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Table of Contents
Related Manuals for Farymann Diesel 15W
Summary of Contents for Farymann Diesel 15W
- Page 1 DIESEL ENGINES : 15 / 18 / 32W - 1 -...
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Page 2: Table Of Contents
TABLE OF CONTENTS GENERAL INFORMATION, HANDLING 1.3 O ................5 RGANISATION AND SE OF THIS EPAIR ANUAL 1.4 S ..............................5 ERVICE 1.5 A : FALKE - S ..............5 FTER ALES ERVICE PARE ARTS ROGRAM 1.6 E ...................6 NGINE ODEL AND ESIGNATION 1.7 S ..........................7 AFETY... - Page 3 TABLE OF CONTENTS 8.2 E ................76 NGINE STARTS BUT FIRES INTERMITTENTLY OR DIES 8.3 P ...............76 OOR ENGINE PERFORMANCE AND OR BLACK SMOKE 8.4 P ................77 OOR ENGINE PERFORMANCE AND OR BLACK SMOKE 8.5 I ....................77 MPERFECT OPERATING BEHAVIOUR - 3 -...
- Page 4 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.
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Page 5: General Information, Handling
GENERAL INFORMATION General Information, Handling FARYMANN DIESEL engines type 15/18/32W are 4 stroke, direct injection diesel engines. They are built as single cylinder engines vertical cylinder configuration. The direct injection guarantees an outstanding level of efficiency, with low fuel consumption and excellent cold starting behaviour. -
Page 6: Engine, Model And Type Designation
GENERAL INFORMATION 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 7: Safety Instructions
GENERAL INFORMATION 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 8 GENERAL INFORMATION 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.
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Page 9: Technical Data
TECHNICAL DATA Technical Data Engine Type Design verticall Number of Cylinders Bore 75 mm 82 mm 95 mm Stroke 55 mm 55 mm 74 mm Cubic capacity (piston displacement) 242 cm3 290 cm3 524 cm3 Direction of rotation (looking at power take- anti clockwise off side) Max. -
Page 10: Construction Data , Consumptions And Pressures
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 Water-cooled Design / Configuration 1-cylinder / vertical Bore (mm) Stroke (mm) Displacement Compression Ratio 1 : 20,0 1 : 19.1 - 1 : 22,6 1 : 20,0... -
Page 11: Construction Data , Consumptions And Pressures
TECHNICAL DATA Construction Data, Consumptions and Pressures Technical Data Table 2 Engine Type Adjustment Data Valves, Inlet / Outlet (mm) 0,2 all Inlet opens BTDC 5,3°- 7,5° = 12 - 17 mm 5,3°- 7,5° = 12 - 17 mm 5,2°- 7,5° = 14 - 20 mm Exhaust closes 4,4°- 6,7°... -
Page 12: Output, Torque, Consumption
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 13: C Onsumption
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 - 13 -... - Page 14 TECHNICAL DATA Verbrauch / Consumption / Consommation / Consumo - 14 -...
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Page 15: Screws - Tightening Torques, Sealing And Adhesive Materials
TECHNICAL DATA Screws - Tightening Torques, Sealing and Adhesive Materials Technical data Table 1 Engine type Tightening torques Cylinder head (Nm) 30- 33 / 13 30 - 33 / 13 52 - 56 / 17 torque / wrench width (mm) Rocker bracket (Nm) torque / wrench width... -
Page 16: Tools
TECHNICAL DATA Tools Part No. Description 748.115.6 Fuel line clamp to clamp fuel supply lines 748.130.2 Hexagonal socket for flywheel nuts wrench, 36 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 TECHNICAL DATA Tools 748.120.4 Bearing driver to press the crankshaft bearing bushes in and 748.121.4 Bearing driver to press the camshaft in and out 748.124.4 Bearing driver to press out the crank- shaft roller bearing 748.173.2 Oil filter wrench to remove the full flow oil filter 748.172.4 Bearing driver...
- Page 18 TECHNICAL DATA Tools 748.126.2 Oil pressure gauge to measure the oil pressure 748.131.5 Valve spring lifter to remove and fit the valve springs - 18 -...
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Page 19: Technical Description
Special modified water-cooled Farymann engines fulfill BSO I/II and EPA – requirements. Applications Diesel engine models 15W / 18W / 32W are suitable for the following applications: − Marine generating sets − Marine propulsion engines −... -
Page 20: Dismantling And Assembly Procedures On The Basic Engine
RE-ASSEMBLING PROCEDURES 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: − Trained specialist staff (of at least the minimum legal age);... -
Page 21: Dismantling Procedures
RE-ASSEMBLING PROCEDURES DISMANTLING PROCEDURES 1. Drain lubrication oil : Place suitable container under the drain hole. Remove 2 screws and cupper washers, remove oilscreen Caution Clean oilscreen carefully. dam- Replace if any deformations or other ages. 2. Air cleaner Engines installed in Generating Sets Aircleaner-assy done from equipment manufac- torer. - Page 22 RE-ASSEMBLING PROCEDURES 4. Fuel lines, fuel filter Remove banjo bolts, copper washers from injec- tion pump and injector. If existing – remove fuel filter bracket, setscrews and spring washers. Close ports of injection pump and injector with banjo bolts to prevent dirt. Caution Use only original fuel filter and fuel persistened fuel lines for replacement.
- Page 23 RE-ASSEMBLING PROCEDURES 5. High pressure fuel line : Loosen the high pressure fuel line by holding a 14 mm wrench on the delivery valve while un- screwing the fuel line fitting Loosen the high pressure line at the injector in the same way.
- Page 24 RE-ASSEMBLING PROCEDURES 7. Cylinder head : Remove the valve cover by removing the lock nuts and the plastic washers. If necessary tap the cover lightly with a soft faced hammer. Dis- card plastic washers and valve cover gasket. Remove the 2 locknuts and washers (1) holding the protection tube retaining spring.
- Page 25 RE-ASSEMBLING PROCEDURES 8. Decompression release Remove 2 screws and pull the decompression Release out of the gearhousing. Check gasket and o-seal. Replace if necessary. Caution Take care not to loose the guide pin ! With missing guide pin shaft will move out when engine is in operation ! 9.
- Page 26 RE-ASSEMBLING PROCEDURES 10. Piston Rotate the flywheel until the piston is in TDC – position. Use a needle nose plier to remove the piston pin retainer. With a drift pin gently hammer piston pin out of the piston ( from flywheel-side ). Caution If the piston pin is sticking you’ve to remove the complete piston and conrod assy.
- Page 27 RE-ASSEMBLING PROCEDURES 12. Crankhandle guide Remove the 2 crankhandle guide screws. Pull of the guide in a twisting motion. 13. Gear end cover Remove the 6 allen screws and pull off the gear end cover.If necessary tap with a soft faced hammer.
- Page 28 RE-ASSEMBLING PROCEDURES Remove the 2 hex nuts and lock washers. Pull off the inj. Pump. If necessary turn the flywheel to decrease force from the camshaft-side. Caution Leave gasket and shimson the gear end hous- ing. Re-install hex nuts and lock washers on their studs.
- Page 29 RE-ASSEMBLING PROCEDURES 16. Speed control assembly Remove the retaining ring from the eccenter shaft using a pliers. Pull the exc. shaft outwards till the ratchet plate is free from the compression pin. Unhook the outer torsion spring from the boss ( use a pliers and watch out for your fin- gers).
- Page 30 RE-ASSEMBLING PROCEDURES 18. Oil pump Remove the oil pump and valve bracket by un- screwing the 3 mounting screws. Discard gasket. 19. Flywheel Remove the oil pump and valve bracket by un- screwing the 3 mounting screws. Discard gasket. Leave the flywheel nut on the shaft. Install fly- wheel puller and turn the screws until the fly- wheel breaks loose from the crankshaft tapper.
- Page 31 RE-ASSEMBLING PROCEDURES Remove the key, belleville washers, angle ringe, o-ring and thrust washer. 21. Crankshaft Remove the crankshaft from the crankcase, be- ing careful not to drag the crankshaft gear on the main bearing bushing. Use a puller to pull of the crankshaft gear. In case the roller bearing needs replacement, replace also the inner race, which is shrunk fit on to the crankshaft.
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Page 32: Measurement Table- Wearing Parts
MEASUREMENT TABLE, WEAR MEASUREMENT TABLE- WEARING PARTS CRANKCASE - 32 -... -
Page 33: Crankshaft
MEASUREMENT TABLE, WEAR CRANKSHAFT - 33 -... -
Page 34: Camshaft
MEASUREMENT TABLE, WEAR CAMSHAFT - 34 -... -
Page 35: Gear Cover
MEASUREMENT TABLE, WEAR GEAR COVER - 35 -... -
Page 36: Shafts, Bearings
MEASUREMENT TABLE, WEAR SHAFTS, BEARINGS - 36 -... -
Page 37: Connecting Rod
MEASUREMENT TABLE, WEAR CONNECTING ROD - 37 -... -
Page 38: Cylinder Liner
MEASUREMENT TABLE, WEAR CYLINDER LINER Dimensions : 92 –0,05 92 –0,05 109,2 –0,1 75,050 – 75,030 82,050 – 82,030 95,040 – 95,020 78,8 –0,1 85,0 –0,2 100,5 –0,2 95 –0,036 /-0,071 95 –0,036 /-0,071 117 –0,1 / -0,15 86,75 –0,025 86,75 –0,025 111,2 –0,025 105,75 –0,1... -
Page 39: Piston 15/18W
MEASUREMENT TABLE, WEAR PISTON 15/18W - 39 -... -
Page 40: Piston 32W
MEASUREMENT TABLE, WEAR PISTON 32W - 40 -... -
Page 41: 4.10 Cylinder Head 15/18W
MEASUREMENT TABLE, WEAR 4.10 CYLINDER HEAD 15/18W Cylinder head 15W Cylinder head 18W - 41 -... -
Page 42: 4.11 Cylinder Head 32W
MEASUREMENT TABLE, WEAR 4.11 CYLINDER HEAD 32W Cylinder head 32W Rocker arm 15/18/32W - 42 -... -
Page 43: Engine Reassembly
REASSEMBLY PROCEDURES ENGINE REASSEMBLY 1. Crankcase Press the bearing bush with a suitable driver. Caution Take care that the joining line of the bearing bush is located as shown and that the oil holes in the bushing and in the crankcase bore are properly linedup. -
Page 44: Reassembly Procedures
REASSEMBLY PROCEDURES 3. Main bearing housing Press the outer race of the driver into the bear- ing cover. Insert the retaining ring with pliers. Press the oil sealing ring into the housing using the correct driver. Don’t use grease for assem- bly. - Page 45 REASSEMBLY PROCEDURES 5. Oilpump Reassemble oilpump with thin pressure relief plate, spring retaining clip and gasket. Before tightening the screws to specified torque pull the pump downwards. The clearance in the screw holes allows a sufficient backslash between crankshaft gear and pump gear. 6.
- Page 46 REASSEMBLY PROCEDURES Notice the stamped numbers on conrod and cap – side . These are matcjing marks i.e. identical numbers must be on rod and cap. Oil the bearing shells and install conrod into the crankcase until it seats on the crank pin. Insert conrod cap through the bottom inspection cover Attention The stamped numbers must be aligned on the...
- Page 47 REASSEMBLY PROCEDURES Now press the camshaft with a driver into the bearing. Use another driver as counter pressure piece for the bearing. Make sure that the bearing sears fully against the seat flange. Insert retaining ring. Install camfol- lower for the injection pump and tighten the fixing screw.
- Page 48 REASSEMBLY PROCEDURES the notch of the eccentric shaft. Attention Initiate performance test. The tension of the return spring must be acting against the pressure onto the seting screw. Speed control - Stationary The outer torsion spring pulls the acceleration lever from the stop-position back into idle- position.
- Page 49 REASSEMBLY PROCEDURES Oil the ring and piston skirts. Check that piston ring gaps are 120 degrees offset. Compress rings with ring compressor. Lay the cylinder down on the bench with bottom facing up. Install piston from bottom side of the cylinder. Never tap on the piston crown.
- Page 50 On the shorter stud – intake side –fit the tote bracket and cylinder haed nut without washer. Attention Model 15W doesn’t have any cylinder head gas- ket. At this stage don’t torque down the cylinder head nuts as the rocker arms and push rods still...
- Page 51 REASSEMBLY PROCEDURES 12. Gear end cover To install the gear end cover, first bring the pis- ton to TDC ( Top dead center ) position by aligning the flywheel timing mark with the TDC mark stamped on the crankcase. Insert the governor pin into the bore in the gov- ernor.
- Page 52 REASSEMBLY PROCEDURES Move the timing mark on the camshaft gearex- actly 3 teeth to the left. Install the gear end cover. Align the flywheel mark and the crankcase timing mark. Check timing marks on camshaft gear and gear end cover. The timing is acceptable if these are within 0 –...
- Page 53 REASSEMBLY PROCEDURES When a new decompression device is installed the correct function must be checked. To do so install the decompression device with the 0,4 mm thick gasket. Continue with steps 14, 15 and 16. Turn the flywheel approx. 1/8 revolution be- fore TDC and measure with a depth gauge the distance between bracket of the rocker arm shaft and spring collar of the intake valve.
- Page 54 REASSEMBLY PROCEDURES 16. Valve setting Check that the decompression device is in oper- ating position ( pin on 9 o’clock ). Set piston on TDC compression stroke. Use a 0,2 mm feeler gauge to control and reset the valve clearance of both valves.
- Page 55 REASSEMBLY PROCEDURES 19. Injection pump Place acceleration lever in full load (max speed) position and pull excess fuel button. Place rod of the fuel injection pump to max position. When sliding in the pump, the pin of the rod must grip into the yoke of the control lever.
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Page 56: Test Run, Adjustments, Checks
TEST RUN, ADJUSTMENTS Test run, adjustments, checks 1. TEST RUN The engine is now completely reassembled. Install engine on test bench and carry out test run. The engine does not require a long time running-in program. After a ahort run according to low specifications the engine is ready for normal operation. - Page 57 TEST RUN, ADJUSTMENTS 3. Oil pressure check The oil pressure depends mostly on the wearing conditions of the bearings. Before checking the oil pressure make sure that the oil level is topped and oil with correct viscosity is used. Remove the oil channel plug screw and connect oil pressure gauge with adaptor.
- Page 58 TEST RUN, ADJUSTMENTS 6. Fuel injector, injector nozzle The injector nozzle injects the fuel in a fine mist and under a high pressure into the combustion space. Due to the high mechanical and thermal stress, the nozzle requires regular maintenance. Carbon resuides on the nozzle tip are removed with a brass wire brush.
- Page 59 TEST RUN, ADJUSTMENTS 7. Excess starting fuel button For ease of starting all engines are fitted with an excess starting pull button. A cone limits the travel of the fuel rack. When the starting fuel button is pulled down prior to start, the cone allows the fuel rack to travel to a higher fuel quantity position.
- Page 60 TEST RUN, ADJUSTMENTS 8. Adjustment of fuel injection timing The correct setting of the commencement of delivery is a basic requirement for a troublefree function of the engine. As the injection timing is fixed, a check and re-adjustment is only neces- sary when the engine speed is altered or the–...
- Page 61 TEST RUN, ADJUSTMENTS If shims have been added or removed the in- stallation deepth muist be checked. Measure distance from the mounting flange down to the edge inside the roller tapped. This value plus the thickness of the installed adjust- ment shims should be between 57,5 mm (2.263”) and 59,1 mm (2,327”) ! If it is not possible to set the correct injection...
- Page 62 TEST RUN, ADJUSTMENTS 9. Governor 1. Governor body 2. Governor spring, middle speed range in case of variable speed governor 3. Spacer, instead of item 2, end speed gover- 4. Governor pin 5. Spring bridge 6. Guide bush 7. Governor spring, max speed 8.
- Page 63 TEST RUN, ADJUSTMENTS A small tension spring assembled to the lever system ensures that there is always contact between the tapped bolt and the governor pin. The fuel pump rack is controlled whenever the engine is running. More fuel means higher speed, i.e. the governor pin is being pushed out further and pressed against the tapped bolt, resulting in a movement of the control lever / fuel pump rack towards the...
- Page 64 TEST RUN, ADJUSTMENTS 12. Speed setting To increase speed tighten the cross slotted nut on the governor shaft. ( turn clockwise )..To reduce speed loosen the slotted nut ( turn anti- clockwise ). Procedure : For correct speed setting the use of the gover- nor adjustment tool is recommended ! Don’t use other tools ( screwdriver, i.e.
- Page 65 TEST RUN, ADJUSTMENTS 13. Acceleration lever The acceleration lever is fixed in ist position on the eccentric shaft with a pin. The rachet plate behind the lever is not fixed and only kept in place by the M8 – thread lock nut. As the rachet plate is used as a buffer for the engine shut down, the correct position between plate an lever is important.
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Page 66: Electrical System
ELECTRICAL SYSTEM Electrical system Flywheel – dynamo / Regulator 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 regulator (3) and continuously regulated to approximately 14.2... -
Page 67: Hazards / Causes Of Failure
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 68: Flywheel - Dynamo / Regulator, Graphs
ELECTRICAL SYSTEM 12 V Flywheel – dynamo / regulator, GRAPHs 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] - 68 -... -
Page 69: Wiring Diagrams
ELECTRICAL SYSTEM WIRING DIAGRAMS 7.5.1 Diagram 1 - 69 -... - Page 70 ELECTRICAL SYSTEM - 70 -...
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Page 71: Diagram 2
ELECTRICAL SYSTEM 7.5.2 DIAGRAM 2 - 71 -... -
Page 72: Diagram 3
ELECTRICAL SYSTEM 7.5.3 DIAGRAM 3 - 72 -... -
Page 73: Diagram 4
ELECTRICAL SYSTEM 7.5.4 DIAGRAM 4 - 73 -... -
Page 74: Diagram 5
ELECTRICAL SYSTEM 7.5.5 DIAGRAM 5 - 74 -... -
Page 75: 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”. Engine will not start Reason Causes Remedy... -
Page 76: Or Black Smoke
TROUBLESHOOTING 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 77: Or Black Smoke
TROUBLESHOOTING 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 78 TROUBLESHOOTING 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. high.
- Page 79 NOTES - 79 -...
- Page 80 NOTES - 80 -...