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 TABLE OF CONTENTS

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

General Information, Handling

All FARYMANN DIESEL engines are 4 stroke, direct injection diesel engines. They are
built as single cylinder engines in vertical and horizontal cylinder configuration. The direct
injection guarantees an outstanding level of efficiency, with low fuel consumption and ex-
cellent cold starting behaviour. Bosch fuel injection equipment is used on all engines. A
precision centrifugal governor ensures accurate speed (RPMs) and load regulation. For air
cooling, a noise-optimised, maintenance-free flywheel fan circulates the cooling air
through the cooling fins on the cylinder and the cylinder head.

Organisation and Use of this Repair Manual

The descriptions, data and illustrations refer to those assembly and adjustment proce-
dures where FARYMANN engines differ from ordinary diesel engines.
Well~known procedures (such as how to set the start of delivery) are not described in de-
tail.
- It is assumed that all work on the engine will be carried out by competent staff who
have received training.
- Special tools must be available, as described in the manual, together with good-quality
standard tools.

Service

- If you have any further questions about the Repair Manual, we recommend you to con-
tact your nearest FARYMANN Service Centre.
- Circular letters and training courses ensure that our service personnel have an answer
to every question. Please ask for a list of all our service locations from your own
FARYMANN Service Centre.

After Sales - Service: FALKE - Spare Parts Program

"Service, Quality and Progress"

is our motto. This is why we have developed our very own computer-aided "FALKE" Ser-
vice System.

I The FALKE System makes it possible for FARYMANN's world-wide network of distributors
to satisfy all spare parts and service requirements quickly and reliably, ensuring
that we maintain a close relationship with our customers.
I

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 GENERAL INFORMATION, HANDLING

Engine, Model and Type Designation

Every engine can be unmistakably identified using the manufacturer's nameplate. As well
as the clearly defined 12-digit code number, this refers to the order number (SN) and the
date of construction. This information must always be provided when making any enquir-
ies or complaints, etc.
As of July 1985, the consecutive engine number is also imprinted on the crankcase.

,
~
'-
[Q)~ ." III
,11111 ./
FARYHANN DIESEL GMBH
0 GERMANY 0
MODEL TYP TRIM
43F II 437 I 0001D5
SIN I [
I
960830 I
pI11 ,0 Ikll n 13UUUlmln'!
As of July 1982, the type designation (a 12-digit code number) is used in addition to the
series number (SN = Order Number). (See manufacturer's nameplate).

e.g. 43E437 2373 D5

95 03 20

T
Date of Production

43 E 437 ~L5~~-Trim_no. Engine speed and governor

L-~~~_ Typ.no. Engine specification

Start -0 Manual crank start

-5 Electric starter
-6 Alternator without starter
-7 Alternator wlth starter

L-~~~~_ Bearing -3 Roller bearing at flywheel side

' - - - - - - - Crankshaft -4 Honzontal crankshaft

r Basic engine -A = Vertical cylinder configuration, anti

design clockwlse rotation (former version)
-B = Vertical cylinder configuration,
clockwise rotation (new version)
-D = Vertical cylinder configuration, anti
clockwlse rotation (new version)
-E/F= Horizontal cylinder configuration, anti
clockwise rototlon
-W = Watercooled cylinder conflgurafton,
anti clockwlse rotation
'--------Displacement = in cubic Inch
 SAFETY INSTRUCTIONSATA·

Safety Instructions

~
Only use transport devices specified by the manufacturer, and only follow
hoisting instructions specified by the manufacturer.

~
When handling fuels, lubricants and other chemical substances, follow the
safety regulations which apply to the product.
--

~
Do not smoke when handling inflammable fuels or lubricants.

~
Vapours from lubricating oil or fuel may catch fire if they come into contact
with sources of ignition.

~. Be careful when handling hot or corrosive fuels, lubricants or other sub-

stances (risk of burning or scalding).

~
Never carry out maintenance and repair work when the engine is running.
Ensure that the engine cannot start unintentionally.

Before turning the engine over, make sure that nobody is in the danger

~
area. When you have finished working on the engine, always check that
the safety devices have been refitted, and that all tools have been re-
moved from the engine.

~
Never carry out any work on safety valves (e.g. modification of the spring
tension). Defective safety valves must be replaced with new ones.

~
When disposing of used fuels, lubricants and filters, follow the regulations
which apply locally.

~
Before or when you start the engine, check:
- all lines, hoses and screwed connections for leaks;
- safety devices for completeness and ability to operate.

When starting the engine by hand, only use the starting device specified by

~
the manufacturer (starting handle with kick back limiter, recoil starting) and
follow the handling instructions.
Never use cold starting aids based on ethyl oxide.

~
Because of the explosion hazard, it is forbidden to start up a compressed-
air start engine with combustible gases (fuel gases) or oxygen, even in an
emergency.
 SAFETY INSTRUCTIONS

Safety Instructions

Only operate IC engines in enclosed areas if there is adequate ventilation.

~
Before you start the engine in an enclosed environment, make sure that
there is sufficient ventilation.

~
Ensure that the engine only slows down to full stop after 10 - 20 seconds!

~
If there are any safety devices on the engine, or on the machine into which
the engine is built, they must be refitted when the maintenance and repair
work has been finished.

~
Before starting any work on the electrical components, the power supply to
all live parts must be cut off.
.

~
Only carry out maintenance and repair work when the engine parts are in a
stable position.

~
Liquids ejected under high pressure (such as fuels or oils) may penetrate
the skin and cause severe injuries.

~
To carry out cleaning work on the engine, always use a non-combustible
detergent, or one which has a flash point of more than 65 ·C.

CALIFORNIA

Proposition 65 Warning

Diesel engine exhaust and some of its

constituents are known to the State of
California to cause cancer, birth de-
fects, and other reproductive harm.
 · TECHNICAL DATA I

Technical Data

37E I 43E-Engine 43F-Engine

Engine Type 37E I 43E I 43F

Design horizontal
Number of Cylinders 1
Bore 95mm0
Stroke 100 mm
Cubic capacity (piston displacement) 708 cm 3
Direction of rotation (looking at power take- anti clockwise
off side)
Max. power
F (DIN 70020) 9,1 kW 12,4 HP 10,6 kW 14,4 HP 11,4 kW 15,5 HP
IFN-ISO (DIN 6271) 8,3kW 11,3 HP 9,7kW 13,2 HP 11,0 kW 15,0 HP
ICFN-ISO (DIN 6271) 75kW 10,2 HP ·87kW 11,8 HP 9,9kW 13,5 HP
Max. torque 31 Nm 37Nm 40,6 Nm
(DIN 70020) at 2200 RPM at 2000 RPM at 2300 RPM
Max. speed 3000 RPM
Mean piston speed 10 mls at 3000 RPM
Compression ratio 1 : 19
Valve clearance, exhaust valve 0,1 mm
intake valve 0,1 mm
Tank capacity 8,31 I 8,31 I 7,51
LubricatinQ oil volume (sump capacity) 2,11
Lubricating oil consumption 10 g/kWh
Starter
rated voltage 12V
battery capacity required 55Ah
Weight 87 kg
Overall dimensions approx. 500 mm • 440 mm • 590 mm approx. 360mm • 430mm
(H' W' L) 580mm
Permissible till during operation:
0
10nQitudinai 15
0
lateral 15
 TECHNICAL DATA I
Construction Data, Consumptions and Pressures

Technical Data Table 1

Engine Type
dimen-
37E
I 43E 43F
Construction data

System
sion

~ . four stroke

Combu~~on Proce- • direet injection

~ Cooling System • .. . air-cooled
Design I Configuration • 1-cylinder 1 horizontal
.

Bore (mm) 95
Stroke (mm) 100
3
Displacement (cm ) 708

Compression Ratio •
dimen-
1 : 18,7 - 1 : 20,5 I 1 : 17.5 - 1 : 19,1 1 : 19 - 1 : 19,5

Temperatures sion
Permissible air intake
temperature (max.) ('C) 50
Permissible exhaust
gas temperature (max) ('C) 580
Permi~siblecooling air
temperature {max.} ('C) 50
Permissible fuel
temperature (max.) ('C) . 80
Permissible lub. oil
temperature (max.) ('C) 130

Consumptions (at IFN Out Jut)

Specific fuel con-
5umption (glkWh) 268 262 I 280 I • I 258 I 251 I 280 I • 225 I 217 I 235 I •
Fuel tank content (I) 8,3 7,5
Feed pump (max. 11ft)
(mm) 300

Fuel • to DIN 51 6011 ASTM D 975-77 + 2D/BS 28669 1970 A1 + A2

Specific IUb. oil con-
(glkWh) 1
sumptlon

max. IUb. oil capacity (g/l) 1860/2,1

Topping up volume
lower-upper mark (g/l) 71010,8

Lub. oil quality • HD oil: minimum quality CC; better, CD quality (API-spec.) and multigrade oils

Pressures
Injector setting (bar) 175 250
Oil pressure (max.)
(bar) 5
Permissible air intake (kPa) 2
Permissible exhaust
gas back pressure (kPa) 5
 TECHNICAL DATA

Construction Data, Consumptions and Pressures

Technical Data Table 2

Engine Type 37E 43E 43F

Adjustment Data

Valves

Inlet opens BlOC * 38'_42' = 103 - 114 mm 38'-42' = 103 - 114 mm 40'_55' = 108 - 149 mm
Exhaust closes
AIDC * 50'-55' = 135 - 148 mm 50'-55' = 135 - 148 mm 55'_60'= 149 -162 mm
Flywheel diameter
(mm) 310
Injection pump: end of delivery, plunger with control edge "above"

Engine RPMs (min"') 1500 1800 2000 2400 1500 1800 2000 2400 1500 1800 2000 2400
End of delivery BTDC
(mm) 21 24 26 30 24 27 29 33 * * * *
Engine RPMs (min"') 2500 2800 3000 3600 2500 2800 3000 3600 2500 2800 3000 3600
End of delivery BTDC
(mm) 32 35 37 * 35 38 40 * 34 36 39 *

Injection pump: start of delivery, plunger with control edge "below" (engines for generator and pump drive)

Engine RPMs (min"') 1500 1800 3000 • 1500 1800 3000 * • * • *

Start of delivery BTDC
(mm) * * * * * • * * * * * *
Vaive clearance (cold)
inlet and outiet valve (mm) 0,1
Dimen-
Repair Data sion
Inletvaive
recedes by: (mm) 0-0,1 0-0,1 2,5 - 2,6
Exhaust valve
recedes by: (mm) 0- 0,1 0-0,1 2,5 - 2,6
Piston protrudes by: (mm) 0,635 - 0,9 0,635 - 0,9 0,635 - 0,9
Gap measurement (mm) 0,55 - 0,865 0,55 - 0,865 0,55 - 0,865
Piston ring joint (mm) 0,4 -1,0 0,4 -1,0 0,4 -1,0
Crankshaft plain bearing
clearance - new condition (mm) 0,03 - 0,07 0,03 - 0,Q7 0,03 - 0,07
Crankshaft plain bearing
ctearance - wear limit (mm) 0,1 0,1 0,1
Connecting rod plain bearing
clearance - new condWoo (mm) 0,03 - 0,07 0,03 - 0,07 0,03 - 0,Q7
CoMecting rod plain bearing .

clearance - wear limit (mm) 0,13 0,13 0,13

Crankshaft end play
(mm) 0,05 - 0,15 0,05 - 0,15 0,05 - 0,15
 TECHNICAL DATA

Output, Torque, Consumption

37E Leistung / Output / 43E Leistung / Output /

Puissance / Potencia Puissance / Potencia
kif PS/HP k\l PS/HP
16 16
11 11
10 10 FV
1/
9 F 9 V IFN
/' IFN- 12 / j 12
,
"- ~CFN 10
I' /
8 /'
8
<
10 / 1/ .'
7 V V
. ICFN '" 7
/ "- "-0 "- "-
6 /' / '
. 8 6 / 8
5 V ,
v.
.
/'
"- "-
"- "-
5
/ I " "- "- "- "- "-
, i"- "-
"- '(
"- "- "- "- "-
4 <" ," "- "- " "- 6
4
6

1400 2000 2500 3000 1 1m In 1 400 2000 2500 3000 11m I n

Drehmoment I Torque / Drehmoment / Torque /
Couple / Par Couple / Par
Nm f t Ib Nm f lib
2'1
32 M FI
37 27
r---
23 MI FI '" ~ 26
30 --- '--.. 22 35 <' " 25
21
28 33 24
20
1 '100 2000 2500 3000 1/mln 1 400 2000 2500 3000 1/min
Verbrauch / Consumption / Verbrauch / Consumption /
Consommation / Consumo Consommation / Consumo
g/ki/h ·lb/HPh g/k\lh Ib/HPh
280 I 280 0.%
0.46
/' /
t:>,,t'IFNI /
260 0.43 260 0.43
240 0.40 240 be IFNI 0.40
'j 1

1400· 20002500 3000 1/mln 1 400· 2000 2500 3000 11m In

DIN ratings
F Vehicle rating: intermittent duty at variable speed and load.
IFN-ISO DIN-ISO 3046 Blocked useful performance for intermittent loads.
ICFN-ISO DIN-ISO 3046 Standard performance, blocked continuous useful performance for constant
RPMs and constant load.
D Continuous operation: - contact factory for use beyond the limits indicated.
Decrease of approx. 1% for every 100 m altitude and approx. 2% for every 5'C above
20'C
Rating certified within tolerance of 5% after engine has been run in with standard air filter
and exhaust muffler.
 TECHNICAL DATA

Output, Torque, Consumption

43F Leistung , Output!

Puissance' Potencia
k\l PS/HP
12 18
F
_.-' -
11
.' /IFN -
,./
The values shown are
14
10
.' ~~ - related to the optimal load
9 ·7 ,I"ICFN setting at the correspond-
., I":
~
.'/ 12
ing nominal engine speed.
8
f7
// ,
" "
"' '" "' "'
10
7.
"
,- ,
"- 0 "-
8
5 7
r.¥

'"
,
'" "'
"- "- "- "-
r-... r-... 8

"- "- "- 6

4

1400 2000 2500 3000 1/mln

Drehmoment' Torque'
Couple' Par
Nm r II b r
40 30
1/ MIF f':: Mmax= 40,6 Nm at RPMs
38
/' "- 27 of 2300 min-1 .
I 24
32

1400 2000 2500 3000 1/min

Verbrauch , Consumption'
Consommation , Consumo
g/k\lh I b/HPh
~~~~~~~~~~

1400 2000 2500 3000 1/min

 TECHNICAL DATA

Screws - Tightening Torques, Sealing and Adhesive Materials

Technical data Table 1

Engine type 37E 43E 43F
Tightening torques
Cylinder head (Nm)
torque I wrench width (mm) 52-56/17 52-56d7 52-56/17
Rocker bracket (Nm)
torque f wrench width (mm) 42-46/17 42 -46/17 •
Bearing cover (Nm)
torque I wrench width (inmi 42-46/17 42 -46/17 42-46/17

I~~l
Connecting rod
torque Jwrench width 58-62/17 58-62/17 58-62/17
Nozzle holder (Nm)
torque Jwrench width (mm"t 20-23/13 20.-23/13 20-23113

I~~l
Injection pump
torque I wrench width 20-23/13 20 - 23/13 20-23/13
Delivery valve (Nm)
torque I wrench width (mm) 34 - 39/22 34 - 39/22 34 - 39/22

I~~l
Flywheel
torque I wrench width 390 -410146 390-410/46 390-410/46
Oil filter plate (Nm)
torque Iwrench width (mm) 20 - 23 Iinbus 20 - 23 1 Inbus 20 - 23 Iinbus
Maximum operation angles
Longitudinal
(in dir. of crankshaft) (deg.) 15 15 15
Transverse
(deg.) 15 15 15

Sealing and adhesive materials

Text Code Type

A Loctite 573
B Loctite 270
C Loctite 415
 SPECIAL TOOLS .

Tools

Part No. Description Use

~
748.115.6 Fuel line clamp to clamp fuel supply
lines

748.154.2 Hexagonal socket

wrench, 46 mm
for flywheel nuts

6)
~
748.128.4 Drive wrench for use with socket
wrench, 748.154.2

748.108.5 Special screw to adjust governor

driver spring nuts

~
748.132.6 Crankshaft race use with part no.
puller 748.136.2 to pull off
main bearing race
from crankshaft

~
748.137.2 Crankshaft gear use with part
wheel puller 748.136.2 to pull off
crankshaft gear wheel

~
"
748.136.2 Puller plate use with parts
148.132.6 and
~ ~Cb
~
748.137.2

~~
748.122.6 Flywheel puller to loosen flywheel

~
748.119.4 Bearing driver to press in crankshaft
roller bearing and shaft
seal
 SPECIAL TOOLS

~
748.120.4 Bearing driver to press the crankshaft
bearing bushes in and
out

~
748.121.4 Bearing driver to press the camshaft
in and out

748.124.4 Bearing driver to press out the crank-

shaft roller bearing

748.173.2 Oil filter wrench to remove the full flow

oil filter

748.172.4 Bearing driver to press the little end

bearing bush in and
out (connecting rod)

748.129.4 Bearing driver to press the regulator

shaft bearing bush in
and out

37E/43E: Guide punch to press the valve

748.125.4
guides in and out
43F:
748.211.4

748.097.6 Drop tube to measure the injec-

tion timing

748.192.4 Slotted screw driver to set the adjustment

748.126.2 Oil pressure gauge to measure the oil

pressure
 SPECIAL TOOLS .

~
748.131.5 Valve spring lifter to remove and fit the
valve springs
 TECHNICAL DESCRIPTION I

Presentation: 43E - engine

Technical Description
Diesel engine models 37E I 43EI 43F are horizontal, air-cooled, single-cylinder, four-
stroke diesel engines with direct injection. The engines have oil pressure forced lubrica-
tion. The fuel injection pump and the valves are controlled by the camshaft which is driven
by the crankshaft. The fuel injection pump (self-venting fuel system) is driven directly while
the valves are driven by push rods and rockers. An electric starter and a manual starting
device are provided to start the engine. The engines are equipped with a fully automatic
decompression system and a fully automatic starting enrichment quantity. Models 37E I.
43E are available with a dry type air filter or an oil bath air filter.

43F - engines meet 2000 U.S. EPA - Limits and U.S. MSHA - exhaust-emission-
regulations.
 TECHNICAL DESCRIPTION I
Applications

Diesel engine models 37E I 43E I 43F are suitable for the following applications:
- construction machinery
- power-generating sets
- agricultural machinery
- water pumps
- compressors
- fork lift drives, etc.

Special applications
Auxiliary Power Units, Military

I
 DISMANTLING I REASSEMBLY OF THE BASIC ENGINE .. I
Dismantling and Assembly Procedures on the Basic Engine

Basic Requirements

- The aim of this Repair Manual is to pro-

vide help with carrying out repairs to the
engine.
The requirements for this are as follows:
- Trained specialist staff (of at least the
minimum legal age);
- and a workshop where the necessary
equipment, standard tools and special
tools are available
- A well-lit, unrestricted working area, free
from dirt and swarf, will make the work
considerably easier.
- Clean the engine thoroughly before dis-
mantling it.
- Attention must be paid to all the informa-
tion and warning notices which have been
affixed.
- Particular care is called for in the vicinity
of rotating, moving or hot parts.

This symbol is used whenever failure to

comply precisely with instructions or proce-
dures may cause accidents which can result
in injuries or death.
ATTENTION

This symbol is used whenever failure to

comply precisely with instructions or proce-
dures may cause damage to the engine.
CAUTION

Advice and tips about special features when

+
handling the engine.
 · DISMANTLING/REASSEMBLY OFTHEBASICENGINEI

Intake Manifold (on 37E I 43E only)

Airfilter-Assy 37E I 43E Airfilter-Assy-Anbau 43F

2
g
--4

1--5

~,-----1

1. Filter base 1. Filter-base

2. Cover with preliminary filter 2. Cover
3. Strainer 3. Strainer
4. Fitting hex-nut 4. Fastening strainer-cover
5. Centering ring

Intake elbow, 37E I 43E - engines

~AHe"t;O"'
- The socket head cap screw M 8x25 (1)
must be fitted using "Loctite 415" adhe-
sive (C).

- Generally renew the seal (2+3)

847.192.4.
 DISMANTLING I REASSEMBLY OF THE.BASICENGINE ·1

Valve Cover with Oil Return Line

37E I 43E - engines:

Drain the engine oil.

- Before dismantling, seal the oil return line

(1) using clamp "748.115.6".
- The PVC sealing washer (2) can be used
several times.
- Generally renew the valve cover seal (3).
 DISMANTLING I REASSEMBLYOF THE BASIC ENGINE···

Rocker Mechanism, Valve Control

37E I 43E - Assy

- Completely dismantle the rocker bracket.
- 43F see page 43 no. 3.12.1
- When assembling, it is absolutely essen-
tial to insert the steel shim (1).
- Centre the rocker bracket.
- Carry out the assembly, using the tighten-
ing torque shown in the list.
- ALL ENGINES:
- Push rods of different lengths with ta-
pered rod ends.
- Always fit tapered rod ends on the tappet
side.
- Longer push rod - exhaust valve, position
relative to engine mounting side.
- The push rod sheath (2) can be removed
from the partly-dismantled engine (after
the tappet guide (3) has been removed).
- Exchange the O-ring seals if necessary.
- Fit the tappet guide, using "Loctite 573"
(A) sealing agent for the socket head cap
screw.
- Generally renew the tappet guide surface
seal (4).

- Before fitting the push rod sheath (2),

make the two O-ring seals oil-dry and
grease them slightly.
- The fitted push rod sheath might be
moved out of position to start with, so
check that the fit is correct.
 DISMANTLING} REASSEMBLY OF THE BASIC ENGINE ·1

Cylinderhead assy 43F - engine

'-.......4

~.

1. Cylinderhead 6. Rocker arm, exhaust

2. Intake valve 7. Valve guide, intake
3. Exhaust valve 8. Valve spring, intake
4. Valve guide, exhaust 9. Rocker arm, intake
5. Valve spring, exhaust 10. Rocker shaft
 DISMANTLING IREASSEMBLY OF THE BASIC ENGINE; I
Injection system

it
ATTENTION

Pressure Line:
- When loosening the pressure line, use
wrench SW22 to hold the delivery valve.

ATTENTION

Injection nozzle

- Always remove the nozzle seal from the

cylinder head seat and renew it.

Attention:
Assembly position for the nozzle:
overflow oil line towards the
valve cover.
-I-
 DISMANTLlNG1REASSEMBLY OF THE BASIC ENGINE

Injection System

ATIENTION

09 - Injection Pump:
1 _3
-C +
04-
- Defined seals are always used when fitting
the injection pump.
- The total thickness of the pump shims is
imprinted on the surface of the crankcase,
next to the injection pump.
- It is absolutely essential to keep this seal
thickness when the injection pump is ex-
changed.
- If the rated RPMs I engine output are modi-
fied, the seal thickness must be corrected
in order to set the new injection timing as
required (see Chapter 4).

~sembly:

- Move the acceleration lever to the "full load"

position. Rotate the flywheel until the pump
roller tappet is in the BOC position.
- Move the pin on the injection pump regulating
lug into the "full quantity" position.
- Put on the requisite pump shims. When do-
ing this, always place the paper seal on the
crankcase surface. Always exchange dam-
aged seals.
- Introduce the injection pump without any
mechanical resistance.
- The pin on the regulating lug engages in the
slot on the transverse lever of the control rod
assembly.
To check correct assembly:
- Visual inspection through flanged bearing
front cover.
- Turn the engine over using the crank handle;
when the acceleration lever is moved from
'full load' to 'stop', the engine must no longer
inject.
- When fitling, always tighten the securing nuts
alternately.
 DISMANTLING IREASSEMBLY OF THE BASIC ENGINE · 1

Oil Filter, Oil Filter Cover, Oil pressure relief valve

ATTENTION

Assembly:

- Generally renew the seal (1) and the 0-

ring seal (2).
- Before fitting the cover, secure the O-ring
seal by greasing it so that it sticks.
- . Secure the oil filter cover fitting screws (3)
with "Loctite 573" (A) sealing agent, and
tighten them alternately and equally. (List
ofTorques).
- Wet the packing rubber of the oil filter
with oil, and hand-tighten without using a
tool.

Oil pressure relief valve:

The oil pressure relief valve (4) is calibrated

by the manufacturer and therefore it can
only be changed completely - no repair is
possible.
Control of operation: The spring loaded
sleeve must be easy moveable.
The oil pressure control sleeve:
- Ball design (engine type 43E)
- Plunger design (engine type 43F)
 DISMANTLING I REASSEMBLY OFTHEBASICENGINE

Cylinder Head 37E 143E

Assembly:

- Generally use a new cylinder head seal.

- Use grease to fix the cylinder head seal
in the head slot.

ATTENTION

Check the valves for:

- wear and tear on the valve guides

- the condition of the stem seals
- leakproofness and deposits
When tightening the securing nuts, lift
the cylinder head slightly and align it
radially. (Table ofTorques).
 DISMANTLING IREASSEMBLY OF THE BASIC ENGINE·

Piston, Cylinder

- If the unit shows any traces of corrosion or cracks, the piston and the cylinder must be
exchanged.

See the Table for wear measurements on the individual components.

- If the limit values are exceeded: exchange the components.

- Oversized pistons I cylinders are not available.

Piston I Cylinder Assy 37E I 43E Piston I Cylinder Assy 43F

Index-arrow points to flywheel side.

Combustion chambers out of center!

Attention
Don't mix up 43E I 43F pistons!
Valves will hit the piston head!
 DISMANTLINGFREASSEMBlYOF THE BASIC ENGINE·· ···1

Piston, Cylinder assembly

It is absolutely essential to use a piston

retaining strap for the assembly.

There is a marking on the side of the

piston which points towards the side
of the flywheel.
Original 37E /43E pistons always
have valve pockets. The 43F does
not have any.

- Oil the piston, push it into the cylinder

and assemble the complete unit.
- Always position the joints with a 120· off-
Schwungradseite
Ftywheelside
set.
COte volant

Connecting Rod

- If the wear measurements are exceeded,

exchange the bearing shells and/or con
rod bearing.

When assembling, the identification

numbers on the con rod and the
bearing cover must be together.

- It is absolutely essential to lubricate the

bearings: List of Torques
 DISMANTLING rREASSEMBLY OF THE BASIC ENGINE .·1

Camshaft with Automatic Decompression

- The unit comprising the camshaft and the

flanged bearing can only be exchanged label
marque
complete.
- It is not possible to carry out repairs on
the decompression unit.

Assembly:

- Position the flywheel on the TOG mark

(crankcase I flywheel)
- When the flanged bearing is pushed in,
the camshaft gearwheel mark be posi-
tioned true to the mark on the crankshaft
gearwheel.
- The long securing screws on the flanged
bearing are fitted using "Loctite 573" (A) 3
sealing agent.
- Do not use any shims, etc.

Attention:
- The top right hand securing screw
(2) is shorter.

+ Do not use any sealing agent here,

but use a copper washer (3) in-
stead.
43F (new series):

+ - The securing screws are of equal

length.
 DISMANTLINGIREASSEMBLY OF THE BASIC ENGINE . . . .

Lubricating oil pump 37E 143E

Zahnftankenspiel 0 os-o 1 'When exchanging the lubricating oil pump,

Backlashofleelh· ,mm no. E724.036.8 or no. 724.040.8, the as-
----C>!: sembly must be carried out as follows:
,
1. Dismantle the intermediate gear wheel
I
I (3).
i 2. CAUTION: Remember the shims for end
float.
3. Remove.the locking ring (1), washers (2)
and intermediate gear wheel (3) from the
lubricating oil pump.
4. Lubricate the pump 'chamber in the
crankcase, and the lubricating oil pump
5 itself.
5. Insert the lubricating oil pump into the
'.
pump chamber and secure the pump
cover (4) with socket head cap screws
:,
I
(5); when doing this, only tighten the
socket head cap screws (5) slightly - it
~, must be possible to turn the toothed driv-
ing wheel (6) without resistance.
6. Tighten the socket head cap screws (5)
2
equally, with torque = 10 Nm; it must still
be possible to turn the toothed driving
wheel (6) without resistance.
7. Fit the intermediate gear wheel (3),
1 washers (2) and locking ring (1).
8. Check the gear backlash between the
intermediate gear wheel (3) and the
crankshaft gear wheel.
This must be between 0,05 and 0,1 mm.

~
6

ATTENTION

Pumps must not be operated if the

gearing jams.
I
 DISMANTLINGIREASSEMBLY OF THE BASIC ENGINEi

Lubricating oil pump 43E, conversion kit

The teeth of gearwheels (1) and (2) may

Zahnflankenspiel
experience premature wear if the engines 0.05-0.1 mm
Backlash of teeth
are used under difficult operating conditions.
For this reason, the gearwheel (1) mounted
on one side with support bracket (3) has
been additionally supported by a pin (4).
6
Proceed as follows when assembling the
lubricating oil pump: 6
1. Lubricate the pump chamber in the
crankcase, and the lubricating oil pump
itself.
2. Apply SILOMAT liquid sealing agent on
pump cover (5) in the area of the sealing
surface. 6
3. Insert the lubrication oil pump into the
,
pump chamber, and secure the pump
6
-c>I
cover (5) with the support bracket (3), us-
ing socket head cap screws (6). Only
tighten the socket head cap screws (6)
slightly.
4. Completely crank the engine once from
the flywheel, tighten the socket head cap
screws evenly (6) to torque = 10 Nm. 5
5. Check gear backlash between gearwheel
(1) and crankshaft gearwheel. This must
be between 0.05 and 0.1 mm.

2
 DISMANTLING I REASSEMBLY OF THE BASIC ENGINE ·1

Lubricating Oil Pump 43F

1/2 For dates of construction from
6/1996 onwards, this pump is also
used for 37E and 43E engines.

When exchanging lubricating oil pump no.

E724.038.8, the assembly must be carried
out as follows:

1. Unscrew four screws, M6 x 25 (1 +2) and

take out the complete oil pump.
2. The pump is supplied pre-assembled,
3. Fit the complete oil pump into the control
casing. The protruding part of the oil
4 5 pump shaft is received by the index bore.
3 If the assembly is correct, the oil pump
6 will (7) lie against the rear wall of the con-
trol housing without a gap. Ensure that
7 the joint surfaces are clean.
4. Position screws, M6 x 25 (1) with spring
lock washers (2) and tighten to.10 Nm
8 torque.
5. Function controll:
9
n ' l -_ _ 10
Check the gear backlash between the oil
pump and the crankshaft gear wheel. It
must be at least 0,05 mm. This will be
guaranteed if rotary play can be seen and
felt in the tooth contact engagement.
The test have to be done on four points
(4x900) of the gear wheel (6).

ATTENTION

1 Screw, M6 x 25
2 Spring lock washer
3 Cover
4 Housing
5 Cover
6 Gearwheel, Z=24 1 m=1.75
7 Pump shaft
8 Gear wheel, Z=07 1 m=3.0 (2x)
9 Bolt (3x)
10 Locking plate
 DISMANTLING! REASSEMBLY OFTHEBASIC ENGINEi

Regulation Mechanism

Preliminary Work:
- Dismantle the injection pump.
- Dismantle the flanged bearing with the
camshaft.
- On the injection pump flange, unscrew
the rear stay bolt (1) until the transverse
lever (2) is released.
- Remove the stop buffer screw (10) on
the eccentric shaft (9) and the external
eccentric screw (8).

Dismantling:
- Determine and note the position of the
setscrew (5).
- Remove the locking nut (6) and screw the
setscrew in until the flange bolt (3) on the
automatic starting enrichment lever (12)
,. 9

(automatic increased starting quantity -

ASM) disengages from the segment (4).
- Screw the setscrew back until it protrudes
about 5 mm in relation to the surface of
the crankcase.
- Unhook the spring on the ASM lever (12)
and remove the setscrew (11).
- Loosen the threaded bushing (16), spe-
cial tool (17), by about 3 revolutions.
- Remove the annular spring from the ec-
centric shaft and remove the eccentric
shaft, rotating it in the direction of 'stop'.
- Dismantle the complete set of levers.
 DISMANTLING/REASSEMBLY OF THE BASIC ENGINE I

Regulation Mechanism

Assembly:

15 ATTENTION: Insert the governor needle,

and secure it with grease.
7
Pre-assemble the eccentric shaft
(9) with the requisite parts.
ATTENTION: For stationary regulation, the
torsion spring can be clamped to
the rest plate in order to make
assembly easier.

11

- Insert the leg of the return spring (18) into the regulating lever (13) and bend it about 5
mm to 75° (x).
- Use the special tool (17) to screw the threaded bushing (16) into the regulating lever.
- The thread must be flush with the rear side of the lever.
- Push the flange bolt (14) into the threaded bushing in the regulating lever.
- Place the automatic increased starting quantity lever (12)- without the setscrew (11)-
over the regulating lever.
- Introduce the eccentric shaft into the lubricated bearing bush. When doing this, set the
acceleration lever (7) approximately to the stop position.
- Push the set of levers (12 + 13) on to the eccentric shaft.
- The return spring must fit into the eccentric shaft slot without resistance.
- At the same time as this operation, turn the acceleration lever in the direction of "full
load".
- Rotate the eccentric shaft while pulling it out of the bearing bush, and press the trans-
verse lever (2) in the direction of the crankcase wall until the pin engages in the forked
bolt (19) of the transverse lever.
- Move the eccentric shaft back into the bearing bush, and secure it with the annular
spring (15).
- Screwin the external eccentric stop screw (8) to fix the regulating lever.

Function Check:
- Move the acceleration lever (7) into the 'full load' position.
- The regulating lever (13) must press AGAINST the governor via the return spring.
- Move the flanged bolt (3) on the automatic increased starting quantity lever into the
bore on the segment (4) by adjusting the setscrew (5).
- Move the setscrew (5) and the locking nut into the previously determined positions, and
lock them.
- Screw in the stay bolt on the injection pump flange; assemble the flanged bearing with
the camshaft.
 I SPECIAL COMPONENTS

Special Components

Centrifugal Speed Governor

2 3
1 Governor body
2 Governor spring - middle speed range in
the case of a variable-speed governor
Spacer (instead of item 2 for end gover-
nor)
Governor pin
Spring bridge
Guide bush
Governor spring: full load rev/min
Governor spring: idling rev/min
Cross slotted nut

4 5 6 7 8 9

.1

1
 SPECIAL COMPONENTS .. I
Crankshaft, Flywheel

- If the flywheel is removed from the complete

engine, the acceleration lever must previ-
ously be set to 'full load'.

Dismantling:

ATTENTION - Use the drive wrench (special tool 748.128.4

and 748.154.2) to loosen the flywheel nut.
Do not screw off.
- Loosen the flywheel from its seat with the
puller, 748.122.6; remove it. .
- Loosen the bearing cover from the slot with
pulling screws M8 x 40.
- The crankshaft gear wheel and the inside
CAUTION bearing washer can be loosened using the
pull-off device, 748.137.2 and 748.132.6.
- Attentionl Lubrication oil pump has to be
taken off before dismantling the bearing plate

7 Assembly:

6 - The inside bearing washer and the crank-

shaft gear wheel are mounted hot. (4) + (5)
- The inside bearing washer and the.cylindrical
roller bearing are always paired.
M~N-- 8 - Gently hammer the bearing cover (2) to
achieve a snug fit in the seat (PVC hammer),
9 and then use the securing nuts (7) to tighten
on altemate sides.
- Generally renew the shaft seal (8).
- Assemble the fitting parts and the flywheel
according to the sequence (see drawing).
- Mounting of lubrication oil pump.
- The fitting surfaces must be free of grease
4 and dirt.
- Please note the position of the disk springs
(9).
- Tighten the flywheel using a torque wrench or
2 a drive wrench (see Table of Torques).

CAUTION
 ADJUSTMENTS, SETTINGS

Adjustments, Settings

Valve Setting

The valve clearance for both valves is 0.1

mm (cold). The valve clearance must be
E
checked for the first time after 20 operating E
hours and thereafter every 300 operating
hours and, if necessary, is to be adjusted as
follows: The clearance is to be set with the
engine cold, at the end of the compression
stroke with both valves closed. c )

c :;
Remove the valve cover. Rotate the fly- :;
wheel until the mark is vertical and right-
c :;
c
hand. Adjust the valves and refit the valve c )

cover.

CAUTION

- To prevent unintentional starting, the

high-pressure line must always be de-
tached at the fuel injection pump.
- Fuel which leaks at high pressure at
the threaded joint may cause severe
injuries.

l J

ATTENTION

To prevent leaks, the valve cover seal is

to be replaced at every adjustment.

The adjustment is to be carried out

-I- when the engine is cold.
 ADJUSTMENTS, SETTINGS

Valve setting procedure

Exhaust valve:

() - Turn crankshaft slowly with the starting

handle until the end of the compression
stroke.
In this position the exhaust valve
is closed (max. clearance between
rocker and valve) and the top dead
centre mark of the flywheel points
to the mark on the crankcase.
- Check clearance between exhaust valve
and rocker with a feeler gauge and, if
necessary, set to 0.1 mm.
It must be possible to slide the
-I- feeler gauge between the valve and
rocker without great force.

Inlet valve:
()
- Turn crankshaft half a revolution from the
top dead centre mark in the direction of
rotation.
On engines with a closed flywheel housing
you can't see the timing marks
(O.T. = T.D.C.).
- Take off rocker cover, turn engine till pis-
ton is in O.T. (T.D.C.) position.
- Mark the position on the crank handle
support bearing
- Turn engine with starting handle ~ rota-
tion in engine rotation sense.
This makes the automatic decom-
pression ineffective.
Check clearance between intake valve and
rocker with a feeler gauge and, if necessary,
set to 0.1 mm.
It must be possible to slide the
feeler gauge between the valve and
rocker without great force.
 ADJUSTMENTS, SETTINGS .

Speed Adjustment I Automatic increased Start Quantity

Lever System Setting

- Set the acceleration lever to the "Full

Load" position.
- Remove the setscrew (3) from the lever 1
(1 ).
- Carefully unhook the spring (4) from the
lever (1).
- Spread the governor weights (7) to the
maximum extent, using a screw driver.
- Use the tool (17, Illustration 2) to turn the
threaded bush (5) until the flanged bolt 3
(6) fits on the governor pin (8) with no
play. 9
- Remove the screw driver and close the
threaded bush (5) by a further half revolu-
tion.
- Carefully hook the spring (4) to the lever
(1 ).

t
Voltast
full load
demarrage
 ADJUSTMENTS, SETTINGS·

Automatic Enriched Starting Mixture (ESM) Setting

- Set the acceleration lever to the "Full Load" position.

- Screw the setscrew (3) into the lever (1) until contact is made with the flanged bolt (6).
- Secure the flanged bolt with the nut (9). (See Illustration 4.1.1)

Attention:
- Divergences in the setting will change the active period for the enriched starting mixture
(1 )
=
- Play between the setscrew (3) and the flanged bolt (6) ESM is active for a longer pe-
riod after starting, and the engine will smoke.
- Setscrew (3) and flanged bolt(6) are tightened = ESM function is not guaranteed.

Function Test:

- Start the engine from the full load position.

- If the ESM has been set correctly, the starting smoke period will last about 2-3 seconds.
This is followed by smoke-free run-up to normal operation.

End Stop

End Stop Adjustment

- Move the acceleration lever (1) to the

"Stop" position.
Loosen the outer end stop eccentric (2) in
advance.
- Screw in the stop screw (5) on the eccen-
tric shaft (3) until contact is made with the
6
regulating lever (6).
- Lock the stop screw with the nut (4).
- Turn the outer end stop eccentric (2)
against the regulating lever until the latter
2 is lifted about 1 mm from the stop posi-
3 tion.
- Lock the eccentric screw.

Attention:

- The outer stop buffer eccentric

prevents damage to the regulating
rod assembly (critical for building
on Bowden pull wires).
 ADJUSTMENTS, SETTINGS ..

Injection pump - Setting Values - End of Delivery

Flvwheel End of delivery (mm) before TOC - Tolerance + - 2mm

Engine type Part Num- Dia- at engine speed (min-1 )
meter
ber
mm 1500 1800 2000 2500 2800 3000 3300 3600
738.265.4

738.293.4 310 21 24 26 32 35 37 * *

738.307.4
...
.
37E 738.266.4 350 24 27 29 36 40 42 * *

738.294.4

738.268.4 375 26 29 32 39 42 45 * *
. .
738.295.4

738.265.4

738.293.4 310 24 27 29 ·35 38 40 * *

.

738.307.4

43E 738.266.4 350 27 31 33 37 43 45 * *

738.294.4

738.268.4 375 29 33 35 42 46 48 * *

738.295.4

·738.265.4
.. .

738.293.4 310 * * * 34 1) 36 1) 39 1) * *

738.307.4

43F 738.266.4 350 * * * 38 1) 41 1) 44 1) * *

738.294.4
 liGHTENING TORQUES I
Tightening Torques for Screwed Connections

37E/43E 43F
Wrench Tightening Wrench Tightening
width Torque width Torque
(Nm) (Nm)
(mm) min max (mm) min max
Rocker bracket 17 42 46 * * *

Cylinder head nuts 17 52 56 15 52 56

Connecting rod nuts 17 58 62 17 58 62

Valve cover nuts 17 44 48 * * •

Valve cover bolts • • • 5 16 20

Bearing cover nuts 17 42 46 17 42 46

Injection pump nuts 13 20 .23 13 20 23

Injection pump pressure valve bracket 14 34 39 14 34 39

Fuel pressure pipe - union nut - injec- 22··
17 18 17 18 22
tion pump
Fuel pressure pipe - union nut - nozzle
17 25 30 17 25 30
holder
Nuts for nozzle holder fixture 13 20 23 10 10 12

Governor 14 55 60 14 55 60

Flywheel nut 46 390 410 46 390 410

Flanged bearing screws 6 20 23 6 20 23

Tappet guide screws 6 20 23 6 20 23

Foot bearing screws 6 20 23 6 20 23

Lubricating oil pump screws 5 10 12 5 10 12

Hatch cover 6 20 23 6 20 23

Hollow bolt on injection pump 17 25 35 17 25 35

Hollow bolt on nozzle holder 11 8 10 11 8 10

Hollow bolt on tank 12 8 10 12 8 10

Oil filter Finger-tighten only!

L -_ _ _ _ _ _ _ _ _ _ ~~ ____ ELECTRICAL
~__ _ _ _ _ _ _ _ _ _SYSTEM
~ _________________ ~ ________
I
~

Electrical System

Flywheel • Dynamo I Governor

Operation:

The permanent magnets in the

magnet holder (1) on the fly-
wheel side induce an alternating
voltage in the coils of the stator
(2): this voltage is proportional
to speed (RPMs). The alternat-
ing voltage is rectified in the
governor (3) and continuously
regulated to approximately 14.2
- 14.5 V.

Connections to the Governor:

• 2x yellow Generator coils, input, interchangeable

• 1x red Output, charging current
• 1x brown Charge control, Terminal 15, ignition
lock
Connection to earth is made via the assembly surface.

Function Tests:

a) Alternating voltage at the coil output

Disconnect the connecting plug (4).
The voltage proportional to speed is measured on the two phases (2x black).
Set values: Graph A, "Idling Voltage without Governor Cut-Out"
b) Coils =single phase to earth
c) Charging current, governor output
Connect a suitable ammeter (lmax=30A) into the charging circuit (red cable).
The charging current depends on the speed and the state of the battery charge. Graph
S, "Charging Current".
d) Charge control circuit
If the electrical system is intact, the charge control indicator must go out in the speed
range from 600-800 revolutions/min.
 I ELECTRICAL SYSTEM

Operating Conditions:

- Permissible operating temperatures: -20 to 70°C (measured on the governor surface)

- An intact earth connection must exist between the governor and the engine, and also
between the governor and directly attached external construction (no painted or enam-
elled assembly surfaces).

Hazards I Causes of Failure

Battery wrongly poled Damage to charging control circuit

Battery is defective or discharged to Governor. is destroyed in a short time.
minimum
Battery is disconnected while the engine Governor is destroyed in a short time.
is running (load shedding)
Charging with start aid cable when bat- Governor is destroyed in a short time.
tery is defective or discharged to mini-
mum
Load shedding when the start aid cable is
removed.
Welding work on the equipment (loosen Governor is destroyed .in a short time.
all plug connections and battery cables
beforehand)
Manual start with battery disconnected Governor is destroyed in a short time.
Interruption of the earth connection be- Governor is destroyed over a long period.
tween the governor housing and the en-
gine
I ELECTRICAL SYSTEM

Flywheel - Dynamo 12V I Governor I Graph

Idling Voltage without Governor Graph A

35

... "",.

,
30

25 ..
./ y
20
~
.".-
V
~
u- f\J
15

10
500 1000 1500 2000 2500 3000 3500
n f1/minl

Charging Current Graph B

20,-----,-----,-----,-----,-----,-----,----,

16+-----+-----+-----+-----+-----+-~~+---~

12+-----+-----+-----+-----~~~~----+---~

8+-----+-----+---~~~~+-----+-----+---~

I fAl

o
500 1000 1500 2500 3000 3500 4000
 ELECTRICAL SYSTEM

Wiring Diagrams

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7 I s I :; I 4 I 3 I . 2 I 1
 ELECTRICAL SYSTEM

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- l'a..ees 601 Ie 70'C (l1Cl'1i 1l:Ie,'6'Ct'Ile,lefl. Qa ~~ tiel le7pelature ~76'G ,*,,11 Oa.age r~la.l{H. -
Reglel ZefS'O( t Itlldl
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Gallery vol to'Q£! t3~ 00'\91<t'11

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Oatenblatt RegIer 547.175.1 250268.7
A ~ SIB Speci I icallon sheel [loa', I"" "" '0.'" A
ISfPl .
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regulator 547.175.1 tl ..tZ' ,"/Cn,
7 I 6 I 5 I 4 I 3 I ~ I I
 ELECTRICAL SYSTEM '·1

7 I 6 I ~ I 4 3 I 2 I I
Fm ijl&OO Z.~I(:f'I(Iu(IO DetlaJtm vH l(\$ (1119 UrMOOnecttl
ge~OUi 34, Abiatz 2 I VOl Ve,v,eJl:tlllgu"9 Oller
J-tllted"'9 a"I Dlltt~ 1St ~llJ len . . efOOlen U"<I'ltalbal
......... --_ .... _--- .. _--
-~

For thl~ (If*l(lg 'Ie fe$erYe ltte Cq)'j'f l(fIt BCCOfdl1'l!) to

onl 34 para 2 1 FepfOOucI""d or MMtg Il a~allCl:)le 10 UHfC
f- j:eIStO; IS IOltllllden by J~" cW(J .able lD re PIDi'ECuted -
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F f

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Magnelvenlll/Fuel conllol solenoid
E
errs E

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Relals/Relay
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5J
ler/1emperature SWIlch
-

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c- f..:-
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IB IB
I I
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Steuerung for Dieselmotor
I

,< 250.284.7
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A
IH 9. mil OldrucK- und 1emp Abschal lung
6,al
Induslr laJ eJectr w'rl~dlaglam
IE,eeil 101'
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7 I 6 I 5 I 4 I 3 I 2 I I
 ELECTRICAL SYSTEM

7 I 6 I :; I 4 I 3 I 2 I 1
rut 01,.. Zel<N'<.l>l beN II'" Itll Ui\> 009 UII'<01,,""1
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............... __ ....... -_.
for Ull9 dlif,tI{lO.,,-e lesellft! I.te COI)'rf l(fl~ .xo:lldlrg to
om:¥l pata 2 I FtploQ...clf'19 Of &)111:'11'9 It aYallable lo '''lid
r--< , -11l- " I:::
t::;
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I- BaltelY cohlge .alnleg loop 2~ ~ ~
-

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OldluckkonllDlle 2VI LlcOtllQOCfllne/AllelnalOr
Luball " •• nleg I""P 211
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Relals/Relay
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y, 6elblYelJ ...
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-
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87

We nlCllI getemze.(11reten Lelt"'!jef!I.:; wlAll rot Il3fkOO C<iJle ,,,,I De Srze I.:; rn>' £
Allenliool 10 opel.le Ille engine ., Ih<lul ballelV ., II
-
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C ablellung ge\dt1llelstet 191 Ole Te'pelalur d!i9 Ga· besl real OIOOlpellflll sffiJld be ~Ied. G
ro.ms roJile i"We nlGnll1lelSCillelle!l III OOI'GI ilel lenpeldlure >ill"C .i II tlaJage Il9Jldlol
Reglel zerslorlVlrd!
-
1
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Steuerlt1g lur Oleeeimotor
11". 13 07 s: mil Slarlauloij.u.Oldluck-ObeI~achung 250.286.7
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lildJstJ laJ electr .WII iog diagrOill
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 ELECTRICAL SYSTEM

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Fm dlege lel(tl(luflQ oeoal1EO 'III IJl9 4cn 1I1heOOrreCl'll
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Reglel zer910ct Vlldl

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Sleuerung lur Dleeelfl\Olor

mi 1 Ducall-RegJel V'V..
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 ELECTRICAL SYSTEM

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Del Pegle, 191 90"" 1O'l1ieres>. tlm .,~ gule ~ar.e· da",~ 1"}.Ila\ol1 koortlilflil Ire '~Jlalol
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 TROUBLESHOOTING

Troubleshooting

This section aims to suggest possible causes and remedies for faults. Please note that
this list can never be complete. Whenever there is a fault, the guiding principle should be:
"Think Before You Act".

Engine will not start

Reason Causes Remedy

..
If the injection noise (rasping) No fuel in tank. Fill with fuel; no venting needed.
cannot be heard: Acceleration lever at stop. Set lever to full load
Vent valve in tank cap blocked. Renew cap

Fuel line blocked. Check lines.

Fuel supply failure - turn the Fuel filter clogged. Renew filter.
engine over by hand crank- Broken fuel line or leaking connec- Renew pipe' tighten connections.
tions.
ing,.and listen for the charac-
Vapor lock (fuel too hot). Cool the fuel.
teristic rasping noise in the Paraffin precipitation in fuel (in cold Drainand flush system, renew fuel
injector. seasons) filter. Use winter fuel.

Faulty injector nozzle. Check' repair' renew nozzle.

Faulty injector pump. Check' repair' renew pump.

Gasoline instead of diesel in tank. Drain gasoline, flush and fill with
If the rasping noise can be diesel.
Air intake blocked. Check intake system.
heard:
Change filter insert.

Poor compression Incorrect valve clearance. Adjust valve clearance.

Decompression device defective. Check' renew decompression
device.
Leaky valves. Check 'repair' renew valves.
Valves sticking. Free valves.
Leaky cylinder head' Tighten nuts' renew seal.
cylinder head seal.

Piston rings stuck in grooves. Check' free' renew the rings.

Worn cylinder and piston. Overhaul the engine.

Difficult to crank start the Starting load too high. Reduce load.
engine Lubricating oil too thick. Change oil; use correct viscosity.
Bearings seized. Overhaul engine.
Piston seized. Overhaul engine.
 TROUBLESHOOTING·

Engine starts but fires intermittently or dies

Poor fuel supply Fuel filter choked. Renew filter.

Fuel line blocked. Check lines.
Leaking fuel lines. Check lines / tighten connections.
Water in fuel. Drain fuel, fill with clean diesel.
Faulty injector nozzle. Check / repair / renew nozzle.
Faulty injector pump. Check / repair / renew pump.

Poor compression Incorrect valve clearance. Adjust valve clearance.

Worn valves. Overhaul cylinder head.
Valves sticking. Free valves.
Piston rings stuck in grooves. Check / free / renew rings.
Worn cylinder and piston. Overhaul engine.

Faulty intake and exhaust Restricted / blocked intake. Check / clean / exchange intake
system system.
Restricted / blocked exhaust. Check / clean / exchange exhaust
system.

Poor engine performance and I or black smoke

Operating conditions Engine overloaded. Redi,loe load. Fault search on

equipment.
Power reduction due to altitude, Better operating conditions.
and/or increased intake tempera-
ture has been ignored.

Poor fuel supply Gasket under injector nozzle miss- Install gasket / Correct number of
ing, or too many installed. gaskets.
Fuel filter blocked. Renew filter.
Faulty injector nozzle. Check / repair /renew nozzle.
Faultv iniector pump. Check / repair / renew pump.

Out of adjustment Incorrect valve clearance. Adjust valve clearance.

Incorrect end of delivery. Adjust end of delivery.
Incorrect valve control timings. Check gear wheel setting mark.
Piston installed wrongly. Correct piston installation.
 TROUBLESHOOTING

Poor engine performance and/or black smoke

Dirty engine Dirty air filter. Clean I renew filter.

Excessive oil carbon deposits on Decoke components I change vent
piston and cylinder head. valve.

General Engine Condition Worn piston rings. Renew rings I check air filter.
Worn piston and cylinder. Overhaul engine.
Worn bearing. Overhaul engine.

Imperfect operating behaviour

Overheating Engine overloaded. Reduce load.

Cooling fins dirty. Clean cooling fins.
Cool air intake obstructed. Remove obstruction.
Short circuit of cooling air. Improve cooling air flow (check
engine installation).
Oil level in crankcase is too high. Drain to proper level.
Faulty injector nozzle. Check I repair I renew nozzle.

;
Knocking Noises Oil carbon deposits on piston. Decoke.
Injector needle sticking. Fit new nozzle.
, Advanced ignition. Check/adjust end of delivery.
Broken piston rings. Fit new rings.
Worn piston and cylinder. Overhaul engine.
Worn bearings. Overhaul engine.
Loose flywheel. Tighten flywheel nut.
Gasoline mixture in tank. Change fuel.

Major fluctuations in speed Overheating. See above.

(RPMs) Air in fuel. Check the fuel system for leaks I
check the return line.
Governor sticking or faulty. Check I repair I renew governor.

Fuel filter choked. Renew filter.

Regulating lever sticking or faulty. Check I renew.

Engine stops suddenly. Empty fuel tank. Fill.withfuel.

Vent valve in tank cap is blocked. Renew tank cap.
Vapor lock (fuel too hot). Cool fuel.
Choked injection nozzle. Check I repair I renew nozzle.
 TROUBLESHOOTING I
Imperfect Operating Behaviour

Engine stops suddenly Fuel pipe broken. Renew pipe.

Seized piston. Renew piston and cylinder.
Seized crankshaft bearing. Repair / renew crankshaft and
bearings.

Blue smoke from engine Oil level in oil bath air filter too high. Fill to proper level.
Faulty vent valve in cylinder head.
Sealing ring damaged on intake Renew valve.
valve guide. Renew sealing ring.
Worn valves / valve guide. Overhaul engine.
Worn piston / cylinder. Renew.

White smoke from engine Ignition too late. Check / adjust end of delivery.
Injector nozzle is worn. Renew nozzle.

Oil pressure warning light on Oil pressure warning lamp is defec- Exchange warning lamp.
tive. Measure oil level; if necessary. top
Oil level is too low. up oil.
De/ective oil pressure switch. Exchanae.

Oil pressure is too low Overpressure valve is defective. Check. clean. exchange ifneces"
sary.
Dirty ball seat in overpressure Check. clean •. exchange if neces-
•
valve. sary.
Oil filter is clogged. Exchange.
Lubricating oil pump is faulty. Check. clean. exchange if neces-
sary.

Cold starting problems Acceleration lever not at maximum Adjust.

stop buffer.
Lubrication oil too thick. Change to correct viscosity.
Crank handle defective. Check crank handle.

Paraffin precipitation in fuel. Use winter fuel/ and/or drain and

flush system.
Renew fuel filter.