Documente Academic
Documente Profesional
Documente Cultură
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
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.
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1. General
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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
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Engine illustrations
26
22
21
25
23
13
5
1680/18
24
1680/4
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
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11
27
10
12
1681/4
Engine illustrations
15 22 24 14 1
9
25 23 7
2
1583/6
26
27
20
23
17
1583/12
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
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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
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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.
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Engine serial No.: The serial no. begins with 10 and changes continously (11, 12) if any major changes are carried out.
GMBH +CO
KG
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
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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
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
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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
2.6
3.9
4.2
5.2
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
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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
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
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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
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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
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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
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23
24
25
26
27
28
29
30
31
32 / 33
34
35 / 36
37
38 46
39
40
41
42 43 44
45
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2. Additional equipment
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A 01.00 Fuel
A 01.40
-3General:
2 3 4 5 6
12
7 8 9 10 11
182
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Removing and installing the silencer (muffler) enclosure(L 30, L 31, L 40, C/K)
2
184
L3 / 229
185
2 1
L3 / 230
186
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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
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Crank handle
2 1
191
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Crank handle
12
8 11
A
9 6 5
16 15 2 1
192
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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.
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kompr.
1
dekompr.
L3 / 1
2
dekompr.autom.
93
L3 / 42
94
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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
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).
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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
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Recoil starter
L3 / 44
190
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2 1
113
5 4 6 8 7
14 3 13 9
114
Stop
115
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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.
Sta
rt
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approx. 25 A 40-45 A
approx. 5 A 25-30 A
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- 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
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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).
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- 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
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- 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
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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
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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
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- 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
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A 15.00 Housing
A 15.20
Assembling:
Adapter housing
2 4
3 1
5
200
6
L3 / 143
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1 7 6 4
10
9 8 5 3
201
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1 2 3 4 6 5
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M 01.00 Crankcase
M 01.10
Preparatory work:
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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
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M 01.00 Crankcase
M 01.20
Preparatory work:
- Remove the crankshaft; see M 02.00. - Take off the oil sump.
Dismantling:
- Unscrew splash plate (9/1) and take out balancing weights (9/2), then remove splash plate (9/3).
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Assembling:
12
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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
15
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16
17
18
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M 01.00 Crankcase
M 01.30.
- 41 Cleaning the crankcase
171
172
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173
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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.
- 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
20
21
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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
- 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
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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
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28
29
30
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32
33
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34
- Drive the locking collet to secure the gearwheel (21/1) into the end of the crankshaft.
35
36
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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
38
39
L / M . . 01.97
40
41
- Heat the camshaft gearwheel to app. 150 200C on a hotplate, and press it on.
42
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43
- Install the camshaft, noting the correct positions of the marks, and insert circlip (44/1).
44
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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.
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:
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.
L / M . . 01.97
M 04.00 Camshaft
M 04.30 Governor and injection timer
- 30 - 31 - 40 Preparatory work:
48a
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
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
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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
56
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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:
62
63
64
L / M . . 01.97
- 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.
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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
67
L / M . . 01.97
- 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
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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.
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.
70
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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
72
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Air-cooled engines
74
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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.
- 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
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78
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- 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
-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
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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
83
84
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85
86
87
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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
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-1-2-6-7Preparatory work:
89
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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
- 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 -.
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- 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
98
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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
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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
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L / M . . 01.97
106
- Inspect the piston and cylinder of the extrafuel device for score-marks or worn areas.
107
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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
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- 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
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
- 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.
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119
- Take off the oil filler pipe, the starting charge control device and all side covers.
120
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121
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
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L / M . . 01.97
- 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
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- 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
129
L / M . . 01.97
130
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Injector nozzle
6 5 4 3 2a 2
132
L / M . . 01.97
- 10 - 11 - 29 -
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
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.
- 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.
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:
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
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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
- 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
- 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
140
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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
- 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
143
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- 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
146
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- 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 %.
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M 17.00 Flywheel
Dismantling:
- Remove bolts (148/3) and disc (148/2). - Screw in two suitable stud bolts to act as
guides.
148
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149
150
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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.
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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.
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175
2 3
3 7
4 5
6 5
L3/58
177
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3 2
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- 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:
157
158
L / M . . 01.97
- 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:
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
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161
- Take out the screws holding the fan impeller (162/2) and remove the impeller.
163
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4. Tables
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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
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 30
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
inner
9.05 15
+0.006 -0.012
N mm 20.5
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
mm mm
18.90 21 H 7
+0.021 0 +0.046 -0.012
Rocker bushing
inner mm
19
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
mm mm
53.85 20 m 6
+0.021 +0.008
+0.058
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
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
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
39 H 6 67 H 6 39 36
internal internal
36.30 0.08
mm mm mm Ra
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 *
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
32 H 9
+0.062 0
4.0 +0.3
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
+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
mm mm mm
mm
72 72.25 71.5
+0.099 +0.056
+0.099 +0.056
mm mm mm
mm
0.3
L / M . . 01.97
Engine type
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
HATZ-Ident-No.
Spray pressure
+8
401 209 01
250
bar
504 440 00
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
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 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.
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4
3 4 5 6
30 15 50
30 86
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19 17 K2 H3 V2 H6 H6 P1
87 85
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
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
Starting device
Monitoring + display
Engine shut-down
Pre-heating
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
D+
B+
30
50
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Monitoring + display
Starting device
Engine shut-down
Pre-heating
4
! " # $
30 87 85 86 30 86
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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
D+
B+
30
50
Starting device
Monitoring + display
Engine shut-down
Pre-heating
! "
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
D+
B+
30
50
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Monitoring + display
Starting device
Engine shut-down
Pre-heating
4
! " # $
30 86 85 86 30
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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
D+
B+
30
50
Starting device
Monitoring + display
Engine shut-down
Pre-heating
! "
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
D+
B+
30
50
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Monitoring + display
Starting device
Engine shut-down
Pre-heating
4
! " # $
86 30
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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
D+
B+
30
50
Starting device
Monitoring + display
Engine shut-down
Pre-heating
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
D+
B+
30
50
L / M . . 01.97
Monitoring + display
Starting device
Engine shut-down
Pre-heating
4
! " # $
50 15 31 87 50 31 87 15 30 87 SE
86 30
L / M . . 01.97
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
D+
B+
30
50
Starting device
Engine shut-down
Pre-heating
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
D+
B+
30
50
L / M . . 01.97
Monitoring + display
Starting device
Engine shut-down
Pre-heating
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
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.
L / M . . 01.97
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.
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).
L / M . . 01.97
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
L / M . . 01.97
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
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 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
Starter motor Noise of continues to run rotation. after switch was released.
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
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
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
L / M . . 01.97
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.
L / M . . 01.97
L / M . . 01.97