months Dealer stamp Hours Date Hours Date Hours Date after 3500 operating hours 84 months Dealer stamp after 3750 operating hours 90 months Dealer stamp after 4000 operating hours 96 months Dealer stamp Hours Date Hours Date Hours...

Page 132: ...tamp Hours Date Hours Date Hours Date after 5000 operating hours 120 months Dealer stamp after 5250 operating hours 126 months Dealer stamp after 5500 operating hours 132 months Dealer stamp Hours Date Hours Date Hours Date after 5750 operating hours 138 months Dealer stamp after 6000 operating hours 144 months Dealer stamp after 6250 operating hours 150 months Dealer stamp Hours Date Hours Date H...

Page 133: ...stamp after 7500 operating hours 180 months Dealer stamp after 7750 operating hours 186 months Dealer stamp Hours Date Hours Date Hours Date after 8000 operating hours 192 months Dealer stamp after 8250 operating hours 198 months Dealer stamp after 8500 operating hours 204 months Dealer stamp Hours Date Hours Date Hours Date NOTE Further service histories can be ordered from the nearest Greaves Fa...

Page 134: ...f failure 35 Decommissioning 66 Dimensions 27 E Ear defenders 15 Electrical System 33 EMERGENCY STOP 53 Engine data 25 Engine oil changing 75 filling 47 Specification 29 Engine type code 24 Engine type plate 24 Environmental protection 21 Exhaust gases 51 F Faults 114 Fire 20 First aid 20 Fuel system 81 Fuels 21 H Hard hat 15 I Installation 42 Instruction 13 L Liability 9 Lubricants 21 M Maintenan...

Page 135: ...filter 81 Replacing oil filter 79 Risk of fire 18 S Safety general 11 Safety boots 15 Safety devices 20 Safety goggles 15 Service 10 Service history 129 Spare parts 125 Ordering 125 Standard configuration 23 Starting with electric starter 61 Storage 39 41 Surfaces hot 18 51 Switching off 64 Symbols in the operator s manual 8 T Technical data 22 Technical personnel 13 Temperatures 27 Transport 39 4...

Page 136: ...Diesel engine Series 15W 18W Notes 136 2008 12 09 Notes ...

Page 137: ...Diesel engine Series 15W 18W Notes 2008 12 09 137 Art 903 01 44 08 08 ...

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