Operations Manual 18W

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!

© 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
2 2008-12-09
Diesel engine Series 15W / 18W
Table of contents
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
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Table of contents
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
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Table of contents
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
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Table of contents
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
6 2008-12-09
General
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.
2008-12-09 7
General
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!
which can result in minor or slight injuries if it is not
avoided.
CAUTION!
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.
8 2008-12-09
General
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.
2008-12-09 9
General
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.
10 2008-12-09
Safety
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.
2008-12-09 11
Safety
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.
12 2008-12-09
Safety
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.
2008-12-09 13
Safety
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.
14 2008-12-09
Safety
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 When performing special tasks it is necessary to wear personal
special tasks 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.
2008-12-09 15
Safety
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.
16 2008-12-09
Safety
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.
2008-12-09 17
Safety
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 CAUTION!

components 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.
18 2008-12-09
Safety
Antifreeze (for engines with WARNING!

radiators and, e.g. electric water Danger of poisoning and danger of skin rashes
pump) 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
– Collect coolant drained from the engine in a
suitable container and dispose of in accordance
with the environmental regulations.
2008-12-09 19
Safety
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.
20 2008-12-09
Safety
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.
2008-12-09 21
Technical data
3 Technical data
3.1 Technical specifications
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
Fig. 1
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)
22 2008-12-09
Technical data
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)
2008-12-09 23
Technical data
3.5 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)
Fig. 2: Example of the engine type plate
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
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
Fig. 3
Displacement = in cubic inches (approx.)
24 2008-12-09
Technical data
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 0.2 mm
Exhaust valve 0.2 mm
Type of starting
all engines Manual starting with crank handle
Option Starter (12 V or 24 V)
Required battery 36 Ah (12 V)

capacity 72 Ah (2 batteries a = 12 V) for 24 V
Permitted operating 15° longitudinal

inclined position 15° lateral
(permanent)
2008-12-09 25
Technical data
3.8 Performance data

Description Value 15W Value 18W
Max. power IFN-ISO* 4.3 kW IFN-ISO* 5.2 kW

(at 3600 rpm) ICFN-ISO* 3.9 kW ICFN-ISO* 4.7 kW
Max. speed 3600 rpm
Max. torque 13.0 Nm 15.3 Nm

(2500 rpm) (2500 rpm)
Bore 82 mm
Stroke 55 mm
Displacement 290 cm3
Mean piston 6.6 m/s (3600 rpm )

speed
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.
26 2008-12-09
Technical data
3.9 Dimensions and weight

Description Value
Overall length 374 mm
Overall height 422 mm
Overall width 401 mm
Dry weight: standard 39 kg

engine with air filter and
exhaust silencer
3.10 Temperatures
Description Value
Max. permissible air 50 °C

intake temperature
Max. permissible 580 °C

exhaust temperature
cooling air temperature
Max. permissible fuel 70 °C

temperature

engine oil temperature
cooling water
temperature
2008-12-09 27
Technical data
3.11 Pressures
Description Value
Injector setting - nozzle 200 bar

opening pressure
Oil pressure (max.) 5 bar
Intake vacuum permitted 2 kPa
Exhaust gas back permitted 5 kPa

pressure
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) approx. 1.2 litres
Max. engine oil filling
quantity (version with
oil strainer) 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 7 – 8 l/min

direct cooling
28 2008-12-09
Technical data
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
2008-12-09 29
Structure and function
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 7 Starting handle support bearing

2 Dry type air cleaner (oval flange / option) 8 Speed adjusting lever
3 Decompression unit 9 Fuel feed pump
4 Engine mounting point 10 Lifting eye for transport
5 Cooling water pump (neoprene impeller pump) 11 Starter
6 Oil drain plug
NOTE!
The engine with D/W crankcase has an oil filter.
30 2008-12-09
Fig. 6: Output side Right view
12 Thermostat housing 17 Injection pump

13 Bell housing (option) 18 Water-cooled exhaust manifold (option)
14 Stub shaft (option) 19 Oil filler cap
15 Oil dipstick 20 Excess fuel device
16 Oil filter (D/W crankcase) 21 Fuel filter (standard)
2008-12-09 31
NOTE!
The engine shown in pictures 7 and 8 is the
standard engine.
Fig. 7: Front view Left view
1 Valve cover 7 Excess fuel device

2 Oil bath air cleaner 8 Starting handle support bearing
3 Decompression unit 9 Speed adjusting lever
4 Engine mounting point 10 Fuel feed pump
5 Cooling water pump (neoprene impeller pump) 11 Lifting eye for transport
6 Oil drain plug
NOTE!
The standard engine 15W / 18W has an oil strainer
and no oil filter.
32 2008-12-09
Fig. 8: Output side Right view
12 Thermostat housing 16 Injection pump

13 Flywheel 17 Oil dipstick
14 Water-cooled exhaust manifold (option) 18 Fuel filter
15 Oil filler cap
4.2 Electrical System

4.2.1 Alternator (option)
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.
Fig. 9: Example: Alternator
2008-12-09 33
4.2.2 Alternator regulator (option)

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)
Fig. 10: Example: Alternator regulator 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).
34 2008-12-09
4.2.4 Dangers and cause of failure

Dangers Cause of failure
Battery terminals incorrectly Damage to the charging circuit

connected
Defective battery or complete Destruction of the alternator

discharge regulator
Disconnection of the battery Immediate destruction of the

when the engine is running alternator regulator
External start with jump leads Destruction of the alternator

for defective or completely regulator
discharged battery
Manual starting with Destruction of the alternator

disconnected battery regulator
Interruption of the earth Destruction of the alternator

connection of the alternator regulator
regulator to the engine
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.
2008-12-09 35
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.
36 2008-12-09
4.3 Cooling system

4.3.1 Open cooling water circuit with direct sea water cooling without thermostat
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.
Fig. 11
4.3.2 Open cooling water circuit with direct sea water cooling with thermostat
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.
Fig. 12 The opening temperature prevents the separation and deposit of
salt crystals from the sea water in the cooling water area of the
engine
2008-12-09 37
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).
38 2008-12-09
Transport, packing and storage
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.
2008-12-09 39
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 The engine has one lifting eye (Fig. 13/1) and can be transported
crane 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.
Fig. 13: Transport with the crane
40 2008-12-09
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 non-
functional 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.
2008-12-09 41
Installation and commissioning
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
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
Fig. 14 easier.
3. Place both plate washers (2) on the crankshaft (3).
NOTE!
The flat sides of the plate washers face each other.
42 2008-12-09
4. Install key (4) into the keyway of the crankshaft and ensure
that this sits correctly.
Fig. 15
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
Fig. 16
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.
2008-12-09 43
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.
Fig. 17
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).
Fig. 18
6.2.2 Attaching stub shaft (option)

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.
Fig. 19: Example: Stub shaft
44 2008-12-09
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.).
Example: Speed controller with Bowden cable
Fig. 20
2008-12-09 45
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.
46 2008-12-09
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.
1. Release oil filler cap (1) e.g. with a 13mm jaw spanner and
screw off by hand.
Fig. 21
2. Fill engine oil into the filling opening (2).
Fig. 22
2008-12-09 47
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. 23
5. Check the oil level quantity. The oil level should be just under
the Max. marking.
6. Fill with engine oil if needed.
Fig. 24
7. Only tighten the oil filler cap (1) by hand (risk of breakage).
Fig. 25
48 2008-12-09
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).
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.
Fig. 26
2008-12-09 49
Operation
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.
50 2008-12-09
Operation
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 CAUTION!

components 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.
2008-12-09 51
Operation
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.

radiator and, e.g. electric water Danger of poisoning and danger of skin rashes
or allergies.
Therefore:
manufacturer.
suitable container and dispose of in accordance
with the environmental regulations.
52 2008-12-09
Operation
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.
2008-12-09 53
Operation
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.
54 2008-12-09
Operation
Setting cold start / warm start
CAUTION!
damage.
Therefore:
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
Fig. 27
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.
2008-12-09 55
Operation
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. 28
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.
Fig. 29: Example: automatic Neutral position: In the neutral position the compression is
decompression with star knob 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.
NOTE!
Never use the automatic decompression to
switch off the engine.
Fig. 30: Example: automatic

decompression with lever
56 2008-12-09
Operation
1 Starting position
2 Neutral position
3 Operating position
Fig. 31: Example: automatic

decompression
The automatic decompression (Fig. 31) is adjusted on the starting

handle (Fig. 33) with the adjusting spanner.
Fig. 32: Example: Adjusting the automatic

decompression on the starting handle with
the adjusting spanner
Starting handle (1) with adjusting spanner (2).
Fig. 33: Adjusting spanner on the starting

handle
2008-12-09 57
Operation
Excess fuel device
NOTE!
The excess fuel device (1) must be pulled out
for cold starting.
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
Fig. 34: Excess fuel device 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
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.
Fig. 35
58 2008-12-09
Operation
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. 36: Starting handle (rigid version)
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. 37: RD crank handle
5. Erect on the right in front of the engine and ensure a secure

position.
Fig. 38
2008-12-09 59
Operation
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.
Fig. 39
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.
60 2008-12-09
Operation
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!
damage.
Therefore:
The engine in the version with a starter is started using a key

switch (see e.g. operating instructions of the device manufacturer).
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
Fig. 40: Example: Key switch
2008-12-09 61
Operation
Starting engine
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.
Fig. 41
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!
damage.
Therefore:
62 2008-12-09
Operation
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.
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.
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.
2008-12-09 63
Operation
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.
64 2008-12-09
Operation
7.6.1 Engine without electric starter

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.
Fig. 42
7.6.2 Engine with electric starter
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.
Fig. 43: Example of key switch
2008-12-09 65
Operation
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.
66 2008-12-09
Operation
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.
2008-12-09 67
Maintenance
8 Maintenance
8.1 Safety
Maintenance work not carried out WARNING!
correctly 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.

ignition sources.
Therefore:
– Do not smoke.
and floor.
68 2008-12-09
Maintenance
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.
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!
of this chapter.
2008-12-09 69
Maintenance
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.
70 2008-12-09
Maintenance
Maintenance table
Components Work to be performed Daily After 25 Every 250 Every 500

Component before operating operating operating
group every hours hours hours
start-up
Engine oil Check oil level, refill with engine oil X

if necessary
Engine oil Replace engine oil at least every X X

(version with oil 12 months
strainer)
Change engine Replace engine oil and oil filter at X X

oil and oil filter least every 12 months
(D/W crankcase
version)
Oil strainer Remove oil strainer and clean, X

replace if necessary
Suction area Check area for intake air, clean if X X X

necessary
Dry type air Clean air filter element and air filter X
cleaner case
Replace air filter element and X

clean air filter case
Oil bath air Check oil contamination and oil X

cleaner level, several times a day in the
case of a high occurrence of dust;
if necessary fill oil up to marking or
change it
Change the oil bath air cleaner's X

oil
Neoprene Check neoprene impeller X

impeller
Valve adjustment Using Greaves Farymann Diesel X X

service partner:
Check valve clearance,
adjust if necessary (cold engine)
Threaded Check for tightness, tighten if X X

connections necessary
(cylinder head nuts must not be
tightened)
2008-12-09 71
Maintenance
Components Work to be performed Daily After 25 Every 250 Every 500

Component before operating operating operating
group every hours hours hours
start-up
Exhaust system Check for leaks, X

arrange repair by a Greaves
Farymann Diesel service partner if
necessary
Fuel filter Replace X
Fuel hoses Check, X

replace if necessary and in any
case at least every 4 years by a
Greaves Farymann Diesel service
partner
Electric cables Check for damage, X

replace by a Greaves Farymann
Diesel service partner if necessary
Cooling water Check, X

hoses and hose replace if necessary and in any
clamps case at least every 2 years by a
Greaves Farymann Diesel service
partner
Thermostat Replace thermostat Recommendation: after 2000 operating hours
Coolant Replace coolant (engines with Recommendation: every 2 years

closed cooling water circuit / with
radiator and e.g. electric water
pump)
Engine Outside cleaning with engine as required

cleaner
72 2008-12-09
Maintenance
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.
Clean dust and contamination in the intake area (1) with a
suitable clean and dry cloth.
Fig. 44
2008-12-09 73
Maintenance
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.
74 2008-12-09
Maintenance
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
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.
Fig. 45
2008-12-09 75
Maintenance
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. 46
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.
the Max. marking.
Fig. 47
15. Start engine and check for leaks.
8.5.2 Version with oil drain valve

1. Switch off the engine.
2. Screw off the sealing cap (1) by hand.
Fig. 48
76 2008-12-09
Maintenance
3. Screw special oil drain hose (2) onto the oil drain valve (3).
This opens the quick-release coupling.
5. Unscrew and remove the oil drain hose (2).
Fig. 49
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. 50

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.
the Max. marking.
Fig. 51
NOTE!
Always replace engine oil and oil filter together
(for engines with D/W crankcase).
2008-12-09 77
Maintenance
8.5.3 Removing and installing oil strainer

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).
6. Clean oil strainer with cold cleaning agent or diesel.
NOTE!
If the oil strainer is deformed or damaged, it must
Fig. 52
absolutely be replaced.
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. 53
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.
the Max. marking.
Fig. 54 16. Start engine and check for leaks.
78 2008-12-09
Maintenance
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.)
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. 55
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
Fig. 56
2008-12-09 79
Maintenance
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. 57
5. Tighten the oil filter (7) only by hand.

Fig. 58
80 2008-12-09
Maintenance
8.7 Fuel system
Fig. 59: Fuel system
1 Fuel pressure line 5 Connection for fuel line to the fuel tank (feed)
2 Connection for fuel line to the fuel tank (return) 6 Fuel filter (standard)
3 Injection nozzle holder 7 Injection pump
4 Fuel feed pump 8 Electric solenoid valve (option)
8.7.1 Replacing fuel filter

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.
Fig. 60: Fuel filter with thread
2008-12-09 81
Maintenance
Fuel filter (2) version (standard): With this version, the fuel lines
are fixed using hose clamps.
Fig. 61: Fuel filter (standard)
8.7.2 Replacing fuel filter (with thread)

2. Disconnect fuel line (1) using special fuel line disconnecting
tool (2).
Fig. 62
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.
Fig. 63
82 2008-12-09
Maintenance
5. Detach fuel line (6) from the fuel filter (4).
Fig. 64
5. Undo hose clamp (7) and remove fuel filter (4).
Fig. 65
6. Collect the fuel from the fuel line (6) in a suitable container (5)
and dispose of in accordance with the environmental
regulations.
Fig. 66
2008-12-09 83
Maintenance
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. 67: Fuel filter with thread
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.
Fig. 68
8.7.3 Replacing fuel filter (standard)

2. Undo hose clamp (1) on the mounting (2) of the fuel filter.
Fig. 69
84 2008-12-09
Maintenance
3. Disconnect fuel line (2) using special fuel line disconnecting

tool (3).
Fig. 70
4. Undo hose clamp (4) and pull off the fuel line (2) from the fuel
filter (5).
Fig. 71
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).
Fig. 72
2008-12-09 85
Maintenance
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. 73
8. Tighten screw (1) of the hose clamp on the mounting.

8. Start engine and check the fuel system for leaks.
Fig. 74
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.
86 2008-12-09
Maintenance
8.8.1 Dry type air cleaner (standard engine)

2. Unscrew and remove the wing nut (1).
3. Release sealing clips (2) and remove air filter case (3).
Fig. 75
4. Remove air filter element (4).
Fig. 76
5. Remove air filter cover (5) with air filter pot (6) and centring
ring (7).
Fig. 77
2008-12-09 87
Maintenance
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. 78
8. Install new air filter element (4).
Fig. 79
9. Position air filter case (3) straight, in the process pay attention
to correct seating, and close sealing clips (2).
Fig. 80
88 2008-12-09
Maintenance
8.8.2 Dry type air cleaner (oval flange)

2. Unscrew and remove the wing nut (1).
3. Remove air filter cover (2).
Fig. 81
4. Remove air filter element (3).
Fig. 82
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.
Fig. 83
2008-12-09 89
Maintenance
6. Install new air filter element (3); in doing so, ensure that the
spacer sleeve (4) is also installed.
Fig. 84
7. Position air filter case (2) straight, in the process pay attention
to correct seating, and fasten with the wing nut (1).
Fig. 85
8.8.3 Oil bath air cleaner (standard engine)
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
Fig. 86
3. Clean the oil container thoroughly.
90 2008-12-09
Maintenance
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
Fig. 87 case. The filter must be completely dry before
fitting.
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.
Fig. 88
2008-12-09 91
Maintenance
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
92 2008-12-09
Maintenance
8.9.1 Engines with visible flywheel and O.T. marking

Preparations 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. 89
3. Detach the high pressure line (4) on the injection nozzle

holder in order to prevent accidental starting of the engine.
Fig. 90
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.
Fig. 91
2008-12-09 93
Maintenance
Adjusting inlet valve - exhaust 5. Insert crank handle (6) in the starting handle support bearing
valve and slowly turn the crankshaft in the engine rotation direction
(anticlockwise) until the end of the compression stroke or
Fig. 92
until the O.T. marking (7) on the flywheel corresponds to the

crankcase marking (8).
Fig. 93
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).
Fig. 94
94 2008-12-09
Maintenance
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. 95
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. 96
11. Tighten the high pressure line (4) on the injection nozzle
holder.
Tightening torque 25 Nm
Fig. 97
2008-12-09 95
Maintenance
12. Replace valve cover gasket (13).
Fig. 98
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.
Fig. 99
96 2008-12-09
Maintenance
8.9.2 Engines with covered flywheel (without visible O.T. marking)

Preparations 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. 100
3. Detach the high pressure line (4) on the injection nozzle

holder in order to prevent accidental starting of the engine.
Fig. 101
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.
Fig. 102
2008-12-09 97
Maintenance
Adjusting exhaust valve 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. 103

rocker arm (9) and the exhaust valve stem and check the
valve clearance of the exhaust valve.
Fig. 104
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).
Fig. 105
98 2008-12-09
Maintenance
Adjusting intake valve
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. 106

rocker arm (9) and the inlet valve stem and check the valve
clearance of the inlet valve.
Fig. 107
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).
Fig. 108
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Maintenance
15. Tighten the high pressure line (4) on the injection nozzle
holder.
Fig. 109
16. Replace valve cover gasket (13).
Fig. 110
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.
Fig. 111
100 2008-12-09
Maintenance
8.10 Cooling water diagram (standard)
Fig. 112: Cooling water diagram (standard)
1 Cylinder head 3 Cooling water flow direction

2 Cylinder 4 Cooling water pump (neoprene impeller pump)
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Maintenance
8.11 Cooling water diagram (with water-cooled exhaust manifold)
Fig. 113: Cooling water diagram
1 Cylinder head 4 Cooling water pump (neoprene impeller pump)

2 Cylinder 5 Water-cooled exhaust manifold
3 Cooling water flow direction
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Maintenance
8.12 Replacing neoprene impeller of the cooling water pump

NOTE!
The neoprene impeller of the cooling water pump
must be considered as a wearing part. The service
life of the neoprene impeller can be extremely
different and depends solely on the operating
conditions.
1. Switch off engine and let it cool down to the ambient

temperature.
2. Place suitable container under the cooling water pump.
3. Mark cooling water pump, e.g. with a touch-up stick (see
arrow).
Fig. 114
4. Unscrew the 4 bolts (1) on the cooling water pump cover (2).
5. Collect water in a suitable container and dispose of in
6. Remove cooling water pump cover (2) with gasket.
Fig. 115
2008-12-09 103
Maintenance
7. Mark neoprene impeller for the case (see arrow).
NOTE!
It is ensured by the marking that the neoprene
impeller is inserted in the correct position in the
event of reinstallation.
Fig. 116
8. Carefully remove the neoprene impeller (3) using two

screwdrivers (4).
Fig. 117
9. Remove calcium deposits and gasket residues from the

cooling water pump case (5).
Fig. 118
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Maintenance
10. Check cooling water pump case (5) and neoprene impeller (3)
for damage; replace if necessary.
NOTE!
Coat the neoprene impeller with some Vaseline®
before installing in the water pump case.
Fig. 119
11. Insert neoprene impeller (3) in the recess of the pump shaft
(see black arrow); in doing so, ensure that it is fixed properly.
NOTE!
If the "old" neoprene impeller is reused, place this
on the previously applied marking (see arrow).
Fig. 120
2008-12-09 105
Maintenance
12. Clean the sealing surface of the cooling water pump cover (6).
13. Use new gasket (7).
Fig. 121
14. Replace cooling water pump cover (2), screw in all screws (1)
and tighten with a screwdriver.
15. Fill with water.
16. Start engine and check cooling system for leaks.
NOTE!
Never operate the neoprene impeller pump without
sea water (never let it run "dry"). Even very short
dry running can result in destruction of the impeller.
Fig. 122
NOTE!
If there is a danger of frost during the process of
decommissioning, remove water from the cooling
system by undoing the screws (1) of the cooling
water pump cover (2).
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Maintenance
8.13 Removing, installing and checking thermostat

1. Switch off engine and let it cool down to the ambient
temperature.
2. Drain coolant and collect in a suitable container.
3. Unscrew both bolts (1).
4. Remove thermostat housing (2) with gasket.
Fig. 123
5. Remove thermostat (3).
Fig. 124
Functional check
6. Fill a container with water.

7. Attach thermostat (3) to a wire (4) and submerge in the water.
8. Heat the water slowly using, for example, a submersible
heater.
Fig. 125
2008-12-09 107
Maintenance
9. Measure the water temperature with a suitable temperature

measuring instrument.
10. The thermostat must be completely open at 50 °C water
temperature (for the salt water version) or at 70 °C water
temperature (for the fresh water version).
Fig. 126
Example: Thermostat completely opened (see arrow).
Fig. 127
Example: Thermostat closed (see arrow).
Fig. 128
108 2008-12-09
Maintenance
11. Remove deposits and gasket residues on the

cylinder head (5) and on the thermostat housing (2); in doing
so, ensure that no dirt gets into the water channel in the
cylinder head.
Fig. 129
12. Install thermostat (3).
NOTE!
Ensure when installing the thermostat that the
small bore hole (see arrow) is not covered or
closed and that the split pin is in the hole.
Fig. 130
13. Replace thermostat housing (2) with new gasket.

14. Screw in and tighten both bolts (1).
15. Fill with coolant (for engines with radiator) or water
(for engines with neoprene impeller pump).
16. Start engine and check cooling system for leaks.
Fig. 131
2008-12-09 109
Maintenance
8.14 Checking the cooling system for leaks

8.14.1 Engines with radiator (and e.g. electric water pump)
during operation and cause burns in the case of
contact.
Therefore:
– Never open the radiator cap at operating
temperature.
– Let the cooling water cool down to the ambient
temperature and open the radiator cap slowly
so that the pressure can escape.
In the case of engine overheating or loss of cooling fluid in the

cooling circuit (e.g. radiator, water pump and cooling water hoses),
switch off the engine immediately and make the following checks:
Checking the cooling system for leaks.
Checking thermostat Ö Chapter 8.12.
Check electric water pump (e.g. pay attention to running
noises).
If the cause of the error cannot be determined, contact your
nearest Greaves Farymann Diesel service partner or call us.
8.14.2 Engines with direct sea water cooling

In the case of engine overheating or leaks in the sea water cooling
circuit (e.g. impeller pump and cooling water hoses), switch off the
engine immediately and make the following checks:
Checking the cooling system for leaks.
Checking cooling water pump impeller Ö Chapter 8.11.
Checking thermostat Ö Chapter 8.12.
110 2008-12-09
Maintenance
8.14.3 Checking the cooling water hoses and hose clamps

Check the cooling water hoses daily. If a cooling water hose is
damaged or sea water / coolant discharges, this can result in
overheating of the engine. This can also result in severe skin
burns / scalding.
Check the cooling water hoses daily in order to avoid damage
to the engine and cooling system.
If a hose clamp of the cooling water hoses has loosened itself
and cooling water discharges, the hose clamp must be
tightened or replaced if necessary.
If cooling water hoses are frayed, swollen, hardened or
damages, the cooling water hoses and the hose clamps must
be replaced immediately.
Cooling water hoses and hose clamps must be replaced at
least every 2 years.
8.14.4 Precautions in the case of engine overheating

If the engine overheats during operation and the cooling liquid
temperature rises to near or even above boiling point, the following
actions must be performed immediately.
Switch off the engine immediately in the unloaded condition.
Immediately leave the area around the engine or the machine
and maintain a safety distance.
Never remove covers or other parts on the engine as there is a
danger that "hot" cooling water can discharge and thus result in
skin burns / scalding.
If hot steam discharges, leave the immediate danger area
immediately and maintain a safety distance.
When the engine has cooled down to the ambient temperature
and there is no more danger of burns or scalding, investigate
the cause of the overheating in accordance with the operating
manual.
CAUTION!
The use of radiator sealants is basically not
permitted.
2008-12-09 111
Maintenance
8.15 Checking level of the coolant (for engines with radiator)

during operation and cause burns / scalding in the
case of contact.
Therefore:
– Never open the radiator cap at operating
temperature.
– Let the cooling water cool down to the ambient
temperature and open the radiator cap slowly
so that the pressure can escape.

or allergies.
Therefore:
manufacturer.
112 2008-12-09
Maintenance
Determine coolant level by visual inspection and coolant if

necessary (the coolant level should be up to the bottom edge of
the radiator filler neck (see also the operating manual of the device
manufacturer).
Do not start work on the cooling system until the engine and the
cooling system are cooled down to the ambient temperature.
Never open the radiator cap at operating temperature. Do not open
the radiator cap until the cooling water has cooled down to the
ambient temperature. Opening the radiator cap at operating
temperature can result in severe skin burns / scalding.
If the radiator cap is loose or not mounted properly, the engine can
overheat due to loss of coolant. This can result in engine damage.
8.15.1 Replacing coolant (for engines with radiator)
If the cooling water freezes, the engine and cooling system

(e.g. radiator) can be severely damaged. If the outside temperature
falls below 0 °C, the cooling water must be drained or mixed with
antifreeze. It is recommended to replace the coolant (antifreeze /
water) every 2 years (see also the operating manual of the device
manufacturer).
2008-12-09 113
Faults
9 Faults
Possible causes of faults and the work for rectifying them are
described in the following chapter.
In the case of increasingly occurring faults, reduce the
maintenance intervals in accordance with the actual load.
In the case of faults which cannot be rectified using the following
information, contact the nearest Greaves Farymann Diesel service
partner or the manufacturer.
9.1 Safety
Personnel The work described here for fault clearance can be performed
by the operator unless otherwise indicated.
Some work must only be performed by a Greaves Farymann
Diesel service partner; this is specially pointed out in the
description of the individual faults.
Personal protective equipment Wear the following protective equipment for all maintenance work:
Protective clothing
Safety footwear
NOTE!
of this chapter.
114 2008-12-09
Faults
Improper fault clearance WARNING!

Risk of injury due to improper fault clearance!
Improper fault clearance can result in severe
personal injuries or material damage.
Therefore:
– 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 cause accidents.
– If parts have been removed, pay attention to
correct assembly, reinstall all fixing elements
and comply with the tightening torques for
threaded connections.

ignition sources.
Therefore:
– Do not smoke.
and floor.
CAUTION!
Danger of poisoning due to fuel and engine oil!
Contact with engine oil and fuel can result in
damage to health.
Therefore:
– Avoid skin contact with engine oil and fuel.
– Remove oil and fuel splashes from the skin
immediately.
2008-12-09 115
Faults

or allergies.
Therefore:
manufacturer.
Procedure for faults The basic rule is:

1. Stop the engine immediately in the case of faults which
represent an immediate danger for persons or property.
2. Determine the cause of the fault.
3. Inform the responsible person at the usage location about the
fault.
4. Arrange for rectification by a Greaves Farymann Diesel
service partner or yourself depending on the type of the fault.
NOTE!
The fault table listed below gives information about
who is authorised for rectification of the fault.
116 2008-12-09
Faults
9.2 Troubleshooting chart

9.2.1 Engine does not start
Error Possible cause Troubleshooting Clearance by
If the injection No fuel in the tank Filling with fuel Operator

noise (chattering)
cannot be heard Speed adjusting lever is in the Put speed adjusting lever in the Operator
Stop position "full load" position
Ventilation in the fuel filler cap Replace fuel filler cap Operator
blocked
Fuel line interrupted Check fuel lines Operator
Fuel filter blocked Replace fuel filter Operator
Failure of the fuel Fuel line broken or leaky Replace fuel line or tighten Operator
system; turn connection connection
engine by hand
and pay attention Vapour bubble formation caused Let fuel cool down Operator
to the typical by too hot fuel
"chatter" of the
injection nozzle. Paraffin precipitation in the fuel Drain and flush fuel system, Skilled
(for low external temperature replace fuel filter, use winter fuel employee
approx. -10 °C)
Defective injection nozzle Check injection nozzle, replace if Skilled

necessary employee
If the injection Petrol instead of diesel in the tank Drain tank and fuel system and Skilled
noise (chattering) arrange for engine to be checked employee
can be heard by a Greaves Farymann Diesel
service partner (petrol in the tank
results in engine damage)
Air intake tract blocked Check intake area of the air filter Operator
case and air filter cartridge
Incorrect valve clearance Adjust valve clearance Skilled

employee
2008-12-09 117
Faults
Compression too Decompression unit defective Check decompression unit, Skilled

low replace if necessary employee
Leaky valves Check valves, repair or replace Skilled

employee
Leaky cylinder head / cylinder Replace cylinder head gasket Skilled

head gasket employee
Sticking piston rings Check piston rings, replace if Skilled

necessary and check piston ring employee
grooves
Piston and cylinder worn Overhaul engine (change piston Skilled

and cylinder) employee
Starting load too high Reduce load Operator
Engine can only Engine oil too viscous Change engine oil, use correct Operator
be turned with viscosity
difficulty
Main bearing or piston "seized" Overhaul engine Skilled
employee
118 2008-12-09
Faults
9.2.2 Engine starts, however runs irregularly or stops

Error Possible cause Troubleshooting Clearance
by
Bad fuel supply Fuel filter blocked Replace fuel filter Operator
Fuel line interrupted Check fuel line Operator
Leaky fuel line Check fuel line, tighten Operator

connection
Water in the fuel Drain tank and fuel system, flush Skilled
with diesel and refill and check employee
injection system
Defective injection nozzle Check injection nozzle, repair or Skilled

replace employee
Injection pump defective Check injection pump, repair or Skilled

replace employee
Bad compression Incorrect valve clearance Adjust valve clearance Skilled

employee
Worn valves Replace cylinder head Skilled

employee
Sticking piston rings Check piston rings, replace if Skilled

necessary and check piston ring employee
grooves
Piston and cylinder worn Overhaul engine (change piston Skilled

Defective intake Intake area blocked Check intake area of the air filter Operator
system case and air filter cartridge
Defective exhaust Exhaust blocked Check exhaust, clean or replace Operator

system
2008-12-09 119
Faults
9.2.3 Bad engine performance

Error Possible cause Troubleshooting Clearance
by
Operating conditions Engine overloaded Reduce load; troubleshooting at Operator

machine
Performance reduction due to Improve operating conditions Operator

increased intake temperature
Bad fuel supply Fuel filter blocked Replace fuel filter Operator
Seal under the injection nozzle Install seal or correct the number Skilled
missing or there are too many of seals, employee
seals installed check injection nozzle holder
Defective injection nozzle Check injection nozzle, replace if Skilled

necessary employee
Injection pump defective Check injection pump, repair or Skilled

replace employee
Incorrect adjustment Incorrect valve clearance Adjust valve clearance Skilled

employee
Incorrect end of delivery Adjust end of delivery Skilled

employee
Incorrect valve timing Check sprocket adjustment Skilled

markings employee
Piston incorrectly installed Install piston correctly Skilled

(marking on piston head not employee
pointing in the direction of the
flywheel side)
120 2008-12-09
Faults
9.2.4 Operating behaviour not faultless

Overheating Engine overloaded Reduce load Operator

(engine becomes
too hot) Cooling air inlet blocked Clear blockage Operator
Cooling air supply blocked Improve cooling air supply, check Operator
engine installation
Oil level in the crankcase too Correct oil level Operator

high

replace employee
Insufficient coolant level Fill with coolant Operator
Coolant thermostat defective Check coolant thermostat, Operator

Impeller of the neoprene impeller Replace impeller Operator

pump defective
Loss of cooling water Check the cooling system for Operator

leaks
Temperature switch or Check temperature switch or Skilled

temperature sensor defective temperature sensor, replace if employee
necessary
Cylinder head gasket or cylinder Check cylinder head gasket and Skilled
head defective cylinder head, replace if employee
necessary
End of delivery of the injection Check and adjust end of delivery Skilled
pump incorrectly adjusted employee
Knocking noises Carbon deposit on piston head Remove carbon deposits on Skilled
piston, replace piston and employee
cylinder if necessary
Injection nozzle needle sticks / Replace injection nozzle Skilled

jams employee
Incorrect end of delivery Check and adjust begin of Skilled

Incorrect begin of delivery delivery / end of delivery employee
Broken piston rings Replace piston rings, check Skilled

piston and cylinder employee
2008-12-09 121
Faults
Knocking noises Piston and cylinder worn Overhaul engine (change piston Skilled
Main bearing, connecting Overhaul engine Skilled

road bearing worn employee
Loose flywheel Check flywheel and crankshaft Skilled

for damage, overhaul engine if employee
necessary
Petrol mixture in the tank Drain tank and fuel system, flush Skilled
with diesel, fill with new fuel and employee
check engine, arrange overhaul if
necessary
Strong speed Overheating See: Overheating

fluctuations
Air in the fuel system Check fuel system for leaks Operator
Speed governor jammed or Check speed governor, replace if Skilled

defective necessary employee
Fuel filter blocked Replace fuel filter Operator
Adjusting lever jammed or Check adjusting lever, replace if Skilled

defective necessary employee
Engine stops Empty tank Filling with fuel Operator

suddenly
Ventilation in the fuel filler cap Replace fuel filler cap Operator
blocked
Vapour bubble formation caused Let fuel cool down Operator

by too hot fuel

replace employee
Fuel line broken Replace fuel line Skilled

employee
"Piston seizure" Overhaul engine (change piston Skilled

Crankshaft bearings "seized" or Overhaul engine Skilled

worn employee
122 2008-12-09
Faults
Engine emits blue Oil level too high Correct oil level Operator
smoke
Crankcase ventilation valve Replace crankcase ventilation Skilled
defective valve employee
Valve stem seal on intake valve Replace valve stem seal Skilled
guide defective employee
Worn valves, valve guides Replace cylinder head Skilled

employee
Piston and cylinder worn Replace piston and cylinder Skilled

employee
Engine emits white End of delivery too late Check and adjust end of delivery Skilled
smoke employee
Injection nozzle worn Replace injection nozzle Skilled

employee
Coolant temperature Coolant level too low Check and correct coolant level Operator
warning lamp lights
(if present) Coolant temperature switch Replace coolant temperature Skilled
defective switch employee
Coolant thermostat defective Check coolant thermostat, Operator

Impeller of the neoprene impeller Replace impeller of the neoprene Operator

pump defective impeller pump
Oil pressure Oil level too low Correct oil level Operator
warning lamp lights
(if present) Oil pressure switch defective Replace oil pressure switch Skilled
employee
Oil pressure too low Pressure relief valve defective Check pressure relief valve, Skilled
clean, replace if necessary employee
Bearing seat in pressure relief Check pressure relief valve, Skilled

valve dirty clean, replace if necessary employee
Oil filter blocked Replace oil filter and engine oil Operator
Oil pump defective Replace oil pump, overhaul Skilled

engine if necessary employee
2008-12-09 123
Faults
Cold start problems Speed adjusting lever is not at Set speed adjusting lever to the Operator
the maximum position maximum position (increased
speed)
Engine oil too viscous Change engine oil, use correct Operator
viscosity
Paraffin precipitation in the fuel Drain and flush fuel system, Skilled
replace fuel filter, use winter fuel employee
Starting speed too low Check battery, replace if Operator

necessary
9.3 Startup after eliminating fault

After rectifying the fault, carry out the following steps for restarting:
1. Ensure there are no persons in the danger zone.
2. Start engine and check the engine for correct functioning.
124 2008-12-09
Replacement Parts List
10 Replacement Parts List

10.1 Spare parts
WARNING!
Risk to safety due to use of non-original spare
parts!
Defective and non-original spare parts can
adversely affect the safety and result in damage
and malfunctions or total failure of the engine.
Therefore:
– Only use original spare parts from the
manufacturer.
Spare parts can be ordered from the nearest Greaves Farymann
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.
10.2 Ordering spare parts

Always state the following when ordering spare parts:
1 MODEL, e.g. 18W 430 (see type plate)
2 TYPE, e.g. 0001 (see type plate)
Spare parts orders without this information cannot be processed.
Spare parts can be ordered from the nearest
Greaves Farymann Diesel service partner.
Fig. 132
2008-12-09 125
Wearing parts for maintenance work
Order Description Quantity

number
541.052.2 Air filter element (dry type air cleaner) 1
555.129.1 Sealing clip 2
514.093.2 Wing nut 1
541.059.2 Air filter cover 1
541.058.2 Air filter pot 1
541.057.2 Guide-blade disc rim 1
541.056.2 Centring ring 1
512.158.2 M6 stud 1
741.138.5 Complete oil bath air cleaner 1
541.065.2 Air filter element (filter element for the 1

version with oval flange)
541.038.2 Fuel filter (standard) 1
541.069.2 Fuel filter (with thread) 1
890.74.18 Copper sealing ring A14x18x1.5 (for 4

fuel filter with thread)
770.142.4 Valve cover gasket 1
890.08.15 Plastic seals 8.0x17x2 2
E734.032.8 Oil strainer, complete 1
770.168.4 Gasket for oil strainer 1
890.74.04 Copper sealing ring A6x10x1.5 2

(for the bolts on the oil strainer)
890.30.03 Oil drain plug 1
890.74.25 Copper sealing ring A17x23x1.5 1

(for oil drain plug)
541.050.2 Oil filter (D/W crankcase version) 1
239.012.2 Oil drain valve with sealing cap 1
955.131.1 Oil drain hose 1
126 2008-12-09
Order Description Quantity

number
555.003.2 Cooling water thermostat 50 °C 1

(salt water)
555.006.2 Cooling water thermostat 70 1

(fresh water)
890.07.03 Split pin for thermostat 1
770.108.4 Thermostat housing gasket 1
538.219.2 Neoprene impeller for cooling water 1

pump with gasket
2008-12-09 127
Special tools
Order number Description
748.115.6 Fuel line

disconnecting tool
748.173.2 Oil filter wrench

(for engines with (dismantling the oil
D/W crankcase) filter)
Special tools can be ordered from the nearest Greaves Farymann

128 2008-12-09
Service history
11 Service history
11.1 Proof of purchase
Using the type plate, copy the following information on to the proof
of purchase and arrange confirmation.
There is a type plate on the engine with the following information:
1 Model
2 Type number
3 Version of the speed governor
4 Serial number
5 Date of manufacture
Fig. 133
Description Please fill in:
1 Model
2 Type number
3 TRIM
4 Serial number (S/N)
5 Date of manufacture
Date of purchase
by Dealer stamp
2008-12-09 129
Service history
11.2 Handover and servicing history

Arrange maintenance work during the warranty period and
afterwards to be carried out by one of our authorised Greaves
Farymann Diesel sales and service partners.
Comply with the maintenance intervals and have the following
evidence of maintenance confirmed by the specialist workshop.
The maintenance intervals must not be exceeded by more than
10% or maximum 25 operating hours.
Engine, equipment after 25 operating hours / after 250 operating hours /

installation and handover 1 month 6 months
Dealer stamp: Dealer stamp: Dealer stamp:
Hours ........................... Hours ........................... Hours ...........................

Date ............................. Date ............................. Date .............................
after 500 operating hours / after 750 operating hours / after 1000 operating hours /
12 months 18 months 24 months

Date ............................. Date ............................. Date .............................

Date ............................. Date ............................. Date .............................
130 2008-12-09
Service history

Date ............................. Date ............................. Date .............................

Date ............................. Date ............................. Date .............................

Date ............................. Date ............................. Date .............................
2008-12-09 131
Service history

Date ............................. Date ............................. Date .............................

Date ............................. Date ............................. Date .............................

Date ............................. Date ............................. Date .............................
132 2008-12-09
Service history

Date ............................. Date ............................. Date .............................

Date ............................. Date ............................. Date .............................

Date ............................. Date ............................. Date .............................
NOTE!
Further service histories can be ordered from the
nearest Greaves Farymann Diesel sales and
service partner. Refer to our website for a list of our
sales partners.
2008-12-09 133
Index
12 Index
A Environmental protection ................................... 21
Accident ............................................................. 20 Exhaust gases.................................................... 51
Adjusting valve clearance .................................. 92 F
Applications........................................................ 22 Faults ............................................................... 114
Appropriate use.................................................. 14 Fire ..................................................................... 20
Attachment points .............................................. 40 First aid .............................................................. 20
B Fuel system........................................................ 81
Batteries............................................................. 36 Fuels .................................................................. 21
C H
Checking level of the coolant........................... 112 Hard hat ............................................................. 15
Checking the cooling system for leaks ............ 110 I
Checking threaded connections ........................ 74 Installation .......................................................... 42
Cleaning the intake area.................................... 73 Instruction........................................................... 13
Cold start............................................................ 55 L
Cold starting aids ............................. 46, 55, 61, 62 Liability ................................................................. 9
Commissioning .................................................. 46 Lubricants........................................................... 21
Cooling system .................................................. 37 M
Copyright............................................................ 10 Maintenance....................................................... 68
Customer service ............................................... 10 Maintenance plan............................................... 70
D Manual start ....................................................... 55
Danger zone ...................................................... 20 Misuse................................................................ 14
Dangers and cause of failure............................. 35 O
Decommissioning............................................... 66 Oil bath air cleaner............................................. 90
Dimensions ........................................................ 27 Operating conditions .......................................... 34
E Operating materials...................... 18, 28, 110, 112
Ear defenders .................................................... 15 Operation ..................................................... 50, 62
Electrical System ............................................... 33 Options............................................................... 23
EMERGENCY STOP......................................... 53 Overview ............................................................ 30
Engine data........................................................ 25 Owner................................................................. 11
Engine oil P
changing......................................................... 75 Packing ........................................................ 39, 40
filling ............................................................... 47 Parts
Specification ................................................... 29 rotating............................................................ 50
Engine type code ............................................... 24 Personal protective equipment .......................... 15
Engine type plate ............................................... 24 Personnel ........................................................... 13
134 2008-12-09
Index
commissioning ................................................42 Spare parts .......................................................125

Faults ............................................................114 Ordering ........................................................125
installation .......................................................42 Standard configuration........................................23
Maintenance ...................................................69 Starting with electric starter ................................61
Pressures............................................................27 Storage .........................................................39, 41
Protective equipment..........................................15 Surfaces, hot.................................................18, 51
Faults ............................................................114 Switching off .......................................................64
Installation.......................................................69 Symbols
Operation ........................................................53 in the operator's manual....................................8
Protective gloves ................................................15 T
R Technical data ....................................................22
Replacement parts ...........................................125 Technical personnel............................................13
Replacement parts list ......................................125 Temperatures .....................................................27
Replacing air filter...............................................86 Transport.......................................................39, 40
Replacing fuel filter .............................................81 Crane...............................................................40
Replacing oil filter ...............................................79 Inspection........................................................39
Risk of fire...........................................................18 Troubleshooting
S Chart..............................................................117
Safety U
general ............................................................11 Usage..................................................................14
Safety boots........................................................15 W
Safety devices ....................................................20 Warm start ..........................................................55
Safety goggles....................................................15 Warranty .............................................................10
Service................................................................10 Weight.................................................................27
Service history ..................................................129
2008-12-09 135
Notes
Notes
136 2008-12-09
Notes
Art. 903.01.44 08.08
2008-12-09 137

Operations Manual 18W

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Table of contents

Doc-ID: Grea-8247 Read the operating instructions before starting work!

3 Technical data ......................................................................22

4 Structure and function........................................................ 30

5 Transport, packing and storage ........................................ 39

6 Installation and commissioning ........................................ 42

8.10 Cooling water diagram (standard)............................. 101

9 Faults .................................................................................. 114

10 Replacement Parts List..................................................... 125

11 Service history................................................................... 129

12 Index ................................................................................... 134

Notes .......................................................................................... 136

1.2 Explanation of the symbols

Tips and recommendations NOTE!

1.3 Limitation of liability

We reserve the right to make technical modifications in order to

1.5 Warranty terms

1.6 Customer service

2.1 Customer’s responsibility

2.2 Personnel requirements

2.3 Appropriate use

2.4 Personal protective equipment

Wear generally Generally wear for all kind of work:

2.5 Specific dangers

Rotating parts WARNING!

Substances harmful to health WARNING!

Highly flammable materials WARNING!

Hot operating materials WARNING!

Hot surfaces of the engine CAUTION!

Antifreeze (for engines with WARNING!

2.6 Safety devices

2.7 Behaviour in the case of danger and accidents

2.8 Environmental protection

The following environmentally hazardous substances are used:

3.3 Standard configuration

3.5 Engine type plate

Fig. 2: Example of the engine type plate

3.6 Engine type code

Trim No. = speed governor version

3.7 Engine data

Type Vertical single-cylinder diesel engine

Operating method Four-stroke

Combustion method Direct injection

Rotation direction Anticlockwise

Type of cooling Water-cooled

Valve control Overhead valves with push rods and

Valves Two-valve technology

Required battery 36 Ah (12 V)

Permitted operating 15° longitudinal

3.8 Performance data

Max. power IFN-ISO* 4.3 kW IFN-ISO* 5.2 kW

Max. speed 3600 rpm

Max. torque 13.0 Nm 15.3 Nm

Displacement 290 cm3

Mean piston 6.6 m/s (3600 rpm )

Compression ratio 20:1

3.9 Dimensions and weight

Overall length 374 mm

Overall height 422 mm

Overall width 401 mm

Special tool needed: