Workshop manual

2-4L30.H2-3L30.

2-4L31.2-4L40.2-4L41.

2-4M31.2-4M40.2-4M41.

438 402 00 - 1.97 - 0.4 Printed in Germany

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MIN-1

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Contents

Introduction

1. General

Sealants and adhesivesIllustrations of engineType plate dataTechnical dataLubricating oil circuitSpecial tools andWorkshop equipment

2. Additional equipment

A 01.00 FuelA 01.40 Delivery pump with hand pumpA 03.00 ExhaustA 03.12 Detaching and attaching

enclosure for silencer (muffler)A 04.00 Mechanical startingA 04.10 Crank handleA 04.20 Automatic decompressorA 04.70 Engine rotating deviceA 04.80 Start releaseA 05.00 Electric startingA 05.40 AlternatorA 07.00 Lubricating oilA 07.10 Lubricating oil cooler,

air coolingA 07.11 Lubricating oil cooler,

water coolingA 11.00 Automatic mechanismsA 11.70 Temperature-controlled

starting fuel volume regulatorA 15.00 HousingA 15.20 Adapter housingA 30.00 Liquid coolingA 30.20 Water pumpA 30.40 Thermostat

L / M . . 01.97

Contents

3. Basic engine equipment

M 01.00 CrankshaftM 01.10 Balancing weights 2L / 3LM 01.20 Balancing weights, 4LM 01.30 Cleaning crankcase,

installing injector nozzlesM 02.00 CrankshaftM 04.00 CamshaftM 04.10 Camshaft for valve timingM 04.20 Camshaft for injection pumpM 04.30 Governor and injection timerM 05.00 ConrodM 06.00 Piston and cylinderM 06.10 Air-cooled enginesM 06.20 Water-cooled enginesM 07.00 Cylinder headM 07.10 Air-cooled enginesM 07.20 Cylinder head repairs

(air-cooled engines)M 07.30 Water-cooled enginesM 07.40 Cylinder head repairs

(water-cooled engines)M 10.00 Oil pumpM 11.00 Timing case coverM 12.00 Extra fuel deviceM 12.10 with injection pump

PFR 1K 80M 12.20 with injection pump

PFR 1K 90M 12.30 with injection pump

PFR 1K 90from serial No. L/M31.12, M40.16, 2L40.19, 3-4L40.18 and L/M41

M 13.00 FanM 14.00 Fuel injection equipmentM 14.00 Injection pump, functional testM 14.10 with injection pump

PFR 1K 80M 14.20 with injection pump

PFR 1K 90M 14.30 InjectorM 14.40 Injector nozzle

M 14.50 Adjusting work with injection pump PFR 1K 80

M 14.60 Adjusting work with injectionpump PFR 1K 90

M 17.00 FlywheelM 20.00 Engine shutdown device,

belt tensionerM 22.00 Air cleanerM 31.00 Crankcase breatherM 32.00 Speed controlM 32.10 with injection pump

PFR 1K 80M 32.20 with injection pump

PFR 1K 90M 35.00 Enclosure

4. Tables

Tightening torquesRepair dataFuel injection equipment and adjusting valuesGovernorsLubricating oil contents and dipstickKey to circuit diagramsHATZ wiring identificationCircuit diagramsTrouble-shooting table for the electrical system

L / M . . 01.97

Introduction

This workshop manual is in accordance with the technical status shown on each page(month / year). It has been compiled in such a way that a trained mechanic can performall repair work correctly. Instructions such as "Clean parts" etc. have been omitted, asthey are assumed to be self-evident.

All work must be carried out only with the specified tools or with others of absolutelyequivalent quality.

It is assumed that the normal hand tools will be available, even if not called for specifi-cally in this manual.

Please refer to the operating manual for details of routine maintenance work, operatingfluids and materials, troubleshooting etc.

Use only genuine HATZ spare parts in repair work.

Comply also with generally or locally valid legislation and with the instructions issued bytrade associations or accident insurers.

The details provided here may differ if special equipment is installed. Please appreciatethat neither the workshop manual nor the spare parts list can take all such deviationsinto account. If problems occur, please contact the nearest HATZ service point.

L / M . . 01.97

1

1. General

L / M . . 01.97

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Sealants and adhesives

Use of sealants and adhesives:Code letters in the text and drawigs refer to the products stated below. The same details appear in our spare part lists.

A = 502 230 01 Loctite Activator 500 ml

B = 502 231 00 Loctite 573 50 ml

C = 502 232 00 Loctite 601 50 ml

D = 502 233 00 Loctite 221 50 ml

E = 502 234 00 Loctite 648 10 ml

F = 502 238 00 Technicoll 8058 750 g

+ 502 239 00 Technicoll 8367 750 g

G = 502 565 01 Loctite IS 407 20 g

H = 502 825 01 Silicon 30 ml

J = 502 830 02 High-temp. paste 1000 g

K = 503 426 00 High-temp. paste 100 g

L = 502 566 00 Silicon 100 g

1 L / M . . 01.97

Engine illustrations

Service and flywheel side

Governor and exhaust side

Starter and flywheel side

Engines: 2 - 4 L . . S / Z1 Lub.-oil filling and dipstick2 Speed control lever3 Exhaust silencer4 Oil drain plug5 Lub.-oil filter6 Engine cover7 Side panel8 Cooling fan with built-in alternator9 Cooling fan drive belt

10 Hydraulic belt tensioner11 Stop device12 Governor housing13 Cooling air duct for lub.-oil cooler21 Cyclone-type pre-cleaner22 Eye hook for transport, disappearing

max. load 500 kg23 Access to fuel feed pump24 Starter25 Fuel feed line26 Fuel return line27 Belt pulley with 1/2" internal square

for cranking engine

1

26 7 1 2

25 23 13 5

1680/18

21

24

6223

1680/4

11 27 10 4 12

89

1681/4

L / M . . 01.97

Engine illustrations

Service and flywheel side

Outgoing air and flywheel side

Service and governor side

Encapsulated design1 Lub.-oil filling and dipstick2 Speed control lever4 Oil drain plug5 Lub.-oil filter6 Battery + terminal7 Battery - terminal8 Wiring harness9 Type plate

10 Fuel feed line11 Fuel return line14 Cover for capsule15 Air intake duct of capsule16 Outgoing air duct17 Exhaust silencer (encapsulated)20 Cover for air duct housing

(Access to governor housing of engine)22 Eye hook for transport, disappearing

max. load 500 kg23 Engine brackets24 Access to fuel feed pump25 Engine flange26 Side panel27 Cover, service side28 Cover, outgoing air side

1

25 4 5 2

15 22 24 14 1

1583/6

8

23 7 6 23202726 17

1583/12

9

28

17 16 14

1583/3

1011

L / M . . 01.97

Engine illustrations

Service and governor side

Engine: 2 ... 4 M 31,2 ... 4 M 40,2 ... 4 M 41

1 Lub.-oil filling and dipstick2 Side panel3 Rain protection cap4 Cooling fan drive belt5 Cooling fan with built-in alternator6 Governor housing7 Hydraulic belt tensioner8 Stop device9 Belt pulley with 1/2" internal square

for cranking engine10 Oil drain plug11 Speed control lever12 Lub.-oil filter13 Oil drain plug (oil sump)14 Cooling air duct for lub.-oil cooler15 Access to fuel feed pump

Starter and flywheel side

Engine: 2 ... 4 M 31,2 ... 4 M 40,2 ... 4 M 41

1 Cylinder head cover2 Fuel pressure pipe3 Cover for air filter(s)4 Eye hook for transport, max. load 500 kg5 Injector6 Fuel return line7 Fuel feed line8 Wiring harness duct9 Flywheel

10 Engine flange11 Starter12 Type plate13 Exhaust silencer

1

1627 / 12 1627 / 61627 / 6

L / M . . 01.97

Engine illustrations

Service sideMotor: H 2 L 30,

H 3 L 301 Fuel line (feed pump - filter)2 Fuel line (filter - injection pumps)3 Hose connection

(Maintenance indicator for air filter)4 Primer pump5 Fuel feed line

(Fuel tank - fuel feed pump)6 Lub.-oil filling and dipstick7 Speed control lever8 Solenoid, engine stop9 V-belt

10 Voltage regulator11 Oil drain plug, governor side12 Lub.-oil filter13 Oil drain plug, lateral14 Fuel pre-filter15 Oil pressure switch16 Fuel feed pump (Bosch)

Governor and exhaust sideMotor: H 2 L 30,

H 3 L 301 Cooling water inlet2 Rain protection cap3 Air filter4 Cylinder head cover5 Fuel pressure pipe6 Temperature switch7 Cooling water outlet8 Exhaust manifold9 Starter

10 Type plate11 Centrifugal pump12 Belt-adjustment link13 Alternator

IMPORTANT ! The standard transport suspension enablessafe transportation of the engine including supplementary equipments, and is designed fora maximum load of 500 kg (1100 lbs).It is neither suitable nor approved to lift complete units.

1 L / M . . 01.97

Type plate data

1

Type designation

e.g.

Engine type

Variant

2 L 40 C

Costumer spec. list No. 1)Customer specification

Output in kW 2)

Execution code 2)

Adjustment instruction 1)Special adjustm. regardingengine speed, power output etc.

Injection pump delivery lift in mmto obtain the required engine output.Governor rod travel for adjusting thecorrect fuel quantity in 1/100 mm

Engine No.

Type No.. 064 10 81 031814

MOTORENFABRIK HATZ KGD-94099 RUHSTORF

GMBHCO+

TYP KENNZ.

MOTOR / FABRIK NO. ABE / AUSF.

MIN NH PV CM

MADE IN GERMANY

-1 3

Displacement in cm 3

3000 / 60

Engine speed

e.g.

Nominal speed

Speed increased underno-load condition

max no-load speed

1) If required

2) In special cases only; e.g. engines acc. to Federal Authority for Automobilism

Engine serial No.:The serial no. beginswith 10 and changescontinously (11, 12)if any major changesare carried out.

Year of production

Fabrication No. (continous)

3000 + 60 = 3060 min-1

L / M . . 01.97

Technical data L 30

Type 2L30 H2L30 3L30 H3L30 4L30

Operating cycle 4-stroke

Combustion system Direct injection

Number of cylinders 2 3 4

Bore / stroke mm 95 / 100

Displacement cm3 1416 2124 2832

Compression ratio 18:1

Firing order. cyl.1:timing end 2-1 1-3-2 1-3-4-2

Direction of rotation anti-clockwise (looking at flywheel)

Cooling air requirement atn = 3000 rpm m3/min

25 - 35 - 45

Combustion air require-ment atn = 3000 rpm m3/min 2.1 3.2 4.2

Net weight approx. kgL 30 SL 30 ZL 30 C / K

223228276

222228

-

255262331

271279

-

291306

396/386

Lubricating oil pressure at n = 800 rpm1 min.: 0.9 bar

Lubricating oil consumption max.: 1 % of fuel consumption, at full load

Starter motor 12 V. 2.7 kW or 24 V. 4.0 kW

Alternator 14 V. 50 A or 28 V. 40 A*

Battery 12 V. 88 / 143 Ah or 24 V. 55 / 110 Ah

Max. continuous inclinationtowards

Control sideFlywheel sideAir outlet/starter sideTiming end

with and withoutoil sump

30°30°30°30°

with withoutoil sump

30° 25°22° 25°30° 30°25° 25°

only withoil sump

25°18°30°15°

* At H 2 L 30 and H 3 L 30: 14 V/ 33 A or 28 V/ 27 A

1 L / M . . 01.97

Technical data L 31. M 31. L 40. M 40

Type2 L 312 M 31

2 L 402 M 40

3 L 313 M 31

3 L 403 M 40

4 L 314 M 31

4 L 404 M 40

Operating cycle 4-stroke

Combustion system Direct injection

Number of cylinders 2 3 4

Bore / stroke mm 102/90 102/105 102/90 102/105 102/90 102/105

Displacement cm3 1470 1716 2205 2574 2940 3432

Compression ratio 18:1

Firing order. cyl.1:timing end 2 - 1 1 - 3 - 2 1 - 3 - 4 - 2

Direction of rotation anti-clockwise (looking at flywheel)

Cooling air requirement atn = 3000 rpm m3/min

25 29 35 39 46 49

Combustion air require-ment atn = 3000 rpm m3/min 2.1 2.6 3.2 3.9 4.2 5.2

Net weight approx. kgL 31 S. L 40 S. M 40 L 31 Z. L 40 Z. M 40 ZL 31 C / K. L 40 C / K

223228276

255262331

291306

396/386

Lubricating oil pressure at n = 800 rpm min.: 0.9 bar

Lubricating oil consumption max.: 1 % of fuel consumption, at full load

Starter motor 12 V. 2.7 kW or 24 V. 4.0 kW

Alternator 14 V. 50 A or 28 V. 40 A

Battery 12 V. 88 / 143 Ah or 24 V. 55 / 110 Ah

Max. continuous inclinationtowards

Control sideFlywheel sideAir outlet/starter sideTiming end

with and withoutoil sump

30°30°30°30°

with withoutoil sump

30° 25°22° 25°30° 30°25° 25°

only withoil sump

25°18°30°15°

1L / M . . 01.97

Technical data L 41, M 41

Type2 L 412 M 41

3 L 413 M 41

4 L 414 M 41

Operating cycle 4-stroke

Combustion system Direct injection

Number of cylinders 2 3 4

Bore / stroke mm 102/105 102/105 102/105

Displacement cm3 1716 2574 3432

Compression ratio 18.7:1

Firing order.cyl.1:timing end 2 - 1 1 - 3 - 2 1 - 3 - 4 - 2

Direction of rotation anti-clockwise (looking at flywheel)

Cooling air requirement atn = 3000 rpm m3/min

29 39 49

Combustion air require-ment atn = 3000 rpm m3/min 1.9 2.9 3.9

Net weight approx. kgM 41 SM 41 ZL 41 C / K

223228276

255262331

291306

396/386

Lubricating oil pressure at n = 800 rpm min.: 0.9 bar

Lubricating oil consumption max.: 1 % of fuel consumption, at full load

Starter motor 12 V. 2.7 kW or 24 V. 4.0 kW

Alternator 14 V. 50 A or 28 V. 40 A

Battery 12 V. 88 / 143 Ah or 24 V. 55 / 110 Ah

Max. continuous inclinationtowards

Control sideFlywheel sideAir outlet/starter sideTiming end

with and withoutoil sump

30°30°30°30°

with withoutoil sump

30° 25°22° 25°30° 30°25° 25°

only withoil sump

25°18°30°15°

1 L / M . . 01.97

Lubricating oil circuit

Suction lineOil pressure feed to filter on engines without oil coolerOil pressure feed to filter on engines with oil coolerOil circuit after oil cooler

1 Rockers2 Pushrods3 Pushrod tubes4 Hydr. starting charge device or oil servo5 Crankshaft6 Main bearings7 Hydraulic belt tensioner8 Lubricating oil pump9 Sump

10 Plug– on engines without oil cooler

11 Threaded rod– on engines with oil cooler

12 Oil suction strainer13 Balancing shaft(s)14 Lub. oil filter with bypass valve15 Oil cooler16 Oil pressure switch17 Oil pressure relief valve

1

12

3

4

5

6

7891011

12

13

14

15

10

16

17

L / M . . 01.97

Special tools and workshop equipment

Series L / M engines

No. Ident-No. Item Code

123456789

10111213141516171819202122

669 350 00612 110 00668 383 00626 753 91630 094 00629 223 01625 739 00612 092 00665 418 00665 030 91612 087 00634 142 00620 926 01624 838 91625 383 02612 090 01626 383 00624 845 01633 178 00631 191 00631 203 00632 913 00

Pressing-in drift ∅ 9 mm for valve guidesReamer 9 H 6 for valve guideClamp for fuel lineImpact extractor with accessoriesTest nozzle 400 barValve lifting toolPressing-in drift for valve stem seal6 mm intl. hex. insert with centering pinDriver sleeve for camshaft bearingsOverflow device for injection pumpDial gauge – 1/100 mmHoning toolOil pressure gauge 0 - 6 bar with flexible tubeRevolution counter for fuel pressure pipeDigital multimeterPiston ring pliersPiston ring clamping tool ∅ 70 - 100 mmCrimping pliers up to 6 mm2

Relay test boxPuller for belt tensioner bushingsInstallation drift for belt tensioner bushingsHigh-pressure pump cpl.

03.1.103.1.201.1.203.1.103.1.203.1.203.2.103.1.205.2.105.1.105.1.203.1.203.1.103.1.203.1.203.1.203.1.203.2.206.2.106.1.206.1.205.1.1

1 L / M . . 01.97

L / M . . 01.97 1

Special tools and workshop equipment

1 2 3 4 5 6 7

8 9 10 11 12 13

14 15 16 17 18

19 20 21 22

Injection - pumptiming set

AB E C

D

Relais-Funktions- undTestbox

1586

87 87a 50

– +

Special tools and workshop equipment

Series L / M engines

No. Ident-No. Item Code

23242526272829

3031323334353637383940414243444546

624 340 01624 346 01624 347 00624 348 01624 349 00624 350 00606 000 00

618 140 01618 418 00610 390 00620 300 00624 393 00621 056 00626 211 00604 628 00620 307 01620 638 01619 746 00630 439 00619 852 02619 854 02619 855 02624 863 02624 864 01

Marking device for radial position of injection pumpGauge for measuring governor rod travelGauge for adjusting start of fuel injectionCalibrating device for tool - 25 -Locating pin for governor rodFuel injection volume adjusting toolWrench for extra fuel device adjustment(mechanical system only)Multipurpose puller for use with tool - 31 -Forcing-off screw for tool - 30 -Forcing-off screw for centrifugal clutchForcing-off screw for centrifugal belt pulleyAssembly sleeveM 10 x 1 guide pin for conrodM 11 x 1 guide pin for conrodTest pressure gauge for fuel injection systemStrap wrenchLocking device for tensioning rollerHolder for injection timer assemblyGauge for oil spray nozzlesAir guide plate for 2 L / MAir guide plate for 3 L / MAir guide plate for 4 L / MElevating table, mobileAdapter elements for - 45 -

05.1.105.1.105.1.105.1.105.1.105.1.105.1.1

03.1.103.1.103.1.103.1.105.1.103.1.103.1.103.1.101.1.202.1.105.1.105.2.15Q.1.15Q.1.15Q.1.103.2.103.2.1

Explanation of classification:Example: 03. 1. 2

Manufacturer: 1 . . . Only available from HATZ2 . . . Same item (or equivalent in function)

available commercialyNecessity: 1 . . . Absolutely essential

2 . . . Useful or convenientType ofrepair 01. . . Maintenance

02. . . Emergency repair03. . . Repair in upper and external areas05. . . Repair in area of driving gear mechanism5Q. . . General overhaul

(including all the necessary tests)06. . . Component repairs

1 L / M . . 01.97

Special tools and workshop equipment

1L / M . . 01/97

23 24 25 26 27

28 29 30 31 32 / 33 34

35 / 36 37 38 39

40

41

424344

46

45

2

2. Additional equipment

L / M . . 01.97

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A 01.00 Fuel

A 01.40 Fuel delivery pump

- 3 -

General:- When installing the fuel delivery pump,

make sure that the delivery and suction li-nes are connected correctly.

Dismantling:- Disconnect fuel feed line with clamp - 3 -.- Separate the fuel lines from the delivery

pump. - Unscrew and remove nuts with spring was-

hers, and take off fuel delivery pump withO-ring.

- Dismantle fuel delivery pump 1 in the nu-merical order of parts illustrated (Fig. 182).

Note:Since September 1992 fuel strainer 12 hasbeen replaced by O-ring 5.Because of this, an input-side fuel filter mustalways be used. This input-side filter is supplied as a sparepart with the fuel delivery pump and alsowith the repair kit for the fuel delivery pump.

Assembling:- Assemble by following the instructions in

the reverse order as appropriate.

182

2

234

5 6

7891011

1

12

L / M . . 01.97

A 03.00 Exhaust system

A 03.12 Removing and installing the silencer (muffler) enclosure(L 30, L 31, L 40, C/K)

–

Prepar atory work:

- Remove the hood from the enclosure andair outlet duct; see M 35.00.

Detaching:- Take out hex bolts (184/1) and detach the

connecting stub pipe with exhaust pipe(184/2).On more recent versions, the exhaust pipeis secured with a clip.

- Take out the machine screws (184/3) andremove the connecting cover (184/4).

- Unscrew and remove the hex bolts (185/1).

- Remove the machine screws (186/1) andbolts (186/2).

184

185

186

2

L3 / 228

1

3

4

2

L3 / 230

1

2

L3 / 229

1

L / M . . 01.97

- Lift off the capsule with exhaust silencer(muffler); see Fig. 187.

Note:In some cases a spacing plate is installedbetween the silencer enclosure and the airduct housing.

- On the 2 - 3 L 40 from date of manufacture5.85 on, 4 L 40 from 1.86 on and L 31, theconnecting stub pipe (189/1), sealing was-her (189/2) and plate (189/3) are deleted.Five sealing washers are installed be-tween the silencer and the exhaustmanifold.

- Pull the upper and lower sections of the en-closure apart and lift out the silencer; seeFig. 188.

Check the parts:- Examine the enclosure sections and the si-

lencer for fractured welds or tapped holeswhich are unfit for further use.

Installing:- Install by following the removal instructions

in the reverse order as appropriate. The silencer must be installed without trap-ped stresses (a two-piece holder for the si-lencer has been installed since March1989).

Note:Before installing the connecting stub pipe(189/1), check free movement of the sealingwasher (189/2).Place the sealing washer in the connectingstub pipe and install the plate (189/3). Itshould be possible to move the sealing was-her radially. Next, place the sealing washeron the silencer. Radial play must not exceed0.1 mm. If necessary, renew thesealing washer.

187

188

189

2

L3 / 231

L3 / 233

1 2 3

L3 / 232

L / M . . 01.97

A 04.00 Mechanical starting

A 04.10 Crank handle

–

Version A 04.10.1Standard crank handle:This handle can be replaced at any time byone with kick-back damping if this becomesnecessary or is required by regulations.

Warning:There is a risk of injury if the shaft of thecrank handle or its tubular handgrip areworn.

Preparatory work: –

Dismantling: –

Checking / repairs:- Visual inspection.- Inspect shaft 1 and tubular handgrip 2 for

wear or breakage.

Note:If the shaft of the crank handle is worn, al-ways renew the complete handle.The tubular handgrip can be renewed sepa-rately if necessary.

191

2

2

1

L / M . . 01.97

A 04.00 Mechanical starting

A 04.10 Crank handle

–

Version A 04.10.2Handle with kick-back damping:The version for M .. engines is marked A onits housing, and takes the place of the stand-ard crank handle if required. Warning:There is a risk of injury if the shaft of thecrank handle or its tubular handgrip areworn.

Preparatory work: –

Dismantling:- Remove parts in the order 1 ... 3 as illustra-

ted.- Remove machine screws 4.- Take off cover 5 with great care, so that

leaf spring 11 cannot escape.Risk of injury!

- Remove parts in the order 6 ... 10 as illu-strated.

- Hold torsion spring 13 in position in orderto maintain its tension.

- Pull leaf spring 11 away from its lockingpin and out of the hook eye on torsionspring 13.

- Relieve torsion spring tension with a scre-wdriver blade.Caution - risk of injury!

- Take off parts 12 and 13.Housing 14 remains in position with theother parts.

192

2

4 7

8

1514 13

1211

10

96

5

1615 2 1

3

A

L / M . . 01.97

Checking / repairs:- Visual inspection:- Renew the complete starting handle if

there is any damage in the area of cover 5 and/or housing 14.

- If necessary, renew pivot bushings 15 andshaft sealing ring 16.

- Examine tubular handgrip 7 for wearand/or other damage, particularly in thesplined area.

- Install end plug 8, avoiding damage to thesplines. The end plug must be installed to preventdirt and water from entering.

- Check condition of bushing and leaf springat lever 9.

- Check condition of leaf spring 11 and torsi-on spring 13.Renew in case of doubt.

- Check shaft 3 for wear and/or other formsof damage.

- Renew O-rings and small parts.

Assembling:- Install parts 13 and 12.

Use thread sealant D.- Make sure that the torsion spring is not

trapped; insert its longer end into thegroove on the corresponding locating pin.

- Preload torsion spring 13 against the nor-mal spring pressure until the hook eye ofthe spring engages behind the eye ofthe through-hole.Caution - risk of injury!

- Hold torsion spring 13 in position to pre-vent spring pressure from being lost.

- Push leaf spring 11 into the hook eye ontorsion spring 13 and place on lockingpin.The rolled end of the leaf spring mustface toward the center of the housing.

- Attach lever 9.- Push on tubular handgrip 7/8.

Check splines, lever and leaf springs forfree movement.

- Apply app. 50 grams of lubricant K tothe inside of housing 14 and over all me-chanical parts.

- Place a new gasket 6 on the housing.- Carefully place cover 6 over tubular

handle 7.- Insert machine screws 4 and tighten

them evenly in a crosswise pattern.- Install shaft 3 in the order 3 ...1 as illu-

strated.- Check operation of the complete crank

handle.

2L / M . . 01.97

A 04.00 Mechanical starting

A 04.20 Automatic decompressor (M 31, M 40, M 41)

–

The automatic decompressor has the follo-wing positions; Fig. 93:

0 = Operating position, with engine running1 = Permanent decompression, automatic

device switched off 2 = Automatic decompressor switched on,

engine compression is built up auto-matically after about 8 turns of the handle.

Detaching:- Unscrew cap nut (94/4) with sealing ring

(94/5).- Take off cover (94/20) with gasket (94/37).On two-cylinder engines, shafts (94/14) and(94/36) are connected together by couplingsleeve (94/27) and 2 locking collets (94/23). Camwheel (94/22) is then used at the se-cond cylinder (flywheel side) instead of thegearwheel.

Dismantling the automatic decompres-sor:- Unscrew and remove screw plug (94/1).- Take out sealing ring (94/2), spring (94/6),

cap (94/7) and lifting pin with shims andpressure pin (94/8, 9, 10).

- Unscrew threaded rod (94/19) and removespring (94/18) and pressure pin (94/17).

- Using a suitable split-pin driver, drive lock-ing collet (94/16) about 3 mm into gear-wheel (94/21).

- Turn the gearwheel through 180° and pullthe locking collet out with pliers.

- Take out shaft (94/14) and gearwheel.

93

94

2

L3 / 1

1 2

0kompr.

dekompr. dekompr.autom.

L3 / 42

L / M . . 01.97

Checking parts:- Inspect the gearwheel and cap for damage

caused by moving the decompression lever in the wrong direction or operatingthe automatic decompressor when the engine is already running.

- Use new sealing rings.Install by following the dismantling instructi-ons in the reverse order as appropriate.

Note:- With the automatic decompressor in positi-

on ,,0“, note the correct position of the gear-wheel (Fig. 95).

- Check that the lifting pin can move freely.- When installing threaded rod (94/19),

make sure that pressure pin (94/17) is en-gaged in the locating slot on shaft (94/14).

Adjusting the automatic decompressor:

Adjustment is needed if: a) the decompression effect is no longer

sufficient.b) the engine does not reach its full com-

pression ratio (hissing noise when engine is turned over and the decom-pressor is not engaged).

c) cylinder head repairs are carried out.

Check dimension ,,B“:- Use a suitable measuring tool to check di-

mension ,,B“; Fig. 95.

Note:For this check, the rocker should rest lightlyon the valve stem but without opening thevalve (turn the engine over until the tappet isresting on the base circle of the cam).

95

2

L3 / 43

max

.46.

1 m

mm

in.

45.5

mm

BA

b c

L / M . . 01.97

If the limit values are exceeded, adjust thisdimension as follows: - Take off the exhaust rocket, grind down

the pressure pin at the riveted side and dri-ve it out.

- Install the rocker temporarily, insert thenew pressure pin (95/b) and place shims(95/c) under it to the required thickness,until the correct dimension (95/B) is re-ached.Note that when it is riveted into position,the pressure pin is about 0.1 mm lower.

- Rivet the pressure pin into position, pres-sing it firmly into the bore. The pressurepin should project by at least 1 mm at theriveting point, to ensure firm seating. If itdoes not project sufficiently, grind therocker away slightly at the appropriate po-int. Install the rocker finally, noting the end-play; adjust valve clearance and check di-mension (95/B) again.

Checking dimension ,,A“:- Using a depth gauge, determine dimensi-

on “A” (Fig. 95); work out the number ofshim washers (94/9) needed according tothe table, and secure them with the pressu-re pin (94/10) to the actuating pin (94/8).

- Check operation of the automatic decom-pressor.When decompression is active, it must bepossible to turn the engine over withoutcompression resistance, but the exhaustvalve must never strike the piston.

Dimension,,A“ in mm

Number of shim washers (Fig.94/9)

14,0 - 14,514,5 - 15,015,0 - 15,515,5 - 16,016,0 - 16,516,5 - 17,017,0 - 17,5

6543210

2 L / M . . 01.97

A 04.00 Mechanical starting

A 04.70 Recoil starter

–

Prepar atory work:- Remove the silencer (muffler); see A 03.00.- Remove the fan; see M 13.00.

Detaching the r ecoil start er: (Fig. 190)- Take out machine screws 13 incl. spring

washer 5 and screws 12 with bushings 8and washers 7, and remove them with bea-ring bracket 11.

- Detach the hydraulic shutdown device; see M 20.00.

- Remove the timing case cover; see M 11.00.

- Take out machine screws 6 with springwashers 5.

- Take off starting sleeve 4.

Checking part s:- Check the starting sleeve and bearing

bracket for damage.- Check shaft sealing ring 3 for damage and

renew if necessary.

Assemble in the opposite order of work asdescribed here.

190

2

L3 / 44

L / M . . 01.97

A 04.00 Mechanical starting

A 04.80 Start release device (L /M 31/40/41)

–

Prepar ator y work:- On C/K, take off hood at enclosure and

side panel; see M 35.00.- On S/Z and M.., take off side panel and

cooling air duct for lubricating oil cooler.

Detaching and dismantling:- Pull off fuel lines (113/1 and 2). Take out

start release device retaining screws andremove the device.

- Take off spring (114/9), flexible gaiter (8)and nut (6); take off cylinder (114/2) and remove lock washer (114/5), lever (4) andwasher (7).

Checking part s:- Place the cylinder (114/2) in a tank contai-

ning diesel oil. Apply an air pressure ofmax. 1.5 bar to the hose line (114/1). If air bubbles emerge from the cylinder, itmust be renewed.

- Check flexible gaiter for damage and re-new if necessary.

Re-assembling the start release device:Follow the dismantling instructions in the op-posite order as appropriate; refer to Fig. 114.

Note:When attaching to the engine monitoringblock, make sure that locking collet (114/13)is pressed into the start position by lever(114/4), or else the start release action willnot take place; see also Fig. 116/1.Before tightening machine screws (114/14),move bracket (114/3) in the opposite directi-on (see Fig. 116/2), to ensure that lockingcollet (114/13) can move as far as possibleback to the ,,Stop“ position.

113

114

115

2

Stop

5

4

768

3

13

2

14

9

1

2

1

L / M . . 01.97

Important:- The hoses must be correctly connected as

shown in Fig. 113.If the hoses are wrongly connected, theautomatic engine protection function is nolonger available, that is to say the engineis not shut down automatically if lubricatingoil level drops too low.

- On older engine versions, hose (113/1) isconnected to the fuel delivery pump. Thishas no effect on the basic function of thedevice.

Operational check with start release de-vice installed:- Turn lever (114/4) clockwise; locking collet

(114/13) must move to the ,,Stop“ position(Fig. 116). Release the lever; the lockingcollet must move back to the ,,Start“ positi-on.

- Prime the fuel delivery pump with the leverand at the same time check whether the pi-ston in cylinders (114/2) moves the lever(114/4) correctly. Also check the cylinderand hose unions for leaks. When the leveris no longer actuated, spring (114/9) exertspressure on the piston, which should thenmove back slowly (see Fig. 116).

Note:If the fuel tank is located at a higher levelthan the fuel delivery pump, the difference inheight between the fuel level in the tank andthe fuel delivery pump must not exceed 2metres. Failing this, the automatic engine protectiondevice will be put out of action and the engi-ne cannot then be shut down electrically.

116

2

Start

1

2

L / M . . 01.97

A 05.00 Electric starting

General instructions on the engine’selectrical sy stem:- Never interchange the positive and negati-

ve terminals at the battery.- Do not disconnect the battery when the en-

gine is running.- Avoid all risk of short-circuiting live cables

(for instance, never test whether a cable islive by touching it to earth).

- If the charge telltale light bulb blows, re-place it immediately..

- If any welding is done on the engine or theequipment to which it is fitted, attach theearth (ground) clip of the welding set asclose to the weld area as possible, anddisconnect the alternator from the electri-cal circuit at connections ,,B +“ and ,,D -“.

- When cleaning the engine, avoid sprayingwater on the alternator or any other compo-nents of the electrical system.If this is unavoidable, first disconnect thebattery; before it is reconnected, dry allcomponents thoroughly with a compressedair jet.

- If a malfunction, for instance low batterycharge, charge telltale light on etc, shouldbe detected, always check the tightness ofcable connections and correct V-belt tensi-on before making any other operationalchecks.

- For trouble-shooting in the event of a fault,see Section 4.

- When recharging the battery, disconnectthe negative terminal.

- Avoid using electrical starting aids becau-se of the risk of voltage peaks (these coulddamage electronic components).

Checking operation of the alternatorwith voltage regulator (checking char-ging current):- With the engine stopped and the starting-

switch key at ,,0“, detach the B + line(leading to the battery) from the alterna-tor and connect a DC ammeter with ascale reading of 0 .. 50 A between alter-nator terminal B + and the detachedcable. Make sure that the loose cablecannot touch any metal parts of the engi-ne.

- Connect a DC voltmeter with a scale of0 . . 30 V to the battery’s positive and ne-gative posts.

- Start the engine and note the meter rea-dings. Check the voltmeter display. Withthe alternator in good working order andelectrical consumers in circuit, the am-meter should indicate a charging cur-rent. Its value depends on the battery’sstate of charge (if the battery is flat, thecharging current is high, if the battery isfully charged, the charging current islow), but also on the consumpition of electrical equipment actually in use andon alternator and therefore engine run-ning speed. If there are no consumers incircuit, a charging current should evenbe indicated at idle speed. If the alterna-tor voltage is too high, renew the voltageregulator.

Test values System12 V 24 V

Voltmeter reading 13.0-14.5 V 26-29 VCharging current at13.5 V or 27 VBattery voltage- Engine speed

800 rpm (idle)- Engine speed

1500 rpm

approx. 25 A

40-45 A

approx. 5 A

25-30 A

2 L / M . . 01.97

A 05.00 Electric starting

A 05.40 Alternator (air-cooled engines)

–

Prepar atory work:Encapsulated engines:- Take off the hood, the air guide housing co-

ver and the impeller wheel. Unscrew andremove the enclosure side panel; see M35.00.

- Take off the Poly-V belt; see M 20.00.

Non-encapsulat ed engines:- Unscrew and remove the V-belt guard if at-

tached.- Take off the air guide plate.- Take off the Poly-V belt; see M 20.00.

Removing:- Detach the earth (ground) lead from the

battery.- Disconnect the leads from the alternator

and mark them (Fig. 193).- Unscrew the hex nuts and pull the rotor

with alternator out forwards.- Unscrew the hex nut holding the rotor and

drive the alternator shaft through by stri-king it with a plastic-faced hammer; see Fig. 123.

Checking part s:- Examine the fan and the belt pulley for evi-

dence of damage.- If any grooves have broken away or are da-

maged, renew the fan with belt pulley.

Installing:- Install the rotor and the alternator by follo-

wing the above removal instructions in thereverse order as appropriate. Note:When connecting the cables to the alterna-tor, make sure they are not accidentally in-terchanged.

193 (*HATZ internal cable marking)

194

2L / M . . 01.97

Notes on renewing the alternator:

When series production of Series L / M engi-nes began, alternators made by SEV-MAR-CHAL were used.These alternators are no longer available asspare parts, but can be replaced without dif-ficulty by the current VALEO alternator. The MARCHAL voltage regulator is stillavailable.In view of the modified installed position ofthe voltage regulator on PARIS-RHONE orVALEO alternators (removal and installationin a radial direction to reduce the risk of bre-aking off the carbon brushes), the fan hou-sing was also modified in the regulator areawhen the PARIS-RHONE generator was in-troduced. A cutout in the housing and deleti-on of the retaining screw which previouslypassed through at this point ensure that theregulator switch can be renewed without ha-ving to remove the alternator.

When replacing a MARCHAL alternator by aVALEO type, you are recommended to per-form the above modification; refer to Fig.195. The time invested in this will easily bemade good by the time saved if the regula-tor has to be replaced later.

When installing a VALEO voltage regulator,make sure that the condenser supplied withit is also installed (connection diagram is en-closed).

195

2 L / M . . 01.97

A 07.00 Lubricating oil

A 07.10 Oil cooler (air-cooled engines)

–

Prepar atory work:- On engines with enclosure, take off the en-

closure hood and side panel; see M 35.00.- On engines without enclosure, take off the

cooling air duct to the oil cooler.

Removing block- patt ern oil cooler:- Remove the oil line to the servo (only on ol-

der version of the engine).- Take out machine screws (196/1) and de-

tach the oil cooler.

Removing gilled-tu be oil cooler:- Take out machine screws (197/1) with

spring washers and detach oil cooler withsealing rings (197/5).

- To dismantle the oil cooler: Pull the oil gui-des (197/2) apart and take out both gilledtubes (197/3) with O-ring seals (197/4).

Note:The gilled-tube oil cooler is only used ontwo-cylinder engines without enclosure andrated for engine speeds up to a certain limit.

Checking part s:- Make a visual check for cracks or damage

to the sealing faces.- Clean the cooling surfaces.Installing:- Install the oil cooler by following the appro-

priate removal instructions in the reverseorder.

Retrofitting engine w ith oil cooler:- If an engine has an oil cooler retrofitted,

the missing threaded rod (198/3) must beinserted and secured with sealant D. Unless t his w ork is perf ormed, t he oil cooler will be unable to op erate.

196

197

198

2

L3 / 189

1

L3 / 190

3

L3 / 10

1 2 5

3 4 2

L / M . . 01.97

A 07.00 Lubricating oil

A 07.11 Oil cooler (water-cooled engines)

–

Preparatory work:- Drain the coolant.- Detach the coolant lines from the oil cooler.

Removing:- Take off the oil filter (199/1).- Unscrew and remove the threaded sleeve

(199/2).- Take off the oil cooler (199/3) with spacing

ring (199/4) and O-ring seal (199/5).

Checking parts:- Make a visual check for cracks or damage

to the sealing faces.

Installing:- Install the oil cooler by following the remo-

val instructions in the opposite order as ap-propriate.

Note:- Install the oil cooler side with the sealing

ring towards spacing ring (199/4).- Tighten threaded sleeve (199/2) to a

torque of 55 Nm.

199

2

5

1 23

4

L / M . . 01.97

A 11.00 Automatic devices

A 11.10 Engine shutdown solenoid (up to serial numbers 2 L 40.16, 3-4 L 40.15, M 40.12, L 30 and H.L 30)

–

Dismantling:- Disconnect the solenoid and take off the

starting aid housing, taking care not to turnthe volume limiting eccentric.

- Take out machine screws (205/1) and re-move solenoid (205/2).

- Pull eccentric shaft (205/3) towards the so-lenoid and unscrew hex nut (205/4) with a10 mm open-ended wrench.

- Pull out the eccentric shaft and removewasher (205/5), lever (205/6), washer(205/7) and spring (205/8).

Checking / repairs:- Use a new O-ring seal (205/10).- Check flexible gaiter for damage and re-

new if necessary.

Assembling:- Proceed in the opposite order of work;

install end cap (205/9) with sealant C.205

2

L3 / 199

2

110

3

8

7

4

6

5

9

L / M . . 01.97

Adjusting engine shutdown and solenoid:The solenoid does not need adjusting un-less the adjusting nuts were turned or a newsolenoid has been installed. - Press the solenoid fully in against the

spring loading.- Insert solenoid adjusting gauge 621 471 00

(206/1) into the hole in the housing; see Fig. 206.

- Turn adjusting nut (207/1) until lever(206/2) is touching the adjusting tool.

Note:If the adjusting gauge is not available, theshutdown device can be adjusted to thechecking distance of 39.3 ±0.1mm betweenthe inner face of the hole in the cover andthe inner edge of the lever; Fig. 207.- After adjusting, secure the adjusting nut

with locknut (207/2) and seal it withlacquer.

Installing the shutdown device:- Set the speed control to the ,,Stop“ position.- Coat both sides of the gasket (208/1) for

the housing with sealant H. Apply only athin coat of the sealant so that the oil pas-sage in the starting fuel supply device isnot blocked.

- Attach the gasket (note correct position ofoil hole) and press the solenoid by handinto the operating position: angle (208/3)must engage to the left of the driver pin ongovernor rod (208/4).

- In this position, attach the housing and re-connect the solenoid.

Warning:If the angle is positioned incorrectly when in-stalled (at the right of the driver pin), the en-gine will overspeed and could destroy itselfunless the solenoid is put out of action im-mediately.When the U-pattern driver pin was intro-duced, incorrect positioning as describedabove was ruled out.

206

207

208

2

L3 / 200

12

L3 / 201

1

2

39.3 ±0.1

L3 / 202

1

24

3

L / M . . 01.97

A 11.00 Automatic devices

A 11.70 Temperature-controlled starting fuel volume control

- 24 - 28 -

Adjusting:- Screw in adjusting tool - 28 - and attach

measuring device - 24 -.- Pull the speed control lever briefly to

,,Stop“ and then to the full-load position.This places governor lever 1 against full-load stop 2 of the starting fuel volume con-trol.

- Zero the dial gauge.- Screw thermo-element 4 carefully into the

bracket, until the dial gauge just begins tomove (the sickle-shaped lever is thenagainst the governor rod).

- Unscrew adjusting tool - 28 - at the 13 mmhexagon until a clicking sound is clearly he-ard, to indicate that the governor lever isdropping into the increased-volume star-ting position.

- Slowly turn thermo-element 4 back to a lo-wer setting until the dial gauge indicates amovement of 0.2 mm towards increasedvolume from the zero position previouslyobtained.

- In this position, secure the thermo-elementwith the locknut.

- Detach auxiliary tools and install any engi-ne components not yet in place.

Warning:When adjusting, make sure that the thermo-element is at a temperature of at least 20°C.

170

2

3 2 1

4

L / M . . 01.97

A 15.00 Housing

A 15.20 Adapter housing

–

Assembling:- Drive locking collets (200/1) into the crank-

case.- Attach the connecting housing, insert four

M 14 x 1.5 mm hex bolts (200/2) withspring washer (200/3) and tighten to thespecified torque.

Note:Apply sealant D to the bolt above inspectionhole (200/4), since this is a through-hole.On engines without a adapter housing, theequivalent screw plug should also be coatedwith sealant D before inserting.- Insert and tighten the two lower M 10 hex

bolts (200/5) with spring washers (200/6). 200

2

L3 / 143

12

4

3

5 6

L / M . . 01.97

A 30.00 Liquid cooling

A 30.20 Water pump (H.L 30)

–

Preparatory work:- Drain the coolant.- Take off the alternator.

Dismantling:(Fig. 201)- Detach the coolant lines at the water pump.- Unscrew hex bolts 1 with spring washers 2

and take off the water pump.- Remove screws 3 with spring washers 4

and take off V-belt pulley 5.- Take out screws 6 with copper washers 7

and remove pump element 8 with seal 9from housing 10.

Checking parts:- Check housing for evidence of damage.

Note:If the following damage is detected, renewcomplete pump element 8:- Damaged pump impeller.- Worn sealing ring in pump element

(water leaking from the hole in the pumpelement).

- Bearing worn.

Assembling:- Assemble by following the dismantling in-

structions in the reverse order as appro-priate.Install pump element 8 with the wa-ter drain hole facing down.

201

2

12

4

35

67

89

10

L / M . . 01.97

A 30.00 Liquid cooling

A 30.40 Thermostat (H.L 30)

–

Preparatory work:- Drain the coolant (only needed if the upper

edge of the radiator is higher than thethermostat).

- Detach the coolant line from thermostat co-ver (202/3).

Dismantling:- Take out retaining screws (202/1) with

spring washers (2).- Lift off the thermostat cover (202/3).

Remove sealing ring (4) and pull outthermostat (5).

Checking operation of thermostat insert: Note: The temperatures stamped on thethermostat insert indicate the start of itsopening movement and the maximum opera-ting temperature.- Suspend the thermostat insert and a ther-

mometer in the centre of a vessel filledwith water; see Fig. 203.

- Heat the water while stirring it.- Check that the thermostat insert opens at

the temperature stamped on it.- Remove the thermostat insert and check

that it closes correctly.- Renew thermostat insert if defective.

Assembling:- Clean the sealing faces on the cylinder

head, the thermostat cover and the seat ofthe thermostat insert.

- Install the thermostat insert, using a newsealing ring (the arrow stamped on it indi-cates the direction of flow).

- Attach the thermostat cover again andtighten its screws uniformly.

202

203

2

1

2

4

3

56

L / M . . 01.97

3

3. Basic engine equipment

L / M . . 01.97

M 01.00 Crankcase

M 01.10 Removing and installing balancing weights - 2L / 3L

–

Prepar atory wor k:- Remove the crankshaft, see M 02.00.

Dismantling:- Unscrew and remove machine screws

(1/1) at driver (1/2).

Note:On the 3 L, also unscrew and remove themachine screws at the divided driver.

- Unscrew and remove the machine screws(2/1) at the plate (2/2) and take off the pla-te.(On more recent version: secured withstud bolts and nuts)

- Unscrew the plug from the thrust bushingat the timing end of the engine and drivethe shaft out towards the flywheel end; seeFig. 3.

- Drive out the thrust bushing (timing end).- Take the balancing weights and driver out

of the lower part of the crankcase.

Checking / r epair s:- Check the shaft at its bearing points for

score-marks and correct dimensions; forvalues, see Section 4.

- Check the needle roller bearings of the ba-lancing weights for score-marks.

- Check the gearwheel with balancingweight and the crankshaft-end gearwheelfor the balancing weights for signs of dama-ge.

- Renew the O-ring seals at the thrust bus-hings.

1

2

3

3 L / M . . 01.97

Assembling:- Insert the thrust bushing (timing end) until

flush with the housing.- Place the gearwheel with balancing weight

(flywheel end) and the balancing weight (ti-ming end) in the lower part of the crankca-se, insert the driver and screw hand-tightto the balancing weights. Insert the shaftwith thrust bushing (4/1) from the flywheelend , see Fig. 4, and drive it fully into the timing-end thrust bushing.

- Tighten the machine screws for the driverand use a depth gauge to measure end-play at the balancing weights; see Fig. 5.

Note:The timing-end thrust bushing (5/1) formspart of the sealing face at the timing case co-ver, and must therefore be flush with theendface of the crankcase after driving in theshaft.Endplay can be adjusted by moving theflywheel-end thrust bushing axially until thevalue stated in Section 4 is obtained.

- Apply sealant D to the machine screws(6/1) and attach the plate; also coat thescrew plug for the timing-end thrust bus-hing with sealant D and screw it in.Turn the balancing weights to ensure freerotation.

Note:When installing the oil sump and the crank-case cover, apply sealant D to two M8 hexbolts in each case at the timing and flywheelends, where a through-hole has been drilled.

4

5

6

3L / M . . 01.97

M 01.00 Crankcase

M 01.20 Removing and installing balancing weights - 4 L

–

Prepar atory wor k:- Remove the crankshaft; see M 02.00.- Take off the oil sump.

Dismantling:- Unscrew the machine screws (7/1) at the

bearing journals (7/2) and pull them out.Using two machine screws, loosen the bea-ring journals and pull them out.Mark the installed positions of the bearingjournals.

- Invert the lower part of the crankcase.

Note:The joint line is a sealing face, and must notbe damaged. Place the crankcase on a woo-den grid or frame; see Fig. 8.

- Unscrew splash plate (9/1) and take out ba-lancing weights (9/2), then remove splashplate (9/3).

7

8

9

3 L / M . . 01.97

- Check dimensions of bearing bushings(10/1) and, if necessary, drive them outwith a suitable drift. First drive the endcaps out of the crankcase bores (10/2).

Checking / repairs:- Check the bearing journals and bushings

for score-marks and incorrect dimensions;for values, see Section 4.

- Check the balancing weight gearwheelsand the crankshaft-end gearwheel for thebalancing weights for damage.

Assembling:- Blow through the oilways thoroughly with

compressed air.

Note:Before installing the bearing bushings, makesure that the oil hole is in the correct positi-on; see Fig. 11.

- Coat the bearing bushings (12/1) withsealant D and drive them into the housinguntil flush, using a suitable drift; see Fig. 12.

- Coat the sealing faces of the end caps(10/2) with sealant C and insert them again.

- Renew the end caps.

10

11

12

3L / M . . 01.97

- Insert spacing rollers for the M8 screws inthe correct positions as shown in Fig. 13.

Note:Insert the longer spacing rollers (13/1) at theoil filter flange side.

- Insert splash plate as shown in Fig. 14, in-sert the lower machine screws (14/1) andtighten them. Screw the upper machinescrews (14/2) in only hand-tight.

- Insert the balancing weight with circle andline markings as shown in Fig. 15, andpush in the bearing journal.

Note:This balancing weight is driven directly fromthe crankshaft.

13

14

15

3 L / M . . 01.97

- Insert the balancing weight with circle mark(16/1) and push in the bearing journal.

Note:When installing this balancing weight (16/1),make sure that the circle mark on it is be-tween the two line marks on balance weight(16/2).In this position, the circle mark on balancingweight (16/2) must face the crankshaft.

- Take out the two machine screws at holes(17/1) again.Place spacing rollers (17/2) on the splashplate.Insert splash plate (17/3) and screw in hexbolts (17/4) hand-tight.

- Insert machine screws (17/1) and tighten.;also tighten hex bolts (17/4).

- Turn the lower part of the crankcase backupright again (joint line at the top).

- Insert the machine screws at the bearingjournals and tighten them to the specifiedtorque with a torque wrench; Fig. 18.

- Rotate the balancing weights and checkfor free movement.

Note:When attaching the oil sump, apply sealantD to two M8 hex bolts in each case at the ti-ming and flywheel ends, since these are in-serted in through-holes.Engines with an oil sump attached must nothave a ∅ 40 mm end cap installed in the lo-wer part of the crankcase.

16

17

18

3L / M . . 01.97

M 01.00 Crankcase

M 01.30. Cleaning the crankcase, installing the oil spray jets

- 41 -

Cleaning the crankcase- Remove all screw plugs from the oilways

and, after cleaning the crankcase by im-mersion in a cleaning bath or with high-pressure cleaning equipment, blow it drywith compressed air; flush out all oilwaysparticularly thoroughly and blow throughthem, so that no particles of dirt or swarf re-main.

- After this, insert all screw plugs again andcheck that the aluminium or sheet-metalplugs for the oilways are firmly seated. Incase of doubt, renew them; apply sealantE to all plugs before inserting. To ensurefirm location, secure the aluminium plugswith light punch-marks at the edge of thehole in the housing.

Oil spray jets- First check for firm location and accurate

spray direction; if necessary, re-align thespray jet with light hammer-blows or bendit carefully by hand until the correct positi-on is reached. Check this with the gauge - 41 - or work from the drawing shown here(Fig. 171).

If oil spray jets have broken off or are loose,new ones must be inserted. Proceed as fol-lows:- Remove pieces of the old jet from the drill-

way (with a suitable drift or similar tool); de-grease the entire area thoroughly; insertthe new spray jet and drive it in initiallyapp. 6 - 8 mm farther than its final position.Strike the projecting end lightly with a ham-mer to bend it slightly and ensure a firmseating in the bore (Fig. 172).

171

172

3 L / M . . 01.97

- Apply sealant E to the projecting end andmove the spray jet to its final position. Donot dent the jet inlet bore; drive it in untilthe end of the tube is flush with the oil groove in the bearing seat (Fig. 173).

- Check the position of the jet outlet again,and adjust if necessary.

- Apply sealant E again where the spray jetpasses through opposite the bearing seat;the capillary action of the sealant will en-sure that the tube is fully coated and can-not shake loose in its seat.

Note:On Series L 41 and M 41 engines, an oilspray jet is also installed for cylinder 1.

173

3L / M . . 01.97

M 02.00 Crankshaft

- 8 -

Preparatory work:- Take off enclosure parts and air guide pla-

tes; see M 35.00.- Take off cylinder heads; see M 07.00.- Detach fan and V-belt pulley from cranks-

haft; see M 13.00.- Remove piston, conrod and cylinder; see

M 05.00 / M 06.00.- Take off flywheel and connecting housing.- Detach the timing case cover; see M 11.00.- Take off the starter motor.

Dismantling:- Remove machine screws and spring was-

hers for end cover and pull off the end co-ver; see Fig. 19.

- Unscrew the machine screws(20/1) andpull them out.

- Remove machine screws from crankshaftgearwheel, loosen the gearwheel on thecrankshaft with a plastic-faced hammerand pull it off.

- Pull out the locking collet (21/1).

19

20

21

3 L / M . . 01.97

- Unscrew and remove the hex bolts (22/1)at both sides.

- The two halves of the crankcase are secu-red together with straight pins (23/1). Drivethese back with a hammer and a suitabledrift until they are flush with the sealingface. Lift the upper part of the crankcaseup vertically: Fig. 23.

Note:To simplify the loosening and lifting off of theupper part of the crankcase, insert two M 8 x 65 machine screws (retaining screwsof setting-down device) at the timing endand two M 14 x 50 hex bolts (used to secureconnecting housing) at the flywheel end inthe holes provided.

- Lift the crankshaft out of the lower part ofthe crankcase.

- Carefully warm the balancing weight gear-wheel on the 2 and 3 L ... with a weldingtorch and knock it off with an aluminiumdrift. For the 4 L ... crankshaft, unscrew and re-move the flywheel-end counterweight, re-move the machine screws for the gear-wheel and drive out the straight pin (24/1).

22

23

24

3L / M . . 01.97

Checking / repairs:- Check all crankshaft bearing journals for

score-marks and incorrect dimensions; formeasured values, see Section 4. Measure in two planes offset through 90degrees.

- Check the shaft sealing ring contact facefor score-marks.If the contact face is worn, a ,,wear sleeve“can be pushed over it. When doing so, usesealant E. Assembly instructions are inclu-ded with the spare part.

- Renew the shaft sealing ring in the end co-ver.

- Check the bearing shells for damage andvisible signs of wear.

Installing:- Pull the balancing-weight gearwheel on to

the crankshaft.On the 2 and 3 L .. crankshafts, unscrewand remove the flywheel-end counter-weight; this will expose the line marking(25/1) on the crankshaft. Heat the gearwheel to app. 125° C andpull it on so that the line marking (25/1) onthe crankshaft is aligned with the ,,O“ mar-king (25/2) on the gearwheel; see Fig. 25.

On the 4 L ... crankshaft, unscrew and remo-ve the flywheel-end counterweight and ma-noeuvre the balancing-weight gearwheelinto position as shown in Fig. 26.- Apply sealant C to the straight pin (24/1)

and drive it in.- Apply sealant D to the machine screws

and tighten them to the specified torque.Note:From mid-1994 on, a modified gearwheeland different retaining screws were intro-duced. The new screws are not to be usedwith the old gearwheel (Fig. 27).On the 2 and 3 L .. engines, do not installthe counterweights again until the cranks-haft has been placed back in the lower partof the crankcase.

25

26

27

3

5,5 6,5

alt neu

L / M . . 01.97

- Place the thrust washers (28/1) on thecrankshaft so that the lubricating groovesface the thrust face on the crankshaft. Insert the bearing half-shells (28/2) into thelower part of the crankcase, and apply oilto them.

- Place the crankshaft in the lower part ofthe crankshaft and make sure that the ge-arwheels mesh together as indicated bythe marks. For 2 / 3 L ... see Fig. 29.

- For 4 L ... see Fig. 30.

28

29

30

3L / M . . 01.97

- Insert the O-ring seal (31/1) for the mainoilway into the lower part of the crankcase.Apply a thin, uniform coat of sealant B toall areas of the joint line on the lower partof the crankcase, and also on the interme-diate webs of the crankcase; see Fig. 31.

- Insert the bearing shells into the upper partof the crankcase and coat them with oil.

- Position the thrust washers so that thegroove (32/1) faces upwards in each case.Lift upper part of crankcase and place itvery carefully.

Note:When installing, make sure that the two cen-tering pins (32/2) in the upper part of thecrankcase are inserted into the grooves(32/1) of the thrust washers; see Fig. 32.- Drive in the straight pins (23/1) again to

locate the two halves of the crankcase.

- Insert the machine screws and tightenthem to the specified torque in the ordershown in Fig. 33.

31

32

33

3 L / M . . 01.97

- Check crankshaft endplay with a depthgauge, Fig. 34, and compare it with the de-sired value stated in Section 4.

- Drive the locking collet to secure the gear-wheel (21/1) into the end of the crankshaft.

- Turn the camshafts until the two marks(35/1) are aligned and the mark for thecrankshaft gearwheel faces downwards.

- Engage the crankshaft gearwheel, notingthe position of the mark, and tighten it tothe specified torque.

- Place the gasket (36/1) on the lockingcollets.

- Insert a new shaft sealing ring and greaseits sealing lip. Install the end cover, coat the machinescrews with sealant D and tighten them tothe specified torque.

34

35

36

3L / M . . 01.97

M 04.00 Camshaft

M 04.10 Camshaft, valve gear

- 9 - 30 - 31 -

Preparatory work:- Take off the upper part of the crankcase;

see M 02.00.

Dismantling:- Remove the circlip (37/1) at the cover, pull

the cover (37/2) out with water-pump pliersand remove the shim washers.

- Stand the upper part of the crankcase up,take the circlip (38/1) out of the safety groo-ve and press the valve tappet (38/2) off thecamshaft.

- Using a ∅ 47 mm driving-out sleeve, drivethe camshaft out towards the timing end(see Fig. 39) and pull out the valve tappets.

37

38

39

3 L / M . . 01.97

- Remove the circlip and shim washers andpull off the ball bearing with a two-arm pul-ler; see Fig. 40.

- If the gearwheel or camshaft is renewed,use puller - 30 - with forcing-off screw - 31 -to pull the gearwheel off the camshaft; see Fig. 41.

Checking / repairs:- Inspect the camshaft bearing points and

the bearing bores in the crankcase for sco-re-marks and incorrect dimensions; for va-lues, see Section 4.

- Check the camshaft gearwheel for score-marks.

- Check the camshaft ball bearings for wear.- Check the tappets for score-marks.- Check the bores in the crankcase for the

tappets for score-marks and incorrect di-mensions; for values, see Section 4.

Assembly:- Heat the camshaft gearwheel to app. 150 -

200°C on a hotplate, and press it on.- Place the circlip (42/1) in position and pull

on the ball bearing with impact sleeve - 9 -;see Fig. 42.

40

41

42

3L / M . . 01.97

- When installing a new camshaft, makesure that there is no endplay between theball bearing and the circlip (43/1). If necessary, insert shim washers (43/2).

- Install the camshaft, noting the correct posi-tions of the marks, and insert circlip (44/1).

- Drive the camshaft towards the timing endof the engine until the ball bearing is in con-tact with the circlip (44/1).

- Insert shim washers (43/3), push in coverwith O-ring seal (43/4) and attach circlip(43/5).

Note:- Check camshaft endplay; for values, see

Section 4.If necessary, insert shim washers (43/3).

- A special camshaft has been introduced tooperate the valves on the following engi-nes.It can be identified by an “H” cast into thecamshaft. 2 M 31 H from No. 841087 0000083 M 31 H from No. 851087 0000044 M 31 H from No. 861087 0000042 M 40 H from No. 781487 0016313 M 40 H from No. 791487 0009524 M 40 H from No. 801487 000873

43

44

3 L / M . . 01.97

M 04.00 Camshaft

M 04.20 Camshaft for injection pump

- 9 - 30 - 31 -

Preparatory work:- Remove the injection pump; see M 14.00.- Remove the engine speed control;

see M 32.00.- Remove the starting-mixture charging de-

vice; see M 12.00.- Remove the fuel delivery pump.

Dismantling:- See M 04.10.

Detaching the intermediate gearwheel:Note:The intermediate gearwheel can only be pul-led off after removing the injection pumpcamshaft.- Take off the circlip (45/1) and unscrew the

splash plate (45/2).

- Pull off the gearwheel with the puller - 30 -and the forcing-off screw - 31 - : see Fig. 46.

Note:The two ball bearings in the intermediate ge-arwheel are separated by a circlip.

Checking / repairs:- Check the camshaft bearing points and the

bearing points in the crankcase for score-marks and incorrect dimensions; for valu-es, see Section 4.

- Check the ball bearings for the camshaftand the intermediate gearwheel for wear.

45

46

3L / M . . 01.97

Attaching the intermediate gearwheel:

Note:The intermediate gear wheel must be instal-led before the camshaft for the injectionpump is installed.

- Press the ball bearing into the intermediategearwheel and pull the gearwheel on usingimpact sleeve - 9 - , noting the positions ofthe markings; see Fig. 47.

- Place the circlip on the shaft.

Note:Before pulling on, place the intermediate ge-arwheel uniformly on the shaft, to preventthe shaft from being pushed into the crank-case.

Installing the camshaft:- See ,,Installing camshaft for valve gear“

(M 04.10).Note:The camshaft for L 40/M 40 is marked ,,L 40“ next to the delivery pump drive cam.

47

3 L / M . . 01.97

M 04.00 Camshaft

M 04.30 Governor and injection timer

- 30 - 31 - 40 -

Preparatory work:- Removing camshaft for injection pump;

see M 04.20.

Dismantling the governor: (up to engineserial number: 2 L 40.16, 3-4 L 40.15,.M 40.12 and .L 30 and H.L 30)- Remove circlip (48/1) and pull out gover-

nor spring (48/2).- Detach spring from governor (48/3) and

push out pin (48/4) with roller sleeves(48/5).

- Pull out spring sleeve (48/6) with pull rod(48/7).

- Unscrew spring bridge (48/8) and take offholder for governor weights (48/9).

Dismantling governor: (from engine serialnumber: 2 L 40.17, 3-4 L 40.16, .M 40.13,and all L 31 and M 31 engines)- Remove circlip (48a/51) and pull out

spacing ring (48a/50), spring plate(48a/49) and governor spring (48a/45).

- Remove the spring at the governor collar(48a/11) and push out pin (48a/38) with rol-ler sleeves (48a/37).

- Pull out the pull rod (48a/36), unscrew thenuts (48a/44) and take off the spring plateat the governor (48a/43), the locating was-her (48a/42) and needle roller race(48a/41), the shim washer (48a/40) andthe thrust washer (48a/39).

- Unscrew the spring bridge (48a/32) andtake off the holder for the governor weights(48a/26).

Checking / repairs:- Check al parts for damage and signs of

wear.

48

48a

3L / M . . 01.97

Pull off and dismantle the injection timer:- Using puller - 30 - with pressing-off screw

- 31 -, pull the injection timer off the cams-haft; see Fig. 49.

- Clamp the holder for injection timer assem-bly - 40 - into the vise and place the hole inthe injection timer’s support disc on thespecial tool; see Fig. 50.

- Turn the gearwheel counter-clockwise byhand against the spring loading, and lift itcarefully off the support disc.

- Take off the centrifugal weights (51/1), re-taining blocks (51/2) and pins (51/3) withcoil springs (51/4).

- Unscrew and remove the cam tracks(51/5).

Checking / repairs:- Examine the support disc and gearwheel

in the centrifugal weight area for score-marks.

- Inspect the coil springs and their retainingblocks for damage.

- Check the centrifugal weights for score-marks.

49

50

51

3 L / M . . 01.97

Assembling the injection timer:- Assemble the injection timer by following

the dismantling instructions in the reverseorder.

Note:The gearwheel and support disc were modi-fied at the beginning of 1992.Parts from the old and new versions cannotbe combined.If necessary, renew the complete injection ti-mer. After placing the gearwheel on the supportdisc, check that the slots in the gearwheeland support disc are aligned as shown inFig. 52.

- Turn the injection timer clockwise and al-low it to move back to check its freedom ofmovement; see Fig. 53.

- Coat the hole in the support disc withsealant C and press the camshaft (withshaft key) into the injection timer until thegearwheel has 0.05 mm of endplay.

Note:Check endplay with a feeler gauge asshown in Fig. 54.

52

53

54

3L / M . . 01.97

Assembling the governor:- Assemble the governor by working the op-

posite order to that described for dismant-ling; refer to Figs. 48 and 48a.

Note:When assembling the governor, make quitesure that all moving parts are able to movefreely.On L/M 31/40 engines there must be a clea-rance of 0.5 mm between spring plate(48a/43) and nut (48a/44).On L/M 41 engines the spring plate (48a/43)must be held firmly when nut (48a/44) istightened.

- Install the spring for the governor (55/1) sothat the endface of the tapered section po-ints in the direction of rotation.

Renewing governor spring:(without detaching the timing case cover)

Preparatory work:- Remove the engine shutdown device;

see M 20.00.- On the H.L30 take off the cover;

see M 11.00.

Dismantling:- Remove circlip (56/1) and spring plate

(56/2).- Take out governor spring (56/3) and check

it for cracks or breakage.

Assembling:- Choose the correct new governor spring

as stated in Section 4, according to the en-gine’s intended use and speed range.

- Install the governor spring or engine shut-down device by working in the opposite or-der to that described for removal.

55

56

3 L / M . . 01.97

M 05.00 Conrod

- 35 - 36 -

Preparatory work:- Take off the cylinder head; see M 07.00.- Remove the cylinder and piston;

see M 06.00.

Dismantling:- Unscrew and remove the big-end bolts

(62/1) and lift out the conrod and big endcap with the aid of guide pin - 35 - or - 36 -.

Checking / repairs:- Check the conrod bushing, big end bea-

ring and crankpin for score-marks and in-correct dimensions; for values, see Section4.

Assembly:- Press the bushing into the conrod.Note:When pressing in the conrod bushing, makesure that the oil holes are aligned and thatthe bushing projects by an equal amount oneach side.- Insert the big end bearing half-shells into

the conrod, making sure that the locatingnuts are in the grooves provided; see Fig. 63.

- Install the big end cap, using guide pin - 35 - or - 36 -; see Fig. 64.

- Attach the upper part of the conrod, insertthe big end bolts and tighten them to thespecified torque.

Note:The groove (63/1) in the big end cap mustbe on the side nearest the injection pump.The groove (63/2) in the main conrod mustbe on the valve tappet side.

62

63

64

3L / M . . 01.97

M 06.00 Piston and cylinder

M 06.10 Air-cooled engines

- 12 - 16 - 17 -

Preparatory work:- Detach the cylinder head; see M 07.00.

Dismantling:- Mark the relative position of the cylinder

and piston and pull off the cylinder.- Take out the piston pin circlip; see Fig. 65.- Press the piston pin out by hand and lift off

the piston.

Checking / repairs:- Check the cylinder wall for seizure marks

or score-marks.- Check that the dimensions of the cylinder

are correct; for values, see Section 4.- Check the piston for seizure marks or ring

web fractures.- Check piston ring end gaps; for values,

see Section 4.

Checking piston ring end gaps:- Pull the piston rings off the piston.- Place each piston ring in its cylinder bore

and move it to the TDC position of the pi-ston.

- Clean the piston crown and use it to positi-on the piston ring at a right-angle to the cy-linder axis.

- Use feeler gauges to measure the pistonring end gap (where the ends of the pistonring come together).

- For limit values, see Section 4.

65

Checking cylinder wear and suitabilityfor further use:- Repeat the piston ring measuring proce-

dure with a new piston ring.- Compare the measurements obtained in

this way with the maximum wear limits; ifthese are exceeded, the cylinder shouldnot be re-used but an oversize cylindershould be installed instead.

- If the measured values are within the li-mits, the cylinder can be used again,with new piston rings.

In this case, the cylinder wall must beroughened very slightly with a honing tool,since the honed finish will have been lar-gely worn away after a lengthy period ofoperation. If the cylinder were to be usedagain without re-honing (whether the exi-sting piston rings or new ones were fitted),excessive oil consumption would occurand would not drop to the normal level af-ter a time, since the piston rings would notbe able to match themselves to the cylin-der wall.

3 L / M . . 01.97

Procedure:- While turning the honing tool in the cylin-

der, it must also be moved to and fro axially. Recommended speed of rotation approx.350 rpm.

- Depending on the speed, the tool shouldperform about 20 - 30 strokes a minute.This stroke rate will produce a cross-cutpattern at approximately 45°.

- Continue honing only until this crosscut pat-tern can be clearly seen. It is normally ob-tained after a honing time of approx. 20 - 45 seconds per cylinder.

- After honing, clean the cylinder with warmor hot water and a cold cleanser, using abrush, then oil the cylinder wall.

Warning!Do not hone for too long a period, and donot dry-hone. Use honing oil or a mixture of oil and fuel(1:1).If possible, keep below the speed statedabove. Wear protective goggles!

Assembling:To install the piston, follow the dismantling in-structions in the reverse order.

Note:The recess in the piston crown must be loca-ted towards the injection pump; see Fig. 66.

- The piston ring gaps must be offset by120° in each case; oil the piston rings intheir grooves.

- Attach clamping tool - 17 - and carefully in-stall the cylinder; see Fig. 67.

66

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3L / M . . 01.97

M 06.00 Piston and cylinder

M 06.20 Water-cooled engines (H.L 30)

- 16 - 17 -

Preparatory work:- Take off the cylinder head; see M 07.00.- Take off the alternator and water pump.

Dismantling:- Carefully pull the cylinder off.- Take out the piston pin circlip; see Fig. 68.- Press the piston pin out by hand and lift off

the piston.

Checking / repairs:- Examine the cylinder for seizure marks or

score-marks on the cylinder wall.- Check cylinder dimensions and state of

wear; see Section 4.- Inspect piston for seizure marks and ring

web breakage.- Check piston ring end gap; see Section 4.- Check piston ring end gap, cylinder wear

and suitability for further use; see Section 4.

68

3 L / M . . 01.97

Installing:Install the piston by following the removalprocedure in the reverse order as appropri-ate.

Note:The recess in the piston crown must be loca-ted towards the injection pump; see Fig. 69.

- The piston ring gaps must be offset by120° in each case; oil the rings well in theirgrooves. For each cylinder bore a figure is stampedon the crankcase and another figure on thecylinder. The two figures, if added together, represent the thickness of theshim plates to be inserted at the base ofthat cylinder; see Fig. 70.

Example:

Figure on crankcase 15Figure on cylinder 20Shim plate thickness needed 35 = 0.35 mm

These shim plates compensate for cylinderand crankcase manufacturing tolerances; inaddition the gap is reduced to within a to-lerance range of 1.0 - 1.5 mm.

- Attach shim plates 70/1 to the cylinder witha small amount of grease.

- Oil the cylinder bore well.

Note:If spare parts are obtained, the manufactu-rer attaches the shim plates to the crank-case or cylinder. They are not included inthe set of gaskets. To order them separately, please quote thefollowing part numbers:036 330 00 0.10 mm036 388 00 0.15 mm036 329 00 0.20 mm

69

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3L / M . . 01.97

Installing cylinder assembly on H 3 L 30:- Set pistons ,,1“ and ,,3“ to approximately

the same height and attach piston ringclamping tools - 17 -; attach piston ringclamping strap 622 469 00 to the centre pi-ston; see Fig. 71.

- With the help of a second person, carefullyplace the cylinder assembly in position andinsert auxiliary pins 621 646 00 into therecesses on pistons ,,1“ and ,,3“; see Fig.72.

- Lower the cylinder assembly and at thesame time move the auxiliary pins to andfro until the pistons enter the cylinders.

- Take off the piston ring clamping tools andmove the centre piston to and fro duringthe lowering movement until it enters its cy-linder.

- The ring clamping strap is pushed into thecylinder, and can then be pulled out of therectangular side opening in the crankcasewith the aid of a strong piece of wire.

Installing the cylinder assembly on the H 2 L 30:- Set both pistons to approximately the

same height and attach the piston ringclamping tools.

- Further installation work is as described forthe H 3 L 30, but without the work relatingto the centre cylinder.

71

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3 L / M . . 01.97

M 07.00 Cylinder head

M 07.10 Air-cooled engines

–

Prepar atory wor k:- Take off the enclosure hood.- Take off the exhaust-side enclosure and

the muffler (silencer); see A 03.00.- Unscrew and remove the air outlet shaft,

side panel and cross-member; see M 35.00.

- Unscrew and remove the cover plate andtake out the screws for the base plate; seeM 35.00.

- Take off the air cleaner.- Remove the injector; see M 14.00.

Dismantling:- Take off the cylinder-head (rocker) cover.- Unscrew the shouldered nuts (73/1) and

bolts (73/2).- Pull off the centering flanges (73/3).- Detach the support plate mounts.- Press the air guide housing and suction

shaft apart.- Lift off the support plate; see Fig. 74.- Detach the exhaust manifold and air intake

pipe.

Note:To simplify dismantling of the air intake pipe,it is best to unscrew and remove the air clea-ner (74/1).

- Lift off the cylinder head and remove thepushrod protective tubes.

Checking the cylinder head:- Inspect for cracked webs or worn valve ta-

pers.- Check the radius of the rocker pads for

wear.

73

74

3L / M . . 01.97

Installing:- Determine the gap between the cylinder

head and the piston at TDC.

Note:This gap should be re-measured whenevera cylinder, piston, conrod, crankshaft orcrankcase is renewed. Measure at all cylinders, with the enginecold.

- Clamp the cylinder down with a suitabletensioning strap, and use a depth gauge;see Fig. 75.

- Turn the engine over until the piston re-aches and passes through top dead centre(TDC).

- Measurement ,,a“ plus the thickness of gas-ket ,,b“ yields the gap dimension ,,S“ statedin Section 4; see Fig. 76.

75

76

3

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L / M . . 01.97

- Having established the correct gasketthickness, coat it with a little grease on thecylinder head side, and place it in the cen-tering collar on the cylinder head.

Note:Centering on the L 30 is not by means of acentering collar but with centering sleeves;the gasket has two centering holes; see Fig. 77.

- Insert the protective tubes (78/1) withspring (78/2), thrust rings (78/3) and O-ringseals (78/4) into the bore in the crankcase.

Note:Always renew the O-ring seals (78/4) duringcylinder or cylinder head repairs.

- Insert the pushrods (78/5).

- Attach the cylinder head, making sure thatthe protective tubes with O-ring seals enterthe corresponding holes in the cylinderhead correctly; see Fig. 79.

- Oil the stud bolt threads (79/1) and screwon the shouldered nuts.

Note:Apply sealant D or a permanently elasticsealant to the thread of stud bolt (79/2) andthe shouldered nut contact face (79/3).

77

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79

3L / M . . 01.97

- Screw the cylinder head on until it is rest-ing evenly on the cylinder, but without finaltightening.

- Align the cylinder head by attaching the ex-haust manifold; see Fig. 80.

- Install the support plate and the injectorcentering flanges.

- Tighten the cylinder head uniformly, in across-wise pattern, to the specified torque.

- Take off the exhaust manifold, attach thegaskets and install it again.

- Adjust valve clearances to the specified va-lues.

- Further installation work is as described forremoval, but in the reverse order.

80

3 L / M . . 01.97

M 07.00 Cylinder head

M 07.20 Overhauling cylinder head (air-cooled engines)

- 1 - 2 - 6 - 7 -

Preparatory work:- Removing cylinder head - see M 07.10.Dismantling cylinder head:- Place the cylinder head on the centering

collar.Note:On the L 30, pull out the centering sleeves(81/1).The cylinder head sealing face must not bescratched or otherwise damaged; alwaysuse a soft cloth or similar underlay.- Remove circlip (81/2) and pull off rockers

with shims (81/3).- Press spring plate (81/4) down with tool

- 6 - and remove the valve spring collets(81/5).

- Take out the valve springs with underlaywashers (81/6) and lift off the rocker hou-sing (81/7).

- Lift off the intermediate plate (81/8) andtake out the valve cone.

Checking parts:- Check the valve guides and valve stems

for score marks and correct dimensions;for values, see Section 4.

- Inspect the cylinder head for cracks (in themetal webs) or an uneven sealing surface.

- Renew the O-ring seals (81/9); on the L 30,seal them with silicone.

- Check the valve seat rings and valve co-nes for wear; for valve recess into cylinderhead, see Section 4.

- Check correct dimensions of rocker bush-ing, rocker shaft and rocker pad radius; forvalues, see Section 4.

81

3L / M . . 01.97

Assembling cylinder head:- If necessary, use a pressing-in tool - 1 - to

force out the valve guides; see Fig. 82.- Use the pressing-in tool again to insert the

new valve guides - 1 -.

Note:The correct pressing-in depth must be com-plied with; for projection, see Section 4.

- Using a hand-held reamer - 2 -, ream outthe valve guides to their nominal diameter;see Fig. 83.

- Re-machine the valve seats with a valveseat milling cutter; see Fig. 84.

Note:The valve seat must always be re-machinedafter installing new valve guides or before in-stalling new valves, but no more metal thanabsolutely necessary (no patches anywhereon circumference of valve seat).

82

83

84

3 L / M . . 01.97

- Insert valves into valve guide. Lap the valve cones with grinding paste(grade: 180-250).

Note:To check the lapped valve seats, clean thevalves, insert them and pour a small amountof diesel oil into the inlet and exhaust ports.No fuel should seep through past the valveseats.

Assembling the cylinder head:- To assemble the cylinder head, follow the

dismantling instructions in reverse as ap-propriate.

Note:- Engines built in 1979 - 1983 have one

spring per valve; from 1984 onwards, twosprings per valve were installed. If repairwork is carried out in this area, the secondvalve spring should be retrofitted.

- On M 31/M 40 engines up to 2300 min-1,cylinder heads with the code letter ,,H“(high swirl) are used; above 2300 rpm thecylinder head code letter is ,,L“ (low swirl).These code letters are stamped in the inletport.

- On engines built from mid-1986 on with arunning speed below 2300 rpm the longitu-dinally slotted rocker and valve stem sealadjusting screws are used; these screwswere installed on all engines from mid-1989 onwards. Retrofit these screws if re-pairs are carried out.

- Before pressing on the valve stem seals,insert the valves into the valve guides.Press the seals on with assembly tool - 7 -.

3L / M . . 01.97

M 07.00 Cylinder head

M 07.30 Water-cooled engines (H.L 30)

–

Preparatory work:- Drain the coolant and unscrew the coolant

lines from the cylinder head.- Take off the exhaust system and exhaust

manifold.- Take off the air cleaner and detach the air

intake flange.- Remove the injectors.

Dismantling:- Take off the cylinder head cover; Fig. 85.- Slacken off the shouldered nuts by half a

turn (85/4) in the reverse of the ordershown in Fig. 86 or 87.

- Unscrew and remove the nuts in the sameorder. Unscrew the hex nuts (85/5) with springwashers (85/6) and take off the rocker pe-destals.

- Lift off the cylinder head.- Take off the pushrods and protective tubes.- Take off the cylinder head gasket and sea-

ling rings.

Checking the cylinder head:- Visual inspection for cracks in webs.- Visual inspection of cylinder head sealing

face for unevenness.- Check pad radius on rockers for wear.

85

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3 L / M . . 01.97

Assembly:- Clean the sealing faces on the cylinder

head and cylinder. Clean the cylinder.

- Install a new cylinder head gasket (88/1)and sealing rings (88/2).

- Insert the protective tubes (88/3) withsprings (88/4), thrust rings (88/5) and newsealing rings (88/6) into the bore in thecrankcase. Grease the sealing ringsslightly.

- With the aid of a second person, place thecylinder head in position, making sure thatthe protective tubes with O-ring seals enterthe holes in the cylinder head correctly.

- Insert the pushrods.- Install the rocker pedestals. Make sure that

the adjusting screws are inserted correctlyinto the pushrods; if necessary, unscrewthem.

- Coat the thread of the tierod in the oil ca-vity with sealant D.

- Screw on the shouldered nuts and tightenthem by hand in the order 1 - 15 (Fig. 86 or87) until they are firmly against the cylinderhead.

- Tighten nuts 1 - 15 to half the specifiedtorque.

- Tighten nuts 1 - 15 to the full specifiedtorque..

- Adjust valve clearances.

Note:The valve clearance for engines with alumi-nium pushrods is 0.40 mm, for engines withsteel pushrods 0.20 mm.

- Further installation is by following the remo-val instructions in the opposite order.

88

3L / M . . 01.97

M 07.00 Cylinder head

M 07.40 Reconditioning the cylinder head (water-cooled engines)

- 1 - 2 - 6 - 7 -

Preparatory work:- Remove the cylinder head; see M 07.30.

Dismantling the cylinder head:- Remove the circlips (89/10) from the

rocker pedestal and pull off the rocker(89/11) with shim washers (89/12).

- Pull out the centering sleeves (89/1) andplace the cylinder head on its sealing sur-face.

Note:Do not scratch or otherwise damage the cy-linder head sealing face; always place a softcloth or similar underlay beneath it.

- Press the spring plate (89/2) down withtool - 6 - and remove the valve springcollets (89/3).

- Take out the valve springs (89/4) with un-derlay washers (89/6).

Note:Engines with a running speed of less than2300 rpm. are equipped with adjustingscrews with longitudinal slots for the rockers(89/13) and valve stem seals (89/5).You are recommended to retrofit thesescrews during subsequent repair work. Engines built up to and including 1983 (allrunning speeds) have single valve springs.During repairs you are recommended to in-stall double valve springs on engines whichrun at more than 2300 rpm.- Place the cylinder head on the exhaust

side and pull out valve cones (89/16 and 17).

- Take off cover (89/7) with sealing ring(89/8) and take out thermostat (89/9).

89

3 L / M . . 01.97

Checking parts:- Check correct dimensions of bushing for

rocker (89/14), rocker shaft (89/15) androcker pad radius. For values, see Section 4.

- Check valve guides and valve stems forwear; see Section 4.

- Inspect the cylinder head for cracks (inwebs) and unevenness of the sealing sur-face.

- Examine the valve seat rings and valvecollets for wear. Note valve recess in head;see Fig. 90 and Section 4.

Reconditioning cylinder head:- If necessary, press the valve guides out

with pressing-in tool - 1 -, Fig. 91.- Press in new valve guides with the same

tool - 1 -.

Note:The pressing-in depth must be correct; forprojection, see Fig. 92.

- Ream out the valve guides to nominal dia-meter with hand-held reamer - 2 -, Fig. 91.

- If the valve seats are leaking or have beendamaged locally, or after installing new val-ve guides, they must be remachined. Thisis carried out with special milling cutterswhich are available commercially.

- Only mill away sufficient metal to eliminatepatches on the surface of the valve seat.

- After this, lap in the valves with grinding pa-ste, grain size 180 - 250); see Fig. 91.

90

91

92

3L / M . . 01.97

Note:- To check the lapped valve seats, clean and

install the valves, then pour a small quan-tity of diesel oil into the inlet and exhaustports. No diesel oil should seep through past thevalve seats.

- Note correct valve recess measurement;see Fig. 90 and Section 4.

Assembling cylinder head:The cylinder head is assembled by followingthe removal procedure in the reverse order.

Before pressing on the valve stem seals, in-sert the valves into the valve guides. Pressthe seals on with assembly tool - 7 -.

3 L / M . . 01.97

M 10.00 Oil pump

- 13 -

Preparatory work:- Take off the timing case cover;

see M 11.00.

Dismantling:- Take out the machine screws (97/1) and lift

off the oil pump.- If necessary, pull out needle roller bearing

(98/1) with an internal puller.

Checking / repairs:- Examine the contact face for the shaft sea-

ling ring for score-marks.If the contact face is worn, a ,,wear sleeve“can be pushed over it. Use sealant E forthis purpose.Installation instructions are included withthe spare part.

Assembly:- Using a plastic-faced hammer, drive the

needle roller bearing flush into the crankca-se.

- Insert the oil pump with bearing journal intothe needle roller bearing and place it overthe centering sleeves.

- Insert and tighten the machine screws.

Note:- Apply sealant D to the machine screw for

hole (98/2).- Coat the endface of the oil pump which is

in contact with the crankcase with sealantB.

- Re-assemble the engine in the opposite or-der to that described for dismantling.

- When renewing the oil pump, make surethat the correct type is installed (2- / 3- or 4-cylinder engine).

97

98

3L / M . . 01.97

Checking oil pressure:- Unscrew the oil pressure sensing switch

and connect an oil pressure gauge with fle-xible hose - 13 - .

- Install the side panel and enclosure hood.- Start the engine and compare the oil pres-

sure when it is at regular operating tempe-rature. At n = 800 rpm min. 0.9 bar,see Fig. 99.

- Before assembly, coat the thread of the oilpressure sensing switch with sealant D.

99

3 L / M . . 01.97

M 11.00 Timing case cover

–

Prepar atory wor k:- Take off the exhaust silencer (muffler);

see A 03.00.- Take off the air guide housing;

see M 35.00 (engines with enclosure only)- Take off the fan; see M 13.00.- Take off the engine shutdown device;

see M 20.00.

DismantlingTiming ca se cover w ithout hydraulicpump drive:- Pull the hose off the crankcase breather

valve (100/1).Note:From 2 L 40.14, 3/4 L 40.13, M 41 and onthe M 31, M 40 and M 41 the hose connecti-on (101/2) for the crankcase breather hasbeen moved to the top of the crankcase.The valve (101/1) was bonded into the air in-take pipe until early 1987. Since then it hasbeen secured in the air intake pipe by two O-rings.- Remove the circlip (102/1) and coil spring

(102/2) from the pull rod of the engine shut-down device.From early 1996 an additional cup springand an O-ring have been installed to sealthe pull rod.

- Unscrew and remove the belt pulley(102/3) and the machine screws holdingthe timing case cover all round.

- Pull off the timing case cover and removethe gasket.

Checking par ts:- Check the timing case cover for cracks or

unevenness of the sealing surface.- Examine the shaft sealing ring for damage

and renew if necessary.- Press off the breather valve cap and exami-

ne the diaphragm for damage.

100

101

102

3L / M . . 01.97

DismantlingTiming case cover for hydraulic pump dri-ve:Additional work:- Take off the hydraulic lines and hydraulic

pump.- Pull out the driver (103/1).- Remove both machine screws (103/2)

including spring washer (103/3), plate(103/4) and gasket (103/5).

- After removing the timing case cover retai-ning screws (103/4) and taking off the ti-ming case cover (103/6) the support mount(103/9) is exposed and can be taken off af-ter removing the two screws (103/7) withspring washer (103/8).

Note:- On older L 30/L 40 / H.L 30 engines there

is no support mount for the hydraulic pumpdrive.

- H2L30 and H3L30 engines do not have ahydraulic belt tensioner. For this reasonthe pull rod is locked out of action by ahoop. A blank cover is fitted in place of theshutdown device; see Fig. 104.

Assembling:- Apply grease to the contact edge of the

shaft sealing ring.- Before fitting, coat new seals on both sides

with sealant H.- Install the timing case cover.- On the 2 and 3 L ... insert M 8 x 12 machi-

ne screws into holes (105/1) and (105/2)with sealant D.

103

104

105

3 L / M . . 01.97

- Further timing case cover attachment andengine assembly procedures are as descri-bed for removal, but working in the reverseorder.

Note:When renewing the breather valve, securethe new valve housing in the insert (105/3)with sealant E and then seal all round withsealant H.If the insert is renewed, use sealant C forbonding in.The hose spigot opening in the air intakepipe must face toward the intake port of cylinder 1.The position of the opening can be varied byinserting or removing spacing washers (onlyon engines with crankcase breather in ti-ming case cover).

3L / M . . 01.97

M 12.00 Extra-fuel device

M 12.10 with injection pump PFR 1K 80

–

Prepar atory wor k:- Detach the enclosure hood and side panel;

see M 35.00.- On twin-cylinder engines, detach the oil

filler pipe.

Dismantling:- Remove the screws for the extra-fuel de-

vice and take it off; see Fig. 106.

Dismantling the hydr aulic ex tra-fuel de-vice::- Take off the circlip (106/1), unscrew the

threaded pin (106/2) and push out cylinder(107/1).

- Take off the circlip (107/2) and pull out theend cover (107/3) and the piston (107/4)with spring (107/5).

- Take out circlip (107/6) with spring plate(107/7), spring (107/8) and ball (107/9).

Checking / r epair s:- Inspect the piston and cylinder of the extra-

fuel device for score-marks or worn areas.- Check the ball seat of the pressure relief

valve for wear marks.- Renew the O-ring seals.

Assembling the hy draulic extr a-fuel de-vice:- Assembly is as shown in Fig. 107, working

in the opposite order from dismantling.

106

107

3 L / M . . 01.97

Checking the extra-fuel device:- After assembly, check free movement of

the extra-fuel device’s piston by pulling itout and letting it slide back; see Fig. 108.

Attaching:- The extra-fuel device is installed by follow-

ing the removal instructions in the oppositeorder, taking particular care that the gasketis correctly installed as shown in Fig. 109and the scribed mark is noted. Apply seal-ant H to both sides of the gasket. Only athin coat should be applied, so that the oilin the extra-fuel device is not blocked. Install the machine screws with sealant D.

Adjusting the extra-fuel device:- Piston (107/4) also acts as the full-load

stop for the governor lever and is eccentri-cally located in the cylinder (107/1).

The effective stroke and therefore the maxi-mum injected fuel volume are adjusted byturning this cylinder. For effective stroke requirements and adjust-ing procedure, see M 14.00.If the same extra-fuel device is detachedand re-attached, the effective stroke doesnot have to be adjusted, provided that thesetting of the volume limiting eccentric wasnot altered.

108

109

3L / M . . 01.97

M 12.00 Extra-fuel device

M 12.20 with injection pump PFR 1K 90

- 34 -

Preparatory work:- see M 12.10.

Dismantling:- Pull terminal 7 off the solenoid valve (only

version with electric engine shutdown).- Remove the screw (111/28) with sealing

rings (111/36).- Make a scribed mark on the crankcase

and the monitoring block, so that the moni-toring block can later be re-attached in thesame position as before, and the originalpower setting is therefore retained.

- Take out the retaining screws (111/5) andtake off the engine monitoring block.

Dismantling the engine monitoring block:- Unscrew and remove the cover (111/9)

with sealing ring (111/10); on version withelectric engine shutdown, unscrew the so-lenoid valve (110/21) and take it off comple-te with sealing ring (110/23), armature(110/24) and spring (110/25).

- Remove the screw plug(111/8).- Take off the lock washer (111/26), pull up

shaft (111/12) take out lever (111/15), driveout locking collet (111/14) and removeshaft (111/12) from the housing.

- Remove circlip (111/22); hold eccentric(111/21), slacken off grub screw (111/17)and pull out the eccentric with springs(111/20,25) and piston (111/18).

110

111

3 L / M . . 01.97

Checking parts:- Examine the piston for score marks or

wear.- Check the valve seat (111/19) for wear.- Renew the O-rings.

Assembling the engine monitoring block:- Proceed in the opposite order of work to

that described for removal.Note:To install the piston, use auxiliary bushing - 34 -.

Assembly:- Move the speed control lever to the ,,Stop“

position.- To attach, follow the instructions for de-

taching the device in the reverse order.- Make sure that the gasket is correctly sea-

ted and note the scribed mark which indica-tes the correct position; install the machinescrews with sealant D.

Note:When attaching, make sure that lever(112/1) engages to the left of plate (112/2).To do this on engines with the lower idlespeed governed to ≥1700 rpm the shaft(111/12) must be turned counter-clockwisewhen assembling. Check when the monito-ring block is installed by turning shaft(111/12) counter-clockwise; it must thenmove back by itself to its initial position.

Adjusting the engine monitoring block:- The maximum fuel injection volume is adju-

sted by turning the piston (111/18). For theneed to adjust the fuel injection volume,and the correct procedure, see Section M14.00. If the same monitoring block is deta-ched and re-attached, the fuel injection vo-lume need not be adjusted, provided thatthe setting of piston (111/18) was not alte-red.

If the monitoring block is renewed or after ithas been repaired, the fuel injection volume(power setting) must always be adjusted.

112

3L / M . . 01.97

M 12.00 Extra-fuel device

M 12.30 with PFR 1K 90 injection pump (from L / M 31.12, M 40.16, 2 L 40.19, 3-4 L 40.18 and L / M 41)

- 34 -

Preparatory work:- see M 12.10.

Dismantling:- Detach plug connector (164/1) from engine

wiring harness (electric version only).- Take out machine screws (164/3) and de-

tach cover (164/4) and solenoid valve(164/5) with gasket (164/6).

- Make a scriber mark on the crankcase andthe servo block to ensure that they are in-stalled again in the same relative positionsand the power setting therefore remainsunchanged.

- Remove machine screws (164/2) and takeoff the servo block.

Checking / repairs:- Turn lever (165/1) in the ,,Start“ direction.

Shaft (165/2) is then turned by locking pin(165/3) and the sickle-pattern lever (165/4)moved to the starting position. When the lever is released, all elementsmust return to the ,,Stop“ position (Fig. 166).Ensure free movement if necessary bygreasing or oiling lightly.

- Press piston (167/8) by hand in the ,,Start“direction:The sickle-shaped lever must move to thestarting position, but return to the ,,Stop“position when the piston is released.

164

165

166

3 L / M . . 01.97

Dismantling the servo block:- Take off lock washer (164/7).- Hold piston (164/8), raise shaft (164/9) and

take out sickle-shaped lever (164/10).- Release piston (164/8) carefully and take it

out of the housing.- Drive out locking collet (164/11) and pull

shaft (164/9) out of the housing.- Take out grub screw (164/12).- Remove circlip (164/13) and take out was-

her (164/14) and eccentric disc (164/15).

Checking / repairs:- Examine piston for wear or score marks.- Renew gaskets.

Assembling the servo block:- Assemble in the opposite order of work to

that described for removal.When installing the piston, use bushing - 34 -.Note correct position of gasket (164/6) (oilhole).Apply sealant D to machine screws (164/3)and tighten them to a torque of 6.5 Nm.

Caution:If the tightening torque is too high, the servopiston may seize (distortion).

Installing:- Set the speed control lever to ,,Stop“.

Make sure that the gasket is installed inthe correct position (oil hole) and that thescriber markings are aligned. Insert machine screws (164/2) usingsealant D and noting their correct positi-ons; attach a lead seal. When attaching the monitoring block,make sure that sickle-shaped lever (166/4)is located at the left of stop (166/5).

167

Warning:The sickle-shaped lever must never beunder or to the right of the stop.- Screw the block on tightly.- Set the speed control to the ,,Start“ positi-

on and move piston (167/8) to and fro be-tween the start and stop positions. Withthe injection pump removed or the sidecover taken off, the governor lever canbe seen to perform the same movement.

3L / M . . 01.97

Checking valve solenoid:(Fig. 168)- without electric control:

Valve pin 2 is in the rest position; the connection between bores 3 and 4 isclosed.

- Apply the electric current to connection ,,7“(yellow wire):the valve pin must extend by app. 6 mm.F ≈ 15 - 20 N (loading can easily beovercome with the finger), free passage be-tween bores 3 and 4.

- Apply the electric current to connection ,,3“(green wire):the valve pin must extend fully.F ≈ 30 - 50 N (very difficult to overcomeloading with finger pressure), free passagebetween bores 3 and 4.

- If any repairs are made to the wiring, makesure that the plugs are wired up correctly(Fig. 169).

Note:When installing the valve solenoid or cover(164/4), note the correct installed position(this also applies to the gasket); holes 168/3and 5 must be aligned.

168

169

3 L / M . . 01.97

M 13.00 Fan

–

Prepar atory wor k:- Take off the exhaust-system capsule (en-

capsulated engines only) and the silencer(muffler); see A 03.00.

Encapsulated en gines: - Take off the capsule side panel, air outlet

duct, air guide housing and fan impeller;see M 35.00.

Non-encapsulated en gines:- Take off the cooling air guide.- Take off the hydraulic shutdown device;

see M 20.00.- Disconnect the battery.

Removing:- Mark and disconnect the wiring at the alter-

nator. - Take out screws (117/1).- Pull out the fan housing.

Checking par ts:- Check the fan housing sealing strips for

signs of damage; if necessary, attach newsealing strips with adhesive G.

Installing:- Apply a slip agent, e.g. Vaseline, to the

contact faces of the fan housing sealingstrips.

- Install the fan housing and check that thesealing strips are correctly positioned.

- Re-assemble the items removed from theengine in the opposite order of work to thatdescribed for their removal.

- Make sure that the Poly-V belt is installedaccurately.

Note:When connecting cables to the alternator,do not accidentally interchange them; seeFig. 118.

117

118

3L / M . . 01.97

M 14.00 Fuel injection equipment

M 14.00 Injection pump, functional check

- 5 -

Preparatory work:- Take off the capsule hood and side panel.- Detach the fuel delivery pipes from all in-

jector pumps, holding the pipe union to pre-vent it from turning.

Check injection pumps:(Fig. 182)- Attach test nozzle - 5 - with delivery pipe to

the injection pump you wish to check.- Cover the pressure valve holders on the

other injection pumps with absorbent clea-ning cloths.

- Move the speed control lever to the startposition and run the starter.

If the spray pattern is correct, the pump youhave checked is in good mechanical wor-king order (no pump element wear, no leaka-ge at pressure valve).

WARNING!Keep hands away from the injected fuelspray. The fuel spray from the injector nozzle cancause blood poisoning if it contacts the skin.

182

3 L / M . . 01.97

M 14.00 Fuel injection equipment

M 14.10 with injection pump PFR 1K 80

–

Prepar atory wor k:- Take off enclosure hood, side panel and co-

ver for air guide housing; see M 35.00.- Take off fuel filter and fuel delivery pump.- Take off guide plate for oil cooler on S/Z.- On engines with shutdown solenoid, to re-

move pump for cylinder 1 take off the star-ting charge device including the solenoid(see A 11.00); on the two-cylinder engine,also take off the oil filler pipe.

Removing the injection pump:- Set the speed control lever to a central po-

sition.- Remove the hex nuts for the injection

pump mounting, and pull out the injectionpump.

- Take off the shim washers.Note:- Do not install the shim washers at the

wrong points.- On four-cylinder engines, the hollow

restrictor screw for the injection pump atthe timing end has a return-flow restrictor.During repairs, make sure that the correcthollow screw is used, or else the volume offuel in the injection pump will be altered.

Removing the governor rod:- Take off the oil filler pipe, the starting char-

ge control device and all side covers.- Using water pump pliers, press out locking

pin (119/1) until the governor lever can bemoved to the flywheel end; see Fig. 119.

- Unscrew and remove the extended stubbolt or machine screw (119/2) at the in-jection pump for cylinder 1. This alsoacts as a travel limiter for the governorrod.

Note:This device is not fitted to older engines.- Disconnect tension spring (120/1) at the

governor rod (120/2) and pull out the go-vernor rod guide (120/3) with packingseals.

119

120

3L / M . . 01.97

- Drive locking collet (121/1) halfway into thepull rod with a suitable split pin driver.

- Turn the pull rod through 180° and pull outthe locking collet with water pump pliers.

- Take off the Poly-V-belt; see M 20.00. (The pull rod will be pulled out.)

- Pull the governor rod out towards theflywheel end; see Fig. 122.

Note:To remove the governor rod on Types ,,C“and ,,K“, the rear enclosure panel must be ta-ken off.

Checking parts:- Check the governor rod for score-marks in

the governor rod guide area.

Installing the governor rod:- Install the governor rod by following the in-

structions for its removal in the reverse or-der.

- After installing the governor rod, secure itsguide in position with the side cover: see Fig. 123.

Note:Play at the governor rod guide betweencrankcase and cover must not exceed 0.1 mm. If play is greater than this, insert packingseals between the crankcase and the gover-nor rod guide.

121

122

123

3 L / M . . 01.97

- Using the speed control lever, locate thegovernor rod so that the groove for the too-thed rack pin on the flywheel-end injectionpump is precisely in the centre of the mo-unting hole for the injection pump in thecrankcase; see Fig. 124.

- Check the position of the other groovesand if necessary reposition the sliding ele-ments on the governor rod.

- Insert the injection pumps and tightenthem in position.

- For adjusting work, see M 14.50.

Note:When installing the injection pumps, use theshim washers at the points from which theywere previously removed. The figure stam-ped next to the injection pump indicates thethickness of the shims, e.g. 75 = 0.75 mm.

124

3L / M . . 01.97

M 14.00 Fuel injection equipment

M 14.20 with injection pump PFR 1K 90

- 27 -

Preparatory work: - see M 14.10.

Removing the injection pump:- Insert locating pin - 27 - into the hollow-dril-

led stud bolt of pump 1 to lock the gover-nor rod in the ,,X“-Position (141/1).

- Remove the hex nuts and spring washerssecuring the injection pump.

- Pull out the injection pump.- Take off the paper gaskets and shim was-

her.Note:The installed positions of the gaskets, shimwashers and injection pumps must not bechanged, or else the start of fuel injectionwill be altered.

Removing and installing governor rod:- Pull out locking collet (170/5).- Remove the roller guide at the flywheel

end (paper washers 170/3 are used tocompensate for play); note the presence ofspring (170/4).

- Pull the governor rod out towards theflywheel.

- Install in the reverse order of work.Note:When installing the governor rod, the stoppin for the governor rod (126/2) must enga-ge between the governor lever (126/1) andthe leaf spring (126/3).

141

170

126

3 L / M . . 01.97

Installing the injection pump:- Connect the governor rod in the ,,X“-positi-

on.- When installing the injection pumps, use

the same shim washers and gaskets as before.

- Insert the injection pumps and, beforetightening, press them towards the cylinderand position them so that the scribed markon the pump flange is precisely alignedwith the corresponding notch on the crank-case (127/1).

Note:When installing a new injection pump, addup the figures on the pump flange and thecrankcase. The total of the two figures is thethickness of the shim washers with gasketsto be inserted, in tenths of a millimetre. Ne-ver use more than one steel shim washer.How to make up the seal pack:

Totalthickness

(mm)

Papergasket (mm)

Steelwasher(mm)

0.20.30.40.50.60.70.80.91.01.11.21.31.41.51.61.71.8

0.20.3

0.2 + 0.20.3 + 0.20.3 + 0.30.2 + 0.20.3 + 0.20.3 + 0.30.2 + 0.20.3 + 0.20.3 + 0.30.2 + 0.20.3 + 0.20.3 + 0.30.2 + 0.20.3 + 0.20.3 + 0.3

–––––

0.30.30.30.60.60.60.90.90.91.21.21.2

127

3L / M . . 01.97

M 14.00 Fuel injection equipment

M 14.30 Injector

- 4 - 37 -

Preparatory work:- Take off the enclosure hood and side pa-

nel; see M 35.00.

Removing:- Unscrew and remove fuel pressure pipe

(128/1) and oil leak-off line (128/2).

- Unscrew and remove loop for injector(128/3). Take out the injector and sealingring (129/1) using impact extractor tool - 4 -.

Functional check:- Connect extension tube with test pressure

gauge for fuel injection system - 37 - to thepressure tube connection for the injectionpump; see Fig. 129.

- Connect the injector to the tester, cover theremaining injection pumps over with cleancloths and start the engine.

Note:All injectors should be removed for this test. WARNING:Keep the hands away from the fuel sprayemerging from the injectors.The fuel spray from the injectors can causeblood poisoning.

128

129

3 L / M . . 01.97

- Check the spray pattern from the injectoras shown in Fig. 130.

Assembling:- Install the injectors using new sealing rings

and working in the opposite order to thatdescribed for their removal.

Note:- Place the seal on the injector so that the

soft, graphited side is at the top, towardsthe injector.

- Tighten the hex nuts to retain the injectorand the collar nuts on the pressure pipe tothe specified torques (see Section 4), hol-ding the pressure pipe connection on theinjection pump to prevent it from turning.

- The fuel pressure pipes from 2 L 40.17, 3/4L 40.16, M 40 L.13 and M 31 L have asmaller internal diameter and are identifiedby the section of hose pushed on to them.

130

3L / M . . 01.97

M 14.00 Fuel injection equipment

M 14.40 Injector nozzle

–

Prepar atory wor k:- Remove the injector; see M 14.30.

Dismantling:- Take off the collar nut (132/1) and remove

the nozzle with needle (132/2).- Take out spacer (132/3), pressure pin

(132/4), spring (132/5) and shim washers(132/6).

Checking parts:- Inspect the needle of the nozzle for score-

marks or signs of overheating.- The nozzle needle (132/2a) must, when

the nozzle is held vertical, slide down slo-wly and smoothly under its own weight onto its seat.

- Renew the nozzle if necessary.- Check the sealing faces on the nozzle hol-

der for damage.

Assembling:- Install the shim washers, spring, pressure

pin and spacer in the nozzle holder againas shown in Fig. 132, in the opposite orderfrom their removal.

- Attach the injector nozzle so that the pinson the spacer locate in the holes on thenozzle.

- Screw on the collar nut and tighten it.- Mount the injector on the tester and deter-

mine its fuel delivery pressure; for values,see Section 4.

- Correct the fuel delivery pressure by inser-ting shim washers:Thicker washers = higher delivery pressureThinner washers = lower delivery pressure0.15 mm ≈ 15 bar.

132

3

7

6

5

4

3

2a

2

1

L / M . . 01.97

M 14.00 Fuel injection equipment

M 14.50 Adjustment work with PFR 1K 80 injection pump(up to 2 L 40.16, 3-4 L 40.15, M 40.12, also L 30 and H.L 30)

- 10 - 11 - 29 -

Nature of repair Adjustmentsneeded

Notes

Removing and installingor exchanging com-plete injection pump

Repairinginjection pump

Synchronising

Install shims again at thepoint where they were removed

Injection pump must only be repairedby authorised workshop

Renewing camshaftfor injection pump

Renewing crankcase

Start of injection

Synchronising

Effective stroke

Measure effective stroke before removal and restorewhen installing

Removing and installinggovernor rod

Renewing governor rod

Synchronising

SynchronisingEffective stroke

Measure effective stroke before removal and restorewhen installing

Renewing starting chargecontrol

Effective strokeMeasure effective strokebefore removal and restorewhen installing

Conversion from injection-pump with control lip at top(start of series production)to pump with control lip atbottom (current seriesproduction status)

Start of injection

Synchronising

Effective stroke

All pumps on the enginemust be converted

For adjustment data see Section 4

Modifying thepower setting

Effective stroke Measure the original effectivestroke. Alter effective strokeonly by difference value

3L / M . . 01.97

1. Adjusting start of fuel delivery:

Note:Start the adjustment at the timing-end injecti-on pump.

- Move the speed control lever to the full-load position and secure it there.

- Remove the pressure tube connection andpressure valve at the injection pump.

- Screw the overflow device - 10 - into the in-jection pump.

- Screw the extension pin of the overflow de-vice into the dial gauge - 11 - and insert itin the overflow device; see Fig. 133.

- Connect the fuel feed line from the testtank.

Note:The test tank must be attached at least 200 mm (8 in) above the injection pump.

- Turn the crankshaft in the normal directionof rotation (counter-clockwise when loo-king at the flywheel), until the dial gaugeneedle starts to move.

- Open the fuel feed; fuel will emerge fromthe overflow device.

- To turn the engine over, attach a ratchetwith 1/2-inch square end to the squarerecess in the belt pulley.

- Continue to turn the engine over slowly un-til the fuel emerges from the overflow pipeslowly as separate droplets (about. 1 droplet every 5 - 6 seconds).

- This point is the start of fuel delivery.

133

3 L / M . . 01.97

- Read the angle in degrees at the inspecti-on hole in the connecting housing, andcompare it with the desired value in Secti-on 4. To take the reading, remove the pla-stic plug: see Fig. 134. On engines withouta connecting housing, the fixed mark isstamped on the crankcase.Note:On engines built before or in 1980, the ang-le in degrees is only stamped on the engi-ne for the first (timing-end) cylinder; onlytwo marks are provided for the other cylin-ders. The short mark (half diameter of inspectionhole) shows the angle for the start of deli-very, the long mark (full diameter of in-spection hole) shows the piston top deadcentre point.

- If necessary, correct the start of fuel deli-very as follows: If the reading is smaller than the desiredvalue: = fuel delivery starts too late. Remove shims.If the reading is larger than the desired va-lue:= fuel delivery starts too soon. Add more shims.

Note:Use a dial gauge as follows to determine thethickness of the shims needed to correct thevalue:

- Set the dial gauge to “0" at the actual startof fuel delivery, and turn the flywheel to thedesired start of fuel delivery. The dial gauge will now show the thick-ness of the shims to be inserted or remo-ved.

- Repeat the measurement procedure; thefuel drip from the overflow pipe on the adju-sting device must start precisely when thedesired value is reached.

- Carry out the measuring procedure at all in-jection pumps.

134

3L / M . . 01.97

2. Adjusting end of fuel delivery:

Note:Engines equipped with Type PFR 1K 80A439/2 injection pumps must be adjusted tothe correct end of the delivery stroke.- Prepare for the measuring procedure in

the same way as if the start of fuel deliveryis to be measured.

- Turn the crankshaft in the normal directionof engine rotation until the gauge needlebegins to move and the fuel emerging fromthe overflow pipe starts to drip slowly orceases to drip.

- Continue to turn the crankshaft slowly untilthe fuel just begins to drip from the over-flow pipe again (about 1 droplet every 5 - 6 seconds).

- This point is the end of fuel delivery.- The value obtained in this way must agree

with the desired value stated in Section 4.- If necessary, correct it as described above.

3. Synchronising injection pump delivery volume:- Move the governor rod by hand fully to the

right, to the ,,Stop“ position, and hold it the-re.

- Loosen all sliding elements (135/1) on thegovernor rod; the toothed rack on theflywheel-side injection pump must be in the,,Stop“ position.

- Move the sliding elements for the other in-jection pumps to the right (,,Stop“ position)until the pump toothed rack is against itsstop, and tighten there; see Fig. 135.

- Release the governor rod.- Before installing, coat the gaskets for the

cover and the starting charge device onboth sides with sealant H.Apply the sealant only as a very thin coa-ting to the starting charge device, to ensu-re that its oilway is not blocked when as-sembling.

- Coat all bolt threads for the cover and star-ting charge device with sealant D.

Note for engines from serial numberL 30.17, 2 L 40.15, 3 / 4 L 40.14, M 40.11on:

The governor rod travel limit screw(135/2) must be unscrewed during thiswork, or else the ,,Stop“ point for the pumpgovernor rods will not be reached.

135

3 L / M . . 01.97

4. Adjusting effective stroke:(on engines with start of delivery ad-justment)- Install the start charging device and re-

place the cover by hydraulic starting char-ge adjuster 619 845 00; see Fig. 136/3.

- Set the speed control lever to full load andsecure it there.

- Insert the overflow device with dial gauge,as described in the section ,,Adjusting startof fuel delivery“.

- Connect the fuel feed line from the testtank and open the shutoff tap; fuel willemerge from overflow device.

- Turn the crankshaft until the injection pumphas just reached the start of fuel delivery(about 1 droplet of fuel emerges every 5 -6 seconds).

- Set the dial gauge to zero and continue toturn the crankshaft in the normal directionof engine rotation until the dial gauge mo-ves from “0" to precisely the nominal ef-fective stroke value stated on the type pla-te.

- In this position, fuel should start to drip outof the overflow device again.

- If this is not the case, loosen grub screw(136/2) and turn the eccentric flow limiter(136/1) until the fuel begins to drip out slo-wly.

- When the setting is correct, retighten grubscrew (136/2), seal it with lacquer and in-stall the cover again in place of the adju-ster (136/3).

136

3L / M . . 01.97

5. Adjusting the effective stroke(on engines with end-of-delivery ad-justment):- Prepare for the adjustment in the same

way as described for start-of-delivery ad-justment.

- Set the injection pump to the end of fuel de-livery.

- Turn the crankshaft in the opposite directi-on to normal rotation until the dial gaugeshows the nominal effective stroke statedon the type plate.

- Correct if necessary as described above. To do this, use the starting charge wrench - 29 - (see Fig. 137).

- After adjusting correctly, tighten the grubscrew and seal it with lacquer.

- Remove the overflow device, install thepressure valve with pressure tube connecti-on and tighten to the specified torque.

137

6. Note on changing the power setting:

- Measure and make a note of the original power setting. Remember that as a result of tolerances the actual effective stroke setting may not coincide exactly with the effectivestroke value on the type plate.

- The effective stroke setting for the desired power is obtained from the original effectivestroke setting plus (for an increase in power) or minus (for a decrease in power) the difference between the two effective stroke values according to the adjustment data.

Example:

To change an L 30 engine from power output B to power output F:

Effective stroke for power output F from table: 1.14 mm– Effective stroke for power output B from table: 1.07 mmDifference between effective stroke values: 0.07 mmEffective stroke measured at engine: 1.05 mm+ difference value 0.07 mmNew effective stroke setting: 1.12 mm

3 L / M . . 01.97

M 14.00 Fuel injection equipment

M 14.60 Adjustment work with PFR 1K 90 injection pumps(from engine serial numbers 2 L 40.17, 3-4 L 40.16, M 40.13 on L 31 / 41 and M 31 / 41: all engines)

- 23 - 24 - 25 - 26 - 27 - 28 -

Inst. work Work needed on fuel injection system

Renew injectionpump

Start of injection (with shims); precise radial position of pump

Renewing governor rod

Marking crankcase with radial position of injection pumpsAdjusting injected volume for nominal power output

Renewing start charge control

Adjusting injected volume for nominal power outputAdjusting damper spring (generator operation only)

Renewing governor lever

Adjusting injected volume for nominal power output

Renewing injection pump camshaft

Marking crankcase for adjustment of start of fuel injectionAdjusting start of fuel injection

Renewing crankcase

Marking crankcase for adjustment of start of fuel injection and radial position of injection pumpsAdjusting start of fuel injectionAdjusting injected volume for nominal power output

Altering nominal engi-ne speed

Adjusting max. idle speedVarying injected volume for nominal power outputAdjusting damper spring (generator operation only)

Important note:The threaded connections for the injection pump pressure valves must not be opened, or else pump pre-calibration will be changed.

3L / M . . 01.97

1. Crankcase mark for adjusting start of fuel delivery:

- Insert measuring device - 25 - into the cali-brating device - 26 - and adjust it so thatboth needles of the dial gauge are at ,,0“;see Fig. 138.

- Insert the measuring device into the moun-ting hole on the injection pump and screwit down firmly. The correct cam must be onits base circle.

- Turn the flywheel in the normal direction ofengine rotation until the start-of-deliverymark on the flywheel (15° before TDC) forthe cylinder in question is aligned with thefixed mark on the crankcase or in the in-spection hole of the connecting housing;see Fig. 134.

- In this position, take the total dial gaugereading; see Fig. 139.

- From this total dial gauge reading, deduct2.15 ± 0.05 mm and stamp the remainingvalue (without +/- sign or decimal point)into the crankshaft as a tenths of millimetrevalue (140/1).Repeat this procedure for each pump mo-unting hole.

138

139

140

3 L / M . . 01.97

2. Marking the crankcase for the radial position of the injection pumps:

- Insert the locating pin - 27 - into the hollow-drilled stud bolt of pump 1 to lock the go-vernor rod in position ,,X“ (141/1).

- Insert the marking device - 23 - into the in-jection pump mounting hole, turn clockwiseto make proper contact and stamp themark on the crankcase; see Fig. 142.Make this mark for each injection pumpmounting hole.

3. Adjusting injection volume for nominal power output (engine stopped)

- Move the speed control lever to the ,,Stop“position.

- Remove the screw plug from the monito-ring block housing or replace the valve so-lenoid by the plate of the adjusting tool -28-, then use a depth gauge to measure thedistance ,,S“ from the outer edge to the flatface on the piston inside; see Fig. 143.

- Screw in the injection volume adjustingtool - 28 -, using a number of copper sea-ling rings according to the following table:

S(mm) Number of sealing rings

≤ 11.3>11.3

21

see also Fig. 143.

141

142

143

3L / M . . 01.97

- Remove the second injection pump (loo-king from the timing end) and install mea-suring device - 24 - in its place (the ballend on the vertical lever must engage inthe driving slot of the governor rod); see Fig. 144.

- Loosen the grub screw (146/1).- Turn the adjusting screw (19 mm across

flats) by 1/8 of a turn counter-clockwise.- Move the speed control lever to the star-

ting position.- Insert locating pin - 27 - into the hollow-dril-

led stud bolt, then turn the adjusting screwslowly clockwise until the locating pin enga-ges under light pressure in the correspon-ding slot of the governor rod; Figs. 141 and145. This determines the ,,X“ position of the governor rod.

- In this position, set the dial gauge scale onthe adjusting device precisely to ,,0“.

- Pull out the locating pin; the needle of thedial gauge should then move by 0.01 - 0.02 mm.

- Determine the governor rod travel statedon the type plate (the figure is inhundredths of a millimetre).

- Turn the injection volume adjusting tool un-til the dial gauge shows the control distan-ce needed. Do not forget to allow for the0.01 - 0.02 mm already indicated by thedial gauge.

Note:A minus value (= lower power range) is ob-tained by turning the adjusting tool clockwi-se, a plus value (higher power) by turningcounter-clockwise.

- Tighten the grub screw (146/1) carefully toprevent this setting from being lost, andsecure it with lacquer.

144

145

146

3 L / M . . 01.97

- Replace the adjusting tool - 28 - by the screw plug again, using a suitable tool (e.g. screwdriver) to check that the engine monitoring piston slides smoothly. If it tends to stick, slightly reduce the preload at the grub screw (146/1) and repeat thecheck.

- Remove the adjusting device - 24 - and install the injection pump (M 14.20).

Note on changing the power setting

Adjustment data for a change in engine power can be obtained from your HATZ servicepoint. Proceed as follows to change the power setting:- Move the speed control lever to the stop position.- Screw in the injection volume adjusting tool - 28 -.- Move the speed control lever to the start position.- Install measuring device - 24 - and set the dial gauge to precisely ,,0“.- The governor rod travel for the desired power output is obtained from the original gover-

nor rod travel setting plus (for increased power) or minus (for decreased power) the diffe-rence from the adjustment data.

Example:

To change a 3 M 40 engine (n=3000 rpm) from power output B to power output F.Governor rod travel for output F acc. to adjustment data: +0.13 mmGovernor rod travel for output B acc. to adjustment data: -0.26 mmDifference from adjustment values: 0.39 mmThe adjusting tool - 28 - must therefore be turned counter-clockwise until the dial gaugeof the measuring device - 24 - reads 0.39 mm.

If the engine’s running speed is to be altered (with or without a change in power output),the following work is needed:- Set the engine speed to the new value.- Move the governor rod to position ,,X“ and set the dial gauge to ,,0“.- Turn the adjusting tool - 28 - until the dial gauge shows the governor rod travel called for

according to the type plate or adjustment data.

4. Adjusting the damping spring (generator operation, PV 187)

This adjustment can only take place with the engine running at the upper idle speed limitand off-load. In addition, the engine must have reached its regular operating temperature,or else the speed setting will not be accurate.- Turn the stop screw for the upper idle speed limit (146/2) until this speed is about 0.3 %

lower than the desired value according to the type plate.

Example:Type plate data 3000/60 = 3060 - 0.3 % = 3050 rpm. Make sure that the damping springis not yet touching the governor lever. Unscrew the grub screw (146/3) at the monitoringblock until no change in engine speed is detected. After this, retighten the grub screw(146/3) until the upper idle speed rises again by the same value of app. 0.3 %.

3L / M . . 01.97

M 17.00 Flywheel

–

Dismantling:- Remove bolts (148/3) and disc (148/2).- Screw in two suitable stud bolts to act as

guides.- Take off the flywheel.

Assembling:- Drive locking collet (148/1) into the end of

the crankshaft at the flywheel end to pro-vide the necessary centering action.

- Attach the flywheel so that the lockingcollet enters the centering hole.

- Place the disc (148/2) in position, insertthe bolts (148/3) and tighten them to thespecified torque.

148

3 L / M . . 01.97

M 20.00 Engine shutdown device / belt tensioner

- 20 - 21 - 39 -

Preparatory work:Engines with enclosure- Take off the cover for the air guide housing

and front impeller.Engines without enclosure- Take off belt guard, if fitted.

Removing:- Press back the tensioning roller and attach

the locking device - 39 - (Fig. 149).- Take out screws (150/3) with spring was-

hers and remove the drive pulley(150/4)(the drive pulley is not fitted fromyear of manufacture 1985 onwards).

- Pull the belt pulley (150/5) out of its cente-ring mount and take it off together with thePoly-V belt.

- Detach the oil line (150/1) and remove the3 machine screws (150/2) with spring was-hers.

- Detach the mount (150/7) at the coolingfan, noting the installed shims.

- Take off the engine shutdown device(150/6).

149

150

3L / M . . 01.97

Dismantling the engine shutdown de-vice: (from engine serial numbers L 30.15, 2 L 40.12, 3/4 L 40.11).- Remove the locking device.Warning:The piston with tensioning roller are spring-loaded; release the spring loading gradually.- Take out circlip (152/1).- Unscrew the nut (151/1) and take out the

machine screw (151/2) with sleeve (151/3)and washers (151/4) and (151/5), at thesame time forcing the tensioning roller(151/6) back slightly against its spring loa-ding.

- Carefully release the spring loading com-pletely and pull out the piston (152/3) withspring (152/6) and filler (152/7).Remove the support disc (152/2) and quadring (152/4) from the housing.

- Take the restrictor screw (153/1) out of theback of the housing.

- Press the shaft out of the piston and remo-ve the tensioning roller.

- Take off the Nilos rings (151/8). Drive theball bearings (151/9) out towards the outsi-de in each case, since a circlip (151/10) isinstalled between them.

- Take out the support disc (151/11).

Checking the parts:- Check the piston for the tensioning roller

and the bushings in the housing for score-or wear-marks. If damaged, renew the bus-hings or the piston. To renew the bushings, use special tools -20 - 21 - and press the bushings in asshown in Fig. 174.

- Check the tensioning roller ball bearingand renew if necessary.

- Renew quad rings (152/4) and (152/5).- Renew the tensioning roller or belt pulley if

any grooves are damaged or ribs brokenoff.

- Check that the bore in the restrictor screwis not blocked.

151

174

152

3

31

L / M . . 01.97

Assembling:- Assemble by following the dismantling pro-

cedure in the opposite order.- Make sure that the Poly-V belt is fitted cor-

rectly.

Assembly instructions:- Insert restrictor screw (153/1) with sealant

D.- Pack the Nilos rings (151/8) with anti-fricti-

on bearing grease when assembling.

Note for older versions of L 30 / L 40 engi-nes:- The circlip (152/1), support washer (152/2)

and quad rings (152/4) and (152/5) havebeen installed since 1980.

- A ball pressure-relief valve was installed in-stead of the restrictor screw (153/1) untilabout early 1982.

- A modified tensioning roller mount is usedfrom the L 30.15 / 2 L 40.12, 3/4 L 40.11onwards.

153

3L / M . . 01.97

M 22.00 Air cleaner

–

Dismantling:L-engines- Take off the enclosure hood.- Remove dirt adhering in the air cleaner

housing area.- Loosen screws (175/1) only sufficiently to

permit the complete air cleaner housing tobe raised.

- Cover the opening in the intake pipe to pre-vent dirt or other foreign bodies from ente-ring.

- Open the air cleaner housing and take outthe filter element (176/3).On three-cylinder engines, the cover(176/2) is also held with a clip (176/7).

M-engines- Release the clips (177/1) and take off the

air cleaner housing cover (177/2)- Remove dirt adhering in the region of the

air cleaner housing.- Slacken off screws (177/3) only enough to

permit the cover (177/4) with filter element(177/7) to be raised.

- Cover the opening in the suction pipe toprevent dirt and other foreign bodies fromentering.

Checking / repairs:- Check the sealing faces for signs of dama-

ge.- Clean the filter housing and the cover.Spacer ,,5“ is connected by an elastic sleeve,,6“ with the retaining screw, so that it cannotfall into the intake pipe during maintenancework.- If the spacer is loose, renew bushing ,,6“.

Assembling:- Follow the instructions in the reverse or-

der.

175

176

177

3

1

L3/58

3

6

5

4

5

21

3

7

L / M . . 01.97

M 31.00 Crankcase breather

–

General:The crankcase breather operates by way ofa diaphragm valve in the intake pipe.During maintenance or repair work, in par-ticular if the engine’s oil consumption is highor it is producing too much blue exhaustsmoke, you are recommended to check thecondition of the diaphragm.

Dismantling:- Pull housing 1 with cap 2 and diaphragm

3 out of the intake manifold and hose 4(Fig. 178).

- Pull cap 2 out of housing 1 and remove dia-phragm 3.

Checking / repairs- Examine the diaphragm for cracks and re-

new if necessary.- Renew O-rings 5.

Assembling:- Proceed in the opposite order to that de-

scribed above.

178

3

1

2

3 4

5

L / M . . 01.97

M 32.00 Speed control

M 32.10 Engines with PFR 1K 80 injection pump

–

Prepar ator y work:- Detach the enclosure hood.- Take off the speed control lever and the

side panel; see M 35.00.- Renew the oil cleaner.- On two-cylinder engines, unscrew and re-

move the oil filler pipe; see M 12.00.

Dismantl ing:- Remove machine screws (154/1).- Turn the speed control shaft counter-clock-

wise to the ,,Stop“ position and pull the go-vernor rod towards the flywheel end; see Fig. 155.

- As shown in Fig. (155/1), move the gover-nor lever over to the timing side and pull itout downwards.

Dismantling the speed control:- Pull out the cotter pin or locking collet

(156/1) and push out the bolt (156/2).- Drive out the locking collet (156/3), pull off

the torsion spring (156/4) and sleeve(156/5), drive out locking collet (156/6) andpull off the speed control fork (156/7).

- Unscrew the tensioning plate (156/8) andremove circlip (156/10), support washer(156/11) and shim(s) (156/12).

- Pull off governor shaft stop (156/13), remo-ve circlip (156/14) with spacing washer(156/15) and pull out shaft (156/9).

154

155

156

3 L / M . . 01.97

Checking / repairs:- Check ball bearing at governor lever for

wear.- Check governor lever, pin for speed con-

trol, fork, adjusting shaft and housing forscore-marks; renew parts if damaged.

Assembling:- Push in the shaft and install the spacing

washer, circlip, governor shaft stop,shim(s), support disc, circlip and ten-sioning plate. Push on the fork (157/3) and drive the lock-ing collet 157/4) in flush with the fork; seeFig. 157.

- Push on the sleeve (158/1) and torsionspring (158/2), then drive in the lockingcollet (157/4) flush with the fork; see Fig.158. Preload torsion spring (158/2) by aquarter-turn clockwise, then connect to thelocking collet.

- Further assembly is in the reverse order tothat described for dismantling; use a newgasket.

- Apply sealant D to screws (154/1) when in-serting.

157

158

3L / M . . 01.97

M 32.00 Speed control

M 32.20 Engines with PFR 1K 90 injection pump

–

Dismantling:- Remove machine screws (154/1).- Turn the speed control shaft anti-clockwise

to the ,,Stop“ position and pull the governorrod towards the flywheel end of the engine;see Fig. 179.

- Turn speed control mount (179/1) to theright and pass governor lever (179/2) un-der governor rod (179/3).

- Carefully pull the speed control mount outdownwards.

Dismantling the speed control:(Bild 180)- Drive out locking collet 1.- Slide out pin 2 and take off governor lever 3.- Take out locking collet 4 for stop 5 and pull

out control shaft 6.- Disconnect spring 7.- Drive out locking pin 8 and pull off fork 9.

Checking / repairs:- Check ball bearing at governor lever for

wear.- Check governor lever, speed control pin,

fork, control shaft and housing for scoremarks and renew all damaged parts.

154

179

180

3 L / M . . 01.97

Assembling:- Drive in locking collet (181/1) until it pro-

jects by 10.5 mm.- Insert spring (181/2) into fork (181/3) and

push on to control shaft.- Drive locking collet (181/4) in flush with the

fork and connect the spring to it, using asuitable tool.

- Continue installation by following the remo-val instructions in the reverse order.

Note:Since there are various patterns of governorlever, make sure when repairing the speedcontrol that the original governor lever is in-stalled again.If the governor lever or the conplete speedcontrol is renewed, note that torque equali-sation may have been activated at the origi-nal governor lever.In case of doubt, contact your nearest HATZservice point.

181

3L / M . . 01.97

M 35.00 Capsule

–

Prepar ator y work:- Remove the engine.

Note:It is normally only necessary to remove theengine from the equipment in which it isbeing used in order to dismantle the capsuleif the air guide housing or rear panel have tobe taken off.

- Remove exhaust capsule; see A 03.00.

Dismantl ing:- Take off the hood (159/1), speed control le-

ver (159/2), side panel (159/3) and coverplate (159/4).

- Detach the air outlet shaft (160/1) and co-ver plate (160/2).

Note for 4 L 40 C:Take out the cooling air guide lining ele-ments.

- Take off the cross-member above the in-jectors and raise the engine slightly at itssuspension lug until the baseplate of theenclosure can be unscrewed and removed.

- Detach the feet from the engine.- When the feet have been removed, the

four 22 mm hex bolts used to attach the ba-seplate should be used to support the engi-ne.

159

160

3 L / M . . 01.97

- Unscrew the earth (ground) strap and the+ line from the rear panel of the enclosure.

- Take off the rear panel with intake duct;see Fig. 161.

- Unscrew the cover from the air guide hou-sing (162/1).

- Take out the screws holding the fan impel-ler (162/2) and remove the impeller.

- Take off the air guide housing; see Fig.163.

Checking the parts:- Examine the various sections of the enclo-

sure for damage.- Renew damaged or incomplete sealing

strips.

Assembling:- Assemble the enclosure by following the

dismantling instructions in the reverse or-der as appropriate.

Note:Make sure that all enclosure sections are ca-refully installed and that all sealing strips areseated correctly. Unless the enclosure iscompletely sealed, neither the potential levelof noise reduction nor adequate cooling canbe ensured.

161

162

163

3L / M . . 01.97

BestelluOrder foCommaPedido dOrdine p

Stück / Qt

TYP

MOTOR

MIN-1

Versanda

Post / Sur

Express /

1

2

3

4

5

6Versanda

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- die näch

- your ne

- votre st

- al servic

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4

4. Tables

L / M . . 01.97

Tightening torques for threaded connections

General requirements in Nm:

Nm ÷ 9.81(10) = kpmNm ÷ 1.3558 = lb.ft

ThreadStrength category

5.8 8.8 10.9 12.9

M 4 1.7 2.8 3.9 4.7

M 5 3.4 5.5 7.8 9.3

M 6 6.0 9.5 13 16

M 8 14 23 33 39

M 10 29 46 65 78

M 12 50 80 110 140

M 14 80 130 180 220

M 16 120 190 270 330

M 18 170 270 380 450

M 20 240 380 530 640

M 22 320 510 720 860

4 L / M . . 01.97

Tightening torques in Nm

Engine L 30L 31. M 31L 40. M 40L 41. M 41

Shouldered nuts on stud bolts (tierods) for cylinder head(Coat the tierod thread and washer contact face in the oil cavity with sealant D) 50 65

Big end bolts: M 10 x 1 (8 mm Allen screw)M 11 x 1 (10 mm Allen screw)

60–

60115

Machine screws for counterweights 65 65

Machine screws for end cover, flywheel end(Coat thread with sealant D) 10 10

Hex nuts for securing injectors 15 15

Pressure valve at injection pump 35 35

Collar nut for injector nozzle 85L41. M41

8540-50

Machine screws at balancing weight bearing journals (4-cyl.) 30 30

Machine screws at drive gearwheel for balancing weights (4-cyl.)(Coat thread with sealant D) 75 75

Hex nut for attaching spring bridge (governor) 25 25

Machine screws M 12 x190 (crankcase halves) 90 90

Flywheel bolts 135 200

Machine screws for gearwheel on crankshaft 30 30

Machine screws, M 6. for securing cam tracks(injection timer)

14 14

Hex bolts for connecting housing(Coat thread with sealant D)

140 140

Front engine feet support mount (Silent Pack) 130 130

Hex bolts for governor weight holder 25 25

Hex nut for cylinder head cover (pressure-cast version) – 10

Machine screws holding solenoid valve to engine monitoring block – 6.5

4L / M . . 01.97

Repair data

Cylinder head L 41 L 31. M 31M 41 L 40. M 40

L 30 H .L 30

Gap

Gasket at cylinder head

Shim washers 1)

mm

mm

mm

0.85-0.95 1.0 - 1.1

0.7 - 0.8 - 0.9 - 1.0 - 1.1 - 1.2

–

1.0 - 1.5

1.2

0.10 - 0.20

Valve clearance, cold(20±10°C)

mm 0.10 0.40 2)

Valve stemWear limit

∅ mm∅ mm

8.96-0.015

8.85

Inlet valve headExhaust valve head

∅ mm∅ mm

43.1-0.3

39.1-0.340.1-0.3

35.1-0.3

Recess of valve head max. mmmin. mm

0.15 1.700.00 0.85

outer

Valve guide inner

Wear limit inner

Bore in cylinder head

Pressing-in force

∅ mm

∅ mm

∅ mm

∅ mm

N

15+0.046

+0.038

9H6+0.009

0

9.05

15+0.006

-0.012

1000

Valve guide projection mm 20.5 23.5 (l=70.5) 20.5 (l=67.5)

20.5 14.5

Valve seat angle 45°

1) As required, between cylinder and crankcase2) If steel pushrods are used: 0.20 mm

4 L / M . . 01.97

Repair data

Cylinder head L 31. M 31L 40. M 40L 41. M 41

L 30 H .L30

Length of inner valve spring, off-load

Wear limit

Length of outervalve spring, off-load

Wear limit

mm

mm

mm

mm

45.5

44.0

58.0

56.5

Rocker shaft ∅ mm 19 f 6-0.020

-0.033

Wear limit ∅ mm 18.90

Bore in rocker ∅ mm 21 H 7+0.021

0

Rocker bushing inner ∅ mm 19+0.046

-0.012

Wear limit

Radius at rocker(no flats must have formed)

Rocker endplay(insert shims only on the circlip side)

inner ∅ mm

mm

mm

19.20

8

0.1 - 0.2

4L / M . . 01.97

Repair data

Camshafts (injection pump drive and valve gear)

Camshaft bearing journal diameters

Timing-gear side and cen-tre

mm 54 e 6-0.060

-0.079

Wear limit mm 53.85

Flywheel end(ball bearing seat)

mm 20 m 6+0.021

+0.008

Internal diameter of bearing bore in crankcase

Timing end mm 54 H 7+0.030

(bushing for. 54+0.058

0

camshaft) -0.002

Wear limit mm 54.10

Centre mm 54 H 7+0.030

0

Wear limit mm 54.10

Flywheel end (ball bearing seat)

mm 47 K 7-0.007

-0.018

Bore for tappetin crankcase

mm 16 H 7+0.018

0

Wear limit mm 16.05

Tappet shaft ∅ mm 16 f 7-0.016

-0.034

Wear limit mm 15.9

Camshaft endplay mm 0.1

4 L / M . . 01.97

Repair data

Balancing weights

Bearing point diameters – two– and three–cylinder engines

Balancing weight shaft mm 28 h 5 0

-0.009

Endplay – two–cylinder engines –three-cylinder engines

mmmm

0.15 - 0.60.15 - 0.7

Wear in the needle rollerbearing area

∅ mm down to 27.97

Bearing point diameters – four-cylinder engines

Bearing journals forbalancing weights

mm 44 d 6-0.080

-0.096

Bearing bushing for balancingweights (pressed-in)

mm 44+0.018

+0.083

Endplay mm 0.15 - 0.4

4L / M . . 01.97

Repair data

.L 30 / H .L30 .L 31 / .M 31.L 40 / .M 40

.L 41 / .M 41

Conrod

Bore for piston pin (small end)bushingBig end bore

Piston pin bushing external

pressed-in internal

Wear limit internalMax. misalignment*

∅ mm

∅ mm

∅ mm

∅ mm

∅ mmmm

35 H 6+0.016

0

63 H 6+0.019

0

35+0.085

+0.045

32+0.075

+0.030

32.300.08

39 H 6+0.016

0

67 H 6+0.019

0

39+0.085

+0.045

36+0.080

+0.035

36.300.08

Cylinder

BoreWear limitOversize

mmmmmm

95 +0.0195.15+1.0

102 +0.01102.15

+0.5 / +1.0**

Roughness Ra 0.9 - 1.3 µ (1µ= 1/1000 mm)

Piston

NormalOversizePlay max.Play min.

Piston pin bore

Wear limit

Piston pin

Wear limitPiston ring endplay max.

∅ mmmmmmmm

∅ mm

mm

∅ mm

mmmm

94.94+1.00.070.06

32+0.009

+0.004

32.05

32 0

-0.006

31.950.2

101.92 101.90+0.5 / +1.0**

0.09 0.110.08 0.10

36+0.010

+0.004

36.05

36 0

-0.006

35.950.2

4 L / M . . 01.97

Repair data

Piston rings.L30. H.L 30

Ring groove No. Designation DimensionsEnd gap mm:

normal max.1)

IStandard

Trapezoidal95 x 87 x 3

0.40 - 0.65 1.0Oversize 96 x 87.9 x 3

IIStandard Cutaway

micro-chamfer95 x 87 x 3

0.40 - 0.65 2.0Oversize 96 x 87.9 x 3

IIIStandard

D-ring95 x 87 x 5

0.30 - 0.60 2.0Oversize 96 x 87.9 x 5

Piston rings.L 31, .M 31, .L 40, .M 40, .L 41, .M 41,

Ring groove No. Designation DimensionsEnd gap mm:

normal max.1)

IStandard

Trapezoidal102 x 93.4 x 3

0.40 - 0.65 1.2Oversize

102.5 x 93.9 x 3103 x 94.4 x 3 *

IIStandard

Cutaway micro-chamfer

102 x 93.4 x 2.50.40 - 0.65 2.5

Oversize102.5 x 93.9 x 2.5103 x 94.4 x 2.5 *

IIIStandard

D-ring102 x 93.4 x 4

0.30 - 0.60 2.5Oversize

102.5 x 93.9 x 4103 x 94.4 x 4 *

1)These are maximum limit values which can still be accepted without risk of engine power output, oil consumption and exhaust emissions being affected.The piston rings should be renewed duringrepair work if they have worn to 60 % ofthe limit value.

* These oversize piston rings are no longeravailable.

4L / M . . 01.97

Repair data

Crankshaft.L 30 / H .L 30

.L 31 / .M 31

.L 40 / .M 40

.L 41 / .M 41

Crankpins

Wear limit

∅ mm

mm

60 h 6 0

-0.019

59.88

64 h 6 0

-0.019

63.88

Out-of-roundness max.Conicity max.

mmmm

0.050.003

Width

Radius

mm

mm

32 H 9+0.062

0

3.5

32 H 9+0.062

0

4.0 +0.3

Centre bearing journal

Out-of-roundness max.Conicity max.Width

∅ mm

mmmmmm

72 h 6 0

-0.019

0.050.003

32 +0.3

Radius mm 3.5 -0.2 3.75 -0.2

Main bearing journal, timing endOut-of-roundness max.Conicity max.WidthRadius

∅ mm

mmmmmmmm

72 h 6 0

-0.019

0.050.00326.5 -0.2

3.5 -0.2

Main bearing journal. flywheel endOut-of-roundness max.Conicity max.

∅ mm

mmmm

72 h 6 0

-0.019

0.050.003

WidthRadius

Contact face for shaftsealing ring, flywheel side

mmmm

∅ mm

27 ±0.23.5 -0.2

70 h 11 0

-0.190

32 +0.33.75 -0.2

80 h 11 0

-0.190

4 L / M . . 01.97

Repair data

Crankshaft.L 30 / H .L 30

.L 31 / .M 31

.L 40 / .M 40

.L 41 / .M 41

Regrinding during repairsHardnessHardening depth

mmRc

mm

0.550 - 55

2.5

Big end bearing, internal (installed)Normal

Wear limit

Undersize

Wear limit

∅ mm

∅ mm

∅ mm

∅ mm

60+0.083

+0.040

60.20

59.5+0.083

+0.040

59.7

64+0.063

+0.040

64.20

63.5+0.083

+0.040

63.7

Wall thickness, normalUndersize

mmmm

1.468 - 1.4801.718 - 1.730

Main bearing, internal (installed)Normal

Wear limit

Undersize

Wear limitWall thickness, normalUndersize

∅ mm

∅ mm

∅ mm

∅ mmmmmm

72+0.099

+0.056

72.25

71.5+0.099

+0.056

71.752.960 - 2.9723.210 - 3.222

Crankshaft endplay mm 0.15 - 0.65

Max. permissible bearingplay after wear mm 0.3

4L / M . . 01.97

Fuel injection equipment

Up to engine serial numbers: 2 L 40.16. 3 - 4 L 40.15. .M 40.12. L 30 and H.L 30

Engine type Injection pump HATZ Ident No.Start of delivery

2 - 4 L 30H .L 30

PFR 1 K 80 A 442/2 1)

17 - 18°before TDC

PFR 1 K 80 A 442/11 1)

PFR 1 K 80 A 467 1) 2) 501 407 00

PFR 1 K 80 A 467 3) 501 407 10

2 - 4 L 402 - 4 M 40

PFR 1 K 80 A 477 2) 502 368 00 17 - 18°before TDCPFR 1 K 80 A 477 3) 502 368 10

1) Interchangeable2) With governor-rod stop at pump3) Without governor-rod stop at pump:

governor-rod limiter needed on engine

From engine serial No.: 2 L 40.17. 3 - 4 L 40.16. M 40.13. L 31. M 31. L 41. M 41

Engine type Injection pump HATZ Ident No.Start of delivery

L 31. M 31L 40. M 40

PFR 1 K 90 A 498 502 630 0015°

before TDC

L 41. M 41 PFR 1 K 90 A 546 504 442 0110°

before TDC

Injectors

Engine type HATZ-Ident-No.Injector nozzle Spray

pressureBosch HATZ

L 30. H.L 30L 31. M 31L 40. M 40

401 209 01 DLLA 160 S 908 501 413 01 250 +8

bar

L 41. M 41 504 440 00 DSLA 150 P 645 504 441 00 230 +12

bar

4 L / M . . 01.97

Governors

L 30. H .L30

Speed ApplicationGovernor spring Governor weight

Ident-No.Ident-No. Wire ∅ mm

≤ 2300 Normal operation

036 012 01 3.0

035 729 00> 2300 035 744 01 3.2

1500 *Generator

drive

036 014 01 2.5

1800 * 036 013 01 2.6

3000 035 744 01 3.2* When driving a generator at 1500 and 1800 rpm governor weights with Ident No.

036 349 00 were used from 1979 to 1982. They are identifiable by a ,,G“ stamped on the end or a white spot.If needed, renew these governor weights as a complete set, since governor weights with Ident-No. 035 729 00 are now installed for all running-speed ranges.

L 40. M 40 with injection pumps PFR 1K 80A 477

Speed ApplicationGovernor spring Governor weight

Ident-No.Ident-No. Wire ∅ mm

≤ 2300 Normal operation

036 012 01 3.0

035 729 00> 2300 035 744 01 3.2

1500Generator

drive

037 739 00 2.5 *

1800 036 013 01 2.6

3000 035 744 01 3.2 * Identifiction: windings are ground away slightly at circumference.

L 31. M 31. L 40. M 40 with injection pump PFR 1K 90A 498 and L 41 and M 41

Speed ApplicationGovernor spring Governor weight

Ident-No.Ident-No. Wire ∅ mm

≤ 2300 Normal operation

036 012 01 3.0

035 729 00

> 2300 035 744 01 3.2

1500

Generator drive

038 670 00 2.3 *

1500 036 014 01 2.5

1800 036 013 01 2.6

3000 035 744 01 3.2 * With this governor spring the spacing ring, Ident No. 037 729 00, is deleted

(Fig. 48a/50)

4L / M . . 01.97

Lubricating oil content and dipstick

Engine type Oil sumpOil content

lDipstickmarking

Two-cylinder engines.L.. C / Z

withwithout

7.54.5

CA

.L.. S. M..with

without8.55.5

CA

Three-cylinderengines.L.. C / Z

withwithout

10.58.0

DA

.L.. S. M..with

without11.08.5

DA

Four-cylinder engines.L.. C / Z with 13 D

.L.. S. M.. with 14 D

Note:The lubricating oil contents stated here are to be understood as approximate; they applyto engines with a lubricating oil cooler and refer to oil changes including renewal of thelubricating oil filter.

In certain cases engines of versions ,,S“ and ,,Z“ are not equipped with an oil cooler. Inthis case the oil content is reduced by app. 0.2 - 0.5 litre.

In all cases fill to the ,,Max“ mark on the dipstick.

4 L / M . . 01.97

Key to circuit diagrams (DIN 40719)

Key Designation of electrical componentA 1A 2A 3A 4

Instrument boxInstrument panelAutomatic start-stopStarter protection module

B 1B 2B 3B 4

Temperature sensorSpeed pulse transmitterOil pressure sensorSignal horn

C 1 CondenserE 1 Fuel filter heaterF 1 FuseG 1G 2G 3

BatteryAlternatorFlywheel generator

H 1H 2H 3H 4H 5H 6H 7H 8

Generator telltale lightOil pressure warning lightEngine overheat warning lightAir cleaner telltale light (maintenance switch)Belt break warning lightPre-heat monitor telltale lightFan monitor warning lightRemote display: engine running

K 1K 2K 3K 4K 5K 6K 7K 8

Control relay 1 for start / start repeat interlockControl relay 2 for pre-heatingControl relay 3 for speed controlEngine protection relayDelaying relayStart inhibit relayTimer (impulse) relayPower relay

M 1MG

Starter motorStarter generator

N 1N 2N 3N 4

Voltage regulator for starter generatorVoltage regulator for flywheel generatorVoltage regulator for alternator (unless integrated)Pulse transmitter (additional item for synchro-regulator)

4L / M . . 01.97

Key to circuit diagrams (DIN 40719)

Key Designation of electrical componentP 1P 2P 3

Operating hours counterRevolution counterPressure gauge

R 1R 2R 3R 4R 5

Pre-heat plugHeating flangeLine resistor for pre-heat systemResistorLine resistor with thermo-times switch

S 1S 2S 3S 4S 5S 6S 7S 8S 9S 10S 11S 12

Pre-heat start switch (5-position)Master switchPre-heat/start switch (3-position)Start-stop-switchSwich for speed controlEngine temperature switchOil pressure switchPressure switch for air-cleanerFan monitoring switchPre-heat temperature switchRemote-start switchRemote stop switch

T 1 Transducer for speed measurementV 1V 2V 3V 4

Decoupling diodeFreewheeling diodeZener diodeSuppressor diode

W 1W 2

Earth (ground), negative return lineScreened line at generator

X 1X 2X 3X 4X 5

Terminal strip at instrument boxFlat-pin junction boxPlug at emergency stop switchSocket at emergency stop switchTerminal block in control box / terminal box

Y 1Y 2Y 3Y 4Y 5

Solenoid for speed controlSolenoid for engine shutdownServo (valve) solenoid for engine shutdownFuel shut-off valveHigh-pressure shut-down valve

Z 1Z 2

Suppressor chokeSuppressor capacitor

4 L / M . . 01.97

HATZ - Wiring identification

Terminal Designation0 Earth (ground)1 Alternator B+2 With alternator: D+

With flywheel generator: terminal L at voltage regulator3 Starter terminal 504 Oil pressure switch5 Temperature switch on cylinder head6 Pre-heat plug I7 Engine shut-down solenoid8 Pre-heat II9 Start-stop input

10 Positive terminal for DC fine speed control motor11 Negative terminal for DC fine speed control motor12 Oil pressure sensor13 * * * Reserved for special purpose * * *14 Speed control solenoid hold-on winding15 * * * Reserved for special purpose * * *16 Decompression solenoid17 Air cleaner maintenance switch18 Engine shut-down solenoid (energizing winding)19 Temperature sensor on cylinder head20 Oil temperature switch21 Fan monitoring switch22 Terminal W for engine speed measurement23 Starter 30 (if ammeter is connected)24 Terminal C if voltage regulator is on flywheel generator25 Oil temperature sensor26 Terminal 50f at starter protection module27 * * * Reserved * * *28 Speed control solenoid (energizing winding)29 * * * Reserved * * *

4L / M . . 01.97

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Trouble-shooting table for electrical system

Trouble-shooting at instrument box

Malfunction Cause RemedyStarter remains enga-ged although pre-heat/starter switchwas released.

Pre-heat/starter switch sticks inposition 3 after starting and doesnot return automatically toposition I.

Set pre-heat/starter immediatelyto 0 by force; if this is notpossible, disconnect the batteryat once.(If the starter remains engagedfor more than 2 to 3 minutes, itwill burn out.)Renew the pre-heat/starter switch.

Alternator telltalelight does not comeon when engine isstopped and pre-heat/starter switch is on.

Bulb has blown or contacts arecorroded.

Insert a new bulb, clean the contacts.

Battery is flat. Recharge the battery.Battery is defective (internalshort-circuits or sulphatised).

Renew the battery.

Defective pre-heat/starter switch,poor connections, defectivewiring, contact resistance incharging current circuit or line togenerator telltale light.

Eliminate contact resistance,renew wiring, tighten looseterminals, if necessary renew pre-heat/starter switch.

Defective voltage regulator. Renew voltage regulator.Short-circuit at exciter or positivediode in generator.

Disconnect charge line B+ (toprevent discharge at a standstill),have generator repaired.

Worn carbon brushes. Renew carbon brushes.Oxide desposit on sliprings,exciter winding is interrupted.

Have generator repaired.

Generator telltalelight flickers.

V-belt loose at generator. Correct V-belt tension.

Generator telltalelight continues toglow, after startingengine.

Poor earth (ground) connectionin instrument box.

Make a clean earth connection inthe instrument box.

Wiring error, e.g. generatortelltale light leads to oil pressureswitch.

Check the line from the generatortelltale light to the generator andcorrect the wiring if necessary.

4 L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the battery

Malfunction Indication Cause RemedyBattery notrecharged,recharged toolittle or goesflat rapidly.

Terminal voltagedrops even a shorttime after rechargingto 7 V despite a 12 Vnominal voltage (or 14 V if nominalvoltage is 24 V).

Poor connections, opencircuit or contactresistance in chargingcircuit, short-circuit inline.

Eliminate the opencircuit, clean theterminals, tightenterminals if slack.

Battery defective, internalshort-circuit.

Renew battery.

Capacity of battery hasdropped severely,because it was heavilydischarged for a lengthyperiod (greyish-white cellplates = ,,sulphatised“).

Recharge battery at lowcurrent (app. 1/40 ofNominal capacity inAmps) for about 50hours. (This is onlypossible if sulphatecoating is not yet toostron.)Otherwise: renew the battery.

Battery poles connectedup wrongly, destroyingone or more diodes inthe generator.

Have generator repaired.

Charge current too weak(esp. in winter).

Recharge the battery.

Battery capacity is toolarge.

Install a smaller batteryor a larger generator.

Defective voltageregulator (e.g.overheated/overloaded).

Renew the voltageregulator.

Loose V-belt at generator. Correct V-belt tension.

4L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the battery

Malfunction Indication Cause RemedyCorroded termi-nal clips.

Inadequate currentflow, white saltdeposits.

Sulphuric acid attacsmetals (except lead).

Wash down terminals withhot soda lye (but thismust not enter thebattery!), rinse with coldwater and apply acid-resistant grease.

Battery isovercharged.

Voltage at terminalsis always above 16.5V with 12 V nominalvoltage (or above 33 V with 24 Vnominal votage),specific gravity ofacid is above 1.285kg/l so that thebattery boils.

Charging voltage toohigh.

Check voltage regulator,renew if necessary.

Capacity of chosenbattery is too small.

Install a battery oflarger capacity. As atemporary measure,discharge the battery atintervals, e.g. byswitching on anelectrical consumerwhen the engine is notrunning

Engine was runcontinuously (severaldays) with very littleelectrical consumption(e.g. as a boat engine).

Install a voltage regulatorwith a differentcharacteristic (lowercharge-end voltage).

Defect in voltageregulator or generator.

Have the voltage regulatorand generator checked,renew defectivecomponents.

Acid is escaping fromthe cell plugs.

Acid level is too high. Siphon off excess acid.

Acid level is tolow

Acid level less than10 mm (0.4 in) belowtop of cell plates.

Overloading or naturalwater loss byevaporation(particularly insummer).

Add distilled water ordemineralised water.

4 L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the batteryMalfunction Indication Cause RemedyBattery failsprematurely.

Battery was dischargedtoo often and tooserverely.

Check ratings of battery andgenerator, if necessary fit aspecial ,,Z“ or ,,HD“ battery.

Battery becomes toowarm.

Install it at a more favourablepoint.

Excessive vibration. Install battery at a morefavourable point or use an ,,Rf“battery (shakeproof)

Battery is dischargingsulphates.

Charge the battery at a smallcurrent level (app. 1/40 of itsnorminal capacity in Amps) forabout 50 hours.Failing this, renew the battery.

Battery acid iscontaminated.

Renew the battery.

Too little po-wer from battery.

Voltage dropsseverely whenload is applied.

Run the battery down. Recharge battery with asuitable charger.

Voltage regulator isdefective, so thatcharging voltage is toolow.

Renew voltage regulator ongenerator.

Connecting terminalsloose or oxidised.

Clean the terminal clips andapply acid-proof grease tothem, then retighten theterminal clips.

Battery capacity is toosmall (too manyconsumers).

Install a larger battery and ifnecessary a larger generator.

Battery is going flatbecause of impurities inits acid.

Renew the battery.

Sulphate deposits frombattery (white coating onplates).

Charge the battery for app. 50hours at a low current.

Battery is exhausted,active substance hasfallen out of plates.

Renew the battery.

Acid level too low. Top up with distilled water.

4L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the battery

Malfunction Indication Cause RemedyRate of chargenever adequate.

Terminal voltagesoon drops to 7 Vafter recharging (12 V nominalvoltage) or to 14 V(24 V nominalvoltage).

Fault in generator,voltage regulator orwiring connections.

Repair or renewgenerator and voltageregulater. Connect wiringfirmly.

V-belt too loose. Correct tension or renewV-belt.

To many consumersconnected or generatoris too small.

Install battery andgenerator with similarratings.

4 L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the starting device

Malfunction Indication Cause RemedyStarter motordoes not turnwhen pre-heat/startswitch is ope-rated.

Generator telltalelight does notcome on.

Poor connections (looseor corroded), break incable or short to earth(ground).

Check battery lead andconnections, clean batteryposts and terminals, makesure connections are clean.

Battery flat or defective. Recharge or renew battery.Telltale light growsslowly dimmerwhen pre-heat/startswitch is operated.

Battery is flat. Recharge the battery.

Telltale light is onbrightly.Bridge terminals 30and 50 briefly atthe starter motor,the starter thenturns.

Line between terminal 50and starter switch orbetween terminal 30 andbattery is interrupted orstarter switch is faulty.

Repair the break or ifnecessary renew thestarter switch.

Starter inhibit relay ordelaying relay defective.

Renew defective relay.

Telltale light burnsbrightly. Terminal30 is not connectedto positive batterypole.

Starter pre-engagementwinding has burned out.

Renew the starter motorand ensure a goodconnection betweenterminal 30 at the starterand the positive batterypost (main starter line).

Telltale light burnsbrightly, solenoidswitch is energised,when solenoidswitch is bridged,starter motor turns.

Worn or dirty contacts onsolenoid switch.

Renew solenoid switch.

4L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the starting device

Malfunction Indication Cause RemedyStarter motorturns too slowlyor cannot turnthe engine over.

Lengthyoperating periodwithoutmaintenance orin toughenvironmentalcondition.

Carbon brushes sticking. Renew brushes and brushholder guides.

Carbon brushes worn. Renew carbon brushes.Poor spring pressure,carbon brushes notmaking contact.

Renew springs.

Commutator is dirty. Clean the commutator.Commutator is scoredor burnt.

Recondition or renew startermotor.

Armature or field coilsdefective.

Recondition or renew startermotor.

Starter engagesand is energi-zed, but enginedoes not turn oronly turns jer-kily.

Lengthyoperating periodwithoutmaintenance,electrical systemhas beenneglected.

Battery is flat. Recharge the battery.Low current flowbecause of loose orcorroded connections.

Clean battery terminals,tighten connections.

Carbon brushes sticking. Renew carbon brushes andbrush holder guides.

Carbon brushes worn. Renew carbon brushes.Commutator dirty. Clean commutator.Commutator scored orburnt.

Recondition or renew thestarter motor.

Armature or fieldwindings defective.

Recondition or renew thestarter motor.

Starter piniondoes not enga-ge or disenga-ge.

Engine does notturn, or turnsjerkily.

Starter pinion or helicalthread dirty or damaged.

Renew starter pinion,recondition starter motor.

Flywheel gear ring damaged.

Remachine or renew gearring.

Solenoid switchdefective.

Renew solenoid switch.

Return spring weak orbroken.

Renew return spring.

4 L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the starting device

Malfunction Indication Cause RemedyStarter motorcontinues to runafter switch wasreleased.

Noise of rotation.

Starter relay defective. Switch off engine manuallyat once (set speed controllever to ,,stop“ anddisconnect battery).Consequential damage:electronic componentsdestroyed.For example: diodes ingenerator. Check switches, relays andgenerator, renew parts ifnecessary.

Pre-heat/switch does notreturn automatically fromposition 3 to position 1.

Set pre-heat/start switch to0 immediately using force ifnecessary and renew it. Ifthis is not possible:disconnect the batteryimmediately. Consequential damage:diodes in generatordestroyed.Warning !Unless the abovemeasures are taken within2-3 minutes, the startermotor will burn out(overheating)

Diode in shutdownsolenoid (lifting or servoelectromagnet) isdefective.

Renew solenoid.

Engine does notstart or starts re-luctantly, al-though the star-ter motor is tur-ning strongly.

Valve solenoid onmonitoring block is notopening.

Check operation of valvesolenoid and renew ifnecessary.

Pre-heat system isdefective (only significantat temperatures below -10 to -15°C.)

Check pre-heat circuit andrenew any defective parts.

4L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the pre-heat system

Indication Cause RemedySpiral indicator ele-ment (pre-heat moni-tor) glows brightly al-most immediately.

Short to earth (ground) in a pre-heat plug, pre-heat element(filament) is bent and shortinginside engine.

Renew the pre-heat plug.

Broken pre-heat wires in a lineresistor, winding shorted to anearthed component.

Renew the line resistor.

Unterbrechung derGlühanlage (Glühüber-wacher brennt nicht)

Since the pre-heat monitor, pre-heat plug or heating flange (andalso the second pre-heat plug orline resistor on 24 V systems)are wired in series, the completepre-heat system is out of actionif a component fails.

Use a test lamp or a voltmeter(with the pre-heat systemswitched on) to check all the pre-heat monitor connections.Renew defective parts.

4 L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the alternator

Indication Cause RemedyGenerator telltale lightdoes not go out as en-gine speed increases.

Line D+/61 has a short to earth Renew the line or repair theshort to earth.

Voltage regulator on generator isdefective.

Renew voltage regulator.

Wiring connections interchangedat generator.

Connect the wiring correctly.

V-belt for generator is slipping orbroken.

Correct V-belt tension or renewV-belt.

Defective rectifier on generator,dirty sliprings, short-circuit in lineDF or rotor winding.

Have generator repaired.

Generator telltale lightdoes not go out at lowengine operating speed(e.g. 1500 rpm)

Generator is not sufficientlyexcited by telltale light. A 2 Wattbulb is normally used in the light.

Install a bulb of higher rating,e.g. 2 W -> 3 W.Warning: bulb ratin must notexceed 5 W (or pre-excitercircuit will be destroyed)

Generator telltale lightglows only dimly whenengine is stopped andpre-heat/start switch isoperated, battery notbeing charged, or char-ging only at a low rate.

Rate of charge too low, briefengine operating periods(particularly when a maintenance-free, vibration-proof battery isused).

Short-term remedy: rechargebattery with a suitable charger.Long-term remedy: use abattery with better chargecharacteristic.

Poor connections, open circuit,contact resistance or short-circuitin charging circuit.

Repair the break, clean thebattery terminals, tighten looseclamps.

Battery is defective, internal short-circuit.

Renew battery.

Battery capacity has dropped severely through being left flat fora long time (sulphate deposits).

Recharge battery at low currentfor about 50 hours. (Onlypossible if sulphate depositsare not too extensive).Otherwise: renew battery.

Battery capacity is too large. Install a smaller battery or alarger alternator.

Alternator is defective. Have alternator repaired.Voltage regulator is defective. Renew voltage regulator.Loose V-belt at alternator Correct V-belt tension.

4L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at the alternator

Indication Cause RemedyWhen engine isstopped the gener-ator telltale lightburns brightly, butwhen engine is running telltalelight glows dimmer.

Poor connections, contactresistance in charge circuit or inthe line to the generator telltalelight.

Eliminate contact resistance,clean terminals, tighten looseterminals.

Defective voltage regulator. Renew voltage regulatorDefective alternator. Have alternator repaired.

Generator telltalelight does not comeon when engine isstopped and pre-heat/start switch isturned on.

Generator telltale light bulb hasblown or contacts are corroded.

Install a new bulb. Clean the contacts.

Battery is flat. Recharge with a suitable charger.Battery is defective (internal short-circuit or sulphate deposits).

Renew the battery.

Defective pre-heat/start switch,poor contacts.Defective wiring line resistance incharging circuit or line to generatortelltale light.

Eliminate contact resistance,renew wiring, tighten looseterminals, if necessary renew pre-heat/ start switch.

Defective voltage regulator. Renew the voltage regulator.Short-circuit in an alternatorexciter or positive diode.

Disconnect charging line B+ (toprevent discharge at a standstill),have alternator repaired.

Carbon brushes worn. Renew carbon brushes.Corrosion deposits on sliprings,open circuit in exciter winding.

Have alternator repaired.

Generator telltalelight flickers.

V-belt at alternator is too slack. Tension V-belt correctly.

4 L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at engine monitor and display

Indication Cause RemedySudden pressure dropin lubricating oilcircuit.

Leak in oil circuit. Check lines and seals, renew ifnecessary.

Oil lost from damaged sump. Renew the oil sump.Defective oil pump. Renew the oil pump.

Engine cannot be stop-ped at valve solenoidor fuel shut-off valve.

Defective valve solenoid or fuelshut-off valve.

Examine parts and renew ifnecessary.

Defective diode betweengenerator telltale light andterminal 15 at pre-heat/startswitch, or diode by-passed.

Check the circuit and renew thediode if necessary.

Incorrect display, lightdoes not come on al-though a fault is pre-sent.

Short to earth (ground) in wire orswitch.

Check wiring and eliminateshort to earth.

Defective switch. Renew switch.

No display, displaylight does not come ondespite malfunction.

Broken wire. Renew broken wire.Defective switch or relay. Renew defective components.Defective bulb. Renew the bulb.

Engine protection relay: see ,,Instrument box“

4L / M . . 01.97

Trouble-shooting table for electrical system

Trouble-shooting at electromagnetic components

Indication Cause RemedyElectromagnetdoes not switch engine off or varyengine speed.

Defective electromagnet (e.g.winding burned out).

Renew electromagnet.

No power supply or open circuit. Check the circuit.Defective switch or relay. Renew defective component.Decoupling diode betweengenerator telltale light and terminal15 is missing or defective (appliesonly to shut-down solenoid withalternator).

Check the circuit and install orrenew decoupling diode asnecessary.

Malfunction or fai-lure of other electri-cal or electroniccomponents.

Freewheel diode parallel to asolenoid is defective.

Renew freewheel diode.

Starter motor doesnot disengage.

Defective diode in shut-downsolenoid (lifting or servo solenoid).

Renew solenoids.

4 L / M . . 01.97