Farymann Diesel 15D Workshop Manual
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Farymann Diesel 15D Workshop Manual

Farymann Diesel 15D Workshop Manual

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See also: Operator's Manual
I

General Information

I.1.
Introduction
I.2.
I.3.
I.4.
II
II.1.
General engine data
II.2.
Picture of model 15/18
II.3.
Sectional view of model 15/18
II.4.
Special tools
III
III.1.
Engine disassembly
III.2.
Wear and tear measurements
III.3.
III.4.
Lubrication system
III.5.
Function and repair of fuel system
III.6.
III.7.
Resurfacing of valve seats
III.8.
Setting datas for fuel timing
III.9.
Tightening torques
IV
Trouble Shooting
CONTENTS
5
7
7-8
8
9
10
11
12-14
15-27
28-41
42-58
59
60-65
66-70
70
71-72
73
74-78
3

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Summary of Contents for Farymann Diesel 15D

  • Page 1: General Information

    CONTENTS General Information I.1. Introduction Farymann Diesel engines I.2. I.3. Engine identification I.4. Cross reference old - new engine type Technical Data II.1. General engine data II.2. Picture of model 15/18 II.3. Sectional view of model 15/18 II.4. Special tools...
  • Page 2 Because some work is very complicated, we recommend that the Manual be completely read before starting repairs. The repair of FARYMANN DIESEL engines requires some special tools in addition to standart ones. Their use is strongly recommended.

  • Page 3: I.1. Introduction

    I.1. Introduction to Diesel Engines Nowadays diesel engines are well known and quite common in all kinds of machinery and equipement as an alternative to the well established gasoline engine. Most people who are fully familiar with gasoline engines are reluctant to deal with a Diesel. This is without any reason, in fact, you already know more about a Diesel than you may have thought.
  • Page 4 I. GENERAL INFORMATION III. Power stroke A spark created by a spark plug ignites Fuel in a fine mist is sprayed into the the fuel. The resulting expansion of the cylinder and self ignites in the hot air. The combustion gases forces the piston down. resulting expansion of the combustion gases forces the piston down.

  • Page 5: I.2. Farymann Diesel Engines

    I. GENERAL INFORMATION I.2. Farymann Diesel engine 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 efficiency with low fuel consumption and excellent cold starting abilities. Robert Bosch fuel injection equipments are used on all engines.

  • Page 6: I.3. Engine Identification

    The complete engine code must be quoted when ordering spare parts in order to supply the correct parts for the engine. I.4. Cross reference old - new engine type up to 1982 since 1982 K54/15A model range 15D model range 15B K64/18A/C model range 18D model range 18B model range 15W/18W...

  • Page 7: Ii.1. General Engine Data

    II. TECHNICAL DATA II.1. General engine data Specifications/engine type 15B/D 18B/D ______________________________________________________________________ Number of cylinders one, vertical Combustion direct injection, 4 stroke Bore/Stroke [mm] 75/55 82/55 90/74 95/74 Total displacement [cm3] Compression ratio 1:20 1:20 1:19 1:20 ______________________________________________________________________ Direction of rotation A+C+D: counter clockwise when viewed flywheel clockwise when viewed flywheel ______________________________________________________________________...
  • Page 8 III.1. DISASSEMBLY...
  • Page 9 II. TECHNICAL DATA...

  • Page 10: Ii.4. Special Tools

    II. TECHNICAL DATA II.4. Special Tool List It is assumes that authorized Farymann Diesel Dealers have all of the common tools needed to service diesel engines i.e. metric open end and ring spanners, sockets, torque wrench, mtric caliper and depth gauge as well as piston ring pliers, piston ring compressor, etc.
  • Page 11 II. TECHNICAL DATA 748.132.6 Cranksh. Race Puller Use with puller to remove crankshaft roller bearing race 748.137.2 Crankshaft Gear Puller Use with puller to remove crankshaft gear wheel 748.136.2 Puller For parts 148.132.6 and 748.137.2 748.122.6 Flywheel Puller To remove flywheel from crankshaft tapper 748.119.4 Bearing driver...
  • Page 12 III. ENGINE REPAIR 748.129.4 Bearing Driver To remove and install regulation shaft bushing 748.123.4 Bearing Driver Handle Treated handle for various bearing drives 748.125.4 Valve Guide Driver To remove and install valve gides 748.131.5 Valve Sring Compr. To remove and install valves 748.135.2 Retaining Ring Pliers To remove retining rings...

  • Page 13: Iii.1. Engine Disassembly

    II. TECHNICAL DATA III.1. ENGINE DISASSEMBLY Prior to dismantling the engine clean off engine exterior thoroughly.Dismantling will greatlyfacilitated location withgood lighting freedom ofmovement, away from dirt andmetal chips.The work carried isdescribed and illustrated step by step in the following.Please do take the trouble to read the description of thework involved prior to startingso that the scope will beappreciated right from the start.
  • Page 14 III. ENGINE REPAIR 1. Drain lubrication oil Place suitable container under the drain hole. Remove oval flange of oil drain, remove oilfilter. Wait until oil has fully trained, if necessary, tip over engine. (Figures 1 and 1a) 2.Air cleaner Remove the two aircleaner selflocking nuts. Pull off the air cleaner and discard gasked.
  • Page 16 III.1. DISASSEMBLY 5. Fuel tank support brackets Pull off the fuel tank upport brackets as well as the intake and the exhaust manifold gaskets. Figure 4) 6. Air deflectors Remove the two screws and lockwashers holding the air deflector shields on top of the crankcase.
  • Page 17 III. ENGINE REPAIR Loosen the high pressure line at the injector in the same way. (Figure 8) 9. Fuel injector Remove the two hex nuts and their lockwashers from thr injector clamp. and pull out the injector. If the injector sticks in the hand, use a soft faced hammer and tap slightly on the injector.
  • Page 18 II. TECHNICAL DATA Remove the cylinder head nuts and the cylinder head. (Figure 12) For dismantling valves use special tool. Watch out for the two thin steel washers under the inlet valve spring. (Figure 13) If the valve guides need replacement (for wear and tear measurements refer to section III.2.),use driver to press old guides out.
  • Page 19 III. ENGINE REPAIR Shout the valve seat be damaged to the point that grinding of valves is not sufficient, the seat can be resurfaced with tool (for wear and tear limits and detailed instructions for use of tool refer to section III.2. resp. III.7.) (Figure 15) 11.
  • Page 20 II. TECHNICAL DATA Compression release After removing screws, pull compression release out of the gearcase. (Figure 18) 13. Cylinder Rotate the flywheel until the piston reaches the bottom of its stroke. Carefully slide the cylinder up off the studs. Attention: If the repair does not require the renewal of piston and liner, leave the liner on the piston.
  • Page 21 III. ENGINE REPAIR With a drift pin gently hammer piston pin out of the piston from flywheel side. Attention: If piston pin sticks in piston, remove piston compete with connecting rod (step 15 and hammer out piston pin after the assembly has been removed from engine.
  • Page 22 II. TECHNICAL DATA 17. Gear cover Remove the six allen screws and pull off the gear cover. If nenecessary, tap at the gear cover with a soft faced hammer to loosen it.If, when removing, the cover should catch on the governor beneath, turning the flywheel slightly will free it.
  • Page 23 III. ENGINE REPAIR 17.2. Cramshaft Remove the snap ring holding the cramshaft in the gear cover. Press out the cramshaft using the driver. (Figure 28) To pull off the camshaft gear wheel, use puller or press out the camshaft. (Figure 29) After the camshaft is removed, the roller bearing can be pressed out from the inside of the cover using driver.
  • Page 24 II. TECHNICAL DATA 17.3. Speed regulation assembly Lay the gear cover down on the work bench. Remove the retaining ring from the regulation shaft with a pliers.Pull the shaft outwards till the ratchet plate is free from the pin.Unhook the outer torsion spring from the boss(use a pliers and watch out for your fingers).Hold the inner control lever and twist the acceleration lever down below the-normally - stop position...
  • Page 25 III. ENGINE REPAIR 20. Flywheel Using socket on stricker and a hammer, loosen the flywheel nut by two turns. Attention:If the flywheel has to be removed from an engine without dismantling the governor/regulation linkage, it is necessary to place the acceleration lever at full load position.
  • Page 26 II. TECHNICAL DATA 22. Crankshaft Remove the crankshaft from the crankcase, being careful not to drag the crankshaft gear on the main bearing bushing. To pull off the crankshaft gear wheel,use puller. (Figure 38) 22.1. In case the roller bearing needs replacement, replace also the inner race,which is shrunk fit on to the crankshaft.Use race puller, pull off the inner race.
  • Page 27 III. ENGINE REPAIR III. 2. DIMENSION TABLE - WEARING PARTS...
  • Page 28 III. ENGINE REPAIR...
  • Page 29 III. ENGINE REPAIR...
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  • Page 32 III. ENGINE REPAIR...
  • Page 33 III. ENGINE REPAIR...
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  • Page 39 III. ENGINE REPAIR...
  • Page 40 III. ENGINE REPAIR...
  • Page 41 III. ENGINE REPAIR III. 3. ENGINE REASSEMBLY...
  • Page 42 III. ENGINE REPAIR 1. Crankcase Press the bearing bush with driver. Take care that the joining line of the bearing bush is located as shown and that the oil holes in the bushing and the crankcase are properly lined up. (Figure 1) 2.
  • Page 43 III. ENGINE REPAIR 3. Main bearing cover Press the outer race of the driver into the bearing cover. Insert the retaining ring with pliers. Press the oil sealing ring into the cover with driver. Before assembling oil crankshaft journal and the sealing ring lip, do not use grease.
  • Page 44 III. ENGINE REPAIR 5. Oil pump Reassemble oil pump with thin covering plate (only for securing bolts) and gasket. Before tightening screws specified torque, pull the pump downwards. The clearance in the srew holes of the pump allows a sufficient backlash between the crankshaft gear and the pump gear.
  • Page 45 III. ENGINE REPAIR 7. Connecting rod To install new bearing shells, take a shell half and lay it to approx. ¾ into the cap. Now press with your thumb the bearing in a sliding movement onto ist seat. The bearing lip must fit into the grove in the cap.
  • Page 46 III. ENGINE REPAIR Using a driver press the camshaft bearing into the gear cover. (Figure 14) Now press the camshaft with driver into the bearing using a driver as a counter pressure piece for the bearing. Make sure that the bearing seats fully against the bearing seat flange.
  • Page 47 III. ENGINE REPAIR Slide the eccentric shaft through the bearing bush in the housing and into the control lever. Turn the acceleration lever downwards („stop“-position) until spring leg of the return spring can be managed to get into the notch of the eccentric shaft. (Figure 16c) Use a wire loop to move and hook torsion spring leg to the boss of the gear housing.
  • Page 48 III. ENGINE REPAIR 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 the bottom facing up. Install the piston into the cylinder from the bottom.
  • Page 49 III. ENGINE REPAIR Grind in the valves. The rotocap and the conical shaped spring belong to the exhaust valve. The two thin steel washers must be under the cylindrical spring of the inlet valve. Fit new sealing cap onto the inlet valve guide. Before fitting the rotocap check for proper function: Spin the cap, if rattling sound or hard movement replace it.
  • Page 50 III. ENGINE REPAIR Insert the governor pin into the bore in the governor. Use grease to keep the pin in place. Line up the timing mark on the camshaftgear with the mark on the gear cover. (marks „A“ and „B“). Install the gear cover (remember to place the gaskets) onto the crankcase being careful not to move the camshaft gear.
  • Page 51 III. ENGINE REPAIR - Install the cover. Align the camshaft gear and gear cover timing marks. Now check the flywheel and crankcase timing marks. The timing is acceptable, if they are within ± 2 mm (± 0.0787) of each other. When installing the gear cover screws, note that the top two and bottom left screw are longer than the other three.
  • Page 52 III. ENGINE REPAIR When a new decompression device is installed the correct function must be checked. install decompression device with the 0.4 mm (0.0157“) thick gasket, continue with step 14, 15 and 16. Turn the piston approx. 1/8 revolution before TDC and measure with a depth gauge the distance between bracket for rocker arm shaft and spring collar of the inlet valve.
  • Page 53 III. ENGINE REPAIR 15. Rocker arms Place piston to TDC position. Line up rocker arms and push rods and oil the rocker arm bolt before installing it into the support. Attention: To prevent damage of push rods while torquing the cylinder head nuts, ensure sufficient...
  • Page 54 III. ENGINE REPAIR 18. Cylinder shields and air guides Install both halves of cylinder shields and the clamping bolt. Do not overtighten the bolt. It is sufficient when the bold protrudes about 1-2 mm (0.0394“-0.0787“) out of the locknut. Install the two air guides on top of the crankcase.
  • Page 55 III. ENGINE REPAIR 21. High pressure fuel pipe Install the high pressure fuel pipe and tighten the union nuts on injector and pump. While tightening nut on pump and injector maintain counter parts with a 14 mm wrench. (Figure 39) 22.
  • Page 56 III. ENGINE REPAIR 24. Fuel tank Place the fuel tank on the tank brackets. Slide both tank straps over the tank and brackets. Do not forget to reinstall the two tank seam protectors. Tighten the straps. (Figure 42) 25. Fuel leak-off and supply line Install banjo bolts on the fuel leak- off/supply line at the fuel tank and fuel...
  • Page 57 III. ENGINE REPAIR 27. Test run engine completely reassembled. Install engine on a test bench and carry out a test run. The engine does not require a long time running-in program. After a short run according to below specifications the engine is ready for normal operation.
  • Page 58 III. ENGINE REPAIR Figure 1 Figure 2 A gear pump (2) sucks the oil from the oil sump (1) and pumps it through the oilfilter (3) to the main bearing (5) and to the conrod bearing. Piston, piston pin, cylinder liner and rocker arms are splash lubricated. When oil pressure rise above 4,5 bar (63 PSI) the oil pressure relief valve (4) opens and the oil flows back into the oil sump partly.
  • Page 59 III. ENGINE REPAIR The fuel flows from the tank (1) through the filter (2) to the injector pump (3). As the quality supplied is higher than required for the injection, most of it goes back to the tank via the return pipe (4), simultaneously carrying heat away from the pump. Also the return pipe ensures a constant bleed of the fuel system.
  • Page 60 III. ENGINE REPAIR III.5.1. Fuel System The fuel filter prevents the entry of dirt into the injection pump. The normal lifespan of the filter is approx. 2000 operation hrs., however, it depends on the purity of the fuel used. Prior to changing fuel filter, clean the fuel pipe from dirt with a rag and close off the line between tank and filter with clamp.
  • Page 61 III. ENGINE REPAIR To check the injection pressure, connect the complete injector valve to a nozzle tester. Pump with the hand lever till the nozzle ejects.The fuel must be ejected evently atomized without drippling specified pressure. (Figure 6) Caution: Keep hands away from nozzle spray! spray from nozzle...
  • Page 62 III. ENGINE REPAIR III.5.3. Excess starting fuel button For ease of starting all engines are fitted with an excess startingfuel pull button. (Figure 8) A cone limits the travel of the injector pump fuel rack. When the starting fuel button is pulled down prior to start, the cone allows the fuel rack to travel a longer way.
  • Page 63 III. ENGINE REPAIR III.5.4. Adjustment of fuel injection timing correct setting commencement of delivery is a basic requirement for a troublefree function of the engine. As the injection timing is fixed, check respectively readjustment is only necessary when the engine speed was altered, a new injection pump was installed or the camshaft/camshaft gear was renewed.
  • Page 64 III. ENGINE REPAIR Use a flexible ruler and measure the distance between TDC marks on the flywheel and housing. (Figure 12) Compare the measurement with the valves at the table III.8 observing the correct flywheel diameter and engine speed. If the measured value is out of tolerance, readjust the commencement of delivery, either by adding or removing shims under the injection pump.
  • Page 65 III. ENGINE REPAIR Figure 15 1. Governor body 2. Midrange spring 3. Spacer ((instead of 2 for generator application) 4. Governor pin 5. Bridge 6. Support 7. Full load spring 8. Idle speed spring 9. Cross slotted nut...
  • Page 66 III. ENGINE REPAIR The purpose of governor is to maintain constantly the specified speed of the engine. Therefore, centrifugal resilient spring forces are used to monitor the amount of fuel injected by the injection pump. According to the utilization of the engine, there are several types of governor: 1.
  • Page 67 III. ENGINE REPAIR Due to the control lever pivoting on the eccentric regulation shaft the distance between tappet bolt and governor pin increases when the acceleration lever is moved towards full load position. Thus enabling the small tension spring to push control lever...
  • Page 68 III. ENGINE REPAIR Crank engine until governor flyweights stand in a vertical position. Put the acceleration lever in full load position. Open the lock plate and loosen the castle nut. Screw in tappelt bolt completely till tappet rests on control lever. Insert a screwdriver between the flyweights and force them apart to maximum opening.
  • Page 69 III. ENGINE REPAIR III.6.3. Acceleration lever The acceleration lever is fixed in its position on the excentric shaft with a pin. The rachet plate located behind the lever is not fixed and only kept in place by the M8 nut. As the ratched plate is used as a buffer for the engine shut down, the correct position between plate and lever is important.
  • Page 70 III.8. Adjustment – Injection pump – begin of delivery Flywheel- Begin of delivery (mm) BTDC - Toleranz Engine type Part-No.: +-2mm engine speed (mm dia- meter mm 1500 1800 2000 2500 2800 3000 3300 3600 738.146.4 15B/D 738.149.4 738.158.4 738.160.4 738.174.4 738.181.4 738.185.4...
  • Page 71 III.8.1 Adjustment – Injection pump – begin of delivery Flywheel- End of delivery (mm) BTDC - Toleranz Engine type Part-No.: +-2mm engine speed (mm dia- meter mm 1500 1800 2000 2500 2800 3000 3300 3600 738.146.4 15B/D 738.149.4 738.158.4 738.160.4 738.174.4 738.181.4 738.185.4...
  • Page 72 III.9 Torque specifications 15B/15D/18B/18D 29C/32A Spanner Tightening Spanner Tightening size tourque (Nm) size tourque (Nm) (mm) (mm) Cylinder head nuts Connecting road nuts Valve cover nuts Main bearing plate nuts Fuel pump nuts Delivery valve holder – fuel pump High pressure fuel pipe nut – fuel pump High pressure fuel pipe nut –...

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