Sunteți pe pagina 1din 174

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

Contents
Introduction 1. General
Sealants and adhesives Illustrations of engine Type plate data Technical data Lubricating oil circuit Special tools and Workshop equipment

2. Additional equipment
A 01.00 A 01.40 A 03.00 A 03.12 A 04.00 A 04.10 A 04.20 A 04.70 A 04.80 A 05.00 A 05.40 A 07.00 A 07.10 A 07.11 A 11.00 A 11.70 A 15.00 A 15.20 A 30.00 A 30.20 A 30.40 Fuel Delivery pump with hand pump Exhaust Detaching and attaching enclosure for silencer (muffler) Mechanical starting Crank handle Automatic decompressor Engine rotating device Start release Electric starting Alternator Lubricating oil Lubricating oil cooler, air cooling Lubricating oil cooler, water cooling Automatic mechanisms Temperature-controlled starting fuel volume regulator Housing Adapter housing Liquid cooling Water pump Thermostat

L / M . . 01.97

Contents
3. Basic engine equipment
M 01.00 M 01.10 M 01.20 M 01.30 M 02.00 M 04.00 M 04.10 M 04.20 M 04.30 M 05.00 M 06.00 M 06.10 M 06.20 M 07.00 M 07.10 M 07.20 M 07.30 M 07.40 M 10.00 M 11.00 M 12.00 M 12.10 M 12.20 M 12.30 Crankshaft Balancing weights 2L / 3L Balancing weights, 4L Cleaning crankcase, installing injector nozzles Crankshaft Camshaft Camshaft for valve timing Camshaft for injection pump Governor and injection timer Conrod Piston and cylinder Air-cooled engines Water-cooled engines Cylinder head Air-cooled engines Cylinder head repairs (air-cooled engines) Water-cooled engines Cylinder head repairs (water-cooled engines) Oil pump Timing case cover Extra fuel device with injection pump PFR 1K 80 with injection pump PFR 1K 90 with injection pump PFR 1K 90 from serial No. L/M31.12, M40.16, 2L40.19, 3-4L40.18 and L/M41 Fan Fuel injection equipment Injection pump, functional test with injection pump PFR 1K 80 with injection pump PFR 1K 90 Injector Injector nozzle M 14.50 Adjusting work with injection pump PFR 1K 80 M 14.60 Adjusting work with injection pump PFR 1K 90 M 17.00 Flywheel M 20.00 Engine shutdown device, belt tensioner M 22.00 Air cleaner M 31.00 Crankcase breather M 32.00 Speed control M 32.10 with injection pump PFR 1K 80 M 32.20 with injection pump PFR 1K 90 M 35.00 Enclosure

4. Tables
Tightening torques Repair data Fuel injection equipment and adjusting values Governors Lubricating oil contents and dipstick Key to circuit diagrams HATZ wiring identification Circuit diagrams Trouble-shooting table for the electrical system

M 13.00 M 14.00 M 14.00 M 14.10 M 14.20 M 14.30 M 14.40

L / M . . 01.97

Introduction

This workshop manual is in accordance with the technical status shown on each page (month / year). It has been compiled in such a way that a trained mechanic can perform all repair work correctly. Instructions such as "Clean parts" etc. have been omitted, as they are assumed to be self-evident. All work must be carried out only with the specified tools or with others of absolutely equivalent quality. It is assumed that the normal hand tools will be available, even if not called for specifically in this manual. Please refer to the operating manual for details of routine maintenance work, operating fluids 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 by trade associations or accident insurers. The details provided here may differ if special equipment is installed. Please appreciate that neither the workshop manual nor the spare parts list can take all such deviations into account. If problems occur, please contact the nearest HATZ service point.

L / M . . 01.97

1. General

L / M . . 01.97

Sealants and adhesives


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

A = 502 230 01 B = 502 231 00 C = 502 232 00 D = 502 233 00 E = 502 234 00 F = 502 238 00 + 502 239 00 G = 502 565 01 H = 502 825 01 J = 502 830 02 K = 503 426 00 L = 502 566 00

Loctite Activator Loctite 573 Loctite 601 Loctite 221 Loctite 648 Technicoll 8058 Technicoll 8367 Loctite IS 407 Silicon High-temp. paste High-temp. paste Silicon

500 ml 50 ml 50 ml 50 ml 10 ml 750 g 750 g 20 g 30 ml 1000 g 100 g 100 g

L / M . . 01.97

Engine illustrations

26

22

21

25

23

13

5
1680/18

24
1680/4

Service and flywheel side

Starter and flywheel side Engines: 2 - 4 L . . S / Z 1 Lub.-oil filling and dipstick 2 Speed control lever 3 Exhaust silencer 4 Oil drain plug 5 Lub.-oil filter 6 Engine cover 7 Side panel 8 Cooling fan with built-in alternator 9 Cooling fan drive belt 10 Hydraulic belt tensioner 11 Stop device 12 Governor housing 13 Cooling air duct for lub.-oil cooler 21 Cyclone-type pre-cleaner 22 Eye hook for transport, disappearing max. load 500 kg 23 Access to fuel feed pump 24 Starter 25 Fuel feed line 26 Fuel return line 27 Belt pulley with 1/2" internal square for cranking engine
L / M . . 01.97

11

27

10

12
1681/4

Governor and exhaust side

Engine illustrations
15 22 24 14 1
9

25 23 7

2
1583/6

26

27

20

23

17
1583/12

Service and flywheel side

Service and governor side Encapsulated design 1 Lub.-oil filling and dipstick 2 Speed control lever 4 Oil drain plug 5 Lub.-oil filter 6 Battery + terminal 7 Battery - terminal 8 Wiring harness 9 Type plate 10 Fuel feed line 11 Fuel return line 14 Cover for capsule 15 Air intake duct of capsule 16 Outgoing air duct 17 Exhaust silencer (encapsulated) 20 Cover for air duct housing (Access to governor housing of engine) 22 Eye hook for transport, disappearing max. load 500 kg 23 Engine brackets 24 Access to fuel feed pump 25 Engine flange 26 Side panel 27 Cover, service side 28 Cover, outgoing air side

17

16

14

28

11 10
1583/3

Outgoing air and flywheel side

L / M . . 01.97

Engine illustrations

1627 / 12

1627 / 6

Service and governor side Engine: 2 ... 4 M 31, 2 ... 4 M 40, 2 ... 4 M 41 1 Lub.-oil filling and dipstick 2 Side panel 3 Rain protection cap 4 Cooling fan drive belt 5 Cooling fan with built-in alternator 6 Governor housing 7 Hydraulic belt tensioner 8 Stop device 9 Belt pulley with 1/2" internal square for cranking engine 10 Oil drain plug 11 Speed control lever 12 Lub.-oil filter 13 Oil drain plug (oil sump) 14 Cooling air duct for lub.-oil cooler 15 Access to fuel feed pump

Starter and flywheel side Engine: 2 ... 4 M 31, 2 ... 4 M 40, 2 ... 4 M 41 1 Cylinder head cover 2 Fuel pressure pipe 3 Cover for air filter(s) 4 Eye hook for transport, max. load 500 kg 5 Injector 6 Fuel return line 7 Fuel feed line 8 Wiring harness duct 9 Flywheel 10 Engine flange 11 Starter 12 Type plate 13 Exhaust silencer

L / M . . 01.97

Engine illustrations

Service side Motor: H 2 L 30, H 3 L 30 1 Fuel line (feed pump - filter) 2 Fuel line (filter - injection pumps) 3 Hose connection (Maintenance indicator for air filter) 4 Primer pump 5 Fuel feed line (Fuel tank - fuel feed pump) 6 Lub.-oil filling and dipstick 7 Speed control lever 8 Solenoid, engine stop 9 V-belt 10 Voltage regulator 11 Oil drain plug, governor side 12 Lub.-oil filter 13 Oil drain plug, lateral 14 Fuel pre-filter 15 Oil pressure switch 16 Fuel feed pump (Bosch)

Governor and exhaust side Motor: H 2 L 30, H 3 L 30 1 Cooling water inlet 2 Rain protection cap 3 Air filter 4 Cylinder head cover 5 Fuel pressure pipe 6 Temperature switch 7 Cooling water outlet 8 Exhaust manifold 9 Starter 10 Type plate 11 Centrifugal pump 12 Belt-adjustment link 13 Alternator IMPORTANT !
The standard transport suspension enables safe transportation of the engine including supplementary equipments, and is designed for a maximum load of 500 kg (1100 lbs). It is neither suitable nor approved to lift complete units.

L / M . . 01.97

Type plate data


Engine No. Type No.. 064 10 81 031814

Type designation e.g. Engine type Variant 2 L 40 C

Engine serial No.: The serial no. begins with 10 and changes continously (11, 12) if any major changes are carried out.

Year of production Fabrication No. (continous)

MOTORENFABRIK HATZ D-94099 RUHSTORF


TYP
KENNZ. MOTOR / FABRIK NO. MIN -1 NH

GMBH +CO

KG

Costumer spec. list No. 1) Customer specification

ABE / AUSF. PV CM 3

Output in kW 2)

Execution code 2)

MADE IN GERMANY

Displacement in cm 3

Engine speed e.g. Nominal speed Speed increased under no-load condition max no-load speed 3000 + 60 = 3060 min -1
1) If required

3000 / 60

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

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

2) In special cases only; e.g. engines acc. to Federal Authority for Automobilism
L / M . . 01.97

Technical data L 30
Type Operating cycle Combustion system Number of cylinders Bore / stroke mm Displacement Compression ratio Firing order. cyl.1:timing end Direction of rotation Cooling air requirement at n = 3000 rpm m3/min Combustion air requirement at n = 3000 rpm m3/min Net weight approx. kg L 30 S L 30 Z L 30 C / K Lubricating oil pressure Lubricating oil consumption Starter motor Alternator Battery Max. continuous inclination towards Control side Flywheel side Air outlet/starter side Timing end 223 228 276 25 2-1 cm3 1416 18:1 1-3-2 1-3-4-2 2 95 / 100 2124 2832 2L30 H2L30 3L30 4-stroke Direct injection 3 4 H3L30 4L30

anti-clockwise (looking at flywheel) 35 45

2.1 222 228 255 262 331

3.2 271 279 -

4.2 291 306 396/386

at n = 800 rpm1 min.: 0.9 bar max.: 1 % of fuel consumption, at full load 12 V. 2.7 kW or 24 V. 4.0 kW 14 V. 50 A or 28 V. 40 A* 12 V. 88 / 143 Ah or 24 V. 55 / 110 Ah with and without oil sump 30 30 30 30 with without oil sump 30 22 30 25 25 25 30 25 only with oil sump 25 18 30 15

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

L / M . . 01.97

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


2 L 31 2 M 31 2 L 40 2 M 40 3 L 31 3 M 31 3 L 40 3 M 40 4 L 31 4 M 31 4 L 40 4 M 40

Type Operating cycle Combustion system Number of cylinders Bore / stroke mm Displacement Compression ratio Firing order. cyl.1:timing end Direction of rotation Cooling air requirement at n = 3000 rpm m3/min Combustion air requirement at n = 3000 rpm m3/min Net weight approx. kg L 31 S. L 40 S. M 40 L 31 Z. L 40 Z. M 40 Z L 31 C / K. L 40 C / K Lubricating oil pressure Lubricating oil consumption Starter motor Alternator Battery cm
3

4-stroke Direct injection 2 102/90 1470 102/105 1716 102/90 2205 18:1 2-1 1-3-2 1-3-4-2 3 102/105 2574 102/90 2940 4 102/105 3432

anti-clockwise (looking at flywheel) 25 29 35 39 46 49

2.1 223 228 276

2.6

3.2 255 262 331

3.9

4.2

5.2

291 306 396/386

at n = 800 rpm min.: 0.9 bar max.: 1 % of fuel consumption, at full load 12 V. 2.7 kW or 24 V. 4.0 kW 14 V. 50 A or 28 V. 40 A 12 V. 88 / 143 Ah or 24 V. 55 / 110 Ah with without oil sump 30 22 30 25 25 25 30 25 only with oil sump 25 18 30 15

Max. continuous inclination with and without towards oil sump Control side Flywheel side Air outlet/starter side Timing end 30 30 30 30

L / M . . 01.97

Technical data L 41, M 41


2 L 41 2 M 41 3 L 41 3 M 41 4-stroke Direct injection 2 102/105 cm3 1716 3 102/105 2574 18.7:1 2-1 1-3-2 1-3-4-2 4 102/105 3432 4 L 41 4 M 41

Type Operating cycle Combustion system Number of cylinders Bore / stroke mm Displacement Compression ratio Firing order. cyl.1:timing end Direction of rotation Cooling air requirement at n = 3000 rpm m3/min Combustion air requirement at n = 3000 rpm m3/min Net weight approx. kg M 41 S M 41 Z L 41 C / K Lubricating oil pressure Lubricating oil consumption Starter motor Alternator Battery

anti-clockwise (looking at flywheel) 29 39 49

1.9 223 228 276

2.9 255 262 331 at n = 800 rpm min.: 0.9 bar

3.9 291 306 396/386

max.: 1 % of fuel consumption, at full load 12 V. 2.7 kW or 24 V. 4.0 kW 14 V. 50 A or 28 V. 40 A 12 V. 88 / 143 Ah or 24 V. 55 / 110 Ah with without oil sump 30 22 30 25 25 25 30 25 only with oil sump 25 18 30 15

Max. continuous inclination with and without towards oil sump Control side Flywheel side Air outlet/starter side Timing end 30 30 30 30

L / M . . 01.97

Lubricating oil circuit


1 2 3 4

17 16 10

5 6

13 12 15

14

11 10

1 2 3 4 5 6 7 8 9

Suction line Oil pressure feed to filter on engines without oil cooler Oil pressure feed to filter on engines with oil cooler Oil circuit after oil cooler Rockers 10 Plug Pushrods on engines without oil cooler Pushrod tubes 11 Threaded rod Hydr. starting charge device or oil servo on engines with oil cooler Crankshaft 12 Oil suction strainer Main bearings 13 Balancing shaft(s) Hydraulic belt tensioner 14 Lub. oil filter with bypass valve Lubricating oil pump 15 Oil cooler Sump 16 Oil pressure switch 17 Oil pressure relief valve
L / M . . 01.97

Special tools and workshop equipment


Series L / M engines
No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 Ident-No. 669 612 668 626 630 629 625 612 665 665 612 634 620 624 625 612 626 624 633 631 631 632 350 110 383 753 094 223 739 092 418 030 087 142 926 838 383 090 383 845 178 191 203 913 00 00 00 91 00 01 00 00 00 91 00 00 01 91 02 01 00 01 00 00 00 00 Item Pressing-in drift 9 mm for valve guides Reamer 9 H 6 for valve guide Clamp for fuel line Impact extractor with accessories Test nozzle 400 bar Valve lifting tool Pressing-in drift for valve stem seal 6 mm intl. hex. insert with centering pin Driver sleeve for camshaft bearings Overflow device for injection pump Dial gauge 1/100 mm Honing tool Oil pressure gauge 0 - 6 bar with flexible tube Revolution counter for fuel pressure pipe Digital multimeter Piston ring pliers Piston ring clamping tool 70 - 100 mm Crimping pliers up to 6 mm2 Relay test box Puller for belt tensioner bushings Installation drift for belt tensioner bushings High-pressure pump cpl. Code 03.1.1 03.1.2 01.1.2 03.1.1 03.1.2 03.1.2 03.2.1 03.1.2 05.2.1 05.1.1 05.1.2 03.1.2 03.1.1 03.1.2 03.1.2 03.1.2 03.1.2 03.2.2 06.2.1 06.1.2 06.1.2 05.1.1

L / M . . 01.97

Special tools and workshop equipment

10

11

12

13

14

15

16

17

18

ktion Relais-Fun

s- und Testb

ox

15 86

87

87a
+

50
Injection - pump timing set

19

20

21

22

L / M . . 01.97

Special tools and workshop equipment


Series L / M engines
No. 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 Ident-No. 624 624 624 624 624 624 606 618 618 610 620 624 621 626 604 620 620 619 630 619 619 619 624 624 340 346 347 348 349 350 000 140 418 390 300 393 056 211 628 307 638 746 439 852 854 855 863 864 01 01 00 01 00 00 00 01 00 00 00 00 00 00 00 01 01 00 00 02 02 02 02 01 Item Marking device for radial position of injection pump Gauge for measuring governor rod travel Gauge for adjusting start of fuel injection Calibrating device for tool - 25 Locating pin for governor rod Fuel injection volume adjusting tool Wrench for extra fuel device adjustment (mechanical system only) Multipurpose puller for use with tool - 31 Forcing-off screw for tool - 30 Forcing-off screw for centrifugal clutch Forcing-off screw for centrifugal belt pulley Assembly sleeve M 10 x 1 guide pin for conrod M 11 x 1 guide pin for conrod Test pressure gauge for fuel injection system Strap wrench Locking device for tensioning roller Holder for injection timer assembly Gauge for oil spray nozzles Air guide plate for 2 L / M Air guide plate for 3 L / M Air guide plate for 4 L / M Elevating table, mobile Adapter elements for - 45 Code 05.1.1 05.1.1 05.1.1 05.1.1 05.1.1 05.1.1 05.1.1 03.1.1 03.1.1 03.1.1 03.1.1 05.1.1 03.1.1 03.1.1 03.1.1 01.1.2 02.1.1 05.1.1 05.2.1 5Q.1.1 5Q.1.1 5Q.1.1 03.2.1 03.2.1

Explanation of classification: Example: 03. 1. 2 Manufacturer: 1 . . . Only available from HATZ 2 . . . Same item (or equivalent in function) available commercialy Necessity: 1 . . . Absolutely essential 2 . . . Useful or convenient Type of repair 01. . . Maintenance 02. . . Emergency repair 03. . . Repair in upper and external areas 05. . . Repair in area of driving gear mechanism 5Q. . . General overhaul (including all the necessary tests) 06. . . Component repairs

L / M . . 01.97

Special tools and workshop equipment

23

24

25

26

27

28

29

30

31

32 / 33

34

35 / 36

37

38 46

39

40

41

42 43 44

45

L / M . . 01/97

2. Additional equipment

L / M . . 01.97

A 01.00 Fuel
A 01.40
-3General:

Fuel delivery pump

- When installing the fuel delivery pump,


make sure that the delivery and suction lines 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 delivery pump with O-ring. - Dismantle fuel delivery pump 1 in the numerical order of parts illustrated (Fig. 182). Note: Since September 1992 fuel strainer 12 has been replaced by O-ring 5. Because of this, an input-side fuel filter must always be used. This input-side filter is supplied as a spare part with the fuel delivery pump and also with the repair kit for the fuel delivery pump. Assembling: - Assemble by following the instructions in the reverse order as appropriate.

2 3 4 5 6

12

7 8 9 10 11

182

L / M . . 01.97

A 03.00 Exhaust system


A 03.12
Preparatory work:

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

- 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 exhaust pipe (184/2). On more recent versions, the exhaust pipe is secured with a clip. - Take out the machine screws (184/3) and remove the connecting cover (184/4).
L3 / 228

2
184

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

L3 / 229

185

- Remove the machine screws (186/1) and


bolts (186/2).

2 1

L3 / 230

186
L / M . . 01.97

- Lift off the capsule with exhaust silencer


(muffler); see Fig. 187. Note: In some cases a spacing plate is installed between the silencer enclosure and the air duct housing.

- On the 2 - 3 L 40 from date of manufacture


5.85 on, 4 L 40 from 1.86 on and L 31, the connecting stub pipe (189/1), sealing washer (189/2) and plate (189/3) are deleted. Five sealing washers are installed between the silencer and the exhaust manifold.

L3 / 231

187

- Pull the upper and lower sections of the enclosure apart and lift out the silencer; see Fig. 188. Check the parts: - Examine the enclosure sections and the silencer for fractured welds or tapped holes which are unfit for further use. Installing: - Install by following the removal instructions in the reverse order as appropriate. The silencer must be installed without trapped stresses (a two-piece holder for the silencer has been installed since March 1989). Note: Before installing the connecting stub pipe (189/1), check free movement of the sealing washer (189/2). Place the sealing washer in the connecting stub pipe and install the plate (189/3). It should be possible to move the sealing washer radially. Next, place the sealing washer on the silencer. Radial play must not exceed 0.1 mm. If necessary, renew the sealing washer.

L3 / 232

188

1
L3 / 233

189
L / M . . 01.97

A 04.00 Mechanical starting


A 04.10
Version A 04.10.1 Standard crank handle: This handle can be replaced at any time by one with kick-back damping if this becomes necessary or is required by regulations. Warning: There is a risk of injury if the shaft of the crank handle or its tubular handgrip are worn. Preparatory work: Dismantling: Checking / repairs: - Visual inspection. - Inspect shaft 1 and tubular handgrip 2 for wear or breakage. Note: If the shaft of the crank handle is worn, always renew the complete handle. The tubular handgrip can be renewed separately if necessary.

Crank handle

2 1

191

L / M . . 01.97

A 04.00 Mechanical starting


A 04.10
Version A 04.10.2 Handle with kick-back damping: The version for M .. engines is marked A on its housing, and takes the place of the standard crank handle if required. Warning: There is a risk of injury if the shaft of the crank handle or its tubular handgrip are worn. Preparatory work: Dismantling: - 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 as illustrated. - Hold torsion spring 13 in position in order to maintain its tension. - Pull leaf spring 11 away from its locking pin and out of the hook eye on torsion spring 13. - Relieve torsion spring tension with a screwdriver blade. Caution - risk of injury! - Take off parts 12 and 13. Housing 14 remains in position with the other parts.
3 15 14 13 10

Crank handle

12

8 11

A
9 6 5

16 15 2 1

192

L / M . . 01.97

Checking / repairs: - Visual inspection: - Renew the complete starting handle if there is any damage in the area of cover 5 and/or housing 14. - If necessary, renew pivot bushings 15 and shaft sealing ring 16. - Examine tubular handgrip 7 for wear and/or other damage, particularly in the splined area. - Install end plug 8, avoiding damage to the splines. The end plug must be installed to prevent dirt and water from entering. - Check condition of bushing and leaf spring at lever 9. - Check condition of leaf spring 11 and torsion spring 13. Renew in case of doubt. - Check shaft 3 for wear and/or other forms of damage. - Renew O-rings and small parts.

Assembling: - Install parts 13 and 12. Use thread sealant D. - Make sure that the torsion spring is not trapped; insert its longer end into the groove on the corresponding locating pin. - Preload torsion spring 13 against the normal spring pressure until the hook eye of the spring engages behind the eye of the through-hole. Caution - risk of injury! - Hold torsion spring 13 in position to prevent spring pressure from being lost. - Push leaf spring 11 into the hook eye on torsion spring 13 and place on locking pin. The rolled end of the leaf spring must face toward the center of the housing. - Attach lever 9. - Push on tubular handgrip 7/8. Check splines, lever and leaf springs for free movement. - Apply app. 50 grams of lubricant K to the inside of housing 14 and over all mechanical 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.

L / M . . 01.97

A 04.00 Mechanical starting


A 04.20
The automatic decompressor has the following positions; Fig. 93: 0 = Operating position, with engine running 1 = Permanent decompression, automatic device switched off 2 = Automatic decompressor switched on, engine compression is built up automatically after about 8 turns of the handle. Detaching:

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

kompr.

1
dekompr.
L3 / 1

2
dekompr.autom.

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


(94/5).

- Take off cover (94/20) with gasket (94/37).


On two-cylinder engines, shafts (94/14) and (94/36) are connected together by coupling sleeve (94/27) and 2 locking collets (94/23). Camwheel (94/22) is then used at the second cylinder (flywheel side) instead of the gearwheel. Dismantling the automatic decompressor: - Unscrew and remove screw plug (94/1). - Take out sealing ring (94/2), spring (94/6), cap (94/7) and lifting pin with shims and pressure pin (94/8, 9, 10). - Unscrew threaded rod (94/19) and remove spring (94/18) and pressure pin (94/17). - Using a suitable split-pin driver, drive locking collet (94/16) about 3 mm into gearwheel (94/21). - Turn the gearwheel through 180 and pull the locking collet out with pliers. - Take out shaft (94/14) and gearwheel.

93

L3 / 42

94

L / M . . 01.97

Checking parts: - Inspect the gearwheel and cap for damage caused by moving the decompression lever in the wrong direction or operating the automatic decompressor when the engine is already running. - Use new sealing rings. Install by following the dismantling instructions in the reverse order as appropriate. Note: - With the automatic decompressor in position ,,0, note the correct position of the gearwheel (Fig. 95). - Check that the lifting pin can move freely. - When installing threaded rod (94/19), make sure that pressure pin (94/17) is engaged in the locating slot on shaft (94/14). Adjusting the automatic decompressor: Adjustment is needed if: a) the decompression effect is no longer sufficient. b) the engine does not reach its full compression ratio (hissing noise when engine is turned over and the decompressor is not engaged). c) cylinder head repairs are carried out.
L3 / 43

max. 46.1 mm min. 45.5 mm

b c

B
95 Check dimension ,,B:

- Use a suitable measuring tool to check dimension ,,B; Fig. 95. Note: For this check, the rocker should rest lightly on the valve stem but without opening the valve (turn the engine over until the tappet is resting on the base circle of the cam).

L / M . . 01.97

If the limit values are exceeded, adjust this dimension as follows: - Take off the exhaust rocket, grind down the pressure pin at the riveted side and drive it out. - Install the rocker temporarily, insert the new pressure pin (95/b) and place shims (95/c) under it to the required thickness, 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. The pressure pin should project by at least 1 mm at the riveting point, to ensure firm seating. If it does not project sufficiently, grind the rocker away slightly at the appropriate point. Install the rocker finally, noting the endplay; adjust valve clearance and check dimension (95/B) again. Checking dimension ,,A: - Using a depth gauge, determine dimension A (Fig. 95); work out the number of shim washers (94/9) needed according to the table, and secure them with the pressure pin (94/10) to the actuating pin (94/8). - Check operation of the automatic decompressor. When decompression is active, it must be possible to turn the engine over without compression resistance, but the exhaust valve must never strike the piston. Dimension ,,A in mm 14,0 14,5 15,0 15,5 16,0 16,5 17,0 - 14,5 - 15,0 - 15,5 - 16,0 - 16,5 - 17,0 - 17,5 Number of shim washers (Fig.94/9) 6 5 4 3 2 1 0

L / M . . 01.97

A 04.00 Mechanical starting


A 04.70
Preparatory work: - Remove the silencer (muffler); see A 03.00. - Remove the fan; see M 13.00. Detaching the recoil starter: (Fig. 190) - Take out machine screws 13 incl. spring washer 5 and screws 12 with bushings 8 and washers 7, and remove them with bearing 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 spring washers 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 the opposite order of work as described here.

Recoil starter

L3 / 44

190

L / M . . 01.97

A 04.00 Mechanical starting


A 04.80
Preparatory work: - On C/K, take off hood at enclosure and side panel; see M 35.00. - On S/Z and M.., take off side panel and cooling air duct for lubricating oil cooler. Detaching and dismantling:

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

2 1
113

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


start release device retaining screws and 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 containing diesel oil. Apply an air pressure of 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 and renew if necessary. Re-assembling the start release device: Follow the dismantling instructions in the opposite order as appropriate; refer to Fig. 114. Note: When attaching to the engine monitoring block, make sure that locking collet (114/13) is pressed into the start position by lever (114/4), or else the start release action will not take place; see also Fig. 116/1. Before tightening machine screws (114/14), move bracket (114/3) in the opposite direction (see Fig. 116/2), to ensure that locking collet (114/13) can move as far as possible back to the ,,Stop position.

5 4 6 8 7

14 3 13 9

114

Stop

115

L / M . . 01.97

Important: - The hoses must be correctly connected as shown in Fig. 113. If the hoses are wrongly connected, the automatic engine protection function is no longer available, that is to say the engine is not shut down automatically if lubricating oil level drops too low. - On older engine versions, hose (113/1) is connected to the fuel delivery pump. This has no effect on the basic function of the device. Operational check with start release device 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 the lever


and at the same time check whether the piston in cylinders (114/2) moves the lever (114/4) correctly. Also check the cylinder and hose unions for leaks. When the lever is no longer actuated, spring (114/9) exerts pressure on the piston, which should then move back slowly (see Fig. 116). Note: If the fuel tank is located at a higher level than the fuel delivery pump, the difference in height between the fuel level in the tank and the fuel delivery pump must not exceed 2 metres. Failing this, the automatic engine protection device will be put out of action and the engine cannot then be shut down electrically. 116

Sta

rt

L / M . . 01.97

A 05.00 Electric starting


General instructions on the engines electrical system: - Never interchange the positive and negative 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 whether a 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 or the equipment to which it is fitted, attach the earth (ground) clip of the welding set as close to the weld area as possible, and disconnect the alternator from the electrical circuit at connections ,,B + and ,,D -. - When cleaning the engine, avoid spraying water on the alternator or any other components of the electrical system. If this is unavoidable, first disconnect the battery; before it is reconnected, dry all components thoroughly with a compressed air jet. - If a malfunction, for instance low battery charge, charge telltale light on etc, should be detected, always check the tightness of cable connections and correct V-belt tension before making any other operational checks. - For trouble-shooting in the event of a fault, see Section 4. - When recharging the battery, disconnect the negative terminal. - Avoid using electrical starting aids because of the risk of voltage peaks (these could damage electronic components). Checking operation of the alternator with voltage regulator (checking charging current): - With the engine stopped and the startingswitch key at ,,0, detach the B + line (leading to the battery) from the alternator and connect a DC ammeter with a scale reading of 0 .. 50 A between alternator terminal B + and the detached cable. Make sure that the loose cable cannot touch any metal parts of the engine. - Connect a DC voltmeter with a scale of 0 . . 30 V to the batterys positive and negative posts. - Start the engine and note the meter readings. Check the voltmeter display. With the alternator in good working order and electrical consumers in circuit, the ammeter should indicate a charging current. Its value depends on the batterys state of charge (if the battery is flat, the charging current is high, if the battery is fully charged, the charging current is low), but also on the consumpition of electrical equipment actually in use and on alternator and therefore engine running speed. If there are no consumers in circuit, a charging current should even be indicated at idle speed. If the alternator voltage is too high, renew the voltage regulator.
Test values 12 V Voltmeter reading Charging current at 13.5 V or 27 V Battery voltage - Engine speed 800 rpm (idle) - Engine speed 1500 rpm 13.0-14.5 V System 24 V 26-29 V

approx. 25 A 40-45 A

approx. 5 A 25-30 A

L / M . . 01.97

A 05.00 Electric starting


A 05.40
Preparatory work: Encapsulated engines: - Take off the hood, the air guide housing cover and the impeller wheel. Unscrew and 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 by striking it with a plastic-faced hammer; see Fig. 123. Checking parts:

Alternator (air-cooled engines)

193 (*HATZ internal cable marking)

- 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 instructions in the reverse order as appropriate. Note: When connecting the cables to the alternator, make sure they are not accidentally interchanged. 194

L / M . . 01.97

Notes on renewing the alternator: When series production of Series L / M engines began, alternators made by SEV-MARCHAL were used. These alternators are no longer available as spare parts, but can be replaced without difficulty by the current VALEO alternator. The MARCHAL voltage regulator is still available. In view of the modified installed position of the voltage regulator on PARIS-RHONE or VALEO alternators (removal and installation in a radial direction to reduce the risk of breaking off the carbon brushes), the fan housing was also modified in the regulator area when the PARIS-RHONE generator was introduced. A cutout in the housing and deletion of the retaining screw which previously passed through at this point ensure that the regulator switch can be renewed without having to remove the alternator.

195

When replacing a MARCHAL alternator by a VALEO type, you are recommended to perform the above modification; refer to Fig. 195. The time invested in this will easily be made good by the time saved if the regulator has to be replaced later.

When installing a VALEO voltage regulator, make sure that the condenser supplied with it is also installed (connection diagram is enclosed).

L / M . . 01.97

A 07.00 Lubricating oil


A 07.10
Preparatory work: - On engines with enclosure, take off the enclosure hood and side panel; see M 35.00. - On engines without enclosure, take off the cooling air duct to the oil cooler. Removing block-pattern oil cooler:

Oil cooler (air-cooled engines)

- 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 cooler with sealing rings (197/5). - To dismantle the oil cooler: Pull the oil guides (197/2) apart and take out both gilled tubes (197/3) with O-ring seals (197/4). Note: The gilled-tube oil cooler is only used on two-cylinder engines without enclosure and rated for engine speeds up to a certain limit.
L3 / 10 L3 / 189

196

3
197

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 the reverse order. Retrofitting engine with oil cooler: - If an engine has an oil cooler retrofitted, the missing threaded rod (198/3) must be inserted and secured with sealant D. Unless this work is performed, the oil cooler will be unable to operate.

L3 / 190

198

L / M . . 01.97

A 07.00 Lubricating oil


A 07.11
Preparatory work:

Oil cooler (water-cooled engines)

- Drain the coolant. - Detach the coolant lines from the oil cooler.
Removing: - Take off the oil filter (199/1). - Unscrew and remove the threaded sleeve (199/2). - Take off the oil cooler (199/3) with spacing ring (199/4) and O-ring seal (199/5). Checking parts: - Make a visual check for cracks or damage to the sealing faces. Installing: - Install the oil cooler by following the removal instructions in the opposite order as appropriate. Note: - Install the oil cooler side with the sealing ring towards spacing ring (199/4). - Tighten threaded sleeve (199/2) to a torque of 55 Nm.

5 4 3 1 2
199

L / M . . 01.97

A 11.00 Automatic devices


A 11.10
Dismantling: - Disconnect the solenoid and take off the starting aid housing, taking care not to turn the volume limiting eccentric. - Take out machine screws (205/1) and remove solenoid (205/2). - Pull eccentric shaft (205/3) towards the solenoid and unscrew hex nut (205/4) with a 10 mm open-ended wrench. - Pull out the eccentric shaft and remove washer (205/5), lever (205/6), washer (205/7) and spring (205/8). Checking / repairs:

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)

1 10 3 2

- Use a new O-ring seal (205/10). - Check flexible gaiter for damage and renew if necessary. Assembling: - Proceed in the opposite order of work; install end cap (205/9) with sealant C.

8 7 4
205

6 5 9
L3 / 199

L / M . . 01.97

Adjusting engine shutdown and solenoid: The solenoid does not need adjusting unless the adjusting nuts were turned or a new solenoid has been installed. - Press the solenoid fully in against the spring loading. - Insert solenoid adjusting gauge 621 471 00 (206/1) into the hole in the housing; see Fig. 206. - Turn adjusting nut (207/1) until lever (206/2) is touching the adjusting tool. Note: If the adjusting gauge is not available, the shutdown device can be adjusted to the checking distance of 39.3 0.1mm between the inner face of the hole in the cover and the inner edge of the lever; Fig. 207. - After adjusting, secure the adjusting nut with locknut (207/2) and seal it with lacquer. Installing the shutdown device: - Set the speed control to the ,,Stop position. - Coat both sides of the gasket (208/1) for the housing with sealant H. Apply only a thin coat of the sealant so that the oil passage in the starting fuel supply device is not blocked. - Attach the gasket (note correct position of oil hole) and press the solenoid by hand into the operating position: angle (208/3) must engage to the left of the driver pin on governor rod (208/4). - In this position, attach the housing and reconnect the solenoid. Warning: If the angle is positioned incorrectly when installed (at the right of the driver pin), the engine will overspeed and could destroy itself unless the solenoid is put out of action immediately. When the U-pattern driver pin was introduced, incorrect positioning as described above was ruled out.

2 1

L3 / 200

206

1 2

39.3
L3 / 201

0.1

207

L3 / 202

208

L / M . . 01.97

A 11.00 Automatic devices


A 11.70 Temperature-controlled starting fuel volume control

- 24 - 28 Adjusting: - Screw in adjusting tool - 28 - and attach measuring device - 24 -. - Pull the speed control lever briefly to ,,Stop and then to the full-load position. This places governor lever 1 against fullload stop 2 of the starting fuel volume control. - Zero the dial gauge. - Screw thermo-element 4 carefully into the bracket, until the dial gauge just begins to move (the sickle-shaped lever is then against the governor rod). - Unscrew adjusting tool - 28 - at the 13 mm hexagon until a clicking sound is clearly heard, to indicate that the governor lever is dropping into the increased-volume starting position. - Slowly turn thermo-element 4 back to a lower setting until the dial gauge indicates a movement of 0.2 mm towards increased volume from the zero position previously obtained. - In this position, secure the thermo-element with the locknut. - Detach auxiliary tools and install any engine components not yet in place. Warning: When adjusting, make sure that the thermoelement is at a temperature of at least 20C.

4 3 2 1

170

L / M . . 01.97

A 15.00 Housing
A 15.20
Assembling:

Adapter housing

- 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 tighten to the specified torque. Note: Apply sealant D to the bolt above inspection hole (200/4), since this is a through-hole. On engines without a adapter housing, the equivalent screw plug should also be coated with sealant D before inserting. - Insert and tighten the two lower M 10 hex bolts (200/5) with spring washers (200/6).

2 4

3 1

5
200

6
L3 / 143

L / M . . 01.97

A 30.00 Liquid cooling


A 30.20
Preparatory work: - Drain the coolant. - Take off the alternator. Dismantling: (Fig. 201) - Detach the coolant lines at the water pump. - Unscrew hex bolts 1 with spring washers 2 and take off the water pump. - Remove screws 3 with spring washers 4 and take off V-belt pulley 5. - Take out screws 6 with copper washers 7 and remove pump element 8 with seal 9 from housing 10. Checking parts: - Check housing for evidence of damage. Note: If the following damage is detected, renew complete pump element 8: - Damaged pump impeller. - Worn sealing ring in pump element (water leaking from the hole in the pump element). - Bearing worn. Assembling: - Assemble by following the dismantling instructions in the reverse order as appropriate.Install pump element 8 with the water drain hole facing down.

Water pump (H.L 30)

1 7 6 4

10

9 8 5 3

201

L / M . . 01.97

A 30.00 Liquid cooling


A 30.40
Preparatory work:

Thermostat (H.L 30)

- Drain the coolant (only needed if the upper


edge of the radiator is higher than the thermostat). - Detach the coolant line from thermostat cover (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 out thermostat (5). 202 Checking operation of thermostat insert: Note: The temperatures stamped on the thermostat insert indicate the start of its opening movement and the maximum operating temperature. - Suspend the thermostat insert and a thermometer in the centre of a vessel filled 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 seat of the thermostat insert. - Install the thermostat insert, using a new sealing ring (the arrow stamped on it indicates the direction of flow). - Attach the thermostat cover again and tighten its screws uniformly. 203

1 2 3 4 6 5

L / M . . 01.97

3. Basic engine equipment

L / M . . 01.97

M 01.00 Crankcase
M 01.10
Preparatory work:

Removing and installing balancing weights - 2L / 3L

- 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 the machine screws at the divided driver. 1

- Unscrew and remove the machine screws


(2/1) at the plate (2/2) and take off the plate. (On more recent version: secured with stud bolts and nuts) - Unscrew the plug from the thrust bushing at the timing end of the engine and drive the shaft out towards the flywheel end; see Fig. 3. - Drive out the thrust bushing (timing end). - Take the balancing weights and driver out of the lower part of the crankcase. 2 Checking / repairs: - Check the shaft at its bearing points for score-marks and correct dimensions; for values, see Section 4. - Check the needle roller bearings of the balancing weights for score-marks. - Check the gearwheel with balancing weight and the crankshaft-end gearwheel for the balancing weights for signs of damage. - Renew the O-ring seals at the thrust bushings. 3

L / M . . 01.97

Assembling: - Insert the thrust bushing (timing end) until flush with the housing. - Place the gearwheel with balancing weight (flywheel end) and the balancing weight (timing end) in the lower part of the crankcase, insert the driver and screw hand-tight to the balancing weights. Insert the shaft with thrust bushing (4/1) from the flywheel end , see Fig. 4, and drive it fully into the timingend thrust bushing. 4

- Tighten the machine screws for the driver


and use a depth gauge to measure endplay at the balancing weights; see Fig. 5. Note: The timing-end thrust bushing (5/1) forms part of the sealing face at the timing case cover, and must therefore be flush with the endface of the crankcase after driving in the shaft. Endplay can be adjusted by moving the flywheel-end thrust bushing axially until the value stated in Section 4 is obtained. 5

- Apply sealant D to the machine screws


(6/1) and attach the plate; also coat the screw plug for the timing-end thrust bushing with sealant D and screw it in. Turn the balancing weights to ensure free rotation. Note: When installing the oil sump and the crankcase cover, apply sealant D to two M8 hex bolts in each case at the timing and flywheel ends, where a through-hole has been drilled.

L / M . . 01.97

M 01.00 Crankcase
M 01.20
Preparatory work:

Removing and installing balancing weights - 4 L

- Remove the crankshaft; see M 02.00. - Take off the oil sump.
Dismantling:

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


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

- Invert the lower part of the crankcase.


Note: The joint line is a sealing face, and must not be damaged. Place the crankcase on a wooden grid or frame; see Fig. 8.

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

L / M . . 01.97

- Check dimensions of bearing bushings


(10/1) and, if necessary, drive them out with a suitable drift. First drive the end caps out of the crankcase bores (10/2). Checking / repairs:

- Check the bearing journals and bushings


for score-marks and incorrect dimensions; for values, see Section 4. - Check the balancing weight gearwheels and the crankshaft-end gearwheel for the balancing weights for damage. 10

Assembling:

- Blow through the oilways thoroughly with


compressed air. Note: Before installing the bearing bushings, make sure that the oil hole is in the correct position; see Fig. 11. 11

- Coat the bearing bushings (12/1) with


sealant D and drive them into the housing until flush, using a suitable drift; see Fig. 12. - Coat the sealing faces of the end caps (10/2) with sealant C and insert them again. - Renew the end caps.

12

L / M . . 01.97

- Insert spacing rollers for the M8 screws in


the correct positions as shown in Fig. 13. Note: Insert the longer spacing rollers (13/1) at the oil filter flange side.

13

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

14

- Insert the balancing weight with circle and


line markings as shown in Fig. 15, and push in the bearing journal. Note: This balancing weight is driven directly from the crankshaft.

15

L / M . . 01.97

- Insert the balancing weight with circle mark


(16/1) and push in the bearing journal. Note: When installing this balancing weight (16/1), make sure that the circle mark on it is between the two line marks on balance weight (16/2). In this position, the circle mark on balancing weight (16/2) must face the crankshaft.

16

- Take out the two machine screws at holes


(17/1) again. Place spacing rollers (17/2) on the splash plate. Insert splash plate (17/3) and screw in hex bolts (17/4) hand-tight. - Insert machine screws (17/1) and tighten.; also tighten hex bolts (17/4).

- Turn the lower part of the crankcase back


upright again (joint line at the top).

- Insert the machine screws at the bearing


journals and tighten them to the specified torque with a torque wrench; Fig. 18. - Rotate the balancing weights and check for free movement. Note: When attaching the oil sump, apply sealant D to two M8 hex bolts in each case at the timing and flywheel ends, since these are inserted in through-holes. Engines with an oil sump attached must not have a 40 mm end cap installed in the lower part of the crankcase.

17

18

L / M . . 01.97

M 01.00 Crankcase
M 01.30.
- 41 Cleaning the crankcase

Cleaning the crankcase, installing the oil spray jets

- Remove all screw plugs from the oilways


and, after cleaning the crankcase by immersion in a cleaning bath or with highpressure cleaning equipment, blow it dry with compressed air; flush out all oilways particularly thoroughly and blow through them, so that no particles of dirt or swarf remain. - After this, insert all screw plugs again and check that the aluminium or sheet-metal plugs for the oilways are firmly seated. In case of doubt, renew them; apply sealant E to all plugs before inserting. To ensure firm location, secure the aluminium plugs with light punch-marks at the edge of the hole in the housing. Oil spray jets - First check for firm location and accurate spray direction; if necessary, re-align the spray jet with light hammer-blows or bend it carefully by hand until the correct position is reached. Check this with the gauge - 41 - or work from the drawing shown here (Fig. 171). If oil spray jets have broken off or are loose, new ones must be inserted. Proceed as follows: - Remove pieces of the old jet from the drillway (with a suitable drift or similar tool); degrease the entire area thoroughly; insert the new spray jet and drive it in initially app. 6 - 8 mm farther than its final position. Strike the projecting end lightly with a hammer to bend it slightly and ensure a firm seating in the bore (Fig. 172).

171

172

L / M . . 01.97

- Apply sealant E to the projecting end and


move the spray jet to its final position. Do not dent the jet inlet bore; drive it in until the end of the tube is flush with the oil groove in the bearing seat (Fig. 173). - Check the position of the jet outlet again, and adjust if necessary. - Apply sealant E again where the spray jet passes through opposite the bearing seat; the capillary action of the sealant will ensure that the tube is fully coated and cannot shake loose in its seat. Note: On Series L 41 and M 41 engines, an oil spray jet is also installed for cylinder 1.

173

L / M . . 01.97

M 02.00 Crankshaft
-8Preparatory work:

- 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 housing. - 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 the end cover; see Fig. 19.

19

- Unscrew the machine screws(20/1) and


pull them out.

20

- Remove machine screws from crankshaft


gearwheel, loosen the gearwheel on the crankshaft with a plastic-faced hammer and pull it off. - Pull out the locking collet (21/1).

21

L / M . . 01.97

- Unscrew and remove the hex bolts (22/1)


at both sides.

22

- The two halves of the crankcase are secured together with straight pins (23/1). Drive these back with a hammer and a suitable drift until they are flush with the sealing face. Lift the upper part of the crankcase up vertically: Fig. 23. Note: To simplify the loosening and lifting off of the upper part of the crankcase, insert two M 8 x 65 machine screws (retaining screws of setting-down device) at the timing end and two M 14 x 50 hex bolts (used to secure connecting housing) at the flywheel end in the holes provided. 23

- Lift the crankshaft out of the lower part of


the crankcase.

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

L / M . . 01.97

Checking / repairs: - Check all crankshaft bearing journals for score-marks and incorrect dimensions; for measured values, see Section 4. Measure in two planes offset through 90 degrees. - 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 doing so, use sealant E. Assembly instructions are included with the spare part. - Renew the shaft sealing ring in the end cover. - Check the bearing shells for damage and visible signs of wear. Installing: - Pull the balancing-weight gearwheel on to the crankshaft. On the 2 and 3 L .. crankshafts, unscrew and remove the flywheel-end counterweight; this will expose the line marking (25/1) on the crankshaft. Heat the gearwheel to app. 125 C and pull it on so that the line marking (25/1) on the crankshaft is aligned with the ,,O marking (25/2) on the gearwheel; see Fig. 25. On the 4 L ... crankshaft, unscrew and remove the flywheel-end counterweight and manoeuvre the balancing-weight gearwheel 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 torque. Note: From mid-1994 on, a modified gearwheel and different retaining screws were introduced. The new screws are not to be used with the old gearwheel (Fig. 27). On the 2 and 3 L .. engines, do not install the counterweights again until the crankshaft has been placed back in the lower part of the crankcase.

25

26

alt

neu

5,5

6,5

27

L / M . . 01.97

- Place the thrust washers (28/1) on the


crankshaft so that the lubricating grooves face the thrust face on the crankshaft. Insert the bearing half-shells (28/2) into the lower part of the crankcase, and apply oil to them.

28

- Place the crankshaft in the lower part of


the crankshaft and make sure that the gearwheels mesh together as indicated by the marks. For 2 / 3 L ... see Fig. 29.

29

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

30

L / M . . 01.97

- Insert the O-ring seal (31/1) for the main


oilway into the lower part of the crankcase. Apply a thin, uniform coat of sealant B to all areas of the joint line on the lower part of the crankcase, and also on the intermediate webs of the crankcase; see Fig. 31. - Insert the bearing shells into the upper part of the crankcase and coat them with oil. 31

- Position the thrust washers so that the


groove (32/1) faces upwards in each case. Lift upper part of crankcase and place it very carefully. Note: When installing, make sure that the two centering pins (32/2) in the upper part of the crankcase are inserted into the grooves (32/1) of the thrust washers; see Fig. 32. - Drive in the straight pins (23/1) again to locate the two halves of the crankcase.

32

- Insert the machine screws and tighten


them to the specified torque in the order shown in Fig. 33.

33

L / M . . 01.97

- Check crankshaft endplay with a depth


gauge, Fig. 34, and compare it with the desired value stated in Section 4.

34

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

- Turn the camshafts until the two marks


(35/1) are aligned and the mark for the crankshaft gearwheel faces downwards. - Engage the crankshaft gearwheel, noting the position of the mark, and tighten it to the specified torque.

35

- Place the gasket (36/1) on the locking


collets.

- 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 specified torque.

36

L / M . . 01.97

M 04.00 Camshaft
M 04.10 Camshaft, valve gear

- 9 - 30 - 31 Preparatory work: - Take off the upper part of the crankcase; see M 02.00. Dismantling: - Remove the circlip (37/1) at the cover, pull the cover (37/2) out with water-pump pliers and remove the shim washers.

37

- Stand the upper part of the crankcase up,


take the circlip (38/1) out of the safety groove and press the valve tappet (38/2) off the camshaft.

38

- Using a 47 mm driving-out sleeve, drive


the camshaft out towards the timing end (see Fig. 39) and pull out the valve tappets.

39

L / M . . 01.97

- Remove the circlip and shim washers and


pull off the ball bearing with a two-arm puller; see Fig. 40.

40

- If the gearwheel or camshaft is renewed,


use puller - 30 - with forcing-off screw - 31 to pull the gearwheel off the camshaft; see Fig. 41. Checking / repairs:

- Inspect the camshaft bearing points and


the bearing bores in the crankcase for score-marks and incorrect dimensions; for values, see Section 4. - Check the camshaft gearwheel for scoremarks. - Check the camshaft ball bearings for wear. - Check the tappets for score-marks. - Check the bores in the crankcase for the tappets for score-marks and incorrect dimensions; for values, see Section 4. Assembly:

41

- Heat the camshaft gearwheel to app. 150 200C on a hotplate, and press it on.

- Place the circlip (42/1) in position and pull


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

42

L / M . . 01.97

- When installing a new camshaft, make


sure that there is no endplay between the ball bearing and the circlip (43/1). If necessary, insert shim washers (43/2).

43

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

- Drive the camshaft towards the timing end


of the engine until the ball bearing is in contact with the circlip (44/1). - Insert shim washers (43/3), push in cover with O-ring seal (43/4) and attach circlip (43/5). Note: - Check camshaft endplay; for values, see Section 4. If necessary, insert shim washers (43/3). - A special camshaft has been introduced to operate the valves on the following engines. It can be identified by an H cast into the camshaft. 2 M 31 H from No. 841087 000008 3 M 31 H from No. 851087 000004 4 M 31 H from No. 861087 000004 2 M 40 H from No. 781487 001631 3 M 40 H from No. 791487 000952 4 M 40 H from No. 801487 000873

44

L / M . . 01.97

M 04.00 Camshaft
M 04.20 Camshaft for injection pump

- 9 - 30 - 31 Preparatory work:

- Remove the injection pump; see M 14.00. - Remove the engine speed control;
see M 32.00.

- Remove the starting-mixture charging 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 be pulled off after removing the injection pump camshaft. - Take off the circlip (45/1) and unscrew the splash plate (45/2).

45

- Pull off the gearwheel with the puller - 30 and the forcing-off screw - 31 - : see Fig. 46. Note: The two ball bearings in the intermediate gearwheel are separated by a circlip. Checking / repairs:

- Check the camshaft bearing points and the


bearing points in the crankcase for scoremarks and incorrect dimensions; for values, see Section 4. - Check the ball bearings for the camshaft and the intermediate gearwheel for wear. 46

L / M . . 01.97

Attaching the intermediate gearwheel: Note: The intermediate gear wheel must be installed before the camshaft for the injection pump is installed.

- Press the ball bearing into the intermediate


gearwheel and pull the gearwheel on using impact sleeve - 9 - , noting the positions of the markings; see Fig. 47. - Place the circlip on the shaft. 47 Note: Before pulling on, place the intermediate gearwheel uniformly on the shaft, to prevent the shaft from being pushed into the crankcase. Installing the camshaft: - See ,,Installing camshaft for valve gear (M 04.10). Note: The camshaft for L 40/M 40 is marked ,,L 40 next to the delivery pump drive cam.

L / M . . 01.97

M 04.00 Camshaft
M 04.30 Governor and injection timer

- 30 - 31 - 40 Preparatory work:

- Removing camshaft for injection pump;


see M 04.20. Dismantling the governor: (up to engine serial number: 2 L 40.16, 3-4 L 40.15, .M 40.12 and .L 30 and H.L 30) - Remove circlip (48/1) and pull out 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 pull rod (48/7). - Unscrew spring bridge (48/8) and take off holder for governor weights (48/9). Dismantling governor: (from engine serial number: 2 L 40.17, 3-4 L 40.16, .M 40.13, and all L 31 and M 31 engines) - Remove circlip (48a/51) and pull out spacing ring (48a/50), spring plate (48a/49) and governor spring (48a/45). - Remove the spring at the governor collar (48a/11) and push out pin (48a/38) with roller sleeves (48a/37). - Pull out the pull rod (48a/36), unscrew the nuts (48a/44) and take off the spring plate at the governor (48a/43), the locating washer (48a/42) and needle roller race (48a/41), the shim washer (48a/40) and the thrust washer (48a/39). - Unscrew the spring bridge (48a/32) and take off the holder for the governor weights (48a/26). Checking / repairs: 48

48a

- Check al parts for damage and signs of


wear.
L / M . . 01.97

Pull off and dismantle the injection timer: - Using puller - 30 - with pressing-off screw - 31 -, pull the injection timer off the camshaft; see Fig. 49.

49

- Clamp the holder for injection timer assembly - 40 - into the vise and place the hole in the injection timers support disc on the special tool; see Fig. 50. 50

- Turn the gearwheel counter-clockwise by


hand against the spring loading, and lift 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). Checking / repairs: - Examine the support disc and gearwheel in the centrifugal weight area for scoremarks. - Inspect the coil springs and their retaining blocks for damage. - Check the centrifugal weights for scoremarks.

51

L / M . . 01.97

Assembling the injection timer: - Assemble the injection timer by following the dismantling instructions in the reverse order. Note: The gearwheel and support disc were modified at the beginning of 1992. Parts from the old and new versions cannot be combined. If necessary, renew the complete injection timer. After placing the gearwheel on the support disc, check that the slots in the gearwheel and support disc are aligned as shown in Fig. 52.

52

- Turn the injection timer clockwise and allow it to move back to check its freedom of movement; see Fig. 53.

53

- Coat the hole in the support disc with


sealant C and press the camshaft (with shaft key) into the injection timer until the gearwheel has 0.05 mm of endplay. Note: Check endplay with a feeler gauge as shown in Fig. 54. 54

L / M . . 01.97

Assembling the governor: - Assemble the governor by working the opposite order to that described for dismantling; refer to Figs. 48 and 48a. Note: When assembling the governor, make quite sure that all moving parts are able to move freely. On L/M 31/40 engines there must be a clearance 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.

55

- Install the spring for the governor (55/1) so


that the endface of the tapered section points in the direction of rotation. Renewing governor spring: (without detaching the timing case cover) Preparatory work: - Remove the engine shutdown device; see M 20.00. - On the H.L30 take off the cover; see M 11.00. Dismantling: - Remove circlip (56/1) and spring plate (56/2). - Take out governor spring (56/3) and check it for cracks or breakage. Assembling: - Choose the correct new governor spring as stated in Section 4, according to the engines intended use and speed range. - Install the governor spring or engine shutdown device by working in the opposite order to that described for removal.

56

L / M . . 01.97

M 05.00 Conrod
- 35 - 36 Preparatory work: - Take off the cylinder head; see M 07.00. - Remove the cylinder and piston; see M 06.00. Dismantling:

- Unscrew and remove the big-end bolts


(62/1) and lift out the conrod and big end cap with the aid of guide pin - 35 - or - 36 -. Checking / repairs: - Check the conrod bushing, big end bearing and crankpin for score-marks and incorrect dimensions; for values, see Section 4. Assembly:

62

- Press the bushing into the conrod.


Note: When pressing in the conrod bushing, make sure that the oil holes are aligned and that the bushing projects by an equal amount on each side. - Insert the big end bearing half-shells into the conrod, making sure that the locating nuts are in the grooves provided; see Fig. 63. - Install the big end cap, using guide pin - 35 - or - 36 -; see Fig. 64. - Attach the upper part of the conrod, insert the big end bolts and tighten them to the specified torque. Note: The groove (63/1) in the big end cap must be on the side nearest the injection pump. The groove (63/2) in the main conrod must be on the valve tappet side.

63

64

L / M . . 01.97

M 06.00 Piston and cylinder


M 06.10 Air-cooled engines

- 12 - 16 - 17 Preparatory work: - Detach the cylinder head; see M 07.00. Dismantling: - Mark the relative position of the cylinder and piston and pull off the cylinder. - Take out the piston pin circlip; see Fig. 65. - Press the piston pin out by hand and lift off the piston. 65 Checking / repairs: - Check the cylinder wall for seizure marks or score-marks. - Check that the dimensions of the cylinder are correct; for values, see Section 4. - Check the piston for seizure marks or ring web fractures. - Check piston ring end gaps; for values, see Section 4. Checking piston ring end gaps: - Pull the piston rings off the piston. - Place each piston ring in its cylinder bore and move it to the TDC position of the piston. - Clean the piston crown and use it to position the piston ring at a right-angle to the cylinder axis. - Use feeler gauges to measure the piston ring end gap (where the ends of the piston ring come together). - For limit values, see Section 4. Checking cylinder wear and suitability for further use: - Repeat the piston ring measuring procedure with a new piston ring. - Compare the measurements obtained in this way with the maximum wear limits; if these are exceeded, the cylinder should not be re-used but an oversize cylinder 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 be roughened very slightly with a honing tool, since the honed finish will have been largely worn away after a lengthy period of operation. If the cylinder were to be used again without re-honing (whether the existing piston rings or new ones were fitted), excessive oil consumption would occur and would not drop to the normal level after a time, since the piston rings would not be able to match themselves to the cylinder wall.

L / M . . 01.97

Procedure: - While turning the honing tool in the cylinder, it must also be moved to and fro axially. Recommended speed of rotation approx. 350 rpm. - Depending on the speed, the tool should perform about 20 - 30 strokes a minute. This stroke rate will produce a cross-cut pattern at approximately 45. - Continue honing only until this crosscut pattern can be clearly seen. It is normally obtained after a honing time of approx. 20 - 45 seconds per cylinder. - After honing, clean the cylinder with warm or hot water and a cold cleanser, using a brush, then oil the cylinder wall. Warning! Do not hone for too long a period, and do not dry-hone. Use honing oil or a mixture of oil and fuel (1:1). If possible, keep below the speed stated above. Wear protective goggles! Assembling: To install the piston, follow the dismantling instructions in the reverse order. Note: The recess in the piston crown must be located towards the injection pump; see Fig. 66. 66

- The piston ring gaps must be offset by


120 in each case; oil the piston rings in their grooves. - Attach clamping tool - 17 - and carefully install the cylinder; see Fig. 67.

67

L / M . . 01.97

M 06.00 Piston and cylinder


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

- 16 - 17 Preparatory work:

- Take off the cylinder head; see M 07.00. - Take off the alternator and water pump.
Dismantling: - Carefully pull the cylinder off. - Take out the piston pin circlip; see Fig. 68. - Press the piston pin out by hand and lift off the piston. Checking / repairs: - Examine the cylinder for seizure marks or score-marks on the cylinder wall. - Check cylinder dimensions and state of wear; see Section 4. - Inspect piston for seizure marks and ring web breakage. - Check piston ring end gap; see Section 4. - Check piston ring end gap, cylinder wear and suitability for further use; see Section 4.

68

L / M . . 01.97

Installing: Install the piston by following the removal procedure in the reverse order as appropriate. Note: The recess in the piston crown must be located towards the injection pump; see Fig. 69.

- The piston ring gaps must be offset by


120 in each case; oil the rings well in their grooves. For each cylinder bore a figure is stamped on the crankcase and another figure on the cylinder. The two figures, if added together, represent the thickness of the shim plates to be inserted at the base of that cylinder; see Fig. 70. Example: Figure on crankcase Figure on cylinder Shim plate thickness needed 15 20 35 = 0.35 mm 69

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

- Attach shim plates 70/1 to the cylinder with


a small amount of grease.

- Oil the cylinder bore well.


Note: If spare parts are obtained, the manufacturer attaches the shim plates to the crankcase or cylinder. They are not included in the set of gaskets. To order them separately, please quote the following part numbers: 036 330 00 0.10 mm 036 388 00 0.15 mm 036 329 00 0.20 mm

70

L / M . . 01.97

Installing cylinder assembly on H 3 L 30: - Set pistons ,,1 and ,,3 to approximately the same height and attach piston ring clamping tools - 17 -; attach piston ring clamping strap 622 469 00 to the centre piston; see Fig. 71.

71

- With the help of a second person, carefully


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 the same time move the auxiliary pins to and fro until the pistons enter the cylinders. - Take off the piston ring clamping tools and move the centre piston to and fro during the lowering movement until it enters its cylinder. - The ring clamping strap is pushed into the cylinder, and can then be pulled out of the rectangular side opening in the crankcase with the aid of a strong piece of wire. Installing the cylinder assembly on the H 2 L 30: - Set both pistons to approximately the same height and attach the piston ring clamping tools. - Further installation work is as described for the H 3 L 30, but without the work relating to the centre cylinder.

72

L / M . . 01.97

M 07.00 Cylinder head


M 07.10
Preparatory work: - Take off the enclosure hood. - Take off the exhaust-side enclosure and the muffler (silencer); see A 03.00. - Unscrew and remove the air outlet shaft, side panel and cross-member; see M 35.00. - Unscrew and remove the cover plate and take out the screws for the base plate; 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 intake pipe. Note: To simplify dismantling of the air intake pipe, it is best to unscrew and remove the air cleaner (74/1). 73

Air-cooled engines

- Lift off the cylinder head and remove the


pushrod protective tubes. Checking the cylinder head:

- Inspect for cracked webs or worn valve tapers.

- Check the radius of the rocker pads for


wear.

74

L / M . . 01.97

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, crankshaft or crankcase is renewed. Measure at all cylinders, with the engine cold.

- Clamp the cylinder down with a suitable


tensioning strap, and use a depth gauge; see Fig. 75. 75

- Turn the engine over until the piston reaches and passes through top dead centre (TDC). - Measurement ,,a plus the thickness of gasket ,,b yields the gap dimension ,,S stated in Section 4; see Fig. 76.

76

L / M . . 01.97

- Having established the correct gasket


thickness, coat it with a little grease on the cylinder head side, and place it in the centering collar on the cylinder head. Note: Centering on the L 30 is not by means of a centering collar but with centering sleeves; the gasket has two centering holes; see Fig. 77. 77

- Insert the protective tubes (78/1) with


spring (78/2), thrust rings (78/3) and O-ring seals (78/4) into the bore in the crankcase. Note: Always renew the O-ring seals (78/4) during cylinder or cylinder head repairs.

- Insert the pushrods (78/5).

78

- Attach the cylinder head, making sure that


the protective tubes with O-ring seals enter the corresponding holes in the cylinder head correctly; see Fig. 79. - Oil the stud bolt threads (79/1) and screw on the shouldered nuts. Note: Apply sealant D or a permanently elastic sealant to the thread of stud bolt (79/2) and the shouldered nut contact face (79/3). 79

L / M . . 01.97

- Screw the cylinder head on until it is resting evenly on the cylinder, but without final tightening. - Align the cylinder head by attaching the exhaust manifold; see Fig. 80. - Install the support plate and the injector centering flanges. - Tighten the cylinder head uniformly, in a cross-wise pattern, to the specified torque. - Take off the exhaust manifold, attach the gaskets and install it again. - Adjust valve clearances to the specified values. - Further installation work is as described for removal, but in the reverse order.

80

L / M . . 01.97

M 07.00 Cylinder head


M 07.20 Overhauling cylinder head (air-cooled engines)

-1-2-6-7Preparatory work: - Removing cylinder head - see M 07.10. Dismantling cylinder head: - Place the cylinder head on the centering collar. Note: On the L 30, pull out the centering sleeves (81/1). The cylinder head sealing face must not be scratched or otherwise damaged; always 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 underlay washers (81/6) and lift off the rocker housing (81/7). - Lift off the intermediate plate (81/8) and take out the valve cone. Checking parts: - Check the valve guides and valve stems for score marks and correct dimensions; for values, see Section 4. - Inspect the cylinder head for cracks (in the metal webs) or an uneven sealing surface. - Renew the O-ring seals (81/9); on the L 30, seal them with silicone. - Check the valve seat rings and valve cones 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.

81

L / M . . 01.97

Assembling cylinder head: - If necessary, use a pressing-in tool - 1 - to force out the valve guides; see Fig. 82. - Use the pressing-in tool again to insert the new valve guides - 1 -. Note: The correct pressing-in depth must be complied with; for projection, see Section 4.

82

- Using a hand-held reamer - 2 -, ream out


the valve guides to their nominal diameter; see Fig. 83.

83

- Re-machine the valve seats with a valve


seat milling cutter; see Fig. 84. Note: The valve seat must always be re-machined after installing new valve guides or before installing new valves, but no more metal than absolutely necessary (no patches anywhere on circumference of valve seat).

84

L / M . . 01.97

- Insert valves into valve guide.


Lap the valve cones with grinding paste (grade: 180-250). Note: To check the lapped valve seats, clean the valves, insert them and pour a small amount of diesel oil into the inlet and exhaust ports. No fuel should seep through past the valve seats. Assembling the cylinder head: - To assemble the cylinder head, follow the dismantling instructions in reverse as appropriate. Note: - Engines built in 1979 - 1983 have one spring per valve; from 1984 onwards, two springs per valve were installed. If repair work is carried out in this area, the second valve spring should be retrofitted. - On M 31/M 40 engines up to 2300 min-1, cylinder heads with the code letter ,,H (high swirl) are used; above 2300 rpm the cylinder head code letter is ,,L (low swirl). These code letters are stamped in the inlet port. - On engines built from mid-1986 on with a running speed below 2300 rpm the longitudinally slotted rocker and valve stem seal adjusting screws are used; these screws were installed on all engines from mid1989 onwards. Retrofit these 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 -.

L / M . . 01.97

M 07.00 Cylinder head


M 07.30
Preparatory work:

Water-cooled engines (H.L 30)

- Drain the coolant and unscrew the coolant


lines from the cylinder head.

- Take off the exhaust system and exhaust


manifold.

- Take off the air cleaner and detach the air


intake flange.

- Remove the injectors.


Dismantling: - Take off the cylinder head cover; Fig. 85. - Slacken off the shouldered nuts by half a turn (85/4) in the reverse of the order shown in Fig. 86 or 87. - Unscrew and remove the nuts in the same order. Unscrew the hex nuts (85/5) with spring washers (85/6) and take off the 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 sealing face for unevenness. - Check pad radius on rockers for wear.

85

86

87

L / M . . 01.97

Assembly: - Clean the sealing faces on the cylinder head and cylinder. Clean the cylinder. - Install a new cylinder head gasket (88/1) and sealing rings (88/2). - Insert the protective tubes (88/3) with springs (88/4), thrust rings (88/5) and new sealing rings (88/6) into the bore in the crankcase. Grease the sealing rings slightly. - With the aid of a second person, place the cylinder head in position, making sure that the protective tubes with O-ring seals enter the holes in the cylinder head correctly. - Insert the pushrods. - Install the rocker pedestals. Make sure that the adjusting screws are inserted correctly into the pushrods; if necessary, unscrew them. - Coat the thread of the tierod in the oil cavity with sealant D. - Screw on the shouldered nuts and tighten them by hand in the order 1 - 15 (Fig. 86 or 87) until they are firmly against the cylinder head. - Tighten nuts 1 - 15 to half the specified torque. - Tighten nuts 1 - 15 to the full specified torque.. - Adjust valve clearances. Note: The valve clearance for engines with aluminium pushrods is 0.40 mm, for engines with steel pushrods 0.20 mm.

88

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

L / M . . 01.97

M 07.00 Cylinder head


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

-1-2-6-7Preparatory work:

- Remove the cylinder head; see M 07.30.


Dismantling the cylinder head:

- Remove the circlips (89/10) from the


rocker pedestal and pull off the rocker (89/11) with shim washers (89/12). - Pull out the centering sleeves (89/1) and place the cylinder head on its sealing surface. Note: Do not scratch or otherwise damage the cylinder head sealing face; always place a soft cloth or similar underlay beneath it.

- Press the spring plate (89/2) down with


tool - 6 - and remove the valve spring collets (89/3). - Take out the valve springs (89/4) with underlay washers (89/6). Note: Engines with a running speed of less than 2300 rpm. are equipped with adjusting screws with longitudinal slots for the rockers (89/13) and valve stem seals (89/5). You are recommended to retrofit these screws during subsequent repair work. Engines built up to and including 1983 (all running speeds) have single valve springs. During repairs you are recommended to install double valve springs on engines which 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).

89

L / M . . 01.97

Checking parts: - Check correct dimensions of bushing for rocker (89/14), rocker shaft (89/15) and rocker pad radius. For values, see Section 4. - Check valve guides and valve stems for wear; see Section 4. - Inspect the cylinder head for cracks (in webs) and unevenness of the sealing surface. - Examine the valve seat rings and valve collets for wear. Note valve recess in head; see Fig. 90 and Section 4. Reconditioning cylinder head:

90

- 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; for projection, see Fig. 92.

- Ream out the valve guides to nominal diameter with hand-held reamer - 2 -, Fig. 91. - If the valve seats are leaking or have been damaged locally, or after installing new valve guides, they must be remachined. This is carried out with special milling cutters which are available commercially. - Only mill away sufficient metal to eliminate patches on the surface of the valve seat. - After this, lap in the valves with grinding paste, grain size 180 - 250); see Fig. 91.

91

92

L / M . . 01.97

Note: - To check the lapped valve seats, clean and install the valves, then pour a small quantity of diesel oil into the inlet and exhaust ports. No diesel oil should seep through past the valve seats. - Note correct valve recess measurement; see Fig. 90 and Section 4. Assembling cylinder head: The cylinder head is assembled by following the removal procedure in the reverse order. Before pressing on the valve stem seals, insert the valves into the valve guides. Press the seals on with assembly tool - 7 -.

L / M . . 01.97

M 10.00 Oil pump


- 13 Preparatory work:

- Take off the timing case cover;


see M 11.00. Dismantling:

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


off the oil pump.

- If necessary, pull out needle roller bearing


(98/1) with an internal puller. Checking / repairs:

- Examine the contact face for the shaft sealing ring for score-marks. If the contact face is worn, a ,,wear sleeve can be pushed over it. Use sealant E for this purpose. Installation instructions are included with the spare part. Assembly: 97

- Using a plastic-faced hammer, drive the


needle roller bearing flush into the crankcase. - Insert the oil pump with bearing journal into the needle roller bearing and place it 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 opposite order to that described for dismantling. - When renewing the oil pump, make sure that the correct type is installed (2- / 3- or 4-cylinder engine).

98
L / M . . 01.97

Checking oil pressure: - Unscrew the oil pressure sensing switch and connect an oil pressure gauge with flexible hose - 13 - . - Install the side panel and enclosure hood. - Start the engine and compare the oil pressure when it is at regular operating temperature. At n = 800 rpm min. 0.9 bar, see Fig. 99. - Before assembly, coat the thread of the oil pressure sensing switch with sealant D. 99

L / M . . 01.97

M 11.00 Timing case cover


Preparatory work: - 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. Dismantling Timing case cover without hydraulic pump drive: 100 - Pull the hose off the crankcase breather valve (100/1). Note: From 2 L 40.14, 3/4 L 40.13, M 41 and on the M 31, M 40 and M 41 the hose connection (101/2) for the crankcase breather has been moved to the top of the crankcase. The valve (101/1) was bonded into the air intake pipe until early 1987. Since then it has been secured in the air intake pipe by two O-rings. - Remove the circlip (102/1) and coil spring (102/2) from the pull rod of the engine shutdown device. 101 From early 1996 an additional cup spring and an O-ring have been installed to seal the pull rod. - Unscrew and remove the belt pulley (102/3) and the machine screws holding the timing case cover all round. - Pull off the timing case cover and remove the gasket. Checking parts: - Check the timing case cover for cracks or unevenness of the sealing surface. - Examine the shaft sealing ring for damage and renew if necessary. - Press off the breather valve cap and exami102 ne the diaphragm for damage.

L / M . . 01.97

Dismantling Timing case cover for hydraulic pump drive: Additional work: - Take off the hydraulic lines and hydraulic pump. - Pull out the driver (103/1). - Remove both machine screws (103/2) including spring washer (103/3), plate (103/4) and gasket (103/5). - After removing the timing case cover retaining screws (103/4) and taking off the timing case cover (103/6) the support mount 103 (103/9) is exposed and can be taken off after 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 hydraulic pump drive. - H2L30 and H3L30 engines do not have a hydraulic belt tensioner. For this reason the pull rod is locked out of action by 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 case cover. - On the 2 and 3 L ... insert M 8 x 12 machine screws into holes (105/1) and (105/2) with sealant D.

104

105

L / M . . 01.97

- Further timing case cover attachment and


engine assembly procedures are as described for removal, but working in the reverse order. Note: When renewing the breather valve, secure the new valve housing in the insert (105/3) with sealant E and then seal all round with sealant H. If the insert is renewed, use sealant C for bonding in. The hose spigot opening in the air intake pipe must face toward the intake port of cylinder 1. The position of the opening can be varied by inserting or removing spacing washers (only on engines with crankcase breather in timing case cover).

L / M . . 01.97

M 12.00 Extra-fuel device


M 12.10
Preparatory work:

with injection pump PFR 1K 80

- Detach the enclosure hood and side panel;


see M 35.00.

- On twin-cylinder engines, detach the oil


filler pipe. Dismantling: - Remove the screws for the extra-fuel device and take it off; see Fig. 106. Dismantling the hydraulic extra-fuel device:: - Take off the circlip (106/1), unscrew the threaded pin (106/2) and push out cylinder (107/1). - Take off the circlip (107/2) and pull out the 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). Checking / repairs:

106

- Inspect the piston and cylinder of the extrafuel device for score-marks or worn areas.

- Check the ball seat of the pressure relief


valve for wear marks.

- Renew the O-ring seals.


Assembling the hydraulic extra-fuel device: - Assembly is as shown in Fig. 107, working in the opposite order from dismantling.

107

L / M . . 01.97

Checking the extra-fuel device: - After assembly, check free movement of the extra-fuel devices piston by pulling it out and letting it slide back; see Fig. 108.

108 Attaching:

- The extra-fuel device is installed by following the removal instructions in the opposite order, taking particular care that the gasket is correctly installed as shown in Fig. 109 and the scribed mark is noted. Apply sealant H to both sides of the gasket. Only a thin coat should be applied, so that the oil in the extra-fuel device is not blocked. Install the machine screws with sealant D. Adjusting the extra-fuel device: - Piston (107/4) also acts as the full-load stop for the governor lever and is eccentrically located in the cylinder (107/1). The effective stroke and therefore the maximum injected fuel volume are adjusted by turning this cylinder. For effective stroke requirements and adjusting procedure, see M 14.00. If the same extra-fuel device is detached and re-attached, the effective stroke does not have to be adjusted, provided that the setting of the volume limiting eccentric was not altered. 109

L / M . . 01.97

M 12.00 Extra-fuel device


M 12.20
- 34 Preparatory work:

with injection pump PFR 1K 90

- see M 12.10.
Dismantling: - Pull terminal 7 off the solenoid valve (only version with electric engine shutdown). - Remove the screw (111/28) with sealing rings (111/36). - Make a scribed mark on the crankcase and the monitoring block, so that the monitoring block can later be re-attached in the same position as before, and the original power setting is therefore retained. - Take out the retaining screws (111/5) and take off the engine monitoring block. Dismantling the engine monitoring block: - Unscrew and remove the cover (111/9) with sealing ring (111/10); on version with electric engine shutdown, unscrew the solenoid valve (110/21) and take it off 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 with springs (111/20,25) and piston (111/18).

110

111

L / M . . 01.97

Checking parts: - Examine the piston for score marks or wear. - Check the valve seat (111/19) for wear. - Renew the O-rings. Assembling the engine monitoring block: - Proceed in the opposite order of work to that described for removal. Note: To install the piston, use auxiliary bushing - 34 -. Assembly: - Move the speed control lever to the ,,Stop position. - To attach, follow the instructions for detaching the device in the reverse order. - Make sure that the gasket is correctly seated and note the scribed mark which indicates the correct position; install the machine 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 lower idle speed governed to 1700 rpm the shaft (111/12) must be turned counter-clockwise when assembling. Check when the monitoring block is installed by turning shaft (111/12) counter-clockwise; it must then move back by itself to its initial position. Adjusting the engine monitoring block: - The maximum fuel injection volume is adjusted by turning the piston (111/18). For the 112 need to adjust the fuel injection volume, and the correct procedure, see Section M 14.00. If the same monitoring block is detached and re-attached, the fuel injection volume need not be adjusted, provided that the setting of piston (111/18) was not altered. If the monitoring block is renewed or after it has been repaired, the fuel injection volume (power setting) must always be adjusted.

L / M . . 01.97

M 12.00 Extra-fuel device


M 12.30
- 34 Preparatory work:

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)

- see M 12.10.
Dismantling: - Detach plug connector (164/1) from engine wiring harness (electric version only). - Take out machine screws (164/3) and detach cover (164/4) and solenoid valve (164/5) with gasket (164/6). - Make a scriber mark on the crankcase and the servo block to ensure that they are installed again in the same relative positions and the power setting therefore remains unchanged. - Remove machine screws (164/2) and take off the servo block. Checking / repairs: - Turn lever (165/1) in the ,,Start direction. Shaft (165/2) is then turned by locking pin (165/3) and the sickle-pattern lever (165/4) moved to the starting position. When the lever is released, all elements must return to the ,,Stop position (Fig. 166). Ensure free movement if necessary by greasing or oiling lightly. - Press piston (167/8) by hand in the ,,Start direction: The sickle-shaped lever must move to the starting position, but return to the ,,Stop position when the piston is released.

164

165

166

L / M . . 01.97

Dismantling the servo block: - Take off lock washer (164/7). - Hold piston (164/8), raise shaft (164/9) and take out sickle-shaped lever (164/10). - Release piston (164/8) carefully and take it out of the housing. - Drive out locking collet (164/11) and pull shaft (164/9) out of the housing. - Take out grub screw (164/12). - Remove circlip (164/13) and take out washer (164/14) and eccentric disc (164/15). Checking / repairs: - Examine piston for wear or score marks. - Renew gaskets. Assembling the servo block: - Assemble in the opposite order of work to that described for removal. When installing the piston, use bushing - 34 -. Note correct position of gasket (164/6) (oil hole). Apply sealant D to machine screws (164/3) and tighten them to a torque of 6.5 Nm. Caution: If the tightening torque is too high, the servo piston may seize (distortion). Installing: - Set the speed control lever to ,,Stop. Make sure that the gasket is installed in the correct position (oil hole) and that the scriber markings are aligned. Insert machine screws (164/2) using sealant D and noting their correct positions; attach a lead seal. When attaching the monitoring block, make sure that sickle-shaped lever (166/4) is located at the left of stop (166/5). 167 Warning: The sickle-shaped lever must never be under or to the right of the stop. - Screw the block on tightly. - Set the speed control to the ,,Start position and move piston (167/8) to and fro between the start and stop positions. With the injection pump removed or the side cover taken off, the governor lever can be seen to perform the same movement.

L / M . . 01.97

Checking valve solenoid: (Fig. 168) - without electric control: Valve pin 2 is in the rest position; the connection between bores 3 and 4 is closed. - Apply the electric current to connection ,,7 (yellow wire): the valve pin must extend by app. 6 mm. F 15 - 20 N (loading can easily be overcome with the finger), free passage between 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 overcome loading with finger pressure), free passage between bores 3 and 4. - If any repairs are made to the wiring, make sure that the plugs are wired up correctly (Fig. 169). Note: When installing the valve solenoid or cover (164/4), note the correct installed position (this also applies to the gasket); holes 168/3 and 5 must be aligned.

168

169

L / M . . 01.97

M 13.00 Fan
Preparatory work: - Take off the exhaust-system capsule (encapsulated engines only) and the silencer (muffler); see A 03.00. Encapsulated engines: - Take off the capsule side panel, air outlet duct, air guide housing and fan impeller; 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. 117 Checking parts: - Check the fan housing sealing strips for signs of damage; if necessary, attach new sealing strips with adhesive G. Installing: - Apply a slip agent, e.g. Vaseline, to the contact faces of the fan housing sealing strips. - Install the fan housing and check that the sealing strips are correctly positioned. - Re-assemble the items removed from the engine in the opposite order of work to that described for their removal. - Make sure that the Poly-V belt is installed accurately. Note: When connecting cables to the alternator, do not accidentally interchange them; see Fig. 118.

118

L / M . . 01.97

M 14.00 Fuel injection equipment


M 14.00
-5Preparatory work:

Injection pump, functional check

- Take off the capsule hood and side panel. - Detach the fuel delivery pipes from all injector pumps, holding the pipe union to prevent it from turning. Check injection pumps: (Fig. 182) - Attach test nozzle - 5 - with delivery pipe to the injection pump you wish to check. - Cover the pressure valve holders on the other injection pumps with absorbent cleaning cloths. - Move the speed control lever to the start position and run the starter. If the spray pattern is correct, the pump you have checked is in good mechanical working order (no pump element wear, no leakage at pressure valve). 182 WARNING! Keep hands away from the injected fuel spray. The fuel spray from the injector nozzle can cause blood poisoning if it contacts the skin.

L / M . . 01.97

M 14.00 Fuel injection equipment


M 14.10
Preparatory work: - Take off enclosure hood, side panel and cover for air guide housing; see M 35.00. - Take off fuel filter and fuel delivery pump. - Take off guide plate for oil cooler on S/Z. - On engines with shutdown solenoid, to remove pump for cylinder 1 take off the starting charge device including the solenoid (see A 11.00); on the two-cylinder engine, also take off the oil filler pipe. Removing the injection pump:

with injection pump PFR 1K 80

- Unscrew and remove the extended stub


bolt or machine screw (119/2) at the injection pump for cylinder 1. This also acts as 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 the governor rod guide (120/3) with packing seals.

- Set the speed control lever to a central position.

- Remove the hex nuts for the injection


pump mounting, and pull out the injection 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 correct hollow screw is used, or else the volume of fuel in the injection pump will be altered. Removing the governor rod:

119

- Take off the oil filler pipe, the starting charge control device and all side covers.

- Using water pump pliers, press out locking


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

120
L / M . . 01.97

- Drive locking collet (121/1) halfway into the


pull rod with a suitable split pin driver.

- Turn the pull rod through 180 and pull out


the locking collet with water pump pliers.

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


(The pull rod will be pulled out.)

121

- Pull the governor rod out towards the


flywheel end; see Fig. 122. Note: To remove the governor rod on Types ,,C and ,,K, the rear enclosure panel must be taken 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 reverse order. - After installing the governor rod, secure its guide in position with the side cover: see Fig. 123. Note: Play at the governor rod guide between crankcase and cover must not exceed 0.1 mm. If play is greater than this, insert packing seals between the crankcase and the governor rod guide.

122

123

L / M . . 01.97

- Using the speed control lever, locate the


governor rod so that the groove for the toothed rack pin on the flywheel-end injection pump is precisely in the centre of the mounting hole for the injection pump in the crankcase; see Fig. 124. - Check the position of the other grooves and if necessary reposition the sliding elements on the governor rod. - Insert the injection pumps and tighten them in position. - For adjusting work, see M 14.50. Note: When installing the injection pumps, use the shim washers at the points from which they were previously removed. The figure stamped next to the injection pump indicates the thickness of the shims, e.g. 75 = 0.75 mm. 124

L / M . . 01.97

M 14.00 Fuel injection equipment


M 14.20
- 27 Preparatory work:

with injection pump PFR 1K 90

- see M 14.10.
Removing the injection pump: - Insert locating pin - 27 - into the hollow-drilled stud bolt of pump 1 to lock the governor rod in the ,,X-Position (141/1). - Remove the hex nuts and spring washers 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 must not be changed, or else the start of fuel injection 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 to compensate for play); note the presence of spring (170/4). - Pull the governor rod out towards the flywheel. - Install in the reverse order of work. Note: When installing the governor rod, the stop pin for the governor rod (126/2) must engage between the governor lever (126/1) and the leaf spring (126/3).

141

170

126

L / M . . 01.97

Installing the injection pump: - Connect the governor rod in the ,,X-position. - When installing the injection pumps, use the same shim washers and gaskets as before. - Insert the injection pumps and, before tightening, press them towards the cylinder and position them so that the scribed mark on the pump flange is precisely aligned with the corresponding notch on the crankcase (127/1). Note: When installing a new injection pump, add up the figures on the pump flange and the crankcase. The total of the two figures is the thickness of the shim washers with gaskets to be inserted, in tenths of a millimetre. Never use more than one steel shim washer. How to make up the seal pack: Total thickness (mm) 0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1.0 1.1 1.2 1.3 1.4 1.5 1.6 1.7 1.8 Paper gasket (mm) 0.2 0.3 0.2 + 0.2 0.3 + 0.2 0.3 + 0.3 0.2 + 0.2 0.3 + 0.2 0.3 + 0.3 0.2 + 0.2 0.3 + 0.2 0.3 + 0.3 0.2 + 0.2 0.3 + 0.2 0.3 + 0.3 0.2 + 0.2 0.3 + 0.2 0.3 + 0.3 Steel washer (mm) 0.3 0.3 0.3 0.6 0.6 0.6 0.9 0.9 0.9 1.2 1.2 1.2

127

L / M . . 01.97

M 14.00 Fuel injection equipment


M 14.30 Injector

- 4 - 37 Preparatory work:

- 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).

128

- Unscrew and remove loop for injector


(128/3). Take out the injector and sealing ring (129/1) using impact extractor tool - 4 -. Functional check:

- Connect extension tube with test pressure


gauge for fuel injection system - 37 - to the pressure tube connection for the injection pump; see Fig. 129. - Connect the injector to the tester, cover the remaining injection pumps over with clean cloths and start the engine. Note: All injectors should be removed for this test. WARNING: Keep the hands away from the fuel spray emerging from the injectors. The fuel spray from the injectors can cause blood poisoning.

129

L / M . . 01.97

- Check the spray pattern from the injector


as shown in Fig. 130. Assembling:

- Install the injectors using new sealing rings


and working in the opposite order to that described for 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 injector and the collar nuts on the pressure pipe to the specified torques (see Section 4), holding the pressure pipe connection on the injection pump to prevent it 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 and are identified by the section of hose pushed on to them.

130

L / M . . 01.97

M 14.00 Fuel injection equipment


M 14.40
Preparatory work:

Injector nozzle

- Remove the injector; see M 14.30.


Dismantling:

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


the nozzle with needle (132/2). - Take out spacer (132/3), pressure pin (132/4), spring (132/5) and shim washers (132/6). Checking parts: - Inspect the needle of the nozzle for scoremarks or signs of overheating. - The nozzle needle (132/2a) must, when the nozzle is held vertical, slide down slowly and smoothly under its own weight 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, pressure pin and spacer in the nozzle holder again as shown in Fig. 132, in the opposite order from their removal. - Attach the injector nozzle so that the pins on the spacer locate in the holes on the nozzle. - Screw on the collar nut and tighten it. - Mount the injector on the tester and determine its fuel delivery pressure; for values, see Section 4. - Correct the fuel delivery pressure by inserting shim washers: Thicker washers = higher delivery pressure Thinner washers = lower delivery pressure 0.15 mm 15 bar.

6 5 4 3 2a 2

132

L / M . . 01.97

M 14.00 Fuel injection equipment


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

- 10 - 11 - 29 -

Nature of repair Removing and installing or exchanging complete injection pump

Adjustments needed

Notes Install shims again at the point where they were removed

Synchronising Repairing injection pump Renewing camshaft for injection pump Renewing crankcase Effective stroke Removing and installing governor rod Renewing governor rod Synchronising Synchronising Effective stroke Measure effective stroke before removal and restore when installing Measure effective stroke before removal and restore when installing Start of injection Synchronising Measure effective stroke before removal and restore when installing Injection pump must only be repaired by authorised workshop

Renewing starting charge control

Effective stroke

Conversion from injectionpump with control lip at top Start of injection (start of series production) to pump with control lip at Synchronising bottom (current series Effective stroke production status) Modifying the power setting Effective stroke

All pumps on the engine must be converted For adjustment data see Section 4 Measure the original effective stroke. Alter effective stroke only by difference value

L / M . . 01.97

1. Adjusting start of fuel delivery: Note: Start the adjustment at the timing-end injection pump.

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

- Remove the pressure tube connection and


pressure valve at the injection pump.

- Screw the overflow device - 10 - into the injection pump.

- Screw the extension pin of the overflow device into the dial gauge - 11 - and insert it in the overflow device; see Fig. 133. - Connect the fuel feed line from the test tank. Note: The test tank must be attached at least 200 mm (8 in) above the injection pump.

- Turn the crankshaft in the normal direction


of rotation (counter-clockwise when looking at the flywheel), until the dial gauge needle starts to move. - Open the fuel feed; fuel will emerge from the overflow device. - To turn the engine over, attach a ratchet with 1/2-inch square end to the square recess in the belt pulley. - Continue to turn the engine over slowly until the fuel emerges from the overflow pipe slowly as separate droplets (about. 1 droplet every 5 - 6 seconds). - This point is the start of fuel delivery.

133

L / M . . 01.97

- Read the angle in degrees at the inspection hole in the connecting housing, and compare it with the desired value in Section 4. To take the reading, remove the plastic plug: see Fig. 134. On engines without a connecting housing, the fixed mark is stamped on the crankcase. Note: On engines built before or in 1980, the angle in degrees is only stamped on the engine for the first (timing-end) cylinder; only two marks are provided for the other cylinders. The short mark (half diameter of inspection hole) shows the angle for the start of delivery, the long mark (full diameter of inspection hole) shows the piston top dead centre point.

134

- If necessary, correct the start of fuel delivery 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 desired value: = fuel delivery starts too soon. Add more shims. Note: Use a dial gauge as follows to determine the thickness of the shims needed to correct the value:

- Set the dial gauge to 0" at the actual start


of fuel delivery, and turn the flywheel to the desired start of fuel delivery. The dial gauge will now show the thickness of the shims to be inserted or removed. - Repeat the measurement procedure; the fuel drip from the overflow pipe on the adjusting device must start precisely when the desired value is reached. - Carry out the measuring procedure at all injection pumps.
L / M . . 01.97

2. Adjusting end of fuel delivery: Note: Engines equipped with Type PFR 1K 80A 439/2 injection pumps must be adjusted to the correct end of the delivery stroke. - Prepare for the measuring procedure in the same way as if the start of fuel delivery is to be measured. - Turn the crankshaft in the normal direction of engine rotation until the gauge needle begins to move and the fuel emerging from the overflow pipe starts to drip slowly or ceases to drip. - Continue to turn the crankshaft slowly until the fuel just begins to drip from the overflow pipe again (about 1 droplet every 5 - 6 seconds). - This point is the end of fuel delivery. - The value obtained in this way must agree with the desired value stated in Section 4. - If necessary, correct it as described above. 3. Synchronising injection pump delivery volume: - Move the governor rod by hand fully to the right, to the ,,Stop position, and hold it there. - Loosen all sliding elements (135/1) on the governor rod; the toothed rack on the flywheel-side injection pump must be in the ,,Stop position. - Move the sliding elements for the other injection pumps to the right (,,Stop position) until the pump toothed rack is against its stop, and tighten there; see Fig. 135. - Release the governor rod. - Before installing, coat the gaskets for the cover and the starting charge device on both sides with sealant H. Apply the sealant only as a very thin coating to the starting charge device, to ensure that its oilway is not blocked when assembling. - Coat all bolt threads for the cover and starting charge device with sealant D. Note for engines from serial number L 30.17, 2 L 40.15, 3 / 4 L 40.14, M 40.11 on: The governor rod travel limit screw (135/2) must be unscrewed during this work, or else the ,,Stop point for the pump governor rods will not be reached.

135

L / M . . 01.97

4. Adjusting effective stroke: (on engines with start of delivery adjustment) - Install the start charging device and replace the cover by hydraulic starting charge adjuster 619 845 00; see Fig. 136/3. - Set the speed control lever to full load and 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 test tank and open the shutoff tap; fuel will emerge from overflow device. - Turn the crankshaft until the injection pump has just reached the start of fuel delivery (about 1 droplet of fuel emerges every 5 6 seconds). - Set the dial gauge to zero and continue to turn the crankshaft in the normal direction of engine rotation until the dial gauge moves from 0" to precisely the nominal effective stroke value stated on the type plate. - In this position, fuel should start to drip out of the overflow device again. - If this is not the case, loosen grub screw (136/2) and turn the eccentric flow limiter (136/1) until the fuel begins to drip out slowly. - When the setting is correct, retighten grub screw (136/2), seal it with lacquer and install the cover again in place of the adjuster (136/3).

136

L / M . . 01.97

5. Adjusting the effective stroke (on engines with end-of-delivery adjustment): - Prepare for the adjustment in the same way as described for start-of-delivery adjustment. - Set the injection pump to the end of fuel delivery. - Turn the crankshaft in the opposite direction to normal rotation until the dial gauge shows the nominal effective stroke stated on the type plate. - Correct if necessary as described above. To do this, use the starting charge wrench - 29 - (see Fig. 137). - After adjusting correctly, tighten the grub screw and seal it with lacquer. - Remove the overflow device, install the pressure valve with pressure tube connection and tighten to the specified torque. 137 6. Note on changing the power setting:

- Measure and make a note of the original power setting. Remember that as a result of
tolerances the actual effective stroke setting may not coincide exactly with the effective stroke value on the type plate. - The effective stroke setting for the desired power is obtained from the original effective 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 from table: Effective stroke for power output B from table: Difference between effective stroke values: Effective stroke measured at engine: + difference value New effective stroke setting: 1.14 mm 1.07 mm 0.07 mm 1.05 mm 0.07 mm 1.12 mm

L / M . . 01.97

M 14.00 Fuel injection equipment


M 14.60 Adjustment work with PFR 1K 90 injection pumps (from engine serial numbers 2 L 40.17, 3-4 L 40.16, M 40.13 on L 31 / 41 and M 31 / 41: all engines)

- 23 - 24 - 25 - 26 - 27 - 28 -

Inst. work Renew injection pump Renewing governor rod Renewing start charge control Renewing governor lever Renewing injection pump camshaft

Work needed on fuel injection system Start of injection (with shims); precise radial position of pump Marking crankcase with radial position of injection pumps Adjusting injected volume for nominal power output Adjusting injected volume for nominal power output Adjusting damper spring (generator operation only) Adjusting injected volume for nominal power output Marking crankcase for adjustment of start of fuel injection Adjusting start of fuel injection Marking crankcase for adjustment of start of fuel injection and radial position of injection pumps Adjusting start of fuel injection Adjusting injected volume for nominal power output

Renewing crankcase

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

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

L / M . . 01.97

1. Crankcase mark for adjusting start of fuel delivery:

- Insert measuring device - 25 - into the calibrating device - 26 - and adjust it so that both needles of the dial gauge are at ,,0; see Fig. 138. - Insert the measuring device into the mounting hole on the injection pump and screw it down firmly. The correct cam must be on its base circle. - Turn the flywheel in the normal direction of engine rotation until the start-of-delivery mark on the flywheel (15 before TDC) for the cylinder in question is aligned with the fixed mark on the crankcase or in the inspection hole of the connecting housing; see Fig. 134. - In this position, take the total dial gauge reading; see Fig. 139.

138

139

- From this total dial gauge reading, deduct


2.15 0.05 mm and stamp the remaining value (without +/- sign or decimal point) into the crankshaft as a tenths of millimetre value (140/1). Repeat this procedure for each pump mounting hole.

140

L / M . . 01.97

2. Marking the crankcase for the radial position of the injection pumps:

- Insert the locating pin - 27 - into the hollowdrilled stud bolt of pump 1 to lock the governor rod in position ,,X (141/1).

- Insert the marking device - 23 - into the injection pump mounting hole, turn clockwise to make proper contact and stamp the mark on the crankcase; see Fig. 142. Make this mark for each injection pump mounting hole. 141

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 monitoring block housing or replace the valve solenoid by the plate of the adjusting tool -28, then use a depth gauge to measure the distance ,,S from the outer edge to the flat face on the piston inside; see Fig. 143. - Screw in the injection volume adjusting tool - 28 -, using a number of copper sealing rings according to the following table:

142

S(mm) 11.3 >11.3 see also Fig. 143.

Number of sealing rings 2 1

143

L / M . . 01.97

- Remove the second injection pump (looking from the timing end) and install measuring device - 24 - in its place (the ball end on the vertical lever must engage in the driving slot of the governor rod); see Fig. 144. - Loosen the grub screw (146/1). - Turn the adjusting screw (19 mm across flats) by 1/8 of a turn counter-clockwise. - Move the speed control lever to the starting position. - Insert locating pin - 27 - into the hollow-drilled stud bolt, then turn the adjusting screw slowly clockwise until the locating pin engages under light pressure in the corresponding slot of the governor rod; Figs. 141 and 145. This determines the ,,X position of the governor rod. - In this position, set the dial gauge scale on the adjusting device precisely to ,,0. - Pull out the locating pin; the needle of the dial gauge should then move by 0.01 - 0.02 mm. - Determine the governor rod travel stated on the type plate (the figure is in hundredths of a millimetre). - Turn the injection volume adjusting tool until the dial gauge shows the control distance needed. Do not forget to allow for the 0.01 - 0.02 mm already indicated by the dial gauge. Note: A minus value (= lower power range) is obtained by turning the adjusting tool clockwise, a plus value (higher power) by turning counter-clockwise.

144

145

- Tighten the grub screw (146/1) carefully to


prevent this setting from being lost, and secure it with lacquer.

146

L / M . . 01.97

- Replace the adjusting tool - 28 - by the screw plug again, using a suitable tool
(e.g. screwdriver) to check that the engine monitoring piston slides smoothly. If it tends to stick, slightly reduce the preload at the grub screw (146/1) and repeat the check. - Remove the adjusting device - 24 - and install the injection pump (M 14.20). Note on changing the power setting Adjustment data for a change in engine power can be obtained from your HATZ service point. 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 mm Governor rod travel for output B acc. to adjustment data: -0.26 mm Difference from adjustment values: 0.39 mm The adjusting tool - 28 - must therefore be turned counter-clockwise until the dial gauge of the measuring device - 24 - reads 0.39 mm. If the engines 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 temperature, or else the speed setting will not be accurate. - Turn the stop screw for the upper idle speed limit (146/2) until this speed is about 0.3 % lower than the desired value according to the type plate. Example: Type plate data 3000/60 = 3060 - 0.3 % = 3050 rpm. Make sure that the damping spring 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 the same value of app. 0.3 %.

L / M . . 01.97

M 17.00 Flywheel
Dismantling:

- Remove bolts (148/3) and disc (148/2). - Screw in two suitable stud bolts to act as
guides.

- Take off the flywheel.


Assembling: - Drive locking collet (148/1) into the end of the crankshaft at the flywheel end to provide the necessary centering action. - Attach the flywheel so that the locking collet enters the centering hole. - Place the disc (148/2) in position, insert the bolts (148/3) and tighten them to the specified torque.

148

L / M . . 01.97

M 20.00 Engine shutdown device / belt tensioner


- 20 - 21 - 39 Preparatory work: Engines with enclosure - Take off the cover for the air guide housing and front impeller. Engines without enclosure - Take off belt guard, if fitted. Removing: - Press back the tensioning roller and attach the locking device - 39 - (Fig. 149). - Take out screws (150/3) with spring washers and remove the drive pulley (150/4)(the drive pulley is not fitted from year of manufacture 1985 onwards). - Pull the belt pulley (150/5) out of its centering mount and take it off together with the Poly-V belt. - Detach the oil line (150/1) and remove the 3 machine screws (150/2) with spring washers. - Detach the mount (150/7) at the cooling fan, noting the installed shims. - Take off the engine shutdown device (150/6).

149

150

L / M . . 01.97

Dismantling the engine shutdown device: (from engine serial numbers L 30.15, 2 L 40.12, 3/4 L 40.11). - Remove the locking device. Warning: The piston with tensioning roller are springloaded; release the spring loading gradually. - Take out circlip (152/1). - Unscrew the nut (151/1) and take out the machine screw (151/2) with sleeve (151/3) and washers (151/4) and (151/5), at the same time forcing the tensioning roller (151/6) back slightly against its spring loading. - Carefully release the spring loading completely 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 the housing. - Take the restrictor screw (153/1) out of the back of the housing. - Press the shaft out of the piston and remove the tensioning roller. - Take off the Nilos rings (151/8). Drive the ball bearings (151/9) out towards the 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 roller and the bushings in the housing for scoreor wear-marks. If damaged, renew the bushings or the piston. To renew the bushings, use special tools 20 - 21 - and press the bushings in as shown in Fig. 174. - Check the tensioning roller ball bearing and renew if necessary. - Renew quad rings (152/4) and (152/5). - Renew the tensioning roller or belt pulley if any grooves are damaged or ribs broken off. - Check that the bore in the restrictor screw is not blocked.
L / M . . 01.97

151

31

174

152

Assembling: - Assemble by following the dismantling procedure in the opposite 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 assembling. Note for older versions of L 30 / L 40 engines: - 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 installed in- 153 stead of the restrictor screw (153/1) until about early 1982. - A modified tensioning roller mount is used from the L 30.15 / 2 L 40.12, 3/4 L 40.11 onwards.

L / M . . 01.97

M 22.00 Air cleaner


Dismantling: L-engines - Take off the enclosure hood. - Remove dirt adhering in the air cleaner housing area. - Loosen screws (175/1) only sufficiently to permit the complete air cleaner housing to be raised. - Cover the opening in the intake pipe to prevent dirt or other foreign bodies from entering. - Open the air cleaner housing and take out 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 filter element (177/7) to be raised. - Cover the opening in the suction pipe to prevent dirt and other foreign bodies from entering. Checking / repairs: - Check the sealing faces for signs of damage. - Clean the filter housing and the cover. Spacer ,,5 is connected by an elastic sleeve ,,6 with the retaining screw, so that it cannot fall into the intake pipe during maintenance work. - If the spacer is loose, renew bushing ,,6. 176 Assembling: - Follow the instructions in the reverse order.

175

2 3

3 7

4 5

6 5

L3/58

177

L / M . . 01.97

M 31.00 Crankcase breather


General: The crankcase breather operates by way of a diaphragm valve in the intake pipe. During maintenance or repair work, in particular if the engines oil consumption is high or it is producing too much blue exhaust smoke, you are recommended to check the condition of the diaphragm. Dismantling: - Pull housing 1 with cap 2 and diaphragm 3 out of the intake manifold and hose 4 (Fig. 178). - Pull cap 2 out of housing 1 and remove diaphragm 3. Checking / repairs - Examine the diaphragm for cracks and renew if necessary. - Renew O-rings 5. Assembling:

3 2

- Proceed in the opposite order to that described above. 178

L / M . . 01.97

M 32.00 Speed control


M 32.10
Preparatory work:

Engines with PFR 1K 80 injection pump

- 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 pull the governor rod towards the flywheel end; see Fig. 155. - As shown in Fig. (155/1), move the governor lever over to the timing side and pull it out downwards.

154

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), support washer (156/11) and shim(s) (156/12). - Pull off governor shaft stop (156/13), remove circlip (156/14) with spacing washer (156/15) and pull out shaft (156/9).

155

156

L / M . . 01.97

Checking / repairs: - Check ball bearing at governor lever for wear. - Check governor lever, pin for speed control, fork, adjusting shaft and housing 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 tensioning plate. Push on the fork (157/3) and drive the locking collet 157/4) in flush with the fork; see Fig. 157. - Push on the sleeve (158/1) and torsion spring (158/2), then drive in the locking collet (157/4) flush with the fork; see Fig. 158. Preload torsion spring (158/2) by a quarter-turn clockwise, then connect to the locking collet. - Further assembly is in the reverse order to that described for dismantling; use a new gasket. - Apply sealant D to screws (154/1) when inserting.

157

158

L / M . . 01.97

M 32.00 Speed control


M 32.20
Dismantling:

Engines with PFR 1K 90 injection pump

- Remove machine screws (154/1). - Turn the speed control shaft anti-clockwise
to the ,,Stop position and pull the governor rod towards the flywheel end of the engine; see Fig. 179. - Turn speed control mount (179/1) to the right and pass governor lever (179/2) under governor rod (179/3). - Carefully pull the speed control mount out downwards. Dismantling the speed control: (Bild 180) - Drive out locking collet 1. - Slide out pin 2 and take off governor lever 3. - Take out locking collet 4 for stop 5 and pull out control shaft 6. - Disconnect spring 7. - Drive out locking pin 8 and pull off fork 9. Checking / repairs: - Check ball bearing at governor lever for wear. - Check governor lever, speed control pin, fork, control shaft and housing for score marks and renew all damaged parts.

154

179

180

L / M . . 01.97

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, using a suitable tool. - Continue installation by following the removal instructions in the reverse order.

181 Note: Since there are various patterns of governor lever, make sure when repairing the speed control that the original governor lever is installed again. If the governor lever or the conplete speed control is renewed, note that torque equalisation may have been activated at the original governor lever. In case of doubt, contact your nearest HATZ service point.

L / M . . 01.97

M 35.00 Capsule
Preparatory work:

- Remove the engine.


Note: It is normally only necessary to remove the engine from the equipment in which it is being used in order to dismantle the capsule if the air guide housing or rear panel have to be taken off.

- Remove exhaust capsule; 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).

159

- Detach the air outlet shaft (160/1) and cover plate (160/2). Note for 4 L 40 C: Take out the cooling air guide lining elements.

- Take off the cross-member above the injectors and raise the engine slightly at its suspension lug until the baseplate of the enclosure can be unscrewed and removed. - Detach the feet from the engine. - When the feet have been removed, the four 22 mm hex bolts used to attach the baseplate should be used to support the engine. 160
L / M . . 01.97

- Unscrew the earth (ground) strap and the


+ line from the rear panel of the enclosure.

- Take off the rear panel with intake duct;


see Fig. 161.

161

- Unscrew the cover from the air guide housing (162/1).

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

- Take off the air guide housing; see Fig.


163. Checking the parts:

- Examine the various sections of the enclosure for damage.

- Renew damaged or incomplete sealing


strips. 162 Assembling:

- Assemble the enclosure by following the


dismantling instructions in the reverse order as appropriate. Note: Make sure that all enclosure sections are carefully installed and that all sealing strips are seated correctly. Unless the enclosure is completely sealed, neither the potential level of noise reduction nor adequate cooling can be ensured.

163

L / M . . 01.97

4. Tables

L / M . . 01.97

Tightening torques for threaded connections


General requirements in Nm:
Nm 9.81(10) = kpm Nm 1.3558 = lb.ft

Strength category Thread 5.8 M M M M 4 5 6 8 1.7 3.4 6.0 14 29 50 80 120 170 240 320 8.8 2.8 5.5 9.5 23 46 80 130 190 270 380 510 10.9 3.9 7.8 13 33 65 110 180 270 380 530 720 12.9 4.7 9.3 16 39 78 140 220 330 450 640 860

M 10 M 12 M 14 M 16 M 18 M 20 M 22

L / M . . 01.97

Tightening torques in Nm
Engine Shouldered nuts on stud bolts (tierods) for cylinder head
(Coat the tierod thread and washer contact face in the oil cavity with sealant D)

L 30

L 31. M 31 L 40. M 40 L 41. M 41 65 60 115 65 10 15 35 85 40-50 30 75 25 90 200 30 14 140 130 25 10 6.5

50 60 65 10 15 35 85 L41. M41 30 75 25 90 135 30 14 140 130 25

Big end bolts:

M 10 x 1 (8 mm Allen screw) M 11 x 1 (10 mm Allen screw)

Machine screws for counterweights Machine screws for end cover, flywheel end
(Coat thread with sealant D)

Hex nuts for securing injectors Pressure valve at injection pump Collar nut for injector nozzle Machine screws at balancing weight bearing journals (4-cyl.) Machine screws at drive gearwheel for balancing weights (4-cyl.)
(Coat thread with sealant D)

Hex nut for attaching spring bridge (governor) Machine screws M 12 x190 (crankcase halves) Flywheel bolts Machine screws for gearwheel on crankshaft Machine screws, M 6. for securing cam tracks (injection timer) Hex bolts for connecting housing
(Coat thread with sealant D)

Front engine feet support mount (Silent Pack) Hex bolts for governor weight holder Hex nut for cylinder head cover (pressure-cast version) Machine screws holding solenoid valve to engine monitoring block

L / M . . 01.97

Repair data
Cylinder head L 41 M 41 mm 0.85-0.95 mm mm mm mm mm mm mm max. mm 0.15 min. mm 0.00 outer Valve guide inner mm mm mm 9H6 mm 43.1-0.3 39.1-0.3 1.70 0.85 15
+0.046 +0.038 +0.009 0

L 31. M 31 L 40. M 40 1.0 - 1.1

L 30

H .L 30 1.0 - 1.5 1.2 0.10 - 0.20 0.40


2)

Gap Gasket at cylinder head Shim washers


1)

0.7 - 0.8 - 0.9 - 1.0 - 1.1 - 1.2 0.10 8.96 8.85


-0.015

Valve clearance, cold (2010C) Valve stem Wear limit Inlet valve head Exhaust valve head Recess of valve head

40.1-0.3 35.1-0.3

Wear limit Bore in cylinder head

inner

9.05 15
+0.006 -0.012

Pressing-in force Valve guide projection Valve seat angle

N mm 20.5

1000 23.5 (l=70.5) 20.5 (l=67.5) 45 20.5 14.5

1) As required, between cylinder and crankcase 2) If steel pushrods are used: 0.20 mm

L / M . . 01.97

Repair data
Cylinder head L 31. M 31 L 40. M 40 L 41. M 41 L 30 H .L30

Length of inner valve spring, off-load Wear limit Length of outer valve spring, off-load Wear limit Rocker shaft

mm mm

45.5 44.0

mm mm mm

58.0 56.5 19 f 6
-0.020 -0.033

Wear limit Bore in rocker

mm mm

18.90 21 H 7
+0.021 0 +0.046 -0.012

Rocker bushing

inner mm

19

Wear limit Radius at rocker


(no flats must have formed)

inner mm mm

19.20 8

Rocker endplay
(insert shims only on the circlip side)

mm

0.1 - 0.2

L / M . . 01.97

Repair data
Camshafts (injection pump drive and valve gear)
Camshaft bearing journal diameters Timing-gear side and centre mm 54 e 6
-0.060 -0.079

Wear limit Flywheel end (ball bearing seat)

mm mm

53.85 20 m 6
+0.021 +0.008

Internal diameter of bearing bore in crankcase Timing end mm 54 H 7


+0.030 0

(bushing for. 54 -0.002 camshaft)

+0.058

Wear limit Centre

mm mm

54.10 54 H 7
+0.030 0

Wear limit Flywheel end (ball bearing seat) Bore for tappet in crankcase Wear limit Tappet shaft

mm mm

54.10 47 K 7
-0.007 -0.018 +0.018 0

mm

16 H 7

mm mm

16.05 16 f 7
-0.016 -0.034

Wear limit Camshaft endplay

mm mm

15.9 0.1

L / M . . 01.97

Repair data
Balancing weights
Bearing point diameters two and threecylinder engines Balancing weight shaft mm 28 h 5
0 -0.009

Endplay twocylinder engines three-cylinder engines Wear in the needle roller bearing area

mm mm mm

0.15 - 0.6 0.15 - 0.7 down to 27.97

Bearing point diameters four-cylinder engines Bearing journals for balancing weights Bearing bushing for balancing weights (pressed-in) Endplay mm 44 d 6
-0.080 -0.096 +0.018 +0.083

mm

44

mm

0.15 - 0.4

L / M . . 01.97

Repair data
.L 30 / H .L30 .L 31 / .M 31 .L 41 / .M 41 .L 40 / .M 40 Conrod Bore for piston pin (small end) bushing Big end bore Piston pin bushing external pressed-in Wear limit Max. misalignment* Cylinder Bore Wear limit Oversize Roughness Piston Normal Oversize Play max. Play min. Piston pin bore Wear limit Piston pin Wear limit Piston ring endplay max. mm mm mm mm mm mm mm mm mm 94.94 +1.0 0.07 0.06 32 32.05 32 31.95 0.2
0 -0.006 +0.009 +0.004

mm mm mm mm mm mm

35 H 6 63 H 6 35 32 32.30 0.08

+0.016 0 +0.019 0 +0.085 +0.045 +0.075 +0.030

39 H 6 67 H 6 39 36

+0.016 0 +0.019 0 +0.085 +0.045 +0.080 +0.035

internal internal

36.30 0.08

mm mm mm Ra

95 +0.01 95.15 +1.0

102 +0.01 102.15 +0.5 / +1.0**

0.9 - 1.3 (1= 1/1000 mm)

101.92 101.90 +0.5 / +1.0** 0.09 0.11 0.08 0.10 36


+0.010 +0.004

36.05 36 -0.006 35.95 0.2


0

L / M . . 01.97

Repair data
Piston rings .L30. H.L 30 Ring groove No. I II III Standard Oversize Standard Oversize Standard Cutaway micro-chamfer Designation Trapezoidal Dimensions 95 x 87 x 3 96 x 87.9 x 3 95 x 87 x 3 96 x 87.9 x 3 95 x 87 x 5 96 x 87.9 x 5 0.30 - 0.60 2.0 0.40 - 0.65 2.0 End gap mm: normal 0.40 - 0.65 max. 1.0
1)

D-ring Oversize Piston rings .L 31, .M 31, .L 40, .M 40, .L 41, .M 41, Ring groove No. Standard I Oversize Standard II Oversize Standard III Oversize D-ring Cutaway micro-chamfer Trapezoidal Designation

Dimensions 102 x 93.4 x 3 102.5 x 93.9 x 3 103 x 94.4 x 3 * 102 x 93.4 x 2.5 102.5 x 93.9 x 2.5 103 x 94.4 x 2.5 * 102 x 93.4 x 4 102.5 x 93.9 x 4 103 x 94.4 x 4 *

End gap mm: normal 0.40 - 0.65 max. 1.2


1)

0.40 - 0.65

2.5

0.30 - 0.60

2.5

1)These are maximum limit values which can still be accepted without risk of engine power output, oil consumption and exhaust emissions being affected. The piston rings should be renewed during repair work if they have worn to 60 % of the limit value. * These oversize piston rings are no longer available.

L / M . . 01.97

Repair data
Crankshaft .L 30 / H .L 30 mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm mm 27 0.2 3.5 -0.2 70 h 11
0 -0.190 0 -0.019

.L 31 / .M 31 .L 40 / .M 40 .L 41 / .M 41 64 h 6 63.88
0 -0.019

Crankpins Wear limit Out-of-roundness max. Conicity max. Width Radius Centre bearing journal Out-of-roundness max. Conicity max. Width Radius Main bearing journal, timing end Out-of-roundness max. Conicity max. Width Radius Main bearing journal. flywheel end Out-of-roundness max. Conicity max. Width Radius Contact face for shaft sealing ring, flywheel side

60 h 6 59.88

0.05 0.003 32 H 9 3.5 72 h 6


0 -0.019 +0.062 0

32 H 9

+0.062 0

4.0 +0.3

0.05 0.003 32 +0.3 3.5 -0.2 72 h 6


0 -0.019

3.75 -0.2

0.05 0.003 26.5 -0.2 3.5 -0.2 72 h 6 0.05 0.003 32 +0.3 3.75 -0.2 80 h 11
0 -0.190 0 -0.019

L / M . . 01.97

Repair data
Crankshaft .L 30 / H .L 30 mm Rc mm 0.5 50 - 55 2.5 .L 31 / .M 31 .L 40 / .M 40 .L 41 / .M 41

Regrinding during repairs Hardness Hardening depth Big end bearing, internal (installed) Normal Wear limit Undersize Wear limit Wall thickness, normal Undersize Main bearing, internal (installed) Normal Wear limit Undersize Wear limit Wall thickness, normal Undersize Crankshaft endplay Max. permissible bearing play after wear

mm mm mm mm

60 60.20 59.5 59.7

+0.083 +0.040

64 64.20

+0.063 +0.040

+0.083 +0.040

63.5 63.7

+0.083 +0.040

mm mm

1.468 - 1.480 1.718 - 1.730

mm mm mm
mm

72 72.25 71.5

+0.099 +0.056

+0.099 +0.056

mm mm mm

71.75 2.960 - 2.972 3.210 - 3.222 0.15 - 0.65

mm

0.3

L / M . . 01.97

Fuel injection equipment


Up to engine serial numbers: 2 L 40.16. 3 - 4 L 40.15. .M 40.12. L 30 and H.L 30 Start of delivery 17 - 18 before TDC

Engine type

Injection pump PFR 1 K 80 A 442/2 1)

HATZ Ident No.

2 - 4 L 30 H .L 30

PFR 1 K 80 A 442/11 1) PFR 1 K 80 A 467 1) 2) PFR 1 K 80 A 467 3) PFR 1 K 80 A 477 2) PFR 1 K 80 A 477 3) 501 407 00 501 407 10 502 368 00 502 368 10

2 - 4 L 40 2 - 4 M 40
1) 2) 3)

17 - 18 before TDC

Interchangeable With governor-rod stop at pump Without governor-rod stop at pump: governor-rod limiter needed on engine

From engine serial No.: 2 L 40.17. 3 - 4 L 40.16. M 40.13. L 31. M 31. L 41. M 41 Start of delivery 15 before TDC 10 before TDC

Engine type L 31. M 31 L 40. M 40 L 41. M 41 Injectors

Injection pump PFR 1 K 90 A 498 PFR 1 K 90 A 546

HATZ Ident No. 502 630 00 504 442 01

Engine type L 30. H.L 30 L 31. M 31 L 40. M 40 L 41. M 41

HATZ-Ident-No.

Injector nozzle Bosch HATZ 501 413 01

Spray pressure
+8

401 209 01

DLLA 160 S 908

250

bar

504 440 00

DSLA 150 P 645

504 441 00

230

+12

bar

L / M . . 01.97

Governors
L 30. H .L30 Speed 2300 > 2300 1500 * 1800 * Application Normal operation Generator drive Governor spring Ident-No. 036 012 01 035 744 01 036 014 01 036 013 01 Wire mm 3.0 3.2 2.5 2.6 035 729 00 Governor weight Ident-No.

3000 035 744 01 3.2 * When driving a generator at 1500 and 1800 rpm governor weights with Ident No. 036 349 00 were used from 1979 to 1982. They are identifiable by a ,,G stamped on the end or a white spot. If needed, renew these governor weights as a complete set, since governor weights with Ident-No. 035 729 00 are now installed for all running-speed ranges. L 40. M 40 with injection pumps PFR 1K 80A 477 Speed 2300 > 2300 1500 1800 Application Normal operation Generator drive Governor spring Ident-No. 036 012 01 035 744 01 037 739 00 036 013 01 Wire mm 3.0 3.2 2.5 * 2.6 035 729 00 Governor weight Ident-No.

3000 035 744 01 3.2 * Identifiction: windings are ground away slightly at circumference. L 31. M 31. L 40. M 40 with injection pump PFR 1K 90A 498 and L 41 and M 41 Speed 2300 > 2300 1500 1500 1800 Generator drive Application Normal operation Governor spring Ident-No. 036 012 01 035 744 01 038 670 00 036 014 01 036 013 01 Wire mm 3.0 3.2 2.3 * 2.5 2.6 035 729 00 Governor weight Ident-No.

3000 035 744 01 3.2 * With this governor spring the spacing ring, Ident No. 037 729 00, is deleted (Fig. 48a/50)

L / M . . 01.97

Lubricating oil content and dipstick

Engine type Two-cylinder engines .L.. C / Z .L.. S. M.. Three-cylinder engines .L.. C / Z .L.. S. M.. Four-cylinder engines .L.. C / Z .L.. S. M..

Oil sump

Oil content l 7.5 4.5 8.5 5.5 10.5 8.0 11.0 8.5

Dipstick marking C A C A D A D A

with without with without with without with without

with with

13 14

D D

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 case the oil content is reduced by app. 0.2 - 0.5 litre. In all cases fill to the ,,Max mark on the dipstick.

L / M . . 01.97

Key to circuit diagrams (DIN 40719)


Key A1 A2 A3 A4 B1 B2 B3 B4 C1 E1 F1 G1 G2 G3 H1 H2 H3 H4 H5 H6 H7 H8 K1 K2 K3 K4 K5 K6 K7 K8 M1 MG N1 N2 N3 N4 Designation of electrical component Instrument box Instrument panel Automatic start-stop Starter protection module Temperature sensor Speed pulse transmitter Oil pressure sensor Signal horn Condenser Fuel filter heater Fuse Battery Alternator Flywheel generator Generator telltale light Oil pressure warning light Engine overheat warning light Air cleaner telltale light (maintenance switch) Belt break warning light Pre-heat monitor telltale light Fan monitor warning light Remote display: engine running Control relay 1 for start / start repeat interlock Control relay 2 for pre-heating Control relay 3 for speed control Engine protection relay Delaying relay Start inhibit relay Timer (impulse) relay Power relay Starter motor Starter generator Voltage regulator for starter generator Voltage regulator for flywheel generator Voltage regulator for alternator (unless integrated) Pulse transmitter (additional item for synchro-regulator)

L / M . . 01.97

Key to circuit diagrams (DIN 40719)


Key P1 P2 P3 R1 R2 R3 R4 R5 S1 S2 S3 S4 S5 S6 S7 S8 S9 S 10 S 11 S 12 T1 V1 V2 V3 V4 W1 W2 X1 X2 X3 X4 X5 Y1 Y2 Y3 Y4 Y5 Z1 Z2 Designation of electrical component Operating hours counter Revolution counter Pressure gauge Pre-heat plug Heating flange Line resistor for pre-heat system Resistor Line resistor with thermo-times switch Pre-heat start switch (5-position) Master switch Pre-heat/start switch (3-position) Start-stop-switch Swich for speed control Engine temperature switch Oil pressure switch Pressure switch for air-cleaner Fan monitoring switch Pre-heat temperature switch Remote-start switch Remote stop switch Transducer for speed measurement Decoupling diode Freewheeling diode Zener diode Suppressor diode Earth (ground), negative return line Screened line at generator Terminal strip at instrument box Flat-pin junction box Plug at emergency stop switch Socket at emergency stop switch Terminal block in control box / terminal box Solenoid for speed control Solenoid for engine shutdown Servo (valve) solenoid for engine shutdown Fuel shut-off valve High-pressure shut-down valve Suppressor choke Suppressor capacitor

L / M . . 01.97

HATZ - Wiring identification


Terminal 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 Designation Earth (ground) Alternator B+ With alternator: D+ With flywheel generator: terminal L at voltage regulator Starter terminal 50 Oil pressure switch Temperature switch on cylinder head Pre-heat plug I Engine shut-down solenoid Pre-heat II Start-stop input Positive terminal for DC fine speed control motor Negative terminal for DC fine speed control motor Oil pressure sensor * * * Reserved for special purpose * * * Speed control solenoid hold-on winding * * * Reserved for special purpose * * * Decompression solenoid Air cleaner maintenance switch Engine shut-down solenoid (energizing winding) Temperature sensor on cylinder head Oil temperature switch Fan monitoring switch Terminal W for engine speed measurement Starter 30 (if ammeter is connected) Terminal C if voltage regulator is on flywheel generator Oil temperature sensor Terminal 50f at starter protection module * * * Reserved * * * Speed control solenoid (energizing winding) * * * Reserved * * *

L / M . . 01.97

4
3 4 5 6
30 15 50
30 86

L / M . . 01.97
19 17 K2 H3 V2 H6 H6 P1
87 85

Circuit diagram 12 V - system with fault display

S1 V1 H1 H4 H2

58 P0123

50a

15

19

17

W-1 S5
86

15 K3
30

P, 0, 1

30

P2

n h
85 87

W-6

F1 8A V2 X1 2 17 4 5 X1 7 X1 0 6 8 14 4 L / M 31,40,41 only Instrument box Engine

X1

1 22 3

D+

B+

30

50

S8

S7

S6

R1 7 HW 0 3 AW Y3

R1 7 Y1 0 31

Pu P t

G2

G1

M1

Power supply Charging device

Starting device

Monitoring + display

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

Circuit diagram 12 V - system with fault display and starter protection module

! "

)"
30 87 85 86

58

50a

15

19

17

P, 0, 1

86

30

30

n h
85 87

1 22 3 7

2 17 4 5

0 6 8 14

4 L / M 31,40,41 only Instrument box Engine

D+

B+

30

50

L / M . . 01.97
Monitoring + display

Power supply Charging device

Starting device

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

4
! " # $
30 87 85 86 30 86

L / M . . 01.97
50 15 31 87 SE

Circuit diagram 12 V - system with automat. shut down and starter protection module

)"

58

50a

15

19

17

P, 0, 1

30

n h
85 87

1 22 3 7

2 17 4 5

0 6 8 14

4 L / M 31,40,41 only Instrument box Engine

D+

B+

30

50

Power supply Charging device

Starting device

Monitoring + display

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

Circuit diagram 12 V - system with automatic shut-down and time relay

! "

30 87 85

86

58

50a

15

19

17

85 50 15 31 87 50 31 87 15 30 87 SE

30

P, 0, 1

86

30

30

86

87a

n h
85 87

1 22 3

2 17 4 5

18 7

0 6 8 14

4 L / M 31,40,41 only Instrument box Engine

D+

B+

30

50

L / M . . 01.97
Monitoring + display

Power supply Charging device

Starting device

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

4
! " # $
30 86 85 86 30

L / M . . 01.97
15
87

Circuit diagram 12 V - automatic start/stop with repeat start interlock and time relay

58

50a

15

19

17

86 31 15 15 50 50 31 87 31 87 30 87

30

30

P, 0, 1

85 87 SE

30

n h
85 87

30 31

61

1 22 3

87

50e

2 17 4 5

18 7

0 6 8 14

4 L / M 31,40,41 only Instrument box Engine

D+

B+

30

50

Power supply Charging device

Starting device

Monitoring + display

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

Circuit diagram 24 V - system with fault display

! "

58

50a

15

19

17

P, 0, 1

86

30

30

n h
85 87

1 22 3 7

2 17 4 5

0 6 8 14

4 L / M 31,40,41 only Instrument box Engine

D+

B+

30

50

L / M . . 01.97
Monitoring + display

Power supply Charging device

Starting device

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

4
! " # $
86 30

L / M . . 01.97

Circuit diagram 24 V - system with fault display and starter protection module

)"

58

50a

15

19

17

P, 0, 1

30

n h
85 87

1 22 3 7

2 17 4 5

0 6 8 14

4 L / M 31,40,41 only Instrument box Engine

D+

B+

30

50

Power supply Charging device

Starting device

Monitoring + display

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

Circuit diagram 24 V - system with automatic shut-down and starter protection module

! "

)"

58

50a

15

19

17

P, 0, 1

50 15 31 87 SE

86

30

30

n h
85 87

1 22 3 7

2 17 4 5

0 6 8 14

4 L / M 31,40,41 only Instrument box Engine

D+

B+

30

50

L / M . . 01.97
Monitoring + display

Power supply Charging device

Starting device

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

4
! " # $
50 15 31 87 50 31 87 15 30 87 SE
86 30

L / M . . 01.97

Circuit diagram 24 V - system with automatic shut-down and time relay

58

50a

15

19

17

85

30

P, 0, 1

30

86

87a

n h
85 87

1 22 3

2 17 4 5

18 7

0 6 8 14

4 L / M 31,40,41 only Instrument box Engine

D+

B+

30

50

Power supply Charging device Monitoring + display

Starting device

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

Circuit diagram 24 V - automatic start/stop with repeat start interlock and time relay

! "

58

50a

15

19

17

86 31 15 15 50 50 31 87 31 87 30 87

30

15

30

P, 0, 1

85 87 SE

86

30

30

n h
85 87

30 31

61

1 22 3

87

50e

2 17 4 5

18 7

0 6 8 14

4 L / M 31,40,41 only Instrument box Engine

D+

B+

30

50

L / M . . 01.97
Monitoring + display

Power supply Charging device

Starting device

Engine shut-down

Pre-heating

Optiones (Hour-run meter, speed adjustment)

Trouble-shooting table for electrical system


Trouble-shooting at instrument box
Malfunction Starter remains engaged although preheat/starter switch was released. Cause Pre-heat/starter switch sticks in position 3 after starting and does not return automatically to position I. Remedy Set pre-heat/starter immediately to 0 by force; if this is not possible, disconnect the battery at once. (If the starter remains engaged for more than 2 to 3 minutes, it will burn out.) Renew the pre-heat/starter switch. Insert a new bulb, clean the contacts. Recharge the battery. Renew the battery. Eliminate contact resistance, renew wiring, tighten loose terminals, if necessary renew preheat/starter switch. Renew voltage regulator.

Alternator telltale light does not come on when engine is stopped and pre-heat/ starter switch is on.

Bulb has blown or contacts are corroded. Battery is flat. Battery is defective (internal short-circuits or sulphatised). Defective pre-heat/starter switch, poor connections, defective wiring, contact resistance in charging current circuit or line to generator telltale light. Defective voltage regulator.

Short-circuit at exciter or positive Disconnect charge line B+ (to diode in generator. prevent discharge at a standstill), have generator repaired. Worn carbon brushes. Oxide desposit on sliprings, exciter winding is interrupted. Generator telltale light flickers. Generator telltale light continues to glow, after starting engine. V-belt loose at generator. Poor earth (ground) connection in instrument box. Wiring error, e.g. generator telltale light leads to oil pressure switch. Renew carbon brushes. Have generator repaired. Correct V-belt tension. Make a clean earth connection in the instrument box. Check the line from the generator telltale light to the generator and correct the wiring if necessary.

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the battery
Malfunction Battery not recharged, recharged too little or goes flat rapidly. Indication Terminal voltage drops even a short time after recharging to 7 V despite a 12 V nominal voltage (or 14 V if nominal voltage is 24 V). Cause Poor connections, open circuit or contact resistance in charging circuit, short-circuit in line. Remedy Eliminate the open circuit, clean the terminals, tighten terminals if slack.

Battery defective, internal Renew battery. short-circuit. Capacity of battery has dropped severely, because it was heavily discharged for a lengthy period (greyish-white cell plates = ,,sulphatised). Recharge battery at low current (app. 1/40 of Nominal capacity in Amps) for about 50 hours. (This is only possible if sulphate coating is not yet too stron.) Otherwise: renew the battery. Have generator repaired.

Battery poles connected up wrongly, destroying one or more diodes in the generator. Charge current too weak (esp. in winter). Battery capacity is too large. Defective voltage regulator (e.g. overheated/overloaded).

Recharge the battery. Install a smaller battery or a larger generator. Renew the voltage regulator.

Loose V-belt at generator. Correct V-belt tension.

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the battery
Malfunction Indication Corroded termi- Inadequate current nal clips. flow, white salt deposits. Cause Sulphuric acid attacs metals (except lead). Remedy Wash down terminals with hot soda lye (but this must not enter the battery!), rinse with cold water and apply acidresistant grease. Check voltage regulator, renew if necessary.

Battery is overcharged.

Voltage at terminals is always above 16.5 V with 12 V nominal voltage (or above 33 V with 24 V nominal votage), specific gravity of acid is above 1.285 kg/l so that the battery boils.

Charging voltage too high. Capacity of chosen battery is too small.

Install a battery of larger capacity. As a temporary measure, discharge the battery at intervals, e.g. by switching on an electrical consumer when the engine is not running Engine was run Install a voltage regulator continuously (several with a different days) with very little characteristic (lower electrical consumption charge-end voltage). (e.g. as a boat engine). Defect in voltage Have the voltage regulator regulator or generator. and generator checked, renew defective components.

Acid is escaping from Acid level is too high. the cell plugs. Acid level is to low Acid level less than Overloading or natural 10 mm (0.4 in) below water loss by top of cell plates. evaporation (particularly in summer).

Siphon off excess acid. Add distilled water or demineralised water.

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the battery
Malfunction Battery fails prematurely. Indication Cause Battery was discharged too often and too serverely. Battery becomes too warm. Excessive vibration. Remedy Check ratings of battery and generator, if necessary fit a special ,,Z or ,,HD battery. Install it at a more favourable point. Install battery at a more favourable point or use an ,,Rf battery (shakeproof) Charge the battery at a small current level (app. 1/40 of its norminal capacity in Amps) for about 50 hours. Failing this, renew the battery. Renew the battery. Recharge battery with a suitable charger. Renew voltage regulator on generator.

Battery is discharging sulphates.

Battery acid is contaminated. Too little power from battery. Voltage drops severely when load is applied. Run the battery down. Voltage regulator is defective, so that charging voltage is too low. Connecting terminals loose or oxidised.

Clean the terminal clips and apply acid-proof grease to them, then retighten the terminal clips. Install a larger battery and if necessary a larger generator. Renew the battery.

Battery capacity is too small (too many consumers). Battery is going flat because of impurities in its acid.

Sulphate deposits from Charge the battery for app. 50 battery (white coating on hours at a low current. plates). Battery is exhausted, Renew the battery. active substance has fallen out of plates. Acid level too low. Top up with distilled water.
L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the battery
Malfunction Rate of charge never adequate. Indication Terminal voltage soon drops to 7 V after recharging (12 V nominal voltage) or to 14 V (24 V nominal voltage). Cause Fault in generator, voltage regulator or wiring connections. V-belt too loose. To many consumers connected or generator is too small. Remedy Repair or renew generator and voltage regulater. Connect wiring firmly. Correct tension or renew V-belt. Install battery and generator with similar ratings.

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the starting device
Malfunction Starter motor does not turn when preheat/start switch is operated. Indication Generator telltale light does not come on. Cause Poor connections (loose or corroded), break in cable or short to earth (ground). Battery flat or defective. Telltale light grows Battery is flat. slowly dimmer when pre-heat/start switch is operated. Telltale light is on brightly. Bridge terminals 30 and 50 briefly at the starter motor, the starter then turns. Line between terminal 50 and starter switch or between terminal 30 and battery is interrupted or starter switch is faulty. Starter inhibit relay or delaying relay defective. Remedy Check battery lead and connections, clean battery posts and terminals, make sure connections are clean. Recharge or renew battery. Recharge the battery.

Repair the break or if necessary renew the starter switch.

Renew defective relay. Renew the starter motor and ensure a good connection between terminal 30 at the starter and the positive battery post (main starter line). Renew solenoid switch.

Telltale light burns Starter pre-engagement brightly. Terminal winding has burned out. 30 is not connected to positive battery pole. Telltale light burns Worn or dirty contacts on brightly, solenoid solenoid switch. switch is energised, when solenoid switch is bridged, starter motor turns.

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the starting device
Malfunction Starter motor turns too slowly or cannot turn the engine over. Indication Lengthy operating period without maintenance or in tough environmental condition. Cause Remedy Carbon brushes sticking. Renew brushes and brush holder guides. Carbon brushes worn. Poor spring pressure, carbon brushes not making contact. Commutator is dirty. Commutator is scored or burnt. Armature or field coils defective. Starter engages and is energized, but engine does not turn or only turns jerkily. Lengthy operating period without maintenance, electrical system has been neglected. Battery is flat. Renew carbon brushes. Renew springs.

Clean the commutator. Recondition or renew starter motor. Recondition or renew starter motor. Recharge the battery.

Low current flow Clean battery terminals, because of loose or tighten connections. corroded connections. Carbon brushes sticking. Renew carbon brushes and brush holder guides. Carbon brushes worn. Commutator dirty. Commutator scored or burnt. Armature or field windings defective. Renew carbon brushes. Clean commutator. Recondition or renew the starter motor. Recondition or renew the starter motor.

Starter pinion does not engage or disengage.

Engine does not turn, or turns jerkily.

Starter pinion or helical Renew starter pinion, thread dirty or damaged. recondition starter motor. Flywheel gear ring damaged. Solenoid switch defective. Return spring weak or broken. Remachine or renew gear ring. Renew solenoid switch. Renew return spring.

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the starting device
Malfunction Indication Cause Starter relay defective. Remedy Switch off engine manually at once (set speed control lever to ,,stop and disconnect battery). Consequential damage: electronic components destroyed. For example: diodes in generator. Check switches, relays and generator, renew parts if necessary. Set pre-heat/start switch to 0 immediately using force if necessary and renew it. If this is not possible: disconnect the battery immediately. Consequential damage: diodes in generator destroyed. Warning ! Unless the above measures are taken within 2-3 minutes, the starter motor will burn out (overheating) Renew solenoid.

Starter motor Noise of continues to run rotation. after switch was released.

Pre-heat/switch does not return automatically from position 3 to position 1.

Diode in shutdown solenoid (lifting or servo electromagnet) is defective. Engine does not start or starts reluctantly, although the starter motor is turning strongly. Valve solenoid on monitoring block is not opening. Pre-heat system is defective (only significant at temperatures below 10 to -15C.)

Check operation of valve solenoid and renew if necessary. Check pre-heat circuit and renew any defective parts.

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the pre-heat system
Indication Spiral indicator element (pre-heat monitor) glows brightly almost immediately. Cause Short to earth (ground) in a preheat plug, pre-heat element (filament) is bent and shorting inside engine. Broken pre-heat wires in a line resistor, winding shorted to an earthed component. Unterbrechung der Since the pre-heat monitor, preGlhanlage (Glhber- heat plug or heating flange (and wacher brennt nicht) also the second pre-heat plug or line resistor on 24 V systems) are wired in series, the complete pre-heat system is out of action if a component fails. Remedy Renew the pre-heat plug.

Renew the line resistor.

Use a test lamp or a voltmeter (with the pre-heat system switched on) to check all the preheat monitor connections. Renew defective parts.

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the alternator
Indication Generator telltale light does not go out as engine speed increases. Cause Line D+/61 has a short to earth Voltage regulator on generator is defective. Wiring connections interchanged at generator. V-belt for generator is slipping or broken. Remedy Renew the line or repair the short to earth. Renew voltage regulator. Connect the wiring correctly. Correct V-belt tension or renew V-belt.

Defective rectifier on generator, Have generator repaired. dirty sliprings, short-circuit in line DF or rotor winding. Generator telltale light Generator is not sufficiently does not go out at low excited by telltale light. A 2 Watt engine operating speed bulb is normally used in the light. (e.g. 1500 rpm) Generator telltale light glows only dimly when engine is stopped and pre-heat/start switch is operated, battery not being charged, or charging only at a low rate. Rate of charge too low, brief engine operating periods (particularly when a maintenancefree, vibration-proof battery is used). Poor connections, open circuit, contact resistance or short-circuit in charging circuit. Battery is defective, internal shortcircuit. Install a bulb of higher rating, e.g. 2 W -> 3 W. Warning: bulb ratin must not exceed 5 W (or pre-exciter circuit will be destroyed) Short-term remedy: recharge battery with a suitable charger. Long-term remedy: use a battery with better charge characteristic. Repair the break, clean the battery terminals, tighten loose clamps. Renew battery.

Battery capacity has dropped Recharge battery at low current severely through being left flat for for about 50 hours. (Only a long time (sulphate deposits). possible if sulphate deposits are not too extensive). Otherwise: renew battery. Battery capacity is too large. Alternator is defective. Voltage regulator is defective. Loose V-belt at alternator Install a smaller battery or a larger alternator. Have alternator repaired. Renew voltage regulator. Correct V-belt tension.
L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at the alternator
Indication When engine is stopped the generator telltale light burns brightly, but when engine is running telltale light glows dimmer. Generator telltale light does not come on when engine is stopped and preheat/start switch is turned on. Cause Poor connections, contact resistance in charge circuit or in the line to the generator telltale light. Defective voltage regulator. Defective alternator. Generator telltale light bulb has blown or contacts are corroded. Battery is flat. Battery is defective (internal shortcircuit or sulphate deposits). Defective pre-heat/start switch, poor contacts. Defective wiring line resistance in charging circuit or line to generator telltale light. Defective voltage regulator. Short-circuit in an alternator exciter or positive diode. Carbon brushes worn. Corrosion deposits on sliprings, open circuit in exciter winding. Generator telltale light flickers. V-belt at alternator is too slack. Remedy Eliminate contact resistance, clean terminals, tighten loose terminals. Renew voltage regulator Have alternator repaired. Install a new bulb. Clean the contacts. Recharge with a suitable charger. Renew the battery. Eliminate contact resistance, renew wiring, tighten loose terminals, if necessary renew preheat/ start switch. Renew the voltage regulator. Disconnect charging line B+ (to prevent discharge at a standstill), have alternator repaired. Renew carbon brushes. Have alternator repaired. Tension V-belt correctly.

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at engine monitor and display
Indication Sudden pressure drop in lubricating oil circuit. Cause Leak in oil circuit. Oil lost from damaged sump. Defective oil pump. Engine cannot be stop- Defective valve solenoid or fuel ped at valve solenoid shut-off valve. or fuel shut-off valve. Defective diode between generator telltale light and terminal 15 at pre-heat/start switch, or diode by-passed. Incorrect display, light does not come on although a fault is present. Remedy Check lines and seals, renew if necessary. Renew the oil sump. Renew the oil pump. Examine parts and renew if necessary. Check the circuit and renew the diode if necessary.

Short to earth (ground) in wire or Check wiring and eliminate switch. short to earth. Defective switch. Renew switch. Renew broken wire. Renew defective components. Renew the bulb.

No display, display Broken wire. light does not come on Defective switch or relay. despite malfunction. Defective bulb.

Engine protection relay: see ,,Instrument box

L / M . . 01.97

Trouble-shooting table for electrical system


Trouble-shooting at electromagnetic components
Indication Electromagnet does not switch engine off or vary engine speed. Cause Defective electromagnet (e.g. winding burned out). No power supply or open circuit. Defective switch or relay. Decoupling diode between generator telltale light and terminal 15 is missing or defective (applies only to shut-down solenoid with alternator). Malfunction or fai- Freewheel diode parallel to a lure of other electri- solenoid is defective. cal or electronic components. Starter motor does not disengage. Remedy Renew electromagnet. Check the circuit. Renew defective component. Check the circuit and install or renew decoupling diode as necessary.

Renew freewheel diode.

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

L / M . . 01.97

S-ar putea să vă placă și