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.: +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
Diesel engine Series 15W / 18W
Table of contents
2008-12-09 3
1
General....................................................................................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
2 Safety ....................................................................................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
3 Technical 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
Diesel engine Series 15W / 18W
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4 2008-12-09
4 Structure 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
5 Transport, packing and storage ........................................ 39
5.1 Safety notes for transport............................................ 39
5.2 Transport inspection.................................................... 39
5.3 Packing ....................................................................... 40
5.4 Transport..................................................................... 40
6 Installation 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
Diesel engine Series 15W / 18W
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2008-12-09 5
7 Operation..............................................................................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
8 Maintenance .........................................................................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
Diesel engine Series 15W / 18W
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6 2008-12-09
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
9 Faults.................................................................................. 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
12 2008-12-09
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
14 2008-12-09
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.
Diesel engine Series 15W / 18W
Safety
2008-12-09 21
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.
– Take immediate action if environmentally
hazardous materials reach the environment.
Inform the responsible local authorities about
the damage in the case of doubt.
The following environmentally hazardous substances are used:
Lubricants, fuels
Fuels, coolants and lubricants such as, e.g. diesel fuel, antifreeze
and engine oil contain toxic substances. They must not reach the
environment. The disposal must be performed by a specialist
disposal company.
Diesel engine Series 15W / 18W
Technical data
22 2008-12-09
3 Technical data
3.1 Technical specifications
Fig. 1
Single-cylinder, four-stroke diesel engine, water-cooled, with the
following characteristics:
Direct injection (Bosch injection system)
Power take-off at the flywheel
Safe manual start with starting handle or electric starter
Automatic decompression and automatic starting quantity
Self-venting fuel system
Mechanical speed governor
Oil forced-feed lubrication system with gear pump,
oil filter (option) for increased operational reliability
Exhaust silencer
Dry type air filter or oil bath filter
Cooling water pump (neoprene impeller pump)
Fuel feed pump and fuel filter
Crankcase of high tensile light alloy
Plain bearings on conrod and crankshaft on the control side
Roller bearing on output side
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:
z Generators (marine and industrial applications)
z Vehicle cooling systems
z Special applications (according to customer requirements)
Diesel engine Series 15W / 18W
Technical data
2008-12-09 23
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)
Cooling water pump (neoprene impeller pump)
Exhaust silencer
Crank handle (rigid)
3.4 Options
The engine is available with the following options:
Crankcase with oil filter (version D/W crankcase)
Dry type air cleaner (various versions)
Water-cooled exhaust manifold
Electric water pump (12 V or 24 V)
Starter (12 V or 24 V)
Solenoid valve open or closed with zero current (12 V or 24 V)
Alternator (12 V or 24 V)
Oil pressure switch
Temperature switch
Stub shafts (various versions)
Bell housings (various versions)
Crank handle RD (limited kickback)
Diesel engine Series 15W / 18W
Technical data
24 2008-12-09
3.5 Engine type plate
Fig. 2: Example of the engine type plate
There is an engine type plate on the engine with the following
information:
1 Manufacturer
2 Series
3 Type number
4 Version of the speed governor
5 Serial number
6 Power
7 Speed
8 Emissions code
9 Date of manufacture (e.g. 07/2008 = July 2008)
3.6 Engine type code
The engine type code is a 12-digit code in addition to the serial
number e.g. 18W 430.0001 M5
Fig. 3
Trim No. = speed governor version
Type No. = engine version
Start 0 = crank handle
5 = electric start
6 = alternator without starter
7 = alternator with starter
Bearings 3 = roller bearing on the flywheel side
Crankshaft 4 = horizontal position
Basic engine design A = vertical cylinder, anticlockwise rotation
(old version)
B = vertical cylinder, clockwise rotation
(new version)
D = vertical cylinder, anticlockwise rotation
(new version)
E/F = horizontal cylinder, anticlockwise
rotation
W = water-cooled cylinder, anticlockwise
rotation
Displacement = in cubic inches (approx.)
Diesel engine Series 15W / 18W
Technical data
2008-12-09 25
3.7 Engine data
Description Value
Type Vertical single-cylinder diesel engine
Design Vertical
Cylinders 1
Operating method Four-stroke
Combustion method Direct injection
Rotation direction Anticlockwise
(as seen from output or flywheel side)
Type of cooling Water-cooled
Valve control Overhead valves with push rods and
rocker arms
Valves Two-valve technology
Valve clearance
(cold engine)
Intake valve
Exhaust valve
0.2 mm
0.2 mm
Type of starting
all engines
Option
Manual starting with crank handle
Starter (12 V or 24 V)
Required battery
capacity
36 Ah (12 V)
72 Ah (2 batteries a = 12 V) for 24 V
Permitted operating
inclined position
(permanent)
15° longitudinal
15° lateral
Diesel engine Series 15W / 18W
Technical data
26 2008-12-09
3.8 Performance data
Description Value 15W Value 18W
Max. power
(at 3600 rpm)
IFN-ISO* 4.3 kW
ICFN-ISO* 3.9 kW
IFN-ISO* 5.2 kW
ICFN-ISO* 4.7 kW
Max. speed 3600 rpm
Max. torque 13.0 Nm
(2500 rpm)
15.3 Nm
(2500 rpm)
Bore 82 mm
Stroke 55 mm
Displacement 290 cm3
Mean piston
speed
6.6 m/s (3600 rpm )
Compression ratio 20:1
* IFN-ISO
Blocked performance for intermittent load.
* ICFN-ISO
Power for constant speed and constant load. Contact the
manufacturer for continuous use outside the stated
performance limit.
Power reduction
Reduction approx. 1% for each 100 m height and approx. 2% for
each 5 °C over 20 °C. Performance guaranteed with 5 % deviation
for the run-in engine with standard air filter and exhaust silencer.
Diesel engine Series 15W / 18W
Technical data
2008-12-09 27
3.9 Dimensions and weight
Description Value
Overall length 374 mm
Overall height 422 mm
Overall width 401 mm
Dry weight: standard
engine with air filter and
exhaust silencer
39 kg
3.10 Temperatures
Description Value
Max. permissible air
intake temperature
50 °C
Max. permissible
exhaust temperature
580 °C
Max. permissible
cooling air temperature
50 °C
Max. permissible fuel
temperature
70 °C
Max. permissible
engine oil temperature
130 °C
Max. permissible
cooling water
temperature
90 °C
Diesel engine Series 15W / 18W
Technical data
28 2008-12-09
3.11 Pressures
Description Value
Injector setting - nozzle
opening pressure
200 bar
Oil pressure (max.) 5 bar
Intake vacuum permitted 2 kPa
Exhaust gas back
pressure
permitted 5 kPa
3.12 Operating materials
Description Value
Fuel Diesel EN 590
DIN 51601-OK
BS 2869 A1/A2
ASTM D 975-1D/D2
Engine oil Multigrade oil
SAE 10W40 mineral oil API
(CD or higher)
Max. engine oil filling
quantity (version with
oil filter)
Max. engine oil filling
quantity (version with
oil strainer)
approx. 1.2 litres
approx. 1.1 litres
Engine oil refill quantity
bottom – top mark (oil
dipstick)
Standard engine
approx. 0.3 litres
Engine oil consumption 1.0 g/kWh
Coolant requirement for
direct cooling
7 – 8 l/min
Diesel engine Series 15W / 18W
Technical data
2008-12-09 29
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.
Too high viscosity can result in starting difficulties; too low viscosity
can endanger the lubrication effect and result in high lubrication oil
consumption. The viscosity is classified according to SAE.
Basically, use mulltigrade oils.
Depending on the lubrication oil temperature, we recommend the
following common viscosity classes.
Viscosity classes according to
ambient temperature
Fig. 4
Diesel engine Series 15W / 18W
Structure and function
30 2008-12-09
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
1 Valve cover
2 Dry type air cleaner (oval flange / option)
3 Decompression unit
4 Engine mounting point
5 Cooling water pump (neoprene impeller pump)
6 Oil drain plug
7 Starting handle support bearing
8 Speed adjusting lever
9 Fuel feed pump
10 Lifting eye for transport
11 Starter
NOTE!
The engine with D/W crankcase has an oil filter.
Diesel engine Series 15W / 18W
Structure and function
2008-12-09 31
Fig. 6: Output side Right view
12 Thermostat housing
13 Bell housing (option)
14 Stub shaft (option)
15 Oil dipstick
16 Oil filter (D/W crankcase)
17 Injection pump
18 Water-cooled exhaust manifold (option)
19 Oil filler cap
20 Excess fuel device
21 Fuel filter (standard)
Diesel engine Series 15W / 18W
Structure and function
32 2008-12-09
NOTE!
The engine shown in pictures 7 and 8 is the
standard engine.
Fig. 7: Front view Left view
1 Valve cover
2 Oil bath air cleaner
3 Decompression unit
4 Engine mounting point
5 Cooling water pump (neoprene impeller pump)
6 Oil drain plug
7 Excess fuel device
8 Starting handle support bearing
9 Speed adjusting lever
10 Fuel feed pump
11 Lifting eye for transport
NOTE!
The standard engine 15W / 18W has an oil strainer
and no oil filter.
Diesel engine Series 15W / 18W
Structure and function
2008-12-09 33
Fig. 8: Output side Right view
12 Thermostat housing
13 Flywheel
14 Water-cooled exhaust manifold (option)
15 Oil filler cap
16 Injection pump
17 Oil dipstick
18 Fuel filter
4.2 Electrical System
4.2.1 Alternator (option)
Fig. 9: Example: Alternator
The permanent magnets on the magnet carrier (1) on the flywheel
side induce an alternating current proportional to speed in the coils
of the stator (3).
NOTE!
The connector at cable (2) on the alternator can be
one of various versions.
Diesel engine Series 15W / 18W
Structure and function
34 2008-12-09
4.2.2 Alternator regulator (option)
Fig. 10: Example: Alternator regulator
The alternating current is rectified in the alternator regulator
(Fig. 10) and constantly regulated to approx. 14.2-14.5 V.
z 2 x yellow (alternator coils input, can be connected either
way)
z 1 x red (charging current output)
z 1 x brown (charge indicator, connecting terminal 15 ignition
switch)
z Earth connection is made using mounting surface.
4.2.3 Operating conditions
Permitted operating temperatures -20 °C to 70 °C (measured
on the alternator regulator surface).
There must be an intact earth connection between alternator
regulator and engine and between alternator regulator and
external attachment (no painted mounting surfaces).
Diesel engine Series 15W / 18W
Structure and function
2008-12-09 35
4.2.4 Dangers and cause of failure
Dangers Cause of failure
Battery terminals incorrectly
connected
Damage to the charging circuit
Defective battery or complete
discharge
Destruction of the alternator
regulator
Disconnection of the battery
when the engine is running
Immediate destruction of the
alternator regulator
External start with jump leads
for defective or completely
discharged battery
Destruction of the alternator
regulator
Manual starting with
disconnected battery
Destruction of the alternator
regulator
Interruption of the earth
connection of the alternator
regulator to the engine
Destruction of the alternator
regulator
Welding work
WARNING!
Material damage due to welding work on the
machine!
Welding work on the machine can cause high
material damage.
Therefore:
– always disconnect the negative pole of the
battery in advance.
– disconnect the plug connection to the
alternator regulator.
Diesel engine Series 15W / 18W
Structure and function
36 2008-12-09
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.
Always disconnect the negative pole of the battery before
performing work on the electrical system.
Do not mix up the + (plus) and - (minus) poles of the battery.
Connect the plus cable first and the minus cable afterwards
when installing the battery.
Disconnect the minus cable first and the plus cable afterwards
when removing the battery.
Always avoid short-circuits and earth contact of live cables.
In the case of faults in the electrical system, first check the
cable connections for good contact.
Replace defective indicator lamps immediately.
Do not remove the ignition key during operation.
Do not disconnect the battery while the engine is running
(occurring voltage peaks can destroy electronic components,
e.g. the alternator regulator).
Do not spray parts of the electrical system during engine
cleaning with a water jet or high pressure jet.
Always disconnect the minus terminal of the battery and
disconnect the plug connection to the alternator regulator for
welding work.
Batteries
WARNING!
Risk of injury due to incorrect handling of
batteries!
Batteries must be handled with particular caution.
Therefore:
– Never expose batteries to high temperatures.
There is a risk of explosion.
– Escaping liquid due to incorrect use can result
in skin rashes. Avoid contact with the liquid.
Always rinse with a lot of water in the case of
contact with the liquid. If the liquid gets into the
eyes, rinse immediately with water and contact
a doctor immediately.
Diesel engine Series 15W / 18W
Structure and function
2008-12-09 37
4.3 Cooling system
4.3.1 Open cooling water circuit with direct sea water cooling without thermostat
Fig. 11
Among other things, the engine is designed for direct sea water
cooling. The cooling water is circulated using an impeller pump (1).
The pump is driven by the camshaft via gear wheels. With this type
of sea water cooling, the required cooling water quantity which is
delivered by the impeller pump is limited so that operation without
thermostat and without bypass line is possible.
4.3.2 Open cooling water circuit with direct sea water cooling with thermostat
Fig. 12
The cooling water is also circulated here using an
impeller pump (1). The temperature of the cooling water circulating
around the cylinder and cylinder head is regulated by a thermostat
in the cylinder head. The cooling water thermostat is set to a
maximum temperature.
There are two versions of cooling water thermostats:
Cooling water thermostat for use with "salt water".
z Opening temperature of the thermostat 50 °C.
Cooling water thermostat for use with "fresh water".
z Opening temperature of the thermostat 70 °C.
The opening temperature prevents the separation and deposit of
salt crystals from the sea water in the cooling water area of the
engine
Diesel engine Series 15W / 18W
Structure and function
38 2008-12-09
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.
NOTE!
A neoprene impeller pump cannot be used here.
4.4 Galvanic corrosion (electrolysis) on engines for marine generators
applications
It can happen with applications of marine generators that very
strong corrosion which damages these parts can occur at different
parts of the engine.
This is usually a galvanic decomposition process (electrolytically
caused corrosion) where the cause is outside the affected
application (for marine electricity generation applications). External
influences become effective due to electrical voltage.
As aluminium as a material reacts very sensitively to these
influences, this problem should be paid a lot of attention to in
advance so that damage can be detected in good time or the
conditions or causes can be established in good time and
preferably rectified.
However, the effectiveness of this process also depends on
various other conditions. For example, one precondition for this
decomposition process is a high salt content of the water
(electrolyte) with simultaneous high water temperature (see the
operating manual of the generator manufacturer).
Diesel engine Series 15W / 18W
Transport, packing and storage
2008-12-09 39
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.
Therefore:
– Proceed carefully when unloading the packages
and on delivery and internal transport and
observe the signs and notices on the packing.
– Only use the attachment points provided.
– Do not remove packing until just before the
installation.
5.2 Transport inspection
Check the delivery immediately on receipt for completeness and
transport damage.
If externally detectable transport damage is found, proceed as
follows:
Do not accept the delivery, or only with reservation.
Record the extent of transport damage in the transport
documents or on the delivery note of the forwarding agent.
Start complaints procedure.
NOTE!
Claim any damage as soon as it is detected.
Compensation claims can only be submitted within
the applicable complaints periods.
Diesel engine Series 15W / 18W
Transport, packing and storage
40 2008-12-09
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
assembled. The packing material must therefore not be damaged
and should only be removed just before assembly takes place.
Handling packing materials
If there is no returns agreement for the packing, separate materials
according to type and size and direct to further use or recycling.
CAUTION!
Environmental damage caused by incorrect
waste disposal!
Packing materials are valuable raw materials and
can continue to be used in many cases or sensibly
reconditioned and recycled.
Therefore:
– Dispose of packing materials environmentally.
– Follow the locally valid waste disposal
regulations. If necessary employ a special
waste disposal company to dispose of packing
material.
5.4 Transport
Transport of the engine with the
crane
Fig. 13: Transport with the crane
The engine has one lifting eye (Fig. 13/1) and can be transported
directly with a crane under the following conditions:
Crane and lifting gear must be designed for the weight of the
engine.
Only lift and transport the engine in the normal position
(engine mounting points at the bottom).
The operator must wear a safety helmet, safety shoes and
protective gloves and must be authorised to operate the crane.
Attaching:
1. Attach ropes, belts or chains according to Fig. 13.
2. Ensure that the engine is attached straight.
3. Do not start the transport until then.
Diesel engine Series 15W / 18W
Transport, packing and storage
2008-12-09 41
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.
Avoid mechanical vibrations.
Storage temperature: 15 to 35 °C.
Relative humidity: max. 60 %.
In the case of storage for longer than 3 months, check the
general condition of all parts and the packing regularly. If
required, refresh or renew the anti-corrosion protection.
Storage of the engines up to 12 months is possible under the
above conditions.
CAUTION!
Damage due to improper storage!
Parts of the engine can corrode and become nonfunctional in the case of too high relative
humidity or air containing salt.
Therefore:
– In the case of storage for longer than 6 months,
contact the nearest Greaves Farymann Diesel
service partner in order to agree suitable
precautions.
Diesel engine Series 15W / 18W
Installation and commissioning
42 2008-12-09
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.
6.2 Installation
6.2.1 Mounting the flywheel
Must only be performed by a specialist.
Additional protective equipment required:
z Safety footwear
Special tool needed:
z Torque wrench
Fig. 14
NOTE!
Always check the flywheel nut with a
torque wrench set for 216 to 226 Nm before
every installation in or attachment to the machine.
1. Install engine on suitable mounting.
2. Turn engine slowly with the crank handle until the keyway (1)
in the crankshaft (3) faces upwards.
NOTE!
This position makes installation of the flywheel
easier.
3. Place both plate washers (2) on the crankshaft (3).
NOTE!
The flat sides of the plate washers face each other.
Diesel engine Series 15W / 18W
Installation and commissioning
2008-12-09 43
Fig. 15
4. Install key (4) into the keyway of the crankshaft and ensure
that this sits correctly.
Fig. 16
5. 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. for engines
with alternator) can be damaged. The alternator
does not function correctly if the magnets are
damaged.
6. After the installation of the flywheel, check without fail that the
key (arrow) is seated in the keyway of the crankshaft before
screwing on the flywheel nut.
NOTE!
In the case of improper mounting of the flywheel,
the key can fall out of the crankshaft keyway. This
results in the flywheel not being properly fixed. Due
to the missing key, the flywheel nut can slacken
when starting the engine. This results in the
crankshaft and the flywheel being severely
damaged.
Diesel engine Series 15W / 18W
Installation and commissioning
44 2008-12-09
Fig. 17
Fig. 18
7. 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.
8. Screw two bolts (6) into the thread provided on the flywheel.
9. Fix the flywheel with a suitable lever (e.g. tyre lever) (7).
10. Tighten the flywheel nut with a torque wrench (8) to
216 – 226 Nm.
11. Turn the flywheel by hand and examine for unobstructed
movement (must not jam).
6.2.2 Attaching stub shaft (option)
Fig. 19: Example: Stub shaft
Example: Not all applications need a stub shaft.
12. Attach stub shaft (1) to the flywheel.
NOTE!
Depending on the type of installation, the stub shaft
can be different from that shown in the picture.
Diesel engine Series 15W / 18W
Installation and commissioning
2008-12-09 45
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.
rods, Bowden cables, manual, electric, etc.).
Fig. 20
Example: Speed controller with Bowden cable
Diesel engine Series 15W / 18W
Installation and commissioning
46 2008-12-09
6.3 Initial commissioning
CAUTION!
Engine damage due to missing operating
materials!
The engine is delivered without operating
materials. Operation without all required operating
materials can destroy the engine.
Therefore:
– Fill with engine oil and diesel fuel before first
use.
– Only use operating materials which are
specified in the technical data.
– Observe the filling quantities.
– Before first use or after a long decommissioning
(more than 6 months), operate the engine after
starting for approx. 1 minute at low speed and
without load.
Due to this action, an optimum lubrication of all
bearings is achieved and a lack of lubrication is
avoided.
CAUTION!
Engine damage due to cold start aids!
The use of cold starting aid results in engine
damage.
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.
Diesel engine Series 15W / 18W
Installation and commissioning
2008-12-09 47
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.
Never drop below the minimum level.
– The engine must stand up straight for checking
the oil level.
Fig. 21
1. Release oil filler cap (1) e.g. with a 13mm jaw spanner and
screw off by hand.
Fig. 22
2. Fill engine oil into the filling opening (2).
Diesel engine Series 15W / 18W
Installation and commissioning
48 2008-12-09
Fig. 23
3. Pull out oil dipstick (3) and clean the bottom end with a clean
and fluff-free cloth.
4. Replace the oil dipstick (3) and pull it out again.
Fig. 24
5. Check the oil level quantity. The oil level should be just under
the Max. marking.
6. Fill with engine oil if needed.
Fig. 25
7. Only tighten the oil filler cap (1) by hand (risk of breakage).
Diesel engine Series 15W / 18W
Installation and commissioning
2008-12-09 49
6.4.1 Venting the fuel system for engines with fuel feed pump (option)
NOTE!
The engine has a self-venting fuel system. In the
case of the fuel tank running empty, faultless
operation after refilling is ensured by the
self-venting.
The venting can be accelerated using the lever (1)
on the fuel feed pump (2).
Fig. 26
8. Using the lever (1) on the fuel feed pump (2), pump by hand
until the counter pressure becomes noticeable.
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.
Diesel engine Series 15W / 18W
Operation
50 2008-12-09
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.
– Ensure that all covers and safety devices are
installed and in proper working condition before
starting the work.
– Never deactivate safety devices during
operation.
– Ensure tidiness and cleanliness in the working
area. Loose components and tools lying around
or on top of each other cause accidents.
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 covers during operation.
– Note the run-on time of 10 to 20 seconds of the
engine:
Ensure there are no parts still moving and the
engine is not running before opening the
covers.
– Wear close-fitting clothing in the danger zone.
Diesel engine Series 15W / 18W
Operation
2008-12-09 51
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.
– Only operate the engine in well-ventilated
areas.
Hot surfaces of the engine
components
CAUTION!
Risk of burns due to hot surfaces of the engine
components!
The engine can become very hot during operation.
Contact with the exhaust system and the engine
can cause burns.
Therefore:
– Never touch the engine during operation.
– Ensure that all parts have cooled down to the
ambient temperature before all work.
Engine oil and fuel
WARNING!
Danger of fire due to fuel and engine oil!
Oil and fuel vapours can ignite on contact with
ignition sources.
Therefore:
– No naked flames during work on the engine.
– Do not smoke.
– Remove oil and fuel residues from the engine
and floor.
Diesel engine Series 15W / 18W
Operation
52 2008-12-09
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.
– Remove oil, fuel and antifreeze splashes from
the skin immediately.
– Do not inhale oil and fuel vapours.
Antifreeze (for engines with
radiator 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
Operation
2008-12-09 53
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.
The engine must be switched off as quickly as possible in
dangerous situations.
Emergency shutdown
Proceed as follow in the case of danger:
1. Switch off the engine immediately.
2. Inform the responsible person at the usage location.
3. Rescue people from the danger zone, initiate First Aid actions.
4. Switch off the main switch on the machine (if present) and
secure it against being switched on again.
5. Keep access routes clear for rescue vehicles.
After the rescue actions
6. If required for the severity of the emergency, inform the
responsible authorities.
7. Assign specialist personnel to the fault rectification.
WARNING!
Risk of fatal injury due to premature restarting!
There is a risk of fatal injury for all persons in the
danger zone when the machine is restarted.
Therefore:
– Ensure there are no persons in the danger zone
before restarting.
8. Before restarting, ensure that all safety devices are installed
and functional.
Diesel engine Series 15W / 18W
Operation
54 2008-12-09
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.
Check cooling water level, refill if necessary.
Check air filter for soiling, clean if necessary or replace air filter
element.
Check engine mounting.
Check machine for completeness of the safety equipment.
Check engine and machine for missing covers.
Check engine for damaged oil and fuel lines.
Check engine for damaged electrical cables and insulation.
Check engine and cooling system for leaks.
Ensure sufficient supply air for combustion.
Diesel engine Series 15W / 18W
Operation
2008-12-09 55
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.
Fig. 27
The speed can be controlled using the speed adjustment lever.
The following positions are possible:
1 Stop – Engine off
2 Partial load range
3 Cold start and full load
7.3 Manual start
NOTE!
In the case of outdoor temperatures below 5 °C,
the engine must be rotated to the speed
adjustment "max" position.
Put the speed adjustment lever into the increased
idle speed position in the case of a cold engine.
If the engine does not start, the starting speed is
too low. Constant and accelerated turning the
starting handle supports the engine starting.
Manual start
The engine is equipped with an automatic decompression and an
excess fuel device for a safe manual start.
Diesel engine Series 15W / 18W
Operation
56 2008-12-09
Fig. 28
1. 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).
Fig. 29: Example: automatic
decompression with star knob
2. Turn decompression button to the right (clockwise) to the
starting position (1).
1 Starting position
2 Neutral position
3 Operating position
Starting position: The automatic decompression operates for
the manual starting of the engine with the crank handle. If the
decompression unit's pin has moved to the operating position,
the decompression has finished. The compression begins and
the engine starts.
Neutral position: In the neutral position the compression is
switched off. By turning the engine with the crank handle all
bearings are provided with engine oil (e.g. following repair or
before commencement of cold start at extremely low
temperatures).
Operating position: In the operating position the
decompression is switched off and the engine is under
compression.
Fig. 30: Example: automatic
decompression with lever
NOTE!
Never use the automatic decompression to
switch off the engine.
Diesel engine Series 15W / 18W
Operation
2008-12-09 57
Fig. 31: Example: automatic
decompression
1 Starting position
2 Neutral position
3 Operating position
Fig. 32: Example: Adjusting the automatic
decompression on the starting handle with
the adjusting spanner
The automatic decompression (Fig. 31) is adjusted on the starting
handle (Fig. 33) with the adjusting spanner.
Fig. 33: Adjusting spanner on the starting
handle
Starting handle (1) with adjusting spanner (2).
Diesel engine Series 15W / 18W
Operation
58 2008-12-09
Excess fuel device
NOTE!
The excess fuel device (1) must be pulled out
for cold starting.
Fig. 34: Excess fuel device
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.
As soon as the engine has reached the maximum speed permitted
by the governor the mechanical speed governor pushes the control
shaft to stop and the starting excess button returns to its starting
position.
Therefore it is important that the engine is started without load
and can reach its maximum speed. Otherwise the starting excess
button does not return to its starting position and the engine is
overloaded.
NOTE!
When starting the engine when warm (operating
temperature) do not pull out the excess fuel device.
Manual start
Fig. 35
1. Turn decompression knob to the right (clockwise) to the
starting position (Fig. 29/1).
2. Put the speed adjustment lever in the increased idle speed
position (Fig. 28/3).
3. Pull out excess fuel device for cold start (Fig. 34/1).
4. Insert the crank handle (1) in the starting handle support
bearing (2) and turn slowly anticlockwise until the crank is
engaged.
Diesel engine Series 15W / 18W
Operation
2008-12-09 59
Fig. 36: Starting handle (rigid version)
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" shown as an example in picture 36
can be used.
Fig. 37: RD crank handle
NOTE!
Due to the design, the RD (limited kickback)
crank handle shown in picture 37 cannot be
used for engines with a cooling water pump
(neoprene impeller pump).
Fig. 38
5. Erect on the right in front of the engine and ensure a secure
position.
Diesel engine Series 15W / 18W
Operation
60 2008-12-09
Fig. 39
6. 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.
7. Hold crank handle with your left hand and thumb on top (4)
and turn to the left (anticlockwise); in doing so increase the
speed continuously.
Turning further and faster with the crank handle supports starting
the engine.
NOTE!
The automatic decompression operates for the
manual starting of the engine. If the pin has
moved to the operating position (Fig. 29/3), the
decompression is finished. The compression
begins and the engine starts.
8. Absolutely continue turning after the first compression until
the crank handle is overtaken by the running engine and
disengaged.
NOTE!
If the engine does not start, repeat the starting
procedure (continuous cranking at a steadily
increasing speed will help starting) and
increase the speed.
NOTE!
When starting the engine when warm
(operating temperature) do not pull out the
excess fuel device.
Diesel engine Series 15W / 18W
Operation
2008-12-09 61
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.
Therefore:
– Only operate the starter when the engine is not
running.
– Do not operate the starter for longer than 10 to
20 seconds and release the key when the
engine is running.
– Wait approx. 30 seconds before repeating
starting.
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 engine in the version with a starter is started using a key
switch (see e.g. operating instructions of the device manufacturer).
Fig. 40: Example: Key switch
Example of the key switch positions:
0 Electrical system switched off. Key can be removed.
I Electrical system switched on.
Operating position
II Electrical system switched on.
Starting position
Diesel engine Series 15W / 18W
Operation
62 2008-12-09
Starting engine
Fig. 41
1. 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).
2. Turn key e.g. to position I. Any existing indicator lamps from
the machine must light afterwards (e.g. oil check, battery
charge check, etc.).
3. Press in the key, turn as far as position II and release
immediately after the engine starts.
NOTE!
If the engine does not start, the battery voltage can
be too low. Charge the battery or replace it if
necessary.
7.5 Operation
CAUTION!
Engine damage due to incorrect operation!
The lifetime of the engine can be reduced due to
incorrect operation.
Therefore:
– Strictly observe the following instructions for first
use, normal operation and continuous
operation.
CAUTION!
Engine damage due to cold start aids!
The use of cold starting aid results in engine
damage.
Therefore:
– Never use cold starting aids.
Diesel engine Series 15W / 18W
Operation
2008-12-09 63
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.
– If fuel escapes, switch off the engine and
contact the nearest Greaves Farymann Diesel
service partner.
Let the engine warm up for approx. 5 minutes after starting.
Increase load slowly.
After the first 25 operating hours, carry out the following
work in accordance with the maintenance work:
z Change the engine oil and replace oil filter (see Chapter 8.6
Changing engine oil and oil filter).
z Arrange for the valve clearance to be checked by the
nearest Greaves Farymann Diesel service partner (see
Chapter 8.10 Adjusting valve clearance).
Note!
Replace oil filter (engines with D / W crankcase).
Normal operation
Let the engine warm up for approx. 5 minutes after starting.
Increase load slowly.
Do not let the engine idle longer than 30 minutes and do not
operate without load (longer idling of the engine can result in
excessive carbonisation on the piston and cylinder barrel).
Continuous operation
Let the engine warm up for approx. 5 minutes after starting.
Increase load slowly.
Check the engine oil level every 15 hours during continuous
operation and refill with engine oil if necessary (see Chapter
Filling engine oil).
For this purpose:
z Switch off the engine
z Wait 5 minutes so that the oil can flow back from all bearings
into the oil sump or additional oil sump (for engines with
additional oil sump).
z Check engine oil level and correct if necessary.
z Start the engine again.
Diesel engine Series 15W / 18W
Operation
64 2008-12-09
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.
CAUTION!
Engine damage due to premature switching off!
Switching off under load can reduce the lifetime of
the engine.
Therefore:
– During full load operation, let the engine idle for
approx. 5 minutes without load before switching
off.
Diesel engine Series 15W / 18W
Operation
2008-12-09 65
7.6.1 Engine without electric starter
Fig. 42
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.
NOTE!
Never turn off the engine with the automatic
decompression at full load. Before turning off first
let the engine run for approx. 5 minutes in idle
mode and then pull the speed adjustment lever to
the stop position (Fig. 42/1) and hold it there until
the engine stops after approx. 10 to 20 seconds.
7.6.2 Engine with electric starter
Fig. 43: Example of key switch
NOTE!
See e.g. operating instructions of the device
manufacturer.
1. Turn the key switch to the position "0". The engine comes to a
standstill after approx. 10 to 20 seconds.
2. Remove key.
Diesel engine Series 15W / 18W
Operation
66 2008-12-09
7.7 Decommissioning
Decommissioning and preservation
The following preservation protects the engine during
decommissioning (e.g. winter break) for 3 months.
1. Perform thorough external cleaning of the engine.
2. Drain engine oil and fill engine with approx. 1.0 litre of
corrosion protection oil.
3. Detach fuel line from the fuel tank (on the machine side) to the
fuel feed pump. Fill a suitable container with approx. 0.5 litre
mixture of nine parts of diesel fuel and one part of corrosion
protection oil. Afterwards, connect a short suction line to the
fuel feed pump and insert in the container so that the fuel feed
pump can intake the mixture.
4. Put the speed adjustment lever in full load position. Turn the
automatic decompression to the neutral position and rotate
the engine slowly for approx. 20 revolutions with the
crankhandle.
5. Drain the cooling system of the engine by detaching the
cooling water pump (neoprene impeller pump) cover.
6. Seal inlet and exhaust openings with textile adhesive tape.
7. Store the engine in a dry place and protected against the
effects of weather.
Storing for longer than 3 months
Repeat the following work every 2 months in the case of longer
storage.
1. Remove adhesive tape from the inlet and exhaust openings.
2. Put the speed adjustment lever at full load, turn the automatic
decompression to the neutral position and slowly rotate the
engine with the starting handle for approx. 20 revolutions.
3. Seal inlet and exhaust openings with textile adhesive tape.
4. Store the engine in a dry place and protected against the
effects of weather.
Diesel engine Series 15W / 18W
Operation
2008-12-09 67
Restarting
Perform the following work for restarting the engine:
1. Perform thorough external cleaning of the engine.
2. Remove textile adhesive tape from the inlet and exhaust
openings.
3. Drain corrosion protection oil from the engine into a suitable
container and dispose of in accordance with the
environmental regulations.
4. Fill engine with engine oil (see Chapter 6.4 "Filling engine oil)
and replace oil filter (engine with D/W crankcase).
5. Connect fuel supply hose to fuel feed pump and tighten hose
clamp.
6. Fill the fuel tank on the machine side with diesel fuel.
7. Filling cooling system.
8. Start engine and check the cooling and fuel system for leaks.
Diesel engine Series 15W / 18W
Maintenance
68 2008-12-09
8 Maintenance
8.1 Safety
Maintenance work not carried out
correctly
WARNING!
Risk of injury due to incorrectly carried out
maintenance work!
Improper maintenance can result in severe
personal injuries or material damage.
Therefore:
– Always undertake maintenance work when the
engine is switched off.
– Ensure there is sufficient installation clearance
before starting work.
– Ensure tidiness and cleanliness at the
workplace. Loose components and tools lying
around or on top of each other are sources of
accidents.
– Only perform maintenance work using
commercially available tools and special tools.
Incorrect or damaged tools can result in injuries.
Engine oil and fuel
WARNING!
Danger of fire due to fuel and engine oil!
Oil and fuel vapours can ignite on contact with
ignition sources.
Therefore:
– No naked flames during work on the engine.
– Do not smoke.
– Remove oil and fuel residues from the engine
and floor.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 69
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.
– Remove oil and fuel splashes and antifreeze
from the skin immediately.
– Do not inhale oil and fuel vapours.
Personnel
The maintenance work described here can be performed by the
operator unless otherwise indicated.
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.
Personal protective equipment
Wear the following protective equipment for all maintenance 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.
Diesel engine Series 15W / 18W
Maintenance
70 2008-12-09
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.
Do not tighten cylinder head nuts!
In the case of use where there is an excessive
occurrence of dust, shorten the maintenance
intervals by at least half.
In the case of low operating time, the engine oil
and oil filter (engines with D/W crankcase) must be
replaced at least every 12 months irrespective of
the actual operating hours.
Only use original Greaves Farymann Diesel
spare parts.
8.2 Maintenance plan
The various tasks are listed in the maintenance plan.
The maintenance intervals must be complied with as follows:
daily before every start-up
after 25 operating hours
every 250 operating hours
every 500 operating hours
NOTE!
The maintenance interval for 500 operating
hours includes all the work for the interval of
250 operating hours.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 71
Maintenance table
Components
Component
group
Work to be performed
Daily
before
every
start-up
After 25
operating
hours
Every 250
operating
hours
Every 500
operating
hours
Engine oil Check oil level, refill with engine oil
if necessary
X
Engine oil
(version with oil
strainer)
Replace engine oil at least every
12 months
X X
Change engine
oil and oil filter
(D/W crankcase
version)
Replace engine oil and oil filter at
least every 12 months
X X
Oil strainer Remove oil strainer and clean,
replace if necessary
X
Suction area Check area for intake air, clean if
necessary
X X X
Clean air filter element and air filter
case
X Dry type air
cleaner
Replace air filter element and
clean air filter case
X
Check oil contamination and oil
level, several times a day in the
case of a high occurrence of dust;
if necessary fill oil up to marking or
change it
X Oil bath air
cleaner
Change the oil bath air cleaner's
oil
X
Neoprene
impeller
Check neoprene impeller X
Valve adjustment
Using Greaves Farymann Diesel
service partner:
Check valve clearance,
adjust if necessary (cold engine)
X X
Threaded
connections
Check for tightness, tighten if
necessary
(cylinder head nuts must not be
tightened)
X X
Diesel engine Series 15W / 18W
Maintenance
72 2008-12-09
Components
Component
group
Work to be performed
Daily
before
every
start-up
After 25
operating
hours
Every 250
operating
hours
Every 500
operating
hours
Exhaust system Check for leaks,
arrange repair by a Greaves
Farymann Diesel service partner if
necessary
X
Fuel filter Replace X
Fuel hoses Check,
replace if necessary and in any
case at least every 4 years by a
Greaves Farymann Diesel service
partner
X
Electric cables Check for damage,
replace by a Greaves Farymann
Diesel service partner if necessary
X
Cooling water
hoses and hose
clamps
Check,
replace if necessary and in any
case at least every 2 years by a
Greaves Farymann Diesel service
partner
X
Thermostat Replace thermostat Recommendation: after 2000 operating hours
Coolant Replace coolant (engines with
closed cooling water circuit / with
radiator and e.g. electric water
pump)
Recommendation: every 2 years
Engine Outside cleaning with engine
cleaner
as required
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 73
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.
Therefore:
– Observe the following points.
Excessive occurrence of dust
In the case of use where there is an excessive occurrence of
dust, shorten the maintenance intervals by at least half.
Low operating time
In the case of low operating time, the engine oil and oil filter (for
the D/W crankcase version) must be replaced at least every
12 months irrespective of the actual operating hours.
8.3 Cleaning the intake area
CAUTION!
Engine damage due to dust in the intake area!
Dust in the combustion chamber can result in
premature engine wear and reduced engine
performance.
Therefore:
– Keep the area for the intake air free of dust and
contamination.
Fig. 44
Clean dust and contamination in the intake area (1) with a
suitable clean and dry cloth.
Diesel engine Series 15W / 18W
Maintenance
74 2008-12-09
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.
– Do not exceed the tightening torques stated
here.
CAUTION!
Cylinder head nuts must not be tightened!
Therefore:
– Do not tighten cylinder head nuts without
authorisation.
– Arrange for work on the cylinder head to be
carried out by a Greaves Farymann Diesel
service partner.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 75
Tightening torques
Threaded connection relevant for safety Tightening torque Nm
High pressure line of the injection nozzle holder 25
Mounting of the fuel filter 10
Wing nut of sealing cap of the air filter case After cleaning or replacing the
air filter only tighten the wing
nut of the air filter case by
hand.
Exhaust silencer bolts 10
Oil filter (for engines with D/W crankcase) Only tighten oil filter by hand.
Valve cover 8 – 12
Oil drain plug 12
Oil strainer bolts 3 – 4
Thermostat housing bolts 10
8.5 Changing engine oil
NOTE!
Only change engine oil when the engine is at a
standstill and at operating temperature. Always
replace engine oil and oil filter together.
8.5.1 Version with oil drain plug
Fig. 45
1. Switch off the engine
2. Slacken oil drain plug (1) (e.g. with a ring spanner SW 13).
3. Place a suitable container underneath.
4. Screw out oil drain plug by hand.
Caution: Engine oil can be hot.
5. Collect old oil in a suitable container and dispose of in
accordance with the environmental regulations.
Diesel engine Series 15W / 18W
Maintenance
76 2008-12-09
Fig. 46
6. Check oil drain plug (1) for damage and replace if necessary.
7. Always replace the copper seal (2).
8. Screw in oil drain plug by hand and tighten with e.g.
ring spanner SW 13.
Tightening torque: 12 Nm
Fig. 47
9. Release oil filler cap (3) e.g. with a flat wrench
(wrench size: 13 mm) and screw off by hand.
10. Fill with engine oil.
11. Pull out oil dipstick (2) and clean the bottom end with a clean
and fluff-free cloth.
12. Replace the oil dipstick (2) and pull it out again.
13. Check the oil level quantity. The oil level should be just under
the Max. marking.
14. Only tighten the oil filler cap (3) by hand (risk of breakage).
15. Start engine and check for leaks.
8.5.2 Version with oil drain valve
Fig. 48
1. Switch off the engine.
2. Screw off the sealing cap (1) by hand.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 77
Fig. 49
3. Screw special oil drain hose (2) onto the oil drain valve (3).
This opens the quick-release coupling.
4. Collect old oil in a suitable container and dispose of in
accordance with the environmental regulations.
5. Unscrew and remove the oil drain hose (2).
Fig. 50
6. Check O-rings (4) for damage and replace oil drain valve
(Fig. 49/3) if necessary.
7. Tighten the sealing cap (5) by hand.
Fig. 51
8. Release oil filler cap (3) e.g. with a flat wrench
(wrench size: 13 mm) and screw off by hand.
9. Fill with engine oil.
10. Pull out oil dipstick (Fig. 47/2) and clean the bottom end with a
clean and fluff-free cloth.
11. Replace the oil dipstick (Fig. 47/2) and pull it out again.
12. Check the oil level quantity. The oil level should be just under
the Max. marking.
13. Only tighten the oil filler cap (3) by hand (risk of breakage).
14. Start engine and check for leaks.
NOTE!
Always replace engine oil and oil filter together
(for engines with D/W crankcase).
Diesel engine Series 15W / 18W
Maintenance
78 2008-12-09
8.5.3 Removing and installing oil strainer
Fig. 52
1. Place a suitable container underneath.
2. Drain engine oil (see Chapter 8.5.1).
3. Unscrew both bolts (1).
4. Remove oil strainer housing (2).
5. Collect old oil in a suitable container and dispose of in
accordance with the environmental regulations.
6. Clean oil strainer with cold cleaning agent or diesel.
NOTE!
If the oil strainer is deformed or damaged, it must
absolutely be replaced.
Fig. 53
7. Install cleaned or new oil strainer (4) with new gasket (3)
carefully.
8. Screw in both bolts (5) with new copper seals (6) and tighten.
Tightening torque: 3 – 4 Nm
9. Screw in oil drain plug (7) with new copper seal (8) and
tighten with ring spanner SW 13.
Tightening torque: 12 Nm
Fig. 54
10. Release oil filler cap (9) e.g. with a flat wrench
(wrench size: 13 mm) and screw off by hand.
11. Fill with engine oil.
12. Pull out oil dipstick (Fig. 47/2) and clean the bottom end with a
clean and fluff-free cloth.
13. Replace the oil dipstick (Fig. 47/2) and pull it out again.
14. Check the oil level quantity. The oil level should be just under
the Max. marking.
15. Only tighten the oil filler cap (9) by hand (risk of breakage).
16. Start engine and check for leaks.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 79
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.)
Fig. 55
1. 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.
NOTE!
The oil filter can be hot.
Fig. 56
2. Collect the engine oil from the oil filter (4) and oil filter case in
a suitable container (5) and dispose of in accordance with the
environmental regulations.
Diesel engine Series 15W / 18W
Maintenance
80 2008-12-09
Fig. 57
3. Clean the sealing surface on the oil filter case.
4. Use new oil filter (7) and wet seal (6) with clean engine oil.
Fig. 58
5. Tighten the oil filter (7) only by hand.
6. Fill with engine oil.
7. Start engine and check for leaks.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 81
8.7 Fuel system
Fig. 59: Fuel system
1 Fuel pressure line
2 Connection for fuel line to the fuel tank (return)
3 Injection nozzle holder
4 Fuel feed pump
5 Connection for fuel line to the fuel tank (feed)
6 Fuel filter (standard)
7 Injection pump
8 Electric solenoid valve (option)
8.7.1 Replacing fuel filter
Fig. 60: Fuel filter with thread
There are two versions of the fuel filter:
Fuel filter (1) with thread version (option): With this version, the
fuel lines are screwed on to the fuel filter.
Diesel engine Series 15W / 18W
Maintenance
82 2008-12-09
Fig. 61: Fuel filter (standard)
Fuel filter (2) version (standard): With this version, the fuel lines
are fixed using hose clamps.
8.7.2 Replacing fuel filter (with thread)
Fig. 62
1. Switch off the engine
2. Disconnect fuel line (1) using special fuel line disconnecting
tool (2).
Fig. 63
3. Unscrew fuel line (3) from the fuel filter (4).
4. Collect the fuel from the fuel line (3) in a suitable container (5)
and dispose of in accordance with the environmental
regulations.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 83
Fig. 64
5. Detach fuel line (6) from the fuel filter (4).
Fig. 65
5. Undo hose clamp (7) and remove fuel filter (4).
Fig. 66
6. Collect the fuel from the fuel line (6) in a suitable container (5)
and dispose of in accordance with the environmental
regulations.
Diesel engine Series 15W / 18W
Maintenance
84 2008-12-09
Fig. 67: Fuel filter with thread
Fuel filter with thread (option)
6. 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. 68
7. Check banjo bolts (9) for damage and replace
copper seals (10).
8. Assembly is in the reverse order to the dismantling.
9. Start engine and check the fuel system for leaks.
8.7.3 Replacing fuel filter (standard)
Fig. 69
1. Switch off the engine.
2. Undo hose clamp (1) on the mounting (2) of the fuel filter.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 85
Fig. 70
3. Disconnect fuel line (2) using special fuel line disconnecting
tool (3).
Fig. 71
4. Undo hose clamp (4) and pull off the fuel line (2) from the fuel
filter (5).
Fig. 72
5. 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.
6. Undo hose clamp (Fig. 71/7) and pull off the fuel line
(Fig. 71/8) from the fuel filter (Fig. 71/5).
Diesel engine Series 15W / 18W
Maintenance
86 2008-12-09
Fig. 73
7. 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.
Fig. 74
8. Tighten screw (1) of the hose clamp on the mounting.
8. Start engine and check the fuel system for leaks.
8.8 Replacing air filter
CAUTION!
Engine damage due to use of non-original air
filter!
Unfiltered air can result in rough engine running
and engine damage. A dusty air filter reduces the
engine power and increases the fuel consumption.
Therefore:
– Do not operate the engine without the air filter.
– Clean or replace air filter according to the
maintenance plan.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 87
8.8.1 Dry type air cleaner (standard engine)
Fig. 75
1. Switch off the engine
2. Unscrew and remove the wing nut (1).
3. Release sealing clips (2) and remove air filter case (3).
Fig. 76
4. Remove air filter element (4).
Fig. 77
5. Remove air filter cover (5) with air filter pot (6) and centring
ring (7).
Diesel engine Series 15W / 18W
Maintenance
88 2008-12-09
Fig. 78
6. 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.
7. After cleaning assemble the centring ring, air filter pot and air
filter cover. While doing this only tighten the wing nut
(Fig. 75/1) by hand.
Fig. 79
8. Install new air filter element (4).
Fig. 80
9. Position air filter case (3) straight, in the process pay attention
to correct seating, and close sealing clips (2).
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 89
8.8.2 Dry type air cleaner (oval flange)
Fig. 81
1. Switch off the engine.
2. Unscrew and remove the wing nut (1).
3. Remove air filter cover (2).
Fig. 82
4. Remove air filter element (3).
Fig. 83
5. Clean suction area (Fig. 83/4) and air filter cover (Fig. 81/2)
thoroughly.
NOTE!
When removing the air filter and when cleaning the
air filter case, always ensure that no dirt gets into
the intake tract.
Diesel engine Series 15W / 18W
Maintenance
90 2008-12-09
Fig. 84
6. Install new air filter element (3); in doing so, ensure that the
spacer sleeve (4) is also installed.
Fig. 85
7. Position air filter case (2) straight, in the process pay attention
to correct seating, and fasten with the wing nut (1).
8.8.3 Oil bath air cleaner (standard engine)
Fig. 86
NOTE!
Check oil contamination and oil level several times
a day in the case of a high occurrence of dust, if
necessary fill oil up to marking or change it
(see maintenance plan).
1. Open fasteners (2) and remove oil container (1).
2. Remove contaminated oil and sludge from oil container.
Collect old oil and dispose of it in accordance with
environmental regulations.
3. Clean the oil container thoroughly.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 91
Fig. 87
4. 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.
NOTE!
Do not pull out the filter material (3) from the filter
case. The filter must be completely dry before
fitting.
Fig. 88
5. Fill oil container up to marking (4) with engine oil (use oil in
accordance with the viscosity classes on page 29).
6. Fix oil container to the filter, whilst doing so make sure the
filter sits correctly, and close both fasteners.
Diesel engine Series 15W / 18W
Maintenance
92 2008-12-09
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.
Personnel This work must only be carried out by trained specialist
personnel. In the absence of the required qualifications,
arrange for the work to be carried out by a Greaves Farymann
Diesel service partner.
Prerequisites
Only check and adjust the valve clearance when the engine is cold
(less than 35 °C).
Settings
Exhaust valve 0.2 mm
Intake valve 0.2 mm
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 93
8.9.1 Engines with visible flywheel and O.T. marking
Preparations
Fig. 89
1. Switch off engine and let it cool down to the ambient
temperature.
2. 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.
Fig. 90
3. Detach the high pressure line (4) on the injection nozzle
holder in order to prevent accidental starting of the engine.
Fig. 91
4. Turn automatic decompression to operating position (5), pin
faces forward (9 o'clock position).
NOTE!
The decompression must be turned off at the valve
adjustment (operating position: pin faces forward:
9 o'clock position), only in this way is a correct
adjustment of the valves guaranteed.
Diesel engine Series 15W / 18W
Maintenance
94 2008-12-09
Adjusting inlet valve - exhaust
valve
Fig. 92
5. Insert crank handle (6) in the starting handle support bearing
and slowly turn the crankshaft in the engine rotation direction
(anticlockwise) until the end of the compression stroke or
Fig. 93
until the O.T. marking (7) on the flywheel corresponds to the
crankcase marking (8).
Fig. 94
In this position both valves (inlet and exhaust valves) are
closed (max. clearance between rocker arm and valve stem).
Exhaust valve setting
6. Slide a feeler gauge (10) with thickness 0.2 mm between
rocker arm (9) and the exhaust valve stem and check the
valve clearance of the exhaust valve.
The feeler gauge must be able to be pulled through between
the valve and the cam follower without noticeable resistance
(drag).
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 95
Fig. 95
7. 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).
8. Hold the adjusting screw in place with a screwdriver and
tighten the lock nut.
9. Check the valve clearance again.
Fig. 96
Inlet valve setting
10. Setting the inlet valve is carried out in exactly the same way
as for the exhaust valve (see Fig. 94 and 95).
Fig. 97
11. Tighten the high pressure line (4) on the injection nozzle
holder.
Tightening torque 25 Nm
Diesel engine Series 15W / 18W
Maintenance
96 2008-12-09
Fig. 98
12. Replace valve cover gasket (13).
Fig. 99
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).
Tightening torque 8–12 Nm
NOTE!
Always replace the valve cover gasket and the two
plastic seals under the nuts of the valve cover.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 97
8.9.2 Engines with covered flywheel (without visible O.T. marking)
Preparations
Fig. 100
1. Switch off engine and let it cool down to the ambient
temperature.
2. 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.
Fig. 101
3. Detach the high pressure line (4) on the injection nozzle
holder in order to prevent accidental starting of the engine.
Fig. 102
4. Turn automatic decompression to operating position (5). Pin
faces forward (9 o'clock position).
NOTE!
The decompression must be turned off at the valve
adjustment (operating position: pin faces forward:
9 o'clock position), only in this way is a correct
adjustment of the valves guaranteed.
Diesel engine Series 15W / 18W
Maintenance
98 2008-12-09
Adjusting exhaust valve
Fig. 103
5. 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).
Fig. 104
6. Slide a feeler gauge (10) with thickness 0.2 mm between
rocker arm (9) and the exhaust valve stem and check the
valve clearance of the exhaust valve.
The feeler gauge must be able to be pulled through without
noticeable resistance (drag).
Fig. 105
7. 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).
8. Hold the adjusting screw in place with a screwdriver and
tighten the lock nut.
9. Check the valve clearance again.
Diesel engine Series 15W / 18W
Maintenance
2008-12-09 99
Adjusting intake valve
Fig. 106
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).
Fig. 107
11. Slide a feeler gauge (10) with thickness 0.2 mm between
rocker arm (9) and the inlet valve stem and check the valve
clearance of the inlet valve.
The feeler gauge must be able to be pulled through without
noticeable resistance (drag).
Fig. 108
12. If the clearance is too large or too small, undo the
lock nut (11) and adjust the clearance with the
adjusting screw (12). The feeler gauge must be able to be
pulled through without noticeable resistance (drag).
13. Hold the adjusting screw in place with a screwdriver and
tighten the lock nut.
14. Check the valve clearance again.
Diesel engine Series 15W / 18W
Maintenance
100 2008-12-09
Fig. 109
15. Tighten the high pressure line (4) on the injection nozzle
holder.
Tightening torque 25 Nm
Fig. 110
16. Replace valve cover gasket (13).
Fig. 111
17. Install valve cover (2) using two new plastic seals (14).
18. Mounting bracket (3) of the fuel line.
19. Tighten both nuts (1) of the valve cover (2).
Tightening torque 8–12 Nm
NOTE!
Always replace the valve cover gasket and the two
plastic seals under the nuts of the valve cover.
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