Farymann Diesel 15D Series, Workshop Manual

Page 1: ...l 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 Lu...

Page 2: ...sets 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 repa...

Page 3: ...he 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 gaseou...

Page 4: ...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...

Page 5: ...igure 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...

Page 6: ...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 r...

Page 7: ...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...

Page 8: ...III 1 DISASSEMBLY 10...

Page 9: ...II TECHNICAL DATA 11...

Page 10: ...cription 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...

Page 11: ...tapper 748 119 4 Bearing driver To install crankshaft roller bearing outer race and radial oil sealing ring 748 120 4 Bearing Driver To remove and install crankshaft bearing bushing and to remove cams...

Page 12: ...and install valve gides 748 131 5 Valve Sring Compr To remove and install valves 748 135 2 Retaining Ring Pliers To remove retining rings 748 126 2 Oil Pressure Gauge To check engine oil pressure 748...

Page 13: ...greatlyfacilitated by location withgood lighting and freedom ofmovement away from dirt andmetal chips The work to be carried out isdescribed and illustrated step by step in the following Please do ta...

Page 14: ...and the M6 hex nut of the muffler screen Pull of the screen muffler and discard gasket Figure 2 4 Fuel tank Place clamp close to the injector pump on the fuel supply line coming from the tank Next re...

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Page 16: ...on top of the crankcase Figure 5 7 Valve cover Remove the valve cover and the gasket by removing the two nuts and plastic washers on top of the valve cover If necessary tap lightly on the side of the...

Page 17: ...ed hammer and tap slightly on the injector Do not use too much force as this may damage the injector Attention Undder the injector a special packing washer is located which must also be removed 10 Cyl...

Page 18: ...ead Figure 12 For dismantling valves use special tool Watch out for the two thin steel washers under the inlet valve spring Figure 13 If the valve guides need replacement for wear and tear measurement...

Page 19: ...and tear limits and detailed instructions for use of tool refer to section III 2 resp III 7 Figure 15 11 Cylinder shields Remove the bolt holding the two cylinder air deflector shields together using...

Page 20: ...inder up off the studs Attention If the repair does not require the renewal of piston and liner leave the liner on the piston Pull up the liner only so far that piston pin bore is free and continue wi...

Page 21: ...case inspection cover by unscrewing the six head screws If these srews are very tight tapping on them with a hammer and drift pin or flat faced punch may help loosen them Figure 22 When re using the c...

Page 22: ...her if there is no need for to check wear and tear limits of cramshaft speed regulation shaft and camfollower refer to section III 2 In case the need for dismantling arises proceed as follows 17 1 Inj...

Page 23: ...aft in the gear cover Press out the cramshaft using the driver Figure 28 To pull off the camshaft gear wheel use puller or press out the camshaft Figure 29 After the camshaft is removed the roller bea...

Page 24: ...cceleration lever down below the normally stop position till the inner torsion spring is without tension approx horizontal position of the acceleration lever and then pull eccentric shaft out of contr...

Page 25: ...tion linkage Figure 35 Leave the flywheel nut on the shaft Install the flywheel puller and turn the screws until the flywheel breaks loose from the crankshaft tapper Remove the flywheel nut and flywhe...

Page 26: ...use puller Figure 38 22 1 In case the roller bearing needs replacement replace also the inner race which is shrunk fit on to the crankshaft Use race puller pull off the inner race Figure 39 The engin...

Page 27: ...III ENGINE REPAIR 28 III 2 DIMENSION TABLE WEARING PARTS...

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Page 41: ...III ENGINE REPAIR 42 III 3 ENGINE REASSEMBLY...

Page 42: ...re 1 2 Crankshaft To install the crankshaft gear wheel and the inner race of the roller bearing heat the parts in an oil bath or on an electric heater plate to a temperature of 90 100 C 195 210 F Thru...

Page 43: ...ver onto stud Attention Bearing cover can only be fitted in one position Tap lightly with a soft faced hammer to seat the cover Torque down the fastening nuts crosswise Figure 4 Assemble the thrust wa...

Page 44: ...the right hand side a R is visible on the front of the base plate on the left side Figure 8a The lefthand pump can easily be modified into a righthand pump Punch out the straight pins turn the base pl...

Page 45: ...il the bearing shells and install conrod into the crankcase until it seats on the crank pin Insert the conrod cap through the inspection cover Attention The stamped numbers must be aligned on the same...

Page 46: ...amfollower for the injection pump and tighten its fixing screw Do not forget to install a new o ring on the camshaft prior to pressing the camshaft into the bearing Figure 15 9 Governor control speed...

Page 47: ...notch of the eccentric shaft Figure 16e Attention Initiate performance test The tension of the return spring must be acting against the pressure onto the binding screw Figure 16f Regulation Stationar...

Page 48: ...the cylinder fins facing the gear side of the engine For 18B D engines only The arrow stamped on the piston top must point towards the flywheel Align the piston and connecting rod bores Push the pist...

Page 49: ...lide cylinder head down onto the cylinder Fit spring washers and cylinder head nuts On the shorter stud bolt intake side fit the tote bracket and the cylinder head nut without spring washer Figure 23...

Page 50: ...lywheel If the crankcase and flywheel timing marks are within 2mm 0 0787 of lining up the timing is correct for governor adjustment refer to section III 6 Figure 25 Occasionally however the governor w...

Page 51: ...ricate the camshaft and the sealing lips of the oil sealing ring Do not push the guide straight onto the gear cover Instead use a light twisting motion until the guide seats itself Tighten the two gui...

Page 52: ...s less than 0 7 mm disassemble the decompression divice and replace the 0 4 mm 0 0157 gasket with two 0 3 mm 0 0118 gaskets in extreme cases use one 0 4 mm and one 0 3 mm gasket Carry out the two meas...

Page 53: ...that the decompression device is not activated pin is on 9 o clock position Set the piston on TCD compression stroke see step 15 Loosen the locknuts of valve setting screws insert a 0 1 mm 0 004 feel...

Page 54: ...he injector and the clamp Torque the two nuts as specified Figure 37 20 Injection pump Place acceleration lever in full load position and pull excess fuel button The internal spring pushes the control...

Page 55: ...e 39 22 Valve cover Install the valve cover gasket and the valve cover making certain the gasket is properly seated on the cylinder head Insert new plastic washers under the nuts and tighten to specif...

Page 56: ...at the fuel tank and fuel injector Remember to replace both copper washers on each banjo bolt Route the fuel line as shown Attention On the injector end the thicker copper washer is located between t...

Page 57: ...peration Also the use of special break in oils or lub oil additives are not recom mended Figure 46 Running in instruction 10 min idle speed no load 10 min half speed half load 20 min fuel speed full l...

Page 58: ...operation manual At least once a year crankcase should be flushed to remove all dirt and abrasions that may be in the crankcase Oil pressure testing The oil pressure depends mostly on the bearing play...

Page 59: ...o the tank via the return pipe 4 simultaneously carrying heat away from the pump Also the return pipe ensures a constant bleed of the fuel system From the injection pump fuel is fed through the high p...

Page 60: ...re 3 Take care that no dirt enters the pipes Discard the used filter Do not try to clean it Push the pipes as far as possible onto the connection nipples of the filter Attention Watch out for the corr...

Page 61: ...If injection pressure is too high or too low it must be corrected by replacing shims in the injector valve To do so dismantle the injector valve Unscrew the sleeve nut 1 take of the nozzle 2 pressure...

Page 62: ...isengages and returns to its normal position Therefore it is necessary to start the engine without load in order to reach maximum rpm Otherwise the starting fuel button will not disengage and continou...

Page 63: ...st crank the engine in rotation direction to compression stroke till TDC mark on the flywheel is approx at the 5 o clock position Remove the allen head screw from injector pump head and the sealing wa...

Page 64: ...jection pump ishas been fitted the installation deepth must be checked Measure from the mounting flange down to the edge in the roller tappet not down to the roller This measurement plus the thickness...

Page 65: ...ENGINE REPAIR 66 Figure 15 1 Governor body 2 Midrange spring 3 Spacer instead of 2 for generator application 4 Governor pin 5 Bridge 6 Support 7 Full load spring 8 Idle speed spring 9 Cross slotted n...

Page 66: ...peed relief such as compressors freezer units 3 All speed governor variable speed governor Governs the complete range of speeds from idle up to full speed For applications with variable speed operatio...

Page 67: ...t resulting in a movement of the control lever fuel rack towards the idle position Less fuel is injec ted the speed drops governor pin moves back leaving a gap between tappet bolt and pin and the comp...

Page 68: ...correct setting of the clearance between tappet bolt and governor pin is essential for the proper function of the engine If the clearance is too wide the engine can overspeed is it too small the engi...

Page 69: ...lding the lever as otherwise the regulation linkage may be dented III 7 Resurfacing valve seats The cylinder head is fitted with valve seat rings made of wear resistant steel Should a resurfacing be n...

Page 70: ...81 4 15D 738 185 4 258 36 39 738 219 4 15D 738 223 4 738 237 4 15B D 738 254 4 738 255 4 738 201 4 15B 738 225 4 280 39 42 15D 738 305 4 738 221 4 285 40 43 738 181 4 738 185 4 738 208 4 738 226 4 738...

Page 71: ...38 181 4 15D 738 185 4 258 18 21 27 738 219 4 15D 738 223 4 738 237 4 15B D 738 254 4 738 255 4 738 201 4 15B 738 225 4 280 20 23 29 15D 738 305 4 738 221 4 285 20 23 30 738 181 4 738 185 4 738 208 4...

Page 72: ...pressure fuel pipe nut fuel pump 17 18 22 17 18 22 High pressure fuel pipe nut injector 17 25 30 17 25 30 Injector clamp nuts 10 8 12 13 20 23 Governor on crankshaft 14 55 60 14 55 60 Flywheel nut 36...

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