Farymann Diesel 15W Series Operating instructions

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DIESEL ENGINES : 15 / 18 / 32W

TABLE OF CONTENTS
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1. GENERAL INFORMATION, HANDLING 5
1.3 ORGANISATION AND USE OF THIS REPAIR MANUAL.............................................................................5
1.4 SERVICE .................................................................................................................................................5
1.5 AFTER SALES - SERVICE: FALKE - SPARE PARTS PROGRAM ..............................................................5
1.6 ENGINE, MODEL AND TYPE DESIGNATION ...........................................................................................6
1.7 SAFETY INSTRUCTIONS..........................................................................................................................7
2. TECHNICAL DATA 9
2.1 CONSTRUCTION DATA, CONSUMPTIONS AND PRESSURES ..................................................................10
2.1 CONSTRUCTION DATA, CONSUMPTIONS AND PRESSURES..................................................................11
2.2 OUTPUT, TORQUE, CONSUMPTION ......................................................................................................12
2.2 OUTPUT, TORQUE, CONSUMPTION ......................................................................................................13
2.3 SCREWS - TIGHTENING TORQUES, SEALING AND ADHESIVE MATERIALS..........................................15
2.4 TOOLS ..................................................................................................................................................16
2.5 TECHNICAL DESCRIPTION ...................................................................................................................19
2.6 APPLICATIONS .....................................................................................................................................19
3. DISMANTLING AND ASSEMBLY PROCEDURES ON THE BASIC ENGINE 20
3.1 BASIC REQUIREMENTS ........................................................................................................................20
3.2 DISMANTLING PROCEDURES ......................................................................................................21
4. MEASUREMENT TABLE- WEARING PARTS 32
4.1 CRANKCASE.....................................................................................................................................32
4.2 CRANKSHAFT ..................................................................................................................................33
4.3 CAMSHAFT .......................................................................................................................................34
4.4 GEAR COVER....................................................................................................................................35
4.5 SHAFTS, BEARINGS ........................................................................................................................36
4.6 CONNECTING ROD..........................................................................................................................37
4.7 CYLINDER LINER ............................................................................................................................38
4.8 PISTON 15/18W .................................................................................................................................39
4.9 PISTON 32W ......................................................................................................................................40
4.10 CYLINDER HEAD 15/18W...........................................................................................................41
4.11 CYLINDER HEAD 32W................................................................................................................42
5. ENGINE REASSEMBLY 43
6. TEST RUN, ADJUSTMENTS, CHECKS 56
7. ELECTRICAL SYSTEM 66
7.1 FLYWHEEL – DYNAMO / REGULATOR .................................................................................................66
7.2 FUNCTION TESTS: ................................................................................................................................66
7.3 HAZARDS / CAUSES OF FAILURE .........................................................................................................67
7.4 12 V FLYWHEEL – DYNAMO / REGULATOR, GRAPHS........................................................................68
7.5 WIRING DIAGRAMS........................................................................................................................69
7.5.1 DIAGRAM 1 .................................................................................................................................69
7.5.2 DIAGRAM 2 ..............................................................................................................................71
7.5.3 DIAGRAM 3 ..............................................................................................................................72
7.5.4 DIAGRAM 4 ..............................................................................................................................73
7.5.5 DIAGRAM 5 ..............................................................................................................................74
8. TROUBLESHOOTING 75
8.1 ENGINE WILL NOT START.....................................................................................................................75

TABLE OF CONTENTS
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8.2 ENGINE STARTS BUT FIRES INTERMITTENTLY OR DIES........................................................................76
8.3 POOR ENGINE PERFORMANCE AND / OR BLACK SMOKE.......................................................................76
8.4 POOR ENGINE PERFORMANCE AND/OR BLACK SMOKE ........................................................................77
8.5 IMPERFECT OPERATING BEHAVIOUR ...................................................................................................77

PREFACE
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We congratulate you on your choice of a FARYMANN engine and wish you much pleasure
with this German quality product.
These operating instructions are based on the latest state of technical development. In
preparing them, every effort has been made to avoid errors. However, we accept no liabil-
ity for any errors of presentation or description, nor for any omissions. Modifications may
also occur because of ongoing technical developments. We reserve the right to make
modifications without giving prior notice.
Everyone responsible for the installation, commissioning, operation, maintenance or repair
of the engines must read and follow the operating instructions and particularly the "Safety"
chapter.
The engine is built according to the state-of-the-art, and in compliance with recognised
safety regulations. Nevertheless, while the engine is in use, there may be physical or
mortal dangers to the user or to third parties, and also damage to the engine and to other
property. For these reasons, the engine must only be used when it is in perfect technical
condition, and when those involved are aware of the dangers and the safety precautions.
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.
Correct use also includes following the operating instructions and adhering to the operat-
ing, servicing and maintenance conditions. The engine must only be operated and serv-
iced by reliable, trained personnel in compliance with the relevant accident prevention
regulations as well as other generally-recognised rules of safety and occupational health.
FARYMANN DIESEL GmbH accepts no liability for any damage resulting from unauthor-
ised conversions or modifications to the engine. Replacement parts must meet the techni-
cal requirements specified by FARYMANN DIESEL GmbH. This is always guaranteed if
original replacement parts are used. Fitting and/or using parts and accessories not sup-
plied by FARYMANN DIESEL GmbH may have a detrimental effect on your engine under
certain circumstances.
FARYMANN DIESEL GmbH accepts no liability whatsoever for any damage resulting
from the use of non-original replacement parts or accessories.

GENERAL INFORMATION
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1. 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. Bosch fuel injection equipment is used on all engines. A high-precision
centrifugal governor ensures accurate speed (RPMs) and load control.
Special modified water-cooled Farymann engines fulfill BSO I/II and EPA – requirements.
1.3 Organisation and Use of this Repair Manual
The descriptions, data and illustrations refer to those assembly and adjustment procedures
where FARYMANN engines differ from ordinary diesel engines.
−It is assumed that all work on the engine will be carried out by competent staff who have
received training.
−Special tools must be available, as described in the manual, together with good-quality
standard tools.
1.4 Service
−If you have any further questions about the Repair Manual, we recommend you to
contact your nearest FARYMANN Service Centre.
−Circular letters and training courses ensure that our service personnel have an answer
to every question. Please ask for a list of all our service locations from your own
FARYMANN Service Centre.
1.5 After Sales - Service: FALKE - Spare Parts Program
"Service, Quality and Progress"
is our motto. This is why we have developed our very own computer-aided "FALKE"
Service System.
The FALKE System makes it possible for FARYMANN’s world-wide network of distributors
to satisfy all spare parts and service requirements quickly and reliably, ensuring
that we maintain a close relationship with our customers.

GENERAL INFORMATION
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1.6 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.
As of July 1985, the consecutive engine number is also imprinted on the crankcase.
As of July 1982, the type designation (a 12-digit code number) is used in addition to the
series number (SN = Order Number). (See manufacturer’s nameplate).
e.g. 18W430.0138 M5
98 06 06 Date of Production

GENERAL INFORMATION
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1.7 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.
Be careful when handling hot or corrosive fuels, lubricants or other sub-
stances (risk of burning or scalding).
Never carry out maintenance and repair work when the engine is running.
Ensure that the engine cannot start unintentionally.
Before turning the engine over, make sure that nobody is in the danger
area. When you have finished working on the engine, always check that
the safety devices have been refitted, and that all tools have been removed
from the engine.
Never carry out any work on safety valves (e.g. modification of the spring
tension). Defective safety valves must be replaced with new ones.
When disposing of used fuels, lubricants and filters, follow the regulations
which apply locally.
Before or when you start the engine, check:
−all lines, hoses and screwed connections for leaks;
−safety devices for completeness and ability to operate.
When starting the engine by hand, only use the starting device specified by
the manufacturer (starting handle with kick back limiter, recoil starting) and
follow the handling instructions.
Never use cold starting aids based on ethyl oxide.
Because of the explosion hazard, it is forbidden to start up a compressed-
air start engine with combustible gases (fuel gases) or oxygen, even in an
emergency.

GENERAL INFORMATION
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1.5 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.
Before starting any work on the electrical components, the power supply to
all live parts must be cut off.
Only carry out maintenance and repair work when the engine parts are in a
stable position.
Liquids ejected under high pressure (such as fuels or oils) may penetrate
the skin and cause severe injuries.
To carry out cleaning work on the engine, always use a non-combustible
detergent, or one which has a flash point of more than 65 °C.
CALIFORNIA
Proposition 65 Warning
Diesel engine exhaust and some of its
constituents are known to the State of
California to cause cancer, birth de-
fects, and other reproductive harm.

TECHNICAL DATA
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2. Technical Data
Engine Type 15W 18W 32W
Design verticall
Number of Cylinders 1
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-
off side)
anti clockwise
Max. power / 3000 RPM
F (DIN 70020) 4,76 kW 5,70 kW 9,74 kW
IFN-ISO (DIN 6271) 4,33 kW 5,20 kW 8,85 kW
ICFN-ISO (DIN 6271) 3,90 kW 4,70 kW 8,00 kW
Max. torque 14,4 Nm 16,7 Nm 30,2 Nm
(DIN 70020) at 2400 RPM at 2400 RPM at 2400 RPM
Max. speed 3600 RPM
Mean piston speed at 3000 RPM 5,5 m/s 5,5 m/s 7,4 m/s
Compression ratio 1 : 20 1 : 19,1 – 22,6 1 : 20
Valve clearance, exhaust valve 0,2 mm
intake valve 0,2 mm
Tank capacity --- --- ---
Lubricating oil volume (sump capacity) 1,0 l 1,0 l 1,6 l
Lubricating oil consumption 1,0 g/kWh
Starter motor
rated voltage 12 V
Battery capacity required 55Ah
Weight 37 kg 37 kg 75 kg
Cooling water requirement 7 – 8 l/min
Permissible tilt during operation :
Longitudinal 15 °
Lateral 15 °

TECHNICAL DATA
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2.1 Construction Data, Consumptions and Pressures
Technical Data Table 1
Engine Type 15W 18W 32W
Construction data dimen-
sion
System *four stroke
Combustion Proce-
dure
*direct injection
Cooling System *Water-cooled
Design / Configuration *1-cylinder / vertical
Bore (mm) 75 82 95
Stroke (mm) 55 55 74
Displacement (cm3)242 290 524
Compression Ratio *1 : 20,0 1 : 19.1 - 1 : 22,6 1 : 20,0
Temperatures dimen-
sion
Permissible air intake
temperature (max.) (°C) 50
Permissible exhaust
gas temperature (max) (°C) 580
Permissible cooling air
temperature (max.) (°C) 50
Permissible fuel
temperature (max.) (°C) 80
Permissible lub. oil
temperature (max.) (°C) 130
Consumptions (at IFN Output)
Specific fuel con-
sumption, 3000 RPM (g/kWh) 305 300 255
Fuel tank content (l) NO
Feed pump (max. lift) (mm) 300
Fuel *to DIN 51 601 / ASTM D 975-77 + 2D/BS 28669 1970 A1 + A2
Specific lub. oil con-
sumption (g/kWh) 1
max. lub. oil capacity (g/l) 1100 / 1,25 1100 / 1,25 1380 / 1,56
Topping up volume
lower-upper mark
t/btt k
(g/l) 200 / 0,226 200 / 0,226 240 / 0,270
Lub. Oil quality *HD oil: minimum quality CC; better, CD quality (API-spec.) and multigrade oils
Pressures
Injector setting (bar) 200 200 175
Oil pressure (max.) (bar) 5
Permissible air intake
vacuum
(kPa) 2
Permissible exhaust
gas back pressure (kPa) 5

TECHNICAL DATA
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2.1 Construction Data, Consumptions and Pressures
Technical Data Table 2
Engine Type 15W 18W 32W
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
ATDC *4,4°- 6,7° = 10 - 15 mm 4,4°- 6,7° = 10 - 15 mm 4,5°- 6,7° = 12 - 18 mm
Flywheel diameter (mm) 258 258 308
Injection pump: end of delivery, plunger with control edge “above“
Engine RPMs (min-1)1500 1800 2000 2500 1500 1800 2000 2500 1500 1800 2000 2500
End of delivery BTDC (mm) 17 18 19 17 18 19 28 28 28 32
Engine RPMs (min-1)2800 3000 3300 3600 2800 3000 3300 3600
2800
3000 3300 3600
End of delivery BTDC (mm) 21 22 25 28 21 22 25 28 36 40 40 46
Injection pump: start of delivery, plunger with control edge “below“ (engines for generator and pump drive)
Engine RPMs (min-1)1500 1800 3000 3600 1500 1800 3000 3600 1500 1800 3000 3600
Start of delivery BTDC (mm) * * 39 41 * * 39 41 42 42 60 73
Valve clearance (cold)
inlet and outlet valve (mm) 0,2
Repair Data Dimen-
sion
Inlet valve
Recedes by: (mm) 0,1 - 0,2 0,1 - 0,2 0,1 – 0,2
Exhaust valve
Recedes by: (mm) 0,1 - 0,2 0,1 - 0,2 0,1 – 0,2
Piston protrudes by: (mm) 0,63 - 0,93 0,63 - 0,93 0,65 - 0,98
Gap measurement (mm) 0,47 - 0,82 0,47 – 0,82 0,43 - 0,85
Piston ring joint (mm) 0,2 – 0,8 0,2 – 0,8 0,2 – 0,8
Crankshaft plain bearing
clearance - new condition (mm) 0,02 - 0,05 0,02 - 0,05 0,02 - 0,06
Crankshaft plain bearing
clearance - wear limit (mm) 0,08 0,08 0,09
Connecting rod plain bearing
clearance - new condition (mm) 0,03 - 0,06 0,03 - 0,06 0,03 - 0,08
Connecting rod plain bearing
clearance - wear limit (mm) 0,11 0,11 0,12
Crankshaft end play (mm) 0,05 - 0,15 0,05 - 0,15 0,05 – 0,15

TECHNICAL DATA
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2.2 Output, Torque, Consumption
15W Leistung / Output /
Puissance / Potencia
18W Leistung / Output /
Puissance / Potencia
Drehmoment / Torque /
Couple / Par
Drehmoment / Torque /
Couple / Par
Verbrauch / Consumption /
Consommation / Consumo
Verbrauch / Consumption /
Consommation / Consumo
DIN ratings
FVehicle rating: intermittent duty at variable speed and load.
IFN-ISO DIN-ISO 3046 Blocked useful performance for intermittent loads.
ICFN-ISO DIN-ISO 3046 Standard performance, blocked continuous useful performance for con-
stant RPMs and constant load.
DContinuous operation: - contact factory for use beyond the limits indicated.
-Decrease of approx. 1% for every 100 m altitude and approx. 2% for every 5°C above
20°C
-Rating certified within tolerance of 5% after engine has been run in with standard air filter
and exhaust muffler.

TECHNICAL DATA
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2.2 Output, Torque, Consumption
32W 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

TECHNICAL DATA
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Verbrauch / Consumption /
Consommation / Consumo

TECHNICAL DATA
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2.3 Screws - Tightening Torques, Sealing and Adhesive Materials
Technical data Table 1
Engine type 15W 18W 32W
Tightening torques
Cylinder head
torque / wrench width
(Nm)
(
mm
)
30- 33 / 13 30 - 33 / 13 52 - 56 / 17
Rocker bracket
torque / wrench width
(Nm)
(
mm
)
* * *
Bearing cover
torque / wrench width
(Nm)
(
mm
)
30 - 33 / 13 30 - 33 / 13 30 - 33 / 13
Connecting rod
torque / wrench width
(Nm)
(
mm
)
30- 33 / 13 30- 33 / 13 52 - 56 / 17
Nozzle holder
torque / wrench width
(Nm)
(
mm
)
20 - 23 / 13 20 - 23 / 13 20 - 23 / 13
Injection pump
torque / wrench width
(Nm)
(
mm
)
8 – 12 / 10 8 – 12 / 10 20 - 23 / 13
Delivery valve
torque / wrench width
(Nm)
(
mm
)
34 - 39 / 22 34 - 39 / 22 34 - 39 / 22
Flywheel
torque / wrench width
(Nm)
(
mm
)
8 – 12 / 10 8 – 12 / 10 390 - 410 / 46
Speed governor
torque / wrench width
(Nm)
(
mm
)
55 - 60 / 14 55 - 60 / 14 55 - 60 / 14
Maximum operation angles
Longitudinal
(in dir. of crankshaft) (deg.) 15 15 15
Transverse (deg.) 15 15 15
Sealing and adhesive materials
Text Code Type
ALoctite 573
BLoctite 270
CLoctite 415

TECHNICAL DATA
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2.4 Tools
Part No. Description Use
748.115.6 Fuel line clamp to clamp fuel supply
lines
748.130.2 Hexagonal socket
wrench, 36 mm
for flywheel nuts
748.128.4 Drive wrench for use with socket
wrench, 748.154.2
748.108.5 Special screw
driver
to adjust governor
spring nuts
748.132.6 Crankshaft race
puller
use with part no.
748.136.2 to pull off
main bearing race
from crankshaft
748.137.2 Crankshaft gear
wheel puller
use with part
748.136.2 to pull off
crankshaft gear wheel
748.136.2 Puller plate use with parts
148.132.6 and
748.137.2
748.122.6 Flywheel puller to loosen flywheel
748.119.4 Bearing driver to press in crankshaft
roller bearing and shaft
seal

TECHNICAL DATA
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2.4 Tools
748.120.4 Bearing driver to press the crankshaft
bearing bushes in and
out
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 to press the little end
bearing bush in and
out (connecting rod)
748.129.4 Bearing driver to press the regulator
shaft bearing bush in
and out
37E/43E:
748.125.4
43F:
748.211.4
Guide punch to press the valve
guides in and out
748.117.6 Drop tube to measure the injec-
tion timing

TECHNICAL DATA
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2.4 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

TECHNICAL DATA
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2.5 Technical Description
Diesel engine models 15W / 18W / 32W are water-cooled, single-cylinder, four-stroke die-
sel engines with direct injection. The engines have oil pressure forced lubrication. The fuel
injection pump and the valves are controlled by the camshaft which is driven by the crank-
shaft. The fuel injection pump (self-venting fuel system) is driven directly while the valves
are driven by push rods and rockers. An electric starter and a manual starting device are
provided to start the engine. The engines are equipped with an automatic decompression
system and a manual forced starting enrichment quantity.
Special modified water-cooled Farymann engines fulfill BSO I/II and EPA – requirements.
2.6 Applications
Diesel engine models 15W / 18W / 32W are suitable for the following applications:
−Marine generating sets
−Marine propulsion engines
−Vehicle cooling systems
−Military Equip. ( APU, ... )
−
−.

RE-ASSEMBLING PROCEDURES
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3. Dismantling and Assembly Procedures on the Basic Engine
3.1 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);
−and a workshop where the necessary
equipment, standard tools and special
tools are available
−A well-lit, unrestricted working area, free
from dirt and swarf, will make the work
considerably easier.
−Clean the engine thoroughly before dis-
mantling it.
−Attention must be paid to all the informa-
tion and warning notices which have been
affixed.
−Particular care is called for in the vicinity of
rotating, moving or hot parts.
ATTENTION
This symbol is used whenever failure to
comply precisely with instructions or proce-
dures may cause accidents which can result
in injuries or death.
CAUTION
This symbol is used whenever failure to
comply precisely with instructions or proce-
dures may cause damage to the engine.
Advice and tips about special features when
handling the engine.