Farymann Diesel 37E Repair Manual
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Farymann Diesel 37E Repair Manual

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  • Page 3: Table Of Contents

    ANIFOLD ONLY 5.3 V ....................23 ALVE OVER WITH ETURN 5.4 R ....................24 OCKER ECHANISM ALVE ONTROL 5.4.1 37E / 43E - A ........................24 5.4.2 43F – ..................25 YLINDERHEAD ASSY ENGINE 5.5 I ..........................26 NJECTION SYSTEM 5.6 O ............28 ILTER ILTER...
  • Page 4 TIGHTENING TORQUES FOR SCREWED CONNECTIONS ELECTRICAL SYSTEM 10.1 ....................59 LYWHEEL YNAMO OVERNOR 10.2 12V / G ................61 LYWHEEL YNAMO OVERNOR RAPH 10.3 .........................62 IRING IAGRAMS TROUBLESHOOTING 11.1 ........................68 NGINE WILL NOT START 11.2 ..............69 NGINE STARTS BUT FIRES INTERMITTENTLY OR DIES 11.3 ..............69 OOR ENGINE PERFORMANCE AND...
  • Page 5 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.

  • Page 6: General Information, Handling

    GENERAL INFORMATION, HANDLING 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.

  • Page 7: Engine , Model Andt

    GENERAL INFORMATION, HANDLING Engine, Model and Type Designation Every engine can be unmistakably identified using the manufacturer’s nameplate. As well as the clearly defined 12-digit code number, this refers to the order number (SN) and the date of construction. This information must always be provided when making any enquiries or complaints, etc.

  • Page 8: Safety Instructions

    SAFETY INSTRUCTIONSATA Safety Instructions Only use transport devices specified by the manufacturer, and only follow hoisting instructions specified by the manufacturer. When handling fuels, lubricants and other chemical substances, follow the safety regulations which apply to the product. Do not smoke when handling inflammable fuels or lubricants. Vapours from lubricating oil or fuel may catch fire if they come into contact with sources of ignition.
  • Page 9 SAFETY INSTRUCTIONS Safety Instructions Only operate IC engines in enclosed areas if there is adequate ventilation. Before you start the engine in an enclosed environment, make sure that there is sufficient ventilation. Ensure that the engine only slows down to full stop after 10 - 20 seconds! If there are any safety devices on the engine, or on the machine into which the engine is built, they must be refitted when the maintenance and repair work has been finished.

  • Page 10: Technical Data

    TECHNICAL DATA Technical Data 37E / 43E-Engine 43F-Engine Engine Type Design horizontal Number of Cylinders Bore 95 mm Ø Stroke 100 mm Cubic capacity (piston displacement) 708 cm 3 Direction of rotation (looking at power take- anti clockwise off side) Max.

  • Page 11: Construction Data

    TECHNICAL DATA Construction Data, Consumptions and Pressures Technical Data Table 1 Engine Type Construction data dimen- sion System four stroke Combustion Proce- direct injection dure Cooling System air-cooled Design / Configuration 1-cylinder / horizontal Bore (mm) Stroke (mm) Displacement Compression Ratio 1 : 18,7 - 1 : 20,5 1 : 17.5 - 1 : 19,1 1 : 19 - 1 : 19,5...

  • Page 12: Technical Data

    TECHNICAL DATA Construction Data, Consumptions and Pressures Technical Data Table 2 Engine Type Adjustment Data Valves Inlet opens BTDC 38°-42° = 103 - 114 mm 38°-42° = 103 - 114 mm 40°-55° = 108 - 149 mm Exhaust closes 50°-55° = 135 - 148 mm 50°-55°...

  • Page 13: Output , Torque , C

    TECHNICAL DATA Output, Torque, Consumption Leistung / Output / Leistung / Output / Puissance / Potencia Puissance / Potencia Drehmoment / Torque / Drehmoment / Torque / Couple / Par Couple / Par Verbrauch / Consumption / Verbrauch / Consumption / Consommation / Consumo Consommation / Consumo DIN ratings...
  • Page 14 TECHNICAL DATA Output, Torque, Consumption 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 = 40,6 Nm at RPMs of 2300 min Verbrauch / Consumption / Consommation / Consumo...

  • Page 15: Screws - Tightening

    TECHNICAL DATA Screws - Tightening Torques, Sealing and Adhesive Materials Technical data Table 1 Engine type Tightening torques Cylinder head (Nm) 52 - 56 / 17 52 - 56 / 17 52 - 56 / 17 torque / wrench width (mm) Rocker bracket (Nm)

  • Page 16: Tools

    SPECIAL TOOLS Tools Part No. Description 748.115.6 Fuel line clamp to clamp fuel supply lines 748.154.2 Hexagonal socket for flywheel nuts wrench, 46 mm 748.128.4 Drive wrench for use with socket wrench, 748.154.2 748.108.5 Special screw to adjust governor driver spring nuts 748.132.6 Crankshaft race...

  • Page 17: Special Tools

    (connecting rod) 748.129.4 Bearing driver to press the regulator shaft bearing bush in and out 37E/43E: Guide punch to press the valve 748.125.4 guides in and out 43F: 748.211.4 748.097.6...
  • Page 18 SPECIAL TOOLS 748.131.5 Valve spring lifter to remove and fit the valve springs...

  • Page 19: Technical Description

    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 type air filter or an oilbath air filter.

  • Page 20: Applications

    TECHNICAL DESCRIPTION Applications 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...

  • Page 21: Dismantling And Assembly Procedures On The Basic Engine

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE Dismantling and Assembly Procedures on the Basic Engine Basic Requirements − The aim of this Repair Manual is to pro- vide help with carrying out repairs to the engine. The requirements for this are as follows: −...

  • Page 22: Intake Manifold

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE Intake Manifold (on 37E / 43E only) Airfilter-Assy 37E / 43E Airfilter-Assy-Anbau 43F 1. Filter-base 1. Filter base 2. Cover 2. Cover with preliminary filter 3. Strainer 3. Strainer 4. Fastening strainer-cover 4. Fitting hex-nut 5.

  • Page 23: Oil Return Line

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE 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.

  • Page 24: Rocker Mechanism

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE Rocker Mechanism, Valve Control 5.4.1 37E / 43E - Assy − Completely dismantle the rocker bracket. − 43F see page 43 no. 3.12.1 − When assembling, it is absolutely essen- tial to insert the steel shim (1).

  • Page 25: F – Engine

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE 5.4.2 Cylinderhead assy 43F – engine 1. Cylinderhead 6. Rocker arm, exhaust 2. Intake valve 7. Valve guide, intake 3. Exhaust valve 8. Valve spring, intake 4. Valve guide, exhaust 9. Rocker arm, intake 5.

  • Page 26: Injection System

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE Injection system ATTENTION 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...
  • Page 27 DISMANTLING / REASSEMBLY OF THE BASIC ENGINE Injection System ATTENTION Injection Pump: − Defined seals are always used when fitting the injection pump. − The total thickness of the pump shims is imprinted on the surface of the crankcase, next to the injection pump. −...

  • Page 28: F Ilter C Over , O Il Pressure Relief Valve

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE Oil Filter, Oil Filter Cover, Oil pressure relief valve ATTENTION Assembly: − Generally renew the seal (1) and the O- ring seal (2). − Before fitting the cover, secure the O-ring seal by greasing it so that it sticks. −...
  • Page 29 DISMANTLING / REASSEMBLY OF THE BASIC ENGINE Cylinder Head 37E / 43E Assembly: − Generally use a new cylinder 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 −...

  • Page 30: Piston, Cylinder

    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.

  • Page 31: Connecting Rod

    There is a marking on the side of the piston which points towards the side of the flywheel. Original 37E / 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.

  • Page 32: Camshaft Witha

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE 5.10 Camshaft with Automatic Decompression − The unit comprising the camshaft and the flanged bearing can only be exchanged complete. − It is not possible to carry out repairs on the decompression unit. Assembly: −...
  • Page 33 DISMANTLING / REASSEMBLY OF THE BASIC ENGINE 5.11 Lubricating oil pump 37E / 43E WWhen exchanging the lubricating oil pump, no. E724.036.8 or no. 724.040.8, the as- sembly must be carried out as follows: 1. Dismantle the intermediate gear wheel (3).

  • Page 34: Lubricating Oil Pump

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE 5.12 Lubricating oil pump 43E, conversion kit The teeth of gearwheels (1) and (2) may experience premature wear if the engines are used under difficult operating conditions. For this reason, the gearwheel (1) mounted on one side with support bracket (3) has been additionally supported by a pin (4).

  • Page 35: Oil Pump 43F

    5.13 Lubricating Oil Pump 43F For dates of construction from 6/1996 onwards, this pump is also used for 37E and 43E engines. When exchanging lubricating oil pump no. E724.038.8, the assembly must be carried out as follows: 1. Unscrew four screws, M6 x 25 (1+2) and take out the complete oil pump.

  • Page 36: M Echanism

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE 5.14 Regulation Mechanism Preliminary Work: − Dismantle the injection pump. − Dismantle the flanged bearing with the camshaft. − On the injection pump flange, unscrew the rear stay bolt (1) until the transverse lever (2) is released.

  • Page 37: M Echanism

    DISMANTLING / REASSEMBLY OF THE BASIC ENGINE 5.15 Regulation Mechanism Assembly: ATTENTION: Insert the governor needle, and secure it with grease. Pre-assemble the eccentric shaft (9) with the requisite parts. ATTENTION: For stationary regulation, the torsion spring can be clamped to the rest plate in order to make assembly easier.

  • Page 38: Measurement Table - Wearing Parts

    MEASUREMENT TABLES, WEARING PARTS Measurement Tables - Wearing Parts...
  • Page 39 MEASUREMENT TABLES, WEARING PARTS...
  • Page 40 MEASUREMENT TABLES, WEARING PARTS...
  • Page 41 MEASUREMENT TABLES, WEARING PARTS Comparison of 43E / 43F - Camshafts...
  • Page 42 MEASUREMENT TABLES, WEARING PARTS...
  • Page 43 MEASUREMENT TABLES, WEARING PARTS...
  • Page 44 MEASUREMENT TABLES, WEARING PARTS...
  • Page 45 MEASUREMENT TABLES, WEARING PARTS...
  • Page 46 MEASUREMENT TABLES, WEARING PARTS...
  • Page 47 MEASUREMENT TABLES, WEARING PARTS...
  • Page 48 MEASUREMENT TABLES, WEARING PARTS...
  • Page 49 MEASUREMENT TABLES, WEARING PARTS...
  • Page 50 MEASUREMENT TABLES, WEARING PARTS...

  • Page 51: Special Components

    SPECIAL COMPONENTS Special Components 7.1.1 Centrifugal Speed Governor 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...
  • Page 52 SPECIAL COMPONENTS Crankshaft, Flywheel − If the flywheel is removed from the complete engine, the acceleration lever must previously be set to ‘full load’. Dismantling: ATTENTION − Use the drive wrench (special tool 748.128.4 and 748.154.2) to loosen the flywheel nut. Do not screw off.

  • Page 53: Adjustments, Settings

    ADJUSTMENTS, SETTINGS Adjustments, Settings Valve Setting The valve clearance for both valves is 0.1 mm (cold). The valve clearance must be checked for the first time after 20 operating hours and thereafter every 300 operating hours and, if necessary, is to be adjusted as follows: The clearance is to be set with the engine cold, at the end of the compression stroke with both valves closed.
  • Page 54 ADJUSTMENTS, SETTINGS 8.1.1 Valve setting procedure Exhaust valve: − Turn crankshaft slowly with the starting handle until the end of the compression stroke. In this position the exhaust valve is closed (max. clearance between rocker and valve) and the top dead centre mark of the flywheel points to the mark on the crankcase.

  • Page 55: Speed Adjustment / A

    ADJUSTMENTS, SETTINGS Speed Adjustment / Automatic increased Start Quantity 8.2.1 Lever System Setting − Set the acceleration lever to the “Full Load" position. − Remove the setscrew (3) from the lever (1). − Carefully unhook the spring (4) from the lever (1).

  • Page 56: End Stopa

    ADJUSTMENTS, SETTINGS 8.2.2 Automatic Enriched Starting Mixture (ESM) Setting − Set the acceleration lever to the "Full Load" position. − Screw the setscrew (3) into the lever (1) until contact is made with the flanged bolt (6). − Secure the flanged bolt with the nut (9). (See Illustration 4.1.1) Attention: −...
  • Page 57 ADJUSTMENTS, SETTINGS Injection pump - Setting Values - End of Delivery Flywheel End of delivery (mm) before TDC - Tolerance + - 2mm Engine type Part Num- Dia- at engine speed (min meter 1500 1800 2000 2500 2800 3000 3300 3600 738.265.4 738.293.4 738.307.4...

  • Page 58: Injection Pump

    ADJUSTMENTS, SETTINGS Tightening Torques for Screwed Connections 37E/43E Wrench Tightening Wrench Tightening width Torque width Torque (Nm) (Nm) (mm) (mm) Rocker bracket Cylinder head nuts Connecting rod nuts Valve cover nuts Valve cover bolts Bearing cover nuts Injection pump nuts...

  • Page 59: Electrical System

    ELECTRICAL SYSTEM Electrical System 10.1 Flywheel - Dynamo / Governor Operation: The permanent magnets in the magnet holder (1) on the fly- wheel side induce an alternating voltage in the coils of the stator (2): this voltage is proportional to speed (RPMs). The alternat- ing voltage is rectified in the governor (3) and continuously regulated to approximately 14.2...
  • Page 60 ELECTRICAL SYSTEM Operating Conditions: − Permissible operating temperatures: -20 to 70°C (measured on the governor surface) − An intact earth connection must exist between the governor and the engine, and also between the governor and directly attached external construction (no painted or enam- elled assembly surfaces).
  • Page 61 ELECTRICAL SYSTEM 10.2 Flywheel - Dynamo 12V / Governor / Graph Idling Voltage without Governor Graph A U~ [V] 1000 1500 2000 2500 3000 3500 n [1/min] Charging Current Graph B I [A] 1000 1500 2000 2500 3000 3500 4000 n [1/min]...
  • Page 62 ELECTRICAL SYSTEM 10.3 Wiring Diagrams...
  • Page 63 ELECTRICAL SYSTEM...
  • Page 64 ELECTRICAL SYSTEM...
  • Page 65 ELECTRICAL SYSTEM...
  • Page 66 ELECTRICAL SYSTEM...
  • Page 67 ELECTRICAL SYSTEM...

  • Page 68: Troubleshooting

    TROUBLESHOOTING Troubleshooting This section aims to suggest possible causes and remedies for faults. Please note that this list can never be complete. Whenever there is a fault, the guiding principle should be: “Think Before You Act”. 11.1 Engine will not start Reason Causes Remedy...
  • Page 69 TROUBLESHOOTING 11.2 Engine starts but fires intermittently or dies Poor fuel supply Fuel filter choked. Renew filter. Fuel line blocked. Check lines. Leaking fuel lines. Check lines / tighten connections. Water in fuel. Drain fuel, fill with clean diesel. Faulty injector nozzle. Check / repair / renew nozzle.
  • Page 70 TROUBLESHOOTING 11.3 Poor engine performance and/or black smoke Dirty engine Dirty air filter. Clean / renew filter. Excessive oil carbon deposits on Decoke components / change vent piston and cylinder head. valve. General Engine Condition Worn piston rings. Renew rings / check air filter. Worn piston and cylinder.
  • Page 71 TROUBLESHOOTING 11.4 Imperfect Operating Behaviour Fuel pipe broken. Renew pipe. Engine stops suddenly Seized piston. Renew piston and cylinder. Seized crankshaft bearing. Repair / renew crankshaft and bearings. Blue smoke from engine Oil level in oil bath air filter too Fill to proper level.
  • Page 72 NOTES...
  • Page 73 NOTES...

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