Farymann Diesel 15W Series Operator's Manual
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Farymann Diesel 15W Series Operator's Manual

Diesel engine series 15w / 18w
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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!

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Summary of Contents for Farymann Diesel 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 © Greaves-Farymann 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: Table Of Contents

    Diesel engine Series 15W / 18W Table of contents General..................7 Information about this manual ........7 Explanation of the symbols..........8 Limitation of liability............9 Copyright..............10 Warranty terms ............10 Customer service ............10 Safety ..................11 Customer’s responsibility..........11 Personnel requirements..........13 2.2.1 Qualifications ..........13 Appropriate use ............14 Personal protective equipment ........15...
  • Page 4 Diesel engine Series 15W / 18W Table of contents Structure and function............30 Overview ..............30 Electrical System............33 4.2.1 Alternator (option) ........33 4.2.2 Alternator regulator (option)......34 4.2.3 Operating conditions........34 4.2.4 Dangers and cause of failure....... 35 4.2.5...
  • Page 5 Diesel engine Series 15W / 18W Table of contents Operation ................50 Safety................50 Preparing for start ............54 Manual start ..............55 Starting with electric starter .........61 Operation ..............62 Switching off..............64 7.6.1 Engine without electric starter ......65 7.6.2 Engine with electric starter ......65 Decommissioning ............66...
  • Page 6 Diesel engine Series 15W / 18W Table of contents 8.10 Cooling water diagram (standard)......101 8.11 Cooling water diagram (with water-cooled exhaust manifold) ..............102 8.12 Replacing neoprene impeller of the cooling water pump ..............103 8.13 Removing, installing and checking thermostat ..107 8.14 Checking the cooling system for leaks......

  • Page 7: General

    Diesel engine Series 15W / 18W General 1 General 1.1 Information about this manual This manual makes safe and efficient use of the engine possible. The manual is an integral part of the machine and must be kept in the immediate vicinity of the machine and accessible at any time for the personnel.

  • Page 8: Explanation Of The Symbols

    Diesel engine Series 15W / 18W General 1.2 Explanation of the symbols Safety information in this manual is identified using symbols. The Safety information safety information is introduced using signal words which express the scale of the hazard. Always comply with the safety instructions and act cautiously in order to avoid accidents, injuries to persons and damage to property.

  • Page 9: Limitation Of Liability

    Diesel engine Series 15W / 18W General 1.3 Limitation of liability All information and instructions for use in this manual have been compiled taking account of the applicable standards and regulations, the latest state of technology and our many years of expertise and experience.

  • Page 10: Copyright

    Diesel engine Series 15W / 18W General 1.4 Copyright This manual is protected by copyright law and exclusively to be used for internal purposes. Passing this manual on to third parties, duplication of any kind – even in form of excerpts – as well as the use and/or disclosure of the contents without the written consent of the manufacturer is not permitted, except for internal purposes.

  • Page 11: Safety

    Diesel engine Series 15W / 18W Safety 2 Safety This paragraph provides an overview of all important safety aspects for optimal protection of personnel as well as safe and trouble-free operation. Disregarding this manual and safety regulations specified therein may result in considerable danger.
  • Page 12 The engine must be checked for intactness 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.

  • Page 13: Personnel Requirements

    Diesel engine Series 15W / 18W Safety 2.2 Personnel requirements 2.2.1 Qualifications WARNING! Danger of injury for unqualified personnel! Improper handling can result in severe personal injury and/or material damage. Therefore: – Have all jobs carried out by qualified personnel only.

  • Page 14: Appropriate Use

    Any other use is considered to be improper. Greaves Farymann Diesel GmbH accepts no liability for any dangers and damage resulting from this. The risk is borne solely by the user.

  • Page 15: Personal Protective Equipment

    Diesel engine Series 15W / 18W Safety 2.4 Personal protective equipment Wearing of personal protective equipment is required when working to minimize the health hazards. Always wear the protective equipment that is necessary for the respective task when working. Follow the instructions on personal protective equipment that are posted in the work area.

  • Page 16: Specific Dangers

    Diesel engine Series 15W / 18W Safety 2.5 Specific dangers The following section lists the residual risks that have been determined by the risk assessment. Heed the safety instructions listed here, and the warnings in subsequent chapters of this manual, to reduce health hazards and to avoid dangerous situations.
  • Page 17 Diesel engine Series 15W / 18W Safety Substances harmful to health WARNING! Danger of poisoning and danger of skin rashes and allergies! Fuels, antifreeze and lubricants contain substances harmful to health and can result in severe poisoning and skin rashes or allergies.
  • Page 18 Diesel engine Series 15W / 18W Safety Highly flammable materials WARNING! Fire hazard by highly flammable materials! Highly flammable materials, liquids or gases may catch fire causing serious and even fatal injuries. Therefore: – Do not smoke within the danger zone and the immediate vicinity.
  • Page 19 Diesel engine Series 15W / 18W Safety Antifreeze (for engines with WARNING! radiators and, e.g. electric water Danger of poisoning and danger of skin rashes pump) and allergies! Antifreeze contains substances harmful to health and can result in severe poisoning and skin rashes or allergies.

  • Page 20: Safety Devices

    Diesel engine Series 15W / 18W Safety 2.6 Safety devices WARNING! Risk of injury due to non-functional safety devices! Safety is only ensured if the safety devices are intact. Therefore: – Check whether the safety devices are functional and correctly installed before starting work.

  • Page 21: Environmental Protection

    Diesel engine Series 15W / 18W Safety 2.8 Environmental protection CAUTION! Danger to the environment due to mishandling! Significant environmental damage can occur, particularly for incorrect disposal, if environmentally hazardous operating materials are mishandled. Therefore: – Always observe the instructions mentioned below.

  • Page 22: Technical Data

    Engine mounting points integrally cast on the crankcase Environmentally friendly due to internal crankcase venting and valve stem seals 3.2 Applications The engine series 15W /18W is suitable, for example, for the following applications: Generators (marine and industrial applications) Vehicle cooling systems...

  • Page 23: Standard Configuration

    Diesel engine Series 15W / 18W Technical data 3.3 Standard configuration The engine is delivered with the following standard configuration: Fuel filter Dry type air cleaner or oil bath air cleaner Fuel feed pump Coolant thermostat (opening temperature 50 °C or 70 °C)

  • Page 24: Engine Type Plate

    Diesel engine Series 15W / 18W Technical data 3.5 Engine type plate There is an engine type plate on the engine with the following information: Manufacturer Series Type number Version of the speed governor Serial number Power Speed Emissions code Date of manufacture (e.g.

  • Page 25: Engine Data

    Diesel engine Series 15W / 18W Technical data 3.7 Engine data Description Value Type Vertical single-cylinder diesel engine Design Vertical Cylinders Operating method Four-stroke Combustion method Direct injection Rotation direction Anticlockwise (as seen from output or flywheel side) Type of cooling...

  • Page 26: Performance Data

    Diesel engine Series 15W / 18W Technical data 3.8 Performance data Description Value 15W Value 18W Max. power IFN-ISO* 4.3 kW IFN-ISO* 5.2 kW (at 3600 rpm) ICFN-ISO* 3.9 kW ICFN-ISO* 4.7 kW Max. speed 3600 rpm Max. torque 13.0 Nm 15.3 Nm...

  • Page 27: Dimensions And Weight

    Diesel engine Series 15W / 18W Technical data 3.9 Dimensions and weight Description Value Overall length 374 mm Overall height 422 mm Overall width 401 mm Dry weight: standard 39 kg engine with air filter and exhaust silencer 3.10 Temperatures...

  • Page 28: Pressures

    Diesel engine Series 15W / 18W Technical data 3.11 Pressures Description Value Injector setting - nozzle 200 bar opening pressure Oil pressure (max.) 5 bar Intake vacuum permitted 2 kPa Exhaust gas back permitted 5 kPa pressure 3.12 Operating materials...

  • Page 29: Engine Oil Specification

    Diesel engine Series 15W / 18W Technical data 3.13 Engine oil specification The engine oil quality has a significant influence on the lifetime, performance and thus also the cost-effectiveness of the engine. The ambient temperature at the installation location or application of the engine is crucial for the selection of the correct viscosity class.

  • Page 30: Structure And Function

    Diesel engine Series 15W / 18W Structure and function 4 Structure and function 4.1 Overview NOTE! The engine shown in the pictures 5 and 6 is the D/W crankcase version. Fig. 5: Front view Left view Valve cover Starting handle support bearing...
  • Page 31 Diesel engine Series 15W / 18W Structure and function Fig. 6: Output side Right view 12 Thermostat housing 17 Injection pump 13 Bell housing (option) 18 Water-cooled exhaust manifold (option) 14 Stub shaft (option) 19 Oil filler cap 15 Oil dipstick...
  • Page 32 Speed adjusting lever Engine mounting point 10 Fuel feed pump Cooling water pump (neoprene impeller pump) 11 Lifting eye for transport Oil drain plug NOTE! The standard engine 15W / 18W has an oil strainer and no oil filter. 2008-12-09...

  • Page 33: Electrical System

    Diesel engine Series 15W / 18W Structure and function Fig. 8: Output side Right view 12 Thermostat housing 16 Injection pump 13 Flywheel 17 Oil dipstick 14 Water-cooled exhaust manifold (option) 18 Fuel filter 15 Oil filler cap 4.2 Electrical System 4.2.1 Alternator (option)

  • Page 34: Alternator Regulator (Option)

    Diesel engine Series 15W / 18W Structure and function 4.2.2 Alternator regulator (option) The alternating current is rectified in the alternator regulator (Fig. 10) and constantly regulated to approx. 14.2-14.5 V. 2 x yellow (alternator coils input, can be connected either...

  • Page 35: Dangers And Cause Of Failure

    Diesel engine Series 15W / 18W Structure and function 4.2.4 Dangers and cause of failure Dangers Cause of failure Battery terminals incorrectly Damage to the charging circuit connected Defective battery or complete Destruction of the alternator discharge regulator Disconnection of the battery...

  • Page 36: Batteries

    Diesel engine Series 15W / 18W Structure and function 4.2.5 Batteries Observe the following safety factors: Batteries produce explosive gases. Keep away from naked flames and other ignition sources. Do not smoke. Do not lay any tools on the battery.

  • Page 37: Cooling System

    Diesel engine Series 15W / 18W Structure and function 4.3 Cooling system 4.3.1 Open cooling water circuit with direct sea water cooling without thermostat Among other things, the engine is designed for direct sea water cooling. The cooling water is circulated using an impeller pump (1).

  • Page 38: Closed Cooling Water Circuit With Radiator And Thermostat

    Diesel engine Series 15W / 18W Structure and function 4.3.3 Closed cooling water circuit with radiator and thermostat With this type of cooling, for example, a radiator, an electric water pump and a thermostat with an opening temperature of 70 °C are used.

  • Page 39: Transport, Packing And Storage

    Diesel engine Series 15W / 18W Transport, packing and storage 5 Transport, packing and storage 5.1 Safety notes for transport Improper transport CAUTION! Damage due to improper transport! Significant damage to property and injuries to persons can occur in the case of improper transport.

  • Page 40: Packing

    Diesel engine Series 15W / 18W Transport, packing and storage 5.3 Packing Concerning packing The individual packages have been packed to match the transport conditions that can be expected. Only environmentally friendly materials were used for packing. The packing has the function of protecting the individual components against damage, corrosion, etc., until they are finally...
  • Page 41 Diesel engine Series 15W / 18W Transport, packing and storage Storage of the engine Store new engines under the following conditions: Do not store outdoors. Store dry and dust-free. Do not expose to any aggressive media. Protect against direct sunlight.

  • Page 42: Installation And Commissioning

    Diesel engine Series 15W / 18W Installation and commissioning 6 Installation and commissioning 6.1 Safety Personnel Installation and commissioning may be executed only by specially trained personnel. All work on the electrical system must be performed by a qualified electrician.
  • Page 43 Diesel engine Series 15W / 18W Installation and commissioning Install key (4) into the keyway of the crankshaft and ensure that this sits correctly. Fig. 15 Install the flywheel (5) ensuring that it is not twisted during the installation. NOTE! In the case of improper installation of the flywheel, the magnets of the magnet carrier (e.g.

  • Page 44: Attaching Stub Shaft (Option)

    Diesel engine Series 15W / 18W Installation and commissioning Screw on the flywheel nut as far as possible by hand. NOTE! In doing so, ensure that the machined flat side (arrow) of the flywheel nut is facing the crankshaft. Fig. 17 Screw two bolts (6) into the thread provided on the flywheel.

  • Page 45: Attaching Speed Controller

    Diesel engine Series 15W / 18W Installation and commissioning 6.2.3 Attaching speed controller NOTE! Depending on the version 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.

  • Page 46: Initial Commissioning

    Therefore: – Never use cold starting aids. NOTE! The 15W / 18W engine is supplied without fuel tank. Due to the design, no fuel tank is included in the scope of delivery of the 15W / 18W engine. 2008-12-09...

  • Page 47: Filling With Engine Oil

    Diesel engine Series 15W / 18W Installation and commissioning 6.4 Filling with engine oil CAUTION! Engine damage due to incorrect oil quantity! Too high or too low an engine oil level can result in damage to the engine. Therefore: – Never exceed the maximum level.
  • Page 48 Diesel engine Series 15W / 18W Installation and commissioning Pull out oil dipstick (3) and clean the bottom end with a clean and fluff-free cloth. Replace the oil dipstick (3) and pull it out again. Fig. 23 Check the oil level quantity. The oil level should be just under the Max.

  • Page 49: Venting The Fuel System For Engines With Fuel Feed Pump (Option)

    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 included in the scope of delivery of the 15W / 18W engine. Fig. 26 2008-12-09...

  • Page 50: Operation

    Diesel engine Series 15W / 18W Operation 7 Operation 7.1 Safety Improper operation WARNING! Risk of injury due to improper operation! Improper operation can result in severe personal injuries or material damage. Therefore: – Perform all the operating steps in accordance with the information in this operator's manual.
  • Page 51 Diesel engine Series 15W / 18W Operation Exhaust gases WARNING! Danger of poisoning due to exhaust gases! There is a danger of poisoning by odourless carbon monoxide of the exhaust gases are inhaled. Therefore: – Never inhale the exhaust gases.
  • Page 52 Diesel engine Series 15W / 18W Operation CAUTION! Danger of poisoning due to fuel, antifreeze and engine oil! Contact with engine oil, antifreeze and fuel can result in damage to health. Therefore: – Avoid skin contact with engine oil, fuel and antifreeze.
  • Page 53 Diesel engine Series 15W / 18W Operation Personal protective equipment Wear the following protective equipment for all operation work: Protective clothing Safety footwear NOTE! Protective equipment which must be worn for certain work is specially pointed out in the warnings of this chapter.

  • Page 54: Preparing For Start

    Diesel engine Series 15W / 18W Operation 7.2 Preparing for start Checks Carry out the following checks in order to avoid damage to the engine: Check engine oil level, refill with engine oil if necessary. Check fuel level, refill with diesel fuel if necessary.

  • Page 55: Manual Start

    Diesel engine Series 15W / 18W Operation Setting cold start / warm start 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 speed can be controlled using the speed adjustment lever.
  • Page 56 Diesel engine Series 15W / 18W Operation If the engine is cold, put the speed adjustment lever (3) in the increased idle speed position. If the engine is warm, put the speed adjustment lever into position (2) (depending on the application).
  • Page 57 Diesel engine Series 15W / 18W Operation Starting position Neutral position Operating position Fig. 31: Example: automatic decompression The automatic decompression (Fig. 31) is adjusted on the starting handle (Fig. 33) with the adjusting spanner. Fig. 32: Example: Adjusting the automatic...
  • Page 58 Diesel engine Series 15W / 18W Operation Excess fuel device NOTE! The excess fuel device (1) must be pulled out for cold starting. All engines are equipped with an excess fuel device (1) to make starting them easier. A lever limits the injection pump control shaft's path. If the starting excess button (1) is pulled out when starting the lever allows a longer path for the control shaft.
  • Page 59 Diesel engine Series 15W / 18W Operation NOTE! In the case of engines with cooling water pump (neoprene impeller pump), manual starting with an RD crank handle (limited kickback crank handle) is not possible due to the design. Only the "rigid version"...
  • Page 60 Diesel engine Series 15W / 18W Operation Support the air filter with your right hand (3). CAUTION! Risk of injury due to rotating crank handle! There is a risk of injury when starting the engine by hand. Therefore: – Do not encircle the handle with your thumb.

  • Page 61: Starting With Electric Starter

    Diesel engine Series 15W / 18W Operation 7.4 Starting with electric starter NOTE! For engines with an electric starter the automatic compression does not need to be activated. The engine is started with e.g. a key switch. CAUTION! Damage due to starting while the engine is running! Incorrect operation of the starter can damage it.

  • Page 62: Operation

    Diesel engine Series 15W / 18W Operation Starting engine If the engine is cold, put the speed adjustment lever in the increased idle speed position (3). If the engine is warm, put the speed adjustment lever in the position (2) (depending on the application of the engine).
  • Page 63 Diesel engine Series 15W / 18W Operation First use WARNING! Risk of injury due to leaking fuel! Fuel escaping from the injection system can penetrate the skin and eyes due to the high pressure and cause severe injuries. Therefore: – Wear safety goggles during first use and check the fuel system for leak tightness.

  • Page 64: Switching Off

    Diesel engine Series 15W / 18W Operation 7.6 Switching off CAUTION! Risk of injury due to engine run-on! After switching off, the engine runs on for approx. 10 to 20 seconds. Therefore: – Wait until the engine is at a standstill before starting all work.

  • Page 65: Engine Without Electric Starter

    Diesel engine Series 15W / 18W Operation 7.6.1 Engine without electric starter Put the speed adjustment lever (1) in the STOP position and hold it there until the engine comes to a complete standstill after approx. 10 to 20 seconds.

  • Page 66: Decommissioning

    Diesel engine Series 15W / 18W Operation 7.7 Decommissioning Decommissioning and preservation The following preservation protects the engine during decommissioning (e.g. winter break) for 3 months. Perform thorough external cleaning of the engine. Drain engine oil and fill engine with approx. 1.0 litre of corrosion protection oil.
  • Page 67 Diesel engine Series 15W / 18W Operation Restarting Perform the following work for restarting the engine: Perform thorough external cleaning of the engine. Remove textile adhesive tape from the inlet and exhaust openings. Drain corrosion protection oil from the engine into a suitable container and dispose of in accordance with the environmental regulations.

  • Page 68: Maintenance

    Diesel engine Series 15W / 18W Maintenance 8 Maintenance 8.1 Safety Maintenance work not carried out WARNING! correctly Risk of injury due to incorrectly carried out maintenance work! Improper maintenance can result in severe personal injuries or material damage. Therefore: –...
  • Page 69 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.

  • Page 70: Maintenance Plan

    Diesel engine Series 15W / 18W Maintenance NOTE! Independent repair and adjustment work on the engine beyond a very limited scope is forbidden for safety reasons. Improper work on components relevant for safety endangers you and others. This particularly applies to work on the valve adjustment, diesel injection system and for the engine repair.
  • Page 71 Diesel engine Series 15W / 18W Maintenance Maintenance table Components Work to be performed Daily After 25 Every 250 Every 500 Component before operating operating operating group every hours hours hours start-up Engine oil Check oil level, refill with engine oil...
  • Page 72 Diesel engine Series 15W / 18W Maintenance Components Work to be performed Daily After 25 Every 250 Every 500 Component before operating operating operating group every hours hours hours start-up Exhaust system Check for leaks, arrange repair by a Greaves...

  • Page 73: Cleaning The Intake Area

    Diesel engine Series 15W / 18W Maintenance Maintenance for special conditions CAUTION! Reduced maintenance intervals in the case of special conditions! Additional maintenance is necessary in the case of special operating conditions in order to maintain the lifetime of the engine.

  • Page 74: Checking Threaded Connections

    Diesel engine Series 15W / 18W Maintenance 8.4 Checking threaded connections CAUTION! Damage due to too high tightening torque! Bolts tightened too much can break off and the thread can be damaged. Therefore: – Only check and tighten threaded connections with appropriate commercially available tools and respective special tools.

  • Page 75: Changing Engine Oil

    Diesel engine Series 15W / 18W Maintenance Tightening torques Threaded connection relevant for safety Tightening torque Nm High pressure line of the injection nozzle holder Mounting of the fuel filter Wing nut of sealing cap of the air filter case...

  • Page 76: Version With Oil Drain Valve

    Diesel engine Series 15W / 18W Maintenance Check oil drain plug (1) for damage and replace if necessary. Always replace the copper seal (2). Screw in oil drain plug by hand and tighten with e.g. ring spanner SW 13. Tightening torque: 12 Nm Fig.
  • Page 77 Diesel engine Series 15W / 18W Maintenance Screw special oil drain hose (2) onto the oil drain valve (3). This opens the quick-release coupling. Collect old oil in a suitable container and dispose of in accordance with the environmental regulations.

  • Page 78: Removing And Installing Oil Strainer

    Diesel engine Series 15W / 18W Maintenance 8.5.3 Removing and installing oil strainer Place a suitable container underneath. Drain engine oil (see Chapter 8.5.1). Unscrew both bolts (1). Remove oil strainer housing (2). Collect old oil in a suitable container and dispose of in accordance with the environmental regulations.

  • Page 79: Changing Oil Filter (For D/W Crankcase Version)

    Diesel engine Series 15W / 18W Maintenance 8.6 Changing oil filter (for D/W crankcase version) NOTE! Always replace engine oil and oil filter together. Changing engine oil (see Chapter 8.5.) 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.
  • Page 80 Diesel engine Series 15W / 18W Maintenance Clean the sealing surface on the oil filter case. Use new oil filter (7) and wet seal (6) with clean engine oil. Fig. 57 Tighten the oil filter (7) only by hand. Fill with engine oil.

  • Page 81: Fuel System

    Diesel engine Series 15W / 18W Maintenance 8.7 Fuel system Fig. 59: Fuel system Fuel pressure line Connection for fuel line to the fuel tank (feed) Connection for fuel line to the fuel tank (return) Fuel filter (standard) Injection nozzle holder...

  • Page 82: Replacing Fuel Filter (With Thread)

    Diesel engine Series 15W / 18W Maintenance Fuel filter (2) version (standard): With this version, the fuel lines are fixed using hose clamps. Fig. 61: Fuel filter (standard) 8.7.2 Replacing fuel filter (with thread) Switch off the engine Disconnect fuel line (1) using special fuel line disconnecting tool (2).
  • Page 83 Diesel engine Series 15W / 18W Maintenance Detach fuel line (6) from the fuel filter (4). Fig. 64 Undo hose clamp (7) and remove fuel filter (4). Fig. 65 Collect the fuel from the fuel line (6) in a suitable container (5) and dispose of in accordance with the environmental regulations.

  • Page 84: Replacing Fuel Filter (Standard)

    Diesel engine Series 15W / 18W Maintenance Fuel filter with thread (option) Install new fuel filter (4) and pay attention to the flow direction. The arrow (8) must point in the direction of the injection pump. Fig. 67: Fuel filter with thread Check banjo bolts (9) for damage and replace copper seals (10).
  • Page 85 Diesel engine Series 15W / 18W Maintenance Disconnect fuel line (2) using special fuel line disconnecting tool (3). Fig. 70 Undo hose clamp (4) and pull off the fuel line (2) from the fuel filter (5). Fig. 71 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.

  • Page 86: Replacing Air Filter

    Diesel engine Series 15W / 18W Maintenance Install new fuel filter (5) and pay attention to the flow direction. The arrow (7) must point in the direction of the injection pump. Assembly is in the reverse order to the dismantling.

  • Page 87: Dry Type Air Cleaner (Standard Engine)

    Diesel engine Series 15W / 18W Maintenance 8.8.1 Dry type air cleaner (standard engine) Switch off the engine Unscrew and remove the wing nut (1). Release sealing clips (2) and remove air filter case (3). Fig. 75 Remove air filter element (4).
  • Page 88 Diesel engine Series 15W / 18W Maintenance Thoroughly clean intake area (Fig. 78/8), air filter cover (Fig. 77/5) and air filter pot (Fig. 77/6) as well as centring ring (Fig. 77/7). NOTE! When removing the air filter and when cleaning the air filter case, always ensure that no dirt gets into the intake tract.

  • Page 89: Dry Type Air Cleaner (Oval Flange)

    Diesel engine Series 15W / 18W Maintenance 8.8.2 Dry type air cleaner (oval flange) Switch off the engine. Unscrew and remove the wing nut (1). Remove air filter cover (2). Fig. 81 Remove air filter element (3). Fig. 82 Clean suction area (Fig. 83/4) and air filter cover (Fig. 81/2) thoroughly.

  • Page 90: Oil Bath Air Cleaner (Standard Engine)

    Diesel engine Series 15W / 18W Maintenance Install new air filter element (3); in doing so, ensure that the spacer sleeve (4) is also installed. Fig. 84 Position air filter case (2) straight, in the process pay attention to correct seating, and fasten with the wing nut (1).
  • Page 91 Diesel engine Series 15W / 18W Maintenance Check filter material (3) depending on occurrence of dust. In the case of severe contamination, remove filter and wash out in diesel fuel or replace complete oil bath air cleaner. NOTE! Before assembly of the filter, let the diesel fuel drip off sufficiently or wipe off.

  • Page 92: Adjusting Valve Clearance

    Diesel engine Series 15W / 18W Maintenance 8.9 Adjusting valve clearance Safety WARNING! Risk of injury due to starting the engine! The engine can be accidentally started when adjusting the valve clearance and thereby cause severe injuries. Therefore: – Disconnect the high pressure line on the injection nozzle holder before starting work.

  • Page 93: Engines With Visible Flywheel And O.t. Marking

    Diesel engine Series 15W / 18W Maintenance 8.9.1 Engines with visible flywheel and O.T. marking Preparations Switch off engine and let it cool down to the ambient temperature. Unscrew the nuts (1) on the valve cover (2) and remove bracket (3) for fuel line and plastic seals, valve cover and valve cover gasket.
  • Page 94 Diesel engine Series 15W / 18W Maintenance Adjusting inlet valve - exhaust Insert crank handle (6) in the starting handle support bearing valve and slowly turn the crankshaft in the engine rotation direction (anticlockwise) until the end of the compression stroke or Fig.
  • Page 95 Diesel engine Series 15W / 18W Maintenance 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 without noticeable resistance (drag).
  • Page 96 Diesel engine Series 15W / 18W Maintenance 12. Replace valve cover gasket (13). Fig. 98 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).

  • Page 97: Engines With Covered Flywheel (Without Visible O.t. Marking)

    Diesel engine Series 15W / 18W Maintenance 8.9.2 Engines with covered flywheel (without visible O.T. marking) Preparations Switch off engine and let it cool down to the ambient temperature. Unscrew both nuts (1) on the valve cover (2) and remove bracket (3) for fuel line and plastic seals, valve cover and valve cover gasket.
  • Page 98 Diesel engine Series 15W / 18W Maintenance Adjusting exhaust valve Insert crank handle (6) into the starting handle support bearing and slowly turn the crankshaft in the engine rotation direction (anticlockwise) until the inlet valve's spring is pushed down completely (inlet valve is now fully open).
  • Page 99 Diesel engine Series 15W / 18W Maintenance Adjusting intake valve 10. Insert crank handle (6) into the starting handle support bearing and slowly turn the crankshaft in the engine rotation direction (anticlockwise) until the exhaust valve's spring is pushed down completely (exhaust valve is now fully open).
  • Page 100 Diesel engine Series 15W / 18W Maintenance 15. Tighten the high pressure line (4) on the injection nozzle holder. Tightening torque 25 Nm Fig. 109 16. Replace valve cover gasket (13). Fig. 110 17. Install valve cover (2) using two new plastic seals (14).

  • Page 101: Cooling Water Diagram (Standard)

    Diesel engine Series 15W / 18W Maintenance 8.10 Cooling water diagram (standard) Fig. 112: Cooling water diagram (standard) Cylinder head Cooling water flow direction Cylinder Cooling water pump (neoprene impeller pump) 2008-12-09...

  • Page 102: Cooling Water Diagram (With Water-Cooled Exhaust Manifold)

    Diesel engine Series 15W / 18W Maintenance 8.11 Cooling water diagram (with water-cooled exhaust manifold) Fig. 113: Cooling water diagram Cylinder head Cooling water pump (neoprene impeller pump) Cylinder Water-cooled exhaust manifold Cooling water flow direction 2008-12-09...

  • Page 103: Replacing Neoprene Impeller Of The Cooling Water Pump

    Diesel engine Series 15W / 18W Maintenance 8.12 Replacing neoprene impeller of the cooling water pump NOTE! The neoprene impeller of the cooling water pump must be considered as a wearing part. The service life of the neoprene impeller can be extremely different and depends solely on the operating conditions.
  • Page 104 Diesel engine Series 15W / 18W Maintenance Mark neoprene impeller for the case (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. 116 Carefully remove the neoprene impeller (3) using two screwdrivers (4).
  • Page 105 Diesel engine Series 15W / 18W Maintenance 10. Check cooling water pump case (5) and neoprene impeller (3) for damage; replace if necessary. NOTE! ® Coat the neoprene impeller with some Vaseline before installing in the water pump case. Fig. 119 11.
  • Page 106 Diesel engine Series 15W / 18W Maintenance 12. Clean the sealing surface of the cooling water pump cover (6). 13. Use new gasket (7). Fig. 121 14. Replace cooling water pump cover (2), screw in all screws (1) and tighten with a screwdriver.

  • Page 107: Removing, Installing And Checking Thermostat

    Diesel engine Series 15W / 18W Maintenance 8.13 Removing, installing and checking thermostat Switch off engine and let it cool down to the ambient temperature. Drain coolant and collect in a suitable container. Unscrew both bolts (1). Remove thermostat housing (2) with gasket.
  • Page 108 Diesel engine Series 15W / 18W Maintenance Measure the water temperature with 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).
  • Page 109 Diesel engine Series 15W / 18W Maintenance 11. Remove deposits and gasket residues on the cylinder head (5) and on the thermostat housing (2); in doing so, ensure that no dirt gets into the water channel in the cylinder head.

  • Page 110: Checking The Cooling System For Leaks

    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 the case of engine overheating or leaks in the sea water cooling circuit (e.g.

  • Page 111: Checking The Cooling Water Hoses And Hose Clamps

    If the cause of the error cannot be determined, contact your nearest Greaves Farymann Diesel service partner or call us. CAUTION! The use of radiator sealants is basically not permitted.

  • Page 112: Checking Level Of The Coolant (For Engines With Radiator)

    Diesel engine Series 15W / 18W Maintenance 8.15 Checking level of the coolant (for engines with radiator) Hot operating materials WARNING! Risk of burns due to hot operating materials! Operating materials can reach high temperatures during operation and cause burns / scalding in the case of contact.

  • Page 113: Replacing Coolant (For Engines With Radiator)

    Diesel engine Series 15W / 18W Maintenance Determine coolant level by visual inspection and coolant if necessary (the coolant level should be up to the bottom edge of the radiator filler neck (see also the operating manual of the device manufacturer).

  • Page 114: Faults

    In the case of increasingly occurring faults, reduce the maintenance intervals in accordance with the actual load. In the case of faults which cannot be rectified using the following information, contact the nearest Greaves Farymann Diesel service partner or the manufacturer. 9.1 Safety...
  • Page 115 Diesel engine Series 15W / 18W Faults Improper fault clearance WARNING! Risk of injury due to improper fault clearance! Improper fault clearance can result in severe personal injuries or material damage. Therefore: – Ensure there is sufficient installation clearance before starting work.
  • Page 116 Determine the cause of the fault. Inform the responsible person at the usage location about the fault. Arrange for rectification by a Greaves Farymann Diesel service partner or yourself depending on the type of the fault. NOTE! The fault table listed below gives information about who is authorised for rectification of the fault.

  • Page 117: Troubleshooting Chart

    Diesel engine Series 15W / 18W Faults 9.2 Troubleshooting chart 9.2.1 Engine does not start Error Possible cause Troubleshooting Clearance by If the injection No fuel in the tank Filling with fuel Operator noise (chattering) Speed adjusting lever is in the...
  • Page 118 Diesel engine Series 15W / 18W Faults Error Possible cause Troubleshooting Clearance by Compression too Decompression unit defective Check decompression unit, Skilled replace if necessary employee Leaky valves Check valves, repair or replace Skilled employee Leaky cylinder head / cylinder...

  • Page 119: Engine Starts, However Runs Irregularly Or Stops

    Diesel engine Series 15W / 18W Faults 9.2.2 Engine starts, however runs irregularly or stops Error Possible cause Troubleshooting Clearance Bad fuel supply Fuel filter blocked Replace fuel filter Operator Fuel line interrupted Check fuel line Operator Leaky fuel line...

  • Page 120: Bad Engine Performance

    Diesel engine Series 15W / 18W Faults 9.2.3 Bad engine performance Error Possible cause Troubleshooting Clearance Operating conditions Engine overloaded Reduce load; troubleshooting at Operator machine Performance reduction due to Improve operating conditions Operator increased intake temperature Bad fuel supply...

  • Page 121: Operating Behaviour Not Faultless

    Diesel engine Series 15W / 18W Faults 9.2.4 Operating behaviour not faultless Error Possible cause Troubleshooting Clearance by Overheating Engine overloaded Reduce load Operator (engine becomes Cooling air inlet blocked Clear blockage Operator too hot) Cooling air supply blocked Improve cooling air supply, check...
  • Page 122 Diesel engine Series 15W / 18W Faults Error Possible cause Troubleshooting Clearance by Knocking noises Piston and cylinder worn Overhaul engine (change piston Skilled and cylinder) employee Main bearing, connecting Overhaul engine Skilled road bearing worn employee Loose flywheel Check flywheel and crankshaft...
  • Page 123 Diesel engine Series 15W / 18W Faults Error Possible cause Troubleshooting Clearance by Engine emits blue Oil level too high Correct oil level Operator smoke Crankcase ventilation valve Replace crankcase ventilation Skilled defective valve employee Valve stem seal on intake valve...

  • Page 124: Startup After Eliminating Fault

    Diesel engine Series 15W / 18W Faults Error Possible cause Troubleshooting Clearance by Cold start problems Speed adjusting lever is not at Set speed adjusting lever to the Operator the maximum position maximum position (increased speed) Engine oil too viscous...

  • Page 125: Replacement Parts List

    Diesel engine Series 15W / 18W Replacement Parts List 10 Replacement Parts List 10.1 Spare parts WARNING! Risk to safety due to use of non-original spare parts! Defective and non-original spare parts can adversely affect the safety and result in damage and malfunctions or total failure of the engine.
  • Page 126 Diesel engine Series 15W / 18W Replacement Parts List Wearing parts for maintenance work Order Description Quantity number 541.052.2 Air filter element (dry type air cleaner) 555.129.1 Sealing clip 514.093.2 Wing nut 541.059.2 Air filter cover 541.058.2 Air filter pot 541.057.2...
  • Page 127 Diesel engine Series 15W / 18W Replacement Parts List Order Description Quantity number 555.003.2 Cooling water thermostat 50 °C (salt water) 555.006.2 Cooling water thermostat 70 (fresh water) 890.07.03 Split pin for thermostat 770.108.4 Thermostat housing gasket 538.219.2 Neoprene impeller for cooling water...
  • Page 128 Diesel engine Series 15W / 18W Replacement Parts List Special tools Order number Description 748.115.6 Fuel line disconnecting tool 748.173.2 Oil filter wrench (for engines with (dismantling the oil D/W crankcase) filter) Special tools can be ordered from the nearest Greaves Farymann Diesel service partner.

  • Page 129: Service History

    Diesel engine Series 15W / 18W Service history 11 Service history 11.1 Proof of purchase Using the type plate, copy the following information on to the proof of purchase and arrange confirmation. There is a type plate on the engine with the following information:...

  • Page 130: Handover And Servicing History

    Diesel engine Series 15W / 18W Service history 11.2 Handover and servicing history Arrange maintenance work during the warranty period and afterwards to be carried out by one of our authorised Greaves Farymann Diesel sales and service partners. Comply with the maintenance intervals and have the following evidence of maintenance confirmed by the specialist workshop.
  • Page 131 Diesel engine Series 15W / 18W Service history after 2000 operating hours / after 2250 operating hours / after 2500 operating hours / 48 months 54 months 60 months Dealer stamp: Dealer stamp: Dealer stamp: Hours ......Hours ......Hours ......
  • Page 132 Diesel engine Series 15W / 18W Service history after 4250 operating hours / after 4500 operating hours / after 4750 operating hours / 102 months 108 months 114 months Dealer stamp: Dealer stamp: Dealer stamp: Hours ......Hours ......Hours ......
  • Page 133 Diesel engine Series 15W / 18W Service history after 6500 operating hours / after 6750 operating hours / after 7000 operating hours / 156 months 162 months 168 months Dealer stamp: Dealer stamp: Dealer stamp: Hours ......Hours ......Hours ......

  • Page 134: Index

    Diesel engine Series 15W / 18W Index 12 Index Environmental protection ........21 Exhaust gases............ 51 Accident ............. 20 Adjusting valve clearance ........92 Faults ............... 114 Applications............22 Fire ..............20 Appropriate use..........14 First aid .............. 20 Attachment points ..........40 Fuel system............
  • Page 135 Diesel engine Series 15W / 18W Index commissioning ..........42 Spare parts ............125 Faults ............114 Ordering ............125 installation ............42 Standard configuration........23 Maintenance ...........69 Starting with electric starter ........61 Pressures............27 Storage ............39, 41 Protective equipment..........15 Surfaces, hot..........18, 51 Faults ............114 Switching off ............64 Installation............69...

  • Page 136: Notes

    Diesel engine Series 15W / 18W Notes Notes 2008-12-09...
  • Page 137 Diesel engine Series 15W / 18W Notes Art. 903.01.44 08.08 2008-12-09...

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