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GENERAL INFORMATION, HANDLING

6

1.

General Information, Handling

All

FARYMANN DIESEL

engines are 4 stroke, direct injection diesel engines. They are

built as single cylinder engines in vertical and horizontal cylinder configuration. The direct
injection guarantees an outstanding level of efficiency, with low fuel consumption and ex-
cellent cold starting behaviour. Bosch fuel injection equipment is used on all engines. A
precision centrifugal governor ensures accurate speed (RPMs) and load regulation. For air
cooling, a noise-optimised, maintenance-free flywheel fan circulates the cooling air through
the cooling fins on the cylinder and the cylinder head.

1.1 Organisation and Use of this Repair Manual

The descriptions, data and illustrations refer to those assembly and adjustment procedures
where

FARYMANN

engines differ from ordinary diesel engines.

Well-known procedures (such as how to set the start of delivery) are not described in de-
tail.

−

It is assumed that all work on the engine will be carried out by competent staff who have

received training.

−

Special tools must be available, as described in the manual, together with good-quality

standard tools.

1.2 Service

−

If you have any further questions about the Repair Manual, we recommend you to

contact your nearest

FARYMANN

Service Centre.

−

Circular letters and training courses ensure that our service personnel have an answer

to every question. Please ask for a list of all our service locations from your own

FARYMANN

Service Centre.

1.3 After Sales - Service: FALKE - Spare Parts Program

"

Service, Quality and Progress

"

is our motto. This is why we have developed our very own computer-aided "FALKE"
Service System.

The FALKE System makes it possible for

FARYMANN

’s world-wide network of distributors

to

satisfy all spare parts and service requirements quickly and reliably, ensuring

that we maintain a close relationship with our customers.

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Содержание 37E

Страница 1: ......

Страница 2: ...2 ...

Страница 3: ...CYLINDERHEAD ASSY 43F ENGINE 25 5 5 INJECTION SYSTEM 26 5 6 OIL FILTER OIL FILTER COVER OIL PRESSURE RELIEF VALVE 28 5 7 CYLINDER HEAD 37E 43E 29 5 8 PISTON CYLINDER 30 5 8 1 PISTON CYLINDER ASSEMBLY 31 5 9 CONNECTING ROD 31 5 10 CAMSHAFT WITH AUTOMATIC DECOMPRESSION 32 5 11 LUBRICATING OIL PUMP 37E 43E 33 5 12 LUBRICATING OIL PUMP 43E CONVERSION KIT 34 5 13 LUBRICATING OIL PUMP 43F 35 5 14 REGULA...

Страница 4: ...EEL DYNAMO GOVERNOR 59 10 2 FLYWHEEL DYNAMO 12V GOVERNOR GRAPH 61 10 3 WIRING DIAGRAMS 62 11 TROUBLESHOOTING 68 11 1 ENGINE WILL NOT START 68 11 2 ENGINE STARTS BUT FIRES INTERMITTENTLY OR DIES 69 11 3 POOR ENGINE PERFORMANCE AND OR BLACK SMOKE 69 11 4 IMPERFECT OPERATING BEHAVIOUR 70 ...

Страница 5: ...al condition and when those involved are aware of the dangers and the safety precautions In particular malfunctions which could impair safety must be rectified immediately The engine must only be used as intended FARYMANN DIESEL GmbH is not responsible for damage resulting from incorrect use Such risk is borne solely by the user Correct use also includes following the operating instructions and ad...

Страница 6: ...el engines Well known procedures such as how to set the start of delivery are not described in de tail It is assumed that all work on the engine will be carried out by competent staff who have received training Special tools must be available as described in the manual together with good quality standard tools 1 2 Service If you have any further questions about the Repair Manual we recommend you t...

Страница 7: ...s to the order number SN and the date of construction This information must always be provided when making any enquiries or complaints etc As of July 1985 the consecutive engine number is also imprinted on the crankcase As of July 1982 the type designation a 12 digit code number is used in addition to the series number SN Order Number See manufacturer s nameplate e g 43E437 2373 D5 95 03 20 Date o...

Страница 8: ...s in the danger area When you have finished working on the engine always check that the safety devices have been refitted and that all tools have been removed from the engine Never carry out any work on safety valves e g modification of the spring tension Defective safety valves must be replaced with new ones When disposing of used fuels lubricants and filters follow the regulations which apply lo...

Страница 9: ...epair work has been finished Before starting any work on the electrical components the power supply to all live parts must be cut off Only carry out maintenance and repair work when the engine parts are in a stable position Liquids ejected under high pressure such as fuels or oils may penetrate the skin and cause severe injuries To carry out cleaning work on the engine always use a non combustible...

Страница 10: ...CFN ISO DIN 6271 7 5 kW 10 2 HP 8 7 kW 11 8 HP 9 9 kW 13 5 HP Max torque 31 Nm 37 Nm 40 6 Nm DIN 70020 at 2200 RPM at 2000 RPM at 2300 RPM Max speed 3000 RPM Mean piston speed 10 m s at 3000 RPM Compression ratio 1 19 Valve clearance exhaust valve 0 1 mm intake valve 0 1 mm Tank capacity 8 3 l 8 3 l 7 5 l Lubricating oil volume sump capacity 2 1 l Lubricating oil consumption 1 0 g kWh Starter rate...

Страница 11: ...Permissible cooling air temperature max C 50 Permissible fuel temperature max C 80 Permissible lub oil temperature max C 130 Consumptions at IFN Output Specific fuel con sumption g kWh 268 262 280 258 251 280 225 217 235 Fuel tank content l 8 3 7 5 Feed pump max lift mm 300 Fuel to DIN 51 601 ASTM D 975 77 2D BS 28669 1970 A1 A2 Specific lub oil con sumption g kWh 1 max lub oil capacity g l 1860 2...

Страница 12: ...ump start of delivery plunger with control edge below engines for generator and pump drive Engine RPMs min 1 1500 1800 3000 1500 1800 3000 Start of delivery BTDC mm Valve clearance cold inlet and outlet valve mm 0 1 Repair Data Dimen sion Inlet valve recedes by mm 0 0 1 0 0 1 2 5 2 6 Exhaust valve recedes by mm 0 0 1 0 0 1 2 5 2 6 Piston protrudes by mm 0 635 0 9 0 635 0 9 0 635 0 9 Gap measuremen...

Страница 13: ...termittent duty at variable speed and load IFN ISO DIN ISO 3046 Blocked useful performance for intermittent loads ICFN ISO DIN ISO 3046 Standard performance blocked continuous useful performance for con stant RPMs and constant load D Continuous operation contact factory for use beyond the limits indicated Decrease of approx 1 for every 100 m altitude and approx 2 for every 5 C above 20 C Rating ce...

Страница 14: ...n 43F Leistung Output Puissance Potencia The values shown are related to the optimal load setting at the correspond ing nominal engine speed Drehmoment Torque Couple Par Mmax 40 6 Nm at RPMs of 2300 min 1 Verbrauch Consumption Consommation Consumo ...

Страница 15: ...dth Nm mm 58 62 17 58 62 17 58 62 17 Nozzle holder torque wrench width Nm mm 20 23 13 20 23 13 20 23 13 Injection pump torque wrench width Nm mm 20 23 13 20 23 13 20 23 13 Delivery valve torque wrench width Nm mm 34 39 22 34 39 22 34 39 22 Flywheel torque wrench width Nm mm 390 410 46 390 410 46 390 410 46 Oil filter plate torque wrench width Nm mm 20 23 Inbus 20 23 Inbus 20 23 Inbus Maximum opera...

Страница 16: ...ial screw driver to adjust governor spring nuts 748 132 6 Crankshaft race puller use with part no 748 136 2 to pull off main bearing race from crankshaft 748 137 2 Crankshaft gear wheel puller use with part 748 136 2 to pull off crankshaft gear wheel 748 136 2 Puller plate use with parts 148 132 6 and 748 137 2 748 122 6 Flywheel puller to loosen flywheel 748 119 4 Bearing driver to press in crank...

Страница 17: ...h to remove the full flow oil filter 748 172 4 Bearing driver to press the little end bearing bush in and out connecting rod 748 129 4 Bearing driver to press the regulator shaft bearing bush in and out 37E 43E 748 125 4 43F 748 211 4 Guide punch to press the valve guides in and out 748 097 6 Drop tube to measure the injec tion timing 748 192 4 Slotted screw driver to set the adjustment 748 126 2 ...

Страница 18: ...SPECIAL TOOLS 18 748 131 5 Valve spring lifter to remove and fit the valve springs ...

Страница 19: ...which is driven by the crankshaft The fuel injection pump self venting fuel system is driven directly while the valves are driven by push rods and rockers An electric starter and a manual starting de vice are provided to start the engine The engines are equipped with a fully automatic de compression system and a fully automatic starting enrichment quantity Models 37E 43E are available with a dry t...

Страница 20: ... Diesel engine models 37E 43E 43F are suitable for the following applications construction machinery power generating sets agricultural machinery water pumps compressors fork lift drives etc Special applications Auxiliary Power Units Military ...

Страница 21: ...g area free from dirt and swarf will make the work considerably easier Clean the engine thoroughly before dis mantling it Attention must be paid to all the informa tion and warning notices which have been affixed Particular care is called for in the vicinity of rotating moving or hot parts ATTENTION This symbol is used whenever failure to comply precisely with instructions or proce dures may cause...

Страница 22: ...2 Cover with preliminary filter 3 Strainer 4 Fitting hex nut 5 Centering ring Airfilter Assy Anbau 43F 1 Filter base 2 Cover 3 Strainer 4 Fastening strainer cover Intake elbow 37E 43E engines Attention The socket head cap screw M 8x25 1 must be fitted using Loctite 415 adhe sive C Generally renew the seal 2 3 847 192 4 ...

Страница 23: ...GINE 23 5 3 Valve Cover with Oil Return Line 37E 43E engines Drain the engine oil Before dismantling seal the oil return line 1 using clamp 748 115 6 The PVC sealing washer 2 can be used several times Generally renew the valve cover seal 3 ...

Страница 24: ...ways fit tapered rod ends on the tappet side Longer push rod exhaust valve position relative to engine mounting side The push rod sheath 2 can be removed from the partly dismantled engine after the tappet guide 3 has been removed Exchange the O ring seals if necessary Fit the tappet guide using Loctite 573 A sealing agent for the socket head cap screw Generally renew the tappet guide surface seal ...

Страница 25: ... ENGINE 25 5 4 2 Cylinderhead assy 43F engine 1 Cylinderhead 2 Intake valve 3 Exhaust valve 4 Valve guide exhaust 5 Valve spring exhaust 6 Rocker arm exhaust 7 Valve guide intake 8 Valve spring intake 9 Rocker arm intake 10 Rocker shaft ...

Страница 26: ...ON Pressure Line When loosening the pressure line use wrench SW22 to hold the delivery valve ATTENTION Injection nozzle Always remove the nozzle seal from the cylinder head seat and renew it Attention Assembly position for the nozzle overflow oil line towards the valve cover ...

Страница 27: ...e full load position Rotate the flywheel until the pump roller tappet is in the BDC position Move the pin on the injection pump regulating lug into the full quantity position Put on the requisite pump shims When doing this always place the paper seal on the crankcase surface Always exchange dam aged seals Introduce the injection pump without any mechanical resistance The pin on the regulating lug ...

Страница 28: ... with Loctite 573 A sealing agent and tighten them alternately and equally List of Torques Wet the packing rubber of the oil filter with oil and hand tighten without using a tool Oil pressure relief valve The oil pressure relief valve 4 is calibrated by the manufacturer and therefore it can only be changed completely no repair is possible Control of operation The spring loaded sleeve must be easy ...

Страница 29: ...ylinder head seal Use grease to fix the cylinder head seal in the head slot ATTENTION Check the valves for wear and tear on the valve guides the condition of the stem seals leakproofness and deposits When tightening the securing nuts lift the cylinder head slightly and align it radially Table of Torques ...

Страница 30: ...d See the Table for wear measurements on the individual components If the limit values are exceeded exchange the components Oversized pistons cylinders are not available Piston Cylinder Assy 37E 43E Piston Cylinder Assy 43F Index arrow points to flywheel side Combustion chambers out of center Attention Don t mix up 43E 43F pistons Valves will hit the piston head ...

Страница 31: ...E 43E pistons always have valve pockets The 43F does not have any Oil the piston push it into the cylinder and assemble the complete unit Always position the joints with a 120 off set 5 9 Connecting Rod If the wear measurements are exceeded exchange the bearing shells and or con rod bearing When assembling the identification numbers on the con rod and the bearing cover must be together It is absol...

Страница 32: ...lywheel on the TDC mark crankcase flywheel When the flanged bearing is pushed in the camshaft gearwheel mark be posi tioned true to the mark on the crankshaft gearwheel The long securing screws on the flanged bearing are fitted using Loctite 573 A sealing agent Do not use any shims etc Attention The top right hand securing screw 2 is shorter Do not use any sealing agent here but use a copper washe...

Страница 33: ...elf 5 Insert the lubricating oil pump into the pump chamber and secure the pump cover 4 with socket head cap screws 5 when doing this only tighten the socket head cap screws 5 slightly it must be possible to turn the toothed driv ing wheel 6 without resistance 6 Tighten the socket head cap screws 5 equally with torque 10 Nm it must still be possible to turn the toothed driving wheel 6 without resi...

Страница 34: ...l pump 1 Lubricate the pump chamber in the crankcase and the lubricating oil pump itself 2 Apply SILOMAT liquid sealing agent on pump cover 5 in the area of the sealing surface 3 Insert the lubrication oil pump into the pump chamber and secure the pump cover 5 with the support bracket 3 using socket head cap screws 6 Only tighten the socket head cap screws 6 slightly 4 Completely crank the engine ...

Страница 35: ...ete oil pump 2 The pump is supplied pre assembled 3 Fit the complete oil pump into the control casing The protruding part of the oil pump shaft is received by the index bore If the assembly is correct the oil pump will 7 lie against the rear wall of the control housing without a gap Ensure that the joint surfaces are clean 4 Position screws M6 x 25 1 with spring lock washers 2 and tighten to 10 Nm...

Страница 36: ... of the setscrew 5 Remove the locking nut 6 and screw the setscrew in until the flange bolt 3 on the automatic starting enrichment lever 12 automatic increased starting quantity ASM disengages from the segment 4 Screw the setscrew back until it protrudes about 5 mm in relation to the surface of the crankcase Unhook the spring on the ASM lever 12 and remove the setscrew 11 Loosen the threaded bushi...

Страница 37: ...ition Push the set of levers 12 13 on to the eccentric shaft The return spring must fit into the eccentric shaft slot without resistance At the same time as this operation turn the acceleration lever in the direction of full load Rotate the eccentric shaft while pulling it out of the bearing bush and press the trans verse lever 2 in the direction of the crankcase wall until the pin engages in the ...

Страница 38: ...MEASUREMENT TABLES WEARING PARTS 38 6 Measurement Tables Wearing Parts ...

Страница 39: ...MEASUREMENT TABLES WEARING PARTS 39 ...

Страница 40: ...MEASUREMENT TABLES WEARING PARTS 40 ...

Страница 41: ...MEASUREMENT TABLES WEARING PARTS 41 Comparison of 43E 43F Camshafts ...

Страница 42: ...MEASUREMENT TABLES WEARING PARTS 42 ...

Страница 43: ...MEASUREMENT TABLES WEARING PARTS 43 ...

Страница 44: ...MEASUREMENT TABLES WEARING PARTS 44 ...

Страница 45: ...MEASUREMENT TABLES WEARING PARTS 45 ...

Страница 46: ...MEASUREMENT TABLES WEARING PARTS 46 ...

Страница 47: ...MEASUREMENT TABLES WEARING PARTS 47 ...

Страница 48: ...MEASUREMENT TABLES WEARING PARTS 48 ...

Страница 49: ...MEASUREMENT TABLES WEARING PARTS 49 ...

Страница 50: ...MEASUREMENT TABLES WEARING PARTS 50 ...

Страница 51: ...or 1 2 3 4 5 6 7 8 9 Governor body Governor spring middle speed range in the case of a variable speed governor Spacer instead of item 2 for end gover nor Governor pin Spring bridge Guide bush Governor spring full load rev min Governor spring idling rev min Cross slotted nut ...

Страница 52: ...48 132 6 Attention Lubrication oil pump has to be taken off before dismantling the bearing plate Assembly The inside bearing washer and the crankshaft gear wheel are mounted hot 4 5 The inside bearing washer and the cylindrical roller bearing are always paired Gently hammer the bearing cover 2 to achieve a snug fit in the seat PVC hammer and then use the securing nuts 7 to tighten on alternate sid...

Страница 53: ...t the end of the compression stroke with both valves closed Remove the valve cover Rotate the flywheel until the mark is vertical and right hand Adjust the valves and refit the valve cover CAUTION To prevent unintentional starting the high pressure line must always be de tached at the fuel injection pump Fuel which leaks at high pressure at the threaded joint may cause severe injuries ATTENTION To...

Страница 54: ...een the valve and rocker without great force Inlet valve Turn crankshaft half a revolution from the top dead centre mark in the direction of rotation On engines with a closed flywheel housing you can t see the timing marks O T T D C Take off rocker cover turn engine till pis ton is in O T T D C position Mark the position on the crank handle support bearing Turn engine with starting handle rota tio...

Страница 55: ...om the lever 1 Carefully unhook the spring 4 from the lever 1 Spread the governor weights 7 to the maximum extent using a screw driver Use the tool 17 Illustration 2 to turn the threaded bush 5 until the flanged bolt 6 fits on the governor pin 8 with no play Remove the screw driver and close the threaded bush 5 by a further half revo lution Carefully hook the spring 4 to the lever 1 ...

Страница 56: ...uaranteed Function Test Start the engine from the full load position If the ESM has been set correctly the starting smoke period will last about 2 3 seconds This is followed by smoke free run up to normal operation 8 3 End Stop 8 3 1 End Stop Adjustment Move the acceleration lever 1 to the Stop position Loosen the outer end stop eccentric 2 in advance Screw in the stop screw 5 on the ec centric sh...

Страница 57: ...2000 2500 2800 3000 3300 3600 738 265 4 738 293 4 310 21 24 26 32 35 37 738 307 4 37E 738 266 4 350 24 27 29 36 40 42 738 294 4 738 268 4 375 26 29 32 39 42 45 738 295 4 738 265 4 738 293 4 310 24 27 29 35 38 40 738 307 4 43E 738 266 4 350 27 31 33 37 43 45 738 294 4 738 268 4 375 29 33 35 42 46 48 738 295 4 738 265 4 738 293 4 310 341 361 391 738 307 4 43F 738 266 4 350 381 411 441 738 294 4 1 1 ...

Страница 58: ...essure valve bracket 14 34 39 14 34 39 Fuel pressure pipe union nut injec tion pump 17 18 22 17 18 22 Fuel pressure pipe union nut nozzle holder 17 25 30 17 25 30 Nuts for nozzle holder fixture 13 20 23 10 10 12 Governor 14 55 60 14 55 60 Flywheel nut 46 390 410 46 390 410 Flanged bearing screws 6 20 23 6 20 23 Tappet guide screws 6 20 23 6 20 23 Foot bearing screws 6 20 23 6 20 23 Lubricating oil...

Страница 59: ...rol Terminal 15 ignition lock Connection to earth is made via the assembly surface Function Tests a Alternating voltage at the coil output Disconnect the connecting plug 4 The voltage proportional to speed is measured on the two phases 2x black Set values Graph A Idling Voltage without Governor Cut Out b Coils single phase to earth c Charging current governor output Connect a suitable ammeter Imax...

Страница 60: ...m Governor is destroyed in a short time Battery is disconnected while the engine is running load shedding Governor is destroyed in a short time Charging with start aid cable when bat tery is defective or discharged to mini mum Load shedding when the start aid cable is removed Governor is destroyed in a short time Welding work on the equipment loosen all plug connections and battery cables beforeha...

Страница 61: ...lywheel Dynamo 12V Governor Graph Idling Voltage without Governor Graph A 10 15 20 25 30 35 U V 500 1000 1500 2000 2500 3000 3500 n 1 min Charging Current Graph B 0 4 8 12 16 20 I A 500 1000 1500 2000 2500 3000 3500 4000 n 1 min ...

Страница 62: ...ELECTRICAL SYSTEM 62 10 3 Wiring Diagrams ...

Страница 63: ...ELECTRICAL SYSTEM 63 ...

Страница 64: ...ELECTRICAL SYSTEM 64 ...

Страница 65: ...ELECTRICAL SYSTEM 65 ...

Страница 66: ...ELECTRICAL SYSTEM 66 ...

Страница 67: ...ELECTRICAL SYSTEM 67 ...

Страница 68: ...jector pump Gasoline instead of diesel in tank Air intake blocked Fill with fuel no venting needed Set lever to full load Renew cap Check lines Renew filter Renew pipe tighten connections Cool the fuel Drain and flush system renew fuel filter Use winter fuel Check repair renew nozzle Check repair renew pump Drain gasoline flush and fill with diesel Check intake system Change filter insert Poor com...

Страница 69: ... intake Restricted blocked exhaust Check clean exchange intake system Check clean exchange exhaust system 11 3 Poor engine performance and or black smoke Operating conditions Engine overloaded Power reduction due to altitude and or increased intake tempera ture has been ignored Reduce load Fault search on equipment Better operating conditions Poor fuel supply Gasket under injector nozzle missing o...

Страница 70: ...k engine installation Drain to proper level Check repair renew nozzle Knocking Noises Oil carbon deposits on piston Injector needle sticking Advanced ignition Broken piston rings Worn piston and cylinder Worn bearings Loose flywheel Gasoline mixture in tank Decoke Fit new nozzle Check adjust end of delivery Fit new rings Overhaul engine Overhaul engine Tighten flywheel nut Change fuel Major fluctu...

Страница 71: ...end of delivery Renew nozzle Oil pressure warning light on Oil pressure warning lamp is de fective Oil level is too low Defective oil pressure switch Exchange warning lamp Measure oil level if necessary top up oil Exchange Oil pressure is too low Overpressure valve is defective Dirty ball seat in overpressure valve Oil filter is clogged Lubricating oil pump is faulty Check clean exchange if neces ...

Страница 72: ...NOTES 72 ...

Страница 73: ...NOTES 73 ...

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