Inhalt L M engl - Dzimavi.dzima.com/wp-content/uploads/2015/01/Hatz-M41-Repair-Manual.pdf · Use only genuine HATZ spare parts in repair work. ... that neither the workshop manual

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

Introduction

1. GeneralIllustrations of engineType plate dataLubricating oil circuitTechnical dataSealants and adhesivesSpecial 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 cooling.A 11.00 Automatic mechanismsA 11.70 Temperature-controlled

starting fuel volume regulator

A 15.00 HousingA 15.20 Connecting housingA 30.00 Liquid coolingA 30.20 Water pumpA 30.40 Thermostat

Contents

3. Basic engine equipmentM 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 Starting chargeM 12.10 with injection pump

PFR 1K 80M 12.20 with injection pump


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

M 13.00 Fan

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


PFR 1K 90M 14.30 InjectorM 14.40 Injector nozzleM 14.50 Adjusting work with

injection pump PFR 1K 80M 14.60 Adjusting work with injection

pump PFR 1K 90M 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 90M 35.00 Enclosure

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

Contents

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.

1L / M . . 10.98

1. General

Service and flywheel side

Governor and exhaust side

1 L / M . . 10.98

Starter and flywheel side

Engines: 2 - 4 L . . S / Z

1 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 Starter motor25 Fuel feed line26 Fuel return line27 Belt pulley with 1/2“ internal square

for cranking engine

Engine illustrations

Operating and flywheel 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

Operating and governor side

Outgoing air and flywheel side


1L / M . . 10.98

Operating 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

1 L / M . . 10.98

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 Starter motor12 Type plate13 Exhaust silencer


Operating side

Engine: H 2 L 30,H 3 L 30

1 Fuel line (feed pump - filter)2 Fuel line (filter - injector 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,14 Fuel pre-filter15 Oil pressure switch16 Fuel feed pump (Bosch)

Governor- and exhaust side

Engine: H 2 L 30,H 3 L 30

1 Cooling water inlet2 Rain protection cap3 Air filter4 Cylinder head cover5 Fuel pressure pipe6 Temperature switch7 Cooling water outlet8 Exhaust manifold9 Starter motor

10 Type plate11 Centrifugal pump12 Belt-adjustment link13 Alternator

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


1L / M . . 10.98

1 L / M . . 10.98

Type plate data

Complete type description

e.g.

Engine type

Engine version

2 L 40 C

Customer 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 number

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 cm3

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 series no.:The serial no. beginswith 10 and changescontinously (11,12) ifany major changes arecarried out.

Year of production

Fabrication-No. (continous)

3000 + 60 = 3060 min-1

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

Lubricating oil circuit

1L / M . . 10.98

12

3

4

5

6

7891011

12

13

14

15

10

16

17

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

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 requirementat n = 3000 rpm m3/min 2.1 3.2 4.2

Net weight approx. kgL 30 S 223 222 255 271 291L 30 Z 228 228 262 279 306L 30 C / K 276 - 331 - 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 inclination with and without with without only withtowards oil sump oil sump oil sump

Operating side 30° 30° 25° 25°Flywheel side 30° 22° 25° 18°Air outlet/starter side 30° 30° 30° 30°Governor side 30° 25° 25° 15°

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

1 L / M . . 10.98

Technical data L 30

1L / M . . 10.98

Type 2L31 2L40 3L31 3L40 4L31 4L402M31 2M40 3M31 3M40 4M31 4M40


Combustion system Direct injection


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

Displacemen 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


Kühlluftbedarf bein = 3000 min-1 m3/min 25 29 35 39 46 49

Combustion air requirementat n = 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 40 223 255 291L 31 Z, L 40 Z, M 40 Z 228 262 306L 31 C / K, L 40 C / K 276 331 396/386

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




Technical data L 31, M 31, L 40, M 40

1 L / M . . 10.98

Type 2L41 3L41 4L412M41 3M41 4M41


Combustion Direct injection


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


Cooling air requirement atn = 3000 rpm m3/min 29 39 49

Combustion air requirementat n = 3000 rpm m3/min 1,9 2,9 3,9

Net weight approx. kgM 41 S 223 255 291M 41 Z 228 262 306L 41 C / K 276 331 396/386

Lubricating oil pressure at n = 800 rpm min.: 0,9 bar

Lubricating oil consumption max.: 0,2 % 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




Technical data L 41, M 41

Sealants and adhesives

Sealants and adhesives:Code letters in the text and drawings refer to the products stated below. The samedetails 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

1L / M . . 10.98

1 L / M . . 10.98

Special tools and workshop equipment

Series L / M engines

No. Ident-Nr. Code Item

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

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

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 6 bar with flexible tubeRev. meter 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.


1L / M . . 10.98

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- und Testbox

15

86

87 87a 50

– +


Series L / M engines

Explanation of classification:

Example: 03. 1. 2Manufacturer: 1 . . . Only available from HATZ

2 . . . Same item (or equivalent in function)available commercialy

Necessity: 1 . . . Absolutely essential2 . . . Useful or convenient

Type of repair: 01. . . Maintenance02. . . 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 . . 10.98

No. Ident-Nr. Code Item

23242526272829

303132333435363738394041424344454647

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 01629 055 00

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.1.103.2.103.2.102.1.2

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 starting charge adjustment(mechanical system only)Multipurpose puller in connection 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 -Disassembly tools for cable plug


1L / M . . 10.98

23 24 25 26 27

28 29 30 31 32 / 33 34

35 / 36 37 38 39

40

44

47

424344

46

45

2L / M . . 09.96

2. Additional equipment

- 3 -

General:– When installing the fuel delivery pump,

make sure that the delivery and suctionlines 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

washers, and take off fuel deliverypump with O-ring.

– Dismantle fuel delivery pump 1 in thenumerical order of parts illustrated (Fig. 182).

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

Assembling:Assemble by following the instructions inthe reverse order as appropriate.

2 L / M . . 09.96

182

A 01.00 Fuel

A 01.40 Fuel delivery pump

234

5 6

7891011

1

12

–

Preparations:– Remove the hood from the enclosure

and air outlet duct; see M 35.00.

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

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

– Take out the machine screws (184/3)and remove the connecting cover(184/4).

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

– Remove the machine screws (186/1)and bolts (186/2).

2L / M . . 09.96

184

185

186

A 03.00 Exhausts

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

L3 / 228

1

3

4

2

L3 / 229

1

L3 / 230

1

2

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

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

– On the 2 - 3 L 40 from date of manufac-ture 5.85 on, 4 L 40 from 1.86 on and L31, the connecting stub pipe (189/1),sealing washer (189/2) and plate(189/3) are deleted.Five sealing washers are installedbetween the silencer and the exhaustmanifold.

– Pull the upper and lower sections of theenclosure apart and lift out the silencer;see Fig. 188.

Check the parts:– Examine the enclosure sections and the

silencer for fractured welds or tappedholes which are unfit for further use.

Installing:– Install by following the removal instruc-

tions in the reverse order asappropriate.The silencer must be installed withouttrapped stresses (a two-piece holder forthe silencer has been installed sinceMarch 1989).

Note:Before installing the connecting stub pipe(189/1), check free movement of the seal-ing washer (189/2).Place the sealing washer in the connect-ing stub pipe and install the plate (189/3).It should be possible to move the sealingwasher radially. Next, place the sealingwasher on the silencer. Radial play mustnot exceed 0.1 mm. If necessary, renewthe sealing washer.

2 L / M . . 09.96

187

188

189

L3 / 231

L3 / 232

L3 / 233

1 2 3

–

Version A 04.10.1Standard crank handle:This handle can be replaced at any timeby one with kick-back damping if thisbecomes necessary or is required by regulations.

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

Preparations: –

Demontage: –

Inspection / repair:– Visual inspection.– Inspect shaft 1 and tubular handgrip 2

for wear or breakage.

Note:If the shaft of the crank handle is worn,always renew the complete handle.The tubular handgrip can be renewedseparately if necessary.

2L / M . . 09.96

191

A 04.00 Start mechanical

A 04.10 Crank handle

2

1

–

Version A 04.10.2Handle with kick-back damping:The version for M .. engines is marked Aon its housing, and takes the place of thestandard crank handle if required.

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

Preparations: –

Demontage:– Remove parts in the order 1 ... 3 as

illustrated.– 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 asillustrated.

– Hold torsion spring 13 in position inorder to 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 ascrewdriver blade.Caution - risk of injury!

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

2 L / M . . 09.96

192


A 04.10 Crank handle

4 7

8

1514 13

1211

10

96

5

1615

3

A

Inspection / repair:– Visual inspection:– Renew the complete starting handle if

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

– If necessary, renew pivot bushings 15and shaft sealing ring 16.

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

– Install end plug 8, avoiding damage tothe splines. The end plug must installedto prevent dirt and water from entering.

– Check condition of bushing and leafspring at lever 9.

– Check condition of leaf spring 11 andtorsion spring 13.Renew in case of doubt.

– Check shaft 3 for wear and/or otherforms of damage.

– Renew O-rings and small parts.

2L / M . . 09.96

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 locatingpin.

– Preload torsion spring 13 against thenormal spring pressure until the hookeye of the spring engages behind theeye of the 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 eyeon torsion spring 13 and place onlocking pin.The rolled end of the leafspring must face toward the center ofthe 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 allmechanical 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

illustrated.– Check operation of the complete crank

handle.

–

The automatic decompressor has thefollowing 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 thehandle.

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 bycoupling sleeve (94/27) and 2 lockingcollets (94/23). Camwheel (94/22) is thenused at the second cylinder (flywheelside) instead of the gearwheel.

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 withshims and pressure pin (94/8, 9, 10).

– Unscrew threaded rod (94/19) andremove spring (94/18) and pressure pin(94/17).

– Using a suitable split-pin driver, drivelocking collet (94/16) about 3 mm intogearwheel (94/21).

– Turn the gearwheel through 180° andpull the locking collet out with pliers.

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

2 L / M . . 09.96

93

94


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

L3 / 1

1 2

0kompr.

dekompr. dekompr.autom.

L3 / 42

Checking parts:– Inspect the gearwheel and cap for dam-

age caused by moving the decompres-sion lever in the wrong direction oroperating the automatic decompressorwhen the engine is already running.

– Use new sealing rings.Install by following the dismantling instruc-tions in the reverse order as appropriate.

Note:– With the automatic decompressor in

position „0“, note the correct position ofthe gearwheel (Fig. 95).

– Check that the lifting pin can movefreely.

– When installing threaded rod (94/19),make sure that pressure pin (94/17)engaged in the locating slot on shaft(94/14).

Adjusting the automaticdecompressor:

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 whenengine 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

dimension „B“; Fig. 95.

Note:For this check, the rocker should restlightly on the valve stem but without open-ing the valve (turn the engine over untilthe tappet is resting on the base circle ofthe cam).

2L / M . . 09.96

95

L3 / 43

max

. 46.

1 m

mm

in.

45.5

mm

BA

b c

If the limit values are exceeded, adjustthis dimension as follows:– Take off the exhaust rocket, grind down

the pressure pin at the riveted side anddrive it out.

– Install the rocker temporarily, insert thenew pressure pin (95/b) and placeshims (95/c) under it to the requiredthickness, until the correct dimension(95/B) is reached.Note that when it is riveted into position,the pressure pin is about 0.1 mm lower.

– Rivet the pressure pin into position,pressing it firmly into the bore. Thepressure pin should project by at least 1 mm at the riveting point, to ensurefirm seating. If it does not projectsufficiently, grind the rocker away slight-ly at the appropriate point.Install the rocker finally, noting theendplay; adjust valve clearance andcheck dimension (95/B) again.

Checking dimension „A“:– Using a depth gauge, determine dimen-

sion „A“ (Fig. 95); work out the numberof shim washers (94/9) neededaccording to the table, and secure themwith the pressure pin (94/10) to theactuating pin (94/8).

– Check operation of the automaticdecompressor.When decompression is active, it mustbe possible to turn the engine over with-out compression resistance, but theexhaust valve must never strike thepiston.

2 L / M . . 09.96

Dimension„A“ in mm

Number of shimwashers (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

–

Preparations:– Remove the silencer (muffler);

see A 03.00.– Remove the fan; see M 13.0

Detaching the recoil starter: (Fig. 190)– Take out machine screws 13 incl. spring

washer 5 and screws 12 with bushings8 and washers 7, and remove them withbearing 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 parts:– Check the starting sleeve and bearing

bracket for damage.– Check shaft sealing ring 3 for damage

and renew if necessary.

Assemble in reverse order as describedhere.

2L / M . . 09.96

190


A 04.70 Recoil starter

L3 / 44

–

Preparations:– 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 screwsand remove 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) and washer (7)..

Checking parts:– Place the cylinder (114/2) in a tank con-

taining diesel oil. Apply an air pressureof max. 1.5 bar to the hose line (114/1).If air bubbles emerge from the cylinder,it must be renewed.

– Check flexible gaiter for damage andrenew if necessary.

Re-assembling the start release device:Follow the dismantling instructions inreverse 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 positionby lever (114/4), or else the start releaseaction will not take place; see also Fig.116/1.Before tightening machine screws(114/14), move bracket (114/3) in theopposite direction (see Fig. 116/2), toensure that locking collet (114/13) canmove as far as possible back to the „Stop“position.

2 L / M . . 09.96

113

114

115


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

1

2

1

5

4

768

3

13

2

14

9

Stop

Important:– The hoses must be correctly connected

as shown in Fig. 113.If the hoses are wrongly connected, theautomatic engine protection function isno longer available, i.e. the engine is notshut down automatically if lubricating oillevel drops too low.

– On older engine versions, hose (113/1)is connected to the fuel delivery pump.This has no effect on the basic functionof the device.

Operational check with start releasedevice installed:– Turn lever (114/4) clockwise; locking

collet (114/13) must move to the „Stop“position (Fig. 116). Release the lever;the locking collet must move back to the„Start“ position.

– Prime the fuel delivery pump with thelever and at the same time checkwhether the piston in cylinders (114/2)moves the lever (114/4) correctly. Alsocheck the cylinder and hose unions forleaks. When the lever is no longeractuated, spring (114/9) exters pressureon the piston, which should then moveback slowly (see Fig. 116).

Note:If the fuel tank is located at a higher levelthan the fuel delivery pump, the differencein height between the fuel level in the tankand the fuel delivery pump must notexceed 2 metres.Failing this, the automatic engine protec-tion device will be put out of action andthe engine then cannot be switched-offelectrically.

2L / M . . 09.96

116

Start

1

2

General instructions on the engine'selectrical system:– Never interchange the positive and neg-

ative terminals at the battery.– Do not disconnect the battery when the

engine is running.– Avoid all risk of short-circuiting live

cables (for instance, never test whethera cable is live by touching it to earth).

– If the charge telltale light bulb blows,replace it immediately.

– If any welding is done on the engine orthe equipment to which it is fitted,attach the earth (ground) clip of thewelding set as close to the weld area aspossible, and disconnect the alternatorfrom the electrical circuit at connections„B +“ and „D -“.

– When cleaning the engine, avoidspraying water on the alternator or anyother components of the electricalsystem.If this is unavoidable, first disconnectthe battery; before it is reconnected, dryall components thoroughly with acompressed air jet.

– If a malfunction, for instance low batterycharge, charge telltale light on etc,should be detected, always check thetightness of cable connections andcorrect V-belt tension before making anyother operational checks.

– For trouble-shooting in the event of afault, see section 4.

– When recharging the battery,disconnect the negative terminal.

– Avoid using electrical starting aidsbecause of the risk of voltage peaks(these could damage electroniccomponents).

2 L / M . . 09.96

Checking operation of the alternatorwith voltage regulator (checking charging current):– With the engine stopped and the

starting-switch key at „0“, detach the B + line (leading to the battery) from thealternator and connect a DC ammeterwith a scale reading of 0 .. 50 Abetween alternator terminal B + and thedetached cable. Make sure that theloose cable cannot touch any metalparts of the engine.

– Connect a DC voltmeter with a scale of0 . . 30 V to the battery's positive andnegative poles.

– Start the engine and note the meterreadings. Check the voltmeter display.With the alternator in good workingorder and electrical consumers incircuit, the ammeter should indicate acharging current. Its value depends onthe battery's state of charge (if thebattery is flat, the charging current ishigh, if the battery is fully charged, thecharging current is low), but also on theconsumpition of electrical equipmentactually in use and on alternator andtherefore engine running speed. If thereare no consumers in circuit, a chargingcurrent should even be indicated at idlespeed. If the alternator voltage is toohigh, renew the voltage regulator.

A 05.00 Start electrical

Test valuesSystem

12 V 24 V

Voltmeter reading13.0 -14.5 V 26 - 29 V

Charging 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

–

Preparations:Encapsulated engines:– Take off the hood, the air guide housing

cover and the impeller wheel. Unscrewand remove the enclosure side panel;see M 35.00.

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

Non-encapsulated engines:– Unscrew and remove the V-belt guard if

attached.– 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 bystriking it with a plastic-faced hammer;see Fig. 123.

Checking parts:– Examine the fan and the belt pulley for

evidence of damage.– If any grooves have broken away or are

damaged, renew the fan with belt pulley.

Installing:– Install the rotor and the alternator by

following the above removal instructionsin the reverse order as appropriate.

Note:When connecting the cables to the alterna-tor, make sure they are not accidentallyinterchanged.

2L / M . . 09.96

193 (*HATZ-internal cable marking)

194

A 05.00 Start electrical

A 05.40 Alternator (air-cooled engines)

Notes on renewing the alternator:

When series production of Series L / Mengines began, alternators made by SEV-MARCHAL were used.These alternators are no longer availableas spare parts, but can be replacedwithout difficulty by the current VALEOalternator.The MARCHAL voltage regulator is stillavailable.In view of the modified installed positionof the voltage regulator on PARIS-RHONE or VALEO alternators (removaland installation in a radial direction toreduce the risk of breaking off the carbonbrushes), the fan housing was alsomodified in the regulator area when thePARIS-RHONE generator was introduced.A cutout in the housing and deletion ofthe retaining screw which previouslypassed through at this point ensure thatthe regulator switch can be renewed with-out having to remove the alternator.

When replacing a MARCHAL alternatorby a VALEO type, you are recommendedto perform the above modification; refer toFig. 195. The time invested in this willeasily be made good by the time saved ifthe regulator has to be replaced later.

When installing a VALEO voltageregulator, make sure that the condensersupplied with it is also installed (connec-tion diagram is enclosed).

2 L / M . . 09.96

195

–

Preparations:– On engines with enclosure, take off

the enclosure hood and side panel;see M 35.00.

– On engines without enclosure, take offthe cooling air duct to the oil cooler.

Removing block-pattern oil cooler:– Remove the oil line to the servo (only

on older version of the engine).– Take out machine screws (196/1) and

detach the oil cooler.

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

spring washers and detach oil coolerwith sealing rings (197/5).

– To dismantle the oil cooler: Pull the oilguides (197/2) apart and take out bothgilled tubes (197/3) with O-ring seals(197/4).

Note:The gilled-tube oil cooler is only used ontwo-cylinder engines without enclosureand rated for engine speeds up to acertain limit.

Checking parts:– Make a visual check for cracks or

damage to the sealing faces.– Clean the cooling surfaces.

Installing:– Install the oil cooler by following the

appropriate removal instructions in thereverse order.

Retrofitting engine with oil cooler:– If an engine has an oil cooler retrofitted,

the missing threaded rod (198/3) mustbe inserted and secured with sealant D.Unless this work is performed, the oilcooler will be unable to operate.

2L / M . . 09.96

196

197

198

A 07.00 Lubricating oil

A 07.10 Oil cooler (air-cooled engines)

L3 / 189

1

L3 / 10

1 2 5

3 4 2

L3 / 190

3

–

Preparations:– 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 spac-

ing 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

removal instructions in the reverse orderas appropriate.

Note:– Install the oil cooler side with the

sealing ring towards spacing ring(199/4).

– Tighten threaded sleeve (199/2) to atorque of 55 Nm.

2 L / M . . 09.96

199

A 07.00 Lubricating oil

A 07.11 Oil cooler (water-cooled engines)

5

1 23

4

–

Demontage:– Disconnect the solenoid and take off the

starting aid housing, taking care not toturn the volume limiting eccentric.

– Take out machine screws (205/1) andremove solenoid (205/2).

– Pull eccentric shaft (205/3) towards thesolenoid and unscrew hex nut (205/4)with a 10 mm open-ended wrench.

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

Inspection / repair:– Use a new O-ring seal (205/10).– Check flexible gaiter for damage and

renew if necessary.

Assembling:– Proceed in the opposite reverse; install

end cap (205/9) with sealant C.

2L / M . . 09.96

205

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)

L3 / 199

2

110

3

8

7

4

6

5

9

Adjusting engine shutdown andsolenoid:The solenoid does not need adjustingunless the adjusting nuts were turned or anew solenoid has been installed.– Press in the solenoid fully against the

spring loading.– Insert solenoid adjusting gauge

621 471 00 (206/1) into the hole in thehousing; 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 ± 0.1mmbetween the inner face of the hole in thecover and the 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“ posi-

tion.– Coat both sides of the gasket (208/1)

for the housing with sealant H. Applyonly a thin coat of the sealant so thatthe oil passage in the starting fuelsupply device is not blocked.

– Attach the gasket (note correct positionof oil hole) and press the solenoid byhand into the operating position: angle(208/3) must engage to the left of thedriver pin on governor rod (208/4).

– In this position, attach the housing andreconnect the solenoid.

Attention!If the angle is positioned incorrectly wheninstalled (at the right of the driver pin), theengine will overspeed and could destroyitself unless the solenoid is put out ofaction immediately.When the U-pattern driver pin wasintroduced, incorrect positioning asdescribed above was ruled out.

2 L / M . . 09.96

206

207

208

L3 / 200

12

L3 / 201

1

2

39.3 ì0.1

L3 / 202

1

24

3

- 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-loadposition.This places governor lever 1against full-load stop 2 of the startingfuel volume control.

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

the bracket, until the dial gauge justbegins to move (the sickle-shaped leveris then against the governor rod).

– Unscrew adjusting tool - 28 - at the 13 mm hexagon until a clicking sound isclearly heard, to indicate that the gover-nor lever is dropping into the increased-volume starting position.

– Slowly turn thermo-element 4 back to alower setting until the dial gauge indi-cates a movement of 0.2 mm towardsincreased volume from the zero positionpreviously obtained.

– In this position, secure the thermo-element with the locknut.

– Detach auxiliary tools and install anyengine components not yet in place.

Attention:When adjusting, make sure that thethermo-element is at a temperature of atleast 20°C.

2L / M . . 09.96

170

A 11.00 Automatic devices

A 11.70 Temperature-controlled starting fuel volume control

3 2 1

4

–

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

crankcase.– Attach the connecting housing, insert

four M 14 x 1.5 mm hex bolts (200/2)with spring washer (200/3) and tightento the specified torque.

Note:Apply sealant D to the bolt aboveinspection hole (200/4), since this is athrough-hole.On engines without a connectinghousing, the equivalent screw plug shouldalso be coated with sealant D beforeinserting.– Insert and tighten the two lower M 10

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

2 L / M . . 09.96

200

A 15.00 Housing

A 15.20 Connecting housing

L3 / 143

12

4

3

5 6

–

Preparations:– 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 seal9 from 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 thepump element).

– Bearing worn.

Assembling:– Assemble by following the dismantling

instructions in the reverse order asappropriate.Install pump element 8 withthe water drain hole facing down.

2L / M . . 09.96

201

A 30.00 Liquid cooling

A 30.20 Water pump (H.L 30)

12

4

35

67

89

10

–

Preparations:– Drain the coolant (only needed if the

upper edge of the radiator is higher thanthe thermostat).

– Detach the coolant line from thermostatcover (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 thermostatinsert:Note:The temperatures stamped on thethermostat insert indicate the start of itsopening movement and the maximumoperating temperature.– Suspend the thermostat insert and a

thermometer in the centre of a vesselfilled with 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 seatof the thermostat insert.

– Install the thermostat insert, using a newsealing ring (the arrow stamped on itindicates the direction of flow).

– Attach the thermostat cover again andtighten its screws uniformly.

2 L / M . . 09.96

202

203

A 30.00 Liquid cooling

A 30.40 Thermostat (H.L 30)

1

2

4

3

56

3. Basic engine

3L / M . . 09.96

3 L / M . . 09.96

1

2

3

–

Preparations:– 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 machinescrews (2/1) at the plate (2/2) and takeoff the plate.(On more recent version:secured with stud bolts and nuts)

– Unscrew the plug from the thrust bus-hing at the timing end of the engine anddrive the shaft out towards the flywheelend; see Fig. 3.

– Drive out the thrust bushing (timingend).

– Take the balancing weights and driverout of the lower part of the crankcase.

Inspection / repair:– Check the shaft at its bearing points for

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

– Check the needle roller bearings of thebalancing weights for score-marks.

– Check the gearwheel with balancingweight and the crankshaft-end gear-wheel for the balancing weights forsigns of damage.

– Renew the O-ring seals at the thrustbushings.

M 01.00 Crankcase

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

Assembling:– Insert the thrush bushing (timing end)

until flush with the housing.– Place the gearwheel with balancing

weight (flywheel end) and the balancingweight (timing end) in the lower part ofthe crankcase, insert the driver andscrew hand-tight to the balancingweights. Insert the shaft with thrust bus-hing (4/1) from the flywheel end , seeFig. 4, and drive it fully into the timing-end thrust bushing.

– Tighten the machine screws for the dri-ver and use a depth gauge to measureendplay at the balancing weights; seeFig. 5.

Note:The timing-end thrust bushing (5/1) formspart of the sealing face at the timing casecover, and must therefore be flush withthe endface of the crankcase after drivingin the shaft.Endplay can be adjusted by moving theflywheel-end thrust bushing axially untilthe value 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 ensurefree rotation.

Note:When installing the oil sump and thecrankcase cover, apply sealant D to twoM8 hex bolts in each case at the timingand flywheel ends, where a through-holehas been drilled.

3L / M . . 09.96

4

5

6

–

Preparations:– 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 themout.Using two machine screws, loosenthe bearing journals and pull themout.Mark the installed positions of thebearing journals.

– Invert the lower part of the crankcase.

Note:The joint line is a sealing face, and mustnot be damaged. Place the crankcase ona wooden grid or frame; see Fig. 8.

– Unscrew splash plate (9/1) and take outbalancing weights (9/2), then removesplash plate (9/3).

3 L / M . . 09.96

7

8

9

M 01.00 Crankcase

M 01.20 Removing and installing balancing weights - 4 L

– 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).

Inspection / repair:– Check the bearing journals and bus-

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

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

Assembling:– Blow through the oilways thoroughly

with compressed air.

Note:Before installing the bearing bushings,make sure that the oil hole is in the cor-rect position; see Fig. 11.

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

– Coat the sealing faces of the end caps(10/2) with sealant C and insert themagain.

– Renew the end caps.

3L / M . . 09.96

10

11

12

– Insert spacing rollers for the M8 screwsin the correct positions as shown in Fig. 13.

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

– Insert splash plate as shown in Fig. 14,insert the lower machine screws (14/1)and tighten them. Screw the upper ma-chine screws (14/2) in only hand-tight.

– Insert the balancing weight with circleand line markings as shown in Fig. 15,and push in the bearing journal.

Note:This balancing weight is driven directlyfrom the crankshaft.

3 L / M . . 09.96

13

14

15

– Insert the balancing weight with circlemark (16/1) and push in the bearingjournal.

Note:When installing this balancing weight(16/1), make sure that the circle mark onit is between the two line marks on balan-ce weight (16/2).In this position, the circle mark on balan-cing weight (16/2) must face the cranks-haft.

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

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

– Turn the lower part of the crankcaseback upright again (joint line at the top).

– Insert the machine screws at the bea-ring journals and tighten them to thespecified torque with a torque wrench;Fig. 18.

– Rotate the balancing weights and checkfor free movement.

Note:When attaching the oil sump, apply sea-lant D to two M8 hex bolts in each case atthe timing and flywheel ends, since theseare inserted in through-holes.Engines with an oil sump attached mustnot have a ∅ 40 mm end cap in the lowerpart of crankcase.

3L / M . . 09.96

16

17

18

- 41 -

Cleaning the crankcase– Remove all screw plugs from the oil-

ways and, after cleaning the crankcaseby immersion in a cleaning bath or withhigh-pressure cleaning equipment, blowit dry with compressed air; flush out alloilways particularly thoroughly and blowthrough them, so that no particles of dirtor swarf remain.

– After this, insert all screw plugs againand check that the aluminium or sheet-metal plugs for the oilways are firmlyseated. In case of doubt, renew them;apply sealant E to all plugs before inser-ting. To ensure firm location, secure thealuminium plugs with light punch-marksat the edge of the hole in the housing.

Oil spray jets– First check for firm location and accura-

te spray direction; if necessary, re-alignthe spray jet with light hammer-blows orbend it carefully by hand until the cor-rect position is reached. Check this withthe gauge - 41 -or work from the dra-wing shown here (Fig. 171).

If oil spray jets have broken off or are loo-se, new ones must be inserted. Proceedas follows:– Remove pieces of the old jet from the

drillway (with a suitable drift or similartool); degrease the entire area tho-roughly; insert the new spray jet and drive it in initially app. 6 - 8 mm fartherthan its final position. Strike the projec-ting end lightly with a hammer to bend itslightly and ensure a firm seating in thebore (Fig. 172).

3 L / M . . 09.96

171

172

M 01.00 Crankcase

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

– Apply sealant E to the projecting endand move the spray jet to its final posi-tion. Do not dent the jet inlet bore; driveit in until the end of the tube is flushwith the oil groove in the bearing seat(Fig. 173).

– Check the position of the jet outletagain, and adjust if necessary.

– Apply sealant E again where the sprayjet passes through opposite the bearingseat; the capillary action of the sealantwill ensure that the tube is fully coatedand cannot shake loose in its seat.

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

3L / M . . 09.96

173

- 8 -

Preparations:– Take off enclosure parts and air guide

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

crankshaft; see M 13.00.– Remove piston, conrod and cylinder;

see M 05.00 / M 06.00.– Take off flywheel and connecting hou-

sing.– Detach the timing case cover;

see M 11.00.– Take off the starter motor.

Dismantling:– Remove machine screws and spring

washers for end cover and pull off theend cover; see Fig. 19.

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

– Remove machine screws from cranks-haft gearwheel, loosen the gearwheelon the crankshaft with a plastic-facedhammer and pull it off.

– Pull out the locking collet (21/1).

3 L / M . . 09.96

19

20

21

M 02.00 Crankshaft

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

– The two halves of the crankcase are se-cured together with straight pins (23/1).Drive these back with a hammer and asuitable drift until they are flush with thesealing face. Lift up the upper part ofthe crankcase vertically: Fig. 23.

Note:To simplify the loosening and lifting off ofthe upper part of the crankcase, inserttwo M 8 x 65 machine screws (retainingscrews of setting-down device) at the timing end and two M 14 x 50 hex bolts(used to secure connecting housing) atthe flywheel end in the holes provided.

– Lift the crankshaft out of the lower partof the crankcase.

– Carefully warm the balancing weight gearwheel on the 2 and 3 L ... with awelding torch and knock it off with analuminium drift.For the 4 L ... crankshaft, unscrew andremove the flywheel-end counterweight,remove the machine screws for the gearwheel and drive out the straight pin(24/1).

3L / M . . 09.96

22

23

24

Inspection / repair:– Check all crankshaft bearing journals

for score-marks and incorrect dimen-sions; for measured values, see Section 4.Measure in two planes offset through 90degrees.

– Check the shaft sealing ring contact face for score-marks.If the contact face is worn, a „wear sleeve“ can be pushed over it. When do-ing so, use sealant E. Assembly instruc-tions are included with the spare part.

– Renew the shaft sealing ring in the endcover.

– Check the bearing shells for damageand visible signs of wear.

Installing:– Pull the balancing-weight gearwheel on

to the crankshaft.On the 2 and 3 L ..crankshafts, unscrew and remove theflywheel-end counterweight; this will ex-pose the line marking (25/1) on thecrankshaft.Heat the gearwheel to app. 125° C andpull it on so that the line marking (25/1)on the crankshaft is aligned with the „O“marking (25/2) on the gearwheel; seeFig. 25.

On the 4 L ... crankshaft, unscrew and re-move the flywheel-end counterweight andmanoeuvre the balancing-weight gearw-heel into 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 tor-que.

Note:From mid-1994 on, a modified gearwheeland different retaining screws were intro-duced. The new screws are not to beused with the old gearwheel (Fig. 27).On the 2 and 3 L .. engines, do not installthe counterweights again until the crank-shaft has been placed back in the lowerpart of the crankcase.

3 L / M . . 09.96

25

26

27

5,5 6,5

alt neu

– Place the thrust washers (28/1) on thecrankshaft so that the lubricating groo-ves face the thrust face on the cranks-haft. Insert the bearing half-shells (28/2)into the lower part of the crankcase,and apply oil to them.

– Place the crankshaft in the lower part ofthe crankshaft and make sure that thegearwheels mesh together as indicatedby the marks.For 2 / 3 L ... see Fig. 29.

– For 4 L ... see Fig. 30.

3L / M . . 09.96

28

29

30

– Insert the O-ring seal (31/1) for themain oilway into the lower part of thecrankcase. Apply a thin, uniform coat ofsealant B to all areas of the joint line onthe lower part of the crankcase, and al-so on the intermediate webs of thecrankcase; see Fig. 31.

– Insert the bearing shells into the upperpart of the crankcase and coat themwith oil.

– Position the thrust washers so that thegroove (32/1) faces upwards in each case. Lift upper part of crankcase andplace it very carefully.

Note:When installing, make sure that the twocentering pins (32/2) in the upper part of the crankcase are inserted into thegrooves (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.

3 L / M . . 09.96

31

32

33

– Check crankshaft endplay with a depthgauge, Fig. 34, and compare it with thedesired value stated in Section 4.

– Drive the locking collet to secure the gearwheel (21/1) into the end of thecrankshaft.

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

– Engage the crankshaft gearwheel, no-ting the position of the mark, and tigh-ten it to the specified torque.

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

– Insert a new shaft sealing ring and grease its sealing lip. Install the end cover, coat the machine screws with sealant D and tighten them to the speci-fied torque.

3L / M . . 09.96

34

35

36

- 9 - 30 - 31 -

Preparations:– Take off the upper part of the crankca-

se; see M 02.00.

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

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

– Stand up the upper part of the crankca-se, take the circlip (38/1) out of the sa-fety groove and press the valve tappet(38/2) off the camshaft.

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

3 L / M . . 09.96

37

38

39

M 04.00 Camshaft

M 04.10 Camshaft, valve gear

– Remove the circlip and shim washersand pull off the ball bearing with a two-arm puller; see Fig. 40.

– If the gearwheel or camshaft is rene-wed, use puller - 30 - with forcing-offscrew - 31 - to pull the gearwheel offthe camshaft; see Fig. 41.

Inspection / repair:– Inspect the camshaft bearing points and

the bearing bores in the crankcase forscore-marks and incorrect dimensions;for values, see Section 4.

– Check the camshaft gearwheel for score-marks.

– Check the camshaft ball bearings forwear.

– Check the tappets for score-marks.–Check the bores in the crankcase for thetappets for score-marks and incorrect dimensions; for values, see Section 4.

Assembling:– Heat the camshaft gearwheel to approx.

150 - 200°C on a hotplate, and press iton.

– Place the circlip (42/1) in position andpull on the ball bearing with impactsleeve - 9 -; see Fig. 42.

3L / M . . 09.96

40

41

42

– When installing a new camshaft, makesure that there is no endplay betweenthe ball bearing and the circlip (43/1). Ifnecessary, insert shim washers (43/2).

– Install the camshaft, noting the correctpositions of the marks, and insert circlip(44/1).

– Drive the camshaft towards the timingend of the engine until the ball bearingis in contact with the circlip (44/1).

– Insert shim washers (43/3), push in co-ver with O-ring seal (43/4) and attachcirclip (43/5).

Note:– Check camshaft endplay; for values,

see Section 4.If necessary, insert shimwashers (43/3).

– A special camshaft has been introducedto operate the valves on the followingengines.It can be identified by an „H“cast into the camshaft.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

3 L / M . . 09.96

43

44

- 9 - 30 - 31 -

Preparations:– Remove the injection pump;

see M 14.00.– Remove the engine speed control;

see M 32.00.– Remove the starting-mixture charging

device; see M 12.00.– Remove the fuel delivery pump.

Dismantling:– See M 04.10.

Detaching the intermediate gearwheel:Note:The intermediate gearwheel can only bepulled off after removing the injectionpump camshaft.– 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 intermediategearwheel are separated by a circlip.

Inspection / repair:– Check the camshaft bearing points and

the bearing points in the crankcase forscore-marks and incorrect dimensions;for values, see Section 4.

– Check the ball bearings for the cams-haft and the intermediate gearwheel forwear.

3L / M . . 09.96

45

46

M 04.00 Camshaft

M 04.20 Camshaft for injection pump

Attaching the intermediate gearwheel:

Note:The intermediate gear wheel must be in-stalled before the camshaft for the injec-tion pump is installed.

– Press the ball bearing into the interme-diate gearwheel and pull the gearwheelon using impact sleeve - 9 - , noting thepositions of the markings; see Fig. 47.

– Place the circlip on the shaft.

Note:Before pulling on, place the intermediategearwheel uniformly on the shaft, to pre-vent the shaft from being pushed into thecrankcase.

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 drivecam.

3 L / M . . 09.96

47

- 30 - 31 - 40 -

Preparations:– 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,.M40.12 and .L 30 and H.L 30)– Remove circlip (48/1) and pull out

governor 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 pullrod (48/7).

– Unscrew spring bridge (48/8) and takeoff holder for governor weights (48/9).

Dismantling governor: (from engine serial number: 2 L 40.17, 3-4 L 40.16, .M40.13, 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 col-lar (48a/11) and push out pin (48a/38)with roller sleeves (48a/37).

– Pull out the pull rod (48a/36), unscrewthe nuts (48a/44) and take off the springplate at the governor (48a/43), the loca-ting washer (48a/42) and needle rollerrace (48a/41), the shim washer (48a/40)and the thrust washer (48a/39).

– Unscrew the spring bridge (48a/32) andtake off the holder for the governorweights (48a/26).

Inspection / repair:– Check al parts for damage and signs of

wear.

3L / M . . 09.96

48

48a

M 04.00 Camshaft

M 04.30 Governor and injection timer

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

screw - 31 -, pull the injection timer offthe camshaft; see Fig. 49.

– Clamp the holder for injection timer as-sembly - 40 - into the vise and place thehole in the injection timer's support discon the special tool; see Fig. 50.

– Turn the gearwheel counter-clockwiseby hand against the spring loading, andlift it carefully off the support disc.

– Take off the centrifugal weights (51/1),retaining blocks (51/2) and pins (51/3)with coil springs (51/4).

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

Inspection / repair:– Examine the support disc and gear-

wheel in the centrifugal weight area forscore-marks.

– Inspect the coil springs and their retai-ning blocks for damage.

– Check the centrifugal weights for score-marks.

3 L / M . . 09.96

49

50

51

Assembling the injection timer:– Assemble the injection timer by follo-

wing the dismantling instructions in thereverse order.

Note:The gearwheel and support disc weremodified at the beginning of 1992.Parts from the old and new versions can-not be combined.If necessary, renew the complete injectiontimer.After placing the gearwheel on the sup-port disc, check that the slots in the gearwheel and support disc are alignedas shown in Fig. 52.

– Turn the injection timer clockwise andallow it to move back to check its free-dom of movement; see Fig. 53.

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

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

3L / M . . 09.96

52

53

54

Assembling of governor:– Assemble the governor by working the

reverse order of dismantling; refer toFigs. 48 and 48a.

Note:When assembling the governor make quite sure that all moving parts are ableto move freely.On L/M 31/40 engines there must be aclearance 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) is tightened.

– Install the spring for the governor (55/1)so that the endface of the tapered sec-tion points in the direction of rotation.

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

Preparations:– 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 theengine's intended use and speed range.

– Install the governor spring or engineshutdown device by working in the reverse order for removal.

3 L / M . . 09.96

55

56

- 35 - 36 -

Preparations:– 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 bigend cap with the aid of guide pin - 35 - or - 36 -.

Inspection / repair:– Check the conrod bushing, big end bea-

ring and crankpin for score-marks andincorrect dimensions; for values, seeSection 4.

Assembling:– Press the bushing into the conrod.Note:When pressing in the conrod bushing,make sure that the oil holes are alignedand that the bushing projects by an equalamount on each side.– Insert the big end bearing half-shells

into the conrod, making sure that the locating nuts are in the grooves provi-ded; see Fig. 63.

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

– Attach the upper part of the conrod, in-sert the big end bolts and tighten themto the specified torque.

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

3L / M . . 09.96

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63

64

M 05.00 Conrod

3 L / M . . 09.96

M 06.00 Piston and cylinder

M 06.10 Air-cooled engines

- 12 - 16 - 17 -

Preparations:– 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.

Inspection / repair:– 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 orring 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 ofthe piston.

– Clean the piston crown and use it to po-sition the piston ring at a right-angle tothe cylinder axis.

– Use feeler gauges to measure thepiston ring end gap (where the ends ofthe piston ring come together).

– For limit values, see Section 4.

65

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

cedure with a new piston ring.– Compare the measurements obtained in

this way with the maximum wear limits;if these are exceeded, the cylindershould not be re-used but an oversizecylinder should be installed instead.

– If the measured values are within the limits, 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 after a lengthy period of opera-tion. If the cylinder were to be used againwithout re-honing (whether the existingpiston rings or new ones were fitted), ex-cessive oil consumption would occur and would not drop to the normallevel after a time, since the piston ringswould not be able to match themselves to the cylinder wall.

Procedure:– While turning the honing tool in the

cylinder, it must also be axially movedback and forth. Recommended speed ofrotation approx. 350 rpm.

– Depending on the speed, the toolshould perform about 20 - 30 strokes aminute. This stroke rate will produce across-cut pattern at approximately 45°.

– Continue honing only until this crosscutpattern can be clearly seen. It is nor-mally obtained after a honing time ofapprox. 20 - 45 seconds per cylinder.

– After honing, clean the cylinder withwarm or hot water and a cold cleanser,using a brush, then oil the cylinder wall.

Attention !Do not hone for too long 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 dismantlinginstructions in the reverse order.

Note:The recess in the piston crown must belocated 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 carefullyinstall the cylinder; see Fig. 67.

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66

67

- 16 - 17 -

Preparations:– 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.

Inspection / repair:– 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.

3 L / M . . 09.96

68

M 06.00 Piston and cylinder

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

Installing:Install the piston by following the removalprocedure in the reverse order as appro-priate.

Note:The recess in the piston crown must belocated towards the injection pump; seeFig. 69.

– The piston ring gaps must be offset by120° in each case; oil the rings well intheir grooves.For each cylinder bore a figure is stam-ped on the crankcase and another figu-re on the cylinder. The two figures, if ad-ded together, represent the thickness ofthe shim plates to be inserted at the ba-se of that cylinder; see Fig. 70.

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

These shim plates compensate for cylin-der and crankcase manufacturing toleran-ces; in addition the gap is reduced to within a tolerance range of 1.0 - 1.5 mm.

– Attach shim plates 70/1 to the cylinderwith a small amount of grease.

– Oil the cylinder bore well.

Note:If spare parts are obtained, the manufac-turer attaches the shim plates to thecrankcase or cylinder. They are not inclu-ded in the set of gaskets.To order them separately, please quotethe following part numbers:036 330 00 0.10 mm036 388 00 0.15 mm036 329 00 0.20 mm

3L / M . . 09.96

69

70

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 centrepiston; see Fig. 71.

– With the help of a second person, care-fully place the cylinder assembly in position and insert auxiliary pins 621 646 00 into the recesses on pistons„1“ and „3“; see Fig. 72.

– Lower the cylinder assembly and at thesame time move the auxiliary pins backand forth until the pistons enter the cy-linders.

– Take off the piston ring clamping toolsand move the centre piston back andforth during the lowering movement untilit enters its cylinder.

– The ring clamping strap is pushed intothe cylinder, and can then be pulled outof the rectangular side opening in thecrankcase with the aid of a strong pieceof wire.

Installing the cylinder assembly on theH 2 L 30:– Set both pistons to approximately the

same height and attach the piston ringclamping tools.

– Further installation work is as describedfor the H 3 L 30, but without the workrelating to the centre cylinder.

3 L / M . . 09.96

71

72

–

Preparations:– 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 plateand take out the screws for the baseplate; see M 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 in-

take pipe.

Note:To simplify dismantling of the air intake pi-pe, it is best to unscrew and remove theair cleaner (74/1).

– Lift off the cylinder head and removethe pushrod protective tubes.

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

tapers.– Check the radius of the rocker pads for

wear.

3L / M . . 09.96

73

74

M 07.00 Cylinder head

M 07.10 Air-cooled engines

Installing:– Determine the gap between the cylinder

head and the piston at TDC.

Note:This gap should be re-measured whenever a cylinder, piston, conrod, crankshaftor crankcase is renewed. Measure at allcylinders, with cold engine.

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

– Turn the engine over until the piston reaches and passes through top deadcentre (TDC).

– Measurement „a“ plus the thickness ofgasket „b“ yields the gap dimension „S“stated in Section 4; see Fig. 76.

3 L / M . . 09.96

75

76

ab S

– Having established the correct gasketthickness, coat it with a little grease onthe cylinder head side, and place it inthe centering collar on the cylinder head.

Note:Centering on the L 30 is not by means ofa centering collar but with centering slee-ves; the gasket has two centering holes;see Fig. 77.

– Insert the protective tubes (78/1) withspring (78/2), thrust rings (78/3) and O-ring seals (78/4) into the bore in thecrankcase.

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

– Insert the pushrods (78/5).

– Attach the cylinder head, making surethat the protective tubes with O-ring seals enter the corresponding holes inthe cylinder head correctly; see Fig. 79.

– Oil the stud bolt threads (79/1) andscrew on the shouldered nuts.

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

3L / M . . 09.96

77

78

79

– Screw the cylinder head on until it is re-sting evenly on the cylinder, but withoutfinal tightening.

– Align the cylinder head by attaching theexhaust manifold; see Fig. 80.

– Install the support plate and the injectorcentering flanges.

– Tighten the cylinder head uniformly, in across-wise pattern, to the specified tor-que.

– Take off the exhaust manifold, attachthe gaskets and install it again.

– Adjust valve clearances to the specifiedvalues.

– Further installation work is as describedfor removal, but in the reverse order.

3 L / M . . 09.96

80

- 1 - 2 - 6 - 7 -

Preparations:– Removing cylinder head - see M 07.10.

Dismantling cylinder head:– Place the cylinder head on the cente-

ring collar.Note:On the L 30, pull out the centering slee-ves (81/1).The cylinder head sealing face must notbe scratched or otherwise damaged; al-ways use 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 rockerhousing (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 (inthe metal webs) or an uneven sealingsurface.

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

– Check the valve seat rings and valvecones for wear; for valve recess into cylinder head, see Section 4.

– Check correct dimensions of rocker bushing, rocker shaft and rocker pad radius; for values, see Section 4.

3L / M . . 09.96

81


M 07.20 Overhauling cylinder head (air-cooled engines)

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 insertthe new valve guides - 1 -.

Note:The correct pressing-in depth must becomplied with; for projection, see section 4.

– Using a hand-held reamer - 2 -, reamout the 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-machi-ned after installing new valve guides orbefore installing new valves, but no moremetal than absolutely necessary (no pat-ches anywhere on circumference of valveseat).

3 L / M . . 09.96

82

83

84

– 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 smallamount of diesel oil into the inlet and ex-haust ports. No fuel should seep throughthe valve seats.

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

the dismantling instructions in reverse asappropriate.

Note:– Engines built in 1979 - 1983 have one

spring per valve; from 1984 onwards,two springs per valve were installed. Ifrepair work is carried out in this area,the second valve spring should be retro-fitted.

– On M 31/M 40 engines up to 2300 rpm,cylinder heads with the code letter „H“(high swirl) are used; above 2300 rpmthe cylinder head code letter is „L“ (lowswirl).These code letters are stamped inthe inlet port.

– On engines built from mid-1986 on witha running speed below 2300 rpm thelongitudinally slotted rocker and valvestem seal adjusting screws are used;these screws were installed on all engi-nes from mid-1989 onwards. Retrofitthese screws if repairs 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 . . 09.96

–

Preparations:– Drain the coolant and unscrew the coo-

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

haust 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 order shown inFig. 86 or 87.

– Unscrew and remove the nuts in thesame order. Unscrew the hex nuts (85/5)with spring washers (85/6) and take offthe rocker pedestals.

– Lift off the cylinder head.– Take off the pushrods and protective

tubes.– Take off the cylinder head gasket and

sealing rings.

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

ling face for unevenness.– Check pad radius on rockers for wear.

3 L / M . . 09.96

85

86

87


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

Assembling:– 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) andnew sealing rings (88/6) into the bore inthe crankcase. Grease the sealing ringsslightly.

– With the aid of a second person, placethe cylinder head in position, making sure that the protective tubes with O-ringseals enter the holes in the cylinder head correctly.

– Insert the pushrods.– Install the rocker pedestals. Make sure

that the adjusting screws are insertedcorrectly into the pushrods; if necessary,unscrew them.

– Coat the thread of the tierod in the oilcavity with sealant D.

– Screw on the shouldered nuts and tigh-ten them by hand in the order 1 - 15(Fig. 86 or 87) until they are firmlyagainst the cylinder head.

– 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 alu-minium pushrods is 0.40 mm, for engineswith steel pushrods 0.20 mm.

– Further installation is by following the re-moval instructions in the reverse order.

3L / M . . 09.96

88

- 1 - 2 - 6 - 7 -

Preparations:– 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 sealingsurface.

Note:Do not scratch or otherwise damage thecylinder head sealing face; always place asoft cloth 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) withunderlay 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 toinstall double valve springs on engineswhich run 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).

3 L / M . . 09.96

89


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

Checking parts:– Check correct dimensions of bushing

for rocker (89/14), rocker shaft (89/15)and rocker pad radius. For values, seeSection 4.

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

– Inspect the cylinder head for cracks (inwebs) and unevenness of the sealingsurface.

– Examine the valve seat rings and valvecollets for wear. Note valve recess inhead; 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 nominaldiameter with hand-held reamer - 2 -,Fig. 91.

– If the valve seats are leaking or havebeen damaged locally, or after installingnew valve guides, they must be rema-chined. This is carried out with specialmilling cutters which are available com-mercially.

– Only mill away sufficient metal to elimi-nate patches on the surface of the valveseat.

– After this, lap in the valves (with grin-ding paste, grain size 180 - 250);see Fig. 91.

3L / M . . 09.96

90

91

92

Note:– To check the lapped valve seats, clean

and install the valves, then pour a smallquantity of diesel oil into the inlet andexhaust ports.No diesel oil should seep through pastthe valve seats.

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

Assembling cylinder head:The cylinder head is assembled by follo-wing the removal procedure in the reverseorder.

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

3 L / M . . 09.96

- 13 -

Preparations:– 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 bea-

ring (98/1) with an internal puller.

Checking / repairs:– Examine the contact face for the shaft

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

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

needle roller bearing flush into thecrankcase.

– Insert the oil pump with bearing journalinto the needle roller bearing and placeit over the 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 sealant B.

– Re-assemble the engine in the reverseorder for dismantling.

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

3L / M . . 09.96

97

98

M 10.00 Oil pump

Checking oil pressure:– Unscrew the oil pressure sensing switch

and connect an oil pressure gauge withflexible hose - 13 - .

– Install the side panel and hood to enclosure.

– Start the engine and compare the oilpressure when it is at regular operatingtemperature with the values in Section4; see Fig. 99.

– Before assembly, coat the thread of theoil pressure sensing switch with sealantD.

3 L / M . . 09.96

99

–

Preparations:– 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 cover without hydraulic pumpdrive:– 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 con-nection (101/2) for the crankcase breatherhas been moved to the top of the crankca-se. The valve (101/1) was bonded into theair intake pipe until early 1987. Since thenit has been secured in the air intake pipeby two O-rings.– Remove the circlip (102/1) and coil

spring (102/2) from the pull rod of theengine shutdown device.From early 1996 an additional cupspring and an O-ring have been installedto seal the pull rod.

– Unscrew and remove the belt pulley(102/3) and the machine screws holdingthe timing cover.

– Pull off the timing cover and remove thegasket.

Checking parts:– Check the timing cover for cracks or un-

evenness of the sealing surface.– Examine the shaft sealing ring for dama-

ge and renew if necessary.– Press off the breather valve cap and

examine the diaphragm for damage.

3L / M . . 09.96

100

101

102

M 11.00 Timing cover

DismantlingTiming cover for hydraulic pump drive:Additional work:– Take off the hydraulic lines and hydrau-

lic 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 cover retai-ning screws (103/4) and taking off thetiming cover (103/6) the support mount(103/9) is exposed and can be taken offafter removing the two screws (103/7)with spring washer (103/8).

Note:– On older L 30/L 40 / H.L 30 engines

there is no support mount for the hy-draulic pump drive.

– H2L30 and H3L30 engines do not havea hydraulic belt tensioner. For this rea-son the pull rod is locked out of actionby a hoop. A blank cover is fitted in place of the shutdown 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 cover.– On the 2 and 3 L ... insert M 8 x 12

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

3 L / M . . 09.96

103

104

105

– Further timing cover attachment and en-gine assembly procedures are as descri-bed for removal, but working in the re-verse order.

Note:When renewing the breather valve, securethe new valve housing in the insert (105/3)with sealant E and then seal all aroundwith sealant 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 ofcylinder 1.The position of the opening can be variedby inserting or removing spacing washers(only on engines with crankcase breatherin timing cover).

3L / M . . 09.96

–

Preparations:– Detach the enclosure hood and side

panel; see M 35.00.– On 2-cylinder engines, detach the oil fil-

ler pipe.

Dismantling:– Remove the screws for the extra-fuel

device and take it off; see Fig. 106.

Dismantling the hydraulic extra-fueldevice:– Take off the circlip (106/1), unscrew the

threaded pin (106/2) and push out cylin-der (107/1).

– Take off the circlip (107/2) and pull outthe end 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).

Inspection / repair:– Inspect the piston and cylinder of the

extra-fuel device for score-marks orworn areas.

– Check the ball seat of the pressure relief valve for wear marks.

– Renew the O-ring seals.

Assembling the hydraulic extra-fuel device:– Assembly is as shown in Fig. 107,

working in the reverse order of dismantling.

3 L / M . . 09.96

106

107

M 12.00 Extra-fuel device

M 12.10 with injection pump PFR 1K 80

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

of the extra-fuel device's piston by pul-ling it out and letting it slide back; seeFig. 108.

Attaching:– The extra-fuel device is installed by fol-

lowing the removal instructions in theopposite order, taking particular carethat the gasket is correctly installed asshown in Fig. 109 and the scribed markis noted. Apply sealant H to both sidesof the gasket. Only a thin coat shouldbe applied, so that the oily in the extra-fuel device is not blocked. Install themachine 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 eccentrically located in the cylinder(107/1).

The effective stroke and, therefore, themaximum injected fuel volume are adjusted by turning this cylinder.For effective stroke requirements and ad-justing 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 eccentricwas not altered.

3L / M . . 09.96

108

109

- 34 -

Preparations:– see M 12.10.

Dismantling:– Pull terminal 7 off the solenoid valve

(only version with electric engine shut-down).

– Remove the screw (111/28) with sealingrings (111/36).

– Make a scribed mark on the crankcaseand the monitoring block, so that themonitoring block can later be re-atta-ched in the same position as before,and the original power setting is there-fore retained.

– Take out the retaining screws (111/5)and take off the engine monitoringblock.

Dismantling the engine monitoringblock:– Unscrew and remove the cover (111/9)

with sealing ring (111/10); on versionwith electric engine shutdown, unscrewthe solenoid valve (110/21) and take itoff complete 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), drive out locking collet(111/14) and remove shaft (111/12)from the housing.

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

3 L / M . . 09.96

110

111



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 monitoringblock:– Proceed in the reverse order of work

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

seated and note the scribed mark whichindicates the correct position; install themachine screws 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 lo-wer idle speed governed to ≥ 1700 rpmthe shaft (111/12) must be turned coun-ter-clockwise when assembling. Checkwhen the monitoring block is installed byturning shaft (111/12) counter-clockwise;it must then move back by itself to its initi-al position.

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

adjusted by turning the piston (111/18).For adjusting the fuel injection volumeand the correct procedure see sectionM 14.00. If the same monitoring block isdetached and re-attached, the fuel in-jection volume does not need to be ad-justed, provided that the setting ofpiston (111/18) was not altered.

If the monitoring block is renewed or afterit has been repaired, the fuel injection vo-lume (power setting) must always be adjusted.

3L / M . . 09.96

112

- 34 -


Dismantling:– Detach plug connector (164/1) from

engine wiring harness (electric versiononly).

– Take out machine screws (164/3) anddetach cover (164/4) and solenoid valve(164/5) with gasket (164/6)

– Make a scriber mark on the crankcaseand the servo block to ensure that theyare installed again in the same relativepositions and the power setting there-fore remains unchanged.

– Remove machine screws (164/2) andtake off the servo block.

Inspection / repair:– Turn lever (165/1) in the „Start“ direc-

tion. Shaft (165/2) is then turned by locking pin (165/3) and the sickle-pat-tern lever (165/4) moved to the startingposition.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 tothe starting position, but return to the„Stop“ position when the piston is relea-sed.

3 L / M . . 09.96

164

165

166


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)

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 pullshaft (164/9) out of the housing.

– Take out grub screw (164/12).– Remove circlip (164/13) and take out

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

Inspection / repair:– Examine piston to wear score marks.– Renew gaskets.

Assembling the servo block:– Assemble in the reverse order of work

for removal.When installing the piston, use bushing - 34 -.Note correct position of gasket (164/6)(oil hole).Apply sealant D to machine screws(164/3) and tighten them to a torque of6.5 Nm.

Attention:If the tightening torque is too high, theservo piston may seize (distortion).

Assembling:– Set the speed control lever to „Stop“.

Make sure that the gasket is installed inthe correct position (oil hole) and thatthe scriber markings are aligned.Insert machine screws (164/2) using sealant D and noting their correct posi-tions; attach a lead seal.

3L / M . . 09.96

167

Attention!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“ po-

sition and move piston (167/8) back andforth between the start and stop posi-tions. With the injection pump removedor the side cover taken off, the governorlever can be seen to perform the samemovement.

Checking valve solenoid:(Fig 168)– without electric control:– Valve pin 2 is in the rest position;

the connection between bores 3 and 4is closed.

– Apply the electric current to connection„7“ (yellow wire):the valve pin must extend by approx.6 mm.F » 15 - 20 N (loading can easily beovercome with the finger), free passagebetween 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 pas-sage between bores 3 and 4.

– If any repairs are made to the wiring,make sure that the plugs are wired upcorrectly (Fig. 169).

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

3 L / M . . 09.96

168

169

–

Preparations:– Take off the exhaust-system enclosure

(engines with enclosure only) and thesilencer (muffler); see A 03.00.

Encapsulated engines:– Take off the enclosure side panel, air

outlet duct, air guide housing and fanimpeller; see M 35.00.

Non-encapsulated engines:– 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

alternator.– Take out screws (117/1).– Pull out the fan housing.

Checking parts:– Check the fan housing sealing strips for

signs of damage; if necessary, attachnew sealing 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 thatthe sealing strips are correctly positio-ned.

– Re-assemble the items removed fromthe engine in the reverse order of workfor their removal.

– Make sure that the Poly-V belt is instal-led accurately.

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

3L / M . . 09.96

117

118

M 13.00 Fan

- 5 -

Preparations:– Take off the capsule hood and side

panel.– Detach the fuel delivery pipes from all

injector pumps, holding the pipe unionto prevent it from turning.

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

pipe to the injection pump you wish tocheck.

– Cover the pressure valve holders on theother injection pumps with absorbentcleaning cloths.

– Move the speed control lever to thestart position and run the starter.

If the spray pattern is correct, the pumpyou have checked is in good mechanicalworking order (no pump element wear, noleakage at pressure valve).

ATTENTION !Keep hands away from the injected fuelspray.The fuel spray from the injector nozzlecan cause blood poisoning if it contactsthe skin.

3 L / M . . 09.96

182

M 14.00 Fuel injection equipment

M 14.00 Injection pump, functional check

–

Preparations:– Take off enclosure hood, side panel

and cover for air guide housing;see M 35.00.

– Take off fuel filter and fuel deliverypump.

– Take off guide plate for oil cooler onS/Z.

– To remove pump for cylinder No. 1 onengines with shutdown solenoid, takeoff the starting charge device includingthe 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

position.– Remove the hex nuts for the injection

pump mounting and pull out the injec-tion pump.

– 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 at the timing end has a return-flow restrictor.During repairs, make sure that the cor-rect hollow screw is used or else the volume of fuel in the injection pump willbe altered.

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

charge control device and all side co-vers.

– Using water pump pliers, press out locking pin (119/1) until the governor lever can be moved to the flywheel end;see Fig. 119.

3L / M . . 09.96

– Unscrew and remove the extended stubbolt or machine screw (119/2) at the in-jection pump for cylinder 1 this also actsas a travel limiter for the governor rod.

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

governor rod (120/2) and pull out thegovernor rod guide (120/3) with packingseals.

119

120



– Drive locking collet (121/1) halfway intothe pull rod with a suitable split pin driver.

– Turn the pull rod through 180° and pullout the locking collet with water pumppliers.

– 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 betaken 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

instructions for its removal in the rever-se order.

– After installing the governor rod, secureits guide in position with the side cover:see Fig. 123.

Note:Clearance at the governor rod guide between crankcase and cover must notexceed 0.1 mm.If clearance is greater than this, insertpacking seals between the crankcase andthe governor rod guide.

3 L / M . . 09.96

121

122

123

– Using the speed control lever, locate thegovernor rod so that the groove for thetoothed rack pin on the flywheel-end in-jection pump is precisely in the centreof the mounting hole for the injectionpump in the crankcase; see Fig. 124.

– Check the position of the other groovesand if necessary reposition the slidingelements 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, usethe shim washers at the points from whichthey were previously removed. The figurestamped next to the injection pump indi-cates the thickness of the shims, e.g. 75 = 0.75 mm.

3L / M . . 09.96

124

-27 -


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

drilled stud bolt of pump 1 to lock thegovernor rod in the „X“-Position (141/1).

– Remove the hex nuts and spring was-hers securing the injection pump.

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

washer.Note:The installed positions of the gaskets,shim washers and injection pumps mustnot be changed, or else the start of fuelinjection will 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 presenceof spring (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 en-gage between the governor lever (126/1)and the leaf spring (126/3).

3 L / M . . 09.96

141

170

126



Installing the injection pump:– Connect the governor rod in the „X“-po-

sition.– When installing the injection pumps,

use the same shim washers and ga-skets as before.

– Insert the injection pumps and, beforetightening, press them towards the cylinder and position them so that thescribed mark on the pump flange isprecisely aligned with the correspon-ding notch on the crankcase (127/1).

Note:When installing a new injection pump,add up the figures on the pump flangeand the crankcase. The total of the two figures is the thickness of the shim washers with gaskets to be inserted, intenths of a millimetre. Never use morethan one steel shim washer. How to makeup the seal pack:

3L / M . . 09.96

127

Total thickness

(mm)

Paper gasket(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

- 4 - 37 -

Preparations:– Take off the enclosure hood and side

panel; 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 sea-ling ring (129/1) using impact extractortool - 4 -.

Functional check:– Connect extension tube with test pres-

sure gauge for fuel injection system- 37 - to the pressure tube connectionfor the injection pump; see Fig. 129.

– Connect the injector to the tester, coverthe remaining injection pumps over withclean cloths and start the engine.

Note:All injectors should be removed for thistest.

ATTENTION !:Keep the hands away from the fuel sprayemerging from the injectors.The fuel spray from the injectors can cause blood poisoning.

3 L / M . . 09.96

128

129


M 14.30 Injector

– Check the spray pattern of the injectoras shown in Fig. 130.

Assembling:– Install the injectors using new sealing

rings and working in the reverse orderfor their removal.

Note:– Place the seal on the injector so that

the soft graphited side is at the top towards the injector.

– Tighten the hex nuts to retain the injec-tor and the collar nuts on the pressurepipe to the specified torques (see Sec-tion 4), holding the pressure pipe con-nection on the injection pump to preventit from turning.

– The fuel pressure pipes from 2 L 40.17,3/4 L 40.16, M 40 L.13 and M 31 L have a smaller internal diameter andare identified by the section of hosepushed on to them.

3L / M . . 09.96

130

–

Preparations:– Remove the injector; see M 14.30.

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

ve 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 downslowly and smoothly under its ownweight on to its seat.

– Renew the nozzle if necessary.– Check the sealing faces on the nozzle

holder for damage.

Assembling:– Install the shim washers, spring, pres-

sure pin and spacer in the nozzle holderagain as shown in Fig. 132, in the oppo-site order from their removal.

– Attach the injector nozzle so that thepins on the spacer locate in the holeson the nozzle.

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

determine its fuel delivery pressure; forvalues, see Section 4.

– Correct the fuel delivery pressure by in-serting shim washers:Thicker washers = higher delivery pressureThinner washers = lower delivery pressure 0.15 mm » 15 bar.

3 L / M . . 09.96

132


M 14.40 Injector nozzle

7

6

5

4

3

2a

2

1

3L / M . . 09.96


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 -

Kind of repairAdjustmentsneeded Notes

Removing and installing resp.exchanging complete injec-tion pump

Repairing injection pump

Synchronising

Install shims again at the pointwhere they were removed

Injection pump must only be re-paired by authorised workshop

Renewing camshaft for injection pump

Renewing crankcase

Start of injection

Synchronising

Effective stroke

Measure effective stroke beforeremoval and restore when installing

Removing and installinggovernor rod

Renewing governor rod

Synchronising

SynchronisingEffective stroke

Measure effective stroke beforeremoval and restore when installing

Renewing starting chargecontrol

Effective strokeMeasure effective stroke beforeremoval and restore when installing

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

Start of injection

Synchronising

Effective stroke

All pumps on the engine must beconverted

For adjustment data see Section 4

Modifying the power setting Effective stroke Measure the original effective-stroke. Alter effective stroke onlyby difference value

1. Adjusting start of fuel delivery:

Note:Start the adjustment at the timing-end injection pump.

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

– Remove the pressure tube connectionand pressure valve at the injectionpump.

– Screw the overflow device - 10 - into theinjection pump.

– Screw the extension pin of the overflowdevice into the dial gauge - 11 - and insert it in the overflow device; see Fig. 133.

– Connect the fuel feed line from the testtank.

Note:The test tank must be attached at least200 mm (8 in) above the injection pump.

– Turn the crankshaft in the normal direc-tion of rotation (counter-clockwise whenlooking at the flywheel), until the dialgauge needle starts to move.

– Open the fuel feed; fuel will emergefrom the 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 slowlyuntil the fuel emerges from the overflowpipe slowly as separate droplets (approx.. 1 droplet every 5 - 6 seconds).

– This point is the start of fuel delivery.

3 L / M . . 09.96

133

– Read the angle in degrees at the in-spection hole in the connecting housing,and compare it with the desired value inSection 4. To take the reading, removethe plastic plug: see Fig. 134.On engines without a connecting housing, the fixed mark is stamped onthe crankcase.

Note:On engines built before or in 1980, theangle in degrees is only stamped on theengine for the first (timing-end) cylinder;only two marks are provided for the othercylinders. The short mark (half diameterof inspection hole) shows the angle forthe start of delivery, the long mark (full diameter of inspection hole) shows thepiston top dead centre point.

– If necessary, correct the start of fuel de-livery as follows:If the reading is smaller than the desired value:= fuel delivery starts too late.Remove shims.If the reading is larger than the desiredvalue:= fuel delivery starts too soon.Add more shims.

Note:Use a dial gauge as follows to determinethe thickness of the shims needed to cor-rect the value:

– Set the dial gauge to „0“ at the actualstart of fuel delivery, and turn the fly-wheel to the desired start of fuel delivery.The dial gauge will now show the thik-kness of the shims to be inserted or re-moved.

– Repeat the measurement procedure;the fuel drip from the overflow pipe onthe adjusting device must start preciselywhen the desired value is reached.

– Carry out the measuring procedure atall injection pumps.

3L / M . . 09.96

134

2. Adjusting end of fuel delivery:Note:Engines equipped with Type PFR 1K 80A439/2 injection pumps must be adjustedto the correct end of the delivery stroke.– Measuring procedure same as adjusting

start of delivery.– Turn the crankshaft in the normal direc-

tion of engine rotation until the gaugeneedle begins to move and the fuelemerging from the overflow pipe startsto drip slowly or ceases to drip.

– Continue to turn the crankshaft slowlyuntil the fuel just begins to drip from theoverflow pipe again (approx. 1 dropletevery 5 - 6 seconds).

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

agree with the desired value stated inSection 4.

– If necessary, correct it as described above.

3. Synchronising injection pump delivery volume:

– Move the governor rod by hand fully tothe right, to the „Stop“ position, andhold it there.

– Loosen all sliding elements (135/1) onthe governor rod; the toothed rack onthe flywheel-side injection pump mustbe in the „Stop“ position.

– Move the sliding elements for the otherinjection pumps to the right („Stop“ posi-tion) until the pump toothed rack isagainst its stop, and tighten there; seeFig. 135.

– Release the governor rod.– Before installing, coat the gaskets for

the cover and the starting charge deviceon both sides with sealant H.Apply the sealant only as a very thin coating to the starting charge device, toensure that its oilway is not blockedwhen assembling.

– Coat all bolt threads for the cover andstarting charge device with sealant D.

3 L / M . . 09.96

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 thepump governor rods will not be reached.

135

4. Adjusting effective stroke:(on engines with start of delivery adjustment)

– Install the start charging device and replace the cover by hydraulic startingcharge adjuster 619 845 00;see Fig. 136/3.

– Set the speed control lever to full loadand secure it there.

– Insert the overflow device with dial gauge, as described in the section „Adjusting start of 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 injectionpump has just reached the start of fueldelivery (approx. 1 droplet of fuel emer-ges every 5 - 6 seconds).

– Set the dial gauge to zero and continueto turn the crankshaft in the normal di-rection of engine rotation until the dialgauge moves from „0“ to precisely thenominal effective stroke value stated onthe type plate.

– In this position, fuel should start to dripout of the overflow device again.

– If this is not the case, loosen grubscrew (136/2) and turn the eccentricflow limiter (136/1) until the fuel beginsto drip out slowly.

– When the setting is correct, retightengrub screw (136/2), seal it with lacquerand install the cover again in place ofthe adjuster (136/3).

3L / M . . 09.96

136

5. Adjusting the effective stroke(on engines with end-of-delivery adjustment):

– Prepare for the adjustment in the sameway as described for start-of-deliveryadjustment.

– Set the injection pump to the end of fueldelivery.

– Turn the crankshaft in the opposite direction to normal rotation until the dialgauge shows the nominal effective stroke stated on the type plate.

– If necessary correct as described above. For 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 con-nection and tighten to the specified tor-que.

3 L / M . . 09.96

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 effecti-ve stroke value on the type plate.

– The effective stroke setting for the desired power is obtained from the original effecti-ve stroke 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 acc. table: 1,14 mm– Effective stroke for power output B acc. 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

3L / M . . 09.96


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 -

Important note:The threaded connections for the injection pump pressure valves must not be opened,or else pump pre-calibration will be changed.

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 engine speed

Adjusting max. idle speed.Varying injected volume for nominal power output.Adjusting damper spring (generator operation only)

1. Crankcase mark for adjusting startof fuel delivery:

– Insert measuring device - 25 - into thecalibrating device - 26 - and adjust it sothat both needles of the dial gauge areat „0“; see Fig. 138.

– Insert the measuring device into themounting hole on the injection pumpand screw it down firmly. The correctcam must be on its base circle.

– Turn the flywheel in the normal directionof engine rotation until the start-of-deli-very mark on the flywheel (15° beforeTDC) for the cylinder in question is alig-ned with the fixed mark on the crank-case or in the inspection hole of theconnecting housing; see Fig. 134.

– In this position, take the total dial gaugereading; see Fig. 139.

– From this total dial gauge reading, deduct 2.15 ± 0.05 mm and stamp theremaining value (without +/- sign or decimal point) into the crankshaft as atenths of millimetre value (140/1).Repeat this procedure for each pumpmounting hole.

3 L / M . . 09.96

138

139

140

2. Marking the crankcase for the radialposition of the injection pumps:

– Insert the locating pin - 27 - into the hollow-drilled stud bolt of pump 1 tolock the governor rod in position „X“(141/1).

– Insert the marking device - 23 - into theinjection pump mounting hole, turn clockwise to make proper contact andstamp the mark on the crankcase; seeFig. 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 moni-toring block housing or replace the val-ve solenoid by the plate of the adjustingtool -28-, then use a depth gauge tomeasure the distance „S“ from the outeredge to the flat face on the piston insi-de; see Fig. 143.

– Screw in the injection volume adjustingtool - 28 -, using a number of coopersealing rings according to the followingtable:

S (mm) Number of sealing rings

≤ 11,3 2≥ 11,3 1

see also Fig. 143.

3L / M . . 09.96

141

142

143

– Remove the second injection pump(looking from the timing end) and installmeasuring device - 24 - in its place (theball end on the vertical lever must enga-ge in the driving slot of the governorrod); 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

starting position.– Insert locating pin - 27 - into the hollow-

drilled stud bolt, then turn the adjustingscrew slowly clockwise until the locatingpin engages under light pressure in thecorresponding slot of the governor rod;Figs. 141 and 145.This determines the „X“ position of thegovernor rod.

– In this position, set the dial gauge scaleon the adjusting device precisely to „0“.

– Pull out the locating pin; the needle ofthe dial gauge should then move by0.01 - 0.02 mm.

– Determine the governor rod travel stated on the type plate (the figure is inhundredths of a millimetre).

– Turn the injection volume adjusting tooluntil the dial gauge shows the controldistance needed. Do not forget the 0.01 - 0.02 mm already indicated by thedial gauge.

Note:A minus value (= lower power range) isobtained by turning the adjusting toolclockwise, a plus value (higher power) byturning counter-clockwise.

– Tighten the grub screw (146/1) carefullyto prevent this setting from being lost,and secure it with lacquer.

3 L / M . . 09.96

144

145

146

3L / M . . 09.96

– 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 tostick, slightly reduce the preload at the grub screw (146/1) and repeat the check.

– Remove the adjusting device - 24 - and install the injection pump (M 14.20).

Note on changing the power settingAdjustment 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

governor rod travel setting plus (for increased power) or minus (for decreased power)the difference 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 limit and off-load. In addition, the engine must have reached its regular operating tem-perature, 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 approx.

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 dampingspring is not yet touching the governor lever. Unscrew the grub screw (146/3) at the monitoring block until no change in engine speed is detected.After this, retighten the grub screw (146/3) until the upper idle speed rises again by thesame value of approx. 0.3 %.

–

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 toprovide 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.

3 L / M . . 09.96

148

M 17.00 Schwungrad

- 20 - 21 - 39 -

Preparations:Encapsulated engines:– Take off the cover for the air guide

housing and front impeller.

Non-encapsulated engines– Take off belt guard, if fitted.

Removing:– Press back the tensioning roller and at-

tach the locking device - 36 - (Fig. 149).– Take out screws (150/3) with spring

washers 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 itscentering mount and take it off togetherwith the Poly-V belt.

– Detach the oil line (150/1) and removethe 3 machine screws (150/2) withspring washers.

– Detach the fixation (150/7) at the coo-ling fan, noting the installed shims.

– Take off the engine shutdown device(150/6).149

3L / M . . 09.96

150

M 20.00 Engine shutdown device / belt tensioner

Dismantling of engine shutdown device: (from engine serial numbers L 30.15, 2 L 40.12, 3/4 L 40.11).– Remove the locking device.

Attention:The piston with tensioning roller arespring-loaded; release the spring loadinggradually.– 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 the same time forcing the ten-sioning roller (151/6) back slightlyagainst its spring loading.

– Carefully release the spring loadingcompletely and pull out the piston(152/3) with spring (152/6) and filler(152/7).Remove the support disc(152/2) and quad ring (152/4) from thehousing.

– Take the restrictor screw (153/1) out ofthe back of the housing.

– Press the shaft out of the piston and remove the tensioning roller.

– Take off the Nilos rings (151/8). Drivethe ball bearings (151/9) out towardsthe outside in each case, since a circlip(151/10) is installed between them.

– Take out the support disc (151/11).

Checking the parts:– Check the piston for the tensioning rol-

ler and the bushings in the housing forscore- or wear-marks. If damaged, re-new the bushings or the piston.To renew the bushings, use specialtools - 20 - 21 - and press the bushingsin as shown 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 pul-

ley if any grooves are damaged or ribsbroken off.

– Check that the bore in the restrictorscrew is not blocked.

3 L / M . . 09.96

151

174

152

31

Assembling:– Assembly by following the dismantling

procedure in the reverse order.– Make sure that the Poly-V belt is fitted

correctly.

Assembly instructions:– Insert restrictor screw (153/1) with

sealant D.– Pack the Nilos rings (151/8) with anti-

friction bearing grease when assem-bling.

Note for older versions of L 30 / L 40engines:– The circlip (152/1), support washer

(152/2) and quad rings (152/4) and(152/5) have been installed since 1980.

– A ball pressure-relief valve was installedinstead of the restrictor screw (153/1)until about early 1982.

– A modified tensioning roller bearing isused from the L 30.15 / 2 L 40.12, 3/4 L 40.11 onwards.

3L / M . . 09.96

153

–

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 hou-sing to be raised.

– Cover the opening in the intake pipe toprevent dirt or other foreign bodies fromentering.

– Open the air cleaner housing and takeout the 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 filterelement (177/7) to be raised.

– Cover the opening in the suction pipe toprevent dirt and other foreign bodiesfrom entering.

Inspection / repair:– Check the sealing faces for signs of

damage.– Clean the filter housing and the cover.Spacer „5“ is connected by an elasticsleeve „6“ with the retaining screw, so thatit cannot fall into the intake pipe duringmaintenance work.– If the spacer is loose, renew bushing

„6“.

Assembling:– Follow the instructions in the reverse

order.

3 L / M . . 09.96

175

176

177

M 22.00 Air cleaner

1

L3/58

3

6

5

4

5

21

3

7

–

General:The crankcase breather operates by wayof a diaphragm valve in the intake pipe.During maintenance or repair work, inparticular if the engine's oil consumptionis high or it is producing too much blueexhaust smoke, you are recommend tocheck the condition of the diaphragm.

Dismantling:– Pull housing 1 with cap 2 and dia-

phragm 3 out of the intake manifold andhose 4 (Fig. 178).

– Pull cap 2 out of housing 1 and removediaphragm 3.

Inspection / repair:– Examine the diaphragm for cracks and

renew if necessary.– Renew O-rings 5.

Assembling:– Proceed in the opposite order to that

described above.

3L / M . . 09.96

178

M 31.00 Crankcase breather

1

2

3 4

5

–

Preparations:– 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

remove the oil filler pipe; see M 12.00.

Dismantling:– Remove machine screws (154/1).– Turn the speed control shaft counter-

clockwise to the „Stop“ position and pullthe governor rod towards the flywheelend; see Fig. 155.

– As shown in Fig. (155/1), move the governor lever over to the timing sideand pull it out 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)and pull off the speed control fork(156/7).

– Unscrew the tensioning plate (156/8)and remove circlip (156/10), supportwasher (156/11) and shim(s) (156/12).

– Pull off governor shaft stop (156/13), remove circlip (156/14) with spacingwasher (156/15) and pull out shaft(156/9).

3 L / M . . 09.96

154

155

156

M 32.00 Speed control

M 32.10 Engines with PFR 1K 80 injection pump

Inspection / repair:– Check ball bearing at governor lever for

wear.– Check governor lever, pin for speed

control, fork, adjusting shaft and hou-sing for score-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 tensio-ning plate. Push on the fork (157/3) anddrive the locking collet (157/4) in flushwith the fork; see Fig. 157.

– Push on the sleeve (158/1) and torsionspring (158/2), then drive in the lockingcollet (157/4) flush with the fork; seeFig. 158. Preload torsion spring (158/2)by a quarter-turn clockwise, then con-nect to the locking collet.

– Further assembly is in the reverse orderfor dismantling; use a new gasket.

– Apply sealant D to screws (154/1) wheninserting.

3L / M . . 09.96

157

158

–

Dismantling:– Remove machine screws (154/1).– Turn the speed control shaft anti-clock-

wise to the „Stop“ position and pull thegovernor rod towards the flywheel endof the engine; see Fig. 179.

– Turn speed control mount (179/1) to theright and pass governor lever (179/2)under governor rod (179/3).

– Carefully pull the speed control mountout downwards.

Dismantling the speed control:(Fig. 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.

Inspection / repair:– 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.

3 L / M . . 09.96

154

179

180

M 32.00 Speed control

M 32.20 Engines with PFR 1K 90 injection pump

Assembling:– Drive in locking collet (181/1) until it

projects 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 byusing a suitable tool.

– Continue installation by following the re-moval instructions in the reverse order.

Note:Since there are various patterns of gover-nor lever, make sure when repairing thespeed control that the original governorlever is installed again.If the governor lever or the completespeed control is renewed, note that torqueequalisation may have been activated atthe original governor lever.In case of doubt, contact your nearestHATZ service point.

3L / M . . 09.96

181

–

Preparations:– Remove the engine.

Note:Normally it is only necessary to removethe engine from the equipment in which itis being used in order to dismantle theenclosure if the air guide housing or rearpanel have to be taken off.– Remove exhaust enclosure;

see A 03.00.

Dismantling:– Take off the hood (159/1), speed control

lever (159/2), side panel (159/3) and cover plate (159/4).

– Detach the air outlet shaft (160/1) andcover plate (160/2).

Note for 4 L 40 C:Take out the cooling air guide lining ele-ments.

– Take off the cross-member above theinjectors and raise the engine slightly atits suspension lug until the baseplate ofthe enclosure can be unscrewed andremoved.

– Detach the feet from the engine.– When the feet have been removed, the

four 22 mm hex bolts used to attach thebaseplate should be used to supportthe engine.

3 L / M . . 09.96

159

160

M 35.00 Capsule

– Unscrew the earth (ground) strap andthe + 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 guidehousing (162/1).

– Take out the screws holding the fan im-peller (162/2) and remove the impeller.

– Take off the air guide housing;see Fig. 163.

Checking the parts:– Examine the various sections of the en-

closure for damage.– Renew damaged or incomplete sealing

strips.

Assembling:– Assemble the enclosure by following the

dismantling instructions in the reverseorder as appropriate.

Note:Make sure that all enclosure sections arecarefully installed and that all sealingstrips are seated correctly. Unless the en-closure is completely sealed, neither thepotential level of noise reduction nor ade-quate cooling can be ensured.

3L / M . . 09.96

161

162

163

4L / M . . / 07.96

4. Tables

4 L / M . . / 07.96

Tightening torques for threaded connections

General requirements in Nm:

Nm ÷ 9.81(10) = kpmNm ÷ 1.3558 = lb ft

8.85.8 10.9 12.9Thread

Screw strength rating

M 4

M 5

M 6

M 8

M 10

M 12

M 14

M 16

M 18

M 20

M 22

1.7

3.4

6.0

14

29

50

80

120

170

240

320

2.8

5.5

9.5

23

46

80

130

190

270

380

510

3.9

7.8

13

33

65

110

180

270

380

530

720

4.7

9.3

16

39

78

140

220

330

450

640

860

Tightening torques in Nm

4L / M . . / 07.96

L 31. M 31Engine L 30 L 40. M 40

L 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) 60 60M 11 x 1 (10 mm Allen screw) – 115

Machine screws for counterweights 65 65

Machine screws for end cover, flywheel side(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 85 85L 41. M 41 40-50

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

Support mount for front engine feet (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

4 L / M . . / 07.96

Repair data

Cylinder head L 41 L 31, M 31 L 30 H .L 30M 41 L 40, M 40

Gap mm 0.85-0.95 1.0 - 1.1 1.0 - 1.1 1.0 - 1.5

Gasket at cylinder head mm 0.7 - 0.8 - 0.9 - 1.0 - 1.1 -1.2 1.2

Shim washers 1) mm – – – 0.1 - 0.2

Valve clearance, cold (20 ± 10°C) mm 0.10 0.10 0.10 0.40 2)

Valve stem ∅ mm 8.96 -0.015

Wear limit ∅ mm 8.85

Inlet valve head ∅ mm 43.1 -0.3 40.1 -0.3

Exhaust valve head ∅ mm 39.1 -0.3 35.1 -0.3

Recess of valve head max. mm 0.15 1.70 1.70 1.70min. mm 0.00 0.85 0.85 0.85

outer ∅ mm 15+0.046 +0.038

Valve guideinner ∅ mm 9H6

+0.0090

Wear limit innen ∅ mm 9.05

Bore in cylinder head ∅ mm 15+0.006

-0.012

Pressing-in force N 1000

Valve guide projection mm 20.5 23.5 (l=70.5) 20.5 14.520.5 (l=67.5)

Valve seat angle 45°

1) As required, between cylinder and crankcase2) If steel pushrods are used: 0.20 mm

Repair data

4L / M . . / 07.96

Cylinder head L 31. M 31L 40. M 40 L 30 H .L30L 41. M 41

Length of inner valve spring,off-load mm 45.5

Wear limit mm 44.0

Length of outer valve spring,off-load mm 58.0

Wear limit mm 56.5

Rocker shaft ∅ mm 19 f 6 -0.020

-0.033

Wear limit ∅ mm 18.90

Bore in rocker ∅ mm 21 H 7 +0.0210

Rocker bushing innen ∅ mm 19 +0.046-0.012

Wear limit innen ∅ mm 19.20

Radius at rocker mm 8(no flats allowed)

Axial clearance of rocker mm 0.1 - 0.2(insert shims only onthe circlip side)

4 L / M . . / 07.96

Repair data

Camshafts (injection pump drive and valve gear)

Camshaft bearing journal diameters

Governor side and centre mm 54 e 6 -0.060-0.079

Wear limit mm 53.85

Flywheel side mm 20 m 6 +0.021

(ball bearing seat)+0.008

Internal diameter of bearing bore in crankcase

Governor side mm 54 H 7 +0.030 (bushing for. 54 +0.0580

camshaft)-0.002

Wear limit mm 54.10

Centre mm 54 H 7 +0.0300

Wear limit mm 54.10

Flywheel side mm 47 K 7 -0.007

((ball bearing seat)-0.018

Bore for tappet mm 16 H 7 +0.018

in crankcase0

Wear limit mm 16.05

Tappet shaft ∅ mm 16 f 7 -0.016-0.034

Wear limit mm 15.9

Axial clearance of camshaft mm 0.1

Repair data

4L / M . . / 07.96

Balancing weights

Bearing point diameters – two- and three-cylinder engines

Balancing weight shaft mm 28 h 5 0

-0.009

Axial clearance – two-cylinder engines mm 0.15 - 0.6– three-cyliner engines mm 0.15 - 0.7

Wear in the needle roller ∅ mm bis 27.97bearing area

Bearing point diameters - four cylinder engines

Bearing journals for balancing weights mm 44 d 6 -0.080-0.096

Bearing bushing for balancing mm 44 +0.018

weights (pressed-in)+0.083

Endplay mm 0.15 - 0.4

4 L / M . . / 07.96

Repair data

.L 30 / H .L30 .L 31 / .M31 .L41/.M41..L 40 / .M40

Conrod

Bore for piston pin (small end) ∅ mm 35 H 6 +0.016

39 H 6 +0.016

bushing0 0

Big end bore ∅ mm 63 H 6 +0.019

67 H 6 +0.019

0 0

Piston pin bushing external ∅ mm 35 +0.085

39 +0.085

+0.045 +0.045

pressed-in internal ∅ mm 32 +0.075

36 +0.080

+0.030 +0.035

Wear limit internal ∅ mm 32.30 36.30 36.30

Max. misalignment.* mm 0.08 0.08 0.08

Cylinder

Bore mm 95 +0.01 102 +0.01Wear limit mm 95.15 102.15Oversize mm +1.0 +0.5 / +1.0**

Roughness Ra 0.9 - 1.3 µ (1 µ = 1/1000 mm)

Piston

Normal ∅ mm 94.94 101.92 101.90Oversize mm +1.0 +0.5 +1.0**Clearance max. mm 0.07 0.09 0.11Clearance min. mm 0.06 0.08 0.10

Piston pin bore ∅ mm 32 +0.009

36 +0.010

+0.004 +0.004

Wear limit mm 32.05 36.05 36.05

Piston pin ∅ mm 32 0

36 0

-0.006 -0.006

Wear limit mm 31.95 35.95 35.95Piston ring endplay max. mm 0.2 0.2 0.2

* At 300 mm length: conrod must not be readjusted.** These oversize-cylinders resp. pistons are no more available.

Repair data

4L / M . . / 07.96

Piston rings.L 30. H.L30

Piston rings.L 31 / .M 31 / .L 40 / .M 40 / .L 41 / .M 41

Ring groove No. Designation Dimensions End 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-chamfer

95 x 87 x 30.40 - 0.65 2.0

Oversize 96 x 87.9 x 3

IIStandard

D-ring95 x 87 x 5

0.30 - 0.60 2.0Oversize 96 x 87.9 x 5

Ring groove No. Designation DimensionsEnd gap mm:

normal max. 1)

IStandard

Trapezoidal102 x 93.4 x3

0.40 - 0.65 1.2Oversize 102.5 x 93.9 x 3

103 x 94.4 x 3*

IIStandard

Cutaway micro-chamfer

102 x 93.4 x 2.50.40 - 0.65 2.5

Oversize 102.5 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 4

103 x 94.4 x 4*

1) These are maximum limit values which canstill be accepted without risk of enginepower output, oil consumption and exhaustemissions being affected.The piston rings should be renewed duringrepair work if they have worn to 60 % of thelimit value.

* These oversize piston rings are no longeravailable.

I

II

III

4 L / M . . / 07.96

Repair data

Crankshaft .L 31 / .M 31.L 30 / H .L 30 .L 40 / .M 40

.L 41 / .M 41

Crankpins ∅ mm 60 h 6 0 64 h 6 0-0.019 -0.019

Wear limit mm 59.88 63.88

Out-of-roundness max. mm 0.05 0.05Conicity max mm 0.003 0.003

Width mm 32 H 9 +0.062 32 H 9 +0.0620 0

Radius mm 3.5 4.0 +0.3

Centre bearing journal ∅ mm 72 h 6 0 72 h 6 0-0.019 -0.019

Out-of-roundness max. mm 0.05 0.05Conicity max. mm 0.003 0.003Width mm 32 +0.3 32 +0.3Radius mm 3.5 -0.2 3.75 -0.2

Main bearing journal, ∅ mm 72 h 6 0 72 h 6 0

governor side-0.019 -0.019

Out-of-roundness max. mm 0.05 0.05Conicity max. mm 0.003 0.003Width mm 26.5 -0.2 26.5 -0.2Radius mm 3.5 -0.2 3.5 -0.2

Main bearing journal, ∅ mm 72 h 6 0 72 h 6 0

flywheel side-0.019 -0.019

Out-of-roundness max. mm 0.05 0.05Conicity max. mm 0.003 0.003Width mm 27 ± 0.2 32 +0.3Radius mm 3.5 -0.2 3.75 -0.2

Contact face for shaft ∅ mm 70 h 11 0 80 h 11 0

sealing ring, flywheel side-0.190 -0.190

Repair data

4L / M . . / 07.96

Crankshaft .L 31 / .M 31.L 30 / H .L 30 .L 40 / .M 40

.L 41 / .M 41

Regrinding during repairs mm 0.5 0.5Hardness Rc 50 - 55 50 - 55Hardening depth mm 2.5 2.5

Big end bearing internal (installed)Normal ∅ mm 60 +0.083 64 +0.063

+0.040 +0.040

Wear limit ∅ mm 60.20 64.20

∅ mm 59.5 +0.083 63.5 +0.083+0.040 +0.040


Normal wall thickness mm 1.468 - 1.480 1.468 - 1.480Undersize mm 1.718 - 1.730 1.718 - 1.730

Internal (installed) main bearing.Normal ∅ mm 72 +0.099 72 +0.099

+0.056 +0.056


Undersize ∅ mm 71.5 +0.099 71.5 +0.099+0.056 +0.056

Wear limit ∅ mm 71.75 71.75Wall thickness. normal mm 2.960 - 2.972 2.960 - 2.972Undersize mm 3.210 - 3.222 3.210 - 3.222

Crankshaft endplay mm 0.15 - 0.65 0.15 - 0.65

Max. permissible bearingclearance after waer mm 0.3 0.3

4 L / M . . / 07.96

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

1) Interchangeable2) With governor-rod stop at pump3) Without governor-rod stop at pump:

governor-rod limiter needed on engine

From engine serial numbers: 2 L 40.17. 3 - 4 L 40.16. M 40.13. L 31. M 31. L 41. M 41

Injectors

Engine type Injection pump HATZ Ident No. Start of delivery

2 - 4 L 30H .L 30

PFR 1 K 80 A 442/2 1)

PFR 1 K 80 A 442/11 1)

PFR 1 K 80 A 467 1)2) 501 407 0017 - 18°

before TDC

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

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 00 15° before TDC

L 41. M 41 PFR 1 K 90 A 546 504 442 01 10° before TDC

Engine type HATZ Ident No. Injector nozzleBosch HATZ Spray pressure

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

Governors

4L / M . . / 07.96

L 30. H .L 30

* When driving a generator at 1500 and 1800 rpm. governor weights with Ident No. 036 349 00were used from 1979 to 1982. They are identifiable by a „G“ stamped on the end or a whitespot.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

* Identifiction: windings are slightly grounded at circumference.

L 31. M 31. L 40. M 40 with injection pumps PFR 1K 90A 498, L 41 and M 41

* With this governor spring the spacing ring ident No. 037 729 00 is deleted (Fig. 48a/50)

Speed ApplicationGovernor spring Governor weight

Ident-No.Ident-No. Wire ∅∅ mm

≤ 2300Normal operation

036 012 01 3.0

035 729 00

> 2300 035 744 01 3.21500 *

Generator drive

036 014 01 2.51800 * 036 013 01 2.63000 035 744 01 3.2


Ident-No.Ident-No. Wire ∅∅ mm

≤ 2300Normal operation

036 012 01 3.0

035 729 00

> 2300 035 744 01 3.21500

Generator drive

037 739 00 2.5*1800 036 013 01 2.63000 035 744 01 3.2


Ident-No.Ident-No. Wire ∅∅ mm≤ 2300

Normal operation036 012 01 3.0

035 729 00

> 2300 035 744 01 3.21500

Generator drive

038 670 00 2.3*1500 036 014 01 2.51800 036 013 01 2.63000 035 744 01 3.2

4 L / M . . / 07.96

Lubricating oil content and dipstick

Note:The lubricating oil contents stated here are to be understood as approximate; they apply to engines with a lubricating oil cooler and refer to oil changes including renewal of the lubricating oil filter.In certain cases engines of versions „S“ and „Z“ are not equipped with an oil cooler. In this casethe oil content is reduced by approx. 0.2 - 0.5 litre.In all cases fill to the „max“ mark on the dipstick.

Engine type Oil sump Oil contentl

Dipstickmarking

2-cylinder engines.L.. C / Z

.L.. S. M..

withwithout

withwithout

7.54.5

8.55.5

CA

CA


.L.. S. M..

withwithout

withwithout

10.58.0

11.08.5

DA

DA


.L.. S. M..

with

with

13

14

D

D

Key to circuit diagrams (DIN 40719)

4L / M . . / 07.96

Key Designation of electrical component

A 1 Instrument boxA 2 Instrument panelA 3 Automatic start-stopA 4 Starter protection moduleB 1 Temperature sensorB 2 Speed-pulse transmitterB 3 Oil pressure sensorB 4 Signal hornC 1 CondenserE 1 Fuel filter heaterF 1 FuseG 1 BatteryG 2 AlternatorG 3 Flywheel generatorH 1 Generator telltale lightH 2 Oil pressure warning lightH 3 Engine overheat warning lightH 4 Air filter telltale light (maintenance switch)H 5 Belt break warning lightH 6 Pre-heat monitor telltale lightH 7 Fan monitor warning lightH 8 Remote desplay: engine lightK 1 Control relay 1 for start / start repeat interlockK 2 Control relay 2 for pre-heatingK 3 Control relay 3 for speed controlK 4 Engine protection relayK 5 Delaying relayK 6 Start inhibit relayK 7 Timer (impulse) relayK 8 Power relayM 1 Starter motorMG Starter generatorN 1 Voltage regulator for starter generatorN 2 Voltage regulator for flywheel generatorN 3 Voltage regulator for alternator (unless integrated)N 4 Pulse transmitter (additional item for synchro-regulator)P 1 Operating hours counterP 2 Revolution counterP 3 Pressure gauge

4 L / M . . / 07.96

Key to circuit diagrams (DIN 40719)

Key Designation of electrical component

R 1 Pre-heat plugR 2 Heating flangeR 3 Line resistor for pre-heat systemR 4 ResistorR 5 Line resistor with thermo-time switch

S 1 Pre-heat start switch (5-position)S 2 Master switchS 3 Pre-heat/start switch (3-position)S 4 Start-stop-switchS 5 Switch for speed controlS 6 Engine temperature switchS 7 Oil pressure switchS 8 Pressure switch for air-filterS 9 Fan monitoring switchS 10 Pre-heat temperature switchS 11 Remote-start switchS 12 Remote stop switch

T 1 Transducer for speed measurement

V 1 Decoupling diodeV 2 Freewheeling diodeV 3 Zener diodeV 4 Suppressor diode

W 1 Earth (ground), negative return lineW 2 Screened line at generator

X 1 Terminal strip at instrument boxX 2 Flat-pin junction boxX 3 Plug at emergency stop switchX 4 Socket at emergency stop switchX 5 Terminal block in control box / terminal box

Y 1 Solenoid for speed controlY 2 Solenoid for engine shutdownY 3 Servo (valve) solenoid for engine shutdownY 4 Fuel shut-off valveY 5 High-presure shut-down valve

Z 1 Suppressor chokeZ 2 Suppressor capacitor

HATZ - Wiring identification

4L / M . . / 07.96

Terminal Designation

0 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 filter 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* * *

4 L / M . . / 07.96

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4 L / M . . / 07.96

Trouble-shooting table for electrical system

Trouble-shooting at instrument box

Malfunction

Starter remains engaged although pre-heat/starterswitch was released.

Alternator telltale light doesnot come on when engine isstopped and pre-heat/starterswitch is on.

Generator telltale light flickers.

Generator telltale light continues to glow, after starting engine.

Cause

Pre-heat/starter switch sticks inposition 3 after starting anddoes not return automatically toposition I.

Bulb has blown or contacts arecorroded.Battery is flat.Battery is defective (internalshort-circuits or sulphatised).Defective pre-heat/starter switch, poor connections, defective wiring, contact resistance in charging currentcircuit or line to generator telltalelight.Defective voltage regulator.Short-circuit at exciter or positive diode in generator.

Worn carbon brushes.Oxide desposit on sliprings,exciter winding is interrupted

V-belt loose at generator.

Poor earth (ground) connectionin instrument box.Wiring error, e.g. generator tell-tale light leads to oil pressureswitch.

Remedy

Set pre-heat/starter immediatelyto 0 by force; if this is not possi-ble, disconnect the battery atonce. (If the starter remainsengaged for more than 2 to 3minutes, it will burn out.)Renew the pre-heat/starterswitch.Insert a new bulb, clean the contacts.Reacharge the battery.Renew the battery.

Eliminate contact resistance,renew wiring, tighten loose terminals, if necessary renewpre-heat/starter switch.

Renew voltage regulator.Disconnect charge line B+ (toprevent discharge at a standstill),have generator repaired.Renew carbon brushes.Have generator repaired.

Correct V-belt tension.

Make a clean earth connection inthe instrument box.Check the line from the generatortelltale light to the generator andcorrect the wiring if necessary.


4L / M . . / 07.96

Trouble-shooting at the battery

Malfunction

Battery not rechargedor insufficientlyrecharged resp. goesflat rapidly.

Indication

Terminal voltage dropseven a short time afterrecharging to 7 Vdespite a 12 V nominalvoltage (or 14 V ifnominal voltage is 24 V).

Cause

Poor connections, open circuit or contactresistance in chargingcircuit, short-circuit inline.Battery defective, inter-nal short-circuit.Capacity of battery hasdropped severely, be-cause it was heavilydischarged for a lengthyperiod (greyish-whitecell plates = „sulphati-sed“).

Battery poles connectedwrongly, destroying oneor more diodes in thegenerator.

Charge current too weak(esp. in winter).Battery capacity is toolarge.

Defective voltage regula-tor (e.g. overheated /overladed).Loose V-belt at generator.

Remedy

Eliminate the open circuit, clean the termi-nals, tighten terminals if slack.

Renew battery.

Recharge battery at lowcurrent (approx. 1/40 ofnominal capacity inAmps) for about 50hours. (This is onlypossible if sulphate coa-ting is not yet toostrong.)Otherwise:renew the battery.

Repair generator

Recharge the battery.

Install a smaller batteryor a larger generator.

Renew the voltage regulator.

Correct V-belt tension.

4 L / M . . / 07.96



Malfunction

Corroded terminalclips.

Battery is overcharged.

Acid level is too low.

Indication

Inadequate currentflow, white salt depo-sits.

Voltage at terminals is always above 16.5 V with 12 Vnominal voltage (orabove 33 V with 24 Vnominal votage), spe-cific gravity of acid isabove 1.285 kg/l sothat the battery boils.

Acid is escaping fromthe cell plugs.Acid level less than10 mm (0.4 in) belowtop of cell plates.

Cause

Sulphuric acid attacsmetals (except lead).

Charging voltage toohigh.Capacity of chosenbattery is too small.

Engine run continuous-ly (several days) withvery little electricalconsumption (e.g. as aboat engine).Defect in voltage regu-lator or generator.

Acid level is too high.

Overloading or naturalwater loss by evapora-tion (particularly insummer).

Remedy

Wash down terminalswith hot soda lye (but thismust not enter the bat-tery!), rinse with coldwater and apply acid-resi-stant grease.

Check voltage regulator,renew if necessary.Install a battery of largercapacity. As a temporarymeasure, discharge thebattery at intervals, e.g.by switching on an elec-trical consumer when theengine is not running.Install a voltage regulatorwith a different characte-ristic (lower charge-endvoltag

Have the voltage regulatorand generator checked,renew defective compo-nents.Siphon off excess acid.

Add distilled water ordemineralised water.


4L / M . . / 07.96


Malfunction

Battery fails pre-maturely.

Too little powerfrom battery.

Indication

Voltage dropsseverely whenload is applied.

Cause

Battery was discharged toooften and too serverely.

Battery becomes too warm.

Excessive vibration.

Battery is discharging sulpha-tes.

Battery acid is contaminated.Run the battery down.

Voltage regulator is defective,so that charging voltage istoo low.Connecting terminals loose oroxidised.

Battery capacity is too small(too many consumers).Battery is going flat becauseof impurities in its acid.Sulphate deposits from bat-tery (white coating on plates).

Battery is exhausted, activesubstance has fallen out ofplates.Acid level too low.

Remedy

Check ratings of battery andgenerator, if necessary fit aspecial „Z“ or „HD“ battery.Install it at a more favourablepoint.Install battery at a morefavourable point or use an„Rf“ battery (shakeproof)Charge the battery at a smallcurrent level (approx. 1/40 ofits norminal capacity inAmps) for about 50 hours.Failing this, renew the bat-tery.Renew the battery.Recharge battery with a sui-table charger.Renew voltage regulator ongenerator.

Clean the terminal clips andapply acid-proof grease tothem, then retighten the ter-minal clips.Install a larger battery and ifnecessary a larger generator.Renew the battery.

Charge the battery for approx.50 hours at a low current.Failing this, renew the bat-tery.Renew the battery.

Top up with distilled water.

4 L / M . . / 07.96



Malfunction

Rate of charge neveradequate.

Indication

Terminal voltage soondrops to 7 V afterrecharging (12 Vnominal voltage) or to14 V (24 V nominalvoltage).

Cause

Fault in generator, volta-ge regulator or wiringconnections.

V-belt too loose.

To many consumers connected or generatoris too small.

Remedy

Repair or renew gene-rator and voltage regu-lator. Connect wiringfirmly.

Corret tension or renewV-beltInstall battery andgenerator with similarratings.


4L / M . . / 07.96

Trouble-shooting at the starting device

Malfunction

Starter motor does not turn when pre-heat/startswitch is operated.

Indication

Generator telltale lightdoes not come on.

Telltale light growsslowly dimmer whenpre-heat/start switch is operateTelltale light burnsbrightly.Bridge terminals 30and 50 briefly at thestarter motor, the starter then turns.

Telltale light burnsbrightly. Terminal 30 isnot connected to posi-tive battery pole.

Telltale light burnsbrightly, solenoidswitch is energised,when solenoid switchis bridged, startermotor turns.

Cause

Poor connections (looseor corroded), break incable or short to earth(ground).

Battery flat or defective.

Battery is flat.

Line between terminal 50and starter switch or bet-ween terminal 30 andbattery is interrupted orstarter switch is faulty.Starter inhibit relay ordelaying relay defective. Starter pre-engagementwinding has burned out.

Worn or dirty contactson solenoid switch.

Remedy

Check battery lead andconnections, clean battery poles and termi-nals, make sure connec-tions are clean.Recharge or renew battery.Recharge the battery.

Repair the break or ifnecessary renew thestarter switch.

Renew defective relay.

Renew the starter motorand ensure a good con-nection between terminal30 at the starter and thepositive battery post(main starter line).Renew solenoid switch.

4 L / M . . / 07.96



Malfunction

Starter motor turnstoo slowly or can-not turn the engineover.

Starter engagesand is energized,but engine doesnot turn or onlyturns jerkily.

Starter pinion does not engage or disengage.

Indication

Lengthy operatingperiod without mainte-nance or in toughenvironmental condi-tion.

Lengthy operatingperiod without mainte-nance, electricalsystem has beenneglected.

Engine does not turn,or turns jerkily.

Cause

Carbon brushes sticking.Carbon brushes worn.Poor spring pressure,carbon brushes notmaking contact.Commutator is dirty.Commutator is scoredor burnt.Armature or field coilsdefective.Battery is flat.Low current flowbecause of loose orcorroded connections.Carbon brushes sticking.Carbon brushes worn.Commutator dirty.Commutator scored orburnt.Armature or field win-dings defective.

Starter pinion or helical thread dirty ordamaged.Flywheel gear ringdamaged.Solenoid switch defective.Return spring weak orbroken.

Remedy

Renew brushes and brushholder guides.Renew carbon brushes.Renew springs.

Clean the commutator.Recondition or renew startermotor.Recondition or renew startermotor.Recharge the battery.Clean battery terminals,tighten connections.

Renew carbon brushes andbrush holder guides.Renew carbon brushes.Clean commutator.Recondition or renew thestarter motor.Recondition or renew thestarter motor.

Renew starter pinion, recon-dition starter motor.

Remachine or renew gearring.Renew solenoid switch.

Renew return spring.


4L / M . . / 07.96


Malfunction

Starter motor continues to runafter switch wasreleased.

Engine does notstart or startsreluctantly, alt-hough the startermotor is turningstrongly.

Indication

Noise of rotation.

Cause

Starter relay defective.

Pre-heat/switch does notreturn automatically fromposition 3 to position 1.

Diode in shutdown soleno-id (lifting or servo electro-magnet) is defective.Valve solenoid on moni-toring block is not opening.

Pre-heat system is defecti-ve (only significant at temperatures below -10 to -15°C.)

Remedy

Switch of engine manuallyat once (set speed controllever to „stop“ and discon-nect battery). Consequentialdamage: electronic compo-nents destroyed.For example: diodes ingenerator. Check switches,relays and generator, renewparts if necessary.Set pre-heat/start switch to0 immediately using force ifnecessary and renew it. Ifthis is not possible: disconnect the batteryimmediately. Consequential damage: dio-des in generator destroyed.Attention!Unless the above measu-res are taken within 2-3minutes, the starter motorwill burn out (overheating)

Renew solenoid.

Check operation of valvesolenoid and renew ifnecessary.Check pre-heat circuit andrenew any defective parts.

4 L / M . . / 07.96


Trouble-shooting at the pre-heat system

Malfunction

Spiral indiator element(pre-heat monitor) glowsbrightly almost immedi-ately.

Interruption of pre-glowdevice pre-heat monitordoes not burning.

Cause

Short to earth (ground) in a pre-heat plug, pre-heat element (fila-ment) is bent and shorting insideengine.Broken pre-heat wires in a lineresistor, winding shorted to anearthed component.Since the pre-heat monitor, pre-heat plug or heating flange (andalso the second pre-heat plug orline resistor on 24 V systems) arewired in series, the complete pre-heat system is out of action if acomponent fails.

Remedy

Renew the pre-heat plug.

Renew the line resistor.

Use a test lamp or a voltmeter (withthe pre-heat system switched on) to check all the pre-heat monitorconnecions.Renew defective parts.


4L / M . . / 07.96

Trouble-shooting at the alternator

Malfunction

Generator telltale light does not go out as engine speed increases.

Generator telltale lightdoes not go out at lowengine operating speed(e.g. 1500 rpm)

Generator telltale lightglows only dimly whenengine is stopped andpre-heat/start switch isoperated, battery notbeing charged, or char-ging only at a low rate.

Cause

Line D+/61 has a short to earth.

Voltage regulator on generatoris defective.Wiring connections interchan-ged at generator.V-belt for generator is slippingor broken.Defective rectifier on generator,dirty sliprings, short-circuit inline DF or rotor winding.Generator is not sufficientlyexcited by telltale light. A 2 Wattbulb is normally used in thelight.Rate of charge too low, briefengine operating periods (parti-cularly when a maintenance-free, vibration-proof battery isused).Poor connections, open circuit,contact resistance or short-cir-cuit in charging circuit.Battery is defective, internalshort-circuit.Battery capacity has droppedseverely through being left flatfor a long time (sulphate depo-sits).Battery capacity is too large.

Alternator is defective.Voltage regulator is defective.Loose V-belt at alternator

Remedy

Renew the line or repair the short toearth.Renew voltage regulator.

Connect the wiring correctly.

Correct V-belt tension or renew V-belt.Repair generator

Install a bulb of higher rating, e.g. 2W -> 3 W.Warning: bulb ratin mustnot exceed 5 W (or pre-exciter circuitwill be destroyed)Short-term remedy: recharge batterywith a suitable charger.Long-termremedy: use a battery with bettercharge characteristic.

Repair the break, clean the batteryterminals, tighten loose clamps.

Renew battery.

Recharge battery at low current forabout 50 hours. (Only possible if sulphate deposits are not too exten-sive); otherwise: renew battery.Install a smaller battery or a largeralternator.Repair alternator.Renew voltage regulator.Correct V-belt tension.

4 L / M . . / 07.96


Trouble-shooting at the alternator

Malfunction

When engine is stop-ped the generatortelltale light burnsbrightly, but whenengine is running.

Generator telltalelight does not burnwhen engine is stop-ped and pre-heat/start switch isturned on.

Generator telltalelight flickers.

Cause

Poor connections, contact resistancein charge circuit or in the line to thegenerator telltale light.Defective voltage regulator.Defective alternator.Generator telltale light bulb hasblown or contacts are corroded.Battery is flat.Battery is defective (internal short-circuit or sulphate deposits). Defective pre-heat/start switch, poorcontacts.Defective wiring line resistance incharging circuit or line to generatortelltale light.Defective voltage regulator.Short-circuit in an alternator exciteror positive diode.

Carbon brushes worn.Corrosion deposites on sliprings,open circuit in exciter winding.KV-belt at alternator is too slack.

Remedy

Eliminate contact resistance, cleanterminals, tighten loose terminals.

Renew voltage regulatorHave alternator repaired.install a new bulb. Clean the con-tacts.Recharge with a suitable charger.Renew the battery.

Eliminate contact resistance, renewwiring, tighten loose terminals ifnecessry renew pre-heat/ startswitch.

Renew the voltage regulator.Disconnect charging line B+ (to pre-vent discharge at a standstill), repairalternator .Renew carbon brushes.Have alternator repaired.

Tension V-belt correctly.


4L / M . . / 07.96

Trouble-shooting at engine monitor and display

Engine protection relay: see „Instrument box“

Malfunction

Sudden pressure drop inlubricating oil circuit.

Engine cannot be stoppedat valve solenoid or fuelshut-off valve.

Incorrect display, light does not burn although afault is present.

No display, display lightdoes not burn despitemalfunction.

Cause

Leak in oil circuit.

Oil lost from damaged sump.Defective oil pump.Defective valve solenoid or fuelshut-off valve.Defective diode between generatortelltale light and terminal 15 atpre-heat/start switch, or diode by-passed.Short to earth (ground) in wire orswitch.Defective switch.Broken wire.Defective switch or relay.Defective bulb.

Remedy

Check lines and seals, renew ifnecessary.Renew the oil sump.Renew the oil pump.Examine parts and renew ifnecessary.Check the circuit and renew thediode if necessary.

Check wiring and eliminate shortto earth.Renew switch.Renew broken wire.Renew defective components..Renew the bulb.

4 L / M . . / 07.96


Trouble-shooting at electromagnetic components

Malfunction

Electromagnet doesnot switch off engineor vary engine speed.

Malfunction or failureof other electrical orelectronic compo-nents.

Starter motor does notdisengage.

Cause

Defective electromagnet (e.g. windingburned out).No power supply or open circuit.Defective switch or relay.Decoupling diode between generatortelltale light and terminal 15 is mis-sing or defective (applies only toshut-down solenoid with alternator).Freewheel diode parallel to solenoidis defecive.

Defective diode in shut-down solenoid (lifting or servo solenoid).

Remedy

Renew electromagnet.

Check the circuit.Renew defective component.Check the circuit and install orrenew decoupling diode as neces-sary.

Renew freewheel diode.

Renew solenois.

Documents

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