Farymann Diesel 15W Series User manual

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!

2 2008-12-09
© Greaves-Farymann Diesel GmbH
Industriestraße 19
68623 Lampertheim
Germany
Tel.: [phone] / 5 07 - 0
Fax: [phone] / 5 07 - 111
E-Mail: [email protected]
Internet: www.farymann.de
Release:
Created by:
Kothes!
Technische Kommunikation GmbH & Co. KG
www.kothes.de

Diesel engine Series 15W / 18W
Table of contents
2008-12-09 3
1General....................................................................................7
1.1 Information about this manual .......................................7
1.2 Explanation of the symbols............................................8
1.3 Limitation of liability........................................................9
1.4 Copyright......................................................................10
1.5 Warranty terms ............................................................10
1.6 Customer service.........................................................10
2Safety ....................................................................................11
2.1 Customer’s responsibility.............................................11
2.2 Personnel requirements...............................................13
2.2.1 Qualifications................................................13
2.3 Appropriate use ...........................................................14
2.4 Personal protective equipment....................................15
2.5 Specific dangers ..........................................................16
2.6 Safety devices..............................................................20
2.7 Behaviour in the case of danger and accidents...........20
2.8 Environmental protection.............................................21
3Technical data......................................................................22
3.1 Technical specifications...............................................22
3.2 Applications..................................................................22
3.3 Standard configuration.................................................23
3.4 Options.........................................................................23
3.5 Engine type plate.........................................................24
3.6 Engine type code.........................................................24
3.7 Engine data..................................................................25
3.8 Performance data ........................................................26
3.9 Dimensions and weight................................................27
3.10 Temperatures...............................................................27
3.11 Pressures.....................................................................28
3.12 Operating materials .....................................................28
3.13 Engine oil specification................................................29

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4Structure and function........................................................ 30
4.1 Overview..................................................................... 30
4.2 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 Batteries....................................................... 36
4.3 Cooling system............................................................ 37
4.3.1 Open cooling water circuit with direct sea
water cooling without thermostat................. 37
4.3.2 Open cooling water circuit with direct sea
water cooling with thermostat...................... 37
4.3.3 Closed cooling water circuit with radiator
and thermostat............................................. 38
4.4 Galvanic corrosion (electrolysis) on engines for
marine generators applications................................... 38
5Transport, packing and storage ........................................ 39
5.1 Safety notes for transport............................................ 39
5.2 Transport inspection.................................................... 39
5.3 Packing ....................................................................... 40
5.4 Transport..................................................................... 40
6Installation and commissioning ........................................ 42
6.1 Safety.......................................................................... 42
6.2 Installation................................................................... 42
6.2.1 Mounting the flywheel.................................. 42
6.2.2 Attaching stub shaft (option)........................ 44
6.2.3 Attaching speed controller........................... 45
6.3 Initial commissioning................................................... 46
6.4 Filling with engine oil................................................... 47
6.4.1 Venting the fuel system for engines with
fuel feed pump (option)................................ 49

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7Operation..............................................................................50
7.1 Safety...........................................................................50
7.2 Preparing for start........................................................54
7.3 Manual start.................................................................55
7.4 Starting with electric starter .........................................61
7.5 Operation.....................................................................62
7.6 Switching off.................................................................64
7.6.1 Engine without electric starter......................65
7.6.2 Engine with electric starter...........................65
7.7 Decommissioning ........................................................66
8Maintenance .........................................................................68
8.1 Safety...........................................................................68
8.2 Maintenance plan ........................................................70
8.3 Cleaning the intake area..............................................73
8.4 Checking threaded connections ..................................74
8.5 Changing engine oil.....................................................75
8.5.1 Version with oil drain plug ............................75
8.5.2 Version with oil drain valve...........................76
8.5.3 Removing and installing oil strainer .............78
8.6 Changing oil filter (for D/W crankcase version)...........79
8.7 Fuel system..................................................................81
8.7.1 Replacing fuel filter.......................................81
8.7.2 Replacing fuel filter (with thread)..................82
8.7.3 Replacing fuel filter (standard) .....................84
8.8 Replacing air filter........................................................86
8.8.1 Dry type air cleaner (standard engine).........87
8.8.2 Dry type air cleaner (oval flange) .................89
8.8.3 Oil bath air cleaner (standard engine)..........90
8.9 Adjusting valve clearance............................................92
8.9.1 Engines with visible flywheel and O.T.
marking.........................................................93
8.9.2 Engines with covered flywheel (without
visible O.T. marking) ....................................97

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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...................... 110
8.14.1 Engines with radiator (and e.g. electric
water pump)............................................... 110
8.14.2 Engines with direct sea water cooling ....... 110
8.14.3 Checking the cooling water hoses and
hose clamps............................................... 111
8.14.4 Precautions in the case of engine
overheating................................................ 111
8.15 Checking level of the coolant (for engines with
radiator) ................................................................... 112
8.15.1 Replacing coolant (for engines with
radiator) ..................................................... 113
9Faults.................................................................................. 114
9.1 Safety........................................................................ 114
9.2 Troubleshooting chart ............................................... 117
9.2.1 Engine does not start................................. 117
9.2.2 Engine starts, however runs irregularly or
stops .......................................................... 119
9.2.3 Bad engine performance........................... 120
9.2.4 Operating behaviour not faultless.............. 121
9.3 Startup after eliminating fault.................................... 124
10 Replacement Parts List..................................................... 125
10.1 Spare parts................................................................ 125
10.2 Ordering spare parts................................................. 125
11 Service history................................................................... 129
11.1 Proof of purchase...................................................... 129
11.2 Handover and servicing history................................. 130
12 Index................................................................................... 134
Notes .......................................................................................... 136

Diesel engine Series 15W / 18W
General
2008-12-09 7
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. The personnel must have carefully read and
understood this manual before starting all work. The basic
prerequisite for safe working is compliance with all the safety and
handling instructions stated in this manual.
Furthermore, the local accident prevention regulations and general
safety conditions for the application of the machine are also
applicable.
Illustrations in this manual are provided for basic understanding
and can be different from the actual version of the engine for the
machine.

Diesel engine Series 15W / 18W
General
8 2008-12-09
1.2 Explanation of the symbols
Safety information Safety information in this manual is identified using symbols. The
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.
DANGER!
… points out a directly dangerous situation which
results in death or severe injuries if it is not
avoided.
WARNING!
… points out a potentially dangerous situation
which can result in death or severe injuries if it is
not avoided.
CAUTION!
… points out a potentially dangerous situation
which can result in minor or slight injuries if it is not
avoided.
CAUTION!
… points out a potentially dangerous situation
which can result in damage to property if it is not
avoided.
Tips and recommendations
NOTE!
… highlights useful tips and recommendations and
information for efficient and trouble-free operation.

Diesel engine Series 15W / 18W
General
2008-12-09 9
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.
The manufacturer accepts no liability for damage due to:
Non-observance of the instructions
Improper use
Use of untrained personnel
Unauthorised modifications
Technical changes
Use of non-original spare parts
The actual scope of delivery can be different from the explanations
and illustrations stated here for special versions, the use of
additional ordered options or due to the latest technical changes.
The agreed obligations in the supply contract, the general terms
and conditions and the delivery conditions of the manufacturer and
the applicable legal regulations in force at the time of the
conclusion of the contract are applicable.
We reserve the right to make technical modifications in order to
improve usability.

Diesel engine Series 15W / 18W
General
10 2008-12-09
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.
Violations oblige to compensation. The right for further claims
remains reserved.
1.5 Warranty terms
The warranty terms are provided in the manufacturer's terms and
conditions.
1.6 Customer service
Our customer service is pleased to provide further technical
information. Please refer to our website (www.farymann.de) or
telephone us on +49 (0)6206/507-0 for a list of our sales and
service partners.
Furthermore, our employees are always interested in new
information and experience arising from use and which can be
valuable for the improvement of our products.

Diesel engine Series 15W / 18W
Safety
2008-12-09 11
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.
2.1 Customer’s responsibility
The system is used commercially. The owner of the machine is
thus subject to the legal obligations for health and safety at work.
As well as the operational safety instructions in this operator's
manual, the applicable safety, accident prevention and
environmental regulations for the application must also be
complied with. The following particularly apply:
The owner must inform himself about the applicable health and
safety conditions and also determine hazards arising from the
special operating conditions at the usage location of the
machine in a risk analysis. He must implement this in the form
of operating instructions for the operation of the machine.
During the complete usage time of the machine, the owner
must check whether the operating instructions created by him
correspond with the current status of the regulations and must
adapt these if necessary.
The owner must clearly regulate and specify the responsibilities
for installation, operation, maintenance and cleaning.
The owner must ensure that all employees involved with the
machine have read and understood the operating instructions.
He must also train the personnel and inform them about the
dangers at regular intervals.
The owner must provide the necessary protective equipment for
the personnel.
The owner is also responsible that the machine is always in proper
working condition. Therefore, strictly observe the following:
The owner must ensure that the maintenance intervals
specified in this manual are complied with.
The owner must arrange for all safety equipment to be checked
regularly for functionality and completeness.
The owner must ensure that antifreeze is filled for engines with
radiators.
Explosive and easily flammable substances must always be
kept away from the engine as the engine can become very hot
during operation.
Do not touch rotating parts while the engine is running.

Diesel engine Series 15W / 18W
Safety
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Only fill with fuel when the engine is switched off. Do not fill in
the vicinity of naked flames or ignitable sparks, do not smoke
and do not spill any fuel.
This operator's manual must be kept in the immediate vicinity of
the engine and must be accessible at any time to all persons
working on and with the engine.
The engine must only be operated if it is in proper working
condition. 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.
Only perform maintenance and cleaning work when the engine
is switched off.
Strictly observe all the information in the operator's manual.
Observe all warning and information signs on the engine and
keep these in legible condition. If a warning or information sign
should be lost or difficult to read, always request a replacement
from the nearest Greaves Farymann Diesel service partner.

Diesel engine Series 15W / 18W
Safety
2008-12-09 13
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.
The following qualifications are specified for different areas of
activity listed in the manual.
Trained person
has been instructed by the owner about the tasks assigned to
him and possible dangers in the case of improper behaviour.
Technical personnel
are persons who on the basis of their professional training by
Greaves Farymann Diesel GmbH, experience and knowledge
of the relevant conditions can perform the work assigned to
them using the operating and repair instructions and can
recognise and avoid possible dangers themselves.
Only persons who are expected to perform their tasks reliably are
permitted as personnel. Persons whose reaction capability is
impaired, e.g. through drugs, alcohol or medication are not
permitted.
When selecting the personnel, the stipulations regarding age
and occupation applying at the location must be observed.

Diesel engine Series 15W / 18W
Safety
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2.3 Appropriate use
The system is designed and constructed exclusively for the
intended purpose described here.
The engine is provided exclusively for the intended purpose which
has been specified and tested by the manufacturer of the
equipment in which the engine is installed. 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.
The installation must be made so that all applicable safety
regulations for the operation of diesel engines are complied with.
Proper use also includes compliance with all the information in this
operator's manual.
Any use beyond the intended use and/or other types of use is
considered misuse and can result in dangerous situations.
WARNING!
Danger due to misuse!
Misuse can result in dangerous situations.
Refrain particularly from the following uses of the
system:
– Operation of the engine while it is not in the
installed condition.
– Operation of the engine without sufficient safety
devices.
– Operation of the engine with non-approved
fuels.
Any types of claims for damage arising from improper use are
excluded.

Diesel engine Series 15W / 18W
Safety
2008-12-09 15
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.
Wear generally Generally wear for all kind of work:
Protective clothing
is close fitting, with low resistance to tearing, with narrow sleeves
and without protruding parts. It mainly provides protection against
being entangled by moving machine parts.
Do not wear any rings and other jewellery.
Safety boots
to protect against heavy parts falling down or slipping on slippery
ground.
Personal protective equipment for
special tasks When performing special tasks it is necessary to wear personal
protective equipment. This personal protective equipment will be
separately specified in the chapters of this manual. This special
protective equipment is explained below.
Ear defenders
to protect against hearing damage.
Hard hat
to protect against parts and materials falling down and flying
around.
Protective gloves
to protect the hand against friction, graze, punctures or deep cuts
as well as contact with hot surfaces.
Safety goggles
to protect the eyes against parts flying around or squirts of fluids.

Diesel engine Series 15W / 18W
Safety
16 2008-12-09
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.
Rotating parts
WARNING!
Risk of injury due to rotating parts
Rotating parts can cause severe injuries.
Therefore:
– Do not reach into or work on rotating parts
during operation.
– Do not open or remove covers during operation.
– Pay attention to the run-on time after switching
off the engine.
Ensure there are no parts still moving or the
engine is not running before opening the
covers.
– Wear close-fitting work clothing.

Diesel engine Series 15W / 18W
Safety
2008-12-09 17
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.
Therefore:
– Observe the safety data sheet of the
manufacturer of fuels, antifreeze and lubricants.
– Avoid spilling fuels and fog formation.
– In the case of inhalation, bring affected person
into the open air immediately. Contact a doctor.
– Contact doctor immediately in the case of
swallowing. Rinse mouth thoroughly with water.
– Avoid skin and eye contact:
Apply suitable skin protection cream before
working on tanks, piping or supply
equipment.
Wear protective gloves made of plastic or
rubber during the work.
– In the case of contact with the skin or eyes,
rinse immediately with a lot of water. Contact a
doctor.
– Dispose of contamination in the working area
properly and in accordance with environmental
regulations. Fuels, antifreeze and lubricants
must not get into the sewer system.
– Do not eat, drink or smoke when working.

Diesel engine Series 15W / 18W
Safety
18 2008-12-09
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. Avoid using open flames or
ignition sources.
– Keep a fire extinguisher ready.
– Report suspicious materials, liquids or gases
immediately to the person in charge.
– Suspend any work activities in case of fire.
Leave the danger zone until the all clear signal
is given.
Hot operating materials
WARNING!
Risk of burns due to hot operating materials!
Operating materials can reach high temperatures
during operation and cause burns in the case of
contact.
Therefore:
– Check whether operating materials are hot
before handling them. If necessary, let them
cool down to the ambient temperature.
Hot surfaces of the engine
components
CAUTION!
Risk of burns due to hot surfaces of the engine
components!
Contact with hot surfaces can cause burns.
Therefore:
– Always wear protective clothing and protective
gloves for all work in the vicinity of hot parts.
– Ensure that all parts have cooled down to the
ambient temperature before all work.

Diesel engine Series 15W / 18W
Safety
2008-12-09 19
Antifreeze (for engines with
radiators and, e.g. electric water
pump)
WARNING!
Danger of poisoning and danger of skin rashes
and allergies!
Antifreeze contains substances harmful to health
and can result in severe poisoning and skin rashes
or allergies.
Therefore:
– Observe the safety data sheet of the antifreeze
manufacturer.
– Wear rubber gloves when handling antifreeze.
– Never mix different types of antifreeze.
– Contact a doctor immediately in the case of
swallowing. Rinse mouth thoroughly with water.
– Avoid skin and eye contact:
Wear protective gloves made of plastic or
rubber during the work.
– Collect coolant drained from the engine in a
suitable container and dispose of in accordance
with the environmental regulations.

Diesel engine Series 15W / 18W
Safety
20 2008-12-09
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.
– Never deactivate safety devices.
NOTE!
See the Chapter "Design and function" for detailed
information about the position of the safety devices.
2.7 Behaviour in the case of danger and accidents
Preventive measures Always be prepared for accidents or fire.
Keep first aid equipment (first aid kit, blankets etc.) and fire
extinguishers ready to hand.
Familiarise personnel with accident reporting, first aid and
rescue equipment.
Keep access routes clear for rescue vehicles.
Actions in the case of accidents Operate the EMERGENCY STOP button on the machine (if
present) immediately.
Initiate first aid actions.
Rescue people from the danger zone.
Inform the responsible person at the usage location.
Notify the rescue services.
Keep access routes clear for rescue vehicles.