Farymann Diesel 15D Series Instruction manual

3
CONTENTS
IGeneral Information
I.1. Introduction 5
I.2. Farymann Diesel engines 7
I.3. Engine identification 7-8
I.4. Cross reference old - new engine type 8
II Technical Data
II.1. General engine data 9
II.2. Picture of model 15/18 10
II.3. Sectional view of model 15/18 11
II.4. Special tools 12-14
III Engine Repair
III.1. Engine disassembly 15-27
III.2. Wear and tear measurements 28-41
III.3. Engine reassembly 42-58
III.4. Lubrication system 59
III.5. Function and repair of fuel system60-65
III.6. Governor 66-70
III.7. Resurfacing of valve seats 70
III.8. Setting datas for fuel timing 71-72
III.9. Tightening torques 73
IV Trouble Shooting 74-78

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PREFACE
This Manual is for workshop use only and intended for use by experienced
mechanics.
Only the standard type of engine models 15B/D 18B/D 29C/32A are illustrated and
dealt with.
Because there are, however, many different type variants which can differ to a greater
or lesser degree from the standard type described, this Manual can and should be
used only as a quideline. 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.
All safety precautions are to be strictly observed, because otherwise:
- death or injury to the user or third parties can occur;
- the machine or other material assets of the user may be impaired;
- efficient operation of the machine may be jeopardized.
Every person in the user`s business who is tasked with the installation,
commissioning, operation, servicing or repair of engine must have read and
understood the „Safety“ chapter of the Operating Instructions.
The engine may be serviced only by trained personnel. Any work procedure which
impairs the saety of the engine is to be forbidden.
Modifications or changes to the engine or the use of non-original replacement parts
without proper authority is not allowed on safety grounds and invalidates the liability of
the FARYMANN DIESEL COMPANY.
This Workshop Manual is technically up-to-date at the time of poing to press. Every
care was taken in its compilation to avoid errors.
We are, however, not responible for any errors in illustrations or descriptions or for any
omissions. There may also be changes due to technical developments.
We reserve the right to make changes without prior notice
.

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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. If you are already familiar with the gasoline 4-stroke engine, study the comparison
below. It will show the differences between a 4-stroke Diesel and a 4-stroke gasoline engine.
Gasoline Diesel
I. Intake stroke
The downwards movement of the piston
draws a mixture of gaseous fuel and air
through the open inlet valve into the
cylinder.
II. Compression stroke
The upwards movement of the piston
compresses the fuel/air mixture. The
temperature rises through the
compression stays below the self-ignition
point of the fuel.
The downwards movement of the piston
draws only air through the open inlet valve
into the cylinder.
The upwards movement of the piston
compresses the air, which causes the
temperature to rise above 500 C (932 F).

I. GENERAL INFORMATION
6
III. Power stroke
A spark created by a spark plug ignites
the fuel. The resulting expansion of the
combustion gases forces the piston down.
Fuel in a fine mist is sprayed into the
cylinder and self ignites in the hot air. The
resulting expansion of the combustion
gases forces the piston down.
IV. Exhaust stroke
The upwards movement of the piston forces the exhaust gases through the open exhaust
valve. This stroke is identical on both engines.
Both engines are of the internal combustion design because they burn fuel within the engine.
Both engines require fuel, air and a method of igniting the fuel.
Both engines can be of 2 - or 4 cycle design.
Both engines can be aircooled or watercooled.
The basic differences are:
The gasoline engine has an external mixture (carburator) of the fuel and combustione air. It needs an
electric source (spark plug) to ignite the fuel.
The diesel engine draws in only air. It has an internal mixture of fuel and combustion air. The fuel is self-
ignited by the high temperature of the compressed air.
To ensure that the air temperature is high enough to ignite the fuel, a diesel engine has a very high
compression ratio compared to a gasoline engine. The diesel engine does not need an ignition system,
due to the self-ignition of the fuel. Needed are a injection pump, fuel lines and a fuel injector. The
injector is often called the heart of the diesel engine. It is a precision manufactured assembly, built to
rigid specifications and clearances. It performs almost the same duties as a carburator. An injection
pump delivers fuel to the injector where it is sprayed into the cylinder. Another difference between diesel
and gasoline engines is that a diesel engine does not use a throttle valve. The governing is done by
varing the amount of fuel injected into the cylinder.
Whereever sturdiness, reliablity, fuel economy and long service life are required, the diesel engine is the
right choice.

I. GENERAL INFORMATION
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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. A high precision centrifugal governor totally enclosed in
the crankcase links to the fuel injector pump and to the speed contol lever.
The flywheel fan cools the engine, eliminating troublesome V-belts. Air is drawn into the flywheel fan and
routed through shouding to the cooling fins of the cylinder head.
I.3. Engine identification
Until July 1982 the engine nomination system consisted of a 10 figure code.
For example: 35K54 0715 F
35 = code figure for the year of manufacture
K54 = engine type
0715 = serial number
F= code figure for month of manufacture
Effective July 1982 the new system consists of a 12 figure code system in addition to the serial
number (see engine name plate).
For example: 15D430 0118 D5
860320 = manufacturing date
15 D430 0118 D5
  Trim-no. = engine speed and governor
 
  Type-no. = engine specification

 Starting 0 = manual crank start
 system 1 = recoil starter
 5 = electric starter
 6 = manual crank start with alternator
 7 = alternator with starter

 Bearing 3 = roller bearing at flywheel side
 Crankshaft 4 = horizontal crankshaft

 Basic A = vertical cylinder configuration anti
Engine clockwise rotation (former execution)
Design B = vertical cylinder configuration
clockwise rotation (new execution)
D = vertical cylinder configuration
anti-clockwise rotation
E = horizontal cylinder configuration
anti-clockwise rotation
W = watercooled cylinder configuration
anti-clockwise rotation

 Displacement in cubic inches

I. GENERAL INFORMATION
8
I.3. Engine identification
An engine name plate is affixed to every engine. In addition to the name plate the engine order
number and, effective July 1985, the running engine number are also stamped on the
crankcase.
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
K55 model range 15B
K64/18A/C model range 18D
K65 model range 18B
K34 model range 15W/18W

II. TECHNICAL DATA
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II.1. General engine data
Specifications/engine type 15B/D 18B/D 29C 32A
______________________________________________________________________
Number of cylinders one, vertical
Combustion direct injection, 4 stroke
Bore/Stroke [mm] 75/55 82/55 90/74 95/74
Total displacement [cm3] 242 290 470 524
Compression ratio 1:20 1:20 1:19 1:20
______________________________________________________________________
Direction of rotation A+C+D: counter clockwise when viewed flywheel
B : clockwise when viewed flywheel
______________________________________________________________________
Performance data (full load)
Working speed, max. [min-1] 3600
Idle speed, min. [min-1] 900-1000
Output „A“ DIN 6270 [kW(Hp)] 3.5 (4.8) 4.2 (5.7) 6.6 (9) 7.1 ( 9.7)
„B“ DIN 6270 [kW(Hp)] 3.9 (5.3) 4.7 (6.4) 7.35(10) 7.9 (10.7)
„F“ DIN 70020 [kW(Hp)] 4.3 (5.8) 5.1 (6.9) 8.1 (11) 8.7 (11.8)
Mean piston speed [m/s] 6.6 6.6 8.88 8.88
Torque („F“ output) Nm/ min -1 12.5/2400 15.2/2500 24.5/2400 27.5/2400
Lub. oil pressure max. [bar] 4.0 4.0 5.0 5.0
(at 100°C (220°F) oil temp.)
Lub. oil pressure min. [bar] 1.8 1.8 2.0 2.0
(at 100°C (220°F) oil temp.)
Fuel consumption [g/kWh] 330 310 295 300
Lub. oil consumption [g/kWh] 1.0 1.0 1.0 1.0
Exhaust back
pressure max. [kPa] 5.0 5.0 5.0 5.0
Intake underpressure max. [kPa] 2.0 2.0 2.0 2.0
Operation temparatures
Lub. oil max. [°C(°F)] 130 (317) 130 (317) 130 (317) 130 (317)
Exhaust gas in
manifold max. [°C(°F)] 580 (1,415) 580 580 580
Entering cool. air max. [°C(°F)] 50 (122) 50 50 50
∆t cooling air
(at outlet cyl.-head) [°C(°F)] 50 (122) 50 50 50
Capacity
Lub. oil [dm3] 1.0 1.0 1.6 1.6
Fuel tank [dm3] 4.0 4.0 6.8 6.8
Weight
Engine (dry, standart,
flywheel) [kg] 39.5 39.2 70.5 70.0
Setting data
Valve clearance
cold engine [mm] 0.1 0.1 0.1 0.1
injection pressure [bar] 200 200 175 175
Working angle (standart oilpan)
lengthwise deg. 25 25 25 25
crosswise deg. 25 25 25 25

III.1. DISASSEMBLY
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II. TECHNICAL DATA
11

II. TECHNICAL DATA
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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.
All “drivers“ should be used with a hydraulic or arbor press.
Part No. Description Use
748.092.2
748.093.2
748.094.2
748.116.6
Pin Allen Wrench 4mm
Pin Allen Wrench 5mm
Pin Allen Wrench 6mm
Pin Allen Wrench 6mm
To remove pin type allen head screws
(only for old models of K5/K6 engines)
748.115.6 Fuel line camp To clamp fuel supply lines
748.117.6 Drip tube assembly To check injection timing
748.171.4 Hexagon Socket 14mm For gorvernor screw
748.170.4 Deep tube Socket 13mm For cylinder head nuts
748.130.2 ¾“ Drive Socket 36mm For flywheel nut
748.128.4 ¾“ Drive Sticker For use with socket
748.108.5 Governor spring tool To adjust governor spring tension